ABB HT603802, Operation Manual

Page 1: ...ion Serial number HT603802 Customer part number X00078528 Delivery date yyyy mm dd 2021 08 02 Weight 190 kg Operating limits according to rating plate Speed limit in test rig operation only nMmax 1031 1 s Speed limit during operation nBmax 1007 1 s Gas inlet temperature limit in test rig operation only tMmax 680 C Gas inlet temperature limit during operation tBmax 650 C ...

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Page 3: ...on on gas engines 15 2 7 Periodic check of the pressure vessels 15 2 8 Warning plates on the turbocharger 16 2 9 Turbocharger rating plate 17 2 10 Lifting of loads 19 2 11 Prerequisites for operation and maintenance 20 2 12 Hazards during operation and maintenance 21 2 13 Safe operation 23 2 14 Safe maintenance 24 3 Removing and Installing 28 3 1 Weight and transportation of the turbocharger 28 3 ...

Page 4: ...essor casing 86 9 7 Pressing off the casing 88 9 8 Removing the cartridge group 89 9 9 Removing the nozzle ring 91 9 10 Installing the cartridge group on the service support 92 9 11 Measuring clearance A and B 93 9 12 Nozzle ring compression PD 94 9 13 Installing the nozzle ring 95 9 14 Installing the cartridge group 96 9 15 Installing the compressor casing 98 9 16 Measuring radial clearances N an...

Page 5: ...ly 2021 12 Material and Disposal 108 12 1 REACH and RoHS Compliance Declaration For Products 108 12 2 Disposing of turbocharger components 109 13 Spare parts 110 13 1 Ordering spare parts 110 13 2 Required customer spare part set 97070 110 13 3 Spare part Illustrations 111 14 Tools 119 Figures 120 Tables 121 ...

Page 6: ...plains 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 it ...

Page 7: ...is 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 ABB Turbocharging Service Station if you have any questions regarding a design variant see Contact information at www abb com turbocharging Accuracy of illustrations The illustrations in this document ar...

Page 8: ...unction of the turbocharger Fig 2 Layout and function of the turbocharger 01 Air suction branch 08 Turbine 02 Compressor casing 09 Gas outlet flange 03 Diffuser 10 Nozzle ring 04 Bearing casing 11 Turbine casing 05 Axial thrust bearing 12 Turbine end bearing flange 06 Radial plain bearing 13 Compressor end bearing flange 07 Gas outlet casing 14 Compressor wheel Page 6 122 ...

Page 9: ... 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 of the bearing casing 04 Function of the comp...

Page 10: ...acilitates the work Definition 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 Turbocharging ABB Switzerland Ltd Turbocharging is identified as ABB Turbocharging in this document Official ser...

Page 11: ...togram 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 compati...

Page 12: ...RNING 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 F...

Page 13: ...nspected by an ABB Turbocharging Service Station and repacked u Inspect the package for damage If the package is damaged the turbocharger must be in spected by an ABB Turbocharging Service Station and repacked After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station Inspect the component Replace the desiccant agent Repackage the component NOTICE 70 fie...

Page 14: ... are a consequence 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 ...

Page 15: ...ory 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 f...

Page 16: ... volume or air gas mixture and the associ ated charging pressure required for operation The turbocharger is solely intended 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 o...

Page 17: ...f during external inspection anomalies are found or if a particularly strong deflagration event has taken place it is also recommended to check the bearings of the turbochargers before the next start An ABB Turbocharging Service Station should be instructed to carry out this inspection 2 7 Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging such as those for wet o...

Page 18: ...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 equipped later ...

Page 19: ... 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 09...

Page 20: ...ntacting the nearest ABB Turbochar ging 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 compone...

Page 21: ...t 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 in...

Page 22: ...ation Manual must 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 Modif...

Page 23: ...ear 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 bur...

Page 24: ...viding 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 allowed...

Page 25: ...before commission ing u Check turbocharger for recognisable damage or defects every 12 hours of operation or at least once a day u Report any damage and any alterations of operational characteristics 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 ...

Page 26: ...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 platforms ...

Page 27: ... 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 vals...

Page 28: ...ns 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 ma...

Page 29: ...he 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 combusti...

Page 30: ...h a sufficient load limit must be used for removing installing and transport ing the turbocharger 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 11 Transportation of the turbocharger Product Weight of complete turbocharger unit kg A130 H 190 A135 H 27...

Page 31: ... work in Do not apply penetrating oil to the pressure screws of the clamping nut B u If present Disconnect the plug to the speed sensor 86505 and secure the rolled up cable on the turbocharger This protects the plug from being crushed u If present Detach the support 61301 from the engine support Depending on the bracket version 04 positioning pins 05 can be used for positioning and safeguarding ag...

Page 32: ...operty can be the consequence if the cooling water freezes in the pipes and in the bearing casing u For transport and storage of the turbocharger drain the cooling water in the bearing casing via two openings of the water connections Manual loosening To remove the turbocharger from the bracket proceed as follows u Loosen and remove water connections Close the openings of the water connections with...

Page 33: ... 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 13 Loosening the clamping nut 1 Working in a circle br...

Page 34: ...it 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 14 Putting down the turbocharger u Remove turbocharger from engine support set it down properly in an appropriate place and secure it u Close or co...

Page 35: ...sealing is provided by O rings The O rings are not included in the ABB scope of delivery Fig 15 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 the le...

Page 36: ...Remove nuts 01 again Requirements for the threaded rods Fig 17 Requirements for threaded rods Product Diameter Threaded rod mm Material DIN ISO 898 Part 1 Thread length L1 mm Length of threaded rod L2 mm A130 H Ø 16 M16 10 9 12 9 30 250 A135 H Ø 20 M20 10 9 12 9 30 325 A140 H Ø 24 M24 10 9 12 9 70 410 420 Table 5 Requirements for threaded rods Fastening material scope of delivery The threaded rods...

Page 37: ... the bearing casing 42001 and loop around the gas outlet casing 4 Position the turbocharger on the bracket 04 and align it If present pay attention to the positioning pin 05 in the bracket 5 When fixing with a standard nut C fit the expansion bushes in the correct position in the slot Safeguard against wrong fitting only for water cooled bearing casings Depending on the bracket version 04 two posi...

Page 38: ...n 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 engine support the bolt threads and screw heads must be lightly oiled assumed friction coeffic...

Page 39: ...bricate 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 19 Preparing the clamping nut for the tightening procedure 1 Check whether the expansion bushes 42190 with recess are correctly positi...

Page 40: ...tening 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 Tighten press...

Page 41: ...ssor 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 21 Connecting the compressor cooling air intake u Remove the screw plug on the connection for the compressor wheel cooling 06 and fit the ...

Page 42: ...h width of 0 034 mm is sufficient for this tur bocharger 4 1 3 Oil pressure Comply precisely with the oil pressure before the turbocharger for trouble free operation Different oil pressures must be taken into account here for different operating states such as for example idling mode and when the engine is started The admissible values are specified in chapter Monitoring operation 45 4 1 4 Startin...

Page 43: ...0_EN Rev G July 2021 4 1 5 Oil orifice in the bearing casing Fig 23 Oil orifice 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 41 122 ...

Page 44: ... 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 l...

Page 45: ... 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 the exhaust gas te...

Page 46: ...er 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 presen...

Page 47: ...ine start Cold oil admissible for a maximum 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 5 Table 8 Lubricating oil pressure at oil inlet before turbocharger Arrangement of temperature and pressure measuring ...

Page 48: ...the outlet 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 acc...

Page 49: ...page or the rating plate on the turbocharger 5 3 Turbocharger speed 5 3 1 Introduction A speed measuring system enables the constant monitoring of the turbocharger speed CAUTION Do not put the 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 CAUTION Machine dama...

Page 50: ...EN Rev G July 2021 5 3 2 Layout and overview Fig 24 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 86528 Tachometer Installation variant for speed sensor 32109 Sealing disc with cams Page 48 122 ...

Page 51: ...t 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 ABB Turbocharging Service Station has to be contacted u Ch...

Page 52: ...h a sealing lip and an O ring No additional gasket is required during assembly Fig 25 Replacing the speed sensor Part number Thread size Tightening torque 86505 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 59 u Switch off the lubricating oil supply to the turbocharger u Disc...

Page 53: ...f 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 eng...

Page 54: ...021 ABB All rights reserved HZTL4030_EN Rev G July 2021 Suggestion for noise insulation bellows Fig 26 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 52 122 ...

Page 55: ...d 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 intervals are...

Page 56: ...d in accordance with the instructions of the enginebuilder 6 2 4 Service work according to data on the rating plate Usually after 8000 12000 operating hours The rotor and bearing parts must be checked and assessed by an ABB Turbocharging Service Station The following work can be carried out as preparation u Remove turbocharger from engine dismantle and measure clearances see Dismantling and fittin...

Page 57: ...otective grid 61205 after 50000 hours and replace it with a new one Pre mix gas engines CAUTION Replace the protective grid of pre mix gas engines after 20000 hours Applications on pre mix gas engines result in a high thermo mechanical load on the protective grid To ensure proper functionality of the protective grid even under these conditions the protective grid of pre mix gas engines must be rep...

Page 58: ...d regularly into the engine logbook of the enginebuilder Number of times the engine is started successfully possible aborted start cycles do not need to be recorded Performance 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 ...

Page 59: ...e start stop cycles or after reaching the number of operating hours specified on the rating plate Non rotating components Depending on the system specific operating conditions a differentiation must be made between the intervals to be expected for replacing the bearing parts and replacing the non rotating components exposed to hot gas A decisive role is played by various influencing parameters whi...

Page 60: ...tervals The specified values are guideline values and not guaranteed values see Influencing para meters Influencing parameters The specified values are guideline values and are not guaranteed The actual values can devi ate significantly from the guideline values for example due to the following influences Fuel quality and fuel treatment Load profile thermal cycling also number of starts stops emer...

Page 61: ... adequately dissipated it may damage the engine u Adequate cooling of the turbocharger must be ensured after stopping the engine Water cooled turbocharger variant u Post lubricate as long as the rotor is turning u Observe the oil pressure while performing post lubrication 0 5 poil 1 0 u Switch off post lubrication as soon as the rotor is stationary or after no more than two minutes Deviating proce...

Page 62: ...nd cleaning operations which are inten ded to ensure the trouble free functioning of the turbocharger Maintenance interval Maintenance work Operating status Similar to the service interval usually every 8000 12000 h Cleaning components mechanically 61 1 Engine stopped Table 13 Maintenance table h Hours of operation 1 ABB Turbocharging recommends having mechanical cleaning carried out by an ABB Tur...

Page 63: ...ly 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 exam...

Page 64: ...esent u Remove filter ring 81265 u Clean filter ring 81265 as required or every 500 hours of operation and replace after the fifth cleaning process at the latest The contamination of the filter ring depends on the degree of purity of the sucked in air u Rinse the filter ring 81265 with water and mild detergent or in the case of heavy con tamination soak and carefully push through Rinse in cold wat...

Page 65: ... 81136 must only be cleaned lightly with compressed air a soft brush or a moist cleaning cloth u Have any heavily contaminated absorption segments replaced by an ABB Turbocharging Service Station Fitting the filter silencer see Fig 28 Cleaning the filter silencer 62 u Insert the absorption segments 81136 into the sheet metal coverings 81137 u Bend the sheet metal coverings 81137 back to their orig...

Page 66: ...ty 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 29 Compressor end non rotating parts 72000 Compressor casing 77000 Wall insert 79000 Diffuser u Clean the ...

Page 67: ... 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 Baked layers of contamination for example from coked oil occur at the turbine end The fol lowing parts which are relevant in terms of performance can be cleaned in accordance with the description below Fig 30 Turbine end non rotating par...

Page 68: ...idge group is not put back into operation immediately after clean ing parts may corrode u Immediately after cleaning install the cartridge group and put it back into operation Compressor wheels can be heavily contaminated due to poorly filtered suction air turbines can be heavily contaminated due to coked oil Contamination such as this must be removed during the standard service intervals see chap...

Page 69: ...ridge 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 surfaces Clean the compressor wheel with a rag or soft brush which has been soaked in wate...

Page 70: ... B mm C mm A130 108 17 205 A135 128 20 245 A140 157 25 300 Table 14 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 contain chlorine co...

Page 71: ...nside 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 h...

Page 72: ...buted 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 horizonta...

Page 73: ...ging Service Station 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 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 cause...

Page 74: ...il filter heavily contaminated Clean Oil pump in lubricating system defect ive Check replace Manometer displays incorrectly Replace manometer Table 18 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 60 Rotor components or bearing damaged C...

Page 75: ...high Check clean cooling system Insufficient ventilation Improve ventilation Table 21 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 con...

Page 76: ...aminated 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 60 Optimize oil separat...

Page 77: ...d remedied immediately by an ABB Turbochar ging Service Station u Have parts assessed for damage and if necessary replaced by an ABB Turbocharging Service Station Possible causes Remedy Turbocharger Filter silencer or diffuser contamin ated Clean see chapter Periodic mainten ance work 60 Heavy contamination deposits in the turbine or in the nozzle ring Engine Protective grating in front of the tur...

Page 78: ...tions 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 c...

Page 79: ...ging Service Station Replacing the speed sensor 50 Table 29 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 a...

Page 80: ...ng on the 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 WARNING Non observance of the work steps and further operations Incorrectly performed work or further operations can cause injury to person ...

Page 81: ...or components of the turbocharger The specified tightening torques of the screw fittings must be observed Table of tightening torques Tightening torques for assembly devices Unless otherwise described the screws and nuts of the assembly devices supplied by ABB must be tightened in such a way that they are tight fitting WARNING Suspended loads Loads that are not attached according to regulations ca...

Page 82: ...of loads ropes chain block crane Lifting gear is not supplied by ABB Swivel lifting eyes to be used Swivel lifting eyes are required for the safe lifting of loads which are not supplied by ABB Fig 32 Swivel lifting eyes Product Thread M Length L mm Minimum load limit kg Quantity A130 M10 17 mm 100 kg 2 A135 M10 17 mm 150 kg 2 A140 M12 21 mm 250 kg 2 Table 32 Swivel lifting eyes Ring nuts to be use...

Page 83: ...35 kg A140 kg 01 Filter silencer 19 30 40 02 Radial air suction branch 6 8 13 03 Axial air suction branch 4 5 6 04 Compressor casing 24 40 60 05 Wall insert 6 8 15 06 Diffuser 3 4 7 07 Cartridge group 40 60 110 08 Nozzle ring 2 2 4 09 Burst ring 2 3 5 10 Turbine casing 45 65 120 11 Gas outlet flange 7 13 20 12 Gas outlet casing 30 35 65 Table 33 Weights of assemblies including burst protection Pag...

Page 84: ...air inlets u Mark the casing position for assembly Fig 35 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 82 122 ...

Page 85: ...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 5 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 86: ...cessary 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 37 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 Table 34 3 press off screws not included in the ABB sc...

Page 87: ...cessary 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 38 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 Table 35 6 press off screws not included in the ABB scope of d...

Page 88: ...o chapter Spare parts 110 1 Loosen screws 72011 and remove 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 or graphite cord sealing 42126 5 Loosen screws 79041 and remove from the compressor casing 72000 with fixing discs 79040 and diffuser ...

Page 89: ... Rev G July 2021 Dismantling the wall insert Fig 40 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 87 122 ...

Page 90: ...sing 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 41 Press off the casing Page 88 122 ...

Page 91: ...ration 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 Fig 42 Oil orifice 01 Bearing casing 02 Oil orifice 03 Circlip Fig 43 Removing cartridge group 1 1 Treat threads of studs 51006 with penetrating ...

Page 92: ... 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 cartridge group cannot be loosened the press off tool 90042 can be used see chapter Pressing off the casing 88...

Page 93: ...ly 2021 9 9 Removing the nozzle ring Fig 45 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 91 122 ...

Page 94: ...All rights reserved HZTL4030_EN Rev G July 2021 9 10 Installing the cartridge group on the service support Fig 46 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 92 122 ...

Page 95: ... 0 70 1 37 Table 36 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 Measure clearance B and...

Page 96: ...e heat shield 42400 and the turbine casing 51000 Fig 48 Nozzle ring compression PD 42001 Bearing casing 51000 Turbine casing 42400 Heat shield 56001 Nozzle ring Product Nozzle ring compression PD mm A130 H 0 15 0 15 A135 H 0 16 0 16 A140 H 0 16 0 16 Table 37 Nozzle ring compression PD 1 Measure dimensions A B and S on cleaned surfaces 2 Calculate compression PD u If the calculated value PD lies ou...

Page 97: ...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 recesses...

Page 98: ... nozzle ring control dimension H 1 Measure dimension H as shown in the illustration and compare it with the minimum di mension H in the table 9 14 Installing the cartridge group Lifting the cartridge group and rotating it by 90 Fig 51 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 ser...

Page 99: ...oduct Size Tightening torque Nm A130 M8 25 A135 M10 45 A140 M12 75 Table 39 Tightening torque 51007 1 Coat thread of 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 6 Tighten t...

Page 100: ...e diffuser Fig 53 Fitting the wall insert and the diffuser Product Size Tightening torque Nm A130 M6 8 A135 M6 8 A140 M6 8 Table 40 Tightening torque 79041 1 Fit new O ring 77005 see chapter Required customer spare part set 97070 110 2 Install the wall insert 77000 into the compressor casing 3 Secure the diffuser 79000 with fixing discs 79040 and new screws 79041 see chapter Required customer spar...

Page 101: ...he O ring 42012 see also chapter Spare parts 110 Product Size Tightening torque Nm A130 M8 35 A135 M10 70 A140 M12 105 Table 41 Tightening torque 72011 1 Fit a new high temperature resisting O ring 42012 red or green see chapter Required customer spare part set 97070 110 2 Thoroughly clean the fastening strips 72012 before assembly 3 Attach swivel lifting eyes 01 to the compressor casing 72000 and...

Page 102: ... 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 outside the tolerance Ser...

Page 103: ...ling the air inlets Product Size Tightening torque Nm A130 M12 60 A135 M12 60 A140 M12 60 Table 43 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 Page 101 12...

Page 104: ...let flange 57002 in the turbine casing 3 Measure radial clearance R see chapter Radial clearances N and R 9 19 Installing the gas outlet casing Fig 58 Installing the gas outlet casing Product Size Tightening torque Nm A130 M8 20 A135 M10 40 A140 M12 65 Table 44 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 tempe...

Page 105: ...able of tightening torques Fig 59 Tightening torques Position Part number A130 A135 A140 02 72020 M12 60 Nm M12 60 Nm M12 60 Nm 04 79041 M6 8 Nm M6 8 Nm M6 8 Nm 08 51007 M8 25 Nm M10 45 Nm M12 75 Nm 09 51009 M8 20 Nm M10 40 Nm M12 65 Nm 11 72011 M8 35 Nm M10 70 Nm M12 105 Nm 15 86505 M12 x 1 5 15 Nm M12 x 1 5 15 Nm M12 x 1 5 15 Nm 16 51101 51103 51104 61201 M8 20 Nm M8 20 Nm M10 40 Nm Table 45 Tig...

Page 106: ... leak u Soak up oil and dispose of in an environmentally compatible 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 ope...

Page 107: ...roup Incorrect handling of a cartridge group can damage the turbocharger and cause injuries to persons u Have repairs to the cartridge group carried out by an ABB Turbocharging Service Station only To enable an engine to be put back into operation quickly after a turbocharger has sustained damage ABB Turbocharging recommends having a replacement cartridge group available in storage The defective c...

Page 108: ...s 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 sheet for the ...

Page 109: ...smantled 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 to the engine...

Page 110: ... 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 ABB Switzerland Ltd Turbocharging do not fall within the Scope of RoHS2 due to their appl...

Page 111: ... 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 fe...

Page 112: ...nt in this document contact an ABB Turbocharging 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 work describ...

Page 113: ...ish Cartridge water cooled 42197 42196 10900 42012 42126 42194 42047 42189 42190 42188 42201 Available within the spare part set if provided HZTL443555 Mod A Part no Designation 10900 Cartridge_water cooled 42012 O ring 42047 Screw plug 42126 Graphite cord sealing 42188 Hexagon head screw 42189 Gasket 42190 Expansion bush 42194 Gasket 42196 Orifice oil inlet 42197 Safety ring 42201 Clamping nut on...

Page 114: ...1 51105 51006 51002 51003 51007 p pre assembled if provided HZTL443558 Mod A Part no Designation 51000 Turbine casing 51002 Fastening strip 51003 Verbusripp washer 51006 Stud 51007 Hexagon nut 51008 Stud 51009 Hexagon nut 51016 Tension washer 51017 Compensator sheet metal 51027 p Screw plug 51101 Hexagon head screw 51102 Tension washer 51105 Metal C ring 51500 Burst protection 56001 Nozzle ring 56...

Page 115: ...030_EN Rev G July 2021 Part no Designation 57003 Metal ring 57210 Burst ring Table 48 Gas outlet casing axial 61002 GH02 61001 61001 GH02 GHV03 Available within the spare part set only if provided HZTL443303 Mod B Part no Designation 61001 Gas outlet casing 61001 Gas outlet casing GHV03 61002 Gasket Table 49 Page 113 122 ...

Page 116: ...21 Gas outlet casing radial 61002 61200 61202 61201 61005 p 61001 61205 p pre assembled Available within the spare part set if provided HZTL443302 Mod C Part no Designation 61001 Gas outlet casing 61002 Gasket 61005 p Screw plug 61200 Burst protection 61201 Hexagon head screw 61202 Tension washer 61205 Protective grid Table 50 Page 114 122 ...

Page 117: ...9041 79040 77005 72000 77000 72080 72005 p 72020 Available within the spare part set p pre assembled HZTL443559 Mod A Part no Designation 72000 Compressor casing 72005 p Screw plug 72006 p Gasket 72011 Hexagon head screw 72012 Fastening strip 72020 V clamp 72080 Warning plate 77000 Wall insert 77005 O ring 79000 Diffuser 79040 Fixing washer 79041 Counter sunk screw Table 51 Page 115 122 ...

Page 118: ...ly 2021 Air suction branch radial 82010 82005 82006 82000 82008 82007 Available within the spare part set HZTL443012 Mod D Fig 60 SPI Air suction branch radial Part no Designation 82000 Air suction branch 82005 Screw plug 82006 Gasket 82007 Screw plug 82008 Gasket 82010 O ring Table 52 Spare parts Air suction branch radial Page 116 122 ...

Page 119: ...d HZTL4030_EN Rev G July 2021 Air suction branch axial 82008 p 82007 p 82010 82000 82006 p 82005 p Available within the spare part set p pre assembled HZTL443560 Mod A Part no Designation 82000 Air suction branch 82005 p Screw plug 82006 p Gasket 82007 p Screw plug 82008 p Gasket 82010 O ring Table 53 Page 117 122 ...

Page 120: ...ations Copyright 2021 ABB All rights reserved HZTL4030_EN Rev G July 2021 Speed measurement system 86505 86515 86528 86526 if provided HZTL443468 Mod A Part no Designation 86505 Speed sensor 86515 Cable connector 86526 F I converter 86528 Tachometer Table 54 Page 118 122 ...

Page 121: ...ustomer tool set 90000 is required 90000 Designation Quantity 90012 Service support 1 90042 Press off tool 1 90070 Extraction device 1 Table 55 Customer tool set 90000 Tool sets can be ordered from any ABB Turbocharging Service Station The following spe cifications must be included in the order Turbocharger type Designation and part number of the tool set Page 119 122 ...

Page 122: ...g 27 Replacing the protective grid 55 Fig 28 Cleaning the filter silencer 62 Fig 29 Compressor end non rotating parts 64 Fig 30 Turbine end non rotating parts 65 Fig 31 Soaking the turbine end 68 Fig 32 Swivel lifting eyes 80 Fig 33 Starpoint ring nut VRM 80 Fig 34 Weights of assemblies 81 Fig 35 Removing the air inlets 82 Fig 36 Removing the gas outlet casing 83 Fig 37 Dismantling the gas outlet ...

Page 123: ...ture too high 73 Table 22 Malfunctions during operation Charge air pressure too low 73 Table 23 Malfunctions during operation Charge air pressure too high 74 Table 24 Malfunctions during operation Engine performance losses 74 Table 25 Malfunction Turbocharger pumping 75 Table 26 Malfunction Sporadic surge blows 75 Table 27 Malfunctions when stopping Runout noises 76 Table 28 Malfunctions when stop...

Page 124: ...Operation Manual A130 H A140 H Tables Copyright 2021 ABB All rights reserved HZTL4030_EN Revision G July 2021 Table 55 Customer tool set 90000 119 Page 122 122 Page 122 122 ...