Page 1 Operation Manual A165-L37 XAC17837 English Original Operation Manual Chapter Document-ID Introduction HZTL4005_EN_F Safety HZTL4024_EN_C Safety data sheet XAC17837 Product description HZTL4034_EN_H 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 Periodic check of the pressure vessels ............Lifting of loads ..................... 1.10 Prerequisites for operation and maintenance ..........1.11 Hazards during operation and maintenance ..........1.12 Safe operation ..................... 1.13 Safe maintenance ..................HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...
Page 13: 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. Nev- ertheless, there may be some residual risks during operation of and work on the turbocharger which: ...
Page 14: Definition Of Mandatory Signs
CAUTION can lead to serious CAUTION damage to engine or property with grave consequences. Caution signs must always be observed.  HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...
Page 15: Intended Use
The specific operating limits of the turbocharger were determined on the basis of information from the enginebuilder about the intended use. These data are given on the rating plate. ABB accepts no liability and rejects all warranty claims for any non-intended uses. Unapproved operation Any operation of the turbocharger outside of its operating limits can be haz- ardous to personnel.
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. HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...
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 11 Year of construction of turbocharger 12 Manufacturing plant HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...
Page 18: Periodic Check Of The Pressure Vessels
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".  The locally applicable legal regulations regarding periodic checks of the pressure vessels must be observed.
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. HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...
Page 20: Prerequisites For Operation And Maintenance
WARNING personnel. Only use original parts from ABB Turbo Systems.  ABB accepts no liability for any damage resulting from the use of non-original parts and corre- sponding accessories. HZTL4024_EN Revision C © Copyright 2016 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. HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...
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, electri-  cal components. Observe national regulations.  HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...
Page 23: Safe Operation
When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay  attention to the risks that may occur as a consequence of this energy input. HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...
Page 24: Safe Maintenance
Have oil binding agents ready and provide or keep oil pans at hand.  Clean up any spills.  Have fire protection means and extinguishing agents available.  HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...
Page 25 Secure rotor against turning. The rotor can rotate due to the stack draught alone.  Observe the material safety data sheet for the cleaning and mothballing agents.  Wear personal protective equipment (PPE) according to the material safety data sheet.  HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...
Page 26  ty 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. HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...
Page 27  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. HZTL4024_EN Revision C © Copyright 2016 ABB. All rights reserved. August 2016...
Page 29 Operation Manual / A165-L37 / Safety data sheet Page 1 / 1 Safety data sheet A165-L37 XAC17837 A165-L37 XAC17837 AV65MZ01041 2017 2300 © Copyright 2017 ABB. All rights reserved. XAC17837 May 2017...
Page 31 Foreword to maintenance ................Cleaning the filter silencer ................Changing the filter strip on the filter silencer casing ........Cleaning the compressor during operation ..........Cleaning the turbine during operation ............HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 32 Taking the engine out of operation for up to 12 months ......101 10.2 Taking the engine out of operation for more than 12 months ...... 102 Disposing of turbocharger components ............103 Spare parts ....................105 HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 33 Page 3 / 113 12.1 Ordering spare parts ................... 12.2 View of turbocharger with part numbers ............12.3 View of cartridge group with part numbers ..........Figures ....................... Tables ......................HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 35: 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 36: Layout And Function Of The Turbocharger
03 Radial plain bearing 10 Diffuser 04 Radial plain bearing 11 Compressor wheel 05 Gas outlet casing 12 Compressor casing 06 Turbine wheel 13 Air-outlet silencer (option) 07 Nozzle ring HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 37 This oil tank supplies the bearings of the rotor with oil until standstill in the event that a mal- function of the lubrication oil system causes an emergency stop of the engine. HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 38: Warning Plates On The Turbocharger
Figure 2: Warning plate locations If warning plates are not present in the designated locations or not readable, proceed as fol- lows: Order new warning plates from ABB Turbocharging Service Stations.  Remove any warning plates that have become unreadable.
Page 39: Locations Of The Rating Plates
Locations of the rating plates Figure 3: Locations of the rating plates One rating plate (01) each is attached on the left and the right side of the turbocharger bearing casing. HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 41: Removal And Installation
Disconnect all pipes according to the instructions of the enginebuilder.  Check lifting gear.  Fasten lifting gear on suspension eyes of the bearing casing and tauten.  HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 42 Figure 4: Fitting lifting gear to turbocharger Loosen fixing screws on compressor-end and turbine-end foot.  Lift turbocharger from engine and put down in a suitable location.  Cover oil connections.  HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 43: Installing The Turbocharger
Remove lifting gear from suspension eyes of the bearing casing.  Connect cable to speed sensor.  Connect all gas, air and oil pipes.  HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 44: Table 3 General Information About
Tighten the foot fixing screws or nuts diagonally according to the selected tightening meth-  Turbine-end foot Figure 7: Turbine-end foot Tighten the foot fixing screws or nuts according to the selected tightening method.  HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 45: Table 4 Tightening Torques (Foot Screws)
Table 5: Tightening angle (foot screws) Pinning of turbocharger feet with positioning pins If the turbocharger is pinned at its feet, one pin hole per foot must be used. HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 47: Commissioning
Inspection procedures include preventative visual controls, monitoring and measuring work before and during commissioning. Inspection procedures enable changes to the turbocharger to be detected. Engine damage can be prevented. HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 48 The admissible values are specified in section Oil supply. Gas, air and oil pipes After starting the engine, check all gas, air and oil pipes for leaks.  HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 49: 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 51: Monitoring During Operation
Not admissible → stop engine > 90 Not admissible → do not start engine (before start: preheat oil) < 30 Table 7: Lubricating oil temperature at the inlet HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 52: Table 8 Lubricating Oil Temperature At
Table 8: Lubricating oil temperature at the outlet If the turbocharger was operated for a longer period of time outside of the admissible range, ABB Turbo Systems recommends to have the turbocharger inspected by an ABB Turbocharg- ing Service Station.
Page 53: Turbocharger Speed
86506 O-ring 42047 Screw plug 86515 Cable connector 32109 Sealing disc with cams 86526 F/I converter Alternative mounting position for speed sensor or for the second speed sensor HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 54 Measure the temperatures in the air lines and gas lines from and to the turbochargers and  compare with normal values. If clear deviations of temperature are found, the nearest ABB Turbocharging Service Sta-  tion has to be contacted.
Page 55: Table 9 Tightening Torques (86505)
Screw in new speed sensor to the stop.  Connect cable connector (86515) with the speed sensor (86505)  Switch on lubricating oil supply to the turbocharger.  HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 56 Monitoring during operation Page 26 / 113 4.2.5 Malfunction of the speed measurement system The possible reasons for malfunction of the speed measuring system are described in chapter Troubleshooting. HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 57: Low Pressure Measurement At The Filter Silencer
NOTICE Better readability of the U-tube manometer can be achieved by filling with slightly coloured water. HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 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 HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 60: Service Work
Service work on the turbocharger that are omitted or performed too late can cause excessive contamination, wear and operating failures. CAUTION Carry out the service work at the specified time intervals.  HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 61 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 5.2.3 Service work on turbocharger every 18000 hours It is recommended to have this service work and these checks carried out by an ABB Turbo- charging Service Station. Damaged and worn out parts must be replaced with original ABB parts.
Page 63  Lubricating oil pressure and lubricating oil temperature  Pressure loss in the filter silencer  Air temperature after the charge air cooler If present:  Air temperature after the compressor HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 64: Expected Replacement Intervals
See rating plate data Bearings See rating plate data Table 11: Recommended replacement intervals for turbocharger parts The specified values are guideline values and not guaranteed values, see Influencing parame- ters. HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 65: Flexible Turbocharger Cut-Out
The air outlet flap and gas inlet flap must be completely open during nor-  mal operation. During cut out operation, the air outlet flap and gas inlet flap must be  completely closed. HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 66: Stopping The Engine
500 hours of operation. NOTICE Stopping the engine Observe the instructions regarding post-lubrication (Pre-lubrication and post-lubrication  [➙ 22]) Stop the engine.  HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 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  Compressor  Turbine and nozzle ring HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 68: Cleaning The Filter Silencer
Body of filter silencer 81268 Connecting strip 81136 Absorption segment 81270 Tension band 81137 Sheet-metal covering 81271 Lock 81265 Filter ring (if present) Insert unit (absorption segment / sheet-metal covering fitted) HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 69 Otherwise there is a danger of damage or changing of the shape. Replace heavily contaminated absorption segments (81136) and any damaged connecting  strips (81268) with original parts from ABB. Fitting the filter silencer Insert the absorption segments (81136) into the sheet-metal coverings (81137). ...
Page 70: Changing The Filter Strip On The Filter Silencer Casing
Figure 13: Dismantling filter ring circumferential part Dismantle circumferential part (9).  Figure 14: Opening filter ring lock Open the lock of the filter ring (81265).  HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 71 Pull on the old filter ring until the new filter ring is completely wrapped around the filter si-  lencer. Undo the connection between the new and the old filter ring.  Fasten the newly installed filter ring (81265), then fit circumferential part (9).  HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 72: Cleaning The Compressor During Operation
The interval between the cleaning cycles depends greatly on the operating conditions. Clean- ing should normally take place about every 50 hours of operation. If the specified cleaning intervals are incompatible with operation of the engine, contact ABB Turbo Systems.
Page 73 Volume of water for cleaning the compressor Uncontrolled volumes of water can damage the turbocharger and the en- gine. CAUTION Do not guide water pipes to the filler openings.  HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 74 Fit insulation to flange of filter silencer (if present).  After cleaning, allow the engine to continue to run for at least 5 minutes under normal load.  HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 75: Table 12 Volume Of Water Per Cleaning
Repeating the cleaning If the cleaning is still unsuccessful after three processes, it is recommended to have the turbo- charger checked and cleaned by an ABB Turbocharging Service Station if the engine values are unsatisfactory. Volume of water per cleaning process...
Page 76: Cleaning The Turbine During Operation
The dry cleaning of the turbine end components is carried out at an engine load of 5 … 85%. Cleaning several turbochargers If several turbochargers are installed on an engine, ABB Turbo Systems recommends clean- ing one turbine after the other.
Page 77 Cleaning instructions (51717) On-Off valve [closed] (51705) Gas inlet casing, insulated Protecting the pressurised air system Protect the pressurised air system against overpressure (> 7 bar).  CAUTION HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 78 Repeating the cleaning If the cleaning is still unsuccessful after three processes, it is recommended to have the turbo- charger checked and cleaned by an ABB Turbocharging Service Station if the engine values are unsatisfactory. Optimum cleaning effect It is important that the specified amount of granulate is blown in for each cleaning process in order to achieve an optimum cleaning effect.
Page 79: Table 14 Amount Of Granulate
Table 14: Amount of granulate Storage of dry cleaning materials The cleaning material must be stored in a dry and clean location to prevent blockage of the pipes when cleaning. NOTICE HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 80: Draining The Gas Outlet Casing
Set the drain cock (02) to position 2 (B) and clean the drain pipe (01) with air from the  compressor casing (04). If cleaning with air is not sufficient, the drain pipe (01) must be cleaned mechanically. HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
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
Contact ABB Turbocharging Service Station Pipes Defects, such as leaks, in the exhaust gas Repair pipes or charge air ducts Table 19: Malfunctions during operation – Speed reductions HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 83: Table 20 Malfunctions During Operation - Exhaust Gas Temperature Too High
Clean or repair boiler or exhaust gas si- lencer Pipes Pipes downstream to the compressor out- Repair. let not sealed. Table 21: Malfunctions during operation – Charge air pressure too low HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 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 HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 86: Speed Measurement System
If none of the above measures eliminates the malfunction, we rec- sources of ommend that you have the speed measuring system inspected by errors an ABB Turbocharging Service Station. Table 26: Malfunctions of the speed measurement system HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
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 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
The total weight of the complete wall insert is made up of the wall insert and diffuser assem- blies. A165-L A170-L A175-L A180-L A185-L A190-L 1290 1770 Table 28: Weight of wall insert [kg] HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 90: Disassembly And Assembly Of The Filter Silencer Casing
01, 02 Bottom part 03, 04, 07, 08 Side part 05, 06, 09 Circumferential part 10, 11 Flange The complete filter silencer casing has the part number 81500. HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 91 NOTICE Before disassembling the bottom part (01), mark the location of screw (A).  Fit all remaining screws on the bottom part (01).  HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 92 Fit the side parts (03) and (04) with the screws on the filter silencer and on the bottom part.  Fit the side parts (07) and (08) with the screws on the filter silencer, on the bottom part,  and on the side parts (03, 04). HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 93 Figure 27: Fitting filter silencer casing 5 Fit the circumferential part (05) with the screws.  Fit the circumferential part (06) with the screws.  Fit the circumferential part (09) with the screws.  HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 94: Table 29: Tightening Torques (Filter Silencer Screws)
Tighten all screws of the circumferential parts (05, 06, 09).  Bellows Figure 28: Fitting the bellows Fit bellows (C) with frame (F), screws (S) and nuts (N) on the filter silencer casing.  HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 95: Dismantling The Filter Silencer
1. Attach the lifting gear to the front lug and rear eyelet of the filter silencer (81000). 2. Loosen nuts (72004) and remove with washers (72003). 3. Remove and put down filter silencer. HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 96: Dismantling The Filter Silencer With Noise Package
3. Loosen nuts (72004) and remove with washers (72003) and insulating discs (81302). 4. Remove and put down filter silencer. 5. Remove the gasket (81301). 6. Loosen counter-sunk screws (74043), remove with air outlet silencer (74040) and gasket (74042). HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 97: Dismantling Wall Insert And Diffuser
5. Fit lifting device (90190) with crane on upper area of wall insert (77000). 6. Change the position of the shackle with the lifting gear to P2 of the lifting device (90190). HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 98 Figure 33: Putting down wall insert Put down wall insert (77000) with diffuser (79000) in horizontal position and use appropri-  ate supports to prevent it from falling over and rolling away. HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 99 1. Put wall insert (77000) down on suitable supports. 2. Tilt wall insert (77000) with diffuser (79000) against lifting device (90190). 3. Place wall insert with the flange (F) on the underlay. HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 100 Figure 35: Dismantling the diffuser 4. Loosen and remove screws (77015). 5. Remove O-rings (79020, 79021). 6. Attach lifting gear (L) to the diffuser (79000). 7. Remove and put down diffuser. HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 101: 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. HZTL4034_EN Revision H ©...
Page 102: Dismantling Insulation, Gas Inlet Casing And Nozzle Ring (A175-L And Smaller)
1. Loosen and remove screws of insulation jackets (51200) from gas outlet casing (61001). 2. Loosen and remove all connecting plates of insulation jackets. 3. Remove insulation jackets. 4. Detach flange connection between gas inlet casing (51001) and bellows. HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 103 Dismantling the nozzle ring Figure 39: Dismantling the nozzle ring (A175-L and smaller) 1. Loosen screws (56014) and remove with washers (56011). 2. Remove and put down nozzle ring (56001). HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 104: Dismantling The Gas Inlet Casing, Nozzle Ring (A180-L And Larger)
6. Loosen remaining screws and carefully move out gas inlet casing. 7. Fit support (90451) on gas inlet casing and put down casing. 8. Remove the guide studs. HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 105 Figure 41: Fitting the nozzle ring holder 1. Remove screws (B 2. Fit the nozzle ring holder (90477) with screws (B ) at the top of the flange of the gas inlet casing (51001). HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 106 ) into the nozzle ring holder. 5. Remove screws (B Figure 43: Putting down the nozzle ring (A180-L and larger) Use the crane to remove and put down the nozzle ring (56001).  HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 107: Fitting Gas Inlet Casing, Nozzle Ring And Insulation (A175-L And Smaller)
) with the flange connection (A ) and slide the nozzle ring (56001) into the gas inlet casing (51001). 2. Fit screws (56014) with high-temperature grease and with washers (56011). HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 108: Table 32 Tightening Torque
6. Fit the screws (61009) by tightening them crosswise, first to the pre-tightening torque, then to the tightening torque. 7. Remove the lifting gear. 8. Connect the flange of the gas inlet casing and the bellows. HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 109 2. Fit the insulation jackets (51200) on the gas inlet casing (51001) with the screws. 3. Fit connecting plates of insulation jackets with screws. 4. Fit insulation jackets with screws on gas outlet casing (61001). HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 110: Fitting The Gas Inlet Casing, Nozzle Ring (A180-L And Larger)
Figure 47: Looping around the nozzle ring (A180-L and larger) Loop around the nozzle ring (56001) with lifting gear on the nozzle ring holder (90477) and  fix on the crane. HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 111: Table 33 Tightening Torque
4. Coat screws (56014) with high-temperature grease and fit with washers (56011). 5. Remove screws (B ) along with the nozzle ring holder (90477). HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 112: Table 34 Tightening Torque
8. Remove the lifting gear. 9. Connect the flanges of the gas inlet casing and the bellows. 10. Fit the insulation segments (51215). HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 113: 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. HZTL4034_EN Revision H ©...
Page 114: Fitting Diffuser, Wall Insert
3. Fit new O-rings (79020, 79021) on the diffuser. 4. Degrease screws (77015) and threaded holes in wall insert. 5. Coat threads of the screws with Loctite® 542. 6. Fit screws. HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 115 Disassembly and assembly Page 85 / 113 Fitting the wall insert Figure 52: Positioning wall insert Carefully bring wall insert (77000) into vertical position with the lifting device (90190).  HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 116: Table 37 Tightening Torque
7. Completely insert the wall insert and then remove the guide studs (90320). Check that both casings are in the correct position (the marking arrows are aligned to one another). 8. Fit screws (72011). HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 117: Fitting The Filter Silencer
1. Attach the lifting gear to the front lug and rear eyelet of the filter silencer (81000). 2. Position filter silencer on compressor casing. 3. Fit nuts (72004) with washers (72003) and tighten. Fit insulation as far as necessary.  HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 118: Fitting The Filter Silencer With Noise Package
72004 130 Nm 200 Nm 300 Nm 420 Nm 570 Nm 710 Nm 74043 45 Nm 45Nm 45Nm 45Nm 45Nm 45 Nm Table 39: Tightening torques (72004, 74043) HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 119 4. Fit nuts (72004) with washers (72003) and insulating discs (81302) and tighten. 5. Fit insulation ring (81300). 6. Fit air outlet silencer (74040) with gasket (74042) and secure with counter-sunk screws (74043). Fit insulation as far as necessary.  HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 120: Table Of Tightening Torques
Operation Manual / 4 Product description / A100-L Disassembly and assembly Page 90 / 113 8.16 Table of tightening torques Figure 56: Overview of tightening torques Figure 57: Overview of speed sensor tightening torque HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 121: Table 40 Overview Of Tightening Torques
2) Pre-tightening torque of the screws Use hydraulic tool for tightening torques exceeding 500 Nm.  compressor casing insulation 25 Nm 45 Nm 85 Nm 50 Nm Table 41: Tightening torque, insulation HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 123: Taking A Turbocharger Out Of Operation
Sound an alarm and depending on the situation, stop the engine.  Seal oil leaks.  Soak up oil and dispose of in an environmentally compatible manner.  Wear safety gloves to protect against thermal hazards. HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 124: Procedure With One Installed Turbocharger
CAUTION unscrewed on the compressor wheel. Before recommissioning of the turbocharger, the compressor wheel must be balanced at an ABB Turbocharging Service Station. Do not screw any set screws that have become unscrewed into the com-  pressor wheel again.
Page 125 Close the lubricating oil supply to the turbocharger.  Open the bypass around the turbocharger.  Observe specifications from enginebuilder.  HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 126: A165-L 0.32
In this case, additional washers (01) must be pro- vided in accordance with the following table. These washers (01) are not supplied by ABB. Figure 59: Ensuring clamping of the cover ring...
Page 127 Page 97 / 113 9.3.4 Continuing to operate the engine Continue to operate engine in accordance with enginebuilder's instructions. Do not exceed prescribed power reduction and maximum turbocharger speed. HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 128: Procedure With Two Or More Installed Turbochargers
The chapter is only applicable for engines with several turbochargers and joint air and exhaust gas receivers. The cover plates for the compressor casing outlet, gas inlet and gas outlet are not included in the ABB scope of delivery. The following figure shows the positions where to fit the cover plates.
Page 129 Page 99 / 113 9.4.2 Continuing to operate the engine Continue to operate engine in accordance with enginebuilder's instructions. Do not exceed prescribed power reduction and maximum turbocharger speed. HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 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.  HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 135: Spare Parts
 Serial number of the turbocharger  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.
Page 136 Operation Manual / 4 Product description / A100-L Spare parts Page 106 / 113 12.2 View of turbocharger with part numbers Figure 61: View of turbocharger with part numbers HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 137: Table 47 Turbocharger With Part Num
81000 Filter silencer 81300* Insulation ring (option) 81301* Gasket (option) 81302* Insulating disc (option) Table 47: Turbocharger with part numbers * Depending on the specification of the turbocharger HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 138 Figure 62: View of cartridge group with part numbers Cartridge group The cartridge group is not delivered as a fitted assembly. Spare parts must be ordered individually. NOTICE HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 139: Table 48 Cartridge Group With Part
42306 O-ring 42307 O-ring 42320 Socket screw 42458 Blind flange 86505 Speed sensor 86506 (in the customer spare part set) O-ring Table 48: Cartridge group with part numbers HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 141 Fig. 29 Dismantling the filter silencer ..65 Fig. 57 Overview of speed sensor tight- ening torque ......Fig. 30 Dismantling the filter silencer with noise package ....66 HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 142 Fig. 60 Position of cover plates ..... Fig. 61 View of turbocharger with part numbers ........106 Fig. 62 View of cartridge group with part numbers ......108 HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...
Page 143 Table 21 Malfunctions during operation – Charge air pressure too low . 53 Table 22 Malfunctions during operation – Charge air pressure too high Table 23 Surging of the turbocharger ..54 HZTL4034_EN Revision H © Copyright 2016 ABB. All rights reserved. November 2016...

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