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ABB HT604072 Operation Manual
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ABB HT604072 Operation Manual

ABB HT604072 Operation Manual

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Turbocharging
Operation Manual / TPS48-H32
HT604072
Document identification
Document number
Revision
Language
Product identification
Serial number
Customer part number
Delivery date (yyyy-mm-dd)
Weight
Operating limits according to rating plate
Speed limit in test rig operation only
Speed limit during operation
Gas inlet temperature limit in test rig operation only
Gas inlet temperature limit during operation
HZTL4037
G
English
Original Operation Manual
HT604072
143920-18020
2021-07-28
180
n
Mmax
n
Bmax
t
Mmax
t
Bmax
kg
1018
1/s
1018
1/s
680
°C
680
°C

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  • Page 1 Turbocharging Operation Manual / TPS48-H32 HT604072 Document identification Document number HZTL4037 Revision Language English Original Operation Manual Product identification Serial number HT604072 Customer part number 143920-18020 Delivery date (yyyy-mm-dd) 2021-07-28 Weight Operating limits according to rating plate 1018 Speed limit in test rig operation only...

  • Page 3: Table Of Contents

    Oil pressure, oil temperature..................38 Exhaust gas temperature before turbine ............... 41 Turbocharger speed ....................41 Operation and service ..................45 Noise emission ......................45 Service work ......................... 47 © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...
  • Page 4 Taking the engine out of operation for more than 12 months ......95 Material and Disposal..................96 13.1 REACH and RoHS Compliance Declaration For Products ........96 13.2 Disposing of turbocharger components ............... 97 © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...
  • Page 5 14.1 Ordering spare parts....................98 14.2 Required customer spare part set (97070)............98 14.3 Spare part - Illustrations.................... 99 Tools ........................107   Figures......................... 108   Tables ........................109 © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 6: Operation Manual / Tps44-H

    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 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 7: Contact 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

    Fig. 2: Layout and function of the turbocharger Air suction branch / filter silencer Plain bearing bush Compressor casing Turbine Diffuser Nozzle ring Bearing casing Turbine casing Axial thrust bearing Compressor wheel Gas outlet casing © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 9: Symbols, Definitions

    The following symbols are used in this document: Indicates an action step. 1. Indicates a numbered action step. →   Refers to a page number Definition of Note NOTICE Note The note provides advice which facilitates the work. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...
  • Page 10 Caution and warning signs are described in chapter Safety. ABB Turbocharging ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging in this document. Official service stations of ABB Turbocharging Official service stations are regularly audited and certified by ABB Turbocharging. See also chapter Contact information →5.

  • Page 11: Table 1: Definition Of Pictograms

    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 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 12: 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 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 13: Fig. 4: Package With Hygrometer

    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 14: 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 15: 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. HZTL4037_EN Rev.G June 2021...

  • Page 16: 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 uses. [1]Euromot = The European Association of Internal Combustion Engine Manufacturers...

  • Page 17: 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 18: 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 19: 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 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 20: Fig. 7: Position Of The Rating Plate

    Operation above the indicated values n can considerably shorten the recommended Bmax Bmax replacement intervals. In such cases, we recommend contacting the nearest ABB Turbochar- ging Service Station. normally apply only when running at overload (110 %) during trials on the engine Mmax Mmax test bed.

  • Page 21: 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. HZTL4037_EN Rev.G June 2021...

  • Page 22: 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 23: 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. HZTL4037_EN Rev.G June 2021...
  • Page 24 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 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 25: 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 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 26: 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 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...
  • Page 27 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. HZTL4037_EN Rev.G June 2021...
  • Page 28 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. HZTL4037_EN Rev.G June 2021...
  • Page 29 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. HZTL4037_EN Rev.G June 2021...

  • Page 30: Removing And Installing

    Product Thread M Length H Diameter D Minimum load limit [mm] [mm] [kg] ≤ 12 ≤ 25 TPS44 ≤ 12 ≤ 25 TPS48 TPS52 ≤ 15 ≤ 25 Table 5: Swivel lifting eyes to be used © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 31: Removing The Turbocharger

    Disconnect all pipes according to the instructions of the enginebuilder. Loosen and remove water connections. Close the openings of the water connections with screw plugs. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 32: Fig. 11: Removing The Turbocharger

    If cooling water freezes in the bearing casing, this can lead to severe dam- age. For transport and storage of the turbocharger, drain the cooling water from the bearing casing via one of the two bottom openings of the water connections. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 33: Installing The Turbocharger

    Always use new gaskets and insert them carefully into the slot. The oil is supplied (02) and drained (03) through the bracket (01). The necessary sealing is provided by O-rings. The O-rings are not included in the ABB scope of delivery. Fig. 12: Inserting gaskets into the bracket...

  • Page 34: Fig. 13: Inserting Threaded Rods Into The Bracket

    Fastening material, scope of delivery The threaded rods and nuts required for attaching the turbocharger to the bracket are not included in the ABB scope of delivery. These parts depend on the version of the engine-side bracket. © Copyright 2021 ABB. All rights reserved.

  • Page 35: Fig. 15: Placing The Turbocharger On The Bracket

    8. Connect cable to speed sensor (86505). Remove the lifting gear. Connect all gas and air lines according to the instructions of the enginebuilder. If the gas outlet casing from ABB has not been dismantled with the turbocharger, refer to chapter Removing the gas outlet casing →74.

  • Page 36: Commissioning

    Filtering the lubricating oil with a filter mesh width of ≤ 0.034 mm is sufficient for this tur- bocharger. 4.1.4 Oil pressure Comply precisely with the oil pressure before the turbocharger for trouble-free operation. The admissible values are specified in chapter Monitoring operation →38. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 37: Inspection Procedures

    Adhere to lubricating oil temperature at the inlet. For permissible values, see chapter Monitoring operation →38. Warning plates Check whether warning plates are present and legible. Check whether the protective sheets have been removed. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...
  • Page 38 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. © Copyright 2021 ABB. All rights reserved.

  • Page 39: Commissioning After Taking Out Of Operation

    Check and clean filter silencer or air supply line, and remove any foreign objects that may be present. Put engine-side oil circulation to the turbocharger into operation. Prepare the turbocharger for operation (see Checks before commissioning →35). The turbocharger is now ready for operation. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 40: Monitoring Operation

    Oil pressure measuring point Oil temperature measuring point For monitoring the lubricating oil pressure, ABB Turbocharging recommends installing a "P" manometer immediately upstream of the turbocharger oil inlet before the orifice. If the pressure is controlled electronically, the relevant signals should be triggered at the warning and alarm values.
  • Page 41 *) If the drain pipe is vented, the lubricating oil temperature measuring point can be installed at the outlet in the vent tank. Otherwise the measurement should be taken in the drain pipe as close to the turbocharger as possible. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G...

  • Page 42: Table 9: Lubricating Oil Temperature At The Inlet

    Table 10: 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 43: Exhaust Gas Temperature Before Turbine

    For operating limits, refer to the Operation Manual title page or the rating plate on the turbocharger. If no speed measurement system is present, the system below can be ordered from an ABB Turbocharging Service Station (see chapter Ordering spare parts →98).

  • Page 44: Fig. 16: Layout And Overview Of The Speed Measurement System

    Speed sensor 42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F/I converter Plug with integrated voltage limiter 86528 Tachometer Alternative mounting position for speed sensor 32109 Sealing disc © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...
  • Page 45 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. 5.3.4 Malfunctions on the speed measurement system...

  • Page 46: Fig. 17: Fitting The Speed Sensor

    Wear safety gloves when disassembling the speed sensor. Wear safety gloves to protect against thermal hazards. The speed sensor supplied by ABB is equipped with a sealing lip and an O-ring. No additional gasket is required during assembly. Fig. 17: Fitting the speed sensor...

  • Page 47: 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. HZTL4037_EN Rev.G June 2021...

  • Page 48: Fig. 18: Noise Insulation, Bellows

    Suggestion for noise insulation, bellows Fig. 18: Noise insulation, bellows Compressor casing Bellows Charge air duct / scavenging air duct Insulation cushion Insulation mat (at least 15 mm) Sheet metal cover © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 49: 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 50 Impairment to the degree of a possible operating failure can be the con- sequence. Have any unknown causes clarified by an ABB Turbocharging Service Sta- tion. Monitoring the engine's operating data makes it possible to draw conclusions about the op- erating behaviour of the turbocharger.
  • Page 51 Service Station. The rotor parts turn very fast and are very sens- itive to unbalance. The rotor and bearing parts must be checked and assessed by an ABB Turbocharging Service Station. The following work can be carried out as preparation.

  • Page 52: Expected Replacement Intervals

    ABB Turbocharging therefore recommends having the components periodically inspected and replaced, if neces- sary, by an ABB Turbocharging Service Station based on the number of successful engine start cycles specified in the following table.

  • Page 53: Table 12: Expected Replacement Intervals

    ¡ Lubricating oil quality (oil filtering, oil condition, oil monitoring) ¡ Load profile (speed, pressure conditions, temperature) ¡ Number of starts/stops ¡ Unbalance of the rotor (degree of contamination). © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 54: Stopping The Engine

    Observe the oil pressure while performing post-lubrication: 0.5 < p Switch off post-lubrication as soon as the rotor is stationary or after no more than two minutes. Deviating procedures must be coordinated with ABB Turbocharging. CAUTION Water cooling after stopping the engine If the heat in the turbocharger is not dissipated after the engine stops, dam- age may result.

  • Page 55: Periodic Maintenance Work

    Cleaning components mechanically Engine stopped (usually every 8000 … 12000 h) →53 Table 13: Maintenance table [h] = Hours of operation ABB Turbocharging recommends having mechanical cleaning carried out by an ABB Tur- bocharging Service Station during the service work. Cleaning components mechanically 8.2.1 Preparation CAUTION...

  • Page 56: Fig. 19: Cleaning The Filter Silencer

    (see Fig. 19: Cleaning the filter silencer →54) Loosen the tension bands (81270). Remove the cover grid (81266). Pull out and bend up the sheet-metal coverings (81137), and remove the absorption seg- ments (81136). © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...
  • Page 57 When cleaning, note that the absorption segments (81136) must only be cleaned lightly with compressed air, a soft brush or a moist cleaning cloth. Have any heavily contaminated absorption segments replaced by an ABB Turbocharging Service Station. Fitting the filter silencer (see Fig. 19: Cleaning the filter silencer →54)

  • Page 58: Fig. 20: Cleaning The Compressor Casing, Diffuser Mechanically

    Spray cleaned surfaces with penetrating oil. Do not spray exterior surfaces of the tur- bocharger. Dispose of contaminated water and cleaning agents in accordance with the information in the material safety data sheet. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 59: Fig. 21: Cleaning The Nozzle Ring, Turbine Casing Mechanically

    Use clean water to completely clean parts of any solvents. Dry components completely. Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the tur- bocharger. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...
  • Page 60 Clean the compressor wheel with a rag or soft brush which has been soaked in water with a household cleaning agent. Do not use a wire brush! © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G...

  • Page 61: Fig. 22: Soaking Contamination Of The Turbine

    To soak the layers of contamination on the turbine, the cartridge group can be immersed vertically in a container (02) with fluid. Place the container (02) inside a larger container (03) so that the overflowing fluid can be collected. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...
  • Page 62 Observe dimension (B) for the supports (01) so that the cartridge group is not immersed too deeply. Let the layers of contamination on the turbine soak for four hours. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...
  • Page 63 Lift up the cartridge group and align it horizontally. Clamp the heat sheet metal to the bearing casing. Dry the turbine and the gap between the turbine and the heat sheet metal with low-pres- sure pressurized air. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...
  • Page 64 Lightly spray the turbine and the gap between the turbine and the heat sheet metal with penetrating oil. Dispose of contaminated water and cleaning agents in accordance with the information in the material safety data sheet. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 65: Eliminating Malfunctions

    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. ¡ Have a dimension check carried out by an ABB Turbocharging Service Sta- tion.

  • Page 66: Malfunctions During Operation

    Turbochar- Turbine and/or nozzle ring severely con- Clean (see chapter Periodic mainten- taminated ance work →53) Rotor components or bearing damaged Contact ABB Turbocharging Service Station Engine Defects on the connected cylinders in Contact enginebuilder pulse charging Pipes Defects, such as leaks, in the exhaust...

  • Page 67: Table 21: Malfunctions During Operation - Exhaust Gas Temperature Too High

    Gas piping between engine and turbine leaking 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. HZTL4037_EN Rev.G June 2021...

  • Page 68: Table 23: Malfunctions During Operation - Charge Air Pressure Too High

    Clean (see chapter Periodic mainten- ance work →53) Table 24: Malfunctions during operation – Engine performance losses © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 69: Turbocharger Is Surging

    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. Possible causes Remedy...

  • Page 70: Malfunctions When Stopping

    →53) Bearing damaged Check clearances (see chapter Measuring clear- ance A and B). If clearances are outside the toler- ance or if in doubt, contact an ABB Turbocharging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station.

  • Page 71: Speed Measurement System

    Table 31: Malfunction of the speed measurement system – Measured speed too low If none of the measures described above remedy the malfunction, have the speed measure- ment system checked by an ABB Turbocharging Service Station. © Copyright 2021 ABB. All rights reserved.

  • Page 72: Dismantling And Fitting

    Further work that is carried out in an incorrect way can lead to serious damage to the machine. ABB Turbocharging recommends having further work carried out only by trained personnel from an ABB Turbocharging Service Station. © Copyright 2021 ABB. All rights reserved.

  • Page 73: Material Required

    Table 32: Swivel lifting eyes to be used Ring nuts Two ring nuts are required for safer lifting of the cartridge group, which are not included in the ABB scope of delivery. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 74: Fig. 24: Ring Nuts

    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. HZTL4037_EN Rev.G June 2021...

  • Page 75: Weights Of Individual Parts

    Radial air suction branch Axial air suction branch Filter silencer Compressor casing Diffuser Cartridge group Nozzle ring Turbine casing 1 inlet Gas outlet casing Table 34: Weights of the assemblies [kg] © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 76: Removing The Gas Outlet Casing

    Mark the casing position for assembly. Fig. 26: Removing the gas outlet casing 1. Manually secure the gas outlet casing (61001). 2. Loosen and remove hexagon nuts (51009). 3. Remove the gas outlet casing (61001). © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 77: Removing Air Inlets

    2. Loosen and remove V-clamp (72020). 3. Remove the filter silencer (81000) or air suction branch (82000). 4. Remove and dispose of O-ring (81010 / 82010) (refer to Disposing of turbocharger com- ponents →97). © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 78: Removing The Compressor Casing

    3. Rotate the compressor casing (72000) through 180° and put it in place. 4. Remove and dispose of O-ring (42012) (see chapter Disposing of turbocharger compon- ents →97). 5. Remove screw (72041). 6. Remove the diffuser (79000) vertically from the compressor casing. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 79: Removing The Cartridge Group

    This can result in an oil leak. Do not loosen screw plugs. If any screw plugs have been loosened accidentally, have these properly fitted by an ABB Turbocharging Service Station. Fig. 31: Do not loosen screw plugs Removing the turbine-end fastening strips Mark the casing position for assembly.

  • Page 80: Fig. 32: Removing The Cartridge Group (1)

    3. Secure the lifting gear to the ring nuts and swivel lifting eye as shown. 4. Remove the cartridge group vertically from the turbine casing. 5. If present: Remove the metal C-ring (51105). © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G...

  • Page 81: Fig. 34: Rotating The Cartridge Group And Fitting The Service Support

    3. Remove the ring nuts (VRM) and screws from the service support. 4. Place the cartridge group onto the fitted service support (90012). 5. Fit and hand-tighten nuts. Measure: Axial clearance A and radial clearance B. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 82: Removing Nozzle Ring

    10 Dismantling and fitting / 10.8 Removing nozzle ring 10.8 Removing nozzle ring Fig. 35: Removing the nozzle ring 1. Remove the nozzle ring (56001) vertically. 2. Remove the lamellar sealing ring (56005). © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 83: Measuring Clearance A And B

    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. © Copyright 2021 ABB. All rights reserved.

  • Page 84: Nozzle Ring Compression Pd

    1. Measure dimensions A, B, and C on cleaned surfaces. 2. Calculate the compression (PD) and compare it with the permissible values in the follow- ing table. If the calculated value (PD) lies outside the specified range, contact an ABB Turbochar- ging Service Station. Product...

  • Page 85: Fitting The Diffuser

    1. Position the diffuser (79000) in the compressor casing (72000). 2. Rotate the diffuser until its bore is aligned with the bore in the compressor casing. 3. Fit and tighten screw (72041). © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 86: Installing The Cartridge Group

    6. Lift cartridge group at the side of the ring nuts (VRM) and turn it into a vertical position (compressor wheel facing downwards). Use edge guard between turbines and lifting gear. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 87: Fig. 40: Fitting The Cartridge Group

    1. Lower cartridge group carefully into the compressor casing. 2. Align cartridge group to the marking. 3. Place first fastening strip (72012) according to illustration. 4. Place remaining fastening strips (72012). 5. Fit and tighten hexagon-head screws (72011). © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 88: Installing The Nozzle Ring

    (see detail A). 2. Secure the lamellar sealing ring (56005) with adhesive tape. 3. Installing the nozzle ring. Ensure correct position according to illustration. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G...

  • Page 89: Fitting The Turbine Casing

    4. If present: Fit the metal C-ring (51105). 5. Align turbine casing with marking and position on cartridge group. 6. Fit fastening strips (51002) with Verbus Ripp® washers (51003) and hexagon nuts (51007). Observe tightening torque. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 90: Turning The Turbocharger

    2. Insert screws from the service support. 3. Fit ring nuts (VRM). 4. Attach lifting gear. 5. Elevate and rotate the turbocharger. 6. Place the turbocharger on a soft underlay. Measure: Radial clearances N and R. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 91: Measuring Radial Clearances N And R

    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. © Copyright 2021 ABB. All rights reserved.

  • Page 92: Installing The Gas Outlet Casing

    3. Position the gas outlet casing and fit with two hexagon nuts (51009) in the upper area. 4. Fit the remaining hexagon nuts (51009), then tighten all the screws. Observe tightening torque. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 93: Installing Air Inlets

    2. Manually position the filter silencer (81000) or the air suction branch (82000) on the com- pressor casing (72000). 3. Fit the V-clamp (72020). 4. Align the casing position of the filter silencer (81000) or the air suction branch (82000) to the marking. 5. Tighten the V-clamp (72020). © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 94: Table Of Tightening Torques

    90 Nm Table 43: Overview of tightening torques *) These screw plugs must not be removed for maintenance work. If the screw plug is loosened, the tightness is no longer guaranteed. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 95: Taking Out Of Operation At Short Notice

    Remove defective turbocharger (see chapter Removing and Installing →28). Install replacement turbocharger (see chapter Removing and Installing →28). Send the defective turbocharger to an ABB Turbocharging Service Station for inspection and repair. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 96: Mothballing The Turbocharger

    Remove turbocharger (see chapter Removing and Installing →28). Dismantle turbocharger (see chapter Dismantling and fitting →70). The rotor and bearing parts must be dismantled and refitted by an ABB Turbocharging Service Station. © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 97: 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 98: 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 99: 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. HZTL4037_EN Rev.G June 2021...

  • Page 100: 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 101: Spare Part - Illustrations

    42183* (p) Gasket 42184* (p) Screw plug 42188(p) Hexagon-head screw 42189(p) Gasket 42196 Orifice oil inlet 98100 Rating plate 98105 Round head threaded rivet Table 45: Spare parts - Cartridge © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 102: Table 46: Spare Parts - Turbine Casing

    Hexagon head screw 51009 Hexagon nut 51027(p) Screw plug 51105** Metal C-ring 52406* ** Gasket 55653** Gasketring 56001 Nozzle ring 56005 Lamellar sealing ring Table 46: Spare parts - Turbine casing © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 103: Table 47: Spare Parts - Compressor Casing

    Compressor casing 72005(p) Screw plug 72006(p) Gasket 72011 Hexagon-head screw 72012 Fastening strip 72020 V-clamp 72041* Counter-sunk screw 72080 Warning plate 79000 Diffuser Table 47: Spare parts - Compressor casing © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 104: Table 48: Spare Parts - Filter Silencer

    Silencer body 81136 Absorption sgment 81137 Sheet-metal covering 81170(p) Screw plug 81171(p) Gasket 81265** Filter ring 81266 Cover grid 81270 Tension band 81271 Lock Table 48: Spare parts - Filter silencer © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 105: Table 49: Spare Parts - Air Suction Branch Radial

    HZTL443416 Mod. A Part no. Designation 82000 Air sucton branch 82005(p) Screw plug 82006(p) Gasket 82007(p) Screw plug 82008(p) Gasket 82010* O-ring Table 49: Spare parts - Air suction branch radial © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 106: Table 50: Spare Parts - Air Suction Brach Axial

    HZTL443418 Mod. A Part no. Designation 82000 Air suction branch 82005(p) Screw plug 82006(p) Gasket 82007(p) Screw plug 82008(p) Gasket 82010* O-ring Table 50: Spare parts - Air suction brach axial © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 107: Table 51: Spare Parts - Gas Outlet Casing

    14 Spare parts / 14.3 Spare part - Illustrations Gas outlet casing 61005(p) 61001 (p) = pre-assembled HZTL443417 Mod. B Part no. Designation 61001 Gas outlet casing 61005(p) Screw plug Table 51: Spare parts - Gas outlet casing © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 108: Table 52: Spare Parts - Speed Measurement System

    86505 86515 ** = if provided HZTL443419 Mod. - Part no. Designation 86505 Speed sensor 86515 Cable connector 86526 F/I-converter 86528** Tachometer Table 52: Spare parts - Speed measurement system © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.G June 2021...

  • Page 109: Tools

    Designation Quantity 90012 Service support Table 53: TPS-H Tool This tool can be ordered from any ABB Turbocharging Service Station. The following spe- cifications must be included in the order: ¡ Turbocharger type ¡ Part number and designation of the tool.

  • Page 110: Figures

    Fig. 27: Removing air inlets.......... 75 Fig. 28: Removing the compressor casing (1/2) ..76 Fig. 29: Removing the compressor casing (2/2) ..76 Fig. 30 ................77 Fig. 31: Do not loosen screw plugs......77 © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Revision G June 2021...

  • Page 111: Tables

    Table 53: TPS-H Tool ........... 107 Table 24: Malfunctions during operation – Engine performance losses ............. 66 Table 25: Malfunction – Turbocharger pumping..67 Table 26: Malfunction – Sporadic surge blows..67 © Copyright 2021 ABB. All rights reserved. HZTL4037_EN Revision G June 2021...

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