Page 1 Turbo Systems Switzerland Ltd Operation Manual / A150-M58 HT613306 Document identification Document number HZTL4041 Revision Language English Original Operation Manual Product identification Serial number HT613306 Customer part number Delivery date (yyyy-mm-dd) 2022-05-25 Weight 1200 Operating limits according to rating plate...
Page 3: Table Of Contents
Exhaust gas temperature before turbine .............. 46 Turbocharger speed ....................47 Operation and service ..................50 Noise emission ......................50 Service work ......................... 52 Expected replacement intervals ................55 © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 4 Installing air inlets ..................... 123 Dismantling and fitting, cartridge concept ........... 124 11.1 Removing air inlets ....................124 11.2 Removing the compressor casing ................125 11.3 Removing the cartridge group ................127 © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 5 Ordering spare parts....................161 18.2 Required customer spare part set (97070)............161 18.3 Spare part – Illustrations ..................162 Tools ........................176 Figures......................... 178 Tables ........................180 © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 6: Operation Manual / A150-M58/68
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 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 7: Contact Information
Please contact an Turbo Systems Service Station if you have any questions regarding a design variant (see Contact information at www.abb.com/turbocharging). Accuracy of illustrations The illustrations in this document are general in nature and intended for ease of understand- ing.
Page 8: Layout And Function Of The Turbocharger
Fig. 2: Layout and function of the turbocharger 01 Filter silencer / air suction branch Gas outlet flange 02 Compressor casing Nozzle ring 03 Diffuser Turbine casing 04 Bearing casing Compressor wheel 05 Turbine © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 9: Fig. 3: Compressor Wheel Cooling
In addition, the turbocharger version with compressor wheel cooling is indicated by the tur- bocharger type (M6..) on the rating plate. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 10: Symbols, Definitions
Official service stations are identified in this document as Turbo Systems service stations. These Turbo Systems service stations are regularly checked and certified by Turbo Systems Switzerland Ltd. See also chapter Contact information →5. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
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 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
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 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 13: Fig. 5: Package With Hygrometer
The corrosion protection effect ends after the material is unpacked from the VCI package. To avoid the formation of condensation, the surroundings and the content of the package must have the same temperature during unpacking. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F...
Page 14: Registered Trademarks
Operation Manual / A150-M58/68 1 Introduction / 1.7 Registered trademarks Registered trademarks The trademarks of outside companies are used in this document. These are marked with the ® symbol. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 15: 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 16: 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 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 17: Intended Use
The intended use of the turbocharger includes compliance with all regulations and condi- tions. In particular, the following must be observed: ¡ Operation Manual ¡ Instructions of the enginebuilder © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 18: Warning Plates On The Turbocharger
Fit new warning plates and remove protective sheets. 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 2022 ABB. All rights reserved. HZTL4041_EN Rev.F...
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 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 20: Fig. 8: Locations Of The Rating Plates
Locations of the rating plates Fig. 8: Locations of the rating plates One rating plate (01) each is attached on the left and the right side of the turbocharger bear- ing casing. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 21: Periodic Check Of The Pressure Vessels
Necessary repair or maintenance work must be performed promptly, and the required safety measures must be taken. Pressure equipment must not be operated if defects are present. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 22: 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 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 23: Prerequisites For Operation And Maintenance
Original parts and accessories are specially designed for Turbo Systems turbochargers. Turbo Systems accepts no liability for any damage resulting from the use of non-original parts and corresponding accessories. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 24: 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 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 25 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 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 26: 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 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 27: 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 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 28 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 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 29 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 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 30 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 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 31: Removing And Installing
Complete turbocharger unit without gas outlet casing Complete turbocharger unit with gas outlet casing Product Weight of complete turbocharger unit [kg] A150-M 1200 Table 4: Weight of complete turbocharger unit © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 32: Removing The Turbocharger
The gas outlet casing (61001) can remain fitted in the exhaust gas pipe if the locking nuts are accessible. Otherwise the complete turbocharger unit including gas outlet casing must be removed. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 33: Fig. 13: Removing The Turbocharger
Do not clean pressure screws. Do not lubricate pressure screws. If a screw jams, the previously loosened screw must be tightened again a little. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 34: Fig. 14: Loosening The Clamping Nut
3. Working in a circle, loosen each pressure screw by 90° in 1…5 rounds until all of the pres- sure screws have been relieved. Loosen clamping nut by hand. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 35: Fig. 15: Turbocharger Centre Of Gravity
Remove and dispose of the O-rings (42195, 42200). Set down and secure the turbocharger properly at a suitable location. Close or cover the openings of the turbocharger and support. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 36: Installing The Turbocharger
Detail A Screw plug with orifice hole (option) Fit the gasket (42200) on the oil inlet (screw plug 01a or 01b with the orifice hole). Fit the gasket (42195) on the oil drain (02). © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F...
Page 37: Fig. 17: Inserting The Threaded Rods
Placing the turbocharger on the bracket Fig. 18: Placing the turbocharger on the bracket Make sure that covers of the oil and water connections are removed. 1. Carefully lower the turbocharger. 2. Check dimensions again. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 38: Fig. 19: Preparing The Clamping Nut For The Tightening Procedure
4. Tighten clamping nut (03) by hand. 5. Unscrew clamping nut (03) by ¼ of a turn (90°). The distance between the thrust washer and the clamping nut is now about 1 mm. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F...
Page 39: Fig. 20: Tightening Pressure Screws
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 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 40: Fig. 21: Connecting The Speed Sensor
Remove the screw plug on the connection for the compressor wheel cooling (06) and fit the cooling air line. 3.3.6 Attaching the support Fig. 23: Attaching the support If present: Attach support (61301) to engine support or to a connecting piece. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 41: 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 →44. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 42: Fig. 24: Oil Orifice
With an oil inlet pressure of more than 3 bar of overpressure (with engine under load) up- stream of the turbocharger, an oil orifice must be installed to reduce the oil pressure. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F...
Page 43: Inspection Procedures
Make sure there is an uninterrupted supply of cooling air during opera- tion. Check whether the compressor wheel cooling is fitted on the bearing casing. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 44 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. In the event of a leak, contact a Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F...
Page 45: 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 →41). The turbocharger is now ready for operation. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 46: Monitoring Operation
*) 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 2022 ABB. All rights reserved. HZTL4041_EN Rev.F...
Page 47: Table 7: Lubricating Oil Temperature At The Inlet
If the turbocharger has been operated for a longer period of time outside the admissible range, Turbo Systems recommends having the turbocharger inspected by a Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 48: Exhaust Gas Temperature Before Turbine
For a definition and explanations concerning the rating plate, refer to chapter Safety / Turbocharger rating plate →17. For operating limits, refer to the Operation Manual title page or the rating plate on the turbocharger. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 49: Turbocharger Speed
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 with cams © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 50 In any case, contacting the nearest Turbo Systems service station is recommended. 5.3.4 Malfunctions on the speed measurement system In the case of malfunctions of the speed measurement system, refer to the chapter entitled Troubleshooting/Speed measurement system →83. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 51: Fig. 26: Replacing 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. 26: Replacing the speed sensor...
Page 52: 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 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 53: Fig. 27: Noise Insulation, Bellows
Suggestion for noise insulation, bellows Fig. 27: Noise insulation, bellows Compressor casing Bellows Charge air duct / scavenging air duct Insulation cushion Insulation mat (at least 15 mm) Sheet metal cover © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 54: Service Work
To prevent machine damage caused by ageing and downtime, we recommend having an in- spection carried out by a Turbo Systems service station no later than 5 years after the last service. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F...
Page 55 Remove turbocharger from engine, dismantle and measure clearances (see Dismantling and fitting, general →84). Clean nozzle ring, turbine casing, compressor casing and diffuser, and check for cracks and erosion/corrosion. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 56 Speed of the turbocharger ¡ Air temperature after the compressor and after the charge-air cooler ¡ Exhaust gas temperature before and after the turbine ¡ Pressure loss in the filter silencer. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 57: Expected Replacement Intervals
Table 10: Expected replacement intervals = Natural Gas = Marine Diesel Oil = Heavy Fuel Oil The specified values are guideline values and not guaranteed values, see Influencing para- meters. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 58 ¡ 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 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 59: Stopping The Engine
Turbo Systems recommends post-lubrication for 10 minutes. Observe the oil pressure specified for post-lubrication (see Table 6: Lubricating oil pres- sure at oil inlet before turbocharger →44). © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 60: Periodic Maintenance Work
→53). Otherwise, only carry out mechanical cleaning if cleaning during opera- tion is not sufficient to achieve the thermal load and the rating of the engine. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 61: Cleaning The Compressor During Operation
The time period between the periodical cleaning cycles depends greatly on the operating conditions. Cleaning should normally be carried out every 24 … 72 hours of operation. If the specified cleaning intervals are incompatible with operation of the engine, contact Turbo Systems. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 62 CAUTION Corrosion and deposits when cleaning Salt water and cooling water treatment substances damage and adversely affect turbocharger parts. Never use salt water, but only pure water for cleaning. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 63: Fig. 28: Carrying Out Wet Cleaning Of Compressor
Not more than three cleaning cycles should be conducted consecutively. Before repeating the process, continue to operate the engine for at least five minutes to ensure that all of the water is flushed out of the system. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F...
Page 64: Cleaning The Turbine During Operation
Cleaning should normally be carried out every 50 to 200 hours of operation. If the specified cleaning intervals are incompatible with operation of the engine, contact Turbo Systems. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 65 To prevent corrosion of the inside surfaces of the casings, the engine must be continued to be operated for 10 minutes after a wet cleaning. The exhaust gas temperature downstream of the turbocharger can drop by up to 180 °C during cleaning. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F...
Page 66: Fig. 29: Turbine Cleaning Devices
If necessary, the engine performance must be reduced to meet these conditions. The clean- ing cycle can be started when the above conditions are fulfilled. ) External air supply for continuous blowing off of the cleaning nozzles between cleaning in- tervals. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 67: Fig. 30: Carrying Out Wet Cleaning Of Turbine
350 ... 430 14.0 Table 14: Wet cleaning of turbines, parameters for 1-nozzle cleaning Corresponds to a water pressure p of 1.5 bar (overpressure compared to atmosphere) before the cleaning nozzle © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 68: Cleaning Components Mechanically
The disassembly and assembly of the components is described in chapter Fitting and dis- mantling. Contaminated water and cleaning agents must be disposed of in an environmentally compatible, professional way and in compliance with locally applicable regulations. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 69: Fig. 31: 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 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 70 Fit the cover grid (81266). Fit the tension bands (81270) and tighten them at the locks (81271). Any tension bands that have become damaged must be replaced. Fit the filter ring (81265), if present. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 71: Fig. 32: Compressor Casing
Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the tur- bocharger. Dispose of contaminated water and cleaning agents in accordance with the information in the safety data sheet. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 72: Fig. 33: Diffuser
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 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 73: Fig. 34: Turbine End, Non-Rotating Parts
Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the tur- bocharger. Dispose of contaminated water and cleaning agents in accordance with the information in the safety data sheet. Option with cleaning nozzle © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 74 Removing and Installing →29). Remove the cartridge group (see chapter Dismantling and fitting, general →84). First clean the compressor end and then the turbine end according to the following descrip- tion. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 75 Lightly spray the compressor wheel and the gap between the compressor and the bearing casing with penetrating oil. Dispose of dirty water and cleaning agents in accordance with the material safety data sheet. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 76: Fig. 35: Soaking The Turbine End
Observe country-specific regulations regarding banned and restricted substances. Fill the container (02) with soaking fluid. To shorten the soaking time, the fluid can be heated up to a maximum of 60 ºC. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 77 Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against mechanical hazards. Lift up the cartridge group and align it horizontally. Remove contamination manually using a soft brush or a wire brush. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 78 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 safety data sheet. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 79: Eliminating Malfunctions
If there is any doubt about the extent of the rubbing, contact a Turbo Sys- tems service station. ¡ Have a dimension check carried out by a Turbo Systems service station. Table 19: Malfunctions when starting – Rubbing of rotating parts © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 80: Malfunctions During Operation
Clean (see chapter Periodic mainten- turbine and/or nozzle ring (with 4- ance work →58) or contact a Turbo Sys- stroke application) tems service station Table 22: Malfunctions during operation – Speed increases © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 81: Table 23: 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 24: Malfunctions during operation – Charge air pressure too low © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 82: Table 25: Malfunctions During Operation - Charge Air Pressure Too High
Clean (see chapter Periodic mainten- ance work →58) Table 26: Malfunctions during operation – Engine performance losses © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 83: Turbocharger Is Surging
When this happens, the flow direc- tion in the compressor is momentar- ily reversed. Such sporadic surge blows do not impair the safe opera- tion of the turbocharger. Table 28: Malfunction – Sporadic surge blows © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 84: Malfunctions When Stopping
Dismantle the turbocharger (see chapter Fitting bocharger and dismantling). In case of damage, replace the corresponding parts or contact a Turbo Systems service station. Table 30: Malfunctions when stopping – Runout time too short © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 85: Speed Measurement System
Table 33: 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 a Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F...
Page 86: Dismantling And Fitting, General
Systems must be tightened in such a way that they are tight-fitting. Oil orifice When disassembling the turbocharger, an oil orifice fitted in the oil inlet must not be re- moved (see also chapter Removing the cartridge group →102). © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 87: Material Required
≤ 21 mm ≥ 1000 kg M58/68 Table 34: Swivel lifting eyes Press-off screws Six press-off screws (01) are required to press off the gas outlet flange, which are not sup- plied by Turbo Systems. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 88: Fig. 37: Press-Off Screws
A dismantling screw (01) is required to dismantle and fit the cleaning nozzles, which is not supplied by Turbo Systems. Fig. 38: Dismantling screw Product Thread Length [mm] Quantity A150-M58 / 68 Table 36: Dismantling screw © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 89 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 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 90: Disassembly And Assembly Concepts
A prerequisite is that the interfaces between the alternative air inlet (filter silencer or air suc- tion branch) and the compressor casing, as well as between the turbine casing and gas out- let casing, are accessible at the engine side. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F...
Page 91: Fig. 40: Cartridge Concept
A prerequisite is that the interfaces between the cartridge group and the turbine casing, as well as between the cartridge group and the compressor casing, are accessible at the engine side. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F...
Page 92: Fig. 41: Optional Spanner Holder
The spanner holder (90165) should only be used for loosening the nuts and applying tighten- ing torques for the nuts at the position shown. Other screws or nuts on the turbocharger should not be tightened with this tool. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F...
Page 93: Weights Of Individual Parts
Turbine casing 1 inlet * 2 inlets * 3 inlets * Gas outlet flange Gas outlet casing with insulation Table 37: Weights of assemblies * including burst protection and insulation © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 94: Table Of Tightening Torques
Part number A150-M58/68 72051 275 Nm 79041 8 Nm 51007 175 Nm 51007 with spanner holder (90165) 85 Nm 51009 200 Nm 72011 275 Nm 86505 M12 x 1.5 15 Nm 200 Nm Table 38: Tightening torques © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 95: Fig. 44: Tightening Torques For Insulation
Fig. 44: Tightening torques for insulation The following tightening torques must be observed for the specified bolted connections: Position Part number A150-M58/68 200 Nm 65 Nm 10 Nm 25 Nm 45 Nm Table 39: Tightening torques for insulation © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 96: Dismantling And Fitting With Removed Air Inlet And Gas Outlet
2. Loosen the hexagon-head screws (72051) and remove them with fastening strips (72012). 3. Remove the filter silencer (81000) or air suction branch (82000). 4. Remove and dispose of the O-ring (81010 or 82010). © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 97: Removing The Gas Outlet Casing
4. Loosen and remove nuts (51009). 5. Remove the gas outlet casing (61001), set it down properly in an appropriate place and secure it. 6. Remove and dispose of the gasket (61002). © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 98: Fig. 47: Removing Gas Outlet Casing With Support 1
4. Remove fixing screws of support (61301) to bracket. 5. Fit swivel lifting eyes (S) to the gas outlet casing (61001). Attach lifting gear to swivel lift- ing eye and secure to a crane hook. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F...
Page 99: Fig. 48: Removing Gas Outlet Casing With Support 1
6. Loosen nuts (51009) and remove together with support (61301). 7. Remove the gas outlet casing (61001), set it down properly in an appropriate place and secure it. 8. Remove and dispose of the gasket (61002). © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 100: Removing The Gas Outlet Flange
2. Attach swivel lifting eye (S) to the gas outlet flange. Secure lifting gear to the swivel lift- ing eye. 3. Remove the gas outlet flange. 4. If present: Remove the metal C-ring (57003). © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 101: Removing The Cartridge Group With Compressor And Turbine Casing
Fig. 51: Remove insulation 2. Remove the compressor casing insulation. 3. Remove the turbine casing insulation. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 102: Fig. 52: Removing The Cartridge Group With Compressor And Turbine Casing
10. Turn the compressor and turbine casing and set down on suitable supports. 11. Remove lifting gear from cartridge group. Leave second lifting gear attached to com- pressor casing for safety. 12. Remove and dispose of the O-rings (42195, 42200). © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 103: Removing The Compressor Casing
3. Remove the compressor casing (72000) and turn it 180°. 4. Remove and dispose of the O-ring (42012). 5. Loosen screws (79041) and remove from the compressor casing (72000) with fixing discs (79040) and diffuser (79000). © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 104: Removing The Cartridge Group
1. Treat threads of studs (51006) with penetrating oil and leave to take effect. 2. Loosen nuts (51007) and remove Verbus Ripp® washers (51003) together with the fasten- ing strips (51002). 3. Fit the cross-piece of the service support (90012). Observe the tightening torque. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 106: Fig. 57: Removing Cartridge Group 3
7. Place a suitable protective cover over the compressor wheel. 8. Turn the cartridge group into the horizontal rotor axis. 9. Remove lifting gear from service support and cross-piece. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 107: Installing The Cartridge Group On The Service Support
Fig. 58: Installing the cartridge group on the service support 1. Assemble the service support (90012) with longitudinal and cross-pieces. 2. Fit service support to cartridge group. 3. Put down cartridge group. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 108: Removing The Nozzle Ring
Removing the nozzle ring Fig. 59: Removing the nozzle ring 1. Pull out the nozzle ring (56001) with the two extraction devices (90070). 2. Remove the lamellar sealing ring (56005). © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 109: 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 a Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 110: Nozzle Ring Compression Pd
1. Measure dimensions A, B and S on cleaned surfaces. 2. Calculate compression (PD). If the calculated value (PD) lies outside the specified range, contact a Turbo Systems ser- vice station. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 111: Installing Nozzle Ring
(see detail B). 2. Align the cams on the nozzle ring with the recesses of the turbine casing (51000). 3. Insert the nozzle ring (56001) into the turbine casing up to the stop. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F...
Page 112: Installing The Cartridge Group
Fig. 63: Lifting the cartridge group and rotating it by 90° 1. Fasten lifting gear to cartridge group and lift cartridge group. 2. Remove service support (90012). 3. Dismantle service support. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 114: Fig. 65: Installing The Cartridge Group
9. Align casing position of cartridge group with marking and lower into the turbine casing. 10. Remove lifting gear cross-piece of service support. 11. Install the fastening strips (51002) with Verbus Ripp® washers (51003) and hexagon nuts (51007). Observe the tightening torque. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 115: Installing The Compressor Casing
1. Secure the diffuser (79000) with fixing discs (79040) and new screws (79041). Observe the tightening torque. 2. Fit lifting gear with swivel lifting eye (S) to compressor casing (72000) and rotate the compressor casing by 180°. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 116: Table 47: Tightening Torque (72011)
Table 47: Tightening torque (72011) 1. Fit new O-ring (42012). 2. Thoroughly clean the fastening strips (72012) before assembly. 3. Install the compressor casing (72000). 4. Install the fastening strips (72012) with screws (72011). Observe the tightening torque. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 117: Turning The Cartridge Group With Compressor And Turbine Casing
2. Lift cartridge group with compressor and turbine casing with the first lifting gear and lower it with the second lifting gear. 3. Remove second lifting gear and swivel lifting eye. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F...
Page 118: Installing The Gas Outlet Flange
2. Fit swivel lifting eye (S) to the gas outlet flange (57002). Secure lifting gear to the swivel lifting eye. 3. Install gas outlet flange in turbine casing (51000). 4. Measure radial clearance (R) (see chapter Radial clearances N and R). © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 119: 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 a Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 120: Fitting The Insulation
10 Dismantling and fitting with removed air inlet and gas outlet / 10.17 Fitting the insulation 10.17 Fitting the insulation Fig. 71: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see Table of tightening torques →92). © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 121: Installing The Cartridge Group With Compressor And Turbine Casing
5. If present: Remove the screw plug from the connection for the compressor wheel cooling (01) and fit the cooling air line. 6. If present: Plug in the plug to the speed sensor (86505). If present: Fit connecting pipe for turbine cleaning. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 122: Installing The Gas Outlet Casing
5. Fit hexagon nuts (51009). Observe the tightening torque. 6. Fit insulation ring. Observe tightening torques (see Table of tightening torques →92). 7. If present: Attach waste gate pipe. Tighten in accordance with enginebuilder’s specifica- tions. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 123: Fig. 75: Installing Gas Outlet Casing With Support 1
3. Fit swivel lifting eyes (S) to gas outlet casing (61001). Secure lifting gear to the swivel lift- ing eye. 4. Place gas outlet casing on the turbine casing (51000). Observe the marking. 5. Fit support (61301). 6. Fit hexagon nuts (51009). Observe the tightening torque. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 124: Fig. 76: Installing Gas Outlet Casing With Support 2
Table of tightening torques →92). 9. Fit gas outlet casing insulation (see Table of tightening torques →92). 10. If present: Attach waste gate pipe. Tighten in accordance with enginebuilder’s specifica- tions. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 125: Installing Air Inlets
2. Fit a new O-ring (81010) to the filter silencer (81000) or a new O-ring (82010) to the air suction branch (82000). 3. Install the filter silencer (81000) or air suction branch (82000). 4. Fit the fastening strips (72012) with hexagon-head screws (72051). Observe the tighten- ing torque. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 126: Dismantling And Fitting, Cartridge Concept
2. Loosen the hexagon-head screws (72051) and remove them with fastening strips (72012). 3. Remove the filter silencer (81000) or air suction branch (82000). 4. Remove and dispose of the O-ring (81010 or 82010). © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 127: Removing The Compressor Casing
2. Fit swivel lifting eye (S) to the compressor casing (72000). Secure lifting gear to the swivel lifting eye. 3. Loosen screws (72011) and remove together with fastening strips (72012). 4. Remove the compressor casing (72000). © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 128: Fig. 80: Pressing Off Compressor Casing
2. Set the compressor casing (72000) down on a suitable support. 3. Loosen screws (79041) and remove from the compressor casing (72000) with fixing discs (79040) and diffuser (79000). © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 129: Removing The Cartridge Group
3. Loosen the clamping nut (42201) (see Loosening the clamping nut →31). 4. Use the hexagon to raise the threaded rod (42191) up to its stop. 5. Attach lifting gear to cartridge group. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 130: Fig. 84: Removing Cartridge Group 2
1. Treat threads of studs (51006) with penetrating oil and leave to take effect. 2. Loosen nuts (51007) and remove Verbus Ripp® washers (51003) together with fastening strips (51002). 3. Pull the cartridge group from the turbine casing and remove it. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 131: Fig. 85: Removing Cartridge Group 3
1. Unscrew the threaded stud (42191) downwards and remove the clamping nut (42201). 2. Remove and dispose of the O-rings (42195, 42200). 3. If present: Remove the metal C-ring (51105). 4. Attach the cartridge group to the service support (90012). © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 132: Fig. 86: S_05180
11.4 Removing the nozzle ring Fig. 86: S_05180 1. Pull out the nozzle ring (56001) with the two extraction devices (90070). 2. Remove the lamellar sealing ring (56005). © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 133: Fig. 87: 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 a Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 134: Fig. 88: Nozzle Ring Compression Pd
1. Measure dimensions A, B and S on cleaned surfaces. 2. Calculate compression (PD). If the calculated value (PD) lies outside the specified range, contact a Turbo Systems ser- vice station. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 135: Fig. 89: Installing The Nozzle Ring
(see detail B). 2. Align the cams on the nozzle ring with the recesses of the turbine casing (51000). 3. Insert the nozzle ring (56001) into the turbine casing up to the stop. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F...
Page 136: Fig. 90: Installing The Cartridge Group
3. Screw the threaded stud (42191) into the clamping nut (42201) from below as far as its stop. 4. Fit new O-rings (42195, 42200). 5. If present: Insert the metal C-ring (51105). © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 137: Fig. 91: Installing The Cartridge Group 2
2. Use the hexagon to screw the threaded rod (42191) down to its stop. 3. Tighten pressure screws of clamping nut (see chapter --- FEHLENDER LINK ---). 4. Secure fastening strips (51002) together with nuts (51007) and Verbus Ripp® wash- ers (51003). © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 138: Fig. 92: Fitting The Diffuser
1. Secure the diffuser (79000) with fixing discs (79040) and new screws (79041). Observe the tightening torque. 2. Fit lifting gear with swivel lifting eye (S) to compressor casing (72000) and rotate the compressor casing. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 139: Fig. 93: Installing The Compressor Casing
Table 57: Tightening torque (72011) Thoroughly clean the fastening strips (72012) before assembly. 1. Fit a new O-ring (42012). 2. Install the compressor casing (72000). 3. Install the fastening strips (72012) with screws (72011). Observe the tightening torque. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 140: Fig. 94: Measuring 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 a Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 141: Fig. 95: Fitting The Insulation
11 Dismantling and fitting, cartridge concept / 11.11 Fitting the insula- tion 11.11 Fitting the insulation Fig. 95: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see Table of tightening torques →92). © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 142: Fig. 96: Installing The Air Inlets
2. Fit a new O-ring (81010) to the filter silencer (81000) or a new O-ring (82010) to the air suction branch (82000). 3. Install the filter silencer (81000) or air suction branch (82000). 4. Fit the fastening strips (72012) with hexagon-head screws (72051). Observe the tighten- ing torque. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 143: Dismantling And Fitting, Special Tools For Fastening Strips
Customer tool (not included in the Turbo Systems scope of delivery) Fig. 97: Customer tool Position Description Quantity Collection tub 500x400x30mm Torque spanner 40-200 Nm with plug connection for holding inser- tion tools 14x18 mm Table 60: Customer tool © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 144: Application, Special Tools
Any falling screw material will be caught in the collection tub (01). 5. Loosen the nuts (51007) from the remaining fastening strips and remove the lugs (51002) with washers (51003). © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 145: Fig. 100: Fitting The Upper Fastening Strips
4. Tighten the two nuts on the other side using the spanner holder (90166). The cartridge group is fitted at this point in time. In order to provide a clear representation of the work step, the cartridge group is not illustrated in work step 5. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F...
Page 146: Fig. 102: Fitting The Bottom Fastening Strip
Tightening torque [Nm] A150-M58/68 Table 62: Tightening torque (51007) with spanner holder 5. Fit the nuts (51007) with spanner holder (90165 / 90166) and attached torque span- ner (02). Observe the tightening torque. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 147: Removing And Installing 6-Nozzle Turbine Cleaning Component (Optional)
Fig. 104: Disassembly of the elbows 1. Just loosen the union nuts (51316) of the elbows (51311). Do not remove them yet. 2. Just loosen the screws (51314). Do not remove them yet. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F...
Page 148: Fig. 105: Disassembly Of The Elbows
Remove the elbows (51311) from the connecting pieces (51313) in the specified order (01, 02, 03, 04, 05). Fig. 106: Pipe disassembly 1. Undo union nuts (51316) of pipe (51312). 2. Remove pipe. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 149: Fig. 107: Disassembly Of The Connecting Pieces
Fig. 108: Disassembly of the cleaning nozzle Remove cleaning nozzles (51301) with screw (01) in accordance with the following table. Product Thread Length [mm] Quantity A150-M58 / 68 Table 63: Dismantling screw © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 150: Assembly
2. Position connecting pieces (51313). 3. Position gaskets (51302) on connecting pieces (51313). 4. Coat thread and contact surfaces of hexagon-head screws (51314) with high-temperat- ure grease. Tighten screws by hand only. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 151: Fig. 111: Pipe Assembly
Coat thread and contact surfaces of cutting ring with high-temperature grease. Screw union nuts (51316) of elbows (51311) in the specified order (01, 02, 03, 04, 05) to the connecting pieces (51313). © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F...
Page 152: Fig. 113: Elbow 2 Assembly
Fig. 113: Elbow 2 assembly Product 51314 [Nm] 51316 [Nm] A150-M58/68 Table 65: Tightening torque (51314 / 51316) 1. Tighten hexagon-head screws (51314) to tightening torque. 2. Tighten union nuts (51316) of elbows (51311) to tightening torque. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 153: Fitting The Cleaning Nozzles With Multi-Inlet Turbine Casings
1. The designation (P . ) on the turbine casing must correspond with the designation (P . ) on the cleaning nozzle. 2. The edges for the defined installation position in the turbine casing and at the cleaning nozzle must correspond. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 154: Taking Out Of Operation At Short Notice
If a replacement turbocharger or cartridge group is not available: Fit the cover plate →154 and contact a Turbo Systems service station. Observe the following sections in connection with the emergency repairs mentioned. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 155: Installing The Replacement Turbocharger
Dismantling and fitting, general →84). Install replacement cartridge group (see chapter Dismantling and fitting, general →84). Send the defective cartridge group to a Turbo Systems service station for inspection and repair. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 156: Fitting The Cover Plate
3. Coat the threads of the studs (51006) with high-temperature grease. 4. Fasten cover plate (01) to turbine casing (51000) with fastening strips (51002), Verbus Ripp® washers (51003) and nuts (51007) and screw to bracket. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F...
Page 157: Cover Plate Drawing
Material: General structural steel, in accordance with DIN EN 10025-2. Fig. 116: Cover plate drawing Product ØD1 ØD2 ± 0.5 ± 0.2 ± 0.1 ± 0.2 A150 138.9 21.4 71.4 413.6 ≤ 196 Table 66: Cover plate dimensions [mm] © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 158: Fig. 117: Dimensions For Cover Plate
15 Taking out of operation at short notice / 15.5 Cover plate drawing Fig. 117: Dimensions for cover plate Product D2 ± 0.1 A150 90 ± 0.2 28.2 Table 67: Cover plate dimensions [mm] © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 159: Mothballing The Turbocharger
The rotor and bearing parts must be dismantled and subsequently refitted by a Turbo Systems service station. Clean all parts. Coat plain surfaces of steel and cast parts with anticorrosive oil. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 160: Taking The Engine Out Of Operation For More Than 12 Months
State of the mothballed turbocharger Check the turbocharger parts annually for corrosion. If there are signs of rust: Thoroughly clean parts and renew corrosion protection. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 161: Material And Disposal
6c) Copper alloy containing up to 4 % lead by weight. The maximum concentration of lead and lead compounds for our products is known to reach max. 0.8 % (mass % in homogeneous material). © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F...
Page 162: 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 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 163: Spare Parts
Counter-sunk screw 81010 / 82010 O-ring Table 68: Customer spare part set 97070 * This gasket can only be installed if a gas outlet casing from Turbo Systems is used. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 164: Spare Part - Illustrations
Screw plug 42166 Screw 42167 Cover 42170 Insulation 42172 Hexagon-head screw 42188 Hexagon-head screw 42189 Gasket 42190** Expansion bush 42191 Threaded rod 42193** Centering bush 42194 Gasket 42195* O-ring © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 165: Table 69: Spare Parts - Cartridge, Oil Cooled
18 Spare parts / 18.3 Spare part – Illustrations Part no. Designation 42196 Orifice oil inlet 42197 Safety-ring 42200* O-ring 42201 Clamping nut 42202 Screw plug Table 69: Spare parts - Cartridge, oil cooled © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 166: Table 70: Spare Parts - Bearing, Casing Oil Cooled
Washer 42301 Bearing cover 42302* ** Piston ring 42303* ** Piston ring 42305* O-ring 42306* O-ring 42308* O-ring 42400 Heat shield Table 70: Spare parts - Bearing, casing oil cooled © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 167: Table 71: Spare Parts - Rotor And Bearing Parts
Bearing flange 32113* Socket screw 32114* Socket screw 32159* Socket screw 32167* ** Snap ring 42002 Socket screw 42302* ** Piston ring Table 71: Spare parts - Rotor and bearing parts © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 168: Table 72: Spare Parts - Turbine Casing, 1 Inlet
Tension washer 51500 Burst protection 56001 Nozzle ring 56005 Lamellar sealing ring 57002 Gas-outlet flange 57003(o) Metal C-ring 57210 Burst ring Table 72: Spare parts – Turbine casing, 1 inlet © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 169: Table 73: Spare Parts - Turbine Casing, 2 Inlets
Tension washer 51500 Burst protection 56001 Nozzle ring 56005 Lamellar sealing ring 57002 Gas-outlet flange 57003** Metal C-ring 57210 Burst ring Table 73: Spare parts – Turbine casing, 2 inlets © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 170: Table 74: Spare Parts - Turbine Casing, 3 Inlets
Screw plug 51500 Burst protection 56001 Nozzle ring 56005 Lamellar sealing ring 57002 Gas-outlet flange 57003** Metal C-ring 57210 Burst ring Table 74: Spare parts – Turbine casing, 3 inlets © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 171: Table 75: Spare Parts - Cleaning Device
51309 Expansion sleeve 51310 Hexagon nut 51311 Pipe elbow 51312 Pipe 51313 Joining piece 51314* Hexagon-head screw 51316 Cap nut 51317 Stop plug Table 75: Spare parts - Cleaning device © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 172: Table 76: Spare Parts - Gas Outlet Casing, Radial
Gas-outlet casing 61002* Gasket 61005(p) Screw plug 61100 Insulation gas-outlet casing GW03 61140 Insulation 61201 Hexagon-head screw 61202 Tension washer 61301** Support Table 76: Spare parts - Gas outlet casing, radial © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 173: Table 77: Spare Parts - Compressor Casing
Insulation sleeve 72062 Hexagon-head screw 72063 Tension washer 77000 Wall insert 77005* O-ring 77006 Stud 79000 Diffuser 79040 Fixing washer 79041* Counter-sunk screw Table 77: Spare parts - Compressor casing © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 174 Flange turbine-end 81147 Fixing ring 81148 Damping element 81149 Holding sheet metal 81150 Clamping strap 81151 Spring-type pin 81152 Hexagon-head screw 81153 Washer 81154 Hex socket head cap screw © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 175: Table 78: Spare Parts - Filter Silencer
HZTL443474 Mod. A Part no. Designation 82000 Air suction branch 82005 Screw plug 82006 Gasket 82007 Screw plug 82008 Gasket 82010* O-ring Table 79: Spare parts - Air suction branch axial © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 176: Table 80: Spare Parts - Air Suction Branch Radial
HZTL443315 Mod. B Part no. Designation 82000 Air suction branch 82005 Screw plug 82006 Gasket 82007 Screw plug 82008 Gasket 82010* O-ring Table 80: Spare parts - Air suction branch radial © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 177: Table 81: Spare Parts - Speed Measurement System
86515** 86505** ** = if provided HZTL443475 Mod. A Part no. Designation 86258** Tachometer 86505** Speed sensor 86515** Cable connector 86526** F/I-Converter Table 81: Spare parts - Speed measurement system © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 178: Tools
Special tool (90160): Fig. 118: Special tool Part number Description Quantity 90160 Special tool, complete 90161 90165 Spanner holder 90166 Spanner holder Table 83: Special tool (90160) © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 179 Tool sets can be ordered from any Turbo Systems service station. The following specifica- tions must be included in the order: ¡ Turbocharger type ¡ Designation and part number of the tool set. © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022...
Page 180 Fig. 59: Removing the nozzle ring......106 Fig. 30: Carrying out wet cleaning of turbine ..65 Fig. 60: Measuring clearance A and B ...... 107 Fig. 31: Cleaning the filter silencer ......67 © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Revision F February 2022...
Page 181 Fig. 87: Measuring clearance A and B ...... 131 Fig. 88: Nozzle ring compression PD ....... 132 Fig. 89: Installing the nozzle ring......133 Fig. 90: Installing the cartridge group ....134 Fig. 91: Installing the cartridge group 2....135 © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Revision F February 2022...
Page 182 .......... 79 Table 52: Permissible clearances A and B ....131 Table 24: Malfunctions during operation – Charge air pressure too low............79 Table 53: Nozzle ring compression PD ....132 © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Revision F February 2022...
Page 183 Table 80: Spare parts - Air suction branch radial.. 174 Table 81: Spare parts - Speed measurement system.. Table 82: Customer tool set 90000 ......176 Table 83: Special tool (90160)........176 © Copyright 2022 ABB. All rights reserved. HZTL4041_EN Revision F February 2022...

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