Page 1 Operation Manual A175-M62 HT574400 English Original Operation Manual Chapter Document-ID Introduction HZTL4005_EN_F Safety HZTL4023_EN_D Safety data sheet HT574400 Product description HZTL4033_EN_A ABB Turbocharging...
Page 2 Operating limits and replacement intervals The recommended replacement intervals 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: Table Of Contents
Operation Manual / 1 Introduction Table of contents Introduction Introduction......................2 Purpose of the manual....................2 Symbols, definitions...................... 3 Storage of new turbochargers and spare parts ............5 Contact information...................... 7 © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017...
Page 4: Introduction
The Operation Manual must be available where the turbocharger is used. All persons operating or working on the turbocharger must have read and fully understood the Operation Manual. © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017...
Page 5: 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 Sta- tions. They are regularly audited and certified by ABB Turbo Systems. Also see chapter Con- tact information →7.
Page 6 Dispose of in an environmentally ance with specifications compatible, professional way and in compliance with locally applic- Oil free, grease free and dry able regulations Table 1: Definition of pictograms © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017...
Page 7: Storage Of New Turbochargers And Spare Parts
Old VCI corrosion protection emitters must be disposed of in an environmentally compat- ible, professional way and in compliance with locally applicable regulations. Close package. The more tightly the package is sealed, the longer the protection dura- tion. © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017...
Page 8 Check the package for damage. If the package is damaged, the turbocharger or cartridge group must be checked and repackaged by an ABB Turbocharging Service Station. After every 3 years, the following steps must be carried out by an ABB Turbocharging Service Station: ¡...
Page 9: Contact Information
Operation Manual / 1 Introduction 1 Introduction / 1.4 Contact information Contact information Contact information for the ABB Turbocharging Service Stations is available online. Scan the QR code to access our website. ABB Turbo Systems Ltd Bruggerstrasse 71a CH-5401 Baden Switzerland www.abb.com/turbocharging...
Page 11 Lifting of loads ......................9 1.11 Prerequisites for operation and maintenance............10 1.12 Hazards during operation and maintenance ............11 1.13 Safe operation ......................13 1.14 Safe maintenance ......................14 © Copyright 2017 ABB. All rights reserved. HZTL4023_EN Revision D June 2017...
Page 12: 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 13: Definition Of Mandatory Signs
CAUTION can lead to seri- ous damage to engine or property with grave consequences. Caution signs must always be observed. © Copyright 2017 ABB. All rights reserved. HZTL4023_EN Revision D June 2017...
Page 14: Intended Use
These data are given on the rating plate. ABB accepts no liability and rejects all warranty claims for any non-intended uses. [1]Euromot = The European Association of Internal Combustion Engine Manufacturers [2]Directive 94/9/EC concerning equipment and protective systems intended for use in po-...
Page 15: 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 16: Warning Plates On The Turbocharger
Manual, Chapter 4 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 2017 ABB. All rights reserved. HZTL4023_EN Revision D June 2017...
Page 17: Turbocharger Rating Plate
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 2017 ABB. All rights reserved. HZTL4023_EN Revision D June 2017...
Page 18: Periodic Check Of The Pressure Vessels
The locations of the rating plates are defined in the Operation Manual, Chapter 4 Product description. 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 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 2017 ABB. All rights reserved. HZTL4023_EN Revision D June 2017...
Page 20: Prerequisites For Operation And Maintenance
Original parts and accessories are specially designed by ABB Turbo Systems for the ABB tur- bochargers. ABB accepts no liability for any damage resulting from the use of non-original parts and cor- responding accessories. © Copyright 2017 ABB. All rights reserved.
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 2017 ABB. All rights reserved. HZTL4023_EN Revision D June 2017...
Page 22 At the same time, electrical or electronic components and parts can also be damaged or destroyed. Only specially trained personnel should perform work on, or with, elec- trical components. Observe national regulations. © Copyright 2017 ABB. All rights reserved. HZTL4023_EN Revision D June 2017...
Page 23: Safe Operation
When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay at- tention to the risks that may occur as a consequence of this energy input. © Copyright 2017 ABB. All rights reserved. HZTL4023_EN Revision D June 2017...
Page 24: Safe Maintenance
Keep the floor, equipment, and turbocharger clean. 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 2017 ABB. All rights reserved. HZTL4023_EN Revision D June 2017...
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 2017 ABB. All rights reserved. HZTL4023_EN Revision D...
Page 26 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 2017 ABB. All rights reserved. HZTL4023_EN Revision D June 2017...
Page 27 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 2017 ABB. All rights reserved. HZTL4023_EN Revision D June 2017...
Page 29 Operation Manual / A175-M62 / Safety data sheet Page 1 / 1 Safety data sheet A175-M62 HT574400 A175-M62 HT574400 HZTL53350K 4600 2017 © Copyright 2017 ABB. All rights reserved. HT574400 December 2017...
Page 31: Table 14 Malfunctions When Starting
Cleaning the filter silencer ................Cleaning the slotted diffuser ............... Cleaning the compressor during operation ..........Cleaning turbine and nozzle ring ..............Troubleshooting ..................Malfunctions when starting ................. © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 32: Table 20 Malfunctions During Operation
Taking the engine out of operation for more than 12 months ...... 102 Disposing of turbocharger components ............ Spare parts ..................... 12.1 Ordering spare parts .................. 105 12.2 View of turbocharger with part numbers ............. 108 Figures ....................Tables ....................© Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
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
Figure 1: Layout and function Filter silencer / air suction branch Gas inlet casing Compressor wheel Nozzle ring Diffuser Turbine Bearing bush Bearing casing Gas outlet casing Compressor casing © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 35 Cooling of the compressor wheel is compulsory to ensure the reliability and replacement inter- vals for the relevant operating conditions. In the turbocharger version with compressor wheel cooling, the cooling air is supplied through the lateral connection (15) in the bearing casing © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A...
Page 36: Warning Plates On The Turbocharger
Figure 3: Warning plates on the turbocharger 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
One rating plate each is attached on the left and the right side of the foot of the turbocharger. On turbochargers with insulation from ABB Turbo Systems, at least one additional rating plate is attached to the insulation of the gas outlet casing.
Page 39: Removal And Installation
Figure 5: Turbocharger suspension points Weight of the entire turbocharger Product Weight [kg] A170-M 3100 A175-M 4600 Table 2: Weight of the turbocharger © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 40: Removing The Turbocharger
If present: Remove insulation segments on bearing casing and feet.  Attach lifting gear to the suspension lug of the bearing casing and through the boles on the  turbine-end foot. © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 41 2. Fit transport screws (90334 / 90335) to secure the sliding block (68003) on the left and right on the turbine-end foot. Lift the turbocharger from the engine and put it down.  Cover all oil connections.  © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 42 Do neither clean nor lubricate the pressure screws. In case of non- compliance, it cannot be ensured that the necessary tension force is reached. Do not clean pressure screws.  Do not lubricate pressure screws.  © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 43: Installing The Turbocharger
Attach lifting gear to the suspension lug of the bearing casing and the turbine-end foot.  Remove the covers from the oil connections.  Align turbocharger and place on bracket.  © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 44 Tighten clamping nuts as described in the following sections.  Connect all gas, air and oil pipes.  If present: Re-fit the insulation segments.  If present: Connect cable to speed sensor.  © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 45: Table 3 Foot Bolt Dimensions
Table 3: Foot bolt dimensions Holes b1/b2 are needed to achieve the required clamping length. An additional drill hole is not needed at the higher turbine-end foot side (01). © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 46 Coat the contact surface (F) for the cup springs (X) (see Table 3) at the foot of the turbine  end (TE) with high-temperature grease. Tighten clamping nuts on turbine end (TE) (see Tightening the clamping nut [➙ 17]).  © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 47 3. Tighten clamping nut (c) by hand. 4. Screw back clamping nut by ¼ of a turn (90°). The distance between the thrust washer and the clamping nut is now about 1 mm. © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A...
Page 48: Table 4 Clamping Screw Tightening Torques
4. Work in a circle to tighten all pressure screws to 100 % of the tightening torque specified in the table. 5. Tighten pressure screws to 100 % in 5 … 7 rounds until the required residual tightening angle of < 20° is achieved. © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 49: Commissioning
Filtering of the lubricating oil with a filter mesh width of ≤ 0.050 mm is sufficient for the turbo- charger. 3.1.4 Oil pressure Comply precisely with the oil pressure before the turbocharger for trouble-free operation. © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 50: Inspection Procedures
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 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 51: Commissioning After Taking Out Of Operation
Continuous escape of NOTICE 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 53: Monitoring During Operation
 necessary pressure assured at the oil inlet. For monitoring the lubricating oil pressure, ABB Turbo Systems recommends installing a ma- nometer "M". If the pressure is controlled electronically, the appropriate signals are to be trig- gered at the warning and alarm values.
Page 54: Table 6 Oil Temperature At The Inlet
Table 7: 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 Turbocharg- ing Service Station. © Copyright 2016 ABB. All rights reserved.
Page 55: Turbocharger Speed
Figure 18: Speed measurement 86505 Speed sensor 86506 O-ring 86515 Cable connector 86526 F/I converter 86528 Tachometer 42047 Screw plug 32118 Auxiliary bearing with cams Alternative mounting position for speed sensor © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 56 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 Sta-  tion. © Copyright 2016 ABB. All rights reserved.
Page 57 Malfunction of the speed measurement system The possible reasons for malfunction of the speed measuring system are described in chapter Troubleshooting (A100 - List of possible diesel engine malfunctions). © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 59: 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 insula- tion versions © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 60 Suggestion for noise insulation, bellows Figure 19: Noise insulation, bellows Compressor casing Bellows Charge air duct / scavenging air duct Insulation cushion Insulation mat (at least 15 mm) Sheet metal cover © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 61: Service Work
Agree on a shortened service interval with ABB Turbo Systems.  5-year service inspection To prevent machine damage caused by ageing and downtime, we recom- mend having an inspection carried out by an ABB Turbocharger Service Sta- NOTICE tion no later than 5 years after the last service. 5.2.1 Service procedures every 25 …...
Page 62 Operation and service Page 32 / 113 5.2.3 Service work every 8000 ... 12000 hours of operation Checking and assessment of the rotor and the bearing parts must be carried out by an ABB Turbocharging Service Station. Dismantle the turbocharger. ...
Page 63  Lubricating oil pressure and lubricating oil temperature If present:  Air temperature after the compressor and after the charge-air cooler  Pressure loss in the filter silencer © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 64: Expected Replacement Intervals
 Turbine cleaning process Influencing parameters for exhaust gas-charged, rotating components  Fuel quality (gas, MDO, HFO)  Frequency of turbine cleaning  Turbine cleaning process  Load profile © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 65: Stopping The Engine
Let the engine continue to run at idling speed for 10 minutes before stop-  ping it. Post-lubrication can be used instead of engine idling (Pre-lubrication and  post-lubrication [➙ 19]). © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 67: 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  Diffuser  Compressor  Turbine and nozzle ring © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 68: Cleaning The Filter Silencer
Rinse in cold water. Avoid high mechanical loads (water jet). Let the filter ring dry completely before assembling.  Dirty water and mild detergent must be disposed of in compliance with locally applicable  regulations. © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 69 Have any heavily contaminated absorption segments and filter rings as well as damaged  connecting rods replaced by an ABB Turbocharging Service Station. Fitting the cover grids and absorption segments (see Figure 20) Penetration of dirt and foreign particles Any penetration of dirt and foreign particles into the compressor can damage it.
Page 70 Fit lock nuts (81273) on screws (81272) and tighten with the following tightening torque:  Lock nut Tightening torque [Nm] 81273 Table 11: Tightening torque (81273) Fit the filter ring (81265), if present.  © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 71: Cleaning The Slotted Diffuser
 When cleaning, please note that this should only take place using compressed air at low pressure, a brush and a moist cleaning cloth. Have any heavily contaminated or damaged diffusers replaced by an ABB Turbocharging  Service Station. © Copyright 2016 ABB. All rights reserved.
Page 72: Cleaning The Compressor During Operation
The time period between the periodical cleaning cycles depends greatly on the operating con- ditions. Cleaning should normally be done every 25 ... 100 hours of operation. If the specified cleaning intervals are incompatible with operation of the engine, contact ABB Turbo Systems.
Page 73 Volume of water Uncontrolled volumes of water can damage the turbocharger and the en- gine. CAUTION Never connect the water line without the orifice specified for the turbo-  charger. © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 74: Table 12: Compressor Cleaning Parameters
Water pressure Water injection period Cleaning interval Ø of orifice [bar] [mm] A170-M 50 … 100 2.5 … 4.5 25 … 100 A175-M Table 12: Compressor cleaning parameters © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 75 To avoid a reduction in engine availability, the compressor stage can be cleaned at re-  duced engine load during the drying time after wet cleaning of the turbine has been com- pleted (see section Cleaning turbine and nozzle ring [➙ 46]). © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 76: Cleaning Turbine And Nozzle Ring
The use of fuels with poor quality in conjunction with high exhaust gas temperatures can lead to extremely hard deposits on turbine components. ABB Turbo Systems recommends the use of fuels with low ash, sulphur, sodium and vanadi- um contents.
Page 77 Cleaning method Cleaning of the turbine and the nozzle ring during operation is carried out by the cleaning method described in the following and is tested and approved by ABB Turbo Systems:  Wet cleaning Wet cleaning makes use of various effects. These effects are used with varying levels of intensity, depending on the type of contamination: ...
Page 78 Wet cleaning of turbine and nozzle ring Prerequisites The following operating state and the following prerequisites have been tested and approved by ABB Turbo Systems for cleaning operations: Set the engine load between 20 … 50 % so that the turbine inlet temperature is between ...
Page 79: Table 13 Cleaning Parameters Wet
If there is no drainage system, the amount of water injected can be monitored with a flowmeter in the water supply. The permitted amount of water must be determined with the help of an ABB Turbocharging Service Station. To be observed during cleaning ...
Page 81: Troubleshooting
To prevent significant loss of effi- ciency, 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 82: Malfunctions During Operation
Remedy Turbocharger Light to medium contamination of the Clean (see chapter Periodic maintenance turbine and/or nozzle ring (with 4-stroke [➙ 37]) or contact an ABB Turbocharging application) Service Station Table 19: Malfunctions during operation – Speed increases © Copyright 2016 ABB. All rights reserved.
Page 83: Table 21 Malfunctions During Operation - Charge Air Pressure Too Low
Clean or repair boiler or exhaust gas silencer Pipes Pipes downstream to the compres- Repair. sor outlet not sealed. Table 21: Malfunctions during operation – Charge air pressure too low © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 84: 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 85: Malfunctions When Stopping
Turbocharger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Table 25: Malfunctions when stopping - run-down time shortened © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 86: Speed Measurement System
Table 28: Malfunction, Measured speed too low Other causes of malfunction If none of the measures described above remedy the malfunction, have the speed measurement system checked by an ABB Turbocharging Service Sta- NOTICE tion. © Copyright 2016 ABB. All rights reserved.
Page 87: Disassembly And Assembly
ABB Turbo Systems recommends having further operations carried out  only by trained personnel from an ABB Turbocharging Service Station. Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to dis- assembly. NOTICE Identification of the assembly devices Not all assembly devices are marked with a part number.
Page 88 Disassembly and assembly Page 58 / 113 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 per- sonnel or fatal accidents.
Page 89: Weights Of Assemblies
Filter silencer Radial air suction branch Wall insert Diffuser Compressor casing Cartridge group 1100 Turbine diffuser Cover ring Nozzle ring Gas inlet casing, radial Table 29: Assembly weights © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 90: Removing / Installing Air-Inlets
The installation of the filter silencer is carried out in reverse order. Tighten nuts (72027) to the specified tightening torque.  Part number A170-M A175-M 27027 170 Nm 220 Nm Table 30: Tightening torque (27027) © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 91: Table 31 Tightening Torque (27027)
The installation of the air suction branch is carried out in reverse order. Tighten nuts (72027) to the specified tightening torque.  Part number A170-M A175-M 27027 170 Nm 220 Nm Table 31: Tightening torque (27027) © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 92: Axial Clearance A Prior To Disassembly
Clearances outside the tolerance Serious damage to engines or property can be caused by clearances out- side the tolerance and excessively worn parts. CAUTION Have the components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. Figure 28: Axial clearance...
Page 93: Removing The Compressor Casing
4. Using shackle (90195) and lifting gear, fit lifting device (90190) to wall insert (77000). 5. Put on shackle (90195) and fasten to lifting gear. 6. Remove locking screw (72011). 7. Pull out wall insert (77000). © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 94 2. Carefully turn wall insert over support angle (90025) and place on supports. Reusing the lifting device Place wall insert such that lifting device (90190/90195) can be removed. NOTICE © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 95 Figure 31: Removing the diffuser 1. Remove and dispose of the O-ring (77040). 2. Loosen and remove screws (77015). 3. Remove diffuser (79000) with swivel lifting eyes (90235). © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 96 2. Loosen and remove nuts (61037). 3. Use press-off nuts (61090) to fully press off and remove compressor casing (72000). 4. Remove and dispose of the O-ring (42012). © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 97: Removing The Cartridge Group
Page 67 / 113 Removing the cartridge group Safety-relevant screws The six screws (01) are relevant for containment safety and must not be loosened. CAUTION Figure 33: Safety-relevant screws © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 98 3. Press off the spinner nose cone (25012) using the press-off screw (90917). 4. Loosen and remove the screw (61059). 5. Loosen and remove nuts (42128). 6. Attach lifting gear to bearing casing. © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 99 1. Evenly press off cartridge group by screwing three press-off screws (90900) into the des- ignated holes. 2. Using two guide rods (90490), move out cartridge group. 3. Fit supports (90450) and put down cartridge group. © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 100: Removing Nozzle Ring
5. Pull turbine diffuser (63000) out as far as it will go at guide plates. 6. Loop around turbine diffuser and secure to lifting gear. 7. Remove nuts (61037) and guide plates (90328). 8. Completely pull out and put down turbine diffuser. © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 101 4. Loop around cover ring and secure to lifting gear. 5. Remove guide plates (90328) and nuts (61037). 6. Fully pull out and put down cover ring (57001). © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 102 Blocked areas on nozzle ring If a nozzle ring is blocked in some areas or is covered by loose parts, we would recommend appointing an ABB Turbocharging Service Station to inspect the turbine blades and carry out a crack inspection.
Page 103: Installing Nozzle Ring
2. Using lifting gear, position nozzle ring (56001) on guide rod (90336). Do not take strain off lifting gear yet. 3. Fit guide plate (90328) with nuts (61037). 4. Remove the lifting gear. 5. Position nozzle ring (56001) in gas outlet casing. © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 104: Table 33 Tightening Torque (56014)
9. Fit the nozzle ring (56001) on the gas inlet casing (51001) using the screws (56014) and locking washers (56015). 10. Bend over locking washers (56015). © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 105: Table 34 Tightening Torque (57005)
4. Slide in cover ring as far as it will go. 5. Remove guide plates (90328) and nuts (61037). 6. Coat threads of screws (57005) with high-temperature grease. 7. Fit and tighten screws (57005). © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 106: Table 35 Tightening Torque (61069)
Part number A170-M A175-M 61069 130 Nm 200 Nm Table 35: Tightening torque (61069) 6. Coat threads of screws (61069) with high-temperature grease. 7. Fit and tighten screws (61069). © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 107: Installing The Cartridge Group
1. Fasten lifting gear to bearing casing and lift cartridge group slightly. 2. Remove support (90450). 3. Using two guide rods (90490), carefully move in cartridge group. 4. Remove guide rods (90490). © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 108: Table 36 Tightening Torque (61059 / 42128 / 86505 / 25013)
3. Fit spinner nose cone (25012) with screw (25013) and washer (25014) and tighten. 4. Remove the lifting gear. 5. Screw in and tighten speed sensor (86505) with new O-ring (86506). 6. Insert cable connector (86515). © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 109 Remove temporary covers on oil connections.  Fit all oil pipes according to instructions of enginebuilder.  Version with compressor wheel cooling Fit air supply line (compressor wheel cooling [➙ 5]).  © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 110: Installing The Compressor Casing
Tighten nuts (61037) crosswise. 5. Remove lifting device (90190 / 90195). 6. Tighten the three press-off nuts (61090) against compressor casing (72000) by applying the corresponding tightening torque. © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 111: Table 38 Tightening Torque (77015)
1. Position diffuser (79000) with swivel lifting eye (90235) on wall insert (77000). 2. Attach diffuser with screws (77015). 3. Grease the new O-ring (77040) and fit it. © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 112 2. Remove support angle (90025), bolts and nuts. 3. Fit guide studs (90319). 4. Carefully install the wall insert (77000) in the compressor casing. Make sure both markings are in the correct position. © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 113: Table 39 Tightening Torque (72011)
2. Slide wall insert (77000) into compressor casing up to stop and remove guide stud (90319). 3. Secure wall insert with screws (72011) and washers (72008). For assembly of the alternative air inlet, see section Removing / Installing air-inlets [➙ 60]. © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 114: Axial Clearance A After Assembly
Clearances outside the tolerance Serious damage to engines or property can be caused by clearances out- side the tolerance and excessively worn parts. CAUTION Have the components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. Figure 53: Axial clearance...
Page 115: Removing And Installing Turbine-End Nozzle Ring
Blocked areas on nozzle ring If a nozzle ring is blocked in some areas or is covered by loose parts, we would recommend appointing an ABB Turbocharging Service Station to in- NOTICE spect the turbine blades and carry out a crack inspection.
Page 116 3. Loosen screws (61009) and move out gas inlet casing with nozzle ring. 4. Bend open locking washers (56015), undo and remove screws (56014). 5. Pull out nozzle ring (56001). 6. Remove spiral-wound gasket (61050) and provide new one. © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 117: Table 41 Tightening Torque
5. Loop round gas inlet casing (51001) and, using lifting gear, slide over guide studs until at the gas outlet casing (61001) and secure with screws (61009). 6. Remove the guide stud (90321). © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A...
Page 118 Disassembly and assembly Page 88 / 113 7. Fit remaining screws (61009), then tighten all screws (61009). 8. If present: Fit connecting pipe for turbine cleaning Refit dismantled insulation.  © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 120: Table Of Tightening Torques
Operation Manual / 4 Product description / A100-M axial Disassembly and assembly Page 90 / 113 8.13 Table of tightening torques Figure 56: Tightening torques 1 Figure 57: Tightening torques 2 © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 121: Table 42 Tightening Torques
63001 56014 61009 57005 42059 72011 1000 72027 72026 25013 86505 M18x1.5 M18x1.5 Table 42: Tightening torques 1) Tighten screws (61009) crosswise in four steps (see Table 43). © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 122: Table 43 Tightening Torques 61009
Tightening sequence Figure 58: Flange tightening sequence Product Tightening torque (61009) [Nm] Step 1 Step 2 Step 3 Step 4 A170-M hand-tight A175-M hand-tight Table 43: Tightening torques 61009 © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 123: Taking A Turbocharger Out Of Operation
 Lock the rotor  Attach a cover plate  Blank off the inlet and outlet flanges of casings  Bypass the turbocharger © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 124: Locking The Rotor
A locked rotor must be removed after emergency operation and checked for unbalance (see chapter Removing the cartridge group [➙ 67]). The unbalance check must be carried out by an ABB Turbocharging Service Station. Exception The exception concerns customer requirements for test bed runs of new engines at a maxi- mum engine load of up to 25 %.
Page 125: Table 44 Locking Device Tightening
Rotate the compressor wheel so that the holes in the lifting spigot (90427) align with the holes in the assembly/disassembly device (94003). 5. Fasten assembly/disassembly device (94003) to lifting spigot (90427) with screws (94006). © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A...
Page 126  In pulse charging (2 to 4 gas inlets), the engine can be operated at a maximum engine load of up to 20 %. The pressure in the charge air receiver must not exceed 0.5 bar over- pressure. © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A...
Page 127: Fitting The Cover Plate
⍺ 1 ⍺ 2 ⍺ 3 A170-M 4 x 90° 37.5° 24 x 15° A175-M 4 x 90° 37.5° 24 x 15° Table 47: Cover plate dimensions 3 © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 128 In engines with separate air and exhaust gas receivers, no further measures are necessary. The engine can be operated as a suction engine according to the instructions of the en- ginebuilder. © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A...
Page 129: Blanking Off The Inlets And Outlets
Close the lubricating oil supply to the turbocharger.  Open the bypass around the turbocharger.  Observe specifications from enginebuilder.  © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 131: 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 132: 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 133: 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.  © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 135: 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. Dispose of placed and unusable parts in an environmentally-friendly and professional ...
Page 136: Table 48 Customer Spare Part Set
56015 Locking washer 57005 Hexagon-head screw 61037 Hexagon nut 61069 Hexagon-head screw 77015 Socket screw 77040 O-ring 86506 O-ring (speed sensor) Table 48: Customer spare part set (97070) © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 138: View Of Turbocharger With Part Numbers
Operation Manual / 4 Product description / A100-M axial Spare parts Page 108 / 113 12.2 View of turbocharger with part numbers Figure 62: Turbocharger with part numbers © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 139: Table 49 Turbocharger With Part Num
Socket screw 77000 Wall insert 77040 (in customer spare part set) O-ring 79000 Diffuser 81000 Filter silencer 82000 Radial air suction branch Table 49: Turbocharger with part numbers © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 141: Figures
Fig. 62 Turbocharger with part numbers 108 suction branch ......Fig. 28 Axial clearance ......Fig. 29 Removing wall insert ....Fig. 30 Transporting and turning wall insert ......... © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...
Page 143: Tables
........109 Table 22 Malfunctions during operation – Charge air pressure too high Table 23 Surging of the turbocharger ..Table 24 Malfunctions when stopping - noises during run-down... © Copyright 2016 ABB. All rights reserved. HZTL4033_EN Revision A July 2016...

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