Page 1 Turbo Systems Switzerland Ltd Operation Manual / A270-L59 XAC24370 Document identification Document number HZTL4036 Revision Language English Original Operation Manual Product identification Serial number XAC24370 Customer part number A270HZ00541 Delivery date (yyyy-mm-dd) 2021-05-27 Weight 3800 Operating limits according to rating plate...
Page 3: Table Of Contents
Low pressure measurement at the filter silencer ..........40 Operation and service ..................41 Noise emission ......................41 Service work ......................... 42 Expected replacement intervals ................46 Flexible turbocharger cut-out .................. 47 © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 4 Mothballing the turbocharger................116 11.1 Taking the engine out of operation for up to 12 months ........116 11.2 Taking the engine out of operation for more than 12 months ......117 © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 5 Disposing of turbocharger components .............. 119 Spare parts ......................120 13.1 Ordering spare parts....................120 13.2 Spare Part - Illustrations................... 122 Tools ........................140 Figures......................... 142 Tables ........................144 © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 7: Essential Information
This document is valid for different design variants of turbochargers. There may be sections and descriptions of components that are not relevant for a specific turbocharger variant. Please contact an ABB Turbocharging Service Station if you have any questions regarding a design variant (see Contact information at www.abb.com/turbocharging).
Page 8: 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 © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 9 This oil tank supplies the bearings of the rotor with oil until standstill in the event that a mal- function of the lubrication oil system causes an emergency stop of the engine. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T...
Page 10: Locations Of The Rating Plates
Locations of the rating plates Fig. 2: 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. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 11: Safety
Safety Introduction Turbochargers manufactured by ABB reflect the state of the art. The respective safety and health protection requirements are met. This ensures safe operation of the turbocharger. Nevertheless, there may be some residual risks during operation of and work on the tur- bocharger which: ¡...
Page 12: Definition Of Mandatory Signs
Non-compliance or inaccurate compliance with working or operating in- structions indicated by this symbol and the word CAUTION can lead to seri- ous damage to engine or property with grave consequences. Caution signs must always be observed. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 13: Intended Use
The use of the turbocharger is limited to the specific application released at the time of de- livery. ABB accepts no liability and rejects all warranty claims for any non-intended applications. [1]Euromot = The European Association of Internal Combustion Engine Manufacturers...
Page 14: Deflagration On Gas Engines
If 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.
Page 15: Warning Plates On The Turbocharger
If warning plates are not present in the designated locations or not readable, proceed as fol- lows: Order new warning plates from ABB Turbocharging Service Stations. Remove any warning plates that have become unreadable. Clean and degrease the areas designated for the warning plates.
Page 16 Further data 06 Customer part number 07 Designation for special design 08 Weight of turbocharger in kg 09 Turbocharger type 10 Serial number Year of construction of turbocharger Manufacturing plant © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 17: Periodic Check Of The Pressure Vessels
Locations of the rating plates The locations of the rating plates are defined in the Operation Manual. Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, are so-called "simple pressure vessels". ¡...
Page 18: Lifting Of Loads
The assembly devices must be completely screwed in and must not loosen 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 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 19: Prerequisites For Operation And Maintenance
Only use original parts from ABB. Original parts and accessories are specially designed for ABB turbochargers. ABB accepts no liability for any damage resulting from the use of non-original parts and cor- responding accessories. © Copyright 2021 ABB. All rights reserved.
Page 20: Hazards During Operation And Maintenance
Do not touch hot surfaces. Observe the warning plate on the turbochar- ger. 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 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 21 Operate the turbocharger in compliance with the specifications. Secure the rotor against unintentional rotation during maintenance. Wear safety gloves to protect against mechanical hazards. Hazards due to electrical installations (if present) © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 22: Safe Operation
Only perform operations that are described in this chapter. Only perform 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. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 23 Observe the material safety data sheet for the cleaning agent or solvent. Wear personal protective equipment (PPE) according to the material safety data sheet. Inspect the electric cables for abrasion and damage before and after your cleaning work. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T...
Page 24 Components of the turbocharger can be damaged or destroyed as a result of improper procedures. Only perform operations that are described in this chapter. Only perform operations for which you have received instruction or train- ing. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 25 Wear personal protective equipment (PPE) according to the material safety data sheet. Comply with local legislation. Wear safety goggles. Wear safety gloves to protect against chemical hazards. Wear a respiratory mask to protect against gases. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 26 Dispose of insulation materials properly and in an environmentally com- patible manner in compliance with the legal regulations. Wear safety goggles. Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against chemical hazards. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 28: Removal And Installation
Secure with lifting gear wherever possible. Loosen cable to speed sensor. Disconnect all pipes according to the instructions of the enginebuilder. Check lifting gear. Attach lifting gear to the turbocharger and tauten. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 29: Fig. 7: Fitting The Lifting Gear
3 Removal and installation / 3.2 Removing the turbocharger Fig. 7: Fitting the lifting gear Loosen fixing screws on compressor-end and turbine-end foot. Lift turbocharger from engine and put down in a suitable location. Cover oil connections. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 30: Installing The Turbocharger
Remove lifting gear from turbocharger. Connect cable to speed sensor. Connect all gas, air and oil pipes. See also 2 Steps for fastening the turbocharger [} 29] © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 31: Fig. 9: Compressor-End Foot
Tighten the foot fixing screws or nuts diagonally according to the selected tightening method. Turbine-end foot Fig. 10: Turbine-end foot Tighten the foot fixing screws or nuts according to the selected tightening method. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 32: Table 5: Tightening Torques (Foot Screws)
A280-L Table 6: 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. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 33: Commissioning
Inspection procedures include preventative visual controls, monitoring and measuring work before and during commissioning. Inspection procedures enable changes to the turbochar- ger to be detected. Machine damage can be prevented. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 34 Check oil inlet temperature. 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. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 35: Commissioning After Taking Out Of Operation
Lubricants and pastes used during assembly can liquefy or vaporise and escape as oily fluids during the initial hours of operation. Continual escape of an oily fluid indicates an oil leak. If there is a leak, contact an ABB Turbocharging Service Station. Commissioning after taking out of operation...
Page 36: Monitoring During Operation
Oil temperature at the inlet [°C] oil,inlet Admissible (see Table 7: Lubricating oil pressure, oil inlet 30 … 80 →34) Temporarily admissible (< 1 h) → alarm > 80 Not admissible → stop engine > 85 © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 37: Fig. 11: Oil Temperature At The Outlet
Table 9: Lubricating oil temperature at the outlet If the turbocharger has been operated for a longer period of time outside the admissible range, ABB Turbocharging recommends having the turbocharger inspected by an ABB Tur- bocharging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 38 The pre-lubrication time is at least 5 minutes. The post-lubrication time is at least 10 minutes. If the engine is operated for 5 to 10 minutes in idle mode before stopping, no additional post-lubrication is required. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 39: Admissible Air Inlet Temperature
Tachometer 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 © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 40 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, gas piping and the turbochargers and remedy any malfunctions. In any case, contacting the nearest ABB Turbocharging Service Station is recommended. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T...
Page 41: Fig. 13: Replacing The Speed Sensor
Unscrew the defective speed sensor. Screw in new speed sensor to the stop. Connect cable connector (86515) with the speed sensor (86505) Switch on lubricating oil supply to the turbocharger. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 42: Low Pressure Measurement At The Filter Silencer
Better readability of the U-tube manometer can be achieved by filling with slightly coloured water. Colour the water with food colouring or ink. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T...
Page 43: 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 in- sulation versions © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 45 6.2.3 Service work on turbocharger every 18000 hours It is recommended to have this service work and these checks carried out by an ABB Tur- bocharging Service Station. Damaged and worn out parts must be replaced with original ABB parts.
Page 46 6.2.4 Service work on turbocharger every 36000 hours Service work on the rotor and bearing parts must be carried out by an ABB Turbocharging Service Station. Damaged and worn out parts must be replaced with original ABB parts. Take note of correct customer spare part set (see chapter Ordering spare parts →120).
Page 47 Lubricating oil pressure and lubricating oil temperature ¡ Pressure loss in the filter silencer ¡ Air temperature after the charge air cooler If present: ¡ Air temperature after the compressor © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 48: Expected Replacement Intervals
See information on rating plate Bearings See information on rating plate Table 12: Recommended replacement intervals for turbocharger parts The specified values are guideline values and not guaranteed values, see Influencing para- meters. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 49: Flexible Turbocharger Cut-Out
Close the compressor outlet flap just before the gas inlet flap. Contamination with closed flaps To limit the contamination deposits when operating with closed flaps, we recommend you open them at least every 500 hours of operation. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 50: Stopping The Engine
Operation Manual / A200-L 6 Operation and service / 6.5 Stopping the engine Stopping the engine Observe the instructions regarding post-lubrication (Pre-lubrication and post-lubrication →36) Stop the engine. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 51: Periodic 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 © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 52: Cleaning The Filter Silencer
Connecting strip 81136 Absorption segment 81270 Tension band 81137 Sheet-metal covering 81271 Lock 81265 Filter ring (if present) 81400 Water connection Insert unit (absorption segment / sheet-metal covering fitted) © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 53 Guide the tension bands (81270) through the eyelets of the connecting strips (81268). Tighten the tension bands (81270) at the locks (81271). Any damaged tension bands must be replaced. Fit filter ring (81265), if present. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 54: Changing The Filter Strip On The Filter Silencer Casing
Fig. 17: Dismantling filter ring circumferential part Dismantle circumferential part (9). Fig. 18: Opening filter ring lock Open the lock of the filter ring (81265). © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 55: Fig. 19: Attaching New Filter Ring
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). © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 56: Cleaning The Compressor During Operation
The interval between the cleaning cycles depends greatly on the operating conditions. Cleaning should normally be carried out every 50 hours of operation. If the specified cleaning interval is incompatible with operation of the engine, contact ABB Turbocharging. Cleaning method and operating state The compressor is cleaned during operation using the wet cleaning method.
Page 57 CAUTION Volume of water for cleaning the compressor Uncontrolled volumes of water can damage the turbocharger and the en- gine. Do not guide water pipes to the filler openings. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 58: Fig. 21: Overview Of Wet Cleaning Of Compressor
Screw in lock and hand-tighten. Fit insulation to flange of filter silencer (if present). After cleaning, allow the engine to continue to run for at least 5 minutes under normal load. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 59: Fig. 22: Filter Plug View
Repeating the cleaning If the cleaning is still unsuccessful after three processes, it is recommended to have the tur- bocharger checked and cleaned by an ABB Turbocharging Service Station if the engine val- ues are unsatisfactory. Volume of water per cleaning process...
Page 60: Cleaning The Turbine During Operation
The dry cleaning of the turbine end components is carried out at an engine load of 5 … 85%. Cleaning several turbochargers If several turbochargers are installed on an engine, ABB Turbocharging recommends clean- ing one turbine after the other. © Copyright 2021 ABB. All rights reserved.
Page 61: Fig. 23: Dry Cleaning Device
Plate Piping Cleaning instructions (51717) On-Off valve [closed] (51705) Gas inlet casing, insulated CAUTION Protecting the pressurised air system Protect the pressurised air system against overpressure (> 7 bar). © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 62 Repeating the cleaning If the cleaning is still unsuccessful after three processes, it is recommended to have the tur- bocharger checked and cleaned by an ABB Turbocharging Service Station if the engine val- ues 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 63: Table 15: Cleaning Parameters
Table 15: Cleaning parameters NOTICE Storage of dry cleaning materials The cleaning material must be stored in a dry and clean location to prevent blockage of the pipes when cleaning. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 64: 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. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T...
Page 65: 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 Tur- bocharging Service Station. ¡...
Page 66: Malfunctions During Operation
Drop in speed Possible causes Remedy Turbochar- Heavy contamination of the turbine Clean Damaged rotor components or bearing Contact ABB Turbocharging Service Station Pipes Defects, such as leaks, in the exhaust Repair gas pipes or charge air ducts Table 20: Malfunctions during operation – Drop in speed ©...
Page 67: Table 21: Malfunctions During Operation - Exhaust Gas Temperature Too High
Injection mistimed Set correctly Valve control misadjusted Pipes Pipes downstream to the compressor Repair. outlet not sealed. Table 22: Malfunctions during operation – Charge air pressure too low © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 68: Surging Of The Turbocharger
Gradually reduce the engine load. Have the cause clarified and remedied immediately by an ABB Turbochar- ging Service Station. Have parts assessed for damage and, if necessary, replaced by an ABB Turbocharging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 69: Malfunctions When Stopping
Possible causes Remedy Turbochar- Turbocharger contaminated Clean Bearing damaged Contact an ABB Turbocharging Service Station Rotor rubbing Foreign object in the turbocharger Table 26: Malfunctions when stopping – Shortened runout time © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 70: Speed Measurement System
If none of the measures described above remedy the malfunc- causes of tion, it is recommended to have the speed measurement sys- malfunc- tem checked by an ABB Turbocharging Service Station. tion Table 27: Malfunctions of the speed measurement system © Copyright 2021 ABB. All rights reserved.
Page 72: Disassembly And Assembly
The specified tightening torques of the bolted connections must be observed. 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.
Page 73: Material Required
Use assembly devices only for the described applica- tions. ¡ Lifting gear Equipment for the lifting and transporting of loads (ropes, chain block, crane). Lifting gear is not supplied by ABB. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 74: Weights Of Assemblies
The total weight of the complete wall insert is made up of the wall insert and diffuser as- semblies. A255-L A260-L A265-L A270-L A275-L A280-L 1230 Table 29: Weight of wall insert [kg] © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 75: Disassembly And Assembly Of The Filter Silencer Casing
Fig. 26: Dismantling 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. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 76: Fig. 27: Fitting The Filter Silencer Casing
The location of screw (A) serves as a reference for the correct assembly of the filter silencer casing. Before disassembling the bottom part (01), mark the location of screw (A). Fit all remaining screws on the bottom part (01). © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 77: Fig. 28: Fitting The Filter Silencer Casing
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). © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 78: Fig. 30: Fitting The Filter Silencer Casing
Insert the flanges (10) and (11) laterally between the side parts and fit the screws. Fig. 31: Fitting the filter silencer casing Fit the circumferential part (05) with the screws. Fit the circumferential part (06) with the screws. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 79: Fig. 32: Fitting The Bellows
Tighten all screws of the side parts (03, 04, 07, 08) and the flanges (10, 11). Tighten all screws of the circumferential parts (05, 06, 09). Bellows Fig. 32: Fitting the bellows Fit bellows (C) with frame (F), screws (S) and nuts (N) on the filter silencer casing. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 80: Dismantling The Filter Silencer
Fig. 33: Dismantling the filter silencer 1. Attach lifting gear to the eyelets of the filter silencer (81000). 2. Loosen nuts (72004) and remove with washers (72003). 3. Remove and put down filter silencer. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 81: Fig. 34: 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. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T...
Page 82: Dismantling Wall Insert And Diffuser
4. Fit shackle (90195) with lifting gear on P1 of lifting device. 5. Fit lifting device with crane on upper area of wall insert. 6. Change the position of the shackle with the lifting gear to P2 of the lifting device. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T...
Page 83: Fig. 36: Moving Out Wall Insert
8. Remove O-ring (77040). Fig. 37: Putting down wall insert 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. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 84 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 insert (77000). 6. Change the position of the shackle with the lifting gear to P2 of the lifting device (90190). © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T...
Page 85: Fig. 39: Moving Out Wall Insert
9. Remove O-ring (77040). Fig. 40: Putting down wall insert 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. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 86: Fig. 41: Putting Down Wall Insert
1. Put wall insert (77000) down on suitable supports. 2. Tilt wall insert (77000) with diffuser (79000) against lifting device (90190). 3. Place wall insert with the flange (F) on the underlay. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 87: Fig. 42: Dismantling The Diffuser
9 Disassembly and assembly / 9.6 Dismantling wall insert and diffuser Fig. 42: 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. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 88: Axial Clearance A Prior To Disassembly
Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. Fig. 43: Measuring axial clearance A The axial clearance (A) of the rotor should always be measured before and after service work.
Page 89: Dismantling The Insulation (≤ A275-L)
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. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 90: Dismantling The Gas Inlet Casing (≤ A275-L)
A275-L Table 32: Maximum admissible loosening torque (51087) If a threaded stud (51086) shears off when loosening, an ABB Turbocharging Service Sta- tion should be contacted. 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.
Page 91: Dismantling The Nozzle Ring (≤ A275-L)
9.10 Dismantling the nozzle ring (≤ A275-L) Fig. 46: Dismantling the nozzle ring (A275-L and smaller) 1. Loosen screws (56014) and remove with washers (56011). 2. Remove and put down nozzle ring (56001). © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 92: Dismantling The Gas Inlet Casing (A280-L)
840 Nm Table 33: Maximum admissible loosening torque (51087) If a threaded stud (51086) shears off when loosening, an ABB Turbocharging Service Sta- tion should be contacted. 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.
Page 93: Dismantling The Nozzle Ring (A280-L)
Fig. 48: Fitting the nozzle ring holder 1. Remove screws (B 2. Fit the nozzle ring holder (90477) with screws (B ) at the top of the flange of the gas inlet casing (51001). © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 94: Fig. 49: Dismantling The Nozzle Ring
4. Screw the screws (B ) into the nozzle ring holder. 5. Remove screws (B Fig. 50: Put down the nozzle ring Use the crane to remove and put down the nozzle ring (56001). © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 95: Fitting The Nozzle Ring (≤ A275-L)
) with the flange connection (A ) and slide the nozzle ring (56001) into the gas inlet casing (51001). 2. Fit screws (56014) with high-temperature grease and washers (56011). © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 96: Fitting The Gas Inlet Casing (≤ A275-L)
2. Loop around the gas inlet casing (51001) with the lifting gear and secure it to the crane. 3. Push gas inlet casing over the threaded studs up to the gas outlet casing. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T...
Page 97: Fitting The Insulation (≤ A275-L)
2. Fit the insulation jackets (51200) on the gas inlet casing (51001) with the screws. 3. Fit connecting plates of insulation jackets with screws. 4. Fit insulation jackets with screws on gas outlet casing (61001). © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T...
Page 98: Fitting The Nozzle Ring (A280-L)
Coat the screw threads with high-temperature grease. Fig. 54: Fitting the nozzle ring (A280-L) Use lifting gear to secure the nozzle ring (56001) on the nozzle ring holder (90477) and transport it. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 99: Fig. 55: Attaching The Nozzle Ring (A280-L)
4. Coat screws (56014) with high-temperature grease and fit with washers (56011). 5. Remove screws (B ) along with the nozzle ring holder (90477). © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 100: Fitting The Gas Inlet Casing (A280-L)
7. Remove the lifting gear. 8. Connect the flange of the gas inlet casing and the bellows. 9. Fit the insulation segments (51215). © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 101: Axial Clearance A After Assembly
Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. Fig. 57: Measuring axial clearance A The axial clearance (A) of the rotor should always be measured before and after service work.
Page 102: Fitting The Diffuser
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 Loctite® 542. 6. Fit screws. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 103: Fitting Wall Insert
9 Disassembly and assembly / 9.20 Fitting wall insert 9.20 Fitting wall insert Fig. 59: Positioning wall insert Carefully bring wall insert (77000) into vertical position with the lifting device (90190). © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 104: Table 40: Tightening Torque (72002)
5. Fit a hexagon nut (72004) with a sleeve (90191) as a safety device. 6. Remove the shackle (90195) with lifting gear. Fit shackle with lifting gear on P1 of the lift- ing device (90190) and remove with the crane. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T...
Page 105 8. Check that 23 threaded studs have been fitted. 9. Press the wall insert into the compressor casing using a hexagon nut (72004) and sleeve (90191). Observe tightening torque. Remove nuts and sleeves. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T...
Page 106: Table 42: Tightening Torque (72011)
P1 of the lifting device (90190) and remove with the crane. 7. Move the wall insert fully in, then remove the guide studs (90320). 8. Fit the screws (72011). Observe tightening torque. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T...
Page 107: Fitting The 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. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 108: Fig. 62: Fitting The Filter Silencer
1. Attach lifting gear to the eyelets of the filter silencer (81000). 2. Position filter silencer on compressor casing. 3. Fit nuts (72004) with washers (72003) and tighten. Fit insulation as far as necessary. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 109: Fig. 63: Fitting The Filter Silencer
1. Attach the lifting gear to the front lug and rear eyelet of the filter silencer (81000). 2. Position filter silencer on compressor casing. 3. Fit nuts (72004) with washers (72003) and tighten. Fit insulation as far as necessary. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 110: Table Of Tightening Torques
Operation Manual / A200-L 9 Disassembly and assembly / 9.22 Table of tightening torques 9.22 Table of tightening torques Fig. 64: Overview of tightening torques Fig. 65: Overview of speed sensor tightening torque © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 111: Fig. 64: Overview Of Tightening Torques
2) Pre-tightening torque of the screws Use hydraulic tool for tightening torques exceeding 500 Nm. Tightening torque, insulation Thread size Tightening torque [Nm] M12 (compressor casing insulation) Table 46: Tightening torque, insulation © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 112: Taking A Turbocharger Out Of Operation
Impermissible vibrations and unbalance values can cause serious damage to the engine or property during operation. It is imperative that the following work is carried out after emergency operation with a locked rotor by an ABB Turbocharging Service Station: Remove rotor and check for unbalance...
Page 113: Taking Defective Turbochargers Out Of Operation
If necessary, remove the nozzle ring (see chapter Engines without bypass around the turbocharger →114) Table 47: Bypass procedure Continue to operate engine in accordance with enginebuilder's instructions. Observe the prescribed power reduction. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 114: Fig. 66: Locking The Rotor
Blanking off the inlets and outlets →115). Continue to operate engine in accordance with enginebuilder's instructions. Observe the prescribed power reduction. 10.2.3 Locking the rotor Fig. 66: Locking the rotor © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 115: Table 48: Tightening Torque B
Close the lubricating oil supply to the turbocharger. Open the bypass around the turbocharger. Observe specifications from enginebuilder. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 116: Fig. 67: Ensuring Clamping Of The Cover Ring
If the nozzle ring is removed for emergency operation, the clamping of the cover ring (57001) to the gas outlet casing must be ensured. In this case, additional washers (01) must be provided in accordance with the following table. These washers (01) are not supplied by ABB. Fig. 67: Ensuring clamping of the cover ring...
Page 117: Fig. 68: Position Of Cover Plates
The chapter is only applicable for engines with several turbochargers 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.
Page 118: Mothballing The Turbocharger
If the acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking the engine out of operation: Dismantle the turbocharger. The rotor and bearing parts must be dismantled and subsequently refitted by an ABB Tur- bocharging Service Station. Clean all parts.
Page 119: 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 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...
Page 120: Material And Disposal
(RoHS2). Products and related accessories manufac- tured by ABB Switzerland Ltd, Turbocharging do not fall within the Scope of RoHS2 due to their application in large scale fixed installations, means of transports for persons or goods, non-road mobile machinery (Directive 2011/65/EC Article 2, 4.(e), (f), (g)).
Page 121: Disposing Of Turbocharger Components
Dispose of metals as scrap metal for recycling. 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. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 122: Spare Parts
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. The customer spare part sets (97070 / 97071) are available for the work described in the op- eration manual.
Page 123: Table 52: Customer Spare Part Set (97071)
77040 O-ring 79020 O-ring 79021 Table 52: Customer spare part set (97071) Dispose of replaced parts and parts that are not reusable in a professional and environ- mentally compatible manner. © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 124: Spare Part - Illustrations
Bearing casing common parts 42039 42015 42011* 42001 42461 42463 42460 42464 42459 42465 42300 42008 61035 42462 42307* 42306* 42305* * = Available within the spare part set HZTL443382 Mod. B © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 125: Table 53: Spare Parts - Bearing Casing Common Parts
42307* O-ring 42459 Hexagon-head screw 42460 Cover 42461 Gasket 42462 Cover 42463 Hexagon-head screw 42464 Cover 42465 Gasket 61035 Socket screw Table 53: Spare parts – Bearing casing common parts © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 126 Bearing casing, common 42294* 42041* 42553* ** 42047 42552 42557 42059 42041* 42458 ** = Upgrade kit sealing air supply * = Available within the spare part set HZTL443381 Mod. C © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 127: Table 54: Spare Parts - Bearing Casing Oil Tank
Gasket 42455 Flange plate 42456 Socket screw 42457 Gasket 42458 Blind flange 42552 Cover 42553* ** Flat gasket 42557 Hexagon-head screw Table 54: Spare parts – Bearing casing oil tank © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 128: Table 55: Spare Parts - Cartridge
* = Available within the spare part set HZTL443573 Mod. A Part no. Designation 10900 Cartridge 25012 Spinner nose cone 25013* Socket screw 25014* Washer Table 55: Spare parts – Cartridge © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 129 72004* Hexagon nut 72011 Hexagon-head screw 72013 Screw plug 72060 Insulation 74040** Air-outlet silencer 74042** Gasket 74043** Counter-sunk screw 77000 Wall insert 77015* Socket screw 77040* O-ring 79000 Diffuser © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 130: Table 56: Spare Parts - Compressor Casing
Operation Manual / A200-L 13 Spare parts / 13.2 Spare Part - Illustrations Part no. Designation 79020* O-ring 79021* O-ring Table 56: Spare parts – Compressor casing © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 131: Table 57: Spare Parts - Filter Silencer
Cover grid 81268 Connecting strip 81270 Tension band 81271 Lock 81300** Insulation 81301** Gasket 81302** Insulating disk 81400** Water connection 81500** Silencer casing Table 57: Spare parts – Filter silencer © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 132: Table 58: Spare Parts - Gas Inlet Casing Axial
Screw Plug 51086 Threaded stud 51087 Hexagon nut 51200 Insulation 51215 Insulation segment 56001 Nozzle ring 56011* Washer 56014* Hexagon-head screw Table 58: Spare parts – Gas inlet casing axial © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 133: Table 59: Spare Parts - Gas Inlet Casing Radial
Screw plug 51086 Threaded stud 51087 Hexagon nut 51200 Insulation 51215 Insulation segment 56001 Nozzle ring 56011* Washer 56014* Hexagon-head screw Table 59: Spare parts – Gas inlet casing radial © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 134: Table 60: Spare Parts - Gas Outlet Casing
Hexagon-head screw 61085 Hexagon-head screw 61086** Hexagon nut 61087 Blind flange 61088 Screw plug 61100 Insulation 68002 Foot TE 68031 Distance sleeve Table 60: Spare parts – Gas outlet casing © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 135 25011* ** O-ring 29000 Turbine blade 32001* Thrust bearing 32101* Radial bearing 32102* Radial bearing 32105* Floating disc 32106* Axial bearing 32109* Sealing disc 32159* Safety screw 32174* O-ring © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 136: Table 61: Spare Parts - Rotor And Bearing Parts
Operation Manual / A200-L 13 Spare parts / 13.2 Spare Part - Illustrations Part no. Designation 42320* Socket screw Table 61: Spare parts – Rotor and bearing parts © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 137: Table 62: Spare Parts - Sealing Air Supply For Flexible Cut-Out
42555* ** O-ring 42556 Socket screw 42557 Socket screw 42559** Socket screw 42560 Plate sealing air 97088* ** Orifice kit Table 62: Spare parts – Sealing air supply for flexible cut-out © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 138: Table 63: Spare Parts - Speed Measurement
* = Available within the spare part set HZTL443252 Mod. B Part no. Designation 86505** Speed sensor 86506* ** O-ring 86515** Cable connector 86526** F/I-converter 86528** Tachometer Table 63: Spare parts – Speed measurement © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 139: Table 64: Spare Parts - U-Tube Manometer
Operation Manual / A200-L 13 Spare parts / 13.2 Spare Part - Illustrations U-tube manometer 81050 HZTL443260 Mod. C Part no. Designation 81050 U-tube manometer Table 64: Spare parts – U-tube manometer © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 140 51716 51714 51713 51719 51711 51724 51701 51703 51723 51700 51708** 51722 51710 51720 51710** 51712 51721 51709 51704 51718 51706 51705 ** = if provided HZTL443343 Mod. B © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 141: Table 65: Spare Parts - Turbine Dry Cleaning Radial
Hexagon-head screw 51719 Hexagon nut 51720 Stud 51721 Hexagon nut 51722 Sleeve 51723 Heat protection hose 51724 Screw-in socket 51725 Pipe Table 65: Spare parts – Turbine dry cleaning radial © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 142: Tools
Lifting device 90195 Shackle 90317 Guide stud 90320 Guide stud 90900 Press-off screw 90924 Press-off screw 94003 Locking device 94020 Bracket Table 68: Customer tool set 90000 (A270-L.. – A275-L..) © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021...
Page 143: Table 69: Customer Tool Set 90000 (A280-L
94003 Locking device 94020 Bracket Table 69: Customer tool set 90000 (A280-L..) This tool set 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 144: Figures
Fig. 30: Fitting the filter silencer casing ....76 Fig. 59: Positioning wall insert........101 Fig. 31: Fitting the filter silencer casing....76 Fig. 60: Fitting the wall insert (A255-L.. - A260-L..) ..Fig. 32: Fitting the bellows .......... 77 © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Revision T December 2021...
Page 145 Fig. 65: Overview of speed sensor tightening torque Fig. 66: Locking the rotor .......... 112 Fig. 67: Ensuring clamping of the cover ring ..114 Fig. 68: Position of cover plates ....... 115 © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Revision T December 2021...
Page 146: Tables
Table 53: Spare parts – Bearing casing common parts ................123 Table 25: Malfunctions when stopping – Runout noises................67 Table 54: Spare parts – Bearing casing oil tank..125 Table 55: Spare parts – Cartridge......126 © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Revision T December 2021...
Page 147 L..) .................. 140 Table 67: Customer tool set 90000 (A265-L..)..140 Table 68: Customer tool set 90000 (A270-L.. – A275- L..) .................. 140 Table 69: Customer tool set 90000 (A280-L..) ..141 © Copyright 2021 ABB. All rights reserved. HZTL4036_EN Revision T December 2021...

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