a165-l37 operation manual...u indicates an action step. 1. indicates a numbered action step. →...

ABB Switzerland Ltd, Turbocharging

Operation Manual

A165-L37XAC22278 English

Original Operation Manual

Chapter Document-ID

1 Introduction HZTL4005_EN_G

2 Safety HZTL4024_EN_D

3 Safety data sheet XAC22278

4 Product description HZTL4034_EN_P

Operating limits and replacement intervals

The recommended replacement intervals and the corresponding operating limits in chapter 3 are jointly definedwith 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.

Operation Manual / 1 IntroductionTable of contents

© Copyright 2020 ABB. All rights reserved. HZTL4005_EN Rev.G March 2020

Introduction1 Introduction............................................................................................................ 21.1 Purpose of the manual.................................................................................................. 21.2 Symbols, definitions...................................................................................................... 31.3 Storage of new turbochargers and spare parts ...................................................... 51.4 Contact information...................................................................................................... 7

Operation Manual / 1 Introduction1 Introduction / 1.1 Purpose of the manual


1 Introduction

1.1 Purpose of the manual

Fig. 1: Serial number (01) on the rating plate

This Operation Manual belongs to the turbocharger with the identical serial number (01), seechapter 3 (Safety data sheet) and the rating plate on the turbocharger.

Operation Manual

The Operation Manual explains the turbocharger and contains instructions for safe opera-tion.

The Operation Manual is a complement to and expansion of existing national regulations foroccupational safety, accident prevention and environmental protection.

Target group

The Operation Manual is aimed at engineers and trained mechanics responsible for theproper operation of the engine and for the turbocharger connected to it.

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 understoodthe Operation Manual.

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Operation Manual / 1 Introduction1 Introduction / 1.2 Symbols, definitions


1.2 Symbols, definitions

Symbols

The following symbols are used in this document:

u Indicates an action step.

1. Indicates a numbered action step.

→ Refers to a page number

Definition of Note

NOTICENoteThe note provides advice which facilitates the work.

Definition of mandatory signs

Mandatory signs show the protective equipment to be worn for a task. The mandatory signsare described in chapter Safety and must be complied with.

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. See alsochapter Contact information →7.

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Operation Manual / 1 Introduction1 Introduction / 1.2 Symbols, definitions


Definition of pictograms

The following pictograms can occur in this document. These point out actions that must betaken in accordance with the meaning of the relevant pictogram.

Pictogram MeaningTighten with specified torque

Tighten over specified tightening angle

Hand-tight, tighten without tools

Oil

Apply screw locking paste (e.g. Loctite)

Apply high-temperature grease

Apply other paste in accordance with specifications

Oil free, grease free and dry

Affix

Measure

Note

Visually inspect

Please note text for numbered work step.

See document

Dispose of in an environmentally compatible, professional way and in compliancewith locally applicable regulations.

Table 1: Definition of pictograms

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Operation Manual / 1 Introduction1 Introduction / 1.3 Storage of new turbochargers and spare parts


1.3 Storage of new turbochargers and spare parts

Storage of new turbochargers and spare parts up to 6 months

New turbochargers and spare parts can be stored in sealed packaging without additionalmothballing measures for up to 6 months from the date of delivery (marked by the VCI labelon the package).

Fig. 2: Volatile Corrosion Inhibitor (VCI)

Only dry rooms in which the relative humidity is between 40…70 % and no condensation canform are suitable for storage.

Storage of new turbochargers and spare parts for more than 6 months

WARNINGProtection of health when handling VCIsVCI products are not hazardous in the sense of the Hazardous SubstancesOrdinance. Nevertheless, the following points are to be observed whenhandling VCIs:

u Observe specifications in the safety data sheet

u Ensure good room ventilation.

u Do not eat, drink or keep food at the workplace while working with VCIs.

u Clean hands and face after working with VCIs.

u For further information refer to www.branopac.com.

Wear safety gloves to protect against mechanical hazards.

The following mothballing measures are required every 6 months:

u Open the package.

u Remove the VCI corrosion protection emitter from the package and replace it with a new,identical VCI corrosion protection emitter. New VCI corrosion protection emitters can beobtained at www.branopac.com.

u Dispose of the old VCI corrosion protection emitter in an environmentally compatiblemanner, professionally and in accordance with local regulations.

u Seal the package. The better the external seal is designed, the more permanent the pro-tection.

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http://www.branopac.com

http://www.branopac.com

Operation Manual / 1 Introduction1 Introduction / 1.3 Storage of new turbochargers and spare parts


Long-term storage of turbochargers

The turbochargers will be prepared for prolonged storage by ABB Turbo Systems on re-quest. The package is equipped with a hygrometer (see illustration).

Fig. 3: Package with hygrometer

The following measures are required every 6 months:

u Check the hygrometer (02) in the sight-glass. There is an opening (01) in the woodencrate which allows this check to be carried out. When the display field has changed colourat the 70% level, the maximum permissible humidity has been exceeded. In this case theturbocharger must be inspected by an ABB Turbocharging Service Station and repacked.

u 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 TurbochargingService Station:

¡ Inspect the components

¡ Replace the desiccant agent

¡ Repackage the components.

If the 70% display field of the hygrometer (02) has not changed colour and the package isundamaged, the turbocharger can be placed into operation without any prior testing by anABB Turbocharging Service Station.

Unpacking turbochargers

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 packagemust have the same temperature during unpacking.

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Operation Manual / 1 Introduction1 Introduction / 1.4 Contact information


1.4 Contact informationContact information for the ABB Turbocharging Service Stations is available online.

u Scan the QR code to access our website.

ABB Switzerland Ltd, TurbochargingBruggerstrasse 71aCH-5401 BadenSwitzerland

www.abb.com/turbocharging

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http://www.abb.com/turbocharging

Operation Manual / 2 Safety / A100-L, A200-LTable of contents

© Copyright 2017 ABB. All rights reserved. HZTL4024_EN Revision D June 2017

Safety1 Safety ...................................................................................................................... 21.1 Introduction .................................................................................................................... 21.2 CE conformity................................................................................................................. 21.3 Definition of mandatory signs .................................................................................... 31.4 Definition of safety instructions ................................................................................ 31.5 Intended use .................................................................................................................. 41.6 Warning plates on the turbocharger.......................................................................... 51.7 Turbocharger rating plate........................................................................................... 61.8 Periodic check of the pressure vessels...................................................................... 71.9 Lifting of loads .............................................................................................................. 81.10 Prerequisites for operation and maintenance........................................................ 91.11 Hazards during operation and maintenance ......................................................... 101.12 Safe operation .............................................................................................................. 121.13 Safe maintenance ........................................................................................................ 13

Operation Manual / 2 Safety / A100-L, A200-L1 Safety / 1.1 Introduction


1 Safety

1.1 IntroductionTurbochargers manufactured by ABB reflect the state of the art. The respective safety andhealth 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:

¡ Are caused by the turbocharger itself or its accessories.

¡ Are caused by the operating equipment used or supplies and materials.

¡ Are a consequence of insufficient compliance with safety instructions.

¡ Are a consequence of insufficient or inappropriate performance of maintenance and in-spection work.

The operating company is responsible for defining measures that regulate safe access toand safe handling of the turbocharger.

All instructions contained in this chapter must be observed for safe and trouble-free opera-tion of the turbocharger and during all work on the turbocharger.

All further safety instructions contained and specifically identified in every chapter of thismanual (Definition of safety instructions →3) must also be observed.

1.2 CE conformity

Information

ABB turbochargers comply with the Machinery Directive 2006/42/EC and are partly com-pleted machinery as defined by Article 2 g in this directive.

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Operation Manual / 2 Safety / A100-L, A200-L1 Safety / 1.3 Definition of mandatory signs


1.3 Definition of mandatory signs

To be worn at all timesProtective clothing Safety footwear to protect

against mechanical hazard andrisk of falling

Table 1: Personal protective equipment to be worn at all times

To be worn specific to the respective taskSafety glasses Safety goggles

Safety gloves to protectagainst- Mechanical hazard- Chemical hazard- Thermal hazard

Respiratory mask to protectagainst- Dusts- Gases

Safety helmet Ear protection

Table 2: Personal protective equipment to be worn specific to the respective task

1.4 Definition of safety instructions

WARNINGDefinition of WarningNon-compliance or inaccurate compliance with working or operating in-structions indicated by this symbol and the word WARNING can lead to seri-ous injuries to personnel and even to fatal accidents.

u Warning signs must always be observed.

CAUTIONDefinition of CautionNon-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.

u Caution signs must always be observed.

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Operation Manual / 2 Safety / A100-L, A200-L1 Safety / 1.5 Intended use


1.5 Intended use

Use on internal combustion engines in general

ABB turbochargers are intended for turbocharging internal combustion engines.

The A...-L turbochargers are designed for use on 2-stroke diesel engines.

The turbocharger supplies the engine with the air volume or air/gas mixture and the associ-ated charging pressure required for operation.

The turbocharger is solely intended to be operated with a clockwise direction of rotation asviewed from the turbine end.

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 ratingplate.

ABB accepts no liability and rejects all warranty claims for any non-intended uses.

WARNINGUnapproved operationAny operation of the turbocharger outside of its operating limits can be haz-ardous to personnel.

u Only operate the turbocharger within the operating limits.

u Only trained personnel must operate the turbocharger.

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

State of the art

The turbocharger is designed and manufactured according to the state of the art and is safeto operate.

Perfect condition

The turbocharger must only be used when it is in a technically flawless condition and oper-ated in compliance with its intended use.

ABB excludes any liability for damage resulting from unauthorized modifications to the tur-bocharger or improper operation.

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Operation Manual / 2 Safety / A100-L, A200-L1 Safety / 1.6 Warning plates on the turbocharger


1.6 Warning plates on the turbochargerWarning plates are attached to the turbocharger, which must be observed. The warningplates must always be present in the intended locations and must be legible.

Fig. 1: Warning plate

If warning plates are not present in the intended locations or are not legible, they must bereplaced with new warning plates. The necessary information can be found in the OperationManual, Chapter 4 Product description.

Turbochargers supplied to the enginebuilder without insulation must be equipped later withwarning plates on the insulation. This is the responsibility of the enginebuilder.

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Operation Manual / 2 Safety / A100-L, A200-L1 Safety / 1.7 Turbocharger rating plate


1.7 Turbocharger rating plate

Fig. 2: Rating plate

Operating limits

01 Turbocharger operating limits at engine overload (110 %). In test rig operation only, unless otherwise agreed with the en-ginebuilder.

02 Turbocharger operating limits during operation

Recommended replacement intervals of turbocharger components

03 Replacement interval of plain bearings in 1000 h04 Replacement interval of compressor in 1000 h05 Replacement interval of turbine in 1000 h

Further data

06 Customer part number07 Designation for special design08 Weight of turbocharger in kg09 Turbocharger type10 Serial number11 Year of construction of turbocharger12 Manufacturing plant

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Operation Manual / 2 Safety / A100-L, A200-L1 Safety / 1.8 Periodic check of the pressure vessels


Explanations regarding the rating plate

The recommended replacement intervals and the corresponding operating limits are jointlydefined with the enginebuilder. This information is specific to the system.

Operation above the indicated values nBmax, tBmax can considerably shorten the recommendedreplacement intervals. In such cases ABB recommends contacting the nearest ABB Tur-bocharging Service Station.

nMmax, tMmax normally apply only when running at overload (110%) during trials on the enginetest bed. These limit values can also be permitted during operation for special applications.Operation above nMmax and tMmax is not permitted.

Non-observance of the recommended replacement intervals increases the risk of unpredict-able component failures.

Locations of the rating plates

The locations of the rating plates are defined in the Operation Manual, Chapter 4 Productdescription.

1.8 Periodic check of the pressure vesselsThe pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, areso-called "simple pressure vessels".

¡ The locally applicable legal regulations regarding periodic checks of the pressure vesselsmust be observed.

¡ The operating company is responsible for the safe operation of the pressure vessel.

WARNINGDanger due to pressure vesselsThe operating company must make sure the pressure vessels are in properworking condition and monitor them. Necessary repair or maintenance workmust be performed promptly, and the required safety measures must betaken.

u Pressure equipment must not be operated if defects are present.Pa

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Operation Manual / 2 Safety / A100-L, A200-L1 Safety / 1.9 Lifting of loads


1.9 Lifting of loads

WARNINGSuspended loadsLoads that are not attached according to regulations can cause injury topersonnel or fatal accidents.

u Loads must always be fastened to properly functional lifting gear with asufficient load limit.

u Pay attention to the correct attachment of loads on the crane hook.

u People must not stand beneath suspended loads.


Wear safety helmet.

Fig. 3: Attachment of loads on the crane hook

Fig. 4: Attachment angle

If there are two or more suspension points, the attachment angle of 45° must not be ex-ceeded. This prevents excessive loading due to diagonal pull.

u Before looping around the components of the turbocharger, let them cool down (max-imum 80 °C).

u Attach components of the turbocharger as described in the respective action steps.

u Use a suitable edge guard if there are sharp edges.

u The assembly devices must be completely screwed in and must not unscrew during use.

u Use assembly devices only for the described applications.

u Put down dismantled components of the turbocharger in such a way that they cannot tipover.

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Operation Manual / 2 Safety / A100-L, A200-L1 Safety / 1.10 Prerequisites for operation and maintenance


1.10 Prerequisites for operation and maintenance

Responsibility of the operating company

In awareness of its responsibility, the operating company must ensure that only authorisedpersonnel work on the turbocharger, who:

¡ Are versed in the general and locally applicable regulations for occupational safety andaccident prevention

¡ Are equipped with the prescribed personal protective equipment

¡ Have read and understood the Operation Manual

¡ Have been instructed in the use of the turbocharger.

The safety-conscious work of the personnel and adherence to the Operation Manual must bechecked periodically.

Suitable working materials and personal protective equipment must be kept in a perfectcondition.

Only authorised personnel may remain in the vicinity of the turbocharger when the engine isrunning.

Competence of personnel

The turbocharger must only be operated and serviced by trained and authorised personnel.Basic mechanical training is a prerequisite.

Modifications to the turbocharger

Modifications to the turbocharger must be approved by ABB Turbo Systems.

WARNINGUse original partsOperation of the turbocharger with non-original parts can impair the safetyof the turbocharger and can cause serious damage to property and injury topersonnel.

u Only use original parts from ABB Turbo Systems.

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.

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Operation Manual / 2 Safety / A100-L, A200-L1 Safety / 1.11 Hazards during operation and maintenance


1.11 Hazards during operation and maintenance

Noise hazards

The turbocharger's noise emission during operation is influenced by its installation and op-erating conditions. A noise level exceeding 85 dB(A) is harmful.

WARNINGDanger due to noiseExposure to noise can harm the hearing system, impair health and the psy-chological state and may lead to lack of attention and irritation.

u When the engine is running, always wear ear protection.

u Always wear ear protection if the sound pressure level exceeds 85 dB(A).

Wear ear protection.

Hazards due to hot surfaces

Surfaces of the turbocharger, attached parts and operating fluids (lubricating oil) get hotduring operation. The surface temperature depends on the efficacy of the existing insula-tion. The temperature may rise to a level that can cause burns.

WARNINGDanger of burnsTouching hot surfaces or contact with hot operating fluids can cause burns.

u Do not touch hot surfaces. Observe the warning plate on the turbochar-ger.

u Wear heat-resistant safety gloves and protective clothing.

u Wait for the turbocharger to cool down before carrying out any work.

Wear safety gloves to protect against thermal hazards.

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Operation Manual / 2 Safety / A100-L, A200-L1 Safety / 1.11 Hazards during operation and maintenance


WARNINGHot surfaces on the non-insulated turbochargerNon-insulated turbochargers can cause serious injuries to personnel (burns).

The turbocharger is supplied with or without insulation in accordance withthe purchase order received from the enginebuilder. If supply is without in-sulation, the enginebuilder is responsible for providing the turbochargerwith proper insulation and for providing protection against contact with hotsurfaces.

u Compliance with the instructions and specifications given by the en-ginebuilder to protect against hot turbocharger surfaces is compulsory.


Hazards due to rotating parts

WARNINGPhysical hazardsContact with rotating parts can cause severe injury. The turbocharger mustnever be used without the filter silencer or the air suction branch. With theengine stopped, the rotor can rotate due to the stack draught alone.

u Operate the turbocharger in compliance with the specifications.

u Secure the rotor against unintentional rotation during maintenance.


Hazards due to electrical installations (if present)

WARNINGDangers during work on electrical installationsElectrical installations use voltages that can lead to severe injury to person-nel or accidents resulting in fatalities.

At the same time, electrical or electronic components and parts can also bedamaged or destroyed.

u Only specially trained personnel should perform work on, or with, elec-trical components.

u Observe national regulations.

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Operation Manual / 2 Safety / A100-L, A200-L1 Safety / 1.12 Safe operation


WARNINGAbsence of grounding on electrical installationsMissing or incorrectly fitted grounding conductors can lead to severe injuryto personnel or accidents resulting in fatalities.

Electric shock or elevated electromagnetic disturbances can damage or des-troy electrical and electronic components.

u Ground electrical installations properly with grounding conductors.

u Check the grounding connections on a regular basis and make sure theyare properly connected.

u Switch off the power supply before working on any electrical installations.

u After switching off the power supply, wait for 5 minutes to allow capacitors to dischargeand hot components to cool down.

u Ensure the power supply is switched off when working on electrical installations.

u Do not carry out any tests with regard to insulation resistance or voltage on the electricalcomponents.

1.12 Safe operation

Mechanical hazards during operation

During standard operation, no mechanical hazards are caused by the turbocharger itself if ithas been properly installed.

Safety during commissioning and operation

u Visually inspect your working environment before starting work.

u Remove any obstacles and objects littering the workplace.

u Check all pipes to and from the turbocharger for damage and leaks before commission-ing.

u Check turbocharger for recognisable damage or defects every 12 hours of operation or atleast once a day.

u Report any damage and any alterations of operational characteristics to the responsibledepartment immediately.

u In case of damage, take the turbocharger out of operation immediately and safeguardagainst accidental/unauthorised use.

u 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.

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Operation Manual / 2 Safety / A100-L, A200-L1 Safety / 1.13 Safe maintenance


1.13 Safe maintenance

Occupational safety

WARNINGInjuries to personsSevere injuries to personnel or fatal accidents can be caused by mechanicalinfluences as a consequence of hazardous and inadequate operational pro-cedures or non-compliance with safety and health standards.

u When working on the turbocharger always wear safety footwear and pro-tective clothing to protect against mechanical hazards.

u Keep personal protective equipment in perfect condition.

u Obey mandatory signs.

u Observe the general rules for occupational safety and prevention of acci-dents.

u Only perform operations that are described in this manual.

u Only perform operations for which you have received instruction or train-ing.

Wear safety footwear to protect against mechanical hazard and risk of fall-ing.

Wear protective clothing.

WARNINGRisk of fallingWhen working on the turbocharger, there is a risk of falling.

u Do not climb onto the turbocharger or onto attached parts and do notuse them as climbing aids.

u Use suitable climbing aids and working platforms for work above bodyheight.

u Comply with the general accident prevention regulations.

u Only perform work on the turbocharger when you are in a physically and psychologicallystable condition.

u Only work with suitable tools, equipment and appliances that function properly.

u Power tools must be grounded and cables must be undamaged.

u Keep the workplace clean; clear away any loose objects and obstacles on the floor.

u Keep the floor, equipment, and turbocharger clean.

u Have oil binding agents ready and provide or keep oil pans at hand.

u Clean up any spills.

u Have fire protection means and extinguishing agents available.

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Welding work in the vicinity of the turbocharger

u When performing welding work in the vicinity of the turbocharger, always cover the filtersilencer to prevent the filter mat from being damaged.

u Keep flammable objects and substances out of the vicinity of flying sparks.

u Cover all connections on the turbocharger so that no foreign objects can enter the tur-bocharger.

u Wear personal protective equipment (PPE) for welding operations.

Safety during cleaning

If cleaning agents or solvents are used for cleaning, the corresponding material safety datasheet and the safety instructions in section Hazards due to operating materials and suppliesmust be observed.

u Observe the material safety data sheet for the cleaning agent or solvent.

u Wear personal protective equipment (PPE) according to the material safety data sheet.

u Inspect the electric cables for abrasion and damage before and after your cleaning work.

Safety during disassembly, assembly, maintenance and repair

u Observe the procedures for set-up, service and inspection work and the inspection inter-vals.

u Inform the operating staff before starting any service or repair work. Make sure the en-gine is not started while work is being conducted on the turbocharger.

u Before taking off any cover or removing any guard from the turbocharger, switch off theengine and wait until the turbocharger has come to a standstill.

u Make sure that the oil supply is interrupted, especially with an external oil supply.

u Only restart the engine after all parts have been properly fitted again and oil supply is en-sured.

CAUTIONMechanical operations on the turbochargerComponents of the turbocharger can be damaged or destroyed as a resultof improper procedures.

u Only perform operations that are described in this manual.

u Only perform operations for which you have received instruction or train-ing.

Safety when taking out of operation or preparing for mothballing

u Secure rotor against turning. The rotor can rotate due to the stack draught alone.

u Observe the material safety data sheet for the cleaning and mothballing agents.

u Wear personal protective equipment (PPE) according to the material safety data sheet.

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Mechanical hazards when working on the turbocharger

WARNINGPhysical hazards due to rotating partsThe rotor can rotate due to the stack draught alone. Contact with rotatingparts can cause severe injury.

u Secure rotor against turning.

WARNINGMechanical hazardsSevere injuries to personnel or fatal accidents can be caused by mechanicalinfluences as a consequence of hazardous and inadequate operational pro-cedures.

u Observe the general rules for occupational safety and prevention of acci-dents.

u Ensure workplace safety.

u Only perform operations that are described in this chapter.

u Only perform operations for which you have previously received instruc-tion or training.

Hazards due to operating materials and supplies

Operating materials and supplies are substances required for the operation of the tur-bocharger or for the performance of maintenance work. Oils, greases, coolants, detergentsand solvents, acids and similar substances can be classified as hazardous substances.

WARNINGHandling operating materials and suppliesSwallowing or inhaling vapours of operating materials and supplies or con-tact with them may be harmful to health.

u Do not breathe in these substances and avoid contact with the skin.

u Ensure proper ventilation.

u Observe the information in the material safety data sheet for the operat-ing materials and supplies.

u Wear personal protective equipment (PPE) according to the materialsafety data sheet.

u Comply with local legislation.

Wear safety goggles.

Wear safety gloves to protect against chemical hazards.

Wear a respiratory mask to protect against gases.

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WARNINGDanger of fire or explosionFlammable and combustible operating materials and supplies can catch fireor resulting vapours can lead to an explosion.



u Do not allow any exposed flame or ignition source during cleaning work.

u Carry out cleaning in the open or provide sufficient ventilation.

CAUTIONEnvironmental hazardImproper handling of operating materials and supplies can lead to environ-mental damage.



Hazards due to the handling of insulation materials

WARNINGDanger from insulation materialsDust or fibres from insulation materials can have adverse effects on thehealth or cause irritations. Unsuitable and combustible insulation materialsare a fire hazard.

u Only use suitable and non-combustible insulation materials.

u Ensure good ventilation at the workplace.

u Avoid whirling up dust.

u Use dust-free tools and working methods.

u Remove package at the workplace only.

u Proceed with particular care when removing old insulation materials.

u Dispose of insulation materials properly and in an environmentally com-patible manner in compliance with the legal regulations.


Wear a respiratory mask to protect against dusts.


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Operation Manual / A165-L37 / Safety data sheet

Page 1 / 1

Safety data sheet

© Copyright 2020 ABB. All rights reserved. XAC22278 July 2020

A165-L37 XAC22278

A165-L37 XAC22278

367 550

352 520

2019000081 2020

2300 36 100 100

Operation Manual / 4 Product description / A100-LTable of contents

© Copyright 2020 ABB. All rights reserved. HZTL4034_EN Rev.P January 2020

Product description1 Introduction............................................................................................................ 31.1 Essential information.................................................................................................... 31.2 Registered trademarks................................................................................................. 31.3 Related documents........................................................................................................ 31.4 Layout and function of the turbocharger ................................................................ 41.5 Warning plates on the turbocharger......................................................................... 61.6 Locations of the rating plates..................................................................................... 7

2 Removal and installation ...................................................................................... 82.1 Turbocharger weight ................................................................................................... 82.2 Removing the turbocharger....................................................................................... 82.3 Installing the turbocharger ....................................................................................... 10

3 Commissioning .................................................................................................... 133.1 Oil supply ....................................................................................................................... 133.2 Inspection procedures................................................................................................ 133.3 Commissioning after taking out of operation....................................................... 15

4 Monitoring during operation.............................................................................. 164.1 Oil pressure, oil temperature..................................................................................... 164.2 Admissible air inlet temperature .............................................................................. 194.3 Turbocharger speed.................................................................................................... 194.4 Low pressure measurement at the filter silencer ................................................. 22

5 Operation and service ......................................................................................... 235.1 Noise emission ............................................................................................................. 235.2 Service work................................................................................................................. 245.3 Expected replacement intervals .............................................................................. 285.4 Flexible turbocharger cut-out .................................................................................. 295.5 Stopping the engine................................................................................................... 30

6 Periodic maintenance.......................................................................................... 316.1 Foreword to maintenance.......................................................................................... 316.2 Cleaning the filter silencer ......................................................................................... 326.3 Changing the filter strip on the filter silencer casing.......................................... 346.4 Cleaning the compressor during operation .......................................................... 366.5 Cleaning the turbine during operation................................................................... 406.6 Draining the gas outlet casing ................................................................................. 44

7 Troubleshooting................................................................................................... 457.1 Malfunctions when starting...................................................................................... 457.2 Malfunctions during operation ................................................................................ 46

Operation Manual / 4 Product description / A100-LTable of contents


7.3 Surging of the turbocharger..................................................................................... 487.4 Malfunctions when stopping.................................................................................... 497.5 Speed measurement system.................................................................................... 50

8 Disassembly and assembly................................................................................. 518.1 Introduction ................................................................................................................. 518.2 Weights of assemblies............................................................................................... 538.3 Disassembly and assembly of the filter silencer casing ..................................... 548.4 Dismantling the filter silencer .................................................................................. 598.5 Dismantling the filter silencer with noise package .............................................. 618.6 Dismantling wall insert and diffuser....................................................................... 628.7 Axial clearance A prior to disassembly ................................................................... 668.8 Dismantling the insulation (≤ A175-L)..................................................................... 678.9 Dismantling the gas inlet casing (≤ A175-L) .......................................................... 688.10 Dismantling the nozzle ring (≤ A175-L) ................................................................... 708.11 Dismantling the gas inlet casing (≥ A180-L)........................................................... 718.12 Dismantling the nozzle ring (≥ A180-L).................................................................... 738.13 Fitting the nozzle ring (≤ A175-L) .............................................................................. 758.14 Fitting the gas inlet casing (≤ A175-L) .................................................................... 768.15 Fitting the insulation (≤ A175-L)............................................................................... 788.16 Fitting the nozzle ring (≥ A180-L) ............................................................................ 798.17 Fitting the gas inlet casing (≥ A180-L)..................................................................... 818.18 Axial clearance A after assembly.............................................................................. 838.19 Fitting the diffuser ..................................................................................................... 848.20 Fitting wall insert ........................................................................................................ 858.21 Fitting the filter silencer............................................................................................ 878.22 Fitting the filter silencer with noise package ....................................................... 898.23 Table of tightening torques...................................................................................... 92

9 Taking a turbocharger out of operation........................................................... 949.1 Possible emergency repairs...................................................................................... 949.2 Taking defective turbochargers out of operation ............................................... 95

10 Mothballing the turbocharger.......................................................................... 10110.1 Taking the engine out of operation for up to 12 months .................................. 10110.2 Taking the engine out of operation for more than 12 months ........................ 102

11 Disposing of turbocharger components ........................................................ 103

12 Spare parts ......................................................................................................... 10412.1 Ordering spare parts................................................................................................ 10412.2 View of turbocharger with part numbers ............................................................ 10612.3 View of cartridge group with part numbers........................................................ 108

Figures................................................................................................................. 110

Tables ................................................................................................................... 112

Operation Manual / 4 Product description / A100-L1 Introduction / 1.1 Essential information


1 Introduction

1.1 Essential information

Design variants

This document is valid for different design variants of turbochargers. There may be sectionsand 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 adesign 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. Differences in detail are therefore possible.

1.2 Registered trademarksThe trademarks of outside companies are used in this document. These are marked with the® symbol.

1.3 Related documents

Chapter Document numberOperation Manual / 1 Introduction HZTL4005Operation Manual / 2 Safety HZTL4024Operation Manual / 3 Safety data sheet *) Serial number of the turbochargerTable 1: Related documents

*) This chapter is only available in serialised operation manuals.Pa

ge

3 /

112

http://www.abb.com/turbocharging

Operation Manual / 4 Product description / A100-L1 Introduction / 1.4 Layout and function of the turbocharger


1.4 Layout and function of the turbocharger

Fig. 1: Layout and function of the turbocharger

01 Filter silencer 08 Gas inlet casing02 Thrust bearing 09 Bearing casing03 Radial plain bearing 10 Diffuser04 Radial plain bearing 11 Compressor wheel05 Gas outlet casing 12 Compressor casing06 Turbine wheel 13 Air-outlet silencer (option)07 Nozzle ring

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Operation Manual / 4 Product description / A100-L1 Introduction / 1.4 Layout and function of the turbocharger


Mode of operation

The turbocharger is a turbomachine and consists of the following main components:

¡ Turbine

¡ Compressor

These components are installed on a common shaft and form the rotor.

The exhaust gases of the internal combustion engine flow through the gas inlet casing (08)and the nozzle ring (07) onto the turbine wheel (06). The turbine wheel uses the energy con-tained in the exhaust gas to drive the rotor and, hence, the compressor wheel (11).

The exhaust gases then reach the atmosphere through the exhaust gas pipe connected tothe gas outlet casing (05).

The compressor wheel (11) sucks in fresh air and presses the compressed air into the cylin-ders.

The air passes through the filter silencer (01) to the compressor wheel (11). The air thenflows through the diffuser (10) and exits the turbocharger through the compressor cas-ing (12). An air outlet silencer (13) is optionally available. If installed, this will reduce theamount of noise generated by the components at the outlet side after the compressor cas-ing.

The rotor runs in two radial plain bearings (03/04) which are located in the bearing cas-ing (09) between the compressor and turbine. The axial thrust bearing (02) is located at thecompressor end.

The plain bearings are connected to a central lubricating oil duct which is normally suppliedby the lubricating oil circuit of the engine. The oil outlet always lies at the deepest point ofthe bearing casing (09).

The turbocharger is equipped with an oil tank which is integrated in the bearing casing (9).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.

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Operation Manual / 4 Product description / A100-L1 Introduction / 1.5 Warning plates on the turbocharger


1.5 Warning plates on the turbochargerWarning plates are affixed at the following locations:

Fig. 2: Warning plate locations

If warning plates are not present in the designated locations or not readable, proceed as fol-lows:

u Order new warning plates from ABB Turbocharging Service Stations.

u Remove any warning plates that have become unreadable.

u Clean and degrease the areas designated for the warning plates.

u Fit new warning plates and remove protective sheets.

Turbochargers supplied to the enginebuilder without insulation must be equipped later withwarning plates on the insulation. This is the responsibility of the enginebuilder.

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Operation Manual / 4 Product description / A100-L1 Introduction / 1.6 Locations of the rating plates


1.6 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.

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Operation Manual / 4 Product description / A100-L2 Removal and installation / 2.1 Turbocharger weight


2 Removal and installation

2.1 Turbocharger weightLifting gear with a sufficient load limit must be used for removing, installing and transport-ing the turbocharger. The weight specified below applies to the heaviest variant possible.Depending on the specification, the weight specified on the rating plate may be lower thanthe standard value specified here.

Product Weight of complete turbocharger unit [kg]A165-L 2300A170-L 3300A175-L 5600A180-L 7500A185-L 10500A190-L 13500Table 2: Total weight

2.2 Removing the turbocharger

WARNINGRisk of tippingIf the turbocharger is not sufficiently supported or not supported at all dur-ing removal and installation, it may tip over and cause severe injury to per-sonnel or accidents resulting in fatalities.

u Support the turbocharger at a suitable location.

u Secure with lifting gear wherever possible.

Wear safety helmet.

u Loosen cable to speed sensor.

u Disconnect all pipes according to the instructions of the enginebuilder.

u Check lifting gear.

u Fasten lifting gear on suspension eyes of the bearing casing and tauten.

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Operation Manual / 4 Product description / A100-L2 Removal and installation / 2.2 Removing the turbocharger


Fig. 4: Fit the lifting gear

u Loosen fixing screws on compressor-end and turbine-end foot.

u Lift turbocharger from engine and put down in a suitable location.

u Cover oil connections.

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Operation Manual / 4 Product description / A100-L2 Removal and installation / 2.3 Installing the turbocharger


2.3 Installing the turbocharger

2.3.1 Placing the turbocharger on the bracket

Fig. 5: Placing the turbocharger

u Remove covers from the oil connections.

u Align turbocharger and place on engine bracket.

u Tighten the fixing screws (Steps for fastening the turbocharger →11) while only slightlyloosening the lifting gear.

u Remove lifting gear from suspension eyes of the bearing casing.

u Connect cable to speed sensor.

u Connect all gas, air and oil pipes.

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2.3.2 Steps for fastening the turbocharger

General information

Subject Requirement / InformationTurbocharger fixing elements ISO property class ≥ 8.8Washers Hardened, thickness ≥ 15 % nominal thread dia-

meterDimension a (compressor end) a = height of turbocharger foot aDimension a (turbine end) a = height of turbocharger foot F + spacer sleeve

DDimension b Hole in bracketDimension c Thread length, ≥ 1.5 x nominal thread diameterCoefficient of friction 0.12 (lightly oiled)Table 3: General information about fastening the turbocharger

Compressor-end foot

Fig. 6: Compressor-end foot

u Tighten the foot fixing screws or nuts diagonally according to the selected tighteningmethod.

Turbine-end foot

Fig. 7: Turbine-end foot

u Tighten the foot fixing screws or nuts according to the selected tightening method.

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Torque-controlled tightening

Product Thread size Height a of foot [mm]

Tightening torque [Nm]

A165-L M22 86 440A170-L M27 100 830A175-L M30 120 1100A180-L M33 136 1500A185-L M39 151 2500A190-L M42 167 3100Table 4: Tightening torques (foot screws)

Angle-controlled tightening

Product Thread size Height a foot[mm]

Pre-tighteningtorque[Nm]

Tighteningangle

height a[DEG]

Additional tightening angle forevery 10 mm of ad-

ditional screwlength b

[DEG]A165-L M22 86 120 30 3.7A170-L M27 100 220 30 3.1A175-L M30 120 300 30 2.6A180-L M33 136 400 35 2.6A185-L M39 151 600 35 2.4A190-L M42 167 700 35 2.2Table 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.

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Operation Manual / 4 Product description / A100-L3 Commissioning / 3.1 Oil supply


3 Commissioning

3.1 Oil supply

3.1.1 Introduction

In all operating states, a functioning and carefully executed oil supply is an important pre-requisite for trouble-free operation of the turbocharger.

The lubrication of the turbocharger is usually carried out with oil from the engine oil circula-tion.

u Comply with the enginebuilder's specifications regarding the selection of lubricating oiland the oil change intervals.

For more information on the oil supply, refer to Chapter Oil pressure, oil temperature →16.

3.1.2 Oil filtering

Filtering of the lubricating oil with a filter mesh width of ≤ 0.050 mm is sufficient for the tur-bocharger.

3.1.3 Oil pressure

Comply precisely with the oil pressure before the turbocharger for trouble-free operation.

If the oil pressure at the inlet of the turbocharger is too high, it can be reduced with athrottle valve. The throttle valve is normally already fitted on the turbocharger and has beencorrectly set by the enginebuilder. This takes place either during the trial run on the enginetest bed or during the trial phase of the system.

If the oil pressure values are outside the admissible range during normal operation, youmust contact the enginebuilder.

3.2 Inspection procedures

3.2.1 Introduction

Inspection procedures include preventative visual controls, monitoring and measuring workbefore and during commissioning. Inspection procedures enable changes to the turbochar-ger to be detected. Machine damage can be prevented.

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Operation Manual / 4 Product description / A100-L3 Commissioning / 3.2 Inspection procedures


3.2.2 Checks before commissioning

Filter mat (if available)

u Check for damage and contamination.

Lubricating system

CAUTIONContaminated oilSerious damage to engine or property can be caused by dirt and solid ma-terial particles in the oil.

u For the initial commissioning phase and after all service work, flush thecomplete lubricating system with warm oil.

u Use special running-in filters when running in the engine and after all ser-vice work on the lubricating system.

u Check that the oil filter is clean before commissioning.

u Check the oil pressure in the oil supply pipes.

Warning plates

u Check whether warning plates are present and legible.

u Check whether the protective sheets have been removed from new warning plates.

3.2.3 Checks after commissioning (engine in idle mode)

Lubricating system

u Check the oil pressure in the oil supply pipes.

u Check oil inlet temperature.

The admissible values are specified in section Oil supply.

Gas, air and oil pipes

u After starting the engine, check all gas, air and oil pipes for leaks.

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Operation Manual / 4 Product description / A100-L3 Commissioning / 3.3 Commissioning after taking out of operation


3.2.4 Checks when starting up the engine

u Measure speed, oil pressure and charging pressure at various engine performances.

u Measure the exhaust gas temperature before and after the turbine.

u Measure the air temperature before and after the compressor.

u Compare the measured values with the values of the acceptance report. Different operat-ing conditions indicate a malfunction (see Chapter Troubleshooting →45).

Escape of oily fluids

Lubricants and pastes used during assembly can liquefy or vaporise and escape as oily fluidsduring the initial hours of operation. Continual escape of an oily fluid indicates an oil leak.

u If there is a leak, contact an ABB Turbocharging Service Station.

3.3 Commissioning after taking out of operation

If present

u Remove cover plates (blind flanges) from the compressor casing, the gas inlet and thegas outlet.

General

u Check the exhaust gas pipe before and after the turbine for combustion residues or wa-ter residues and clean it. Remove any foreign objects that may be present.

u Check and clean filter silencer or air supply line, and remove any foreign objects that maybe present.

u Put engine-side oil circulation to the turbocharger into operation.

u Prepare the turbocharger for operation (see Checks before commissioning →14).

u The turbocharger is now ready for operation.

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Operation Manual / 4 Product description / A100-L4 Monitoring during operation / 4.1 Oil pressure, oil temperature


4 Monitoring during operation

4.1 Oil pressure, oil temperature

Lubricating oil pressure before turbocharger

CAUTIONAssuring lubricating oil pressureSerious damage to the engine or property can result from a missing or insuf-ficient lubricating oil supply.

u The lubricating oil pressure must be monitored during operation and thenecessary pressure assured at the oil inlet.

Status for operation Oil pressure before tur-bocharger

[bar]Admissible for normal operation, with an oil temperature range at the inlet of 30 … 65 °Cwith an oil temperature range at the inlet of 65 … 80 °C

0.8 … 2.51.0 … 2.0

Admissible during engine warm-up, with an oil temperature range at the inlet of 30 … 65 °Cwith an oil temperature range at the inlet of 65 … 80 °C

0.8 … 4.01.0 … 4.0

Temporarily admissible ( < 1 h ) → alarmwith an oil temperature range at the inlet of 30 … 65 °Cwith an oil temperature range at the inlet of 65 … 85 °C

0.6 … 0.80.8 … 1.0

Not admissible → emergency stopwith an oil temperature range at the inlet of 30 … 65 °Cwith an oil temperature range at the inlet of 65 … 85 °C

< 0.6< 0.8

Admissible, during pre-lubrication and post-lubrication (enginestopped)

0.2 … 0.6

Table 6: Lubricating oil pressure, oil inlet

Lubricating oil temperature at the inlet

CAUTIONMachine damageIf the oil temperature at the oil inlet exceeds the admissible range, this maylead to engine damage.

u Observe oil temperature at the oil inlet according to the following table.

Status for operation Oil temperature at the inletToil,inlet [°C]

Admissible (see Table 6: Lubricating oil pressure, oil inlet→16)

30 … 80

Temporarily admissible (< 1 h) → alarm > 80Not admissible → stop engine > 85

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Not admissible → do not start engine (before start: preheatoil)

< 30

Table 7: Lubricating oil temperature at the inlet

Lubricating oil temperature at the outlet

The oil temperature at the outlet is mainly dependant on:

¡ Lubricating oil temperature and pressure at the oil inlet

¡ Engine load and turbocharger speed

¡ Exhaust gas temperature

The maximum admissible oil temperature at the outlet is listed in the following table. Thespecified oil outlet temperature is to be considered as alarm value for the turbocharger op-eration and must be monitored according to the current regulations.

Fig. 8: Oil temperature at the outlet


Oil temperature at the outletToil,outlet [°C]

Admissible 45 ≤ 110Admissible 80 ≤ 125Temporarily admissible → alarm 45 > 110Temporarily admissible → alarm 80 > 125Not admissible → stop engine 45 > 120Not admissible → stop engine 80 > 135Table 8: Lubricating oil temperature at the outlet

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If the turbocharger was operated for a longer period of time outside of the admissiblerange, ABB Turbo Systems recommends to have the turbocharger inspected by an ABB Tur-bocharging Service Station.

4.1.1 Pre-lubrication and post-lubrication

CAUTIONPre-lubricationSerious damage to engine or property can result if the turbocharger is notsupplied with oil from the first moment after starting the engine.

u Activate the pre-lubrication device each time before starting the engine.

The pre-lubrication time is at least 5 minutes.

The post-lubrication time is at least 10 minutes.

If the engine is operated for 5 to 10 minutes in idle mode before stopping, no additionalpost-lubrication is required.

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Operation Manual / 4 Product description / A100-L4 Monitoring during operation / 4.2 Admissible air inlet temperature


4.2 Admissible air inlet temperatureThe permitted air inlet temperature must be between -40C°… +45C°.

4.3 Turbocharger speed

4.3.1 Introduction

The speed of the turbocharger must be permanently monitored.

CAUTIONDo not use cables as a climbing aidIf you pull the speed measurement cables too hard, contacts can be pulledout.

u Do not tension the speed measurement cables.

4.3.2 Layout and overview

Fig. 9: Layout and overview of the speed measurement system

86505 Speed sensor 86528 Tachometer86506 O-ring 42047 Screw plug86515 Cable connector 32109 Sealing disc with cams86526 F/I converter *) Alternative mounting position for speed

sensoror for the second speed sensor

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Operation Manual / 4 Product description / A100-L4 Monitoring during operation / 4.3 Turbocharger speed


4.3.3 Speed differences with several turbochargers per engine

The speeds of all turbochargers on an engine vary only slightly from each other in standardoperation.

The difference between the highest and the lowest turbocharger speed must not be morethan 3 %, relative to the speed limit nBmax.

If this permissible range of difference is exceeded, the following steps must be carried out:

u Reduce the engine performance immediately to the point at which the maximum tur-bocharger speed does not exceed 70 % of nBmax.

u If the engine cannot be stopped, it can continue to be driven at this reduced engine loador turbocharger speed.

u If a turbocharger surges continuously, the engine performance must be reduced further.

u Measure the temperatures in the air lines and gas piping from and to the turbochargersand compare with normal values. If clear deviations of temperature are found, the nearestABB Turbocharging Service Station has to be contacted.

u Check the pressure loss of the alternative air inlet and compare it with normal values.

If the engine can be stopped temporarily:

u Inspect air lines, gas piping and the turbochargers and remedy any malfunctions.

u In any case, contacting the nearest ABB Turbocharging Service Station is recommended.

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Operation Manual / 4 Product description / A100-L4 Monitoring during operation / 4.3 Turbocharger speed


4.3.4 Replacing the speed sensor

WARNINGHot cable connector and hot speed sensorDanger of burns. The cable connector and speed sensor can reach temperat-ures in excess of 100 °C during operation.

u When disassembling the cable connector and speed sensor, wear safetygloves.


u The speed sensor is designed with a sealing lip and does not require a sealing disc for as-sembly.

Fig. 10: Replacing the speed sensor

Part number A165-L A170-L A175-L A180-L A185-L A190-L86505 M18x1.5

150 NmM18x1.5150 Nm

M18x1.5150 Nm

M27x2320 Nm

M27x2320 Nm

M27x2320 Nm

Table 9: Tightening torques (86505)

u Reduce the engine performance to idling and then stop the engine. Pay attention to post-lubrication (Stopping the engine →30).

u Switch off the lubricating oil supply to the turbocharger.

u Disconnect the cable connector from the speed sensor.

u Unscrew the defective speed sensor.

u Screw in new speed sensor to the stop.

u Connect cable connector (86515) with the speed sensor (86505)

u Switch on lubricating oil supply to the turbocharger.

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Operation Manual / 4 Product description / A100-L4 Monitoring during operation / 4.4 Low pressure measurement atthe filter silencer


4.3.5 Malfunction of the speed measurement system

The possible reasons for malfunction of the speed measuring system are described inchapter Troubleshooting.

4.4 Low pressure measurement at the filter silencer

4.4.1 Introduction

The low pressure measurement with a U-tube manometer is used for the following pur-poses:

¡ During acceptance test of the engine: Measurement of the correction factor for the cal-culation of the turbocharger efficiency

¡ When using a filter mat: An increased pressure loss indicates an increase in the fouling ofthe filter material.

4.4.2 U-tube manometer at the filter silencer

Fig. 11: U-tube manometer at the filter silencer

81000 Filter silencer81050 U-tube manometerA [mm H2O] Pressure loss / pressure difference

If the turbocharger is operated at maximum engine power and pressure loss (A) reaches thevalue of 200 mm H2O:

u Clean filter mat.

Reading of pressure loss

For simple reading of the pressure loss (A), the dipstick at the U-tube manometer can bepulled out to the level of the lower water level. Better readability of the U-tube manometercan be achieved by filling with slightly coloured water.

u Colour the water with food colouring or ink.

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Operation Manual / 4 Product description / A100-L5 Operation and service / 5.1 Noise emission


5 Operation and service

5.1 Noise emission

WARNINGNoise hazardsExposure to noise can harm the hearing system, impair health and the psy-chological state and may lead to lack of attention and irritation.

u When the engine is running, always wear ear protection.

u Always wear ear protection if the sound pressure level exceeds 85 dB(A).


The emission sound pressure level (A-weighted) is measured at a distance of 1 meter fromthe turbocharger.

The highest value of the emission sound pressure level1) reaches a maximum of 105 dB(A)near the air inlet. The following prerequisites must be fulfilled with regard to the turbochar-ger to observe this limit value:

¡ Air-inlet system has been fitted

¡ All standard, noise-reducing measures2) have been fitted

¡ Bellows at the air outlet has been acoustically insulated by the enginebuilder (see Fig. 12:Noise insulation, bellows →24).

The enginebuilder is responsible for insulating the charge air/scavenging air line and thecharge air cooler.

1) Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 : A-weighted emission sound pressure level

2) The enginebuilder must provide acoustically equivalent measures in case of deviating in-sulation versions

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Operation Manual / 4 Product description / A100-L5 Operation and service / 5.2 Service work


Suggestion for noise insulation, bellows

Fig. 12: Noise insulation, bellows

01 Compressor casing02 Bellows03 Charge air duct / scavenging air duct04 Insulation cushion05 Insulation mat (at least 15 mm)06 Sheet metal cover

5.2 Service workService work includes visual controls, monitoring, measuring and inspection as well as func-tional checks. Service work enables the detection and rectification of changes to the tur-bocharger and ensures full operability of the turbocharger.

CAUTIONService intervalsAny service work on the turbocharger that is omitted or performed too latecan cause excessive contamination, wear and operating failures.

u Carry out the service work at the specified time intervals.

CAUTIONSpecific service intervalExceptional stresses such as a high number of starts and stops, harsh envir-onmental conditions, poor fuel quality or high system vibrations can lead tountimely machine damage even if the prescribed service intervals are ob-served.

u Agree on a specific service interval with ABB Turbo Systems.

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To prevent machine damage caused by ageing and downtime, we recommend having an in-spection carried out by an ABB Turbocharging Service Station no later than 5 years after thelast service.

5.2.1 Service work every 25 … 50 hours

5.2.2 Service work at 100 hours after commissioning

u 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.

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 originalABB parts.

Take note of correct customer spare part set (see chapter Ordering spare parts →104).

u Remove and clean the filter silencer and check for damage.

u Dismantle the wall insert.

u Check axial clearance A.

u Clean compressor wheel, diffuser, wall insert and compressor casing and check for dam-age.

u Check the nozzle ring, turbine diffuser and turbine blades for any possible contamination,damage or wear using a borescope.This checking can also be carried out after disassembling the gas inlet casing.

u Fit the wall insert.

u Install the filter silencer.

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 TurbochargingService Station. Damaged and worn out parts must be replaced with original ABB parts.

Take note of correct customer spare part set (see chapter Ordering spare parts →104).

u Remove the filter silencer.

u Clean filter silencer and check for damage.

u Dismantle the wall insert.

u Check axial clearance A.

u Clean wall insert, diffuser and compressor casing and check for damage.

u Remove the gas inlet casing and dismantle the nozzle ring and cover ring.

u Clean the nozzle ring and cover ring and check for damage.

u Dismantle, inspect and balance the rotor.

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u Replace the plain bearing

5.2.5 Service work according to instructions of enginebuilder

u 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.

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5.2.6 Entries in the engine logbook

The monitoring of the engine system enables conclusions to be drawn on the behaviour ofthe turbocharger.

The following operating data and measured values must be entered regularly into the enginelogbook of the enginebuilder:

¡ Performance and speed of the engine

¡ Speed of the turbocharger

¡ Air intake temperature

¡ Exhaust gas temperature before and after the turbine

¡ Pressure of the charge air

¡ Pressure loss in the charge air cooler

¡ 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

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Operation Manual / 4 Product description / A100-L5 Operation and service / 5.3 Expected replacement intervals


5.3 Expected replacement intervalsDuring the prescribed periodic service work, the individual parts are examined for wear andreplaced if necessary.

5.3.1 Replacement intervals

Expected replacement intervals [h]

Turbocharger part Operation with HFO *)Gas inlet casing 50000 … 100000

Gas outlet casing 50000 … 100000Nozzle ring 35000 … 50000Cover ring 25000 … 50000

Other casings 100000Table 10: Expected replacement intervals for turbocharger parts

*) HFO = Heavy Fuel Oil

Recommended replacement intervals [h]

Rotor components See information on rating plateBearings 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.

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Operation Manual / 4 Product description / A100-L5 Operation and service / 5.4 Flexible turbocharger cut-out


5.4 Flexible turbocharger cut-outIf the load is low, an engine which is charged by multiple turbochargers can be operated withone turbocharger switched off. The flexible switch-on or switch-off of a turbocharger is re-ferred to as a "flexible turbocharger cut-out". In flexible systems, slide valves or flaps are in-stalled by the enginebuilder before the gas inlet and after the air outlet of the turbocharger.Depending on the version of the system, the turbocharger can be switched off or on manu-ally or automatically. In all cases, you must observe the enginebuilder's recommendations. The lubricating oil supply of the switched-off turbocharger must not be switched off due tothe engine vibrations. To ensure that there are no oil or gas leaks on the switched off tur-bocharger, it must be supplied with external sealing air.The turbocharger may only be switched on or off while the engine is stopped or in idle mode.

CAUTIONFlexible turbocharger cut outImproper manipulations can result in inadmissible turbocharger speedswhich can lead to serious damage to property with grave consequences.

u The air outlet flap and gas inlet flap must be completely open during nor-mal operation.

u During cut out operation, the air outlet flap and gas inlet flap must becompletely closed.

CAUTIONManual switching of the flapsIf the gas inlet flap is opened during cut-out operation or the air-outlet flapis closed during normal operation, this causes very high turbochargerspeeds. These can result in damage with serious consequences or even atotal loss of the turbocharger.

u Never open the gas inlet flap during cut-out operation.

u Never close the air-outlet flap during normal operation.

CAUTIONAutomatic switching of the flapsDuring automatic flap control, there is a risk of the turbocharger rotatingopposite the intended direction of rotation if the air-outlet flap is open fur-ther than the gas inlet flap during the switching process. This can lead todamage on the turbocharger.

u The turbocharger should only be switched on or off below charging pres-sures of 0.3 bar.

u 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 youopen them at least every 500 hours of operation.

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Operation Manual / 4 Product description / A100-L5 Operation and service / 5.5 Stopping the engine


5.5 Stopping the engineu Observe the instructions regarding post-lubrication (Pre-lubrication and post-lubrication→18)

u Stop the engine.

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Operation Manual / 4 Product description / A100-L6 Periodic maintenance / 6.1 Foreword to maintenance


6 Periodic maintenance

6.1 Foreword to maintenanceMaintenance 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

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Operation Manual / 4 Product description / A100-L6 Periodic maintenance / 6.2 Cleaning the filter silencer


6.2 Cleaning the filter silencer

Filter silencer with tension band

Fig. 13: Layout and overview of filter silencer

81126 Lock 81266 Cover grid81135 Body of filter silencer 81268 Connecting strip81136 Absorption segment 81270 Tension band81137 Sheet-metal covering 81271 Lock81265 Filter ring (if present) 81400 Water connectionE Insert unit (absorption segment / sheet-metal covering fitted)

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Operation Manual / 4 Product description / A100-L6 Periodic maintenance / 6.2 Cleaning the filter silencer


Cleaning the filter ring (if present)

u Remove filter ring (81265).

u Clean filter ring (81265) as required or every 500 hours of operation and replace after thefifth cleaning process at the latest.Contamination of the filter ring depends on the degree of purity of the sucked-in air.

u Rinse the filter ring (81265) with water and mild detergent or, in the case of heavy con-tamination, soak and carefully push through. Rinse in cold water. Avoid high mechanicalloads (water jet).

u Let the filter ring dry completely before assembling.

u Dirty water and mild detergent must be disposed of in compliance with locally applicableregulations.

Cleaning the absorption segments

u Loosen the tension bands (81270) at the locks (81271) and remove them along with thecover grid (81266) and connecting strips (81268) (see Fig. 13: Layout and overview of fil-ter silencer →32).

u Pull out insert units (E).

u Bend up the sheet-metal coverings (81137) and remove the absorption segments (81136).

u Clean the absorption segments (81136).When cleaning, note that the absorption segments may only be cleaned lightly with pres-surized air, with a soft brush or a moist cleaning cloth. Otherwise there is a danger ofdamage or changing of the shape.

u Replace heavily contaminated absorption segments (81136) and any damaged connectingstrips (81268) with original parts from ABB.

Fitting the filter silencer

u Insert the absorption segments (81136) into the sheet-metal coverings (81137).

u Bend the sheet-metal coverings (81137) back into the original shape.

u Insert the insert units (E) into the slotted guides in the filter silencer body (81135).

u Fit the cover grid (81266) and connecting strips (81268) on the filter silencer body (81135).

u Guide the tension bands (81270) through the eyelets of the connecting strips (81268).

u Tighten the tension bands (81270) at the locks (81271).

u Any damaged tension bands must be replaced.

u Fit filter ring (81265), if present.

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Operation Manual / 4 Product description / A100-L6 Periodic maintenance / 6.3 Changing the filter strip on the filter si-lencer casing


6.3 Changing the filter strip on the filter silencercasing

This chapter applies only to turbochargers with filter silencer casing. The filter ring (81265) isreplaced with the filter silencer installed.

Fig. 14: Dismantling filter ring circumferential part

u Dismantle circumferential part (9).

Fig. 15: Opening filter ring lock

u Open the lock of the filter ring (81265).

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Operation Manual / 4 Product description / A100-L6 Periodic maintenance / 6.3 Changing the filter strip on the filter si-lencer casing


Fig. 16: Attaching new filter ring

u Attach the new filter ring (81265) on the filter ring to be replaced so they overlap.

Fig. 17: Fitting new filter ring

u Pull on the old filter ring until the new filter ring is completely wrapped around the filtersilencer.

u Undo the connection between the new and the old filter ring.

u Fasten the newly installed filter ring (81265), then fit circumferential part (9).

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Operation Manual / 4 Product description / A100-L6 Periodic maintenance / 6.4 Cleaning the compressor during opera-tion


6.4 Cleaning the compressor during operation

6.4.1 Introduction

Approval by enginebuilder

The following instructions for wet cleaning only apply to cleaning with pure water and underthe precondition that the enginebuilder approves the process.

The contamination of the compressor stage (compressor wheel, wall insert and diffuser) de-pends on the degree of purity of the air that is sucked in.

Deposits can form in the flow channels if salt, oil mist or dust are sucked in with the air.

Consequences of contamination:

¡ Impaired compressor efficiency

¡ Higher exhaust gas temperatures

¡ Increased fuel consumption

¡ Increased rotor unbalance

Periodic cleaning of the compressor during operation prevents or delays any major increasein contamination. But it never replaces the regular service work where the turbocharger iscompletely dismantled and the compressor is mechanically cleaned.

Cleaning interval

The interval between the cleaning cycles depends greatly on the operating conditions.Cleaning should normally take place about every 50 hours of operation. If the specified cleaning intervals are incompatible with operation of the engine, contactABB Turbo Systems.

Cleaning method and operating state

The compressor is cleaned during operation using the wet cleaning method. The cleaningmethod is tested and approved by ABB Turbo Systems.

When undertaking wet cleaning, the following operating state must be ensured:

¡ engine load between 25 … 85 %.

¡ If the engine compartment temperature is below 0°C when wet cleaning the compressor,precautionary measures should be taken to prevent ice from forming.

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Principle of wet cleaning

CAUTIONCorrosion and deposits when cleaningSalt water and cooling water treatment substances damage and adverselyaffect turbocharger parts.

u Never use salt water, but only pure water for cleaning.

To clean the compressor stage during operation, water is injected upstream of the com-pressor wheel.

The water does not act as a solvent. The coating is removed by the mechanical action of theimpacting droplets. The procedure is perfectly suitable, provided that the contaminationhas not progressed too far.

Cleaning several turbochargers

If several turbochargers are installed on an engine, it is recommended to clean one com-pressor after the other.

CAUTIONVolume of water for cleaning the compressorUncontrolled volumes of water can damage the turbocharger and the en-gine.

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6.4.2 Wet cleaning of compressor

WARNINGDamage to hearing due to high noise levelRemoving the screw plug (81126) from the filler orifice (B) may result in ahigh level of noise. Carrying out wet cleaning on the compressor without earprotection may lead to serious hearing damage.

u Always wear ear protection when carrying out wet cleaning on the com-pressor.


Fig. 18: Overview of wet cleaning of compressor

81000 Filter silencer A Can81126 Lock B Filler opening

u Remove insulation from flange of filter silencer (81000) (if present).

u Unscrew lock (81126).

u Measure volume of water according to the following table.

u Pour this water into a clean can (A).

u Carefully pour this water into the filling orifice (B) from the can.

u Screw in lock and hand-tighten.

u Fit insulation to flange of filter silencer (if present).

u After cleaning, allow the engine to continue to run for at least 5 minutes under normalload.

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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

Product Quantity [dm3]A165-L 2.0A170-L 2.0A175-L 3.0A180-L 3.0A185-L 3.0A190-L 3.0Table 12: Volume of water per cleaning process

The filling time is 4 ... 15 seconds.

Checking the filter plug

The filter plug only needs to be checked in the turbocharger version with a cast filter silen-cer. See chapter Design variants →59.

Fig. 19: Filter plug view

Disassembly and checking of the filter plug (81125) is required if, 20 seconds after the clean-ing process, water is still visible in filler opening B.

u Loosen and remove the filter plug (81125) with box spanner

u Clean the drill holes of the plug

u Fit filter plug (81125).

Part number A165-L A170-L A175-L A180-L A185-L A190-L81125 G1/2"

45 NmG1/2"45 Nm

G1/2"45 Nm

G1/2"45 Nm

G1/2"45 Nm

G1/2"45 Nm

Table 13: Tightening torques (81125)

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Operation Manual / 4 Product description / A100-L6 Periodic maintenance / 6.5 Cleaning the turbine during operation


6.5 Cleaning the turbine during operation

6.5.1 Introduction

Combustion of heavy fuel oil in diesel engines causes contamination of the turbine bladesand nozzle rings of the turbochargers. Contamination increases with time, which is why regular and properly carried out cleaningoperations are important to remove any deposits.

Contaminated turbine components lead to a reduction in the turbocharger efficiency. Fur-thermore, the exhaust gas temperature after the cylinders can rise and the charging pres-sure in the air receiver can drop. Contamination of the turbine also leads to rotor unbalance. A very high level of contamina-tion can lead to intolerably high rotor unbalance.

Despite periodic cleaning during operation, experience shows that overhauls during whichthe turbine and nozzle ring (or VTG) are mechanically cleaned cannot be omitted.

Cleaning method

The turbine and the nozzle ring are cleaned during operation using the dry cleaning method. This cleaning method is tested and approved by ABB Turbo Systems.

Interval for dry cleaning

The interval between the cleaning cycles depends greatly on the operating conditions.Cleaning should normally take place about every 50 hours of operation.

Principle of dry cleaning

During dry cleaning, the dirt coating is removed by the mechanical action of the impactingsolids (granulate).

Operating state

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.

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6.5.2 Procedure for dry cleaning the turbine

Dry cleaning device

Fig. 20: Overview of dry cleaning device

11 Granulate container (51702) 16 Protection valve [closed] (51713)12 Cover cap (51703) 17 Pressurised air valve [venting] (51704)13 Pressurised air supply [4 ... 7 bar] 18 Plate14 Piping 19 Cleaning instructions (51717)15 On-Off valve [closed] (51705) 20 Gas inlet casing, insulated

CAUTIONProtecting the pressurised air systemu Protect the pressurised air system against overpressure (> 7 bar).

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Operating the dry cleaning device

CAUTIONEscape of burnt granulate particlesCareless handling may result in incompletely burnt particles of granulateand soot particles escaping from the stack with the exhaust gas.

u Only inject the specified amount of granulate for cleaning.

u Make sure that the conditions with regard to the operating state and the maximum ex-haust gas temperature before the turbine are observed.

u Check that the protection valve (16) is closed (see Fig. 20: Overview of dry cleaning device→41).

u Check that the on-off valve (15) is closed.

u Check that the combined pressurised air valve/pressure release valve (17) is in the neutralposition.

u Loosen and carefully remove the cover cap (12).

u Fill the specified amount of granulate into the container (11).

u Screw on and tighten the cover cap (12).

u Open the combined pressurised air valve/pressure release valve (17) (down lever posi-tion).

u Open the protection valve (16).

u Open the on-off valve (15) for cleaning the turbine for 3 ... 4 minutes.

u Close the on-off valve (15).

u Close the protection valve (16).

u Set the combined pressurised air valve/pressure release valve (17) to venting (up lever po-sition).

u Check that the exhaust gas temperature after the turbine is less than before the cleaning.

u Move the combined pressurised air valve/pressure release valve (17) to the neutral posi-tion.

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 processin order to achieve an optimum cleaning effect.

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6.5.3 Cleaning parameters for dry cleaning

Material selection

Possible suppliers of material for dry cleaning can be found on the Internet.

The following materials are suitable for dry cleaning:

¡ Hard, granulated materials (such as natural core granulates)

¡ Soft-blast media

¡ Activated carbon particles

The average grain size of the cleaning granulate must be between 1.2 and 2.0 mm.

The specific weight of the cleaning granulate must not exceed 1.2 kg/dm3.

Amount of granulate per turbocharger

Product Quantity [dm3]A165-L 1.0A170-L 1.5A175-L 2.0A180-L 2.5A185-L 3.0A190-L 3.5Table 14: Amount of granulate

NOTICEStorage of dry cleaning materialsThe cleaning material must be stored in a dry and clean location to preventblockage of the pipes when cleaning.

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Operation Manual / 4 Product description / A100-L6 Periodic maintenance / 6.6 Draining the gas outlet casing


6.6 Draining the gas outlet casingIf there is a boiler leak into the exhaust gas pipe or an ingress of water due to other causes,the gas outlet casing can be drained.

Fig. 21: Drain pipe diagram

01 Drain pipe A Position 102 Drain cock B Position 203 Drain04 Air line from compressor casing

u On the drain pipe (01), set the drain cock (02) to position 1 (A).

If the drain pipe (01) is blocked:

u Set the drain cock (02) to position 2 (B) and clean the drain pipe (01) with air from thecompressor casing (04).

If cleaning with air is not sufficient, the drain pipe (01) must be cleaned mechanically.

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Operation Manual / 4 Product description / A100-L7 Troubleshooting / 7.1 Malfunctions when starting


7 Troubleshooting

7.1 Malfunctions when starting

Delayed start-up

Possible causes RemedyTurbochar-ger

Turbocharger contaminated Clean (Periodic maintenance →31)Bearing damaged Contact ABB Turbocharging Service

StationRotor rubbingForeign object in the turbocharger

Table 15: Malfunctions when starting – Delayed start-up

Vibrations


Rotor unbalance Contact ABB Turbocharging ServiceStationTurbine or compressor damaged

Bearing damagedEngine Vibrations from engine Contact enginebuilderTable 16: Malfunctions when starting – Vibrations

Rubbing of rotating parts

Normal behaviour, not a malfunctionTurbochar-ger

A slight amount of uniform wear at the circumference of the rotor componentscaused by slight local rubbing against adjacent components is permitted. Thiscauses the compressor or turbine blades to be somewhat shortened. To preventsignificant loss of efficiency, specific tolerances must be fulfilled.

¡ If there is any doubt about the extent of the rubbing, contact an ABB Tur-bocharging Service Station.

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

Table 17: Malfunctions when starting – Rubbing of rotating parts

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Operation Manual / 4 Product description / A100-L7 Troubleshooting / 7.2 Malfunctions during operation


7.2 Malfunctions during operation

Lubricating oil pressure too low

WARNINGDanger of fire and explosion due to lubricating oil leaksLeaking oil may ignite on hot surfaces. This can result in serious injuries topersonnel or fatal accidents.

u Cordon off danger area.

u Raise the alarm and, depending on the situation, stop the engine.

u Seal the oil leak.

u Soak up oil and dispose of in an environmentally compatible manner.



Axial clearance of the rotor excessive Contact an ABB TurbochargingService Station

Engine Oil filter heavily contaminated CleanOil pump in lubricating system defect-ive

Check/replace

Manometer displays incorrectly Replace manometerTable 18: Malfunctions during operation – Lubricating oil pressure too low

Drop in speed


Heavy contamination of the turbine CleanDamaged rotor components or bearing Contact ABB Turbocharging Service

StationPipes Defects, such as leaks, in the exhaust

gas pipes or charge air ductsRepair

Table 19: Malfunctions during operation – Drop in speed

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Operation Manual / 4 Product description / A100-L7 Troubleshooting / 7.2 Malfunctions during operation


Exhaust gas temperature too high

Engine performance and engine speed unchanged

Possible causes RemedyTurbocharger Insufficient air, for example, when fil-

ter silencer is blocked by dirtClean (Periodic maintenance →31)

Compressor/turbine contaminatedExhaust gas back pressure too high Clean or repair boiler or exhaust gas si-

lencerTurbine damaged or eroded Contact ABB Turbocharging Service

StationEngine Malfunction in the injection system Repair or contact manufacturerCharge aircooler

Cooler contaminated CleanCooling water volume too low FillInlet temperature of cooling watertoo high

Check/clean cooling system

Insufficient ventilation Improve ventilationTable 20: Malfunctions during operation – Exhaust gas temperature too high

Charge air pressure too low

Engine performance and engine speed unchanged, suction condition normal


Manometer display not correct Replace manometerSupply pipe to manometer not sealed Repair leakFilter silencer contaminated, thereforepressure drop too high

Clean (Periodic maintenance →31)

Compressor end and/or turbine endcontaminatedCompressor/turbine damaged Contact ABB Turbocharging Service

StationExhaust gas back pressure too high Clean or repair boiler or exhaust gas si-

lencerEngine Air receiver not sealed Repair

Gas pipe between engine and turbinenot sealedInjection mistimed Set correctlyValve control misadjusted

Pipes Pipes downstream to the compressoroutlet not sealed.

Repair.

Table 21: Malfunctions during operation – Charge air pressure too low

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Operation Manual / 4 Product description / A100-L7 Troubleshooting / 7.3 Surging of the turbocharger


Charge air pressure too high

Engine performance and engine speed unchanged, suction condition normal


Manometer display not correct Replace manometer

Engine Malfunction in the injection system Repair or contact manufacturerInjection mistimed Set correctlyEngine performance higher than indic-ated

Check engine performance

Table 22: Malfunctions during operation – Charge air pressure too high

7.3 Surging of the turbocharger

Surging of the turbocharger

Possible causes RemedyTurbocharger Filter silencer or diffuser contamin-

atedClean (Periodic maintenance →31)

Heavy dirt deposits in the turbine orin the nozzle ring

Engine Protective grating in front of the tur-bocharger contaminated or damaged

Clean/replace

Charge aircooler

Cooler contaminated CleanCharge air duct blocked

Table 23: Surging of the turbocharger

CAUTIONContinuous or periodic surgingIf the turbocharger surges continuously or periodically, parts of the tur-bocharger may be damaged.

u Gradually reduce the engine load.

u Have the cause clarified and remedied immediately by an ABB Turbochar-ging Service Station.

u Have parts assessed for damage and, if necessary, replaced by an ABBTurbocharging Service Station.

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Operation Manual / 4 Product description / A100-L7 Troubleshooting / 7.4 Malfunctions when stopping


Sporadic surge blows

Surging of the turbocharger can occur during certain operating states, such as when redu-cing the engine load quickly when manoeuvring. When this happens, the flow direction in thecompressor is momentarily reversed. Such sporadic surge blows do not impair the safe op-eration of the turbocharger.

¡ A surge blow is accompanied by a loud bang and escape of hot air from the filter silencer.

7.4 Malfunctions when stopping

Runout noises


Turbocharger contaminated CleanBearing damaged Contact an ABB Turbocharging

Service StationRotor rubbingForeign object in the turbocharger

Table 24: Malfunctions when stopping – Runout noises

Shortened runout time


Turbocharger contaminated CleanBearing damaged Contact an ABB Turbocharging

Service StationRotor rubbingForeign object in the turbocharger

Table 25: Malfunctions when stopping – Shortened runout time

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Operation Manual / 4 Product description / A100-L7 Troubleshooting / 7.5 Speed measurement system


7.5 Speed measurement system

Possible causes RemedyNo signalor poorsignalamplitudepresent

Assembly fault The screw plug for the sensor is fitted with a gasket.This gasket must be removed when the speed sensor is as-sembled. If the gasket has been inadvertently fitted, the dis-tance of the sensor tip to the sealing disc giving the signal is in-creased. This reduces the voltage amplitude of the speed signalwhich can lead to problems with the evaluation electronics.This problem will be remedied by removing the gasket.

Sensor defective Contact ABB Turbocharging Service StationMeasuredspeed toohigh

Contamination ofthe sensor tip

As the sensor tip is magnetic, it can attract material particles.This reduces the distance to the auxiliary bearing, which canlead to amplification of the noise component and therefore tofalse triggering.Dismantle the sensor, clean the sensor tip, and fit the sensorback on with the specified tightening torque.

Measuredspeed toolow

- - Contact ABB Turbocharging Service Station

Othercauses ofmalfunc-tion

- - If none of the measures described above remedy the malfunc-tion, it is recommended to have the speed measurement sys-tem checked by an ABB Turbocharging Service Station.

Table 26: Malfunctions of the speed measurement system

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.1 Introduction


8 Disassembly and assembly

8.1 Introduction

CAUTIONFurther workThis Operation Manual may be used to carry out only the work described init. Further work that is carried out in an incorrect way can lead to seriousdamage to the machine.

u ABB Turbo Systems recommends having further work carried out only bytrained personnel from an ABB Turbocharging Service Station.

u Mark the casing position for assembly.

Identification of the assembly devices

Not all assembly devices are marked with a part number. Identification is guaranteed by thetool list. This list is enclosed with the toolbox.

WARNINGServicing the assembly devicesAssembly devices must be checked for damage before and after use.

u Visually inspect for corrosion, cracks, deformation and wear.

u Damaged assembly devices must no longer be used and must be re-placed.

Customer spare part set

Before starting work, make sure the required customer spare part set is available (seechapter Spare parts →104).

Tightening torques for components of the turbocharger

The specified tightening torques of the bolted connections must be observed (Table oftightening torques →92).

Tightening torques for assembly devices

Unless described otherwise, the screws and nuts of the assembly devices supplied by ABBmust be tightened so they are tight-fitting.

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.1 Introduction


WARNINGSuspended loadsLoads that are not attached according to regulations can cause injury topersonnel or fatal accidents.

u Only fasten the turbocharger, assemblies or individual parts on properlyfunctional lifting gear with sufficient load limit.

u Pay attention to the correct attachment of loads on the crane hook.

u People must not stand beneath suspended loads.


Wear safety helmet.

Definition of terms

¡ Suspension pointDefined loading point on a component or an assembly (blind hole thread, eyelet, lug).

¡ Assembly deviceDevices that are fitted on the turbocharger in order to obtain a suspension point. As-sembly devices are specially constructed and designed for the defined use; they are notcommercially available products. Use assembly devices only for the described applica-tions.

¡ Lifting gearEquipment for the lifting and transporting of loads (ropes, chain block, crane). Liftinggear is not supplied by ABB.

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.2 Weights of assemblies


8.2 Weights of assembliesThe specified weights of the individual parts or assemblies are rounded-up standard values.

Fig. 22: Weights of assemblies

Position Assembly A165-L A170-L A175-L A180-L A185-L A190-L01 Filter silencer 240 360 600 800 850 105002 Wall insert 240 340 560 820 1090 150003 Diffuser 40 60 100 140 200 27004 Compressor casing 320 450 740 960 1360 180005 Cover ring 30 50 75 90 110 15006 Nozzle ring 10 20 25 50 65 8507 Gas inlet casing 180 240 380 520 700 810

Table 27: Weights of assemblies [kg]

The total weight of the complete wall insert is made up of the wall insert and diffuser as-semblies.

A165-L A170-L A175-L A180-L A185-L A190-L280 400 660 960 1290 1770

Table 28: Weight of wall insert [kg]

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.3 Disassembly and assembly of thefilter silencer casing


8.3 Disassembly and assembly of the filter silencercasing

NOTICEDisassembly / Assembly of the filter silencer casingThis chapter applies only to turbochargers with filter silencer casing.

Only the assembly of the filter silencer casing is described in detail.

The disassembly must be carried out in reverse order of the assembly.

Fig. 23: Dismantling the filter silencer casing

01, 02 Bottom part03, 04, 07, 08 Side part05, 06, 09 Circumferential part10, 11 Flange

The complete filter silencer casing has the part number 81500.

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Assembly

NOTICEScrews on the filter silencer casingNo screws are tightened until end of filter silencer casing assembly. Onlythis way is it possible to fit all the parts.

u Do not tighten the screws during assembly.

Fig. 24: Fitting the filter silencer casing

u Fit the bottom part (01) on the filter silencer (81000) with screws (A) and (B).

NOTICEScrew (A)The location of screw (A) serves as a reference for the correct assembly ofthe filter silencer casing.

u Before disassembling the bottom part (01), mark the location ofscrew (A).

u Fit all remaining screws on the bottom part (01).

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u Fit the bottom part (02) with the screws on the filter silencer.


u Fit the side parts (03) and (04) with the screws on the filter silencer and on the bottompart.

u 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).

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u Insert the flanges (10) and (11) laterally between the side parts and fit the screws.


u Fit the circumferential part (05) with the screws.

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Screws for fastening the individual parts tothe filter silencer

Screws for fastening the individual parts

M1030 Nm

M825 Nm

Table 29: Tightening torques (filter silencer screws)

u Tighten all screws of the bottom parts (01) and (02).

u Tighten all screws of the side parts (03, 04, 07, 08) and the flanges (10, 11).

u Tighten all screws of the circumferential parts (05, 06, 09).

Bellows

Fig. 29: Fitting the bellows

u Fit bellows (C) with frame (F), screws (S) and nuts (N) on the filter silencer casing.

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.4 Dismantling the filter silencer


8.4 Dismantling the filter silencer

8.4.1 Design variants

The turbocharger is equipped with one of the following filter silencer variants:

¡ Welded 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.

8.4.2 Dismantling the filter silencer (welded)

If the turbocharger is also fitted with a noise package, chapter Dismantling the filter silencerwith noise package →61 must be observed.

u Dismantle the insulation if necessary.

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.

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.4 Dismantling the filter silencer


8.4.3 Dismantling the filter silencer (cast)

If the turbocharger is also fitted with a noise package, chapter Dismantling the filter silencerwith noise package →61 must be observed.


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).


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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.5 Dismantling the filter silencer withnoise package


8.5 Dismantling the filter silencer with noise package

The following work steps apply to both the welded and cast versions of the filter silencer.


Fig. 32: Dismantling the filter silencer with noise package

1. Loosen and remove the insulation ring (81300).

2. Attach the lifting gear to the front lug and rear eyelet of the filter silencer (81000), payingattention to the version of the filter silencer.

3. Loosen nuts (72004) and remove with washers (72003) and insulating discs (81302).


5. Remove the gasket (81301).

6. Loosen counter-sunk screws (74043), remove with air outlet silencer (74040) and gasket(74042).

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.6 Dismantling wall insert and diffuser


8.6 Dismantling wall insert and diffuser

8.6.1 Dismantling the wall insert

Fig. 33: Pressing off compressor casing

1. Loosen one screw (72011) and leave 2/3 of the thread length screwed into the com-pressor casing (72000).

2. Loosen and remove the remaining screws (72011).

3. Use the press-off screws (90900) to press off the wall insert (77000) from the com-pressor casing (72000) until the lifting device (90190) can be fitted.

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).

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Fig. 34: Moving out wall insert

7. Remove screw (72011).

8. Carefully move out the wall insert (77000) with diffuser (79000).

9. Remove O-ring (77040).

Fig. 35: Putting down wall insert

u 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.

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8.6.2 Dismantling the diffuser

WARNINGSupport for the wall insertThe support may slip away when the wall insert is placed on flange F.

Any defective or improperly used supports can lead to serious injury to per-sonnel and even to fatal accidents.

u Check the position of the support and correct if necessary.

WARNINGRisk of tippingIf the wall insert is not tilted, it must be put down correctly. Tipping of thewall insert may lead to serious injuries to persons or even to fatal accidents.

u If the wall insert is not tilted, ensure that it is fixed correctly (see Dis-mantling wall insert).

Fig. 36: 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.

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Fig. 37: 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.

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.7 Axial clearance A prior to disas-sembly


8.7 Axial clearance A prior to disassembly

WARNINGPhysical hazards due to sharp edges on compressor wheelThe compressor wheel has sharp edges which can result in injury.

u Wear safety gloves.


CAUTIONClearances outside the toleranceSerious damage to engines or property can be caused by clearances outsidethe tolerance and excessively worn parts.

u Have the components assessed and, if necessary, replaced by an ABB Tur-bocharging Service Station.

Fig. 38: Measuring axial clearance A

The axial clearance (A) of the rotor should always be measured before and after servicework.

Product Axial clearance A [mm]

A165-L 0.32 ... 0.62A170-L 0.33 ... 0.63A175-L 0.38 ... 0.68A180-L 0.41 ... 0.73A185-L 0.43 ... 0.77A190-L 0.45 ... 0.80Table 30: Axial clearance A

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.8 Dismantling the insulation (≤ A175-L)


8.8 Dismantling the insulation (≤ A175-L)

NOTICEDry cleaningThe dry cleaning does not have to be removed to dismantle the insulation.

Fig. 39: Removing the insulation (A175-L and smaller).

1. Loosen and remove screws of insulation jackets (51200) from gas outlet casing (61001).

2. Loosen and remove all connecting plates of insulation jackets.

3. Remove insulation jackets.

4. Detach flange connection between gas inlet casing (51001) and bellows.

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.9 Dismantling the gas inlet casing (≤A175-L)


8.9 Dismantling the gas inlet casing (≤ A175-L)

8.9.1 Variant with screw

Dismantling the gas inlet casing (A175-L and smaller) – screwed variant

Fig. 40: Dismantling the gas inlet casing (A175-L and smaller) – screwed variant

u If one of the screws (61009) shears off when loosening, an ABB Turbocharging ServiceStation should be contacted.

1. Loosen crosswise and remove all but two opposite screws (61009).

2. Fit two guide studs (90317) in the upper area on the gas outlet casing.

3. Loop around the gas inlet casing (51001) with lifting gear.

4. Loosen and remove remaining screws (61009).

5. Carefully move out gas inlet casing and put down, remove guide studs.

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.9 Dismantling the gas inlet casing (≤A175-L)


8.9.2 Variant with threaded stud

Fig. 41: Dismantling the gas inlet casing (A175-L and smaller) – threaded stud variant

Product Maximum loosening torque [Nm]A165-L 245A170-L 350A175-L 665Table 31: Maximum admissible loosening torque (51087)

u If a threaded stud (51086) shears off when loosening, an ABB Turbo Systems Service Sta-tion should be contacted.

u 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 untilhand-tight.

u If the nut (51087) cannot be removed with the maximum permissible loosening torque, itcan be heated and removed with an appropriate tool.

1. Treat nuts (51087) with rust remover

2. Loosen crosswise and remove all nuts except for two opposite nuts (51087). Note max-imum admissible loosening torque.


4. Loosen and remove remaining nuts (51087).

5. Carefully move out gas inlet casing and put down.

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.10 Dismantling the nozzle ring (≤A175-L)


8.10 Dismantling the nozzle ring (≤ A175-L)

Fig. 42: Dismantling the nozzle ring (A175-L and smaller)

1. Loosen screws (56014) and remove with washers (56011).

2. Remove and put down nozzle ring (56001).

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.11 Dismantling the gas inlet casing (≥A180-L)


8.11 Dismantling the gas inlet casing (≥ A180-L)

8.11.1 Variant with screw

Fig. 43: Dismantling the gas inlet casing (A180-L and larger) – screwed variant

u If one of the screws (61009) shears off when loosening, an ABB Turbocharging ServiceStation should be contacted.

1. Dismantle both halves of the insulation segment (51215) and remove with all fixing ele-ments.


3. Loosen and remove all screws (61009) except for two opposite screws.

4. Fit two guide studs (90317) in the upper area on the gas outlet casing (61001).

5. Loop lifting gear around gas inlet casing.

6. Loosen remaining screws and carefully move out gas inlet casing.

7. Fit support (90451) on gas inlet casing and put down casing.

8. Remove the guide studs.

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.11 Dismantling the gas inlet casing (≥A180-L)



Fig. 44: Dismantling the gas inlet casing (180-L and larger) – threaded stud variant

Product Maximum loosening torque [Nm]A180-L 840A185-L 1225A190-L 1610Table 32: Maximum admissible loosening torque (51087)

u If a threaded stud (51086) shears off when loosening, an ABB Turbo Systems Service Sta-tion should be contacted.

u 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 untilhand-tight.

u If the nut (51087) cannot be removed with the maximum permissible loosening torque, itcan be heated and removed with an appropriate tool.

1. Dismantle both halves of the insulation segment (51215) and remove with all fixing ele-ments.


3. Treat nuts (51087) with rust remover.

4. Loosen crosswise and remove all nuts (51087) except for two opposite nuts. Note max-imum admissible loosening torque.


6. Loosen and remove remaining nuts (51087).

7. Fit support (90451) on gas inlet casing and put down casing.

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.12 Dismantling the nozzle ring (≥A180-L)


8.12 Dismantling the nozzle ring (≥ A180-L)

Fig. 45: Fitting the nozzle ring holder

1. Remove screws (B2).

2. Fit the nozzle ring holder (90477) with screws (B1) at the top of the flange of the gas inletcasing (51001).

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.12 Dismantling the nozzle ring (≥A180-L)


Fig. 46: Dismantling the nozzle ring

1. Loop around the nozzle ring holder (90477) with the lifting gear and secure it to thecrane.

2. Loosen screws (56014) and remove with washers (56011).

3. Pull the nozzle ring (56001) towards the front onto the nozzle ring holder.

4. Screw the screws (B2) into the nozzle ring holder.


Fig. 47: Put down the nozzle ring

u Use the crane to remove and put down the nozzle ring (56001).

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.13 Fitting the nozzle ring (≤ A175-L)


8.13 Fitting the nozzle ring (≤ A175-L)u Coat the screw threads with high-temperature grease.

Fig. 48: Fitting the nozzle ring (A175-L and smaller)

Product Size Tightening torque [Nm]A165-L M10 35A170-L M10 35A175-L M10 35Table 33: Tightening torque (56014)

1. Align the notch (A1) with the flange connection (A2) and slide the nozzle ring (56001) intothe gas inlet casing (51001).

2. Fit screws (56014) with high-temperature grease and with washers (56011).

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.14 Fitting the gas inlet casing (≤ A175-L)


8.14 Fitting the gas inlet casing (≤ A175-L)

8.14.1 Variant with screws

Fig. 49: Fitting the gas inlet casing (A175-L and smaller) – screwed variant

Product Size Tightening torque [Nm]A165-L M16 301) / 140A170-L M18 401) / 200A175-L M22 501) / 380Table 34: Tightening torque (61009)

1) Pre-tightening torque of the screws


2. Loop around the gas inlet casing (51001) with the lifting gear and secure it to the crane.

3. Push gas inlet casing over the guide studs up to the gas outlet casing.

4. Coat two opposite screws (61009) with high-temperature grease and screw in.

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.14 Fitting the gas inlet casing (≤ A175-L)


5. Remove the guide studs (90317) and coat the remaining screws (61009) with high-tem-perature grease and fit.

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.


Fig. 50: Fitting the gas inlet casing (A175-L and smaller) – threaded stud variant


1) Pre-tightening torque of the nuts

1. Coat threaded stud (51086) with high-temperature grease, screw in up to the stop in thegas outlet casing (61001) and tighten hand-tight.

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.15 Fitting the insulation (≤ A175-L)



3. Push gas inlet casing over the threaded studs up to the gas outlet casing.

4. Coat two nuts (51087) with high-temperature grease and fix gas inlet casing in two op-posite positions.

5. Coat remaining nuts with high-temperature grease, fit and then tighten crosswise, ini-tially to the pre-tightening torque and then to the tightening torque.



8.15 Fitting the insulation (≤ A175-L)

Fig. 51: Fitting the insulation (A175-L and smaller)

1. Fit flange connection between gas inlet casing (51001) and bellows.

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).

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.16 Fitting the nozzle ring (≥ A180-L)


8.16 Fitting the nozzle ring (≥ A180-L)u Coat the screw threads with high-temperature grease.

Fig. 52: Looping around the nozzle ring (A180-L and larger)

u Loop around the nozzle ring (56001) with lifting gear on the nozzle ring holder (90477)and fix on the crane.

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.16 Fitting the nozzle ring (≥ A180-L)


Fig. 53: Fitting the nozzle ring (A180-L and larger)

Product Size Tightening torque [Nm]A180-L M12 65A185-L M12 65A190-L M16 170Table 36: Tightening torque (56014)

1. Fit the nozzle ring holder (90477) on the flange of the gas inlet casing (51001) withscrews (B1).


3. Align the notch (A1) on the cam of the nozzle ring (56001) with the flange connection (A2)and slide the nozzle ring into the gas inlet casing.

4. Coat screws (56014) with high-temperature grease and fit with washers (56011).

5. Remove screws (B1) along with the nozzle ring holder (90477).

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.17 Fitting the gas inlet casing (≥A180-L)


8.17 Fitting the gas inlet casing (≥ A180-L)

8.17.1 Variant with screws

Fig. 54: Fitting the gas inlet casing (A180-L and larger) – screwed variant





3. Dismantle and remove support (90451) from the gas inlet casing (51001).

4. Push gas inlet casing over the guide studs up to the gas outlet casing (61001).

5. Coat two opposite screws (61009) with high-temperature grease and screw in.

6. Remove the guide studs (90317).

7. Coat remaining screws (61009) with high-temperature grease and fit. Fit the screws bytightening them crosswise, first to the pre-tightening torque, then to the tighteningtorque.


9. Connect the flanges of the gas inlet casing and the bellows.

10. Fit the insulation segments (51215).

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.17 Fitting the gas inlet casing (≥A180-L)


8.17.2 Threaded stud variant

Fig. 55: Fitting the gas inlet casing (A180-L and larger) – threaded stud variant



1. Coat threaded stud (51086) with high-temperature grease, screw in up to the stop in thegas outlet casing (61001) and tighten hand-tight.


3. Dismantle and remove support (90451) from the gas inlet casing.

4. Push gas inlet casing over the threaded studs up to the gas outlet casing.

5. Coat two nuts (51087) with high-temperature grease and fix gas inlet casing in two op-posite positions.

6. Coat remaining nuts with high-temperature grease, fit and then tighten crosswise, ini-tially to the pre-tightening torque and then to the tightening torque.



9. Fit the insulation segments (51215).

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.18 Axial clearance A after assembly


8.18 Axial clearance A after assembly

WARNINGPhysical hazards due to sharp edges on compressor wheelThe compressor wheel has sharp edges which can result in injury.



CAUTIONClearances outside the toleranceSerious damage to engines or property can be caused by clearances outsidethe tolerance and excessively worn parts.

u Have the components assessed and, if necessary, replaced by an ABB Tur-bocharging Service Station.

Fig. 56: Measuring axial clearance A

The axial clearance (A) of the rotor should always be measured before and after servicework.

Product Axial clearance A [mm]

A165-L 0.32 ... 0.62A170-L 0.33 ... 0.63A175-L 0.38 ... 0.68A180-L 0.41 ... 0.73A185-L 0.43 ... 0.77A190-L 0.45 ... 0.80Table 39: Axial clearance A

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.19 Fitting the diffuser


8.19 Fitting the diffuser

Fig. 57: Fitting the diffuser

Product Size Tightening torque [Nm]A165-L M5 6A170-L M6 10A175-L M8 25A180-L M8 25A185-L M10 45A190-L M10 45Table 40: Tightening torque (77015)

1. Attach lifting gear (L) to the diffuser (79000).

2. Carefully place the diffuser on the wall insert (77000), then remove lifting gear.

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.

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.20 Fitting wall insert


8.20 Fitting wall insert

Fig. 58: Positioning wall insert

u Carefully bring wall insert (77000) into vertical position with the lifting device (90190).

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.20 Fitting wall insert


Fig. 59: Fitting wall insert


1. Attach the new O-ring (77040) to the wall insert (77000).

2. Fit two guide studs (90320) in the upper area of the compressor casing (72000).

3. Align arrow markings of wall insert (77000) and compressor casing to one another.

4. Carefully move the wall insert with diffuser (79000) over the guide studs into the com-pressor casing.

5. Fit a screw (72011) as a safeguard.

6. Change the position of the shackle (90195) with the lifting gear to P1 of the lifting device(90190) and remove with the crane.

7. Move the wall insert fully in, then remove the guide studs (90320).Check the correct position of both casings (arrow markings are aligned to one another).

8. Fit screws (72011).

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.21 Fitting the filter silencer


8.21 Fitting the filter silencer

8.21.1 Design variants

The turbocharger is equipped with one of the following filter silencer variants:

¡ Welded 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.

8.21.2 Fitting the filter silencer (welded)

If the turbocharger is also fitted with a noise package, chapter Fitting the filter silencer withnoise package must be observed.

Fig. 60: Fitting the filter silencer


1. Attach lifting gear to the eyelets of the filter silencer (81000).

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.21 Fitting the filter silencer


2. Position filter silencer on compressor casing.

3. Fit nuts (72004) with washers (72003) and tighten.

u Fit insulation as far as necessary.

8.21.3 Fitting the filter silencer (cast)

If the turbocharger is also fitted with a noise package, chapter Fitting the filter silencer withnoise package must be observed.

Fig. 61: Fitting the filter silencer


1. Attach the lifting gear to the front lug and rear eyelet of the filter silencer (81000).


3. Fit nuts (72004) with washers (72003) and tighten.


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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.22 Fitting the filter silencer with noisepackage


8.22 Fitting the filter silencer with noise packageThe following work steps apply to both the welded and cast versions of the filter silencer.

Before fitting ensure that the individual sealing segments of the gasket (81301) and the gas-ket (74042) are not damaged and that the contact surfaces are clean.

Fig. 62: Fitting the filter silencer with noise package

Product 72004 [Nm] 72043 [Nm]A165-L M14

130 NmM10

45 NmA170-L M16

200 NmM10

45 NmA175-L M18

300 NmM10

45 NmA180-L M20

420 NmM10

45 NmA185-L M22

570 NmM10

45 NmA190-L M24

710 NmM10

45 NmTable 44: Tightening torque (51087)

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1. Position segments of the gasket (81301) on threaded studs of the compressor cas-ing (72000).

2. Attach the lifting gear to the front lug and rear eyelet of the filter silencer (81000), payingattention to the version of the filter silencer.


4. Fit nuts (72004) with washers (72003) and insulating discs (81302) and tighten.

5. Fit insulation ring (81300).

6. Fit air outlet silencer (74040) with gasket (74042) and secure with counter-sunkscrews (74043).


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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.23 Table of tightening torques


8.23 Table of tightening torques

Tightening torques [Nm]

Fig. 63: Overview of tightening torques

Fig. 64: Tightening torques of speed sensor

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Operation Manual / 4 Product description / A100-L8 Disassembly and assembly / 8.23 Table of tightening torques


Position Partnumber

A165-L A170-L A175-L A180-L A185-L A190-L

22 57005 M1250

M1250

M1680

M20160

M20160

M24280

61 1) 6100951087

M1630 2)

140

M1840 2)

200

M2250 2)

380

M2480 2)

480

M27100 2)

700

M30100 2)

92062 1) 72011 M18

370M20500

M24900

M271300

M301700

M332300

63 1) 72004 M14130

M16200

M18300

M20420

M22570

M24710

63a 72002 M1440

M1660

M1880

M20100

M22120

M24140

64 77015 M56

M610

M825

M825

M1045

M1045

65 56014 M1035

M1035

M1035

M1265

M1265

M16170

66 81125 G1/2"45

G1/2"45

G1/2"45

G1/2"45

G1/2"45

G1/2"45

67 86505 M18x1.5150

M18x1.5150

M18x1.5150

M27x2320

M27x2320

M27x2320

Table 45: Overview of tightening torques

1) Tighten crosswise


u Use hydraulic tool for tightening torques exceeding 500 Nm.

Thread size Tightening torque [Nm]M8 28M10 45M12 (compressor casing insulation) 50Table 46: Tightening torque, insulation

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Operation Manual / 4 Product description / A100-L9 Taking a turbocharger out of operation / 9.1 Possible emergency re-pairs


9 Taking a turbocharger out of operation

9.1 Possible emergency repairs

WARNINGDanger of fire and explosion due to lubricating oil leaksLeaking oil may ignite on hot surfaces. This can result in serious injuries topersonnel or fatal accidents.

u Cordon off danger area.

u Raise the alarm and, depending on the situation, stop the engine.

u Seal the oil leak.

u Soak up oil and dispose of in an environmentally compatible manner.


CAUTIONMachine damage in emergency operationThe assembly of the locking device on the turbocharger is only permissiblein emergencies. It is not permitted to lock the rotor for an engine test. Seri-ous damage to engine or property can be caused by non-compliance withthe regulations in the event of an emergency.

u The permissible turbocharger speed for the unlocked turbocharger maynot exceed 45% of nBmax. Take note of the rating plate.

u After locking the turbocharger, contact an ABB Turbocharging ServiceStation and find the nearest port.

u Observe the safety regulations.

u Follow the directives of the enginebuilder.

CAUTIONMachine damage following emergency operationImpermissible vibrations and unbalance values can cause serious damage tothe engine or property during operation. It is imperative that the followingwork is carried out after emergency operation with a locked rotor by an ABBTurbocharging Service Station:

u Remove rotor and check for unbalance

u Install rotor

u Fitting the spinner nose cone

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Operation Manual / 4 Product description / A100-L9 Taking a turbocharger out of operation / 9.2 Taking defective tur-bochargers out of operation


CAUTIONMachine damage due to overheatingSerious damage to engine or property can be caused by the overheating ofintact turbocharger components.

u If there is a lubricating oil leak on the turbocharger, stop the oil supply.

9.2 Taking defective turbochargers out of operationIn the event of turbocharger damage, the turbocharger must be taken out of operation. Inorder to ensure that the engine can continue operation as quickly as possible, observe thefollowing instructions.

9.2.1 Procedure with one turbocharger installed per engine

u Stop the engine.

u Close off oil supply to defective turbocharger.

u Dismantle filter silencer (see chapter Dismantling the filter silencer →59).

u Lock rotor with locking device (see chapter Locking the rotor)

Version ProcedureWith bypass Open bypass

(see chapter Engines with bypass around the turbocharger →97)Without bypass If necessary, remove the nozzle ring

(see chapter Engines without bypass around the turbocharger→98)

Table 47: Bypass procedure

u Continue to operate engine in accordance with enginebuilder's instructions. Observe theprescribed power reduction.

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9.2.2 Procedure with two or more installed turbochargers perengine

CAUTIONMachine damage due to too high turbocharger speedThe permissible turbocharger speed for the unlocked turbocharger may notexceed nBmax. Serious damage to engine or property can be caused by ex-cessive speeds. The values provided by the enginebuilder apply to the max-imum admissible engine load.

u Observe the permissible turbocharger speed for the unlocked turbochar-ger.

u Reduce the engine load if necessary.

u Stop the engine.

u Close off oil supply to defective turbocharger.

u Blank off the inlets and outlets of the defective turbocharger (see chapter Blanking offthe inlets and outlets →99).

u Continue to operate engine in accordance with enginebuilder's instructions. Observe theprescribed power reduction.

9.2.3 Locking the rotor

Fig. 65: Locking the rotor

Product Thread Tightening torques of screws B1 ,B2 [Nm]A165-L M6 10A170-L M8 25A175-L M10 45A180-L M10 45

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Product Thread Tightening torques of screws B1 ,B2 [Nm]A185-L M12 75A190-L M12 75Table 48: Tightening torque B1, B2

1. If present: Unscrew and remove the connecting screw at the centre of the spinner nosecone (25012). Dismantle spinner nose cone with press-off screw (90924).

2. Loosen retaining nuts (N) and remove screws (B1).

3. Turn back the screw (B2) until the slot of the locking device (94003) is free.

4. Position the slot of the locking device on a fin of the wall insert (77000).

5. Align the hole circle of the locking device with the threaded holes in the compressorwheel (25000).

6. Secure the locking device to the compressor wheel with the maximum possible numberof screws (B1). Observe the tightening torque. Assembly with at least 6 screws is mandat-ory. The maximum possible number of screws to be fitted (B1) varies, as the threads in thecompressor wheel are partially occupied by set screws.

7. Fit screws (B2). Observe the tightening torque.

9.2.4 Engines with bypass around the turbocharger

The chapter only applies for engines with one turbocharger and for systems on which theconnections for a bypass have been prepared and the necessary pipe connections have beenprovided.

u Close the lubricating oil supply to the turbocharger.

u Open the bypass around the turbocharger.

u Observe specifications from enginebuilder.

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9.2.5 Engines without bypass around the turbocharger

To obtain a higher engine performance, the nozzle ring can be removed if required (seechapter Disassembly and assembly →51).

Securing 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 beprovided in accordance with the following table. These washers (01) are not supplied by ABB.

Fig. 66: Ensuring clamping of the cover ring

Product h [mm] d1 [mm] d2 [mm]A165-L 3.5 … 4.0 13 20A170-L 3.5 … 4.0 13 20A175-L 4.0 … 5.0 17 28A180-L 4.0 … 5.0 21 34A185-L 4.5 … 6.0 21 34A190-L 4.5 … 6.0 25 39Table 49: Required washers (01)

Part number A165-L A170-L A175-L A180-L A185-L A190-L57005 M12

50 NmM12

50 NmM16

80 NmM20

160 NmM20

160 NmM24

280 NmTable 50: Tightening torque (57005)

1. Remove screws (57005).

2. Fit and tighten screws (57005) with high-temperature grease and washers (01) in accord-ance with the table.

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9.2.6 Blanking off the inlets and outlets

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 gasoutlet are not included in the ABB scope of delivery. The following figure shows the positions where to fit the cover plates.

Fig. 67: Position of cover plates

u Stop the engine.

u Shut off the supply of lubricating oil to the turbocharger.

u Blank off flanges of compressor casing outlet (01), gas inlet (02) and gas outlet (03) by in-stalling cover plates.

u Observe specifications from enginebuilder.

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Operation Manual / 4 Product description / A100-L10 Mothballing the turbocharger / 10.1 Taking the engine out of opera-tion for up to 12 months


10 Mothballing the turbocharger

10.1 Taking the engine out of operation for up to12 months

State of the engine lubricating oil

The turbocharger normally remains attached to the engine. The measures to be taken formothballing the turbocharger depend on the state of the lubricating oil. No measures are re-quired under the following conditions:

¡ Acid number (TAN) < 2 mg KOH/g

¡ The engine lubricating oil is replaced by a preservative oil and circulated with the pre-lub-rication pump before the engine is taken out of operation. Residues of old engine oil areflushed away in this way and the bearing parts are largely protected against corrosion.

Preparations for mothballing

WARNINGHandling operating materials and suppliesSwallowing or inhaling vapours of operating materials and supplies or con-tact with them may be harmful to health.

u Do not breathe in these substances and avoid contact with the skin.

u Ensure proper ventilation.


u Wear personal protective equipment (PPE) according to the materialsafety data sheet.




Wear a respiratory mask to protect against gases.

If the acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measuresare necessary after taking the engine out of operation:

u Dismantle the turbocharger.

u The rotor and bearing parts must be dismantled and subsequently refitted by an ABB Tur-bocharging Service Station.

u Clean all parts.

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Operation Manual / 4 Product description / A100-L10 Mothballing the turbocharger / 10.2 Taking the engine out of oper-ation for more than 12 months


u Coat plain surfaces of steel and cast parts with anticorrosive oil.

u Fit turbocharger completely.

Rotation of the rotor in the stack draught

If the rotor turns as a result of the stack draught:

u Install a blind flange between the outlet flange of the compressor casing and the chargeair duct.

10.2 Taking the engine out of operation for more than12 months

If the engine is taken out of operation, the following variants are possible with regard to theturbocharger:

¡ Turbocharger remains attached to the engine

¡ The casings of the turbocharger remain attached to the engine, the rotor and bearingparts 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 Preparationsfor mothballing.

If the turbocharger remains attached to the engine, see section Taking the engine out of op-eration for up to 12 months, subsection Rotor turning in stack draught.

If the complete turbocharger is removed or the turbocharger is assembled again from theindividual parts:

u Seal all openings of the turbocharger with paraffin paper and wooden lids.

Only dry rooms with 40 ... 70 % atmospheric humidity, in which no water condensation canform, are suitable as storage locations.

State of the mothballed turbocharger

u Check the turbocharger parts annually for corrosion.

u If there are signs of rust: Thoroughly clean parts and renew corrosion protection.

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Operation Manual / 4 Product description / A100-L11 Disposing of turbocharger components /


11 Disposing of turbocharger components

WARNINGHandling damaged thermal insulationDamaged thermal insulation can lead to dust exposure. The glass fibres cancause mechanical irritation of the eyes, skin, and respiratory tracts.

u Avoid the formation of dust.

u Vacuum up dust with a suitable vacuum cleaner.

u Wear a respiratory mask to protect against dusts (P1 or P2 mask).



Wear a respiratory mask to protect against dusts.


Disposal must be environmentally compatible, professional, and in compliance with locallyapplicable regulations.

The turbocharger consists largely of metal (cast iron materials, steel, nickel-steel alloys, alu-minium and bearing brass).

Further components are: Non-metallic materials (filter components of felt and polyethylene),lubricants (engine oil), electronic parts (speed sensor and associated components), andthermal insulation.

u Dispose of metals as scrap metal for recycling.

u Dispose of non-metallic materials as waste.

u Dispose of residues of lubricants as waste oil.

u Dispose of electronic components as electronic waste.

u Dispose of thermal insulation as hazardous waste.Pa

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Operation Manual / 4 Product description / A100-L12 Spare parts / 12.1 Ordering spare parts


12 Spare parts

12.1 Ordering spare parts

CAUTIONSpare part storageAll spare parts that were ordered together with the turbocharger must bekept intact and ready for use.

u Carefully clean any rusted parts and grease them.

Please quote the following data when making queries and ordering spare parts:

¡ Turbocharger type

¡ Serial number of the turbocharger

¡ Designation and part number.

Spare parts can be ordered from any ABB Turbocharging Service Station.

u If different model variants are not taken into account in this document, contact an ABBTurbocharging Service Station.

The customer spare part sets (97070 / 97071) are available for the work described in the op-eration manual. The customer spare part set required depends on the service work beingcarried out on the turbocharger. The parts are only available in the complete set.

Customer spare part set (97070)

Customer spare part set is required for service work on the turbocharger after 36,000 hours.

Quantity Designation Part number3 Washer 560113 Hexagon-head screw 560143 Washer 720033 Hexagon nut 720042 Hexagon-head screw 770151 O-ring 770401 O-ring 790201 O-ring 790211 O-ring 86506

Table 51: Customer spare part set (97070)

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Operation Manual / 4 Product description / A100-L12 Spare parts / 12.1 Ordering spare parts


Customer spare part set (97071)

Customer spare part set is required for service work on the turbocharger after 18,000 hours.

Quantity Designation Part number1 O-ring 770401 O-ring 790201 O-ring 79021

Table 52: Customer spare part set (97071)

u Dispose of replaced parts and parts that are not reusable in a professional and environ-mentally compatible manner.

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Operation Manual / 4 Product description / A100-L12 Spare parts / 12.2 View of turbocharger with part numbers


12.2 View of turbocharger with part numbers

Fig. 68: View of turbocharger with part numbers

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Operation Manual / 4 Product description / A100-L12 Spare parts / 12.2 View of turbocharger with part numbers


Turbocharger

Part number Designation- - Cartridge group51001 Gas inlet casing56001 Nozzle ring51086 Threaded stud51087 Hexagon nut56011 (in the customer spare part set) Washer56014 (in the customer spare part set) Hexagon-head screw57001 Cover ring57005 Hexagon-head screw61001 Gas outlet casing61009 Hexagon-head screw68002 Foot, turbine end72000 Compressor casing72002 Threaded stud72003 (in the customer spare part set) Washer72004 (in the customer spare part set) Hexagon nut72011 Hexagon-head screw74040* Air outlet silencer (option)74042* Gasket (option)77000 Wall insert77015 (in the customer spare part set) Hexagon-head screw77040 (in the customer spare part set) O-ring79000 Diffuser79020 (in the customer spare part set) O-ring79021 (in the customer spare part set) O-ring81000 Filter silencer81300* Insulation ring (option)81301* Gasket (option)81302* Insulating disc (option)Table 53: Turbocharger with part numbers

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Operation Manual / 4 Product description / A100-L12 Spare parts / 12.3 View of cartridge group with part numbers


12.3 View of cartridge group with part numbers

Fig. 69: View of cartridge group with part numbers

NOTICECartridge groupThe cartridge group is not delivered as a fitted assembly. Spare parts mustbe ordered individually.

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Operation Manual / 4 Product description / A100-L12 Spare parts / 12.3 View of cartridge group with part numbers


Cartridge group

Part number Designation21000 Turbine25000 Compressor wheel25008 Threaded stud25009 Ring nut25011* O-ring25012* Spinner nose cone25013* Screw25014* Washer32001 Thrust bearing32101 Radial bearing, compressor end32102 Radial bearing, turbine end32105 Floating disc32106 Axial bearing32109 Sealing disc32159 Locking screw32174 O-ring42001 Bearing casing42008 Socket screw42011 O-ring42015 Sealing cover42039 Hexagon-head screw42041 Gasket42059 Hexagon-head screw42064 Hexagon-head screw42185 Socket screw42186 O-ring42295 Pressure adjusting unit42300 Partition wall42305 O-ring42306 O-ring42307 O-ring42320 Socket screw42458 Blind flange86505 Speed sensor86506 (in the customer spare part set) O-ringTable 54: Cartridge group with part numbers

* Depending on the specification of the turbocharger

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Operation Manual / 4 Product description / A100-L Figures

© Copyright 2020 ABB. All rights reserved. HZTL4034_EN Revision P January 2020

FiguresFig. 1: Layout and function of the turbocharger ...... 4

Fig. 2: Warning plate locations .................................... 6

Fig. 3: Locations of the rating plates .......................... 7

Fig. 4: Fit the lifting gear .............................................. 9

Fig. 5: Placing the turbocharger ................................. 10

Fig. 6: Compressor-end foot....................................... 11

Fig. 7: Turbine-end foot................................................ 11

Fig. 8: Oil temperature at the outlet.......................... 17

Fig. 9: Layout and overview of the speed measure-ment system................................................................... 19

Fig. 10: Replacing the speed sensor .......................... 21

Fig. 11: U-tube manometer at the filter silencer...... 22

Fig. 12: Noise insulation, bellows .............................. 24

Fig. 13: Layout and overview of filter silencer ......... 32

Fig. 14: Dismantling filter ring circumferential part....34

Fig. 15: Opening filter ring lock.................................. 34

Fig. 16: Attaching new filter ring ............................... 35

Fig. 17: Fitting new filter ring ..................................... 35

Fig. 18: Overview of wet cleaning of compressor.. 38

Fig. 19: Filter plug view................................................ 39

Fig. 20: Overview of dry cleaning device................... 41

Fig. 21: Drain pipe diagram......................................... 44

Fig. 22: Weights of assemblies ................................. 53

Fig. 23: Dismantling the filter silencer casing ........ 54

Fig. 24: Fitting the filter silencer casing .................. 55

Fig. 25: Fitting the filter silencer casing ................. 56

Fig. 26: Fitting the filter silencer casing ................. 56

Fig. 27: Fitting the filter silencer casing ................... 57

Fig. 28: Fitting the filter silencer casing ................... 57

Fig. 29: Fitting the bellows ......................................... 58

Fig. 30: Dismantling the filter silencer ..................... 59

Fig. 31: Dismantling the filter silencer...................... 60

Fig. 32: Dismantling the filter silencer with noisepackage ........................................................................... 61

Fig. 33: Pressing off compressor casing................... 62

Fig. 34: Moving out wall insert .................................... 63

Fig. 35: Putting down wall insert ................................ 63

Fig. 36: Putting down wall insert ................................ 64

Fig. 37: Dismantling the diffuser ............................... 65

Fig. 38: Measuring axial clearance A .......................... 66

Fig. 39: Removing the insulation (A175-L and smal-ler)..................................................................................... 67

Fig. 40: Dismantling the gas inlet casing (A175-L andsmaller) – screwed variant ........................................... 68

Fig. 41: Dismantling the gas inlet casing (A175-L andsmaller) – threaded stud variant ................................ 69

Fig. 42: Dismantling the nozzle ring (A175-L andsmaller) ............................................................................ 70

Fig. 43: Dismantling the gas inlet casing (A180-L andlarger) – screwed variant............................................... 71

Fig. 44: Dismantling the gas inlet casing (180-L andlarger) – threaded stud variant................................... 72

Fig. 45: Fitting the nozzle ring holder........................ 73

Fig. 46: Dismantling the nozzle ring .......................... 74

Fig. 47: Put down the nozzle ring................................ 74

Fig. 48: Fitting the nozzle ring (A175-L and smaller) ...75

Fig. 49: Fitting the gas inlet casing (A175-L andsmaller) – screwed variant ........................................... 76

Fig. 50: Fitting the gas inlet casing (A175-L andsmaller) – threaded stud variant ................................ 77

Fig. 51: Fitting the insulation (A175-L and smaller). 78

Fig. 52: Looping around the nozzle ring (A180-L andlarger)............................................................................... 79

Fig. 53: Fitting the nozzle ring (A180-L and larger). 80

Fig. 54: Fitting the gas inlet casing (A180-L and lar-ger) – screwed variant .................................................. 81

Fig. 55: Fitting the gas inlet casing (A180-L and lar-ger) – threaded stud variant........................................ 82

Fig. 56: Measuring axial clearance A .......................... 83

Fig. 57: Fitting the diffuser .......................................... 84

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Operation Manual / 4 Product description / A100-L Figures


Fig. 58: Positioning wall insert .................................. 85

Fig. 59: Fitting wall insert .......................................... 86

Fig. 60: Fitting the filter silencer............................... 87

Fig. 61: Fitting the filter silencer ............................... 88

Fig. 62: Fitting the filter silencer with noise package.89

Fig. 63: Overview of tightening torques.................. 92

Fig. 64: Tightening torques of speed sensor ......... 92

Fig. 65: Locking the rotor ........................................... 96

Fig. 66: Ensuring clamping of the cover ring.......... 98

Fig. 67: Position of cover plates ................................ 99

Fig. 68: View of turbocharger with part numbers 106

Fig. 69: View of cartridge group with part numbers...108

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Operation Manual / 4 Product description / A100-L Tables


TablesTable 1: Related documents .......................................... 3

Table 2: Total weight ..................................................... 8

Table 3: General information about fastening theturbocharger .................................................................. 11

Table 4: Tightening torques (foot screws) .............. 12

Table 5: Tightening angle (foot screws)................... 12

Table 6: Lubricating oil pressure, oil inlet ............... 16

Table 7: Lubricating oil temperature at the inlet ... 17

Table 8: Lubricating oil temperature at the outlet. 17

Table 9: Tightening torques (86505)......................... 21

Table 10: Expected replacement intervals for tur-bocharger parts ........................................................... 28

Table 11: Recommended replacement intervals forturbocharger parts ..................................................... 28

Table 12: Volume of water per cleaning process.... 39

Table 13: Tightening torques (81125) ....................... 39

Table 14: Amount of granulate .................................. 43

Table 15: Malfunctions when starting – Delayedstart-up .......................................................................... 45

Table 16: Malfunctions when starting – Vibrations 45

Table 17: Malfunctions when starting – Rubbing ofrotating parts................................................................ 45

Table 18: Malfunctions during operation – Lubricat-ing oil pressure too low............................................... 46

Table 19: Malfunctions during operation – Drop inspeed ............................................................................. 46

Table 20: Malfunctions during operation – Exhaustgas temperature too high .......................................... 47

Table 21: Malfunctions during operation – Charge airpressure too low........................................................... 47

Table 22: Malfunctions during operation – Charge airpressure too high ......................................................... 48

Table 23: Surging of the turbocharger..................... 48

Table 24: Malfunctions when stopping – Runoutnoises.............................................................................. 49

Table 25: Malfunctions when stopping – Shortenedrunout time.................................................................... 49

Table 26: Malfunctions of the speed measurementsystem ............................................................................ 50

Table 27: Weights of assemblies [kg] ........................ 53

Table 28: Weight of wall insert [kg] ........................... 53

Table 29: Tightening torques (filter silencer screws)..58

Table 30: Axial clearance A........................................... 66

Table 31: Maximum admissible loosening torque(51087) ............................................................................. 69

Table 32: Maximum admissible loosening torque(51087) ............................................................................. 72

Table 33: Tightening torque (56014) ......................... 75


Table 35: Tightening torque (51087).......................... 77




Table 39: Axial clearance A ........................................... 83


Table 41: Tightening torque (72011) .......................... 86


Table 43: Tightening torque (72004)......................... 88


Table 45: Overview of tightening torques................ 93

Table 46: Tightening torque, insulation.................... 93

Table 47: Bypass procedure......................................... 95

Table 48: Tightening torque B1, B2.............................. 97

Table 49: Required washers (01)................................. 98

Table 50: Tightening torque (57005)......................... 98

Table 51: Customer spare part set (97070) ............ 104

Table 52: Customer spare part set (97071) ............ 105

Table 53: Turbocharger with part numbers ........... 107

Table 54: Cartridge group with part numbers....... 109

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a165-l37 operation manual...u indicates an action step. 1. indicates a numbered action step. →...

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