Page 1 ABB Turbocharging Operation Manual A180-L37 HT562742 English Original Operation Manual Chapter Document-ID Introduction HZTL4005_EN_D Safety HZTL4024_EN_B Safety data sheet HT562742 Product description HZTL4034_EN_E ABB Turbo Systems Ltd...
Page 2 We herewith confirm that this Operation Manual has been drawn up in compliance with the "EU Product Liability Directive" 85/374/EEC as well as with the "EU Machinery Directive" 2006/42/EC. © Copyright 2016 ABB. All rights reserved. Design and specifications are subject to change without notice.
Page 3: Table Of Contents
Table of contents Page 1 / 8 Introduction Introduction ....................Purpose of the manual ................Symbols, definitions ..................Storage of new turbochargers and spare parts ........... Contact information ..................HZTL4005_EN Revision D © Copyright 2015 ABB. All rights reserved. September 2015...
Page 5: Introduction
3 (Safety data sheet) and the rating plate on the turbocharger. Operation Manual The Operation Manual explains the turbocharger from ABB Turbo Systems and contains instructions for safe operation. The Operation Manual is a complement to and expansion of existing national regulations for occupational safety, accident prevention and environmental protection.
Page 6: Symbols, Definitions
ABB Turbo Systems Ltd is identified as ABB Turbo Systems in this document. Official service stations of ABB Turbo Systems Official service stations are identified in this document as ABB Turbocharging Service Stations. They are regularly audited and certified by ABB Turbo Systems. Also see chapter Contact information [➙ 8]. HZTL4005_EN Revision D ©...
Page 7 Dispose of in an environmentally with specifications compatible, professional way and in compliance with locally Oil free, grease free and dry applicable regulations. Table 1: Definition of pictograms HZTL4005_EN Revision D © Copyright 2015 ABB. All rights reserved. September 2015...
Page 8: Storage Of New Turbochargers And Spare Parts
Storage of new turbochargers and spare parts Storage of new turbochargers and spare parts up to 6 months New turbochargers and spare parts from ABB Turbo Systems can be stored in sealed packaging without additional mothballing measures for up to 6 months from the date of delivery (marked by the VCI label on the package).
Page 9 Inspect the package for damage. If the package is damaged, the turbocharger or cartridge  group must be inspected 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 ...
Page 10: Contact Information
Operation Manual / 1 Introduction Introduction Page 8 / 8 Contact information Contact information for the official service stations of ABB Turbo Systems is available online. Scan the QR code to access our website.  ABB Turbo Systems AG Bruggerstrasse 71a...
Page 11 Periodic check of the pressure vessels ............Lifting of loads .................... 1.10 Prerequisites for operation and maintenance ..........1.11 Hazards during operation and maintenance ..........1.12 Safe operation ................... 1.13 Safe maintenance ..................© Copyright 2016 ABB. All rights reserved. HZTL4024_EN Revision B April 2016...
Page 13: Safety
Safety Introduction Turbochargers manufactured by ABB Turbo Systems are state of the art and comply with the respective health and safety standards in effect at the time the turbocharger was built. This ensures safe operation of the turbocharger. Nevertheless, there may be some residual risks during operation of and work on the turbocharger which: ...
Page 14: Definition Of Mandatory Signs
CAUTION can lead to CAUTION serious damage to engine or property with grave consequences. Caution signs must always be observed.  © Copyright 2016 ABB. All rights reserved. HZTL4024_EN Revision B April 2016...
Page 15: Intended Use
The specific operating limits of the turbocharger were determined on the basis of information from the enginebuilder about the intended use. These data are given on the rating plate. ABB Turbo Systems accepts no liability and rejects all warranty claims for any non-intended uses.
Page 16: Warning Plates On The Turbocharger
Operation Manual / Product description. Turbochargers supplied to the enginebuilder without insulation must be equipped later with warning plates on the insulation. This is the responsibility of the enginebuilder. © Copyright 2016 ABB. All rights reserved. HZTL4024_EN Revision B April 2016...
Page 17: Turbocharger Rating Plate
Further data 06 Customer part number 07 Designation for special design 08 Weight of turbocharger in kg 09 Turbocharger type 10 Serial number 11 Year of construction of turbocharger © Copyright 2016 ABB. All rights reserved. HZTL4024_EN Revision B April 2016...
Page 18: Periodic Check Of The Pressure Vessels
The locations of the rating plates are defined in the Operation Manual / Product description. Periodic check of the pressure vessels The pressure vessels used by ABB Turbo Systems, for example, in the wet or dry cleaning process, are so-called simple pressure vessels.
Page 19: Lifting Of Loads
The assembly devices must be completely screwed in and must not unscrew during use.  Use assembly devices only for the described applications.  Put down dismantled components of the turbocharger in such a way that they cannot tip  over. © Copyright 2016 ABB. All rights reserved. HZTL4024_EN Revision B April 2016...
Page 20: Prerequisites For Operation And Maintenance
WARNING personnel. Only use original parts from ABB Turbo Systems.  ABB Turbo Systems accepts no liability for any damage resulting from the use of non-original parts and associated accessories. © Copyright 2016 ABB. All rights reserved. HZTL4024_EN Revision B...
Page 21: Hazards During Operation And Maintenance
Wear heat-resistant safety gloves and protective clothing.  Wait for the turbocharger to cool down before carrying out any work.  Wear safety gloves to protect against thermal hazards. © Copyright 2016 ABB. All rights reserved. HZTL4024_EN Revision B April 2016...
Page 22 Page 12 / 17 Hot surfaces on the non-insulated turbocharger Non-insulated turbochargers can cause serious injuries to personnel (burns). ABB Turbo Systems supplies the turbocharger with or without insulation in WARNING accordance with the purchase order received from the enginebuilder. If...
Page 23: Safe Operation
When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay  attention to the risks that may occur as a consequence of this energy input. © Copyright 2016 ABB. All rights reserved. HZTL4024_EN Revision B April 2016...
Page 24: Safe Maintenance
Have oil binding agents ready and provide or keep oil pans at hand.  Clean up any spills.  Have fire protection means and extinguishing agents available.  © Copyright 2016 ABB. All rights reserved. HZTL4024_EN Revision B April 2016...
Page 25 Secure rotor against turning. The rotor can rotate due to the stack draught alone.  Observe the material safety data sheet for the cleaning and mothballing agents.  Wear personal protective equipment (PPE) according to the material safety data sheet.  © Copyright 2016 ABB. All rights reserved. HZTL4024_EN Revision B April 2016...
Page 26 Wear personal protective equipment (PPE) according to the material  safety data sheet. Comply with local legislation.  Wear safety goggles. Wear safety gloves against chemical hazards. Wear a respiratory mask to protect against gases. © Copyright 2016 ABB. All rights reserved. HZTL4024_EN Revision B April 2016...
Page 27 Dispose of insulation materials properly and in an environmentally  compatible manner in compliance with the legal regulations. Wear safety goggles. Wear a respiratory mask to protect against particles. Wear safety gloves against chemical hazards. © Copyright 2016 ABB. All rights reserved. HZTL4024_EN Revision B April 2016...
Page 31 Foreword to maintenance ................Cleaning the filter silencer ................Changing the filter strip on the filter silencer casing ........Cleaning the compressor during operation ..........Cleaning the turbine during operation ............HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 32 12.1 Ordering spare parts ..................12.2 View of turbocharger with part numbers ............12.3 View of cartridge group with part numbers ..........Figures ....................... 101 Tables ......................103 HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 33: Introduction
This document is valid for different turbocharger design variants. As a result, it might contain sections and descriptions of components that do not apply to a certain turbocharger. If you have any queries about a design variant, ABB Turbocharging Service Stations will be pleased to provide information (see Contact information at www.abb.com/turbocharging).
Page 34: Layout And Function Of The Turbocharger
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 HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 35 This oil tank supplies the bearings of the rotor with oil until standstill in the event that a malfunction of the lubrication oil system causes an emergency stop of the engine. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 36: Warning Plates On The Turbocharger
Figure 2: Warning plate locations If warning plates are not present in the designated locations or not readable, proceed as follows: Order new warning plates from ABB Turbocharging Service Stations.  Remove any warning plates that have become unreadable. ...
Page 37: Locations Of The Rating Plates
Locations of the rating plates Figure 3: Locations of the rating plates One rating plate (01) each is attached on the left and the right side of the turbocharger bearing casing. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 39: Removal And Installation
Remove cable to speed sensor  Disconnect all gas, air and lubricating oil pipes.  Check lifting gear.  Fasten lifting gear on suspension eyes of the bearing casing and tauten.  HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 40 Figure 4: Fitting lifting gear to turbocharger Loosen fixing screws on compressor-end and turbine-end foot.  Lift turbocharger from the engine and place the turbocharger at a suitable location.  Cover oil connections.  HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 41: Installing The Turbocharger
Remove lifting gear from suspension eyes of the bearing casing.  Connect cable to speed sensor.  Connect all gas, air and lubricating oil pipes.  HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 42: Table 3 General Information About
Tightening torque and tightening angle remain identical to property class 8.8. Compressor-end foot Figure 6: Compressor-end foot Tighten the foot fixing screws or nuts diagonally according to the selected tightening  method. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 43: Table 4 Tightening Torques (Foot Screws)
Table 5: Tightening angle (foot screws) Pinning of turbocharger feet with positioning pins If the turbocharger is pinned at its feet, one pin hole per foot must be used. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 45: Commissioning
Inspection procedures include preventative visual controls, monitoring and measuring work before and during commissioning. Inspection procedures enable changes to the turbocharger to be detected. Engine damage can be prevented. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 46 The admissible values are specified in section Oil supply. Gas, air and oil pipes After starting the engine, check all gas, air and oil pipes for leaks.  HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 47: Commissioning After Taking Out Of Operation
Continuous escape NOTICE of an oily fluid indicates an oil leak. If there is a leak, contact an ABB Turbocharging Service Station. Commissioning after taking out of operation If present Remove cover plates (blind flanges) on the compressor casing, on the gas-inlet as well as ...
Page 49: Monitoring During Operation
Not admissible → stop engine > 90 Not admissible → do not start engine (before start: preheat oil) < 30 Table 7: Lubricating oil temperature at the inlet HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 50: Table 8 Lubricating Oil Temperature At
Table 8: Lubricating oil temperature at the outlet If the turbocharger was operated for a longer period of time outside of the admissible range, ABB Turbo Systems recommends to have the turbocharger inspected by an ABB Turbocharging Service Station. 4.1.1...
Page 51: Turbocharger Speed
86506 O-ring 42047 Screw plug 86515 Cable connector 32109 Sealing disc with cams 86526 F/I converter Alternative mounting position for speed sensor or for the second speed sensor HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 52 Check the pressure loss of the alternative air inlet and compare it with normal values.  If the engine can be stopped temporarily: Inspect air lines, exhaust gas pipes and the turbochargers and remedy any malfunctions.  ABB Turbo Systems recommends contacting the nearest ABB Turbocharging Service  Station. HZTL4034_EN Revision E ©...
Page 53: Table 9 Tightening Torques (86505)
Switch on lubricating oil supply to the turbocharger.  4.2.5 Malfunction of the speed measurement system The possible reasons for malfunction of the speed measuring system are described in chapter Troubleshooting. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 54: Low Pressure Measurement At The Filter Silencer
NOTICE Better readability of the U-tube manometer can be achieved by filling with slightly coloured water. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 55: Operation And Service
Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7: A-weighted emission sound pressure level The enginebuilder must provide acoustically equivalent measures in case of deviating insulation versions HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 56: Service Work
Service work on the turbocharger that are omitted or performed too late can cause excessive contamination, wear and operating failures. CAUTION Carry out the service work at the specified time intervals.  HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 57 CAUTION lead to untimely machine damage even if the prescribed service intervals are observed. Agree on a shortened service interval with ABB Turbo Systems.  5-year service inspection To prevent machine damage caused by ageing and downtime, we...
Page 58 Operation and service Page 28 / 103 5.2.3 Service work on turbocharger every 18000 hours It is recommended to have service work and checks carried out by an ABB Turbocharging Service Station. Remove filter silencer.  Clean filter silencer and check for damage.
Page 59: Expected Replacement Intervals
 replacing the non-rotating components exposed to hot gas. A decisive role is played by various influencing parameters which, in extreme cases, can drastically shorten the replacement interval of these parts. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 60: Flexible Turbocharger Cut-Out
To ensure that there are no oil or gas leaks on the switched off turbocharger, it must be supplied with external sealing air. The turbocharger may only be switched on or off while the engine is stopped or in idle mode. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 61: Stopping The Engine
500 hours of operation. NOTICE Stopping the engine Observe the instructions regarding post-lubrication (Pre-lubrication and post-lubrication  [➙ 20]) Stop the engine.  HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 63: Periodic Maintenance
Maintenance work includes regular visual controls and cleaning operations which are intended to ensure the trouble-free functioning of the turbocharger. Described maintenance points:  Filter silencer  Compressor  Turbine and nozzle ring HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 64: Cleaning The Filter Silencer
Body of filter silencer 81268 Connecting strip 81136 Absorption segment 81270 Tension band 81137 Sheet-metal covering 81271 Lock 81265 Filter ring (if present) Insert unit (absorption segment / sheet-metal covering fitted) HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 65 Replace heavily contaminated absorption segments (81136) and any damaged connecting  strips (81268) with original parts from ABB Turbo Systems. Fitting the filter silencer Insert the absorption segments (81136) into the sheet-metal coverings (81137).
Page 66: Changing The Filter Strip On The Filter Silencer Casing
Figure 12: Dismantling filter ring circumferential part Dismantle circumferential part (9).  Figure 13: Opening filter ring lock Open the lock of the filter ring (81265).  HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 67 Pull on the old filter ring until the new filter ring is completely wrapped around the filter  silencer. Undo the connection between the new and the old filter ring.  Fasten the newly installed filter ring (81265), then fit circumferential part (9).  HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 68: Cleaning The Compressor During Operation
The interval between the cleaning cycles depends greatly on the operating conditions. Cleaning should normally take place about every 50 hours of operation. If the specified cleaning intervals are incompatible with operation of the engine, contact ABB Turbo Systems. Cleaning method and operating state The compressor is cleaned during operation using the wet cleaning method.
Page 69 Volume of water for cleaning the compressor Uncontrolled volumes of water can damage the turbocharger and the engine. CAUTION Do not guide water pipes to the filler openings.  HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 70 After cleaning, allow the engine to continue to run for at least 5 minutes under normal load.  Repeating the cleaning If the cleaning is still unsuccessful after three processes, it is recommended to have the turbocharger checked and cleaned by an ABB Turbocharging Service Station if the engine values are unsatisfactory. HZTL4034_EN Revision E ©...
Page 71: Table 12 Volume Of Water Per Cleaning
A175-L A180-L A185-L A190-L 81125 G1/2" G1/2" G1/2" G1/2" G1/2" G1/2" 45 Nm 45 Nm 45 Nm 45 Nm 45 Nm 45 Nm Table 13: Tightening torques (81125) HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 72: Cleaning The Turbine During Operation
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 Turbo Systems. Interval for dry cleaning The interval between the cleaning cycles depends greatly on the operating conditions.
Page 73 Cleaning instruction (51717) On-Off valve [closed] (51705) Gas inlet casing, insulated Protecting the pressurised air system Protect the pressurised air system against overpressure (> 10 bar).  CAUTION HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 74  Repeating the cleaning If the cleaning is still unsuccessful after three processes, it is recommended to have the turbocharger checked and cleaned by an ABB Turbocharging Service Station if the engine values are unsatisfactory. Optimum cleaning effect It is important that the specified amount of granulate is blown in for each cleaning process in order to achieve an optimum cleaning effect.
Page 75: Table 14 Amount Of Granulate
The cleaning material must be stored in a dry and clean location to prevent blockage of the pipes when cleaning. NOTICE Possible suppliers are listed in section Suppliers of dry cleaning materials. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 76: Suppliers Of Dry Cleaning Materials
Via Al Santuario di N.S. Tel.: +39 010 711 395 della Guardia 58 / A Fax: +39 010 713 120 16162 Genova E-mail: info@uniservicemarine.com Table 15: Supplier list for dry cleaning materials HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 77: Draining The Gas Outlet Casing
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 air is not sufficient, the drain pipe (01) must be cleaned mechanically. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 79: Troubleshooting
To prevent significant loss of efficiency, specific tolerances must be fulfilled.  If there is any doubt about the extent of the rubbing, contact an ABB Turbocharging Service Station.  Have a dimension check carried out by an ABB Turbocharging Service Station.
Page 80: Malfunctions During Operation
Contact ABB Turbocharging Service Station Pipes Defects, such as leaks, in the exhaust gas Repair pipes or charge air ducts Table 20: Malfunctions during operation – Speed reductions HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 81: Table 21 Malfunctions During Operation - Exhaust Gas Temperature Too High
Clean or repair boiler or exhaust gas silencer Pipes Pipes downstream to the compressor Repair. outlet not sealed. Table 22: Malfunctions during operation – Charge air pressure too low HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 82: Surging Of The Turbocharger
If the turbocharger surges continuously or periodically, parts of it can be damaged. CAUTION Slowly reduce the engine load.  Have the cause clarified immediately by an ABB Turbocharging service  station and rectified. Have components inspected for damage and, if necessary, replaced by ...
Page 83: Malfunctions When Stopping
Turbocharger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Table 26: Malfunctions when stopping - run-down time shortened HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 84: Speed Measurement System
If none of the above measures eliminates the malfunction, we sources of recommend that you have the speed measuring system inspected errors by an ABB Turbocharging Service Station. Table 27: Malfunctions of the speed measurement system HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 85: Disassembly And Assembly
ABB Turbo Systems recommends having further operations carried out  only by trained staff or an ABB Turbocharging Service Station. Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to disassembly.
Page 86 Tightening torques for assembly devices Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB Turbo Systems must be tightened so they rest firmly against the surface. Suspended loads Loads that are not attached according to regulations can cause injury to personnel or fatal accidents.
Page 87: Weights Of Assemblies
The total weight of the complete wall insert is made up of the wall insert and diffuser assemblies. A165-L A170-L A175-L A180-L A185-L A190-L 1290 1770 Table 29: Weight of wall insert [kg] HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 88: Disassembly And Assembly Of The Filter Silencer Casing
01, 02 Bottom part 03, 04, 07, 08 Side part 05, 06, 09 Circumferential part 10, 11 Flange The complete filter silencer casing has the part number 81500. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 89 NOTICE Before disassembling the bottom part (01), mark the location of screw (A).  Fit all remaining screws on the bottom part (01).  HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 90 Fit the side parts (03) and (04) with the screws on the filter silencer and on the bottom part.  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). HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 91 Figure 26: Fitting filter silencer casing 5 Fit the circumferential part (05) with the screws.  Fit the circumferential part (06) with the screws.  Fit the circumferential part (09) with the screws.  HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 92: Table 30 Tightening Torques
Tighten all screws of the circumferential parts (05, 06, 09).  Bellows Figure 27: Fitting the bellows Fit bellows (C) with frame (F), screws (S) and nuts (N) on the filter silencer casing.  HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 93: Dismantling And Fitting The Filter Silencer
Fit nuts (72004).  Part number A165-L A170-L A175-L A180-L A185-L A190-L 72004 130 Nm 200 Nm 300 Nm 420 Nm 570 Nm 710 Nm Table 31: Tightening torque (72004) HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 94: Dismantling Wall Insert And Diffuser
5. Fit lifting device (90190) with crane on upper area of wall insert (77000). 6. Change the position of the shackle (90195) with the lifting gear to P2 of the lifting device (90190). HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 95 10. Remove O-ring (77040). Figure 31: Dismantling the wall insert 3 Put the wall insert (77000) with diffuser (79000) down in a horizontal position and support it  with the underlay. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 96 1. Use the lifting device (90190) to tilt the wall insert (77000) with diffuser (79000) over the support angle (90025) and bring to a vertical position. 2. Place wall insert with the flange (F) on the underlay. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 97 Figure 33: Dismantling the diffuser 2 3. Loosen and remove screws (77015). 4. Remove O-rings (79020, 79021). 5. Attach lifting gear (L) to the diffuser (79000). 6. Remove and put down diffuser. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 98: Axial Clearance A Prior To Disassembly
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. CAUTION Have the components assessed and, if necessary, replaced by an  ABB Turbocharging Service Station. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 99: Dismantling The Gas Inlet Casing, Cover Ring, Nozzle Ring
7. Loosen and remove remaining two screws (61009). 8. Carefully move out gas inlet casing and remove with guide studs. 9. Fit support (90451) on the gas inlet casing (51001), then put down the casing. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 100 4. Pull the cover ring (57001) out of the gas outlet casing (61001) no more than 200 mm maximum until the lifting gear can be fitted. 5. Remove the cover ring (57001) via the guide studs (90316) and put it down. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 101 1. Fit the swivel lifting eye (90231) on the nozzle ring holder (90477). 2. Remove screws (B 3. Fit the nozzle ring holder (90477) with screws (B ) at the top of the flange of the gas inlet casing (51001). HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 102 ) into the nozzle ring holder. 5. Remove screws (B Figure 40: Dismantling the nozzle ring 3 Use the crane to remove and put down the nozzle ring (56001).  HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 103: Fitting The Nozzle Ring, Cover Ring, Gas Inlet Casing
2. Fit screws (56014) with high-temperature grease and washers (56011). Part number A165-L A170-L A175-L A180-L A185-L A190-L 56014 35 Nm 35 Nm 35 Nm 65 Nm 65 Nm 170 Nm Table 33: Tightening torque (56014) HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 104: Table 34 Tightening Torque
) along with the nozzle ring holder (90477). Part number A165-L A170-L A175-L A180-L A185-L A190-L 56014 35 Nm 35 Nm 35 Nm 65 Nm 65 Nm 170 Nm Table 34: Tightening torque (56014) HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 105: Table 35 Tightening Torque
4. Remove the guide studs (90316) and fit the screws (57005) with high-temperature grease. Part number A165-L A170-L A175-L A180-L A185-L A190-L 57005 50 Nm 50 Nm 80 Nm 160 Nm 160 Nm 280 Nm Table 35: Tightening torque (57005) HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 106 7. Remove swivel lifting eye (90231) and lifting gear. 8. Connect the flanges of the gas inlet casing and the bellows. 9. Fit both halves of the insulation segment (51215). HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 107: Table 36 Tightening Torque
410 Nm 500 Nm 700 Nm 920 Nm Table 36: Tightening torque (61009) 1) Pre-tightening torque of the screws Assembly of insulation [Nm] Table 37: Tightening torque (insulation) HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 108: Axial Clearance A After Assembly
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. CAUTION Have the components assessed and, if necessary, replaced by an  ABB Turbocharging Service Station. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 109: Fitting Diffuser, Wall Insert
6. Fit screws (77015). Part number A165-L A170-L A175-L A180-L A185-L A190-L 77015 6 Nm 10 Nm 25 Nm 25 Nm 45 Nm 45 Nm Table 39: Tightening torque (77015) HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 110 Figure 48: Fitting wall insert 1 Use the lifting device (90190) to carefully raise the wall insert (77000) over the support  angle (90025) and bring it to a horizontal position. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 111: Table 40 Tightening Torque
9. Fit screws (72011). Part number A165-L A170-L A175-L A180-L A185-L A190-L 72011 400 Nm 500 Nm 950 Nm 1400 Nm 1900 Nm 2570 Nm Table 40: Tightening torque (72011) HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 112: Table Of Tightening Torques
Operation Manual / 4 Product description / A100-L Disassembly and assembly Page 82 / 103 8.11 Table of tightening torques Figure 50: Overview of tightening torques Figure 51: Overview of speed sensor tightening torque HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 113: Table 41 Overview Of Tightening Torques
1) Tighten crosswise 2) Pre-tightening torque of the screws Use hydraulic tool for tightening torques exceeding 500 Nm.  Assembly of insulation [Nm] Table 42: Tightening torque, insulation HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 115: Taking A Turbocharger Out Of Operation
Sound an alarm and depending on the situation, stop the engine.  Seal oil leaks.  Soak up oil and dispose of in an environmentally compatible manner.  Wear safety gloves against thermal risks. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 116: Procedure With One Installed Turbocharger
CAUTION loosened or unscrewed on the compressor wheel. Before recommissioning of the turbocharger, the compressor wheel must be balanced at an ABB Turbocharging Service Station. Do not screw any set screws that have become unscrewed into the  compressor wheel again.
Page 117 Close the lubricating oil supply to the turbocharger.  Open the bypass around the turbocharger.  Observe specifications from enginebuilder.  HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 118: Table 45 Required Washers
280 Nm Table 46: Tightening torque (57005) 1. Remove screws (57005). 2. Fit and tighten screws (57005) with high-temperature grease and washers (01) in accordance with the table. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 119 Page 89 / 103 9.3.4 Continuing to operate the engine Continue to operate engine in accordance with enginebuilder's instructions. Do not exceed prescribed power reduction and maximum turbocharger speed. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 120: Procedure With Two Or More Installed Turbochargers
Observe specifications from enginebuilder.  9.4.2 Continuing to operate the engine Continue to operate engine in accordance with enginebuilder's instructions. Do not exceed prescribed power reduction and maximum turbocharger speed. HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 121: Mothballing The Turbocharger
If the total acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking an engine out of operation: Dismantle the turbocharger.  The rotor and the bearing parts must be removed by an official ABB Turbocharging service  station and refitted afterwards. Clean all parts.
Page 122: Taking The Engine Out Of Operation For More Than 12 Months
 The casings of the turbocharger remain attached to the engine, the rotor and bearing parts are dismantled by an ABB Turbocharging Service Station and stored separately  The turbocharger has been completely removed, either as a whole unit or in individual...
Page 123: Disposing Of Turbocharger Components
Dispose of non-metallic materials as waste.  Dispose of residues of lubricants as waste oil.  Dispose of electronic components as electronic waste.  Dispose of thermal insulation as hazardous waste.  HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 125: Spare Parts
 Serial number (HT……)  Designation and part number. Spare parts can be ordered from any ABB Turbocharging Service Station. If different model variants are not taken into account in this document, contact an ABB  Turbocharging Service Station. Required customer spare part set (97070) For the operations described in the Operation Manual, the customer spare part set (97070) is required.
Page 126: View Of Turbocharger With Part Numbers
Operation Manual / 4 Product description / A100-L Spare parts Page 96 / 103 12.2 View of turbocharger with part numbers Figure 54: View of turbocharger with part numbers HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 127: Table 48 Turbocharger With Part
O-ring 79000 Diffuser 79020 (in the customer spare part set) O-ring 79021 (in the customer spare part set) O-ring 81000 Filter silencer Table 48: Turbocharger with part numbers HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 128: View Of Cartridge Group With Part Numbers
Figure 55: View of cartridge group with part numbers Do not order assembled cartridge groups Cartridge groups are not supplied assembled. Spare parts must be ordered individually. NOTICE HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 129: Table 49 Cartridge Group With Part
42306 O-ring 42307 O-ring 42320 Socket screw 42458 Blind flange 86505 Speed sensor 86506 (in the customer spare part set) O-ring Table 49: Cartridge group with part numbers HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 131: Figures
Fig. 27 Fitting the bellows ...... 62 Fig. 28 Dismantling the filter silencer ..63 Fig. 29 Dismantling the wall insert 1 ..64 Fig. 30 Dismantling the wall insert 2 ..65 HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...
Page 133: Tables
– Exhaust gas temperature too high .......... 51 Table 22 Malfunctions during operation – Charge air pressure too low . 51 Table 23 Malfunctions during operation – Charge air pressure too high HZTL4034_EN Revision E © Copyright 2015 ABB. All rights reserved. August 2015...

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