Page 1 Operation Manual A265-L59 XAC22451 English Original Operation Manual Chapter Document-ID Introduction HZTL4005_EN_G Safety HZTL4024_EN_E Safety data sheet XAC22451 Product description HZTL4036_EN_Q ABB Switzerland Ltd, Turbocharging...
Page 2 Operating limits and replacement intervals The recommended replacement intervals and the corresponding operating limits in chapter 3 are jointly defined with the enginebuilder. This information is specific to the product. Non-observance of the recommended replacement intervals and the operating limits increases the risk of unpre- dictable component failures.
Page 3: Table Of Contents
Operation Manual / 1 Introduction Table of contents Introduction Introduction......................2 Purpose of the manual....................2 Symbols, definitions...................... 3 Storage of new turbochargers and spare parts ............5 Contact information...................... 7 © Copyright 2020 ABB. All rights reserved. HZTL4005_EN Rev.G March 2020...
Page 4: Introduction
Availability of the Operation Manual The Operation Manual must be available where the turbocharger is used. All persons operating or working on the turbocharger must have read and fully understood the Operation Manual. © Copyright 2020 ABB. All rights reserved. HZTL4005_EN Rev.G March 2020...
Page 5: Symbols, Definitions
Definition of Caution / Warning Caution and warning signs are described in chapter Safety. ABB Turbocharging ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging or as ABB Turbo Sys- tems in this document. Official service stations of ABB Turbocharging Official service stations are regularly audited and certified by ABB Turbocharging.
Page 6 Visually inspect Please note text for numbered work step. See document Dispose of in an environmentally compatible, professional way and in compliance with locally applicable regulations. Table 1: Definition of pictograms © Copyright 2020 ABB. All rights reserved. HZTL4005_EN Rev.G March 2020...
Page 7: Storage Of New Turbochargers And Spare Parts
Dispose of the old VCI corrosion protection emitter in an environmentally compatible manner, professionally and in accordance with local regulations. Seal the package. The better the external seal is designed, the more permanent the pro- tection. © Copyright 2020 ABB. All rights reserved. HZTL4005_EN Rev.G March 2020...
Page 8 Inspect the package for damage. If the package is damaged, the turbocharger must be in- spected by an ABB Turbocharging Service Station and repacked. After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station: ¡...
Page 9: Contact Information
Operation Manual / 1 Introduction 1 Introduction / 1.4 Contact information Contact information Contact information for the ABB Turbocharging Service Stations is available online. Scan the QR code to access our website. ABB Switzerland Ltd, Turbocharging Bruggerstrasse 71a CH-5401 Baden Switzerland www.abb.com/turbocharging...
Page 11 Lifting of loads ......................9 1.11 Prerequisites for operation and maintenance............10 1.12 Hazards during operation and maintenance ............11 1.13 Safe operation ......................13 1.14 Safe maintenance ......................14 © Copyright 2020 ABB. All rights reserved. HZTL4024_EN Rev.E July 2020...
Page 12: Safety
Safety Introduction Turbochargers manufactured by ABB reflect the state of the art. The respective safety and health protection requirements are met. This ensures safe operation of the turbocharger. Nevertheless, there may be some residual risks during operation of and work on the tur- bocharger which: ¡...
Page 13: Definition Of Mandatory Signs
Non-compliance or inaccurate compliance with working or operating in- structions indicated by this symbol and the word CAUTION can lead to seri- ous damage to engine or property with grave consequences. Caution signs must always be observed. © Copyright 2020 ABB. All rights reserved. HZTL4024_EN Rev.E July 2020...
Page 14: Intended Use
These data are given on the rating plate. ABB accepts no liability and rejects all warranty claims for any non-intended uses. [1]Euromot = The European Association of Internal Combustion Engine Manufacturers [2]Directive 94/9/EC concerning equipment and protective systems intended for use in po-...
Page 15: Deflagration On Gas Engines
If during external inspection anomalies are found or if a particularly strong deflagration event has taken place, it is also recommended to check the bearings of the turbochargers before the next start. An ABB Turbocharging Service Station should be instructed to carry out this inspection.
Page 16: Warning Plates On The Turbocharger
Manual, Chapter 4 Product description. Turbochargers supplied to the enginebuilder without insulation must be equipped later with warning plates on the insulation. This is the responsibility of the enginebuilder. © Copyright 2020 ABB. All rights reserved. HZTL4024_EN Rev.E July 2020...
Page 17: Turbocharger Rating Plate
Further data 06 Customer part number 07 Designation for special design 08 Weight of turbocharger in kg 09 Turbocharger type 10 Serial number Year of construction of turbocharger Manufacturing plant © Copyright 2020 ABB. All rights reserved. HZTL4024_EN Rev.E July 2020...
Page 18: Periodic Check Of The Pressure Vessels
The locations of the rating plates are defined in the Operation Manual, Chapter 4 Product description. Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, are so-called "simple pressure vessels". ¡...
Page 19: Lifting Of Loads
The assembly devices must be completely screwed in and must not loosen during use. Use assembly devices only for the described applications. Put down dismantled components of the turbocharger in such a way that they cannot tip over. © Copyright 2020 ABB. All rights reserved. HZTL4024_EN Rev.E July 2020...
Page 20: Prerequisites For Operation And Maintenance
Only use original parts from ABB. Original parts and accessories are specially designed for ABB turbochargers. ABB accepts no liability for any damage resulting from the use of non-original parts and cor- responding accessories. © Copyright 2020 ABB. All rights reserved.
Page 21: Hazards During Operation And Maintenance
Do not touch hot surfaces. Observe the warning plate on the turbochar- ger. Wear heat-resistant safety gloves and protective clothing. Wait for the turbocharger to cool down before carrying out any work. Wear safety gloves to protect against thermal hazards. © Copyright 2020 ABB. All rights reserved. HZTL4024_EN Rev.E July 2020...
Page 22 At the same time, electrical or electronic components and parts can also be damaged or destroyed. Only specially trained personnel should perform work on, or with, elec- trical components. Observe national regulations. © Copyright 2020 ABB. All rights reserved. HZTL4024_EN Rev.E July 2020...
Page 23: Safe Operation
In case of damage, take the turbocharger out of operation immediately and safeguard against accidental/unauthorised use. When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay at- tention to the risks that may occur as a consequence of this energy input. © Copyright 2020 ABB. All rights reserved. HZTL4024_EN Rev.E July 2020...
Page 24: Safe Maintenance
Keep the floor, equipment, and turbocharger clean. Have oil binding agents ready and provide or keep oil pans at hand. Clean up any spills. Have fire protection means and extinguishing agents available. © Copyright 2020 ABB. All rights reserved. HZTL4024_EN Rev.E July 2020...
Page 25 Components of the turbocharger can be damaged or destroyed as a result of improper procedures. Only perform operations that are described in this chapter. Only perform operations for which you have received instruction or train- ing. © Copyright 2020 ABB. All rights reserved. HZTL4024_EN Rev.E July 2020...
Page 26 Wear personal protective equipment (PPE) according to the material safety data sheet. Comply with local legislation. Wear safety goggles. Wear safety gloves to protect against chemical hazards. Wear a respiratory mask to protect against gases. © Copyright 2020 ABB. All rights reserved. HZTL4024_EN Rev.E July 2020...
Page 27 Dispose of insulation materials properly and in an environmentally com- patible manner in compliance with the legal regulations. Wear safety goggles. Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against chemical hazards. © Copyright 2020 ABB. All rights reserved. HZTL4024_EN Rev.E July 2020...
Page 29 Operation Manual / A265-L59 / Safety data sheet Page 1 / 1 Safety data sheet A265-L59 XAC22451 A265-L59 XAC22451 A265IH00471 2020 2600 © Copyright 2020 ABB. All rights reserved. XAC22451 August 2020...
Page 31 Cleaning the compressor during operation ............36 Cleaning the turbine during operation..............40 Draining the gas outlet casing ................. 44 Troubleshooting....................45 Malfunctions when starting..................45 Malfunctions during operation ................46 © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 32 Ordering spare parts....................102 12.2 View of turbocharger with part numbers ............104 12.3 View of cartridge group with part numbers............106 Figures......................... 108 Tables ........................110 © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 33: Introduction
This document is valid for different design variants of turbochargers. There may be sections and descriptions of components that are not relevant for a specific turbocharger variant. Please contact an ABB Turbocharging Service Station if you have any questions regarding a design variant (see Contact information at www.abb.com/turbocharging).
Page 34: Layout And Function Of The Turbocharger
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 © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 35 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. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q...
Page 36: Warning Plates On The Turbocharger
If warning plates are not present in the designated locations or not readable, proceed as fol- lows: Order new warning plates from ABB Turbocharging Service Stations. Remove any warning plates that have become unreadable. Clean and degrease the areas designated for the warning plates.
Page 37: Locations Of The Rating Plates
Locations of the rating plates Fig. 3: 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 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 38: Removal And Installation
Secure with lifting gear wherever possible. Loosen cable to speed sensor. Disconnect all pipes according to the instructions of the enginebuilder. Check lifting gear. Attach lifting gear to the turbocharger and tauten. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 39: Fig. 4: Fitting The Lifting Gear
2 Removal and installation / 2.2 Removing the turbocharger Fig. 4: Fitting the lifting gear Loosen fixing screws on compressor-end and turbine-end foot. Lift turbocharger from engine and put down in a suitable location. Cover oil connections. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 40: Installing The Turbocharger
Tighten the fixing screws (Steps for fastening the turbocharger loosening the lifting gear. Remove lifting gear from turbocharger. Connect cable to speed sensor. Connect all gas, air and oil pipes. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 41: Fig. 6: Compressor-End Foot
Tighten the foot fixing screws or nuts diagonally according to the selected tightening method. Turbine-end foot Fig. 7: Turbine-end foot Tighten the foot fixing screws or nuts according to the selected tightening method. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 42: Table 4: Tightening Torques (Foot Screws)
A280-L 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. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 43: Commissioning
Inspection procedures include preventative visual controls, monitoring and measuring work before and during commissioning. Inspection procedures enable changes to the turbochar- ger to be detected. Machine damage can be prevented. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 44 Check oil inlet temperature. The admissible values are specified in section Oil supply. Gas, air and oil pipes After starting the engine, check all gas, air and oil pipes for leaks. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 45: Commissioning After Taking Out Of Operation
Lubricants and pastes used during assembly can liquefy or vaporise and escape as oily fluids during the initial hours of operation. Continual escape of an oily fluid indicates an oil leak. If there is a leak, contact an ABB Turbocharging Service Station. Commissioning after taking out of operation...
Page 46: Monitoring During Operation
Oil temperature at the inlet [°C] oil,inlet Admissible (see Table 6: Lubricating oil pressure, oil inlet 30 … 80 →16) Temporarily admissible (< 1 h) → alarm > 80 Not admissible → stop engine > 85 © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 47: Fig. 8: Oil Temperature At The Outlet
Temporarily admissible → alarm > 110 Temporarily admissible → alarm > 125 Not admissible → stop engine > 120 Not admissible → stop engine > 135 Table 8: Lubricating oil temperature at the outlet © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 48 4 Monitoring during operation / 4.1 Oil pressure, oil temperature If the turbocharger has been operated for a longer period of time outside the admissible range, ABB Turbocharging recommends having the turbocharger inspected by an ABB Tur- bocharging Service Station.
Page 49: Admissible Air Inlet Temperature
Tachometer 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 © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 50 Check the pressure loss of the alternative air inlet and compare it with normal values. If the engine can be stopped temporarily: Inspect air lines, gas piping and the turbochargers and remedy any malfunctions. In any case, contacting the nearest ABB Turbocharging Service Station is recommended. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q...
Page 51: Fig. 10: Replacing The Speed Sensor
Unscrew the defective speed sensor. 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. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 52: Low Pressure Measurement At The Filter Silencer
Better readability of the U-tube manometer can be achieved by filling with slightly coloured water. Colour the water with food colouring or ink. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q...
Page 53: Operation And Service
Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 : A-weighted emission sound pressure level The enginebuilder must provide acoustically equivalent measures in case of deviating in- sulation versions © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 55 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 Tur- bocharging Service Station. Damaged and worn out parts must be replaced with original ABB parts.
Page 56 Service work according to instructions of enginebuilder Clean or replace the oil filter located in the supply pipe to the turbocharger while the en- gine is stopped, in accordance with the instructions of the enginebuilder. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q...
Page 57 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 © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 58: Expected Replacement Intervals
See information on rating plate Bearings See information on rating plate Table 11: Recommended replacement intervals for turbocharger parts The specified values are guideline values and not guaranteed values, see Influencing para- meters. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 59: Flexible Turbocharger Cut-Out
Close the compressor outlet flap just before the gas inlet flap. Contamination with closed flaps To limit the contamination deposits when operating with closed flaps, we recommend you open them at least every 500 hours of operation. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 60: Stopping The Engine
Operation Manual / 4 Product description / A200-L 5 Operation and service / 5.5 Stopping the engine Stopping the engine Observe the instructions regarding post-lubrication (Pre-lubrication and post-lubrication →18) Stop the engine. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 61: Periodic Maintenance
Maintenance work includes regular visual controls and cleaning operations which are inten- ded to ensure the trouble-free functioning of the turbocharger. Described maintenance points: ¡ Filter silencer ¡ Compressor ¡ Turbine and nozzle ring © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 62: Cleaning The Filter Silencer
Connecting strip 81136 Absorption segment 81270 Tension band 81137 Sheet-metal covering 81271 Lock 81265 Filter ring (if present) 81400 Water connection Insert unit (absorption segment / sheet-metal covering fitted) © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 63 Guide the tension bands (81270) through the eyelets of the connecting strips (81268). Tighten the tension bands (81270) at the locks (81271). Any damaged tension bands must be replaced. Fit filter ring (81265), if present. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 64: Changing The Filter Strip On The Filter Silencer Casing
Fig. 14: Dismantling filter ring circumferential part Dismantle circumferential part (9). Fig. 15: Opening filter ring lock Open the lock of the filter ring (81265). © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 65: Fig. 16: Attaching New Filter Ring
Pull on the old filter ring until the new filter ring is completely wrapped around the filter silencer. Undo the connection between the new and the old filter ring. Fasten the newly installed filter ring (81265), then fit circumferential part (9). © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 66: Cleaning The Compressor During Operation
The interval between the cleaning cycles depends greatly on the operating conditions. Cleaning should normally be carried out every 50 hours of operation. If the specified cleaning interval is incompatible with operation of the engine, contact ABB Turbocharging. Cleaning method and operating state The compressor is cleaned during operation using the wet cleaning method.
Page 67 CAUTION Volume of water for cleaning the compressor Uncontrolled volumes of water can damage the turbocharger and the en- gine. Do not guide water pipes to the filler openings. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 68: Fig. 18: Overview Of Wet Cleaning Of Compressor
Screw in lock and hand-tighten. 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. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 69: Fig. 19: Filter Plug View
Repeating the cleaning If the cleaning is still unsuccessful after three processes, it is recommended to have the tur- bocharger checked and cleaned by an ABB Turbocharging Service Station if the engine val- ues are unsatisfactory. Volume of water per cleaning process...
Page 70: 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 Turbocharging recommends clean- ing one turbine after the other. © Copyright 2020 ABB. All rights reserved.
Page 71: Fig. 20: Overview Of Dry Cleaning Device
Plate Piping Cleaning instructions (51717) On-Off valve [closed] (51705) Gas inlet casing, insulated CAUTION Protecting the pressurised air system Protect the pressurised air system against overpressure (> 7 bar). © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 72 Repeating the cleaning If the cleaning is still unsuccessful after three processes, it is recommended to have the tur- bocharger checked and cleaned by an ABB Turbocharging Service Station if the engine val- ues 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 73: Table 14: Cleaning Parameters
Table 14: Cleaning parameters NOTICE 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. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 74: 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. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q...
Page 75: Troubleshooting
To prevent significant loss of efficiency, specific tolerances must be fulfilled. ¡ If there is any doubt about the extent of the rubbing, contact an ABB Tur- bocharging Service Station. ¡...
Page 76: Malfunctions During Operation
Drop in speed Possible causes Remedy Turbochar- Heavy contamination of the turbine Clean Damaged rotor components or bearing Contact ABB Turbocharging Service Station Pipes Defects, such as leaks, in the exhaust Repair gas pipes or charge air ducts Table 19: Malfunctions during operation – Drop in speed ©...
Page 77: Table 20: 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 21: Malfunctions during operation – Charge air pressure too low © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 78: Surging Of The Turbocharger
Gradually reduce the engine load. Have the cause clarified and remedied immediately by an ABB Turbochar- ging Service Station. Have parts assessed for damage and, if necessary, replaced by an ABB Turbocharging Service Station. © Copyright 2020 ABB. All rights reserved.
Page 79: Malfunctions When Stopping
Possible causes Remedy Turbochar- Turbocharger contaminated Clean Bearing damaged Contact an ABB Turbocharging Service Station Rotor rubbing Foreign object in the turbocharger Table 25: Malfunctions when stopping – Shortened runout time © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 80: Speed Measurement System
If none of the measures described above remedy the malfunc- causes of tion, it is recommended to have the speed measurement sys- malfunc- tem checked by an ABB Turbocharging Service Station. tion Table 26: Malfunctions of the speed measurement system © Copyright 2020 ABB. All rights reserved.
Page 82: Disassembly And Assembly
The specified tightening torques of the bolted connections must be observed. Tightening torques for assembly devices Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB must be tightened so they are tight-fitting. © Copyright 2020 ABB. All rights reserved.
Page 83 Use assembly devices only for the described applica- tions. ¡ Lifting gear Equipment for the lifting and transporting of loads (ropes, chain block, crane). Lifting gear is not supplied by ABB. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 84: Weights Of Assemblies
The total weight of the complete wall insert is made up of the wall insert and diffuser as- semblies. A255-L A260-L A265-L A270-L A275-L A280-L 1230 Table 28: Weight of wall insert [kg] © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 85: Disassembly And Assembly Of The Filter Silencer Casing
Fig. 23: Dismantling 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. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 86: Fig. 24: Fitting The Filter Silencer Casing
The location of screw (A) serves as a reference for the correct assembly of the filter silencer casing. Before disassembling the bottom part (01), mark the location of screw (A). Fit all remaining screws on the bottom part (01). © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 87: Fig. 25: Fitting The Filter Silencer Casing
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). © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 88: Fig. 27: Fitting The Filter Silencer Casing
Fig. 27: Fitting the filter silencer casing Insert the flanges (10) and (11) laterally between the side parts and fit the screws. Fig. 28: Fitting the filter silencer casing Fit the circumferential part (05) with the screws. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 89: Fig. 29: Fitting The Bellows
Tighten all screws of the side parts (03, 04, 07, 08) and the flanges (10, 11). Tighten all screws of the circumferential parts (05, 06, 09). Bellows Fig. 29: Fitting the bellows Fit bellows (C) with frame (F), screws (S) and nuts (N) on the filter silencer casing. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 90: Dismantling The Filter Silencer
Fig. 30: Dismantling the filter silencer 1. Attach lifting gear to the eyelets of the filter silencer (81000). 2. Loosen nuts (72004) and remove with washers (72003). 3. Remove and put down filter silencer. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 91: Fig. 31: 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. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q...
Page 92: Dismantling Wall Insert And Diffuser
4. Fit shackle (90195) with lifting gear on P1 of lifting device. 5. Fit lifting device with crane on upper area of wall insert. 6. Change the position of the shackle with the lifting gear to P2 of the lifting device. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q...
Page 93: Fig. 33: Moving Out Wall Insert
8. Remove O-ring (77040). Fig. 34: Putting down wall insert Put down wall insert (77000) with diffuser (79000) in horizontal position and use appro- priate supports to prevent it from falling over and rolling away. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 94 4. Fit shackle (90195) with lifting gear on P1 of lifting device (90190). 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). © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q...
Page 95: Fig. 36: Moving Out Wall Insert
9. Remove O-ring (77040). Fig. 37: Putting down wall insert Put down wall insert (77000) with diffuser (79000) in horizontal position and use appro- priate supports to prevent it from falling over and rolling away. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 96: Fig. 38: Putting Down Wall Insert
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. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 97: Fig. 39: Dismantling The Diffuser
8 Disassembly and assembly / 8.5 Dismantling wall insert and diffuser Fig. 39: 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. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 98: Axial Clearance A Prior To Disassembly
Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. Fig. 40: Measuring axial clearance A The axial clearance (A) of the rotor should always be measured before and after service work.
Page 99: Dismantling The Insulation (≤ A275-L)
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. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 100: Dismantling The Gas Inlet Casing (≤ A275-L)
A275-L Table 31: Maximum admissible loosening torque (51087) If a threaded stud (51086) shears off when loosening, an ABB Turbocharging Service Sta- tion should be contacted. If a threaded stud (51086) works loose when removing the nut (51087), it should be refit- ted, after disassembling the gas outlet casing, up to the stop in the gas inlet casing until hand-tight.
Page 101: Dismantling The Nozzle Ring (≤ A275-L)
8 Disassembly and assembly / 8.9 Dismantling the nozzle ring (≤ A275- Dismantling the nozzle ring (≤ A275-L) Fig. 43: Dismantling the nozzle ring (A275-L and smaller) 1. Loosen screws (56014) and remove with washers (56011). 2. Remove and put down nozzle ring (56001). © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 102: Dismantling The Gas Inlet Casing (A280-L)
840 Nm Table 32: Maximum admissible loosening torque (51087) If a threaded stud (51086) shears off when loosening, an ABB Turbocharging Service Sta- tion should be contacted. If a threaded stud (51086) works loose when removing the nut (51087), it should be refit- ted, after disassembling the gas outlet casing, up to the stop in the gas inlet casing until hand-tight.
Page 103: Dismantling The Nozzle Ring (A280-L)
Fig. 45: 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). © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 104: Fig. 46: Dismantling The Nozzle Ring
4. Screw the screws (B ) into the nozzle ring holder. 5. Remove screws (B Fig. 47: Put down the nozzle ring Use the crane to remove and put down the nozzle ring (56001). © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 105: Fitting The Nozzle Ring (≤ A275-L)
) 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 washers (56011). © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 106: Fitting The Gas Inlet Casing (≤ A275-L)
3. Push gas inlet casing over the threaded studs up to the gas outlet casing. 4. Coat two nuts with high-temperature grease and fix gas inlet casing in two opposite po- sitions. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q...
Page 107: Fitting The Insulation (≤ A275-L)
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). © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q...
Page 108: Fitting The Nozzle Ring (A280-L)
Coat the screw threads with high-temperature grease. Fig. 51: Fitting the nozzle ring (A280-L) Use lifting gear to secure the nozzle ring (56001) on the nozzle ring holder (90477) and transport it. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 109: Fig. 52: Attaching The Nozzle Ring (A280-L)
4. Coat screws (56014) with high-temperature grease and fit with washers (56011). 5. Remove screws (B ) along with the nozzle ring holder (90477). © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 110: Fitting The Gas Inlet Casing (A280-L)
7. Remove the lifting gear. 8. Connect the flange of the gas inlet casing and the bellows. 9. Fit the insulation segments (51215). © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 111: Axial Clearance A After Assembly
Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. Fig. 54: Measuring axial clearance A The axial clearance (A) of the rotor should always be measured before and after service work.
Page 112: Fitting The Diffuser
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. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 113: Fitting Wall Insert
8 Disassembly and assembly / 8.19 Fitting wall insert 8.19 Fitting wall insert Fig. 56: Positioning wall insert Carefully bring wall insert (77000) into vertical position with the lifting device (90190). © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 114: Fig. 57: Fitting The Wall Insert (A255-L
5. Fit a hexagon nut (72004) with a sleeve (90191) as a safety device. 6. Remove the shackle (90195) with lifting gear. Change the position of the shackle with the lifting gear to P1 of the lifting device (90190) and remove with the crane. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q...
Page 115 8. Check that 23 threaded studs have been fitted. 9. Press the wall insert into the compressor casing using a hexagon nut (72004) and sleeve (90191). Observe tightening torque. Remove nuts and sleeves. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q...
Page 116: Fig. 58: Fitting The Wall Insert (A265-L
P1 of the lifting device (90190) and remove with the crane. 7. Move the wall insert fully in, then remove the guide studs (90320). 8. Fit the screws (72011). Observe tightening torque. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q...
Page 117: Fitting The Filter Silencer
Cast filter silencer The filter silencers differ in terms of the fixing eyelets for the lifting gear. The relevant vari- ant must be taken into consideration for disassembly and assembly. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 118: Fig. 59: Fitting The Filter Silencer
1. Attach lifting gear to the eyelets 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. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 119: Fig. 60: 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. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 120: Table Of Tightening Torques
Operation Manual / 4 Product description / A200-L 8 Disassembly and assembly / 8.21 Table of tightening torques 8.21 Table of tightening torques Fig. 61: Overview of tightening torques Fig. 62: Overview of speed sensor tightening torque © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 121: Fig. 61: Overview Of Tightening Torques
2) Pre-tightening torque of the screws Use hydraulic tool for tightening torques exceeding 500 Nm. Tightening torque, insulation Thread size Tightening torque [Nm] M12 (compressor casing insulation) Table 45: Tightening torque, insulation © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 122: Taking A Turbocharger Out Of Operation
Impermissible vibrations and unbalance values can cause serious damage to the engine or property during operation. It is imperative that the following work is carried out after emergency operation with a locked rotor by an ABB Turbocharging Service Station: Remove rotor and check for unbalance...
Page 123: Taking Defective Turbochargers Out Of Operation
If necessary, remove the nozzle ring (see chapter Engines without bypass around the turbocharger →96) Table 46: Bypass procedure Continue to operate engine in accordance with enginebuilder's instructions. Observe the prescribed power reduction. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 124: Fig. 63: Locking The Rotor
Blanking off the inlets and outlets →97). Continue to operate engine in accordance with enginebuilder's instructions. Observe the prescribed power reduction. 9.2.3 Locking the rotor Fig. 63: Locking the rotor © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 125: Table 47: Tightening Torque B
Close the lubricating oil supply to the turbocharger. Open the bypass around the turbocharger. Observe specifications from enginebuilder. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 126: Fig. 64: Ensuring Clamping Of The Cover Ring
If the nozzle ring is removed for emergency operation, the clamping of the cover ring (57001) to the gas outlet casing must be ensured. In this case, additional washers (01) must be provided in accordance with the following table. These washers (01) are not supplied by ABB. Fig. 64: Ensuring clamping of the cover ring...
Page 127: Fig. 65: Position Of Cover Plates
The chapter is only applicable for engines with several turbochargers and joint air and ex- haust 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 128 Operation Manual / 4 Product description / A200-L 9 Taking a turbocharger out of operation / 9.2 Taking defective tur- bochargers out of operation © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 129: Mothballing The Turbocharger
If the acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking the engine out of operation: Dismantle the turbocharger. The rotor and bearing parts must be dismantled and subsequently refitted by an ABB Tur- bocharging Service Station. Clean all parts.
Page 130: Taking The Engine Out Of Operation For More Than 12 Months
¡ The casings of the turbocharger remain attached to the engine, the rotor and bearing parts are dismantled by an ABB Turbocharging Service Station and stored separately ¡ The turbocharger is completely removed, either as a whole unit or in individual parts For the measures always necessary for preparing the turbocharger parts for mothballing, see section Taking the engine out of operation for up to 12 months, subsection Preparations...
Page 131: Disposing Of Turbocharger Components
Dispose of metals as scrap metal for recycling. Dispose of non-metallic materials as waste. Dispose of residues of lubricants as waste oil. Dispose of electronic components as electronic waste. Dispose of thermal insulation as hazardous waste. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 132: Spare Parts
Designation and part number. Spare parts can be ordered from any ABB Turbocharging Service Station. If different model variants are not taken into account in this document, contact an ABB Turbocharging Service Station. The customer spare part sets (97070 / 97071) are available for the work described in the op- eration manual.
Page 133: Table 51: Customer Spare Part Set (97071)
77040 O-ring 79020 O-ring 79021 Table 51: Customer spare part set (97071) Dispose of replaced parts and parts that are not reusable in a professional and environ- mentally compatible manner. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 134: View Of Turbocharger With Part Numbers
Operation Manual / 4 Product description / A200-L 12 Spare parts / 12.2 View of turbocharger with part numbers 12.2 View of turbocharger with part numbers Fig. 66: View of turbocharger with part numbers © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 135: Table 52: Turbocharger With Part Numbers
77040 (in the customer spare part set) O-ring 79000 Diffuser 79020 (in the customer spare part set) O-ring 79021 (in the customer spare part set) O-ring 81000 Filter silencer Table 52: Turbocharger with part numbers © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 136: View Of Cartridge Group With Part Numbers
View of cartridge group with part numbers Fig. 67: View of cartridge group with part numbers NOTICE Cartridge group The cartridge group is not delivered as a fitted assembly. Spare parts must be ordered individually. © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 137: Table 53: Cartridge Group With Part Numbers
42305 O-ring 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 53: Cartridge group with part numbers © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Rev.Q July 2020...
Page 138: Figures
Fig. 58: Fitting the wall insert (A265-L … A280-L) .. 86 Fig. 30: Dismantling the filter silencer ..... 60 Fig. 59: Fitting the filter silencer ........ 88 Fig. 31: Dismantling the filter silencer....... 61 Fig. 60: Fitting the filter silencer ........ 89 © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Revision Q July 2020...
Page 139 Fig. 64: Ensuring clamping of the cover ring..96 Fig. 65: Position of cover plates ........ 97 Fig. 66: View of turbocharger with part numbers 104 Fig. 67: View of cartridge group with part numbers ... © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Revision Q July 2020...
Page 140 Table 53: Cartridge group with part numbers..107 Table 24: Malfunctions when stopping – Runout noises................49 Table 25: Malfunctions when stopping – Shortened runout time..............49 Table 26: Malfunctions of the speed measurement system ................50 © Copyright 2020 ABB. All rights reserved. HZTL4036_EN Revision Q July 2020...

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