Page 1 Operation Manual A265-L59 XAC19590 English Original Operation Manual Chapter Document-ID Introduction HZTL4005_EN_F Safety HZTL4024_EN_D Safety data sheet XAC19590 Product description HZTL4036_EN_M ABB Turbocharging...
Page 2 Operating limits and replacement intervals The recommended replacement intervals and the corresponding operating limits in chapter 3 are jointly defined with the enginebuilder. This information is specific to the product. Non-observance of the recommended replacement intervals and the operating limits increases the risk of unpre- dictable component failures.
Page 3: Table Of Contents
Operation Manual / 1 Introduction Table of contents Introduction Introduction......................2 Purpose of the manual....................2 Symbols, definitions...................... 3 Storage of new turbochargers and spare parts ............5 Contact information...................... 7 © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017...
Page 4: Introduction
The Operation Manual must be available where the turbocharger is used. All persons operating or working on the turbocharger must have read and fully understood the Operation Manual. © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017...
Page 5: Symbols, Definitions
ABB Turbo Systems Ltd is identified as ABB Turbo Systems in this document. Official service stations of ABB Turbo Systems Official service stations are identified in this document as ABB Turbocharging Service Sta- tions. They are regularly audited and certified by ABB Turbo Systems. Also see chapter Con- tact information →7.
Page 6 Dispose of in an environmentally ance with specifications compatible, professional way and in compliance with locally applic- Oil free, grease free and dry able regulations Table 1: Definition of pictograms © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017...
Page 7: Storage Of New Turbochargers And Spare Parts
Old VCI corrosion protection emitters must be disposed of in an environmentally compat- ible, professional way and in compliance with locally applicable regulations. Close package. The more tightly the package is sealed, the longer the protection dura- tion. © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017...
Page 8 Check the package for damage. If the package is damaged, the turbocharger or cartridge group must be checked and repackaged by an ABB Turbocharging Service Station. After every 3 years, the following steps must be carried out by an ABB Turbocharging Service Station: ¡...
Page 9: Contact Information
Operation Manual / 1 Introduction 1 Introduction / 1.4 Contact information Contact information Contact information for the ABB Turbocharging Service Stations is available online. Scan the QR code to access our website. ABB Turbo Systems Ltd Bruggerstrasse 71a CH-5401 Baden Switzerland www.abb.com/turbocharging...
Page 11 Lifting of loads ......................8 1.10 Prerequisites for operation and maintenance............9 1.11 Hazards during operation and maintenance ............10 1.12 Safe operation ......................12 1.13 Safe maintenance ......................13 © Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017...
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
CAUTION can lead to seri- ous damage to engine or property with grave consequences. Caution signs must always be observed. © Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017...
Page 14: Intended Use
The specific operating limits of the turbocharger were determined on the basis of informa- tion from the enginebuilder about the intended use. These data are given on the rating plate. ABB accepts no liability and rejects all warranty claims for any non-intended uses. WARNING Unapproved operation Any operation of the turbocharger outside of its operating limits can be haz- ardous to personnel.
Page 15: 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 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017...
Page 16: Turbocharger Rating Plate
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 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017...
Page 17: 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 18: Lifting Of Loads
The assembly devices must be completely screwed in and must not unscrew during use. Use assembly devices only for the described applications. Put down dismantled components of the turbocharger in such a way that they cannot tip over. © Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017...
Page 19: Prerequisites For Operation And Maintenance
Original parts and accessories are specially designed by ABB Turbo Systems for the ABB tur- bochargers. ABB accepts no liability for any damage resulting from the use of non-original parts and cor- responding accessories. © Copyright 2017 ABB. All rights reserved.
Page 20: Hazards During Operation And Maintenance
Wear heat-resistant safety gloves and protective clothing. Wait for the turbocharger to cool down before carrying out any work. Wear safety gloves to protect against thermal hazards. © Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017...
Page 21 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 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017...
Page 22: Safe Operation
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 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017...
Page 23: 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 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017...
Page 24 Secure rotor against turning. The rotor can rotate due to the stack draught alone. Observe the material safety data sheet for the cleaning and mothballing agents. Wear personal protective equipment (PPE) according to the material safety data sheet. © Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D...
Page 25 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 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017...
Page 26 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 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017...
Page 27 Operation Manual / A265-L59 / Safety data sheet Page 1 / 1 Safety data sheet A265-L59 XAC19590 A265-L59 XAC19590 2018000083 2018 2600 © Copyright 2018 ABB. All rights reserved. XAC19590 September 2018...
Page 29 Cleaning the compressor during operation ............35 Cleaning the turbine during operation..............39 Draining the gas outlet casing ................. 43 Troubleshooting....................44 Malfunctions when starting..................44 Malfunctions during operation ................45 © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 30 Ordering spare parts....................101 12.2 View of turbocharger with part numbers ............102 12.3 View of cartridge group with part numbers............104 Figures......................... 106 Tables ........................108 © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 31: 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 32: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 33 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 2018 ABB. All rights reserved. HZTL4036_EN...
Page 34: 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 35: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 36: Removal And Installation
Loosen cable to speed sensor. Disconnect all pipes according to the instructions of the enginebuilder. Check lifting gear. Fasten lifting gear on suspension eyes of the bearing casing and tauten. © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 37: Fig. 4: Fitting Lifting Gear To Turbocharger
Fig. 4: Fitting lifting gear to turbocharger Loosen fixing screws on compressor-end and turbine-end foot. Lift turbocharger from engine and put down in a suitable location. Cover oil connections. © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 38: Installing The Turbocharger
→11); while doing this, only slightly loosen the lifting gear. Remove lifting gear from suspension eyes of the bearing casing. Connect cable to speed sensor. Connect all gas, air and oil pipes. © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 39: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 40: Table 4: Tightening Torques (Foot Screws)
Table 5: Tightening angle (foot screws) Pinning of turbocharger feet with positioning pins If the turbocharger is pinned at its feet, one pin hole per foot must be used. © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 41: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M...
Page 42 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 43: 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 44: Monitoring During Operation
Temporarily admissible ( < 1 h ) → alarm > 85 Not admissible → stop engine > 90 Not admissible → do not start engine (before start: preheat < 30 oil) Table 7: Lubricating oil temperature at the inlet © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 45: Table 8: Lubricating Oil Temperature At The Outlet
Table 8: Lubricating oil temperature at the outlet If the turbocharger was operated for a longer period of time outside of the admissible range, ABB Turbo Systems recommends to have the turbocharger inspected by an ABB Tur- bocharging Service Station. 4.1.1...
Page 46: Admissible Air Inlet Temperature
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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 47 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 2018 ABB. All rights reserved. HZTL4036_EN...
Page 48: Fig. 9: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 49: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M...
Page 50: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 52 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 53 5.2.4 Service work on turbocharger every 36000 hours Service work on the rotor and bearing parts must be carried out by an ABB Turbocharging Service Station. Damaged and worn out parts must be replaced with original ABB parts. Remove the filter silencer.
Page 54 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 55: Expected Replacement Intervals
See rating plate data Bearings See rating plate data Table 11: Recommended replacement intervals for turbocharger parts The specified values are guideline values and not guaranteed values, see Influencing para- meters. © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 56: Flexible Turbocharger Cut-Out
The air outlet flap and gas inlet flap must be completely open during nor- mal operation. During cut out operation, the air outlet flap and gas inlet flap must be completely closed. © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 57: Stopping The Engine
To limit the deposits of dirt when operating with closed flaps, we recom- mend you open them at least every 500 hours of operation. Stopping the engine Observe the instructions regarding post-lubrication (Pre-lubrication and post-lubrication →17) Stop the engine. © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 58: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 59: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 60 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 61: Changing The Filter Strip On The Filter Silencer Casing
Fig. 13: Dismantling filter ring circumferential part Dismantle circumferential part (9). Fig. 14: Opening filter ring lock Open the lock of the filter ring (81265). © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 62: Fig. 15: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 63: Cleaning The Compressor During Operation
ABB Turbo Systems. Cleaning method and operating state The compressor is cleaned during operation using the wet cleaning method. The cleaning method is tested and approved by ABB Turbo Systems. When undertaking wet cleaning, the following operating state must be ensured: ¡...
Page 64 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 65: Fig. 17: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 66: Fig. 18: 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 67: Cleaning The Turbine During Operation
The dry cleaning of the turbine end components is carried out at an engine load of 5 … 85%. Cleaning several turbochargers If several turbochargers are installed on an engine, ABB Turbo Systems recommends clean- ing one turbine after the other. © Copyright 2018 ABB. All rights reserved.
Page 68: Fig. 19: Overview Of Dry Cleaning Device
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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 69 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 70: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 71: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M...
Page 72: 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 73: Malfunctions During Operation
Table 18: Malfunctions during operation – Lubricating oil pressure too low Drop in speed Possible causes Remedy Turbocharger Heavy contamination of the turbine Clean Damaged rotor components or bearing Contact ABB Turbocharging Service Sta- tion Pipes Defects, such as leaks, in the exhaust gas Repair pipes or charge air ducts Table 19: Malfunctions during operation –...
Page 74: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 75: 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 2018 ABB. All rights reserved.
Page 76: Malfunctions When Stopping
Remedy Turbocharger 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 77: Speed Measurement System
If none of the measures described above remedy the malfunc- causes of tion, it is recommended to have the speed measurement system malfunction checked by an ABB Turbocharging Service Station. Table 26: Malfunctions of the speed measurement system © Copyright 2018 ABB. All rights reserved. HZTL4036_EN...
Page 78: Disassembly And Assembly
Further operations that are executed in an incorrect way can lead to serious damage to the machine. ABB Turbo Systems recommends having further operations carried out only by trained personnel from an ABB Turbocharging Service Station. Mark the casing position for assembly. Identification of the assembly devices Not all assembly devices are marked with a part number.
Page 79 Operation Manual / 4 Product description / A200-L 8 Disassembly and assembly / 8.1 Introduction Tightening torques for assembly devices Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB must be tightened so they rest firmly against the surface. WARNING...
Page 80: Weights Of Assemblies
The total weight of the complete wall insert is made up of the wall insert and diffuser as- semblies. A265-L A270-L A275-L A280-L 1230 Table 28: Weight of wall insert [kg] © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 81: Disassembly And Assembly Of The Filter Silencer Casing
01, 02 Bottom part 03, 04, 07, 08 Side part 05, 06, 09 Circumferential part 10, 11 Flange The complete filter silencer casing has the part number 81500. © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 82: Fig. 23: Fitting Filter Silencer Casing 1
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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 83: Fig. 24: Fitting Filter Silencer Casing 2
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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 84: Fig. 26: Fitting Filter Silencer Casing 4
Insert the flanges (10) and (11) laterally between the side parts and fit the screws. Fig. 27: Fitting filter silencer casing 5 Fit the circumferential part (05) with the screws. Fit the circumferential part (06) with the screws. Fit the circumferential part (09) with the screws. © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 85: Fig. 28: 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. 28: Fitting the bellows Fit bellows (C) with frame (F), screws (S) and nuts (N) on the filter silencer casing. © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 86: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 87: Fig. 30: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M...
Page 88: Dismantling Wall Insert And Diffuser
5. Fit lifting device (90190) with crane on upper area of wall insert (77000). 6. Change the position of the shackle with the lifting gear to P2 of the lifting device (90190). © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M...
Page 89: Fig. 32: Moving Out Wall Insert
Fig. 33: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 90: Fig. 34: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 91: Fig. 35: Dismantling The Diffuser
8 Disassembly and assembly / 8.5 Dismantling wall insert and diffuser Fig. 35: Dismantling the diffuser 4. Loosen and remove screws (77015). 5. Remove O-rings (79020, 79021). 6. Attach lifting gear (L) to the diffuser (79000). 7. Remove and put down diffuser. © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 92: Axial Clearance A Prior To Disassembly
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2018 ABB. All rights reserved.
Page 93: Dismantling The Insulation, The Gas Inlet Casing And The Nozzle Ring (A275-L And Smaller)
1. Loosen and remove screws of insulation jackets (51200) from gas outlet casing (61001). 2. Loosen and remove all connecting plates of insulation jackets. 3. Remove insulation jackets. 4. Detach flange connection between gas inlet casing (51001) and bellows. © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 94: Fig. 38: Dismantling The Gas Inlet Casing (A275-L And Smaller) - Screwed Variant
Dismantling the gas inlet casing (A275-L and smaller) – screwed variant Fig. 38: Dismantling the gas inlet casing (A275-L and smaller) – screwed variant If one of the screws (61009) shears off when loosening, an ABB Turbocharging Service Station should be contacted.
Page 95: Fig. 39: Dismantling The Gas Inlet Casing (275-L And Smaller) - Threaded Stud Variant
665 Nm Table 31: Maximum admissible loosening torque (51087) If a threaded stud (51086) shears off when loosening, an ABB Turbo Systems 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 96: Fig. 40: Dismantling The Nozzle Ring (A275-L And Smaller)
(A275-L and smaller) Dismantling the nozzle ring Fig. 40: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 97: Dismantling The Gas Inlet Casing, Nozzle Ring (A280-L)
Dismantling the gas inlet casing (A280-L) – screwed variant Fig. 41: Dismantling the gas inlet casing (A280-L) – screwed variant If one of the screws (61009) shears off when loosening, an ABB Turbocharging Service Station should be contacted. 1. Dismantle both halves of the insulation segment (51215) and remove with all fixing ele- ments.
Page 98: Fig. 42: Dismantling The Gas Inlet Casing (A280-L) - Threaded Stud Variant
840 Nm Table 32: Maximum admissible loosening torque (51087) If a threaded stud (51086) shears off when loosening, an ABB Turbo Systems 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 99: Fig. 43: Fitting The Nozzle Ring Holder (A280-L)
Fig. 43: Fitting the nozzle ring holder (A280-L) 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 100: Fig. 44: Dismantling The Nozzle Ring (A280-L)
) into the nozzle ring holder. 5. Remove screws (B Fig. 45: Putting down the nozzle ring (A280-L) Use the crane to remove and put down the nozzle ring (56001). © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 101: Fitting Gas Inlet Casing, Nozzle Ring, Insulation (A275-L And Smaller)
) with the flange connection (A ) and slide the nozzle ring (56001) into the gas inlet casing (51001). 2. Fit screws (56014) with high-temperature grease and washers (56011). © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 102: Fig. 47: Fitting The Gas Inlet Casing (A275-L And Smaller) - Screwed Variant
6. Fit the screws (61009) by tightening them crosswise, first to the pre-tightening torque, then to the tightening torque. 7. Remove the lifting gear. 8. Connect the flange of the gas inlet casing and the bellows. © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 103: Fig. 48: Fitting The Gas Inlet Casing (A275-L And Smaller) - Threaded Stud Variant
6. Remove the lifting gear. 7. Connect the flange of the gas inlet casing and the bellows. © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 104: Fig. 49: Fitting The Insulation (A275-L And Smaller)
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 2018 ABB. All rights reserved. HZTL4036_EN Revision M...
Page 105: Fitting The Gas Inlet Casing, Nozzle Ring (A280-L)
Coat the screw threads with high-temperature grease. Fig. 50: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 106: Fig. 51: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 107: Fig. 52: Fitting The Gas Inlet Casing (A280-L) - Screwed Variant
8. Remove the lifting gear. 9. Connect the flanges of the gas inlet casing and the bellows. 10. Fit the insulation segments (51215). © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 108: Fig. 53: Fitting The Gas Inlet Casing (A280-L) - Screwed Variant
7. Remove the lifting gear. 8. Connect the flange of the gas inlet casing and the bellows. 9. Fit the insulation segments (51215). © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 109: Axial Clearance A After Assembly
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2018 ABB. All rights reserved.
Page 110: Fitting Diffuser, Wall Insert
3. Fit new O-rings (79020, 79021) on the diffuser. 4. Degrease screws (77015) and threaded holes in wall insert. 5. Coat threads of the screws with Loctite® 542. 6. Fit screws. © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 111: Fig. 56: Positioning Wall Insert
8 Disassembly and assembly / 8.12 Fitting diffuser, wall insert Fitting the wall insert Fig. 56: Positioning wall insert Carefully bring wall insert (77000) into vertical position with the lifting device (90190). © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 112: Fig. 57: Fitting The Wall Insert
7. Completely insert the wall insert and then remove the guide studs (90320). Check that both casings are in the correct position (the marking arrows are aligned to one another). 8. Fit screws (72011). © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 113: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 114: Fig. 59: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 115 Operation Manual / 4 Product description / A200-L 8 Disassembly and assembly / 8.13 Fitting the filter silencer © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 116: Table Of Tightening Torques
Operation Manual / 4 Product description / A200-L 8 Disassembly and assembly / 8.14 Table of tightening torques 8.14 Table of tightening torques Fig. 60: Overview of tightening torques Fig. 61: Overview of speed sensor tightening torque © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 117: Table 44: Overview Of Tightening Torques
2) Pre-tightening torque of the screws Use hydraulic tool for tightening torques exceeding 500 Nm. Thread size Tightening torque [Nm] M12 (compressor casing insulation) Table 45: Tightening torque, insulation © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 118: Taking A Turbocharger Out Of Operation
Raise the alarm and, depending on the situation, stop the engine. Seal the oil leak. Soak up oil and dispose of in an environmentally compatible manner. Wear safety gloves to protect against thermal hazards. © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 119: Procedure With One Installed Turbocharger
(balancing screws) are loosened or un- screwed on the compressor wheel. Before recommissioning of the turbocharger, the compressor wheel must be balanced at an ABB Turbocharging Service Station. Do not screw any set screws that have become unscrewed into the com- pressor wheel again.
Page 120: Fig. 62: Locking The Rotor
6. Align the bracket (94020) to a fin of the wall insert and fit screws (B ) with washers and screw (B ) (for tightening torques, see table below). © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 121: Table 47: Tightening Torques (Locking Device)
9 Taking a turbocharger out of operation / 9.3 Procedure with one in- stalled turbocharger Product Tightening torques for screws [Nm] A265-L A270-L A275-L A280-L Table 47: Tightening torques (locking device) © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 122: Fig. 63: 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. 63: Ensuring clamping of the cover ring...
Page 123: Procedure With Two Or More Installed Turbochargers
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 124 Observe specifications from enginebuilder. 9.4.2 Continuing to operate the engine Continue to operate engine in accordance with enginebuilder's instructions. Do not exceed prescribed power reduction and maximum turbocharger speed. © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 125 Operation Manual / 4 Product description / A200-L 9 Taking a turbocharger out of operation / 9.4 Procedure with two or more installed turbochargers © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 126: 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 127: 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 128: Disposing Of Turbocharger Components
Dispose of non-metallic materials as waste. Dispose of residues of lubricants as waste oil. Dispose of electronic components as electronic waste. Dispose of thermal insulation as hazardous waste. © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 129: 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. Required customer spare part set (97070) For the operations described in the Operation Manual, the customer spare part set (97070) is required.
Page 130: 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. 65: View of turbocharger with part numbers © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 131: Table 51: 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 51: Turbocharger with part numbers © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 132: View Of Cartridge Group With Part Numbers
View of cartridge group with part numbers Fig. 66: 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 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 133: Table 52: Cartridge Group With Part Numbers
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 52: Cartridge group with part numbers © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 134: Figures
Fig. 29: Dismantling the filter silencer ..... 58 Fig. 56: Positioning wall insert........83 Fig. 30: Dismantling the filter silencer ..... 59 Fig. 57: Fitting the wall insert ........84 Fig. 31: Pressing off compressor casing....60 © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 135 Fig. 63: Ensuring clamping of the cover ring ..94 Fig. 64: Position of cover plates........ 95 Fig. 65: View of turbocharger with part numbers 102 Fig. 66: View of cartridge group with part numbers... © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...
Page 136 Table 23: Surging of the turbocharger..... 47 Table 24: Malfunctions when stopping – Runout noises................48 Table 25: Malfunctions when stopping – Shortened runout time..............48 Table 26: Malfunctions of the speed measurement system ................49 © Copyright 2018 ABB. All rights reserved. HZTL4036_EN Revision M August 2018...

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