ABB XAC22399, Operation Manual

Page 1: ... Turbocharging Operation Manual A165 L37 XAC22399 English Original Operation Manual Chapter Document ID 1 Introduction HZTL4005_EN_G 2 Safety HZTL4024_EN_D 3 Safety data sheet XAC22399 4 Product description HZTL4034_EN_Q ...

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: ...of contents Copyright 2020 ABB All rights reserved HZTL4005_EN Rev G March 2020 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: ...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 5: ... 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 or as ABB Turbo Sys tems in this docume...

Page 6: ...ictogram Meaning Tighten with specified torque Tighten over specified tightening angle Hand tight tighten without tools Oil Apply screw locking paste e g Loctite Apply high temperature grease Apply other paste in accordance with specifications Oil free grease free and dry Affix Measure Note Visually inspect Please note text for numbered work step See document Dispose of in an environmentally compa...

Page 7: ... the sense of the Hazardous Substances Ordinance Nevertheless the following points are to be observed when handling VCIs u Observe specifications in the safety data sheet u Ensure good room ventilation u Do not eat drink or keep food at the workplace while working with VCIs u Clean hands and face after working with VCIs u For further information refer to www branopac com Wear safety gloves to prot...

Page 8: ... the turbocharger must be inspected 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 components Replace the desiccant agent Repackage...

Page 9: ...s reserved HZTL4005_EN Rev G March 2020 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 Switzerland Ltd Turbocharging Bruggerstrasse 71a CH 5401 Baden Switzerland www abb com turbocharging Page 7 7 ...

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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: ...ion Manual A165 L37 Safety data sheet Page 1 1 Safety data sheet Copyright 2020 ABB All rights reserved XAC22399 July 2020 A165 L37 XAC22399 A165 L37 XAC22399 353 550 338 520 AV65HZ00621 2020 2300 36 100 100 ...

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Page 29: ...ing after taking out of operation 15 4 Monitoring during operation 16 4 1 Oil pressure oil temperature 16 4 2 Admissible air inlet temperature 19 4 3 Turbocharger speed 19 4 4 Low pressure measurement at the filter silencer 22 5 Operation and service 23 5 1 Noise emission 23 5 2 Service work 24 5 3 Expected replacement intervals 28 5 4 Flexible turbocharger cut out 29 5 5 Stopping the engine 30 6 ...

Page 30: ...nozzle ring A180 L 71 8 13 Fitting the nozzle ring A175 L 73 8 14 Fitting the gas inlet casing A175 L 74 8 15 Fitting the insulation A175 L 75 8 16 Fitting the nozzle ring A180 L 76 8 17 Fitting the gas inlet casing A180 L 78 8 18 Axial clearance A after assembly 79 8 19 Fitting the diffuser 80 8 20 Fitting wall insert 81 8 21 Fitting the filter silencer 83 8 22 Fitting the filter silencer with no...

Page 31: ...ions 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 Chap...

Page 32: ...y 2020 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: ...r 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 whi...

Page 34: ...es 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 equi...

Page 35: ... of the rating plates Copyright 2020 ABB All rights reserved HZTL4034_EN Rev Q July 2020 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: ... value specified here Product Weight of complete turbocharger unit kg A165 L 2300 A170 L 3300 A175 L 5600 A180 L 7500 A185 L 10500 A190 L 13500 Table 2 Total weight 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 resulti...

Page 37: ...ing the turbocharger Copyright 2020 ABB All rights reserved HZTL4034_EN Rev Q July 2020 Fig 4 Fitting the lifting gear 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: ...r 2 3 1 Placing the turbocharger on the bracket Fig 5 Placing the turbocharger u Remove covers from the oil connections u Align turbocharger and place on engine bracket u Tighten the fixing screws Steps for fastening the turbocharger 11 while only slightly loosening the lifting gear u Remove lifting gear from turbocharger u Connect cable to speed sensor u Connect all gas air and oil pipes Page 10 ...

Page 39: ... compressor end a height of turbocharger foot a Dimension a turbine end a height of turbocharger foot F spacer sleeve D Dimension 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 diago...

Page 40: ... 3100 Table 4 Tightening torques foot screws Angle controlled tightening Product Thread size Height a foot mm Pre tightening torque Nm Tightening angle height a DEG Additional tightening angle for every 10 mm of ad ditional screw length b DEG A165 L M22 86 120 30 3 7 A170 L M27 100 220 30 3 1 A175 L M30 120 300 30 2 6 A180 L M33 136 400 35 2 6 A185 L M39 151 600 35 2 4 A190 L M42 167 700 35 2 2 Ta...

Page 41: ...ith 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 enginebuilder ...

Page 42: ... 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 Checks a...

Page 43: ...embly 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 exhaust g...

Page 44: ...up with an oil temperature range at the inlet of 30 65 C with an oil temperature range at the inlet of 65 80 C 0 8 4 0 1 0 4 0 Temporarily admissible 1 h alarm with an oil temperature range at the inlet of 30 65 C with an oil temperature range at the inlet of 65 85 C 0 6 0 8 0 8 1 0 Not admissible emergency stop with an oil temperature range at the inlet of 30 65 C with an oil temperature range at...

Page 45: ... oil inlet Engine load and turbocharger speed Exhaust gas temperature The maximum admissible oil temperature at the outlet is listed in the following table The specified oil outlet temperature is to be considered as alarm value for the turbocharger op eration and must be monitored according to the current regulations Fig 8 Oil temperature at the outlet Status for operation Oil temperature at the i...

Page 46: ...BB Tur bocharging Service Station 4 1 1 Pre lubrication and post lubrication CAUTION Pre lubrication Serious damage to engine or property can result if the turbocharger is not supplied with oil from the first moment after starting the engine u Activate the pre lubrication device each time before starting the engine The pre lubrication time is at least 5 minutes The post lubrication time is at leas...

Page 47: ...d 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 9 Layout and overview of the speed measurement system 86505 Speed sensor 86528 Tachometer 86506 O ring 42047 Screw plug 86515 Cable connector 32109 Sea...

Page 48: ...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 de...

Page 49: ... with a sealing lip and does not require a sealing disc for as sembly Fig 10 Replacing the speed sensor Part number A165 L A170 L A175 L A180 L A185 L A190 L 86505 M18x1 5 150 Nm M18x1 5 150 Nm M18x1 5 150 Nm M27x2 320 Nm M27x2 320 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 engin...

Page 50: ... 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 11 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 power...

Page 51: ...tance of 1 meter from the turbocharger The highest value of the emission sound pressure level1 reaches a maximum of 105 dB A near the air inlet The following prerequisites must be fulfilled with regard to the turbochar ger to observe this limit value Air inlet system has been fitted All standard noise reducing measures2 have been fitted Bellows at the air outlet has been acoustically insulated by ...

Page 52: ...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 Specific service interval Exceptio...

Page 53: ...the filter silencer and check for damage u Dismantle the wall insert u Check axial clearance A u Clean compressor wheel diffuser wall insert and compressor casing and check for dam age u Check the nozzle ring turbine diffuser and turbine blades for any possible contamination damage or wear using a borescope This checking can also be carried out after disassembling the gas inlet casing u Fit the wa...

Page 54: ...rights reserved HZTL4034_EN Rev Q July 2020 u Replace the plain bearing 5 2 5 Service work according to instructions of enginebuilder u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en gine is stopped in accordance with the instructions of the enginebuilder Page 26 108 ...

Page 55: ...g 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 sil...

Page 56: ...s inlet casing 50000 100000 Gas outlet casing 50000 100000 Nozzle ring 35000 50000 Cover ring 25000 50000 Other casings 100000 Table 10 Expected replacement intervals for turbocharger parts HFO Heavy Fuel Oil Recommended replacement intervals h Rotor components See information on rating plate Bearings See information on rating plate Table 11 Recommended replacement intervals for turbocharger parts...

Page 57: ...lations can result in inadmissible turbocharger speeds which can lead to serious damage to property with grave consequences u The air outlet flap and gas inlet flap must be completely open during nor mal operation u During cut out operation the air outlet flap and gas inlet flap must be completely closed CAUTION Manual switching of the flaps If the gas inlet flap is opened during cut out operation...

Page 58: ...tion and service 5 5 Stopping the engine Copyright 2020 ABB All rights reserved HZTL4034_EN Rev Q July 2020 5 5 Stopping the engine u Observe the instructions regarding post lubrication Pre lubrication and post lubrication 18 u Stop the engine Page 30 108 ...

Page 59: ...served HZTL4034_EN Rev Q July 2020 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 31 108 ...

Page 60: ...e filter silencer Filter silencer with tension band Fig 13 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 32 108 ...

Page 61: ... connecting strips 81268 see Fig 13 Layout and overview of fil ter silencer 32 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 of d...

Page 62: ...v Q July 2020 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 14 Dismantling filter ring circumferential part u Dismantle circumferential part 9 Fig 15 Opening filter ring lock u Open the lock of the filter ring 81265 Page 34 108 ...

Page 63: ...16 Attaching new filter ring u Attach the new filter ring 81265 on the filter ring to be replaced so they overlap Fig 17 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 35 1...

Page 64: ...ncreased 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 b...

Page 65: ...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 clean...

Page 66: ...amage u Always wear ear protection when carrying out wet cleaning on the com pressor Wear ear protection Fig 18 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 Carefu...

Page 67: ...185 L 3 0 A190 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 59 Fig 19 Filter plug view Disassembly and checking of the filter plug 81125 is required if 20 seconds after the clean ing process water is still vis...

Page 68: ...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 Turboch...

Page 69: ...ing device Fig 20 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 agai...

Page 70: ...move 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 pressuri...

Page 71: ...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 A165 L 1 0 A170 L 1 5 A175 L 2 0 A180 L 2 5 A185 L 3 0 A190 L 3 5 Table 14 Amount of gr...

Page 72: ...r due to other causes the gas outlet casing can be drained Fig 21 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 with ...

Page 73: ...e 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 causes the compr...

Page 74: ...an environmentally compatible manner Wear safety gloves to protect against thermal hazards Possible causes Remedy Turbochar ger Axial clearance of the rotor excessive Contact an ABB Turbocharging Service Station Engine Oil filter heavily contaminated Clean Oil pump in lubricating system defect ive Check replace Manometer displays incorrectly Replace manometer Table 18 Malfunctions during operation...

Page 75: ...gh 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 Turbochar ger Manometer display not correct Replace manometer Supply pipe to manometer not sealed Repair leak Filter silencer conta...

Page 76: ...Surging of the turbocharger Surging of the turbocharger Possible causes Remedy Turbocharger Filter silencer or diffuser contamin ated Clean Periodic maintenance 31 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 Surging ...

Page 77: ...n 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 Turbochar ger 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 runo...

Page 78: ... 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 the s...

Page 79: ...s 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 assembly devices must no longer be used and must be re placed Customer spare part s...

Page 80: ...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 turbocharger in order to obtain a suspension point As sembly devices are specially constructed and d...

Page 81: ...5 L A180 L A185 L A190 L 01 Filter silencer 240 360 600 800 850 1050 02 Wall insert 240 340 560 820 1090 1500 03 Diffuser 40 60 100 140 200 270 04 Compressor casing 320 450 740 960 1360 1800 05 Cover ring 30 50 75 90 110 150 06 Nozzle ring 10 20 25 50 65 85 07 Gas inlet casing 180 240 380 520 700 810 Table 27 Weights of assemblies kg The total weight of the complete wall insert is made up of the w...

Page 82: ... Disassembly 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 23 Dismantling the filter silencer casing 01 02 Bottom part 03 04 07 08 Side part 05 06 09 Circumferential part 10 11 Flange The comp...

Page 83: ... filter silencer casing assembly Only this way is it possible to fit all the parts u Do not tighten the screws during assembly Fig 24 Fitting the filter silencer casing u Fit the bottom part 01 on 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 01...

Page 84: ...Rev Q July 2020 Fig 25 Fitting the filter silencer casing u Fit the bottom part 02 with the screws on the filter silencer Fig 26 Fitting the filter silencer casing 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 56 108 ...

Page 85: ...er silencer casing Copyright 2020 ABB All rights reserved HZTL4034_EN Rev Q July 2020 Fig 27 Fitting the filter silencer casing u Insert the flanges 10 and 11 laterally between the side parts and fit the screws Fig 28 Fitting the filter silencer casing u Fit the circumferential part 05 with the screws Page 57 108 ...

Page 86: ... screws Screws for fastening the individual parts 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 29 Fitting the bello...

Page 87: ...encers 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 If the turbocharger is also fitted with a noise package chapter Dismantling the filter silencer with noise package 61 must be observed u Dismantle the insulation if necessary Fig 30 Dismantling the filter ...

Page 88: ...ncer cast If the turbocharger is also fitted with a noise package chapter Dismantling the filter silencer with noise package 61 must be observed u Dismantle the insulation if necessary Fig 31 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 89: ...lencer u Dismantle the insulation if necessary Fig 32 Dismantling the filter silencer with noise package 1 Loosen and remove the insulation ring 81300 2 Attach the lifting gear to the front lug and rear eyelet of the filter silencer 81000 paying attention to the version of the filter silencer 3 Loosen nuts 72004 and remove with washers 72003 and insulating discs 81302 4 Remove and put down filter ...

Page 90: ... 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 wall ...

Page 91: ...TL4034_EN Rev Q July 2020 Fig 34 Moving out wall insert 7 Remove screw 72011 8 Carefully move out the wall insert 77000 with diffuser 79000 9 Remove O ring 77040 Fig 35 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 63 108 ...

Page 92: ...onnel 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 36 Putting down wall i...

Page 93: ...antling wall insert and diffuser Copyright 2020 ABB All rights reserved HZTL4034_EN Rev Q July 2020 Fig 37 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 65 108 ...

Page 94: ...oves to protect against mechanical hazards CAUTION Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts u Have the components assessed and if necessary replaced by an ABB Tur bocharging Service Station Fig 38 Measuring axial clearance A The axial clearance A of the rotor should always be measured before ...

Page 95: ...n A175 L NOTICE Dry cleaning The dry cleaning does not have to be removed to dismantle the insulation Fig 39 Removing the insulation A175 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 Detach flange connection between gas inlet casing 51001 and bellows Pa...

Page 96: ...ng 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 or removed with an appropriate tool 1 Treat nuts 51087 with rust remover...

Page 97: ...g the nozzle ring A175 L Copyright 2020 ABB All rights reserved HZTL4034_EN Rev Q July 2020 8 10 Dismantling the nozzle ring A175 L Fig 41 Dismantling the nozzle ring A175 L and smaller 1 Loosen screws 56014 and remove with washers 56011 2 Remove and put down nozzle ring 56001 Page 69 108 ...

Page 98: ...emoving 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 or 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 b...

Page 99: ...zzle ring A180 L Copyright 2020 ABB All rights reserved HZTL4034_EN Rev Q July 2020 8 12 Dismantling the nozzle ring A180 L Fig 43 Fitting the nozzle ring holder 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 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 4 Screw the screws B2 into the nozzle ring holder 5 Remove screws B1 Fig 45 Put down the nozzle ring u Use the crane to remove and put down the nozzle ring 56001 Page 72...

Page 101: ...L u Coat the screw threads with high temperature grease Fig 46 Fitting the nozzle ring A175 L and smaller Product Size Tightening torque Nm A165 L M10 35 A170 L M10 35 A175 L M10 35 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 with high temperature grease and with washers 56011...

Page 102: ...2020 ABB All rights reserved HZTL4034_EN Rev Q July 2020 8 14 Fitting the gas inlet casing A175 L Fig 47 Fitting the gas outlet casing A175 L and smaller Product Size Tightening torque Nm A165 L M16 301 140 A170 L M18 401 200 A175 L M22 501 380 Table 34 Tightening torque 51087 1 Pre tightening torque of the nuts Page 74 108 ...

Page 103: ...1087 with high temperature grease and fix gas inlet casing in two op posite positions 5 Coat remaining nuts with high temperature grease fit and then tighten crosswise ini tially to the pre tightening torque and then to the tightening torque 6 Remove the lifting gear 7 Connect the flange of the gas inlet casing and the bellows 8 15 Fitting the insulation A175 L Fig 48 Fitting the insulation A175 L...

Page 104: ...2020 ABB All rights reserved HZTL4034_EN Rev Q July 2020 8 16 Fitting the nozzle ring A180 L u Coat the screw threads with high temperature grease Fig 49 Looping around the nozzle ring A180 L and larger u Loop around the nozzle ring 56001 with lifting gear on the nozzle ring holder 90477 and fix on the crane Page 76 108 ...

Page 105: ...M12 65 A185 L M12 65 A190 L M16 170 Table 35 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 R...

Page 106: ...crew 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 support 90451 from the gas inlet casing 4 Push gas inlet casing over the threaded studs up to the gas outlet casing 5 Coat two nuts 51087 with high temperature grease and fix gas inlet casing in two op posite p...

Page 107: ...o protect against mechanical hazards CAUTION Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts u Have the components assessed and if necessary replaced by an ABB Tur bocharging Service Station Fig 52 Measuring axial clearance A The axial clearance A of the rotor should always be measured before and af...

Page 108: ...Tightening torque Nm A165 L M5 6 A170 L M6 10 A175 L M8 25 A180 L M8 25 A185 L M10 45 A190 L M10 45 Table 38 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 with Lo...

Page 109: ...and assembly 8 20 Fitting wall insert Copyright 2020 ABB All rights reserved HZTL4034_EN Rev Q July 2020 8 20 Fitting wall insert Fig 54 Positioning wall insert u Carefully bring wall insert 77000 into vertical position with the lifting device 90190 Page 81 108 ...

Page 110: ... 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 Check the correct position of both casings using the marking arrows 5 Fit a screw 72011 as a safeguard 6 Remove the shackle 90195 with lifting gear Change the po...

Page 111: ...July 2020 8 21 Fitting the filter silencer 8 21 1 Design variants The turbocharger is equipped with one of the following filter silencer 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 Page 83 108 ...

Page 112: ...serve the chapter on dismantling the filter silencer with noise package Fig 56 Fitting the filter silencer Product Size Tightening torque Nm A165 L M14 130 A170 L M16 200 A175 L M18 300 A180 L M20 420 A185 L M22 570 A190 L M24 710 Table 40 Tightening torque 72004 1 Attach lifting gear to the eyelets of the filter silencer 81000 2 Position filter silencer on compressor casing 3 Fit nuts 72004 with ...

Page 113: ...apter on dismantling the filter silencer with noise package Fig 57 Fitting the filter silencer Product Size Tightening torque Nm A165 L M14 130 A170 L M16 200 A175 L M18 300 A180 L M20 420 A185 L M22 570 A190 L M24 710 Table 41 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 7...

Page 114: ...ed and cast versions of the filter silencer Before fitting ensure that the individual sealing segments of the gasket 81301 and the gas ket 74042 are not damaged and that the contact surfaces are clean Fig 58 Fitting the filter silencer with noise package Product 72004 Nm 72043 Nm A165 L M14 130 Nm M10 45 Nm A170 L M16 200 Nm M10 45 Nm A175 L M18 300 Nm M10 45 Nm A180 L M20 420 Nm M10 45 Nm A185 L ...

Page 115: ...compressor cas ing 72000 2 Attach the lifting gear to the front lug and rear eyelet of the filter silencer 81000 paying attention to the version of the filter silencer 3 Position filter silencer on compressor casing 4 Fit nuts 72004 with washers 72003 and insulating discs 81302 and tighten 5 Fit insulation ring 81300 6 Fit air outlet silencer 74040 with gasket 74042 and secure with counter sunk sc...

Page 116: ... and assembly 8 23 Table of tightening torques Copyright 2020 ABB All rights reserved HZTL4034_EN Rev Q July 2020 8 23 Table of tightening torques Tightening torques Nm Fig 59 Overview of tightening torques Fig 60 Tightening torques of speed sensor Page 88 108 ...

Page 117: ...14 130 M16 200 M18 300 M20 420 M22 570 M24 710 63a 72002 M14 40 M16 60 M18 80 M20 100 M22 120 M24 140 64 77015 M5 6 M6 10 M8 25 M8 25 M10 45 M10 45 65 56014 M10 35 M10 35 M10 35 M12 65 M12 65 M16 170 66 81125 G1 2 45 G1 2 45 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 M27x2 320 M27x2 320 Table 43 Overview of tightening torques 1 Tighten crosswise 2 Pre ti...

Page 118: ... on the turbocharger is only permissible in emergencies It is not permitted to lock the rotor for an engine test Seri ous damage to engine or property can be caused by non compliance with the regulations in the event of an emergency u The permissible turbocharger speed for the unlocked turbocharger may not exceed 45 of nBmax Take note of the rating plate u After locking the turbocharger contact an...

Page 119: ...operation In order to ensure that the engine can continue operation as quickly as possible observe the following instructions 9 2 1 Procedure with one turbocharger installed per engine u Stop the engine u Close off oil supply to defective turbocharger u Dismantle filter silencer see chapter Dismantling the filter silencer 59 u Lock rotor with locking device see chapter Locking the rotor Version Pr...

Page 120: ...peeds The values provided by the enginebuilder apply to the max imum admissible engine load u Observe the permissible turbocharger speed for the unlocked turbochar ger u Reduce the engine load if necessary u Stop the engine u Close off oil supply to defective turbocharger u Blank off the inlets and outlets of the defective turbocharger see chapter Blanking off the inlets and outlets 95 u Continue ...

Page 121: ...t 77000 5 Align the hole circle of the locking device with the threaded holes in the compressor wheel 25000 6 Secure the locking device to the compressor wheel with the maximum possible number of screws B1 Observe the tightening torque Assembly with at least 6 screws is mandat ory The maximum possible number of screws to be fitted B1 varies as the threads in the compressor wheel are partially occu...

Page 122: ...001 to the gas outlet casing must be ensured In this case additional washers 01 must be provided in accordance with the following table These washers 01 are not supplied by ABB Fig 62 Ensuring clamping of the cover ring Product h mm d1 mm d2 mm A165 L 3 5 4 0 13 20 A170 L 3 5 4 0 13 20 A175 L 4 0 5 0 17 28 A180 L 4 0 5 0 21 34 A185 L 4 5 6 0 21 34 A190 L 4 5 6 0 25 39 Table 47 Required washers 01 ...

Page 123: ...rgers and joint air and ex haust gas receivers The cover plates for the compressor casing outlet gas inlet and gas outlet are not included in the ABB scope of delivery The following figure shows the positions where to fit the cover plates Fig 63 Position of cover plates u Stop the engine u Shut off the supply of lubricating oil to the turbocharger u Blank off flanges of compressor casing outlet 01...

Page 124: ...n Manual 4 Product description A100 L 9 Taking a turbocharger out of operation 9 2 Taking defective tur bochargers out of operation Copyright 2020 ABB All rights reserved HZTL4034_EN Rev Q July 2020 Page 96 108 ...

Page 125: ...ing 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 sheet ...

Page 126: ...rts 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 to ...

Page 127: ...piratory 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 felt and...

Page 128: ...Turbocharging Service Station u If different model variants are not taken into account in this document contact an ABB Turbocharging Service Station The customer spare part sets 97070 97071 are available for the work described in the op eration manual The customer spare part set required depends on the service work being carried out on the turbocharger The parts are only available in the complete ...

Page 129: ...er spare part set 97071 Customer spare part set is required for service work on the turbocharger after 18 000 hours Quantity Designation Part number 1 O ring 77040 1 O ring 79020 1 O ring 79021 Table 50 Customer spare part set 97071 u Dispose of replaced parts and parts that are not reusable in a professional and environ mentally compatible manner Page 101 108 ...

Page 130: ...on A100 L 12 Spare parts 12 2 View of turbocharger with part numbers Copyright 2020 ABB All rights reserved HZTL4034_EN Rev Q July 2020 12 2 View of turbocharger with part numbers Fig 64 View of turbocharger with part numbers Page 102 108 ...

Page 131: ...sing 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 77040 in the customer spare part set O ring 79000 Diffuser 79020 in the customer sp...

Page 132: ...mbers Copyright 2020 ABB All rights reserved HZTL4034_EN Rev Q July 2020 12 3 View of cartridge group with part numbers Fig 65 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: ...2 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 42306 O ring 42307 O r...

Page 134: ...the filter silencer casing 57 Fig 29 Fitting the bellows 58 Fig 30 Dismantling the filter silencer 59 Fig 31 Dismantling the filter silencer 60 Fig 32 Dismantling the filter silencer with noise package 61 Fig 33 Dismantling the wall insert 62 Fig 34 Moving out wall insert 63 Fig 35 Putting down wall insert 63 Fig 36 Putting down wall insert 64 Fig 37 Dismantling the diffuser 65 Fig 38 Measuring ax...

Page 135: ...N Revision Q July 2020 Fig 60 Tightening torques of speed sensor 88 Fig 61 Locking the rotor 92 Fig 62 Ensuring clamping of the cover ring 94 Fig 63 Position of cover plates 95 Fig 64 View of turbocharger with part numbers 102 Fig 65 View of cartridge group with part numbers 104 Page 107 108 Page 107 108 ...

Page 136: ... during operation Charge air pressure too low 47 Table 22 Malfunctions during operation Charge air pressure too high 48 Table 23 Surging of the turbocharger 48 Table 24 Malfunctions when stopping Runout noises 49 Table 25 Malfunctions when stopping Shortened runout time 49 Table 26 Malfunctions of the speed measurement system 50 Table 27 Weights of assemblies kg 53 Table 28 Weight of wall insert k...