Page 1 Operation Manual A175-M52 HT597528 English Original Operation Manual Chapter Document-ID Introduction HZTL4005_EN_G Safety HZTL4023_EN_E Safety data sheet HT597528 Product description HZTL4033_EN_F ABB Switzerland Ltd, 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 2020 ABB. All rights reserved. HZTL4005_EN Rev.G March 2020...
Page 4: Introduction
Availability of the Operation Manual 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 2020 ABB. All rights reserved. HZTL4005_EN Rev.G March 2020...
Page 5: Symbols, Definitions
Definition of Caution / Warning Caution and warning signs are described in chapter Safety. ABB Turbocharging ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging or as ABB Turbo Sys- tems in this document. Official service stations of ABB Turbocharging Official service stations are regularly audited and certified by ABB Turbocharging.
Page 6 Visually inspect Please note text for numbered work step. See document Dispose of in an environmentally compatible, professional way and in compliance with locally applicable regulations. Table 1: Definition of pictograms © Copyright 2020 ABB. All rights reserved. HZTL4005_EN Rev.G March 2020...
Page 7: Storage Of New Turbochargers And Spare Parts
Dispose of the old VCI corrosion protection emitter in an environmentally compatible manner, professionally and in accordance with local regulations. Seal the package. The better the external seal is designed, the more permanent the pro- tection. © Copyright 2020 ABB. All rights reserved. HZTL4005_EN Rev.G March 2020...
Page 8 Inspect the package for damage. If the package is damaged, the turbocharger must be in- spected by an ABB Turbocharging Service Station and repacked. After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station: ¡...
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 Switzerland Ltd, Turbocharging 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 2020 ABB. All rights reserved. HZTL4023_EN Rev.E October 2020...
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
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 2020 ABB. All rights reserved. HZTL4023_EN Rev.E October 2020...
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 2020 ABB. All rights reserved. HZTL4023_EN Rev.E October 2020...
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 Year of construction of turbocharger Manufacturing plant © Copyright 2020 ABB. All rights reserved. HZTL4023_EN Rev.E October 2020...
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 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 2020 ABB. All rights reserved. HZTL4023_EN Rev.E October 2020...
Page 20: 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 2020 ABB. All rights reserved.
Page 21: 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 2020 ABB. All rights reserved. HZTL4023_EN Rev.E October 2020...
Page 22 Operate the turbocharger in compliance with the specifications. Secure the rotor against unintentional rotation during maintenance. Wear safety gloves to protect against mechanical hazards. © Copyright 2020 ABB. All rights reserved. HZTL4023_EN Rev.E October 2020...
Page 23: Safe Operation
In case of damage, take the turbocharger out of operation immediately and safeguard against accidental/unauthorised use. 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 2020 ABB. All rights reserved. HZTL4023_EN Rev.E October 2020...
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 2020 ABB. All rights reserved. HZTL4023_EN Rev.E October 2020...
Page 25 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 2020 ABB. All rights reserved. HZTL4023_EN Rev.E October 2020...
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 2020 ABB. All rights reserved. HZTL4023_EN Rev.E October 2020...
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 2020 ABB. All rights reserved. HZTL4023_EN Rev.E October 2020...
Page 29 Operation Manual / A175-M52 / Safety data sheet Page 1 / 1 Safety data sheet A175-M52 HT597528 A175-M52 HT597528 A11-TRB-101-INTER 4600 2020 © Copyright 2020 ABB. All rights reserved. HT597528 December 2020...
Page 31 Cleaning turbine and nozzle ring ................44 Troubleshooting....................50 Malfunctions when starting..................50 Malfunctions during operation ................. 51 Surging of the turbocharger..................53 Malfunctions when stopping..................54 Speed measurement system ..................55 © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 32 Disposing of turbocharger components ............106 Spare parts ......................107 12.1 Ordering spare parts....................107 12.2 View of turbocharger with part numbers ............108 Tools ........................110 Figures........................111 Tables ........................113 © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 33: Introduction
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 34: Layout And Function Of The Turbocharger
Filter silencer / air suction branch 06 Gas inlet casing 02 Compressor wheel Nozzle ring 03 Diffuser 08 Turbine 04 Bearing bush 09 Bearing casing 05 Gas outlet casing Compressor casing © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 35: Fig. 2: Connection Of The Compressor Wheel Cooling
Cooling of the compressor wheel is compulsory to ensure the reliability and replacement in- tervals 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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 36: 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 37: Locations Of The Rating Plates
One rating plate (01) each is attached on the left and the right side of the foot of the tur- bocharger. On turbochargers with insulation supplied by ABB, at least one additional rating plate is at- tached to the insulation of the gas outlet casing.
Page 38: Removal And Installation
Depending on the specification, the weight specified on the rating plate may be lower than the standard value specified here. Fig. 5: Turbocharger suspension points Product Weight of complete turbocharger unit [kg] A170-M 3100 A175-M 4600 Table 2: Weight of complete turbocharger unit © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 39: 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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 40: Fig. 7: Removing The Foot Mounting
3. 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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 41: Fig. 8: Loosening The Clamping Nut
3. In 1 to 5 rounds, loosen each pressure screw by 90° in circular order until all pressure screws have been relieved. Unscrew and remove the clamping nut by hand. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 42: Installing The Turbocharger
If present: Remove insulation segment on the bearing casing. 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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 43: Fig. 10: Removing Auxiliary Screw
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. Compressor-end (CE) foot Fig. 11: Compressor-end foot © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 44: Fig. 12: Turbine-End Foot
Table 6: Foot screws, number of cup springs 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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F...
Page 45: Fig. 13: Ce Foot Contact Surface
→14) on the foot of the turbine end (TE) with high-temperature grease. →16). Tighten clamping nuts on turbine end (TE) (see Tightening the clamping nut © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 46: Fig. 15: Tightening The Foot Screws (1)
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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F...
Page 47: Fig. 16: Tightening Procedure
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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 48: Commissioning
Filtering of the lubricating oil with a filter mesh width of ≤ 0.050 mm is sufficient for the tur- bocharger. 3.1.4 Oil pressure Comply precisely with the oil pressure before the turbocharger for trouble-free operation. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 49: Inspection Procedures
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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 50: 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 51: Monitoring During Operation
The lubricating oil pressure must be monitored during operation and the necessary pressure assured at the oil inlet. For monitoring the lubricating oil pressure, ABB Turbocharging recommends installing a manometer "M". If the pressure is controlled electronically, the relevant signals should be triggered at the warning and alarm values.
Page 52: Table 9: Oil Temperature At The Inlet
Table 10: 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 2020 ABB. All rights reserved.
Page 53: Turbocharger Speed
Fig. 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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 54 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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F...
Page 55 4.2.5 Malfunction of the speed measurement system The possible reasons for malfunction of the speed measurement system are described in chapter Troubleshooting (Reasons for malfunction of the speed sensor). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 56: 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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 57: Fig. 19: Noise Insulation, Bellows
Suggestion for noise insulation, bellows Fig. 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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 58: Service Work
Agree on a specific service interval with ABB Turbocharging. To prevent machine damage caused by ageing and downtime, we recommend having an in- spection carried out by an ABB Turbocharging Service Station no later than 5 years after the last service.
Page 59 5 Operation and service / 5.2 Service work 5.2.3 Service work every 8000 ... 16000 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 60 Pressure loss in the charge air cooler ¡ 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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 61: 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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 62: Stopping The Engine
Let the engine continue to run at idling speed for 10 minutes before stop- ping it. Post-lubrication can also be used instead of engine idling (see Pre-lubric- ation and post-lubrication →18). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 63: 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 ¡ Diffuser ¡ Compressor ¡ Turbine and nozzle ring © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 64: 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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 65 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 Fig. 20: Cleaning the filter silencer →34)
Page 66: Fig. 21: Cleaning The Filter Silencer (2)
Fit lock nuts (81273) on screws (81272) and tighten with the following tightening torque: Lock nut Tightening torque [Nm] 81273 Table 14: Tightening torque (81273) Fit the filter ring (81265), if present. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 67: Cleaning The Slotted Diffuser
When cleaning, please note that this should only take place using lightly pressurized air, a brush and a moist cleaning cloth. Have any heavily contaminated or damaged diffusers replaced by an ABB Turbocharging Service Station. © Copyright 2020 ABB. All rights reserved.
Page 68: Cleaning The Compressor During Operation
The time period between the periodical cleaning cycles depends greatly on the operating conditions. 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. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 69 CAUTION Volume of water Uncontrolled volumes of water can damage the turbocharger and the en- gine. Never connect the water line without the orifice specified for the tur- bocharger. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 70: Table 15: Compressor Cleaning Parameters
Cleaning parameters for each compressor Product Engine load Water pres- Water injection Cleaning interval Ø of ori- sure period fice [bar] [mm] A170-M 50 … 100 2.5 … 4.5 25 … 100 A175-M Table 15: Compressor cleaning parameters © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 71 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 →44). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 72: Fig. 23: Operation Of Water Pressure Vessel
On V-engines with several turbochargers per engine, parallel cleaning of both turbochargers is recommended. This cleaning process is faster and reduces the risk of surging of the tur- bocharger. To carry out the cleaning operation checked and recommended by ABB Turbocharging, the following prerequisites must be fulfilled: ¡...
Page 73: Table 16: Compressor Cleaning Parameters
After cleaning operations, a waiting period of at least 5 minutes is required for the tur- bocharger to dry. If the cleaning is unsuccessful after three attempts, we recommend having the turbocharger checked and cleaned by an ABB Turbocharging Service Station in the event of unsatisfactory engine values. Cleaning parameters for each turbocharger compressor...
Page 74: 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 Turbocharging recommends the use of fuels with low ash, sulphur, sodium and vana- dium contents. Consequences of contamination: ¡...
Page 75 6.5.3 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 Turbocharging: ¡ Wet cleaning Wet cleaning makes use of various effects. These effects are used with varying levels of in- tensity, depending on the type of contamination: ¡...
Page 76: Fig. 24: Turbine And Nozzle Ring Cleaning Cycle
Prerequisites: Procedure without automated cleaning The following operating state and the following prerequisites have been tested and ap- proved by ABB Turbocharging for cleaning operations: Set the engine load between 20 … 50 % so that the turbine inlet temperature is between 380 … 430 °C.
Page 77: Fig. 25: Cleaning Cycle Of Turbine And Nozzle Ring With Load Ramp
6 Periodic maintenance / 6.5 Cleaning turbine and nozzle ring Procedure with automated cleaning The following operating state and the following prerequisites have been tested and ap- proved by ABB Turbocharging for cleaning operations: Set the engine load as follows: ¡...
Page 78: Fig. 26: Procedure Wet Cleaning Of Turbine And Nozzle Ring
If there is no drainage system, the amount of water injected can be mon- itored with a flowmeter in the water supply. The permitted amount of water must be de- termined with the help of an ABB Turbocharging Service Station. To be observed during cleaning ¡...
Page 79: Table 17: Cleaning Parameters Wet Cleaning Of Turbine And Nozzle Ring
Table 17: Cleaning parameters Wet cleaning of turbine and nozzle ring 1) Water pressure p as guideline value: water ¡ 2.3 bar when used with an axial gas inlet casing ¡ 3 bar when used with a radial gas inlet casing © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 80: 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 81: Malfunctions During Operation
Turbochar- Heavy contamination of the turbine Clean (see chapter Periodic mainten- and/or nozzle ring ance →33) Damaged rotor components or bearing Contact ABB Turbocharging Service Station Engine Defect on the connected cylinders in Contact enginebuilder pulse charging Pipes Defects, such as leaks, in the exhaust...
Page 82: Table 24: 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 25: Malfunctions during operation – Charge air pressure too low © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 83: 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. Surging of the turbocharger Possible causes...
Page 84: 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 29: Malfunctions when stopping – Shortened runout time © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 85: Speed Measurement System
Table 32: Malfunction, Measured speed too low NOTICE 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- tion. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F...
Page 86: 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 87 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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 88: Weight Of Assemblies
Radial air suction branch Wall insert Diffuser Compressor casing Cartridge group 1100 Turbine diffuser Cover ring Nozzle ring Gas inlet casing, radial Gas inlet casing, axial Table 33: Assembly weights © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 89: Removing The Air Inlets
1. Loop lifting gear through the fin on the filter silencer and secure to the eyelets at the rear with shackles (90195). 2. Loosen nuts (72027) and remove with washers (72028). Remove and put down filter silencer. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 90: Fig. 29: Removing The Air Suction Branch
Fig. 29: Removing the air suction branch 1. Loop lifting gear around air suction branch. 2. Loosen and remove the nuts (72027) with washers (72028). Remove and put down the air suction branch. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 91: 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. 30: Axial clearance...
Page 92: Removing The Compressor Casing
Depending on the hole pattern of the wall insert (77000), the screws (90197) cannot be fitted symmetrically. 5. Put on shackle (90195) and fasten to lifting gear. 6. Remove locking screw (72011). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 93: Fig. 32: Transporting And Turning Wall Insert
1. Fit support angle (90025) with bolts and nuts. 2. Carefully turn wall insert over support angle (90025) and place on supports. Place wall insert such that lifting device (90190/90195) can be removed. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F...
Page 94: Fig. 33: Removing The Diffuser
Removing the diffuser Fig. 33: Removing the diffuser 1. Remove and dispose of the O-ring (77040). 2. Loosen and remove screws (77015). 3. Loop lifting gear around diffuser (79000) and remove diffuser. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 95: Fig. 34: Removing The Compressor Casing
(72000) and secure to crane. 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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 96: Removing The Cartridge Group
Check that the oil orifices have been correctly installed. Version with compressor wheel cooling Dismantle air supply line (see Compressor wheel cooling →5). Separate oil inlet and outlet pipes. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 97: Fig. 36: Removing Cartridge Group 1
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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 98: Fig. 37: Removing Cartridge Group 2
3. Fit supports (90450) and put down cartridge group. 4. Remove guide studs (90490). Fit and tighten the spinner nose cone (25012) together with socket screw (25013) and washer (25014) until hand-tight. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F...
Page 99: Removing The 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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 100: Fig. 40: Removing Cover Ring 1
Press off cover ring with the press-off screws (90916 for A170-M or 90901 for A175-M) in the provided holes. 3. Pull cover ring (57001) out as far as it will go at the guide plates. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F...
Page 101: Fig. 41: Removing Cover Ring 2
1. Bend open locking washers (56015), loosen and remove screws (56014). 2. Secure retaining plate (90338) with screws (90339) and hook guide rod (90336) into re- taining plate. 3. Fit guide plate (90328) with nuts (61037). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 102: Fig. 43: Removing Nozzle Ring 2
Blocked areas on nozzle ring If a nozzle ring is blocked in some areas or is covered by loose parts, it is recommended to appoint an ABB Turbocharging Service Station to inspect the turbine blades and carry out a crack inspection.
Page 103: Installing The 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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 104: Fig. 45: Installing Nozzle Ring 2
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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 105: Fig. 46: Installing Cover Ring
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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 106: Fig. 47: Installing Turbine Diffuser 1
2. Fit guide plates (90328) with nuts (61037). 3. Remove the lifting gear. 4. Slide in turbine diffuser as far as it will go. 5. Remove nuts (61037), guide plates (90328) and guide studs (90802). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 107: Fig. 48: Installing Turbine Diffuser 2
Fig. 48: Installing turbine diffuser 2 Product Size Tightening torque [Nm] A170-M A175-M Table 37: Tightening torque (61069) 6. Coat threads of screws (61069) with high-temperature grease. 7. Fit and tighten screws (61069). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 108: 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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 109: Fig. 50: Installing The Cartridge Group 2
1. Coat thread of screw (61059) and two bolts for the nuts (42128) with high-temperature grease. 2. Secure cartridge group with screw (61059) and nuts (42128). 3. Remove the lifting gear. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 110: Fig. 51: Installing The Cartridge Group 3
Remove temporary covers on oil connections. Fit all oil pipes according to instructions of enginebuilder. Version with compressor wheel cooling Fit air supply line (see Compressor wheel cooling →5). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 111: Fitting The Spinner Nose Cone
8 Disassembly and assembly / 8.10 Fitting the spinner nose cone 8.10 Fitting the spinner nose cone If present: The spinner nose cone (25012) and Loctite®542 are supplied by the ABB service station to- gether with the overhauled cartridge group. CAUTION Total failure of turbocharger...
Page 112: Fig. 53: Fitting The Spinner Nose Cone (25012)
6. Measure and note down distance Z between spinner nose cone and compressor wheel at no less than three points around the circumference. Permissible distance Z: 0.1 – 0.7 mm Permissible difference of the measurements: ± 0.1 mm © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 113: Installing The Compressor Casing
1. Distributed evenly around the circumference, screw the press-off nuts (61090) onto the studs of the bearing casing and turn them by hand until they are at the end of the thread. 2. Grease the new O-ring (42012) and fit it. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F...
Page 114: Fig. 55: Installing Diffuser
1. Loop around diffuser (79000) with lifting gear and position it on the wall insert (77000). 2. Attach diffuser with screws (77015). 3. Grease the new O-ring (77040) and fit it. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F...
Page 115: Fig. 56: Turning And Moving In Wall Insert
2. Remove support angle (90025), screws and nuts. 3. Fit guide studs (90319). 4. Carefully install the wall insert (77000) in the compressor casing. Make sure both mark- ings are in the correct position. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 116: Fig. 57: Fitting Wall Insert
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 Installing air inlets. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 117: 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. 58: Axial clearance...
Page 118: Installing The Air Inlets
2. Fit air suction branch together with nuts (72027) and washer (72028). Observe tightening torque. Disconnect all air lines according to the instructions of the enginebuilder. Dismantle insulation as far as necessary. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 119: Fig. 60: Installing The Filter Silencer
2. Fit filter silencer together with nuts (72027) and washers (72028). Observe tightening torque. Tighten nuts that are difficult to access with a fork/ring spanner. Fit insulation. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 120: 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, it is re- commended to appoint an ABB Turbocharging Service Station to inspect the turbine blades and carry out a crack inspection.
Page 121: Fig. 61: Removing The Nozzle Ring At The Turbine End (Radial Gas Inlet Casing)
3. Loosen screws (61009) and move out gas inlet casing with nozzle ring. 4. Bend open locking washers (56015), loosen and remove screws (56014). 5. Pull out nozzle ring (56001). 6. Remove spiral-wound gasket (61050) and provide new one. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 122: Fig. 63: Installing The Nozzle Ring At The Turbine End (Radial Gas Inlet Casing)
Installing the nozzle ring Fig. 63: Installing the nozzle ring at the turbine end (radial gas inlet casing) Fig. 64: Installing the nozzle ring at the turbine end (axial gas inlet casing) © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 123: Table 50: Tightening Torque (56014)
6. Remove the guide studs (90321). 7. Fit remaining screws (61009), then crosswise tighten all screws (61009). Observe tight- ening torque. 8. If present: Fit connecting pipe for turbine cleaning Refit dismantled insulation. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 124: Table Of Tightening Torques
Operation Manual / 4 Product description / A100-M axial 8 Disassembly and assembly / 8.15 Table of tightening torques 8.15 Table of tightening torques Fig. 65: Tightening torques 1 Fig. 66: Tightening torques 2 © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 125: Table 52: Tightening Torques
56014 61009 57005 42059 72011 1000 72027 72026 25013 86505 M18x1.5 M18x1.5 Table 52: Tightening torques 1) Tighten screws (61009) crosswise in four steps (see Table 53: Tightening torques 61009 →96). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 126: Fig. 67: Flange Tightening Sequence
8 Disassembly and assembly / 8.15 Table of tightening torques Tightening sequence Fig. 67: 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 53: Tightening torques 61009 © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 127: Taking A Turbocharger Out Of Operation
The permissible turbocharger speed for the unlocked turbocharger may not exceed n . Take note of the rating plate. Bmax After locking the turbocharger, contact an ABB Turbocharging Service Station and find the nearest port. Observe the safety regulations. Follow the directives of the enginebuilder.
Page 128: Locking The Rotor
A locked rotor must be removed after emergency operation and checked for unbalance (see chapter Removing the cartridge group). 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 max- imum engine load of up to 25 %.
Page 129: Fig. 68: Fitting The Locking Device
Rotate compressor wheel in such a way that the holes in the lifting spigot (90427) corres- pond with the holes in the assembly/disassembly device (94003). 5. Secure assembly/disassembly device (94003) to the lifting spigot (90427) with screws (94006). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 130 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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F...
Page 131: Fitting The Cover Plate
Table 56: Cover plate dimensions 2 ⍺ 1 ⍺ 2 ⍺ 3 Product A170-M 4 x 90° 37.5° 24 x 15° A175-M 4 x 90° 37.5° 24 x 15° Table 57: Cover plate dimensions 3 © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 132 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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F...
Page 133: 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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 134: 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 135: 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 136: 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 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 137: 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. Dispose of placed and unusable parts in an environmentally-friendly and professional manner in accordance with the local regulations.
Page 138: View Of Turbocharger With Part Numbers
Table 58: Customer spare part set (97070) 12.2 View of turbocharger with part numbers Fig. 71: Turbocharger with part numbers ( ..) only available in customer spare part set (97070) © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 139 77015 (in customer spare part set) Socket screw 77000 Wall insert 77040 (in customer spare part set) O-ring 79000 Diffuser 81000 Filter silencer 82000 Radial air suction branch Table 59: Turbocharger with part numbers © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.F August 2020...
Page 140: Tools
94007 Hexagon-head screw 90321 Guide stud Table 60: Customer tool set 90009 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 141: Figures
Fig. 29: Removing the air suction branch ....60 Fig. 62: Removing the nozzle ring at the turbine end Fig. 30: Axial clearance ..........61 (axial gas inlet casing) ..........91 Fig. 31: Removing wall insert........62 © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Revision F August 2020...
Page 142 Fig. 68: Fitting the locking device......99 Fig. 69: Cover plate (01) / spacer sleeves (02) dimen- sions................101 Fig. 70: Fitting the cover plate......... 102 Fig. 71: Turbocharger with part numbers....108 © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Revision F August 2020...
Page 143 Table 26: Malfunctions during operation – Charge air pressure too high ............53 Table 57: Cover plate dimensions 3 ......101 Table 27: Surging of the turbocharger..... 53 Table 58: Customer spare part set (97070).... 108 © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Revision F August 2020...
Page 144 Operation Manual / 4 Product description / A100-M axial Tables Table 59: Turbocharger with part numbers..109 Table 60: Customer tool set 90009......110 © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Revision F August 2020...

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