ABB XAC19590 Operation Manual Download

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Operation Manual / 4 Product description / A200-L

2 Removal and installation / 2.2 Removing the turbocharger

HZTL4036_EN

Revision M

August 2018

Fig. 4: Fitting lifting gear to turbocharger

Loosen fixing screws on compressor-end and turbine-end foot.

Lift turbocharger from engine and put down in a suitable location.

Cover oil connections.

Page

108

Summary of Contents for XAC19590

Page 1: ...arging Operation Manual A265 L59 XAC19590 English Original Operation Manual Chapter Document ID 1 Introduction HZTL4005_EN_F 2 Safety HZTL4024_EN_D 3 Safety data sheet XAC19590 4 Product description HZTL4036_EN_M ...

Page 2: ...als and the corresponding operating limits in chapter 3 are jointly defined with the enginebuilder This information is specific to the product Non observance of the recommended replacement intervals and the operating limits increases the risk of unpre dictable component failures ...

Page 3: ... contents Copyright 2017 ABB All rights reserved HZTL4005_EN Revision F May 2017 Introduction 1 Introduction 2 1 1 Purpose of the manual 2 1 2 Symbols definitions 3 1 3 Storage of new turbochargers and spare parts 5 1 4 Contact information 7 ...

Page 4: ...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 5: ...n of mandatory signs 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 ABB Turbo Systems ABB Turbo Systems Ltd is identified as ABB Turbo Systems in this document Official service stations of ABB Turbo Systems Offici...

Page 6: ...Meaning Pictogram Meaning Tighten with specified torque Affix Tighten over specified tighten ing angle Measure Hand tight tighten without tools Note Oil Visually inspect Apply screw locking paste e g Loctite Please note text for numbered work step Apply high temperature grease See document Apply other paste in accord ance with specifications Dispose of in an environmentally compatible professional...

Page 7: ...ous 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 For more information see www branopac com Wear safety gloves to protec...

Page 8: ... repackaged by an ABB Turbocharging Service Station u Check the package for damage If the package is damaged the turbocharger or cartridge group must be checked and repackaged by an ABB Turbocharging Service Station After every 3 years the following steps must be carried out by an ABB Turbocharging Service Station Checking the component Replacing the desiccant Repackaging the component NOTICE Repl...

Page 9: ...ights reserved HZTL4005_EN Revision F May 2017 1 4 Contact information Contact information for the ABB Turbocharging Service Stations is available online u Scan the QR code to access our website ABB Turbo Systems Ltd Bruggerstrasse 71a CH 5401 Baden Switzerland www abb com turbocharging Page 7 7 ...

Page 10: ......

Page 11: ... 2 1 3 Definition of mandatory signs 3 1 4 Definition of safety instructions 3 1 5 Intended use 4 1 6 Warning plates on the turbocharger 5 1 7 Turbocharger rating plate 6 1 8 Periodic check of the pressure vessels 7 1 9 Lifting of loads 8 1 10 Prerequisites for operation and maintenance 9 1 11 Hazards during operation and maintenance 10 1 12 Safe operation 12 1 13 Safe maintenance 13 ...

Page 12: ...ence of insufficient 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 a...

Page 13: ...ry mask to protect against Dusts Gases Safety helmet Ear protection Table 2 Personal protective equipment to be worn specific to the respective task 1 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 fa...

Page 14: ...e data are given on the rating plate ABB accepts no liability and rejects all warranty claims for any non intended uses WARNING Unapproved operation Any operation of the turbocharger outside of its operating limits can be haz ardous to personnel u Only operate the turbocharger within the operating limits u Only trained personnel must operate the turbocharger The intended use of the turbocharger in...

Page 15: ... must always be present in the intended locations and must be legible Fig 1 Warning plate If warning plates are not present in the intended locations or are not legible they must be replaced with new warning plates The necessary information can be found in the Operation Manual Chapter 4 Product description Turbochargers supplied to the enginebuilder without insulation must be equipped later with w...

Page 16: ...therwise agreed with the en ginebuilder 02 Turbocharger operating limits during operation Recommended replacement intervals of turbocharger components 03 Replacement 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 0...

Page 17: ...nMmax and tMmax is not permitted Non observance of the recommended replacement intervals increases the risk of unpredict able component failures Locations of the rating plates The locations of the rating plates are defined in the Operation Manual Chapter 4 Product description 1 8 Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging such as those for wet or dry clea...

Page 18: ... against mechanical hazards Wear safety helmet Fig 3 Attachment of loads on the crane hook Fig 4 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 descri...

Page 19: ...e 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 tur...

Page 20: ...is running always 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 WA...

Page 21: ...gloves to protect against thermal hazards Hazards due to rotating parts WARNING Physical hazards Contact with rotating parts can cause severe injury The turbocharger must never be used without the filter silencer or the air suction branch With the engine stopped the rotor can rotate due to the stack draught alone u Operate the turbocharger in compliance with the specifications u Secure the rotor a...

Page 22: ...rical installations u Do not carry out any tests with regard to insulation resistance or voltage on the electrical components 1 12 Safe operation Mechanical hazards during operation During standard operation no mechanical hazards are caused by the turbocharger itself if it has been properly installed Safety during commissioning and operation u Visually inspect your working environment before start...

Page 23: ...ou 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 platforms for work above body he...

Page 24: ...fety during disassembly assembly maintenance and repair u Observe the procedures for set up service and inspection work and the inspection inter vals u Inform the operating staff before starting any service or repair work Make sure the en gine is not started while work is being conducted on the turbocharger u Before taking off any cover or removing any guard from the turbocharger switch off the en...

Page 25: ... 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 materials and supp...

Page 26: ...on in 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 c...

Page 27: ...n Manual A265 L59 Safety data sheet Page 1 1 Safety data sheet Copyright 2018 ABB All rights reserved XAC19590 September 2018 A265 L59 XAC19590 A265 L59 XAC19590 347 550 347 520 2018000083 2018 2600 36 100 100 ...

Page 28: ......

Page 29: ...ioning after taking out of operation 15 4 Monitoring during operation 16 4 1 Oil pressure oil temperature 16 4 2 Admissible air inlet temperature 18 4 3 Turbocharger speed 18 4 4 Low pressure measurement at the filter silencer 21 5 Operation and service 22 5 1 Noise emission 22 5 2 Service work 23 5 3 Expected replacement intervals 27 5 4 Flexible turbocharger cut out 28 5 5 Stopping the engine 29...

Page 30: ...et casing nozzle ring insulation A275 L and smaller 73 8 10 Fitting the gas inlet casing nozzle ring A280 L 77 8 11 Axial clearance A after assembly 81 8 12 Fitting diffuser wall insert 82 8 13 Fitting the filter silencer 85 8 14 Table of tightening torques 88 9 Taking a turbocharger out of operation 90 9 1 Possible emergency repairs 90 9 2 Shutting off oil supply to defective turbocharger 90 9 3 ...

Page 31: ...uestions regarding a design variant see Contact information at www abb com turbocharging Accuracy of illustrations The illustrations in this document are general in nature and intended for ease of understand ing Differences in detail are therefore possible 1 2 Registered trademarks The trademarks of outside companies are used in this document These are marked with the symbol 1 3 Related documents ...

Page 32: ...ugust 2018 1 4 Layout and function of the turbocharger Fig 1 Layout and function of the turbocharger 01 Filter silencer 08 Gas inlet casing 02 Thrust bearing 09 Bearing casing 03 Radial plain bearing 10 Diffuser 04 Radial plain bearing 11 Compressor wheel 05 Gas outlet casing 12 Compressor casing 06 Turbine wheel 13 Air outlet silencer option 07 Nozzle ring Page 4 108 ...

Page 33: ... air passes through the filter silencer 01 to the compressor wheel 11 The air then flows through the diffuser 10 and exits the turbocharger through the compressor cas ing 12 An air outlet silencer 13 is optionally available If installed this will reduce the amount of noise generated by the components at the outlet side after the compressor cas ing The rotor runs in two radial plain bearings 03 04 ...

Page 34: ...lates are not present in the designated locations or not readable proceed as fol lows u Order new warning plates from ABB Turbocharging 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 e...

Page 35: ... the rating plates Copyright 2018 ABB All rights reserved HZTL4036_EN Revision M August 2018 1 6 Locations of the rating plates Fig 3 Locations of the rating plates One rating plate 01 each is attached on the left and the right side of the turbocharger bear ing casing Page 7 108 ...

Page 36: ... Weights of the complete turbocharger Product Weight kg A265 L 2600 A270 L 3800 A275 L 6300 A280 L 8700 Table 2 Weights A200 L with filter silencer 2 2 Removing the turbocharger WARNING Risk of tipping If the turbocharger is not sufficiently supported or not supported at all dur ing removal and installation it may tip over and cause severe injury to per sonnel or accidents resulting in fatalities ...

Page 37: ...urbocharger Copyright 2018 ABB All rights reserved HZTL4036_EN Revision M August 2018 Fig 4 Fitting lifting gear to turbocharger u Loosen fixing screws on compressor end and turbine end foot u Lift turbocharger from engine and put down in a suitable location u Cover oil connections Page 9 108 ...

Page 38: ...e turbocharger on the bracket Fig 5 Placing the turbocharger on the bracket u Remove covers from the oil connections u Align turbocharger and place on engine bracket u Tighten fixing screws Steps for fastening the turbocharger 11 while doing this only slightly loosen the lifting gear u Remove lifting gear from suspension eyes of the bearing casing u Connect cable to speed sensor u Connect all gas ...

Page 39: ...sion a compressor end a height of turbocharger foot a Dimension a turbine end a height of turbocharger foot F spacer sleeve D Value b Hole in bracket Dimension c Thread length 1 5 x nominal thread diameter Coefficient of friction 0 12 lightly oiled Table 3 General information about fastening the turbocharger Compressor end foot Fig 6 Compressor end foot u Tighten the foot fixing screws or nuts dia...

Page 40: ...M33 136 1500 Table 4 Tightening torques foot screws Angle controlled tightening Product Thread size Height a of foot mm Pre tightening torque Nm Tightening angle for height a DEG Additional tightening angle for every 10 mm of additional screw length b DEG A265 L M22 86 120 30 3 7 A270 L M27 100 220 30 3 1 A275 L M30 120 300 30 2 6 A280 L M33 136 400 35 2 6 Table 5 Tightening angle foot screws Pinn...

Page 41: ...l with a filter mesh width of 0 050 mm is sufficient for the tur bocharger 3 1 3 Oil pressure Comply precisely with the oil pressure before the turbocharger for trouble free operation If the oil pressure at the inlet of the turbocharger is too high it can be reduced with a throttle valve The throttle valve is normally already fitted on the turbocharger and has been correctly set by the enginebuild...

Page 42: ...tem 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 legible u Check whether the protective sheets have been removed from new warning plates 3 2 3 Check...

Page 43: ... assembly can liquefy or vaporise and escape as oily fluids during the initial hours of operation Continual escape of an oily fluid indicates an oil leak u If there is a leak contact an ABB Turbocharging Service Station 3 3 Commissioning after taking out of operation If present u Remove cover plates blind flanges from the compressor casing the gas inlet and the gas outlet General u Check the exhau...

Page 44: ...e at the inlet of 30 70 C 0 8 2 5 Admissible for normal operation with an oil temperature range at the inlet of 70 85 C 0 8 2 0 Admissible during engine warm up 0 8 4 0 Temporarily admissible 1 h alarm 0 6 0 8 Not admissible emergency stop 0 0 0 6 Admissible during pre lubrication and post lubrication engine stopped 0 2 0 6 Table 6 Lubricating oil pressure oil inlet Lubricating oil temperature at ...

Page 45: ...il outlet C Admissible 45 110 Admissible 85 130 Temporarily admissible alarm 45 110 Temporarily admissible alarm 85 130 Not admissible stop engine 45 120 Not admissible stop engine 85 140 Table 8 Lubricating oil temperature at the outlet If the turbocharger was operated for a longer period of time outside of the admissible range ABB Turbo Systems recommends to have the turbocharger inspected by an...

Page 46: ...peed of the turbocharger must be permanently monitored CAUTION Do not use cables as a climbing aid If you pull the speed measurement cables too hard contacts can be pulled out u Do not tension the speed measurement cables 4 3 2 Layout and overview Fig 8 Layout and overview of the speed measurement system 86505 Speed sensor 86528 Tachometer 86506 O ring 42047 Screw plug 86515 Cable connector 32109 ...

Page 47: ...nt at which the maximum tur bocharger speed does not exceed 70 of nBmax u If the engine cannot be stopped 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...

Page 48: ...speed sensor is designed with a sealing lip and does not require a sealing disc for as sembly Fig 9 Replacing the speed sensor Part number A265 L A270 L A275 L A280 L 86505 M18x1 5 150 Nm M18x1 5 150 Nm M18x1 5 150 Nm M27x2 320 Nm Table 9 Tightening torques 86505 u Reduce the engine performance to idling and then stop the engine Pay attention to post lubrication Stopping the engine 29 u Switch off...

Page 49: ...tor for the cal culation of the turbocharger efficiency When using a filter mat An increased pressure loss indicates an increase in the fouling of the filter material 4 4 2 U tube manometer at the filter silencer Fig 10 U tube manometer at the filter silencer 81000 Filter silencer 81050 U tube manometer A mm H2O Pressure loss pressure difference If the turbocharger is operated at maximum engine po...

Page 50: ... distance of 1 meter from the turbocharger The highest value of the emission sound pressure level1 reaches a maximum of 105 dB A near the filter silencer The following prerequisites must be fulfilled with regard to the tur bocharger 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 ins...

Page 51: ...ecks Service work enables the detection and rectification of changes to the tur bocharger and ensures full operability of the turbocharger CAUTION Service intervals Any service work on the turbocharger that is 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 Shortened service intervals E...

Page 52: ... of deviations determine the cause 5 2 2 Service work at 100 hours after commissioning u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en gine is stopped 5 2 3 Service work on turbocharger every 18000 hours It is recommended to have this service work and these checks carried out by an ABB Tur bocharging Service Station Damaged and worn out parts must be r...

Page 53: ...u Remove the filter silencer u Clean filter silencer and check for damage u Dismantle the wall insert u Check axial clearance A u Clean wall insert diffuser and compressor casing and check for damage u Remove the gas inlet casing and dismantle the nozzle ring and cover ring u Clean the nozzle ring and cover ring and check for damage u Dismantle inspect and balance the rotor u Replace the plain bea...

Page 54: ...wing operating data and measured values must be entered regularly into the engine logbook of the enginebuilder Performance and speed of the engine Speed of the turbocharger Air intake temperature Exhaust gas temperature before and after the turbine Pressure of the charge air Pressure loss in the charge air cooler Lubricating oil pressure and lubricating oil temperature Pressure loss in the filter ...

Page 55: ...ing the non rotating components exposed to hot gas A decisive role is played by various influencing parameters which in extreme cases can drastically shorten 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 Turbocharger part Operation with HFO Gas inlet casing 50...

Page 56: ...e turbochargers can be operated with one turbocharger switched off The flexible switch on or switch off of a turbocharger is re ferred to as a flexible turbocharger cut out In flexible systems slide valves or flaps are in stalled by the enginebuilder before the gas inlet and after the air outlet of the turbocharger Depending on the version of the system the turbocharger can be switched off or on m...

Page 57: ...n CAUTION Automatic switching of the flaps During automatic flap control there is a risk of the turbocharger rotating opposite the intended direction of rotation if the air outlet flap is open fur ther than the gas inlet flap during the switching process This can lead to damage on the turbocharger u The turbocharger should only be switched on or off below charging pres sures of 0 3 bar u Close the...

Page 58: ...ved HZTL4036_EN Revision M August 2018 6 Periodic maintenance 6 1 Foreword to maintenance Maintenance work includes regular visual controls and cleaning operations which are inten ded to ensure the trouble free functioning of the turbocharger Described maintenance points Filter silencer Compressor Turbine and nozzle ring Page 30 108 ...

Page 59: ...g the filter silencer Filter silencer with tension band Fig 12 Layout and overview of filter silencer 81126 Lock 81266 Cover grid 81135 Body of filter silencer 81268 Connecting strip 81136 Absorption segment 81270 Tension band 81137 Sheet metal covering 81271 Lock 81265 Filter ring if present 81400 Water connection E Insert unit absorption segment sheet metal covering fitted Page 31 108 ...

Page 60: ... and connecting strips 81268 see Fig 12 Layout and overview of fil ter silencer 31 u Pull out insert units E u Bend up the sheet metal coverings 81137 and remove the absorption segments 81136 u Clean the absorption segments 81136 When cleaning note that the absorption segments may only be cleaned lightly with pres surized air with a soft brush or a moist cleaning cloth Otherwise there is a danger ...

Page 61: ...on M August 2018 6 3 Changing the filter strip on the filter silencer casing This chapter applies only to turbochargers with filter silencer casing The filter ring 81265 is replaced with the filter silencer installed Fig 13 Dismantling filter ring circumferential part u Dismantle circumferential part 9 Fig 14 Opening filter ring lock u Open the lock of the filter ring 81265 Page 33 108 ...

Page 62: ...Fig 15 Attaching new filter ring u Attach the new filter ring 81265 on the filter ring to be replaced so they overlap Fig 16 Fitting new filter ring u Pull on the old filter ring until the new filter ring is completely wrapped around the filter silencer u Undo the connection between the new and the old filter ring u Fasten the newly installed filter ring 81265 then fit circumferential part 9 Page ...

Page 63: ... Increased rotor unbalance Periodic cleaning of the compressor during operation prevents or delays any major increase in contamination But it never replaces the regular service work where the turbocharger is completely dismantled and the compressor is mechanically cleaned Cleaning interval The interval between the cleaning cycles depends greatly on the operating conditions Cleaning should normally...

Page 64: ...the compressor stage during operation water is injected upstream of the com pressor wheel The water does not act as a solvent The coating is removed by the mechanical action of the impacting droplets The procedure is perfectly suitable provided that the contamination has not progressed too far Cleaning several turbochargers If several turbochargers are installed on an engine it is recommended to c...

Page 65: ...g damage u Always wear ear protection when carrying out wet cleaning on the com pressor Wear ear protection Fig 17 Overview of wet cleaning of compressor 81000 Filter silencer A Can 81126 Lock B Filler opening u Remove insulation from flange of filter silencer 81000 if present u Unscrew lock 81126 u Measure volume of water according to the following table u Pour this water into a clean can A u Car...

Page 66: ...70 L 2 0 A275 L 3 0 A280 L 3 0 Table 12 Volume of water per cleaning process The filling time is 4 15 seconds Checking the filter plug The filter plug only needs to be checked in the turbocharger version with a cast filter silen cer See chapter Design variants 58 Fig 18 Filter plug view Disassembly and checking of the filter plug 81125 is required if 20 seconds after the clean ing process water is...

Page 67: ...gh level of contamina tion can lead to intolerably high rotor unbalance Despite periodic cleaning during operation experience shows that overhauls during which the turbine and nozzle ring or VTG are mechanically cleaned cannot be omitted Cleaning method The turbine and the nozzle ring are cleaned during operation using the dry cleaning method This cleaning method is tested and approved by ABB Turb...

Page 68: ...eaning device Fig 19 Overview of dry cleaning device 11 Granulate container 51702 16 Protection valve closed 51713 12 Cover cap 51703 17 Pressurised air valve venting 51704 13 Pressurised air supply 4 7 bar 18 Plate 14 Piping 19 Cleaning instructions 51717 15 On Off valve closed 51705 20 Gas inlet casing insulated CAUTION Protecting the pressurised air system u Protect the pressurised air system a...

Page 69: ...y remove the cover cap 12 u Fill the specified amount of granulate into the container 11 u Screw on and tighten the cover cap 12 u Open the combined pressurised air valve pressure release valve 17 down lever posi tion u Open the protection valve 16 u Open the on off valve 15 for cleaning the turbine for 3 4 minutes u Close the on off valve 15 u Close the protection valve 16 u Set the combined pres...

Page 70: ...r dry cleaning Hard granulated materials such as natural core granulates Soft blast media Activated carbon particles The average grain size of the cleaning granulate must be between 1 2 and 2 0 mm The specific weight of the cleaning granulate must not exceed 1 2 kg dm3 Amount of granulate per turbocharger Product Quantity dm3 A265 L 1 0 A270 L 1 5 A275 L 2 0 A280 L 2 5 Table 14 Cleaning parameters...

Page 71: ...water due to other causes the gas outlet casing can be drained Fig 20 Drain pipe diagram 01 Drain pipe A Position 1 02 Drain cock B Position 2 03 Drain 04 Air line from compressor casing u On the drain pipe 01 set the drain cock 02 to position 1 A If the drain pipe 01 is blocked u Set the drain cock 02 to position 2 B and clean the drain pipe 01 with air from the compressor casing 04 If cleaning w...

Page 72: ...vice Sta tion Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Contact enginebuilder Table 16 Malfunctions when starting Vibrations Rubbing of rotating parts Normal behaviour not a malfunction Turbocharger A slight amount of uniform wear at the circumference of the rotor components caused by slight local rubbing against adjacent components is permitted This causes the co...

Page 73: ...f in an environmentally compatible manner Wear safety gloves to protect against thermal hazards Possible causes Remedy Turbocharger Axial clearance of the rotor excessive Contact an ABB Turbocharging Service Station Engine Oil filter heavily contaminated Clean Oil pump in lubricating system defective Check replace Manometer displays incorrectly Replace manometer Table 18 Malfunctions during operat...

Page 74: ... high Check clean cooling system Insufficient ventilation Improve ventilation Table 20 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 Turbocharger Manometer display not correct Replace manometer Supply pipe to manometer not sealed Repair leak Filter silencer con...

Page 75: ... 3 Surging of the turbocharger Surging of the turbocharger Possible causes Remedy Turbocharger Filter silencer or diffuser contamin ated Clean Periodic maintenance 30 Heavy dirt deposits in the turbine or in the nozzle ring Engine Protective grating in front of the tur bocharger contaminated or damaged Clean replace Charge air cooler Cooler contaminated Clean Charge air duct blocked Table 23 Surgi...

Page 76: ...ation of the turbocharger A surge blow is accompanied by a loud bang and escape of hot air from the filter silencer 7 4 Malfunctions when stopping Runout noises Possible causes Remedy Turbocharger Turbocharger contaminated Clean Bearing damaged Contact an ABB Turbocharging Service Station Rotor rubbing Foreign object in the turbocharger Table 24 Malfunctions when stopping Runout noises Shortened r...

Page 77: ...tion electronics This problem will be remedied by removing the gasket Sensor defective Contact ABB Turbocharging Service Station Measured speed too high Contamination of the sensor tip As the sensor tip is magnetic it can attract material particles This reduces the distance to the auxiliary bearing which can lead to amplification of the noise component and therefore to false triggering Dismantle t...

Page 78: ...n u Mark the casing position for assembly Identification of the assembly devices Not all assembly devices are marked with a part number Identification is guaranteed by the tool list This list is enclosed with the toolbox WARNING Servicing the assembly devices Assembly devices must be checked for damage before and after use u Visually inspect for corrosion cracks deformation and wear u Damaged asse...

Page 79: ...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 80: ... assembly weights Position Assembly A265 L A270 L A275 L A280 L 01 Filter silencer 350 470 850 1150 02 Wall insert 300 450 760 1070 03 Diffuser 40 60 110 160 04 Compressor casing 400 620 1030 1350 05 Cover ring 30 50 75 90 06 Nozzle ring 10 20 25 50 07 Gas inlet casing 180 240 380 520 Table 27 Weights of assemblies kg The total weight of the complete wall insert is made up of the wall insert and d...

Page 81: ...embly Assembly of the filter silencer casing This chapter applies only to turbochargers with filter silencer casing Only the assembly of the filter silencer casing is described in detail The disassembly must be carried out in reverse order of the assembly Fig 22 Overview of filter silencer casing disassembly and assembly 01 02 Bottom part 03 04 07 08 Side part 05 06 09 Circumferential part 10 11 F...

Page 82: ...d of filter silencer casing assembly Only this way is it possible to fit all the parts u Do not tighten the screws during assembly Fig 23 Fitting filter silencer casing 1 u Fit the bottom part 01 to the filter silencer 81000 with screws A and B NOTICE Screw A The location of screw A serves as a reference for the correct assembly of the filter silencer casing u Before disassembling the bottom part ...

Page 83: ...vision M August 2018 Fig 24 Fitting filter silencer casing 2 u Fit the bottom part 02 with the screws on the filter silencer Fig 25 Fitting filter silencer casing 3 u Fit the side parts 03 and 04 with the screws on the filter silencer and on the bottom part u Fit the side parts 07 and 08 with the screws on the filter silencer on the bottom part and on the side parts 03 04 Page 55 108 ...

Page 84: ...served HZTL4036_EN Revision M August 2018 Fig 26 Fitting filter silencer casing 4 u Insert the flanges 10 and 11 laterally between the side parts and fit the screws Fig 27 Fitting filter silencer casing 5 u Fit the circumferential part 05 with the screws u Fit the circumferential part 06 with the screws u Fit the circumferential part 09 with the screws Page 56 108 ...

Page 85: ...ts to the filter silencer Screws for fastening the individual parts M10 30 Nm M8 25 Nm Table 29 Tightening torques filter silencer screws u Tighten all screws of the bottom parts 01 and 02 u Tighten all screws of the side parts 03 04 07 08 and the flanges 10 11 u Tighten all screws of the circumferential parts 05 06 09 Bellows Fig 28 Fitting the bellows u Fit bellows C with frame F screws S and nu...

Page 86: ...cer variants Welded filter silencer Cast filter silencer The filter silencers differ in terms of the fixing eyelets for the lifting gear The relevant vari ant must be taken into consideration for disassembly and assembly 8 4 2 Dismantling the filter silencer welded u Dismantle the insulation if necessary Fig 29 Dismantling the filter silencer 1 Attach lifting gear to the eyelets of the filter sile...

Page 87: ...ed HZTL4036_EN Revision M August 2018 8 4 3 Dismantling the filter silencer cast u Dismantle the insulation if necessary Fig 30 Dismantling the filter silencer 1 Attach the lifting gear to the front lug and rear eyelet of the filter silencer 81000 2 Loosen nuts 72004 and remove with washers 72003 3 Remove and put down filter silencer Page 59 108 ...

Page 88: ...11 and leave 2 3 of the thread length screwed into the com pressor casing 72000 2 Loosen and remove the remaining screws 72011 3 Use the press off screws 90900 to press off the wall insert 77000 from the com pressor casing 72000 until the lifting device 90190 can be fitted 4 Fit shackle 90195 with lifting gear on P1 of lifting device 90190 5 Fit lifting device 90190 with crane on upper area of wal...

Page 89: ...6_EN Revision M August 2018 Fig 32 Moving out wall insert 7 Remove screw 72011 8 Carefully move out the wall insert 77000 with diffuser 79000 9 Remove the O ring 77040 Fig 33 Putting down wall insert u Put down wall insert 77000 with diffuser 79000 in horizontal position and use appro priate supports to prevent it from falling over and rolling away Page 61 108 ...

Page 90: ...sonnel and even to fatal accidents u Check the position of the support and correct if necessary WARNING Risk of tipping If the wall insert is not tilted it must be put down correctly Tipping of the wall insert may lead to serious injuries to persons or even to fatal accidents u If the wall insert is not tilted ensure that it is fixed correctly see Dis mantling wall insert Fig 34 Putting down wall ...

Page 91: ...ling wall insert and diffuser Copyright 2018 ABB All rights reserved HZTL4036_EN Revision M August 2018 Fig 35 Dismantling the diffuser 4 Loosen and remove screws 77015 5 Remove O rings 79020 79021 6 Attach lifting gear L to the diffuser 79000 7 Remove and put down diffuser Page 63 108 ...

Page 92: ...t against mechanical hazards Fig 36 Measuring axial clearance A The axial clearance A of the rotor should always be measured before and after service work on the turbocharger u Measure and note axial clearance A Product Axial clearance A mm A265 L 0 32 0 62 A270 L 0 33 0 63 A275 L 0 38 0 68 A280 L 0 41 0 73 Table 30 Admissible axial clearance A CAUTION Clearances outside the tolerance Serious dama...

Page 93: ...inlet casing and the nozzle ring A275 L and smaller Dismantling the insulation NOTICE Dry cleaning The dry cleaning does not have to be removed to dismantle the insulation Fig 37 Removing the insulation A275 L and smaller 1 Loosen and remove screws of insulation jackets 51200 from gas outlet casing 61001 2 Loosen and remove all connecting plates of insulation jackets 3 Remove insulation jackets 4 ...

Page 94: ... Fig 38 Dismantling the gas inlet casing A275 L and smaller screwed variant u If one of the screws 61009 shears off when loosening an ABB Turbocharging Service Station should be contacted 1 Loosen crosswise and remove all but two opposite screws 61009 2 Fit two guide studs 90317 in the upper area on the gas outlet casing 3 Loop around the gas inlet casing 51001 with lifting gear 4 Loosen and remov...

Page 95: ...when loosening an ABB Turbo Systems Service Sta tion should be contacted u If a threaded stud 51086 works loose when removing the nut 51087 it should be refit ted after disassembling the gas outlet casing up to the stop in the gas inlet casing until hand tight u If the nut 51087 cannot be removed with the maximum permissible loosening torque it can be heated and removed with an appropriate tool 1 ...

Page 96: ... inlet casing and the nozzle ring A275 L and smaller Copyright 2018 ABB All rights reserved HZTL4036_EN Revision M August 2018 Dismantling the nozzle ring Fig 40 Dismantling the nozzle ring A275 L and smaller 1 Loosen screws 56014 and remove with washers 56011 2 Remove and put down nozzle ring 56001 Page 68 108 ...

Page 97: ...ws 61009 shears off when loosening an ABB Turbocharging Service Station should be contacted 1 Dismantle both halves of the insulation segment 51215 and remove with all fixing ele ments 2 Detach flange connection between gas inlet casing 51001 and bellows 3 Loosen and remove all but two opposite screws 61009 4 Fit two guide studs 90317 in the upper area on the gas outlet casing 61001 5 Loop lifting...

Page 98: ...he nut 51087 it should be refit ted after disassembling the gas outlet casing up to the stop in the gas inlet casing until hand tight u If the nut 51087 cannot be removed with the maximum permissible loosening torque it can be heated and removed with an appropriate tool 1 Dismantle both halves of the insulation segment 51215 and remove with all fixing ele ments 2 Detach flange connection between g...

Page 99: ...sing nozzle ring A280 L Copyright 2018 ABB All rights reserved HZTL4036_EN Revision M August 2018 Dismantling the nozzle ring Fig 43 Fitting the nozzle ring holder A280 L 1 Remove screws B2 2 Fit the nozzle ring holder 90477 with screws B1 at the top of the flange of the gas inlet casing 51001 Page 71 108 ...

Page 100: ...nozzle ring A280 L 1 Loop around the nozzle ring holder 90477 with the lifting gear and secure it to the crane 2 Loosen screws 56014 and remove with washers 56011 3 Pull the nozzle ring 56001 towards the front onto the nozzle ring holder 90477 4 Screw the screws B2 into the nozzle ring holder 5 Remove screws B1 Fig 45 Putting down the nozzle ring A280 L u Use the crane to remove and put down the n...

Page 101: ...ing insulation A275 L and smaller Fitting the nozzle ring u Coat the screw threads with high temperature grease Fig 46 Fitting the nozzle ring A275 L and smaller Part number A265 L A270 L A275 L 56014 M10 35 Nm M10 35 Nm M10 35 Nm Table 33 Tightening torque 56014 1 Align the notch A1 with the flange connection A2 and slide the nozzle ring 56001 into the gas inlet casing 51001 2 Fit screws 56014 wi...

Page 102: ...torque 61009 1 Pre tightening torque of the screws 1 Fit two guide studs 90317 in the upper area on the gas outlet casing 61001 2 Loop around the gas inlet casing 51001 with the lifting gear and secure it to the crane 3 Push gas inlet casing over the guide studs up to the gas outlet casing 4 Screw in two opposite screws 61009 with high temperature grease 5 Remove the guide studs 90317 and fit the ...

Page 103: ...87 1 Pre tightening torque of the nuts 1 Coat threaded stud 51086 with high temperature grease screw in up to the stop in the gas outlet casing 61001 and tighten hand tight 2 Loop around the gas inlet casing 51001 with the lifting gear and secure it to the crane 3 Push gas inlet casing over the threaded studs up to the gas outlet casing 4 Coat two nuts with high temperature grease and fix gas inle...

Page 104: ...HZTL4036_EN Revision M August 2018 Fitting insulation Fig 49 Fitting the insulation A275 L and smaller 1 Fit flange connection between gas inlet casing 51001 and bellows 2 Fit the insulation jackets 51200 on the gas inlet casing 51001 with the screws 3 Fit connecting plates of insulation jackets with screws 4 Fit insulation jackets with screws on gas outlet casing 61001 Page 76 108 ...

Page 105: ...8 ABB All rights reserved HZTL4036_EN Revision M August 2018 8 10 Fitting the gas inlet casing nozzle ring A280 L Fitting the nozzle ring u Coat the screw threads with high temperature grease Fig 50 Fitting the nozzle ring A280 L u Use lifting gear to secure the nozzle ring 56001 on the nozzle ring holder 90477 and transport it Page 77 108 ...

Page 106: ...A280 L 56014 M12 65 Nm Table 36 Tightening torque 56014 1 Fit the nozzle ring holder 90477 on the flange of the gas inlet casing 51001 with screws B1 2 Remove screws B2 3 Align the notch A1 on the cam of the nozzle ring 56001 with the flange connection A2 and slide the nozzle ring into the gas inlet casing 4 Coat screws 56014 with high temperature grease and fit with washers 56011 5 Remove screws ...

Page 107: ... on the gas outlet casing 61001 2 Loop around the gas inlet casing 51001 with the lifting gear and secure it to the crane 3 Dismantle and remove supports 90481 90482 from the gas inlet casing 4 Push gas inlet casing over the guide studs up to the gas outlet casing 5 Coat two opposite screws 61009 with high temperature grease and screw in 6 Remove the guide studs 7 Coat remaining screws with high t...

Page 108: ...in up to the stop in the gas outlet casing 61001 and tighten hand tight 2 Loop around the gas inlet casing 51001 with the lifting gear and secure it to the crane 3 Dismantle and remove supports 90481 90482 from the gas inlet casing 4 Push gas inlet casing over the threaded studs up to the gas outlet casing 5 Coat two nuts with high temperature grease and fix gas outlet casing in two opposite posit...

Page 109: ...inst mechanical hazards Fig 54 Measuring axial clearance A The axial clearance A of the rotor should always be measured before and after service work on the turbocharger u Measure and note axial clearance A Product Axial clearance A mm A265 L 0 32 0 62 A270 L 0 33 0 63 A275 L 0 38 0 68 A280 L 0 41 0 73 Table 39 Admissible axial clearance A CAUTION Clearances outside the tolerance Serious damage to...

Page 110: ... 55 Fitting the diffuser Part number A265 L A270 L A275 L A280 L 77015 M5 6 Nm M6 10 Nm M8 25 Nm M8 25 Nm Table 40 Tightening torque 77015 1 Attach lifting gear L to the diffuser 79000 2 Carefully place the diffuser on the wall insert 77000 then remove lifting gear 3 Fit new O rings 79020 79021 on the diffuser 4 Degrease screws 77015 and threaded holes in wall insert 5 Coat threads of the screws w...

Page 111: ...embly 8 12 Fitting diffuser wall insert Copyright 2018 ABB All rights reserved HZTL4036_EN Revision M August 2018 Fitting the wall insert Fig 56 Positioning wall insert u Carefully bring wall insert 77000 into vertical position with the lifting device 90190 Page 83 108 ...

Page 112: ... studs 90320 in the upper area of the compressor casing 72000 3 Align arrow markings of wall insert 77000 and compressor casing to one another 4 Carefully move the wall insert with diffuser 79000 over the guide studs into the com pressor casing 5 Fit a screw 72011 as a safeguard 6 Change the position of the shackle 90195 with the lifting gear to P1 of the lifting device 90190 and remove with the c...

Page 113: ...ers differ in terms of the fixing eyelets for the lifting gear The relevant vari ant must be taken into consideration for disassembly and assembly 8 13 2 Fitting the filter silencer welded Fig 58 Fitting the filter silencer Part number A265 L A270 L A275 L A280 L 72004 M14 130 Nm M16 200 Nm M18 300 Nm M20 420 Nm Table 42 Tightening torque 72004 1 Attach the lifting gear to the front lug and rear e...

Page 114: ...r silencer cast Fig 59 Fitting the filter silencer Part number A265 L A270 L A275 L A280 L 72004 M14 130 Nm M16 200 Nm M18 300 Nm M20 420 Nm Table 43 Tightening torque 72004 1 Attach the lifting gear to the front lug and rear eyelet of the filter silencer 81000 2 Position filter silencer on compressor casing 3 Fit nuts 72004 with washers 72003 and tighten u Fit insulation as far as necessary Page ...

Page 115: ...Operation Manual 4 Product description A200 L 8 Disassembly and assembly 8 13 Fitting the filter silencer Copyright 2018 ABB All rights reserved HZTL4036_EN Revision M August 2018 Page 87 108 ...

Page 116: ...mbly and assembly 8 14 Table of tightening torques Copyright 2018 ABB All rights reserved HZTL4036_EN Revision M August 2018 8 14 Table of tightening torques Fig 60 Overview of tightening torques Fig 61 Overview of speed sensor tightening torque Page 88 108 ...

Page 117: ... 500 M24 900 M27 1300 63 1 72004 M14 130 M16 200 M18 300 M20 420 63a 72002 M14 40 M16 60 M18 80 M20 100 64 77015 M5 6 M6 10 M8 25 M8 25 65 56014 M10 35 M10 35 M10 35 M12 65 66 81125 G1 2 45 G1 2 45 G1 2 45 G1 2 45 67 86505 M18x1 5 150 M18x1 5 150 M18x1 5 150 M27x2 320 Table 44 Overview of tightening torques 1 Tighten crosswise 2 Pre tightening torque of the screws u Use hydraulic tool for tighteni...

Page 118: ... Dismantle filter silencer and lock rotor with locking device Fit cover plates to compressor outlet gas in let and gas outlet casing of defective tur bocharger Engines with by pass around the turbocharger Engines without bypass around the turbocharger Open bypass If the nozzle ring is removed not mandatory a higher engine load can be achieved Continue to operate engine in accordance with enginebui...

Page 119: ...g oil supply remains switched on Further information for operation of 2 stroke engines with blocked ro tor u If there is a lubricating oil leak on the turbocharger stop the oil supply CAUTION Locking of the rotor on the compressor wheel Serious damage to engine or property can be caused by excessive vibrations and unbalance values if set screws balancing screws are loosened or un screwed on the co...

Page 120: ...e any set screws from the compressor wheel when fitting the locking device 94003 Fitting the locking device Fig 62 Locking the rotor u Dismantle the filter silencer Dismantling the filter silencer 58 1 If present Remove the spinner nose cone 25012 with the press off screw 90924 2 On locking device 94003 loosen retaining nuts N and remove with screws B1 3 Loosen screws B2 and remove with washers 4 ...

Page 121: ... in stalled turbocharger Copyright 2018 ABB All rights reserved HZTL4036_EN Revision M August 2018 Product Tightening torques for screws Nm B1 B2 B3 A265 L M8 25 M12 75 M8 25 A270 L M10 45 M12 75 M8 25 A275 L M10 45 M12 75 M8 25 A280 L M12 75 M12 75 M8 25 Table 47 Tightening torques locking device Page 93 108 ...

Page 122: ...3 3 Engines without bypass around the turbocharger If the nozzle ring is removed not mandatory higher engine performance can be achieved More information about dismantling the nozzle ring Securing the cover ring If the nozzle ring is removed for emergency operation the clamping of the cover ring 57001 to the gas outlet casing must be ensured In this case additional washers 01 must be provided in a...

Page 123: ...e with two or more installed turbochargers CAUTION Speed limit of the turbocharger The speed limit nBmax specified on the rating plate of the turbocharger must not be exceeded Serious damage to engine or property can be caused by excessive speeds u Observe the speeds of the undamaged turbochargers u Reduce the engine load if necessary 9 4 1 Blanking off the inlets and outlets The chapter is only a...

Page 124: ...18 u Shut off the supply of lubricating oil to the turbocharger u Blank off flanges of compressor casing outlet 01 gas inlet 02 and gas outlet 03 by in stalling cover plates u Observe specifications from enginebuilder 9 4 2 Continuing to operate the engine Continue to operate engine in accordance with enginebuilder s instructions Do not exceed prescribed power reduction and maximum turbocharger sp...

Page 125: ...ual 4 Product description A200 L 9 Taking a turbocharger out of operation 9 4 Procedure with two or more installed turbochargers Copyright 2018 ABB All rights reserved HZTL4036_EN Revision M August 2018 Page 97 108 ...

Page 126: ...earing parts are largely protected against 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 she...

Page 127: ... parts are dismantled by an ABB Turbocharging Service 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 ...

Page 128: ...Wear 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 o...

Page 129: ...pare parts can be ordered from any ABB Turbocharging Service Station u If different model variants are not taken into account in this document contact an ABB Turbocharging Service Station Required customer spare part set 97070 For the operations described in the Operation Manual the customer spare part set 97070 is required These parts are only available in the complete set Quantity Designation Pa...

Page 130: ...200 L 12 Spare parts 12 2 View of turbocharger with part numbers Copyright 2018 ABB All rights reserved HZTL4036_EN Revision M August 2018 12 2 View of turbocharger with part numbers Fig 65 View of turbocharger with part numbers Page 102 108 ...

Page 131: ...Cover ring 57005 Hexagon head screw 61001 Gas outlet casing 61009 Hexagon head screw 68002 Foot turbine end 72000 Compressor casing 72002 Threaded stud 72003 in the customer spare part set Washer 72004 in the customer spare part set Hexagon nut 72011 Hexagon head screw 74040 Air outlet silencer option 74042 Gasket option 77000 Wall insert 77015 in the customer spare part set Hexagon head screw 770...

Page 132: ...rs Copyright 2018 ABB All rights reserved HZTL4036_EN Revision M August 2018 12 3 View of cartridge group with part numbers Fig 66 View of cartridge group with part numbers NOTICE Cartridge group The cartridge group is not delivered as a fitted assembly Spare parts must be ordered individually Page 104 108 ...

Page 133: ...ing compressor end 32102 Radial bearing turbine end 32105 Floating disc 32106 Axial bearing 32109 Sealing disc 32159 Locking screw 32174 O ring 42001 Bearing casing 42008 Socket screw 42011 O ring 42015 Sealing cover 42039 Hexagon head screw 42041 Gasket 42059 Hexagon head screw 42064 Hexagon head screw 42185 Socket screw 42186 O ring 42295 Pressure adjusting unit 42300 Partition wall 42305 O ring...

Page 134: ...ellows 57 Fig 29 Dismantling the filter silencer 58 Fig 30 Dismantling the filter silencer 59 Fig 31 Pressing off compressor casing 60 Fig 32 Moving out wall insert 61 Fig 33 Putting down wall insert 61 Fig 34 Putting down wall insert 62 Fig 35 Dismantling the diffuser 63 Fig 36 Measuring axial clearance A 64 Fig 37 Removing the insulation A275 L and smal ler 65 Fig 38 Dismantling the gas inlet ca...

Page 135: ...ig 59 Fitting the filter silencer 86 Fig 60 Overview of tightening torques 88 Fig 61 Overview of speed sensor tightening torque 88 Fig 62 Locking the rotor 92 Fig 63 Ensuring clamping of the cover ring 94 Fig 64 Position of cover plates 95 Fig 65 View of turbocharger with part numbers 102 Fig 66 View of cartridge group with part numbers 104 Page 107 108 Page 107 108 ...

Page 136: ...eration Charge air pressure too low 46 Table 22 Malfunctions during operation Charge air pressure too high 47 Table 23 Surging of the turbocharger 47 Table 24 Malfunctions when stopping Runout noises 48 Table 25 Malfunctions when stopping Shortened runout time 48 Table 26 Malfunctions of the speed measurement system 49 Table 27 Weights of assemblies kg 52 Table 28 Weight of wall insert kg 52 Table...

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ABB XAC19590, Operation Manual

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