ABB HT612544 Operation Manual Download Page 4

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Operation Manual / A130-M.. - A145-M..

Table of contents

HZTL4031_EN

Rev.P

February 2022

6.3

Expected replacement intervals ............................................................................... 61

6.4

Stopping the engine................................................................................................... 63

Periodic maintenance work ................................................................................ 64

7.1

Foreword to maintenance......................................................................................... 64

7.2

Cleaning the compressor during operation .......................................................... 65

7.3

Cleaning the turbine during operation................................................................... 68

7.4

Cleaning components mechanically ........................................................................ 72

Eliminating malfunctions.................................................................................... 82

8.1

Malfunctions when starting...................................................................................... 82

8.2

Malfunctions during operation ................................................................................ 83

8.3

Turbocharger is surging ............................................................................................ 86

8.4

Malfunctions when stopping.................................................................................... 87

8.5

Speed measurement system .................................................................................... 88

Dismantling and fitting....................................................................................... 89

9.1

Introduction ................................................................................................................. 89

9.2

Material required......................................................................................................... 90

9.3

Weights of individual parts....................................................................................... 92

9.4

Removing the air inlets .............................................................................................. 93

9.5

Removing the gas outlet casing .............................................................................. 94

9.6

Removing the gas outlet flange............................................................................... 95

9.7

Removing the compressor casing ........................................................................... 98

9.8

Pressing off the casing ............................................................................................ 100

9.9

Removing the cartridge group ................................................................................ 101

9.10

Removing the nozzle ring ........................................................................................ 103

9.11

Installing the cartridge group on the service support ...................................... 104

9.12

Measuring clearance A and B.................................................................................. 105

9.13

Nozzle ring compression PD................................................................................... 106

9.14

Installing the nozzle ring ......................................................................................... 107

9.15

Installing the cartridge group ................................................................................ 108

9.16

Installing the compressor casing ........................................................................... 111

9.17

Measuring radial clearances N and R ..................................................................... 113

9.18

Installing the air inlets .............................................................................................. 114

9.19

Installing the gas outlet flange ............................................................................... 115

9.20

Fitting the insulation of the turbine casing ......................................................... 116

9.21

Installing the gas outlet casing............................................................................... 117

9.22

Table of tightening torques..................................................................................... 119

Taking out of operation at short notice .......................................................... 121

10.1

Possible emergency repairs..................................................................................... 121

10.2

Installing the replacement turbocharger .............................................................. 122

10.3

Installing the replacement cartridge group ......................................................... 122

10.4

Fitting the cover plate............................................................................................... 123

10.5

Cover plate drawing .................................................................................................. 124

Mothballing the turbocharger.......................................................................... 125

Summary of Contents for HT612544

Page 1: ...ct identification Serial number HT612544 Customer part number Delivery date yyyy mm dd 2022 05 02 Weight 850 kg Operating limits according to rating plate Speed limit in test rig operation only nMmax 593 1 s Speed limit during operation nBmax 593 1 s Gas inlet temperature limit in test rig operation only tMmax 630 C Gas inlet temperature limit during operation tBmax 600 C ...

Page 2: ......

Page 3: ...n gas engines 16 2 7 Warning plates on the turbocharger 17 2 8 Turbocharger rating plate 18 2 9 Periodic check of the pressure vessels 20 2 10 Lifting of loads 21 2 11 Prerequisites for operation and maintenance 22 2 12 Hazards during operation and maintenance 23 2 13 Safe operation 25 2 14 Safe maintenance 26 3 Removing and Installing 30 3 1 Turbocharger weight and transportation 30 3 2 Removing ...

Page 4: ...moving the gas outlet flange 95 9 7 Removing the compressor casing 98 9 8 Pressing off the casing 100 9 9 Removing the cartridge group 101 9 10 Removing the nozzle ring 103 9 11 Installing the cartridge group on the service support 104 9 12 Measuring clearance A and B 105 9 13 Nozzle ring compression PD 106 9 14 Installing the nozzle ring 107 9 15 Installing the cartridge group 108 9 16 Installing...

Page 5: ...ths 125 11 2 Taking the engine out of operation for more than 12 months 126 12 Material and Disposal 127 12 1 REACH and RoHS Compliance Declaration For Products 127 12 2 Disposing of turbocharger components 128 13 Spare parts 129 13 1 Ordering spare parts 129 13 2 Required customer spare part set 97070 129 13 3 Spare part Illustrations 130 14 Tools 145 Figures 146 Tables 148 ...

Page 6: ...explains the turbocharger and contains instructions for safe opera tion The Operation Manual is a complement to and expansion of existing national regulations for occupational safety accident prevention and environmental protection Target group The Operation Manual is aimed at engineers and trained mechanics responsible for the proper operation of the engine and for the turbocharger connected to i...

Page 7: ...m turbocharging 1 3 Essential information Design variants This document is valid for different design variants of turbochargers There may be sections and descriptions of components that are not relevant for a specific turbocharger variant Please contact an Turbo Systems Service Station if you have any questions regarding a design variant see Contact information at www abb com turbocharging Accurac...

Page 8: ...and function of the turbocharger Fig 2 Layout and function of the turbocharger 01 Filter silencer air suction branch 08 Gas outlet flange 02 Compressor casing 09 Nozzle ring 03 Diffuser 10 Turbine casing 04 Bearing casing 11 Turbine end bearing flange 05 Axial thrust bearing 12 Compressor end bearing flange 06 Radial plain bearing 13 Compressor wheel 07 Turbine Page 6 149 ...

Page 9: ...e cylinders The rotor runs in two radial plain bearings 06 which are located in the bearing casing 04 between the compressor and turbine The axial thrust bearing 05 is located between the two radial plain bearings The plain bearings are connected to a central lubricating oil duct which is normally supplied by the lubricating oil circuit of the engine The oil outlet always lies at the deepest point...

Page 10: ...s Mandatory signs show the protective equipment to be worn for a task The mandatory signs are described in chapter Safety and must be complied with Definition of Caution Warning Caution and warning signs are described in chapter Safety Turbo Systems Turbo Systems Switzerland Ltd is referred to in this document as Turbo Systems Official service stations of Turbo Systems Official service stations ar...

Page 11: ...ictogram Meaning Tighten with specified torque Tighten over specified tightening angle Hand tight tighten without tools Oil Apply screw locking paste e g Loctite Apply high temperature grease Apply other paste in accordance with specifications Oil free grease free and dry Affix Measure Note Visually inspect Please note text for numbered work step See document Dispose of in an environmentally compa...

Page 12: ...WARNING Health protection when handling VCI VCI products are not hazardous in terms of the Ordinance on Hazardous Substances Nevertheless the following points must be observed when handling VCI u Observe information in material safety data sheet u Ensure proper space ventilation u Do not eat drink or store food at the workplace while working with VCI u Clean hands and face after working with VCI u...

Page 13: ...er must be inspected by a Turbo Systems service station and repacked u Inspect the package for damage If the package is damaged the turbocharger must be in spected by a Turbo Systems service station and repacked After every 3 years the following work steps must be performed by a Turbo Systems service station Inspect the component Replace the desiccant agent Repackage the component NOTICE 70 field ...

Page 14: ...oduction 1 7 Registered trademarks Copyright 2022 ABB All rights reserved HZTL4031_EN Rev P February 2022 1 7 Registered trademarks The trademarks of outside companies are used in this document These are marked with the symbol Page 12 149 ...

Page 15: ...t compliance with safety instructions are a consequence of insufficient or inappropriate performance of maintenance and in spection work The operating company is responsible for defining measures that regulate safe access to and safe handling of the turbocharger All instructions contained in this chapter must be observed for safe and trouble free opera tion of the turbocharger and during all work ...

Page 16: ...atory mask to protect against Dusts Gases Safety helmet Ear protection Table 3 Personal protective equipment to be worn specific to the respective task 2 4 Definition of safety instructions WARNING Definition of Warning Non compliance or inaccurate compliance with working or operating in structions indicated by this symbol and the word WARNING can lead to seri ous injuries to personnel and even to...

Page 17: ...d to be operated with a clockwise direction of rotation as viewed from the turbine end The specific operating limits of the turbocharger were determined on the basis of informa tion from the enginebuilder about the intended use These data are given on the rating plate The use of the turbocharger is limited to the specific application released at the time of de livery Turbo Systems accepts no liabi...

Page 18: ...ns to the turbocharger or improper operation 2 6 Deflagration on gas engines ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar After a deflagration event ABB recommends verifying the following points on the turbochar ger Position of the turbine and compressor casings to the bearing casing Shifting of the bearing casing in relation to the bracket Cracks in c...

Page 19: ...not present in the designated locations or not readable proceed as fol lows u Order new warning plates from Turbo Systems service stations u Remove any warning plates that have become unreadable u Clean and degrease the areas designated for the warning plates u Fit new warning plates and remove protective sheets Turbochargers supplied to the enginebuilder without insulation must be equipped later ...

Page 20: ...ed with the en ginebuilder 02 Turbocharger operating limits during operation Recommended inspection and replacement intervals of turbocharger components 03 Inspection interval of plain bearings in 1000 h 04 Replacement interval of compressor in 1000 h 05 Replacement interval of turbine in 1000 h Further data 06 Customer part number 07 Designation for special design 08 Weight of turbocharger in kg ...

Page 21: ...d contacting the nearest Turbo Systems Service Station nMmax tMmax normally apply only when running at overload 110 during trials on the engine test bed These limit values can also be permitted during operation for special applications Operation above nMmax and tMmax is not permitted Non observance of the recommended inspection and replacement intervals increases the risk of unpredictable componen...

Page 22: ... locally applicable legal regulations regarding periodic checks of the pressure vessels must be observed The operating company is responsible for the safe operation of the pressure vessel WARNING Danger due to pressure vessels The operating company must make sure the pressure vessels are in proper working condition and monitor them Necessary repair or maintenance work must be performed promptly an...

Page 23: ...nst mechanical hazards Wear safety helmet Fig 9 Attachment of loads on the crane hook Fig 10 Attachment angle If there are two or more suspension points the attachment angle of 45 must not be ex ceeded This prevents excessive loading due to diagonal pull u Before looping around the components of the turbocharger let them cool down max imum 80 C u Attach components of the turbocharger as described ...

Page 24: ... be checked periodically Suitable working materials and personal protective equipment must be kept in a perfect condition Only authorised personnel may remain in the vicinity of the turbocharger when the engine is running Competence of personnel The turbocharger must only be operated and serviced by trained and authorised personnel Basic mechanical training is a prerequisite Modifications to the t...

Page 25: ... wear ear protection u Always wear ear protection if the sound pressure level exceeds 85 dB A Wear ear protection Hazards due to hot surfaces Surfaces of the turbocharger attached parts and operating fluids lubricating oil get hot during operation The surface temperature depends on the efficacy of the existing insula tion The temperature may rise to a level that can cause burns WARNING Danger of b...

Page 26: ...roviding protection against contact with hot surfaces u Compliance with the instructions and specifications given by the en ginebuilder to protect against hot turbocharger surfaces is compulsory Wear safety gloves to protect against thermal hazards Hazards due to rotating parts WARNING Hazards due to rotating parts Contact with rotating parts can cause severe injury The turbocharger is never allow...

Page 27: ...stics to the responsible department immediately u In case of damage take the turbocharger out of operation immediately and safeguard against accidental unauthorised use u When switching on operating energy supplies hydraulics pneumatics electricity pay at tention to the risks that may occur as a consequence of this energy input WARNING Burst protection and insulation Operation without burst protec...

Page 28: ...m operations for which you have received instruction or train ing Wear safety footwear to protect against mechanical hazard and risk of fall ing Wear protective clothing WARNING Risk of falling When working on the turbocharger there is a risk of falling u Do not climb onto the turbocharger or onto attached parts and do not use them as climbing aids u Use suitable climbing aids and working platform...

Page 29: ... u Observe the material safety data sheet for the cleaning agent or solvent u Wear personal protective equipment PPE according to the material safety data sheet u Inspect the electric cables for abrasion and damage before and after your cleaning work Safety during disassembly assembly maintenance and repair u Observe the procedures for set up service and inspection work and the inspection inter va...

Page 30: ...ions for which you have previously received instruc tion or training Hazards due to operating materials and supplies Operating materials and supplies are substances required for the operation of the tur bocharger or for the performance of maintenance work Oils greases coolants detergents and solvents acids and similar substances can be classified as hazardous substances WARNING Handling operating ...

Page 31: ... the material safety data sheet for the operat ing materials and supplies u Comply with local legislation Hazards due to the handling of insulation materials WARNING Danger from insulation materials Dust or fibres from insulation materials can have adverse effects on the health or cause irritations Unsuitable and combustible insulation materials are a fire hazard u Only use suitable and non combus...

Page 32: ...rbocharger The weight specified below applies to the heaviest variant possible Depending on the specification the weight specified on the rating plate may be lower than the standard value specified here Fig 12 Suspension of complete turbocharger unit A Turbocharger with oil cooled bearing casing B Turbocharger with water cooled bearing casing C Complete turbocharger unit with gas outlet casing Pro...

Page 33: ...ed when screwing in the screw connection 02 and during subsequent opera tion Reuse of the cleaning nozzle after loosening the screw connection 02 can lead to a water leak or the cleaning nozzle breaking off and thus destroy the turbine u Only loosen the screw connection 02 if the cleaning nozzle 51301 needs to be replaced u If the screw connection 02 has been loosened a new cleaning nozzle 51301 m...

Page 34: ...he speed sensor 86505 and secure the rolled up cable on the turbocharger This protects the plug from being crushed Fig 14 Removing the turbocharger A Oil cooled bearing casing D Clamping nut B Water cooled bearing casing E Standard nut C Position of expansion sleeves u Apply penetrating oil to thread of stud 02 and nut and let it work in Do not oil the pressure screws of the clamping nut D u If pr...

Page 35: ...to undo the connection Oil cooled bearing casing A u Attach lifting gear to the suspension eye u Loosen and remove nuts E If clamping nut D is present Loosen in accordance with chapter Loosening the clamping nut 34 u Positioning the turbocharger for storage 35 Water cooled bearing casing B u Loosen and remove water connections Close the openings of the water connections with screw plugs u Attach l...

Page 36: ...an pressure screws The pressure screws are equipped with a permanent sliding layer that must not be removed In case of non compliance it cannot be ensured that the necessary tension force is reached u Do not clean pressure screws u Do not lubricate pressure screws If a screw jams the previously loosened screw must be tightened again a little Fig 15 Loosening the clamping nut 1 Working in a circle ...

Page 37: ...may tip over This can result in serious personal injury u Place the turbocharger on a clean level support u Secure the turbocharger to prevent it from tipping over by using wooden beams and wedges and by taking the centre of gravity into account Fig 16 Turbocharger centre of gravity 01 Centre of gravity u Remove turbocharger from engine support set it down properly in an appropriate place and secu...

Page 38: ...ing is provided by O rings The O rings are not included in the Turbo Sys tems scope of delivery Fig 17 Inserting gaskets into the bracket 01 Bracket 04 Slot for O ring 02 Oil supply 05 O rings 03 Oil drain 06 Pin optional Pin 06 as installation safety device Turbochargers can have an oil inlet either on their right or left side the oil inlet position can be different for the turbocharger fitted on...

Page 39: ...gain Requirements for the threaded rods Fig 19 Requirements for threaded rods Product Diameter Threaded rod mm Material DIN ISO 898 Part 1 Thread length L1 mm Oil cooled L2 mm Water cooled L2 mm A130 Ø 16 M16 10 9 12 9 30 250 250 A135 Ø 20 M20 10 9 12 9 30 270 325 A140 Ø 24 M24 10 9 12 9 70 350 360 410 420 A145 Ø 30 M30 10 9 12 9 80 415 425 Table 5 Requirements for threaded rods The threaded rods ...

Page 40: ...op around the gas outlet casing 61001 If the gas outlet casing is already fitted in the exhaust gas pipe the attachment of the lifting gear on the bearing casing is sufficient 5 Position the turbocharger on the bracket 04 and align it Pay attention to the position ing pins 05 in the bracket 6 When fixing with a standard nut D fit expansion bushes 42190 in the correct position in the slot only rele...

Page 41: ... turbocharger with a standard nut u Fit the nuts and tighten them according to variant 1 or 2 in the table below Product Through hole in bearing casing mm Fixing screws mm Variant 1 Tightening torques Nm Variant 2 Hy draulic pre ten sioning forces kN A130 Ø 17 M16 280 110 A135 Ø 21 M20 560 175 A140 Ø 25 M24 960 250 Table 6 Tightening torque for standard nuts When the turbocharger is mounted on the...

Page 42: ...lubricate pressure screws In order to correctly fit the clamping nuts the pressure screws 04 must not protrude from the clamping nuts 03 in the direction of the thrust washer 02 u Make sure the pressure screws do not protrude in the direction of the thrust washer Fig 21 Preparing the clamping nut for the tightening procedure 1 Check whether the expansion bushes 42190 with recess are correctly posi...

Page 43: ...led tightening of the pressure screws 1 Screw in pressure screws crosswise by hand until reaching the stop 2 Tighten pressure screws crosswise to 50 of the tightening torque specified in the table 3 Tighten pressure screws crosswise to 100 of the tightening torque specified in the table 4 Work in a circle to tighten all pressure screws to 100 of the tightening torque specified in the table 5 Tight...

Page 44: ...rsion with water cooled bearing casing u Fit the water pipes according to the instructions of the enginebuilder Version with compressor wheel cooling CAUTION Failure of compressor wheel cooling Any prolonged failure of the compressor wheel cooling will shorten the re placement interval of the compressor wheel u Make sure there is an uninterrupted supply of cooling air during opera tion Fig 24 Conn...

Page 45: ...ling 3 3 Installing the turbocharger Copyright 2022 ABB All rights reserved HZTL4031_EN Rev P February 2022 3 3 7 Attaching the support Fig 25 Attaching the support u If present Attach support 61301 to engine support or to a connecting piece Page 43 149 ...

Page 46: ...ion of lubricating oil and the oil change intervals 4 1 2 Pre lubrication Pre lubrication must be carried out as follows u Switch on the oil pump u Build up oil pressure u Do not exceed a pre lubrication time of 2 minutes u Start the engine u Let the oil pump run until the pump driven by the engine generates sufficient pressure 4 1 3 Oil filtering Filtering the lubricating oil with a filter mesh w...

Page 47: ...All rights reserved HZTL4031_EN Rev P February 2022 01 Bearing casing 02 Oil orifice 03 Circlip With an oil inlet pressure of more than 3 bar of overpressure with engine under load up stream of the turbocharger an oil orifice must be installed to reduce the oil pressure Page 45 149 ...

Page 48: ... u For the initial commissioning phase and after all service work flush the complete lubricating system with warm oil u Use special running in filters when running in the engine and after all ser vice work on the lubricating system u Check that the oil filter is clean before commissioning u Check the oil pressure in the oil supply pipes Warning plates u Check whether warning plates are present and...

Page 49: ...ipes WARNING Risk of burning from hot gas Escaping gases are hot and will lead to serious burns in the event of contact u Check all pipes for leaks in accordance with the enginebuilder s instruc tions Wear safety gloves to protect against thermal hazards 4 2 4 Checks when starting up the engine If present u Measure speed oil pressure and charging pressure at various engine performances u Measure t...

Page 50: ...ater pipe Version with compressor wheel cooling u Remove the screw plug on the cooling air connection and fit the cooling air line General u Check the exhaust gas pipe before and after the turbine for combustion residues or wa ter residues and clean it Remove any foreign objects that may be present u Check and clean filter silencer or air supply line and remove any foreign objects that may be pres...

Page 51: ...um of 15 minutes 8 0 Engine idling admissible for a maximum of 1 hour 0 5 poil 2 5 Pre lubrication and post lubrication engine stopped 0 5 poil 1 0 Warning signal n 0 5 x nBmax 1 25 Alarm signal Not admissible Stop the engine immedi ately 0 6 Table 8 Lubricating oil pressure at oil inlet before turbocharger Depending on use of an oil orifice in accordance with the enginebuilder s specifications Ar...

Page 52: ...let The oil temperature at the outlet is mainly dependant on Lubricating oil temperature and pressure at the oil inlet Engine load and turbocharger speed Exhaust gas temperature The maximum admissible oil temperature at the outlet is listed in the following table The specified oil outlet temperature is to be considered as alarm value for the turbocharger op eration and must be monitored according ...

Page 53: ... Operation above the operating limits defined on the rating plate can shorten the recommended replacement intervals considerably u Measure exhaust gas temperature upstream of turbine u Comply with operating limits on rating plate u For a definition and explanations concerning the rating plate refer to chapter Safety Turbocharger rating plate 18 u For operating limits refer to the Operation Manual ...

Page 54: ...e speed measurement cables under strain by pulling them If you pull the speed measurement cables too hard contacts can be pulled out u Do not strain the speed measurement cables by pulling 5 3 2 Layout and overview Fig 27 Layout and overview of speed measurement system 86505 Speed sensor 42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F I converter 01 Plug with integrated voltage limiter...

Page 55: ...pped it can continue to be driven at this reduced engine load or turbocharger speed u If a turbocharger surges continuously the engine performance must be reduced further u Measure the temperatures in the air lines and gas piping from and to the turbochargers and compare with normal values If clear deviations of temperature are found the nearest Turbo Systems service station has to be contacted u ...

Page 56: ...ditional gasket is required during assembly Fig 28 Replacing the speed sensor Part number A130 A135 A140 A145 86505 M12 x 1 5 15 Nm M12 x 1 5 15 Nm M12 x 1 5 15 Nm M12 x 1 5 15 Nm Table 11 Tightening torque 86505 u Reduce the engine performance to idling and then stop the engine Pay attention to post lubrication Stopping the engine 63 u Switch off the lubricating oil supply to the turbocharger u D...

Page 57: ... of 1 meter from the turbocharger The highest value of the emission sound pressure level1 reaches a maximum of 105 dB A near the air inlet The following prerequisites must be fulfilled with regard to the turbochar ger to observe this limit value Air inlet system has been fitted All standard noise reducing measures2 have been fitted Bellows at the air outlet has been acoustically insulated by the e...

Page 58: ...2 ABB All rights reserved HZTL4031_EN Rev P February 2022 Suggestion for noise insulation bellows Fig 29 Noise insulation bellows 01 Compressor casing 02 Bellows 03 Charge air duct scavenging air duct 04 Insulation cushion 05 Insulation mat at least 15 mm 06 Sheet metal cover Page 56 149 ...

Page 59: ... omitted or performed too late can cause excessive contamination wear and operating failures u Carry out the service work at the specified time intervals CAUTION Specific service interval Exceptional stresses such as a high number of starts and stops harsh envir onmental conditions poor fuel quality or high system vibrations can lead to untimely machine damage even if the prescribed service interv...

Page 60: ...n the supply pipe to the turbocharger while the en gine is stopped in accordance with the instructions of the enginebuilder 6 2 3 Service work according to instructions of enginebuilder u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en gine is stopped in accordance with the instructions of the enginebuilder 6 2 4 Service work according to data on the rat...

Page 61: ...ights reserved HZTL4031_EN Rev P February 2022 6 2 5 Other service work If a protective grid is installed in the gas outlet casing 61001 by Turbo Systems Fig 30 Replacing the protective grid u Remove the protective grid 61205 after 50000 hours and replace it with a new protect ive grid Page 59 149 ...

Page 62: ...owing operating data and measured values must be entered regularly in the engine logbook of the enginebuilder Rating and speed of the engine Air intake temperature Pressure of the charge air Pressure loss in the charge air cooler Lubricating oil pressure and lubricating oil temperature If present Speed of the turbocharger Air temperature after the compressor and after the charge air cooler Exhaust...

Page 63: ...bearing parts and replacing the non rotating components exposed to hot gas A decisive role is played by various influencing parameters which in extreme cases can sig nificantly reduce the replacement interval of these parts During the prescribed periodic service work the individual parts are examined for wear and replaced if necessary Expected replacement intervals h GAS MDO HFO Turbine casing 250...

Page 64: ...wing influences Fuel quality and fuel treatment Load profile thermal cycling also number of starts stops emergency shutdowns oper ating point Gas inlet temperature Frequency and execution of cleaning process during operation Turbocharger specification System specific operating conditions combustion quality exhaust gas composition For bearing parts Lubricating oil quality oil filtering oil conditio...

Page 65: ... before turbocharger 49 Post lubricate water cooled bearing casings until the rotors come to a standstill Deac tivate post lubrication as soon as the rotor comes to a standstill Deviating procedures must be coordinated with Turbo Systems For oil cooled bearing casings post lubricate for 20 minutes if the turbine inlet temper ature tTE exceeds the following values when the engine is stopped 550 C w...

Page 66: ...ng max imum fuel efficiency Maintenance inter val Maintenance work Operating status 24 72 h 1 Cleaning the compressor during operation 65 Engine load 50 85 50 200 h 1 Cleaning the turbine during operation 68 Engine load 20 40 guideline value According to rating plate 2 Cleaning components mechanically 72 Engine stopped Table 13 Maintenance table h Hours of operation 1 If the maintenance intervals ...

Page 67: ...s recommends mechanical cleaning of the contaminated components Periodic cleaning during operation is not a substitute for the service work during which the turbocharger is completely dismantled and cleaned Cause and consequences of contamination The contamination of the compressor stage depends on the degree of purity of the air that is sucked in Deposits can form in the flow channels if salt oil...

Page 68: ...periods in the lower range of performance that both turbocharger compressors are cleaned 7 2 4 Function and safety of wet cleaning CAUTION Volume of water Uncontrolled volumes of water can damage the turbocharger and the en gine u Never connect the water connection directly to a water pipe or a bigger metering container than the one specified by Turbo Systems WARNING Danger due to pressure vessels...

Page 69: ...the mechanical action of the impacting droplets 7 2 5 Carrying out wet cleaning of the compressor Fig 31 Carrying out wet cleaning of compressor Engine load Filling amount of water pressure vessel dm3 Water temperature C Water injection period s 50 85 0 4 5 30 10 Table 14 Parameters for wet cleaning of compressor u Remove sealing plug 27005 u Fill container with 0 4 dm3 of pure water u Screw in se...

Page 70: ...and consequences of contamination Turbo Systems recommends the use of fuels with low ash sulphur sodium and vanadium contents The combustion of heavy fuel oil HFO in diesel engines causes contamination of the tur bine stage Poor quality fuel in conjunction with high exhaust gas temperatures can lead to extremely hard deposits on turbine components Operating states with incomplete combus tion also ...

Page 71: ...cleaning process is faster and reduces the risk of surging of the tur bocharger 7 3 4 Function and safety of wet cleaning CAUTION Corrosion and deposits when cleaning Salt water and cooling water treatment substances damage and adversely affect turbocharger parts u Never use salt water but only pure water for cleaning To clean the turbine stage during operation water is injected before the nozzle ...

Page 72: ...ust be taken into account when setting the operating point before cleaning If necessary the engine performance must be reduced to meet these conditions The clean ing cycle can be started when the above conditions are fulfilled The water mass flow to be set can be found in the Operation Manual 7 3 6 Carrying out wet cleaning of the turbine CAUTION Inadmissible thermal stress and flooding of the tur...

Page 73: ...low VW on the basis ofthe cleaning parameters in the table see Table 16 Wet cleaning of turbine parameters 71 u Close the stop valve 02 after 10 minutes u Wait for 10 minutes do not change the load during this stabilisation phase If the cleaning result is unsatisfactory or there is water leakage contact a Turbo Systems service station Product Temperature be fore turbine before cleaning C Maximum t...

Page 74: ...asily sustain mechanical dam age The use of needle descalers for example or other striking tools dam ages the components Depending on the specification nozzle rings or tur bine casings may have protective coatings which can also be damaged u Use only soft tools such as rags brushes or wire brushes u In case of heavy contamination the cleaning methods described in this chapter such as soaking for e...

Page 75: ...ter ring 81265 u Remove the filter ring u Clean the filter ring as required or every 500 hours of operation and replace it after the fifth cleaning process at the latest Contamination of the filter ring depends on the degree of purity of the sucked in air u Rinse the filter ring with water and mild detergent or in the case of heavy contamination soak and carefully push through Rinse in cold water ...

Page 76: ...segments When cleaning note that the absorption segments may only be cleaned lightly with pres surized air a soft brush or a moist cleaning cloth u Have any heavily contaminated absorption segment replaced by a Turbo Systems service station Fitting the filter silencer u Insert the absorption segments 81136 into the sheet metal coverings 81137 u Bend the sheet metal coverings 81137 back to their or...

Page 77: ...fety data sheet u Comply with local legislation Wear safety goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mask to protect against gases The following parts which are relevant in terms of performance can be cleaned in accord ance with the description below Fig 34 Compressor end non rotating parts 72000 Compressor casing 77000 Wall insert 79000 Diffuser u Clean th...

Page 78: ...Wear safety goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mask to protect against gases Baked layers of contamination from heavy fuel oil or coked oil for example occur at the tur bine end The following parts which are relevant in terms of performance can be cleaned in accordance with the description below Fig 35 Turbine end non rotating parts 51000 Turbine casi...

Page 79: ...replaced u If the screw connection 02 has been loosened a new cleaning nozzle 51301 must be installed and the screw connection must be refit ted Observe the specified tightening torque from the supplier of the screw connection Water or air can be passed through the piping and into the cleaning nozzle to check whether it is blocked When installed the cleaning nozzle can be mechanically cleaned with...

Page 80: ...d contamination in the cartridge group If water or contamination penetrates the cartridge group this can impair the function of the turbocharger and damage parts inside the cartridge group u Make sure that no water or contamination can enter into the cartridge group u Cleaning procedures should be selected that do not result in removal of the compressor wheel material or cause damage to its surfac...

Page 81: ... mm B mm C mm A130 108 17 205 A135 128 20 245 A140 157 25 300 A145 187 30 357 Table 17 Value table for soaking To soak the layers of contamination on the turbine the cartridge group can be immersed vertically in a container 02 with fluid u Place the container 02 inside a larger container 03 so that the overflowing fluid can be collected CAUTION Selection of the cleaning agent Cleaning agents that ...

Page 82: ... inside the cartridge group u Place the cartridge group on suitable supports 01 made of wood or metal u Observe dimension B for the supports 01 so that the cartridge group is not immersed too deeply u Let the layers of contamination on the turbine soak for four hours Removing contamination WARNING Health hazard due to soot particles If soot particles enter the eyes or respiratory tract this can be...

Page 83: ...ributed residual contamination deposits lead to rotor unbal ance This can result in bearing or turbocharger damage u Remove all traces of contamination from the turbine u After brushing off the contamination fill the container 02 with clean water u Immerse the turbine of the cartridge group in clean water so that any loose contamina tion comes off u Lift up the cartridge group and align it horizon...

Page 84: ...o Systems service sta tion Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Contact enginebuilder Table 19 Malfunctions when starting Vibrations Rubbing of rotating parts Normal behaviour not a malfunction Turbochar ger A slight amount of uniform wear at the circumference of the rotor components caused by slight local rubbing against adjacent components is permitted This...

Page 85: ...e Oil filter heavily contaminated Clean Oil pump in lubricating system defect ive Check replace Manometer displays incorrectly Replace manometer Table 21 Malfunctions during operation Lubricating oil pressure too low Speed reduces Possible causes Remedy Turbochar ger Turbine and or nozzle ring severely con taminated Clean see chapter Periodic mainten ance work 64 Rotor components or bearing damage...

Page 86: ... high Check clean cooling system Insufficient ventilation Improve ventilation Table 24 Malfunctions during operation Exhaust gas temperature too high Charge air pressure too low Engine performance and engine speed unchanged suction condition normal Possible causes Remedy Turbochar ger Manometer display not correct Replace manometer Supply pipe to manometer not sealed Repair leak Filter silencer co...

Page 87: ...minated or corroded compressor wheel can reduce the com pressor wheel s fatigue endurance limit and result in the turbocharger being damaged u Rectify malfunction in accordance with the following table Possible causes Remedy Turbochar ger Compressor components severely con taminated by the ventilation gases that have been fed in Clean see chapter Periodic mainten ance work 64 Optimize oil separati...

Page 88: ...ified and remedied immediately by a Turbo Systems service station u Have parts assessed for damage and if necessary replaced by a Turbo Systems service station Possible causes Remedy Turbocharger Filter silencer or diffuser contamin ated Clean see chapter Periodic mainten ance work 64 Heavy contamination deposits in the turbine or in the nozzle ring Engine Protective grating in front of the tur bo...

Page 89: ...nctions when stopping Runout noises Runout time too short The runout time must be noted down as a reference Because the runout time depends on the oil viscosity the runout time must always be measured at the same oil temperature If the runout time is significantly shorter in comparison to a previous measurement the fol lowing table must be observed Possible causes Remedy Turbochar ger Turbocharger...

Page 90: ...stems service station Replacing the speed sensor 54 Table 32 Malfunction of the speed measurement system No signal or poor signal amplitude Measured speed too high Possible causes Remedy Turbochar ger Sensor tip contaminated since it is magnetic and can attract metallic particles This reduces the distance to the signal emitting sealing disc which can lead to ampli fication of the noise com ponent ...

Page 91: ... turbocharger Some parts on the turbocharger may have sharp edges There is a risk of a cutting injury u Wear safety gloves against mechanical risks when conducting assembly and disassembly work Wear safety gloves to protect against mechanical hazards CAUTION Further work This Operation Manual may be used to carry out only the work described in it Further work that is carried out in an incorrect wa...

Page 92: ... a part number Identification is guaranteed by the tool list This list is enclosed with the tool set WARNING Servicing the tools The tools must be checked for damage before and after use u Visually inspect for corrosion cracks deformation and wear u Damaged tools must no longer be used and must be replaced Swivel lifting eyes Swivel lifting eyes are required for the safe lifting of loads which are...

Page 93: ...fting gear with sufficient load limit u Pay attention to the correct attachment of loads on the crane hook u People must not stand beneath suspended loads Wear safety gloves to protect against mechanical hazards Wear safety helmet Definition of terms Suspension point Defined loading point on a component or an assembly blind hole thread eyelet lug Assembly device Devices that are fitted on the turb...

Page 94: ...A135 kg A140 kg A145 kg 01 Filter silencer 19 30 40 65 02 Radial air suction branch 6 8 13 21 03 Axial air suction branch 4 5 6 9 04 Compressor casing 24 40 60 95 05 Wall insert 6 8 15 24 06 Diffuser 3 4 7 11 07 Cartridge group 40 60 110 180 08 Nozzle ring 2 2 4 6 09 Burst ring 2 3 5 12 10 Turbine casing 1 inlet 50 75 135 210 Turbine casing 2 inlets 45 65 125 190 Turbine casing 3 inlets 125 190 11...

Page 95: ...e air inlets u Mark the casing position for assembly Fig 40 Removing the air inlets 1 Attach lifting gear to the filter silencer 81000 or air suction branch 82000 2 Loosen and remove V clamp 72020 3 Remove filter silencer 81000 or air suction branch 82000 set it down properly in an appropriate place and secure it 4 Remove and dispose of the O ring 81010 82010 Page 93 149 ...

Page 96: ...itting 9 5 Removing the gas outlet casing Copyright 2022 ABB All rights reserved HZTL4031_EN Rev P February 2022 9 5 Removing the gas outlet casing Removing the insulation Fig 41 Removing the insulation u Remove gas outlet casing insulation Page 94 149 ...

Page 97: ...port 61301 from bracket 4 Remove the gas outlet casing 61001 set it down properly in an appropriate place and secure it 5 Remove and dispose of the gasket 61002 9 6 Removing the gas outlet flange Depending on the way of fixing the gas outlet flange the appropriate Working Instruction has to be consulted pressing off using 3 or 6 press off screws If the following Working Instructions are not observ...

Page 98: ...for service work u If necessary Treat the centering seat with rust remover through the press off threads and the clearance holes u Mark the casing position for assembly Fig 43 Dismantling the gas outlet flange Product Press off screws strength 8 8 Tightening torque A130 3 x M 8 x 20 20 Nm A135 3 x M10 x 25 40 Nm A140 3 x M12 x 30 65 Nm A145 3 x M12 x 30 65 Nm Table 37 3 press off screws not includ...

Page 99: ... for service work u If necessary Treat the centering seat with rust remover through the press off threads and the clearance holes u Mark the casing position for assembly Fig 44 Removing the gas outlet flange Product Press off screws strength 8 8 Tightening torque A130 6x M6 x 20 10 Nm A135 6x M8 x 25 20 Nm A140 6x M10 x 30 40 Nm A145 6x M12 x 30 65 Nm Table 38 6 press off screws not included in th...

Page 100: ...together with fastening strips 72012 2 Attach swivel lifting eye S to the compressor casing and the lifting gear 3 Remove the compressor casing 72000 and turn it 180 4 Remove and dispose of the O ring 42012 5 Loosen counter sunk screws 79041 and remove from the compressor casing 72000 with fixing discs 79040 and diffuser 79000 Dispose of counter sunk screws 79041 If the compressor casing cannot be...

Page 101: ...ev P February 2022 Dismantling the wall insert Fig 46 Dismantling the wall insert 1 Knock the wall insert 77000 out of the compressor casing 72000 with a plastic tip hammer 2 Attach swivel lifting eye S to the compressor casing 72000 and the lifting gear 3 Lift up the compressor casing 72000 4 Remove and dispose of the O ring 77005 Page 99 149 ...

Page 102: ...ssing off the casing CAUTION Axial force of the press off tool Using the press off tool 90042 a high level of axial force can be generated If the casing is pressed off with too much force on one side the rotor can be damaged u Use the tool on both sides in alternation and make sure not to press off too hard on either side Fig 47 Press off the casing Page 100 149 ...

Page 103: ...2 03 u Mark the casing position for assembly Do not remove oil orifice if present To limit the oil flow rate through the bearing casing during operation engine under load to the admissible values an oil orifice is mandatory at the oil inlet of the bearing casing if the oil inlet pressure is 3 bar overpressure If an oil orifice is fitted in the oil inlet of the bearing casing it must not be removed...

Page 104: ...ashers 51003 together with fastening strips 51002 Fig 51 Removing cartridge group 2 3 Insert screws from service support into cartridge group 4 Secure ring nuts VRM onto the screws with washers 5 Secure the lifting gear to the ring nuts and suspension eye as shown 6 Remove the cartridge group vertically from the turbine casing 7 Turn the cartridge group into the horizontal rotor axis If the cartri...

Page 105: ...ary 2022 9 10 Removing the nozzle ring Fig 52 Removing the nozzle ring 1 If present Remove the metal C ring 51105 2 Position the fastening strips 51002 in place 3 Pull out the nozzle ring 56001 with the two extraction devices 90070 and the service support base 90012 4 Remove the lamellar sealing ring 56005 5 Remove the burst ring 57210 Page 103 149 ...

Page 106: ...l rights reserved HZTL4031_EN Rev P February 2022 9 11 Installing the cartridge group on the service support Fig 53 Installing the cartridge group on the service support 1 Remove ring nuts VRM 2 Remove service support screws 3 Fit service support 90012 according to the illustration 4 Insert the cartridge group 5 Fit the nuts Page 104 149 ...

Page 107: ...7 A145 M 0 15 0 25 0 88 1 56 Table 39 Permissible clearances A and B 1 Move the rotor to and fro up to the stop In order to obtain a correct measurement elev ate the turbine a little 2 Measure clearance A and compare it with the permissible values in the table 3 Raise the compressor and push the turbine down at the same time 4 Raise the turbine and push the compressor down at the same time 5 Measu...

Page 108: ...t shield 42400 and the turbine casing 51000 Fig 55 Nozzle ring compression PD 42001 Bearing casing 51000 Turbine casing 42400 Heat shield 56001 Nozzle ring Product Nozzle ring compression PD mm A130 M 0 15 0 15 A135 M 0 16 0 16 A140 M 0 16 0 16 A145 M 0 16 0 16 Table 40 Nozzle ring compression PD 1 Measure dimensions A B and S on cleaned surfaces 2 Calculate compression PD u If the calculated valu...

Page 109: ... in the correct slot see detail A1 A2 When doing this pay attention to correct winding of the lamellar sealing ring see detail B 2 Secure the lamellar sealing ring 56005 with adhesive tape 01 3 Place the burst ring 57210 in the turbine casing 4 Insert the nozzle ring 56001 with the cams facing downwards into the turbine casing as far as it will go Align the cams on the nozzle ring with the recesse...

Page 110: ...rtridge group and rotating it by 90 Fig 57 Lifting the cartridge group and rotating it by 90 1 Loosen and remove nuts 2 Lift the cartridge group out of the service support 90012 3 Insert the screws of the service support from above and fit ring nuts VRM with washers 4 Attach lifting gear to the ring nuts VRM 5 Lift cartridge group at the side of the ring nuts VRM and turn it into a vertical positi...

Page 111: ...e Tightening torque Nm A130 M8 25 A135 M10 45 A140 M12 75 A145 M12 75 Table 41 Tightening torque 51007 1 Coat the threads of the studs 51006 with high temperature grease 2 Align the casing position of the cartridge group to the marking 3 Lower the cartridge group into the turbine casing 4 Remove ring nuts and screws 5 Fit fastening strips 51002 with Verbus Ripp washers 51003 and hexagon nuts 51007...

Page 112: ...urst protec tion is integrated into this turbine casing insulation supplied by Turbo Sys tems For turbochargers which were ordered from Turbo Systems without insula tion or which are equipped with the insulation 02 separate burst protec tion 03 is fitted If the insulation from Turbo Systems 01 is not installed the separate burst protection 03 plus either the insulation 02 or an appropriate insulat...

Page 113: ...ys replace the O ring 77005 see section Spare parts A130 A140 1 Fit new O ring 77005 2 Install the wall insert 77000 in the compressor casing 3 Fit diffuser 79000 with fixing discs 79040 and screws 79041 Observe the tightening torque A145 1 Fit the lifting beam 90258 to the wall insert 77000 2 Fit the swivel lifting eye S to the lifting beam Secure lifting gear to the swivel lifting eye 3 Fit new ...

Page 114: ...10 70 A140 M12 105 A145 M14 170 Table 43 Tightening torque 72011 1 Fit a new O ring 42012 2 Thoroughly clean the fastening strips 72012 before assembly 3 Attach swivel lifting eyes S to compressor casing 72000 Secure lifting gear to the swivel lifting eyes 4 Install the compressor casing 72000 5 Install the fastening strips 72012 with screws 72011 Observe the tightening torque If these screws do n...

Page 115: ...ges 01 into the gap without clearance and measure simultaneously at the top N1 and the bottom N2 2 Calculate clearance N and compare it with the permissible values in the table 3 Push the feeler gauges 01 into the gap without clearance and measure simultaneously at the top R2 and the bottom R1 4 Calculate clearance R and compare it with the permissible values in the table CAUTION Clearances outsid...

Page 116: ... the air inlets Product Size Tightening torque Nm A130 M12 60 A135 M12 60 A140 M12 60 A145 M12 60 Table 45 Tightening torque 72020 1 Secure lifting gear to filter silencer 81000 2 Fit a new O ring 81010 to the filter silencer 81000 or a new O ring 82010 to the air suction branch 82000 3 Fit the filter silencer 81000 or air suction branch 82000 with the V clamp 72020 4 Observe tightening torque Pag...

Page 117: ... Rev P February 2022 9 19 Installing the gas outlet flange Fig 63 Installing the gas outlet flange 1 If present Insert the metal C ring 57003 into the turbine casing 51000 and secure with high vacuum grease 2 Install the gas outlet flange 57002 in the turbine casing 3 Measure radial clearance R see chapter Radial clearances N and R Page 115 149 ...

Page 118: ...turbine casing Copyright 2022 ABB All rights reserved HZTL4031_EN Rev P February 2022 9 20 Fitting the insulation of the turbine casing Fig 64 Fitting the insulation u Fit the insulation according to the illustration u Observe tightening torques see Table of tightening torques 119 Page 116 149 ...

Page 119: ...ning torque Nm A130 M8 20 A135 M10 40 A140 M12 65 A145 M12 65 Table 46 Tightening torque 51009 1 Insert a new gasket 61002 into the gas outlet casing 61001 2 Coat the threads of the studs 51008 with high temperature grease 3 Attach the lifting gear to the gas outlet casing 61001 and position the gas outlet casing in the correct position on the turbine casing 51000 4 If present Fit support 61301 5 ...

Page 120: ...g Copyright 2022 ABB All rights reserved HZTL4031_EN Rev P February 2022 Fitting the insulation Fig 66 Fitting the insulation u Fit the insulation according to the illustration Observe tightening torques see Table of tightening torques 119 See also 2 Table of tightening torques 119 Page 118 149 ...

Page 121: ... Nm M6 8 Nm M6 8 Nm M6 8 Nm 08 51007 M8 25 Nm M10 45 Nm M12 75 Nm M12 75 Nm 09 51009 M8 20 Nm M10 40 Nm M12 65 Nm M12 65 Nm 11 72011 M8 35 Nm M10 70 Nm M12 105 Nm M14 170 Nm 15 86505 M12 x 1 5 15 Nm M12 x 1 5 15 Nm M12 x 1 5 15 Nm M12 x 1 5 15 Nm 16a 61201 M10 40 Nm M10 40 Nm M12 65 Nm M12 65 Nm 16c 51101 M10 40 Nm M10 40 Nm M12 65 Nm M12 85 Nm 16d 51101 M10 50 Nm M10 50 Nm Table 47 Tightening tor...

Page 122: ...Position Part number A130 A135 A140 A145 16a 16b 1 M10 40 Nm M10 40 Nm M12 65 Nm M12 65 Nm 16b 2 M8 20 Nm M8 20 Nm M10 40 Nm M10 40 Nm 18 M6 10 Nm M6 10 Nm M6 10 Nm M6 10 Nm 19 M8 25 Nm M8 25 Nm M8 25 Nm M8 25 Nm 20 M10 45 Nm M10 45 Nm M10 45 Nm M10 45 Nm Table 48 Tightening torques for insulation 1 Tightening torque for attaching the insulation with integrated burst protection at the tur bine cas...

Page 123: ...le manner Wear safety gloves to protect against thermal hazards CAUTION Directives for taking out of operation Serious damage to engine or property can be caused by non compliance with the directives for blanking the turbocharger off the engine u Follow the directives of the enginebuilder If the engine has to be brought back into operation again as quickly as possible in the event of a turbocharge...

Page 124: ...ridge group Incorrect handling of a cartridge group can damage the turbocharger and cause injuries to persons u Always have repairs to the cartridge group carried out by a Turbo Sys tems service station To enable an engine to be put back into operation quickly after a turbocharger has sustained damage Turbo Systems recommends having a replacement cartridge group available in storage The defective ...

Page 125: ...ction Gas outlet casing not removed u Fit the turbine casing into the gas pipe and on the gas outlet casing again u Attach the cover plate see following section Fig 69 Fitting the cover plate u Make sure that the oil connections in the bracket are equipped with gaskets 1 Close opening in turbine casing 51000 with cover plate 01 2 Thoroughly clean the fastening strips 51002 before assembly 3 Coat t...

Page 126: ...manufac tured by the operating company according to the following drawing Material General structural steel in accordance with DIN EN 10025 2 Fig 70 Cover plate drawing Product B1 0 5 B2 B3 B4 0 2 B5 B6 B7 ØD1 0 2 ØD2 R1 M A130 65 7 60 130 11 7 1 4 150 35 7 227 7 17 105 M8 A135 79 6 80 155 14 2 1 6 180 39 6 271 7 21 125 M8 A140 98 2 102 190 17 2 2 0 220 48 2 332 5 25 153 M10 A145 116 8 120 226 20 ...

Page 127: ... corrosion Preparations for mothballing WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or con tact with them may be harmful to health u Do not breathe in these substances and avoid contact with the skin u Ensure proper ventilation u Observe the information in the material safety data sheet for the operat ing materials and suppli...

Page 128: ...station and stored separately The turbocharger is completely removed either as a whole unit or in individual parts For the measures always necessary for preparing the turbocharger parts for mothballing see section Taking the engine out of operation for up to 12 months subsection Preparations for mothballing If the turbocharger remains attached to the engine see section Taking the engine out of op ...

Page 129: ...ustomer of the presence of such substance s with sufficient information available to the supplier RoHS2 Directive 2011 65 EC in English only The EU Directive 2011 65 EC recast restricts the use of certain hazardous substances in electrical and electronic equipment RoHS2 Products and related accessories manufac tured by Turbo Systems Switzerland Ltd do not fall within the Scope of RoHS2 due to thei...

Page 130: ...ar a respiratory mask to protect against dusts Wear safety gloves to protect against mechanical hazards Disposal must be environmentally compatible professional and in compliance with locally applicable regulations The turbocharger consists largely of metal cast iron materials steel nickel steel alloys alu minium and bearing brass Further components are Non metallic materials filter components of ...

Page 131: ...en into account in this document contact an Turbo Systems Service Station u Dispose of placed and unusable parts in an environmentally friendly and professional manner in accordance with the local regulations u Dispose of the packaging of new parts in an environmentally friendly and professional manner in accordance with the local regulations 13 2 Required customer spare part set 97070 For the wor...

Page 132: ...00 42194 p 42047 p 42190 42189 p 42201 42188 p p pre assembled Available within the spare part set if provided HZTL443463 Mod A Part no Designation 10900 Cartridge complete 42012 O ring 42047 p Screw plug 42166 Screw 42167 Cover 42168 Hexagon head screw 42169 Hexagon nut 42170 Insulation 42171 Safety washer 42172 Hexagon head screw 42188 p Hexagon head screw 42189 p Gasket 42190 Expansion bush 421...

Page 133: ...p 42047 p 42189 p 42190 42201 42188 p p pre assembled Available within the spare part set if provided HZTL443464 Mod A Part no Designation 10900 Cartidge complete 42012 O ring 42047 p Screw plug 42166 Screw 42167 Cover 42188 p Hexagon head screw 42189 p Gasket 42190 Expansion bush 42194 p Gasket 42196 Orifice oil inlet 42197 Safety ring 42201 Clamping nut Table 52 Spare parts Cartridge water coole...

Page 134: ...7 TW04 51102 TW03 51106 TW04 51101 TW03 p pre assembled Available within the spare part set if provided HZTL443204 Mod L Part no Designation 51000 Turbine casing 51002 Fastening strip 51003 Verbusripp washer 51006 Stud 51007 Hexagon nut 51008 Stud 51009 Hexagon nut 51010 Insulation TW02 51027 p Screw plug 51101 Hexagon head screw 51102 Tension washer 51103 Hexagon head screw 51105 Metal C ring 511...

Page 135: ...lustrations Copyright 2022 ABB All rights reserved HZTL4031_EN Rev P February 2022 Part no Designation 56001 Nozzle ring 56005 Lamellar sealing ring 57002 Gas outlet flange 57003 Metal C ring 57210 Burst ring Table 53 Spare parts Turbine casing 1 inlet Page 133 149 ...

Page 136: ...1 51010 TW02 51101 51500 p pre assembled Available within the spare part set if provided HZTL443220 Mod H Part no Designation 51000 Turbine casing 51002 Fastening strip 51003 Verbusripp washer 51006 Stud 51007 Hexagon nut 51008 Stud 51009 Hexagon nut 51010 Insulation TW02 51027 p Screw plug 51101 Hexagon head screw 51102 Tension washer 51105 Metal C ring 51301 Cleaning nozzle 51302 Gasket 51303 Sc...

Page 137: ...M 13 Spare parts 13 3 Spare part Illustrations Copyright 2022 ABB All rights reserved HZTL4031_EN Rev P February 2022 Part no Designation 57003 Metal C ring 57210 Burst ring Table 54 Spare parts Turbine casing 2 inlets Page 135 149 ...

Page 138: ...TL4031_EN Rev P February 2022 Gas outlet casing axial GH02 61001 61002 GH02 GHV03 61001 GH02 GHV08 61001 Available within the spare part set only if provided HZTL443467 Mod A Part no Designation 61001 Gas outlet casing 61001 Gas outlet casing GHV03 61002 Gasket Table 55 Spare parts Gas outlet casing axial Page 136 149 ...

Page 139: ... 61201 61100 61001 61005 p 61205 61008 61002 p pre assembled Available within the spare part set if provided HZTL443466 Mod B Part no Designation 61001 Gas outlet casing 61002 Gasket 61005 p Screw plug 61008 Gasket 61100 Insulation gas outlet casing 61200 Burst protection 61201 Hexagon head screw 61202 Tension washer 61205 Protective grid 61301 Support Table 56 Spare parts Gas outlet casing radial...

Page 140: ... p pre assembled Available within the spare part set if provided HZTL443201 Mod E Part no Designation 72000 Compressor casing 72005 p Screw plug 72006 p Gasket 72010 Verbus locking disc 72011 Hexagon head screw 72012 Fastening strip 72020 V clamp 72060 Insulation 72061 Insulation sleeve 72062 Hexagon head screw 72080 Warning plate 77000 Wall insert 77005 O ring 79000 Diffuser 79040 Fixing washer 7...

Page 141: ...37 81266 81000 81136 81270 81271 p pre assembled Available within the spare part set HZTL443469 Mod A Part no Designation 81000 Filter silencer complete 81005 Screw plug 81006 Gasket 81010 O ring 81135 Silencer body 81136 Absorption segment 81137 Cover sheet metal 81170 Screw plug 81171 Gasket 81265 Filter ring 81266 Cover grid 81270 Tension band 81271 Lock Table 58 Spare parts Filter silencer Pag...

Page 142: ...L4031_EN Rev P February 2022 Air suction branch axial 82010 82000 82006 82005 82008 82007 Available within the spare part set HZTL443013 Mod D Part no Designation 82000 Air suction branch 82005 Screw plug 82006 Gasket 82007 Screw plug 82008 Gasket 82010 O ring Table 59 Spare parts Air suction branch axial Page 140 149 ...

Page 143: ...4031_EN Rev P February 2022 Air suction branch radial 82010 82005 82006 82000 82008 82007 Available within the spare part set HZTL443012 Mod D Part no Designation 82000 Air suction branch 82005 Screw plug 82006 Gasket 82007 Screw plug 82008 Gasket 82010 O ring Table 60 Spare parts Air suction branch radial Page 141 149 ...

Page 144: ... 42188 p p pre assembled Available within the spare part set if provided HZTL443373 Mod E Part no Designation 42001 Bearing casing 42005 Sealing bush 42006 Spring type pin 42008 Socket screw 42047 p Screw plug 42188 p Hexagon head screw 42189 p Gasket 42194 p Gasket 42196 Orifice oil inlet 42197 Safety ring 42301 Bearing cover 42302 Piston ring 42305 O ring 42306 O ring 42400 Heat shield 42401 Met...

Page 145: ...are part set if provided HZTL443374 Mod E Railway and Traction Application Part no Designation 42001 Bearing casing 42005 Sealing bush 42006 Spring type pin 42008 Socket screw 42047 p Screw plug 42056 Wear protection ring 42140 p Gasket 42141 p Core hole cover 42172 p Socket screw 42188 p Hexagon head screw 42189 p Gasket 42194 p Gasket 42196 Orifice oil inlet 42197 Safety ring 42301 Bearing cover...

Page 146: ...ithin the spare part set if provided HZTL443465 Mod D Part no Designation 21000 Turbine 21002 Piston riing 21006 Piston ring 21011 Sealing bush for shaft 25000 Compressor wheel 32101 Radial bearing CE 32102 Radial bearing TE 32103 Thrust ring 32104 Thrust bearing 32109 Sealing disc 32110 Bearing flange CE 32111 Auxiliary bearing 32112 Bearing flange TE 32113 Socket screw 32114 Socket screw 32167 S...

Page 147: ...red 90000 Designation Quantity 90012 Service support 1 90013 Plastic insert 1 90258 A145 Lifting beam 1 90230 Socket screw 2 90042 Press off tool 1 90070 Extraction device 1 Table 64 Customer tool set 90000 Tool sets can be ordered from any Turbo Systems service station The following specifica tions must be included in the order Turbocharger type Designation and part number of the tool set Page 14...

Page 148: ... the speed sensor 54 Fig 29 Noise insulation bellows 56 Fig 30 Replacing the protective grid 59 Fig 31 Carrying out wet cleaning of compressor 67 Fig 32 Carrying out wet cleaning of turbine 71 Fig 33 Cleaning the filter silencer 73 Fig 34 Compressor end non rotating parts 75 Fig 35 Turbine end non rotating parts 76 Fig 36 Soaking the turbine end 79 Fig 37 Swivel lifting eye example 90 Fig 38 Starp...

Page 149: ... 63 Installing the gas outlet flange 115 Fig 64 Fitting the insulation 116 Fig 65 Installing the gas outlet casing 117 Fig 66 Fitting the insulation 118 Fig 67 Tightening torques 119 Fig 68 Tightening torques for insulation 120 Fig 69 Fitting the cover plate 123 Fig 70 Cover plate drawing 124 Page 147 149 Page 147 149 ...

Page 150: ...able 24 Malfunctions during operation Exhaust gas temperature too high 84 Table 25 Malfunctions during operation Charge air pressure too low 84 Table 26 Malfunctions during operation Charge air pressure too high 85 Table 27 Malfunctions during operation Engine performance losses 85 Table 28 Malfunction Turbocharger surging 86 Table 29 Malfunction Sporadic surge blows 86 Table 30 Malfunctions when ...

Page 151: ...al 137 Table 57 Spare parts Compressor casing 138 Table 58 Spare parts Filter silencer 139 Table 59 Spare parts Air suction branch axial 140 Table 60 Spare parts Air suction branch radial 141 Table 61 Spare parts Bearing casing oil cooled 142 Table 62 Spare parts Bearing casing water cooled 143 Table 63 Spare parts Rotor and bearing parts 144 Table 64 Customer tool set 90000 145 Page 149 149 Page ...

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Summary of Contents for HT612544

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ABB HT612544, Operation Manual, Page: 4 / 152

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Summary of Contents for HT612544

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