Page 1 Turbocharging Operation Manual / A175-M62 HT603383 Document identification Document number HZTL4033 Revision Language English Original Operation Manual Product identification Serial number HT603383 Customer part number Delivery date (yyyy-mm-dd) 2021-06-04 Weight 4600 Operating limits according to rating plate Speed limit in test rig operation only...
Page 3: Table Of Contents
Commissioning after taking out of operation............40 Monitoring during operation................41 Oil pressure, oil temperature..................41 Turbocharger speed ....................43 Operation and service ..................46 Noise emission ......................46 Service work ......................... 48 © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 4 Taking the engine out of operation for up to 12 months ........124 11.2 Taking the engine out of operation for more than 12 months ......125 Disposing of turbocharger components ............126 © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 5 Table of contents Spare parts ......................127 13.1 Ordering spare parts....................127 13.2 Spare part – Illustrations ..................128 Tools ........................139 Figures......................... 140 Tables ........................142 © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 6: Operation Manual / A170-M
Availability of the Operation Manual The Operation Manual must be available where the turbocharger is used. All persons operating or working on the turbocharger must have read and fully understood the Operation Manual. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 7: Contact Information
This document is valid for different design variants of turbochargers. There may be sections and descriptions of components that are not relevant for a specific turbocharger variant. Please contact an ABB Turbocharging Service Station if you have any questions regarding a design variant (see Contact information at www.abb.com/turbocharging).
Page 8: Layout And Function Of The Turbocharger
Filter silencer / air suction branch 06 Gas inlet casing 02 Compressor wheel Nozzle ring 03 Diffuser 08 Turbine 04 Bearing bush 09 Bearing casing 05 Gas outlet casing Compressor casing © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 9: Fig. 3: Connection Of The Compressor Wheel Cooling
Cooling of the compressor wheel is compulsory to ensure the reliability and replacement in- tervals for the relevant operating conditions. In the turbocharger version with compressor wheel cooling, the cooling air is supplied through the lateral connection (15) in the bearing casing. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 10: Symbols, Definitions
Caution and warning signs are described in chapter Safety. ABB Turbocharging ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging in this document. Official service stations of ABB Turbocharging Official service stations are regularly audited and certified by ABB Turbocharging. See also chapter Contact information →5.
Page 11: Table 1: Definition Of Pictograms
Visually inspect Please note text for numbered work step. See document Dispose of in an environmentally compatible, professional way and in compliance with locally applicable regulations. Table 1: Definition of pictograms © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 12: Storage Of New Turbochargers And Spare Parts
Old VCI corrosion protection emitters must be disposed of in an environmentally compat- ible, professional way and in compliance with locally applicable regulations. Close package. The more tightly the package is sealed, the longer the protection dura- tion. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 13: Fig. 5: Package With Hygrometer
Inspect the package for damage. If the package is damaged, the turbocharger must be in- spected by an ABB Turbocharging Service Station and repacked. After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station: ¡...
Page 14: Safety
Safety Introduction Turbochargers manufactured by ABB reflect the state of the art. The respective safety and health protection requirements are met. This ensures safe operation of the turbocharger. Nevertheless, there may be some residual risks during operation of and work on the tur- bocharger which: ¡...
Page 15: Definition Of Mandatory Signs
Non-compliance or inaccurate compliance with working or operating in- structions indicated by this symbol and the word CAUTION can lead to seri- ous damage to engine or property with grave consequences. Caution signs must always be observed. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 16: Intended Use
These data are given on the rating plate. ABB accepts no liability and rejects all warranty claims for any non-intended uses. [1]Euromot = The European Association of Internal Combustion Engine Manufacturers [2]Directive 94/9/EC concerning equipment and protective systems intended for use in po-...
Page 17: Deflagration On Gas Engines
An ABB Turbocharging Service Station should be instructed to carry out this inspection. Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, are so-called "simple pressure vessels". ¡...
Page 18: Warning Plates On The Turbocharger
If warning plates are not present in the designated locations or not readable, proceed as fol- lows: Order new warning plates from ABB Turbocharging Service Stations. Remove any warning plates that have become unreadable. Clean and degrease the areas designated for the warning plates.
Page 19: Turbocharger Rating Plate
Further data 06 Customer part number 07 Designation for special design 08 Weight of turbocharger in kg 09 Turbocharger type 10 Serial number Year of construction of turbocharger Manufacturing plant © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 20: Fig. 8: Locations Of The Rating Plates
One rating plate (01) each is attached on the left and the right side of the foot of the tur- bocharger. On turbochargers with insulation supplied by ABB, at least one additional rating plate is at- tached to the insulation of the gas outlet casing.
Page 21: Lifting Of Loads
The assembly devices must be completely screwed in and must not loosen during use. Use assembly devices only for the described applications. Put down dismantled components of the turbocharger in such a way that they cannot tip over. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 22: Prerequisites For Operation And Maintenance
Only use original parts from ABB. Original parts and accessories are specially designed for ABB turbochargers. ABB accepts no liability for any damage resulting from the use of non-original parts and cor- responding accessories. © Copyright 2020 ABB. All rights reserved.
Page 23: Hazards During Operation And Maintenance
Do not touch hot surfaces. Observe the warning plate on the turbochar- ger. Wear heat-resistant safety gloves and protective clothing. Wait for the turbocharger to cool down before carrying out any work. Wear safety gloves to protect against thermal hazards. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 24 Operate the turbocharger in compliance with the specifications. Secure the rotor against unintentional rotation during maintenance. Wear safety gloves to protect against mechanical hazards. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 25: Safe Operation
In case of damage, take the turbocharger out of operation immediately and safeguard against accidental/unauthorised use. When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay at- tention to the risks that may occur as a consequence of this energy input. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 26: Safe Maintenance
Keep the floor, equipment, and turbocharger clean. Have oil binding agents ready and provide or keep oil pans at hand. Clean up any spills. Have fire protection means and extinguishing agents available. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 27 Components of the turbocharger can be damaged or destroyed as a result of improper procedures. Only perform operations that are described in this chapter. Only perform operations for which you have received instruction or train- ing. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 28 Wear personal protective equipment (PPE) according to the material safety data sheet. Comply with local legislation. Wear safety goggles. Wear safety gloves to protect against chemical hazards. Wear a respiratory mask to protect against gases. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 29 Dispose of insulation materials properly and in an environmentally com- patible manner in compliance with the legal regulations. Wear safety goggles. Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against chemical hazards. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 30: Removal And Installation
Depending on the specification, the weight specified on the rating plate may be lower than the standard value specified here. Fig. 11: Turbocharger suspension points Product Weight of complete turbocharger unit [kg] A170-M 3100 A175-M 4600 Table 4: Weight of complete turbocharger unit © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 31: Removing The Turbocharger
If present: Remove insulation segments on bearing casing and feet. Attach lifting gear to the suspension lug of the bearing casing and through the boles on the turbine-end foot. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 32: Fig. 13: Removing The Foot Mounting
3. Fit transport screws (90334 / 90335) to secure the sliding block (68003) on the left and right on the turbine-end foot. Lift the turbocharger from the engine and put it down. Cover all oil connections. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 33: Fig. 14: Loosening The Clamping Nut
3. In 1 to 5 rounds, loosen each pressure screw by 90° in circular order until all pressure screws have been relieved. Unscrew and remove the clamping nut by hand. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 34: Installing The Turbocharger
If present: Remove insulation segment on the bearing casing. Attach lifting gear to the suspension lug of the bearing casing and the turbine-end foot. Remove the covers from the oil connections. Align turbocharger and place on bracket. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 35: Fig. 16: Removing Auxiliary Screw
Tighten clamping nuts as described in the following sections. Connect all gas, air and oil pipes. If present: Re-fit the insulation segments. If present: Connect cable to speed sensor. Compressor-end (CE) foot Fig. 17: Compressor-end foot © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 36: Fig. 18: Turbine-End Foot
Table 8: Foot screws, number of cup springs Holes b1/b2 are needed to achieve the required clamping length. An additional drill hole is not needed at the higher turbine-end foot side (01). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G...
Page 37: Fig. 19: Ce Foot Contact Surface
→34) on the foot of the turbine end (TE) with high-temperature grease. →36). Tighten clamping nuts on turbine end (TE) (see Tightening the clamping nut © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 38: Fig. 21: Tightening The Foot Screws (1)
3. Tighten clamping nut (c) by hand. 4. Screw back clamping nut by ¼ of a turn (90°). The distance between the thrust washer and the clamping nut is now about 1 mm. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G...
Page 39: Fig. 22: Tightening Procedure
4. Work in a circle to tighten all pressure screws to 100 % of the tightening torque specified in the table. 5. Tighten pressure screws to 100 % in 5 … 7 rounds until the required residual tightening angle of < 20° is achieved. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 40: Commissioning
Filtering of the lubricating oil with a filter mesh width of ≤ 0.050 mm is sufficient for the tur- bocharger. 4.1.4 Oil pressure Comply precisely with the oil pressure before the turbocharger for trouble-free operation. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 41: Inspection Procedures
Check oil inlet temperature. The admissible values are specified in section Oil supply. Gas, air and oil pipes After starting the engine, check all gas, air and oil pipes for leaks. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 42: Commissioning After Taking Out Of Operation
Lubricants and pastes used during assembly can liquefy or vaporise and escape as oily fluids during the initial hours of operation. Continual escape of an oily fluid indicates an oil leak. If there is a leak, contact an ABB Turbocharging Service Station. Commissioning after taking out of operation...
Page 43: Monitoring During Operation
The lubricating oil pressure must be monitored during operation and the necessary pressure assured at the oil inlet. For monitoring the lubricating oil pressure, ABB Turbocharging recommends installing a manometer "M". If the pressure is controlled electronically, the relevant signals should be triggered at the warning and alarm values.
Page 44: Table 11: Oil Temperature At The Inlet
Table 12: Oil temperature at the outlet If the turbocharger has been operated for a longer period of time outside the admissible range, ABB Turbocharging recommends having the turbocharger inspected by an ABB Tur- bocharging Service Station. © Copyright 2020 ABB. All rights reserved.
Page 45: Turbocharger Speed
Fig. 24: Speed measurement 86505 Speed sensor 86506 O-ring 86515 Cable connector 86526 F/I converter 86528 Tachometer 42047 Screw plug 32118 Auxiliary bearing with cams Alternative mounting position for speed sensor © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 46 Check the pressure loss of the alternative air inlet and compare it with normal values. If the engine can be stopped temporarily: Inspect air lines, gas piping and the turbochargers and remedy any malfunctions. In any case, contacting the nearest ABB Turbocharging Service Station is recommended. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G...
Page 47 5.2.5 Malfunction of the speed measurement system The possible reasons for malfunction of the speed measurement system are described in chapter Troubleshooting (Reasons for malfunction of the speed sensor). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 48: Operation And Service
Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 : A-weighted emission sound pressure level The enginebuilder must provide acoustically equivalent measures in case of deviating in- sulation versions © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 49: Fig. 25: Noise Insulation, Bellows
Suggestion for noise insulation, bellows Fig. 25: Noise insulation, bellows Compressor casing Bellows Charge air duct / scavenging air duct Insulation cushion Insulation mat (at least 15 mm) Sheet metal cover © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 50: Service Work
Agree on a specific service interval with ABB Turbocharging. 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 the last service.
Page 51 6 Operation and service / 6.2 Service work 6.2.3 Service work every 8000 ... 16000 hours of operation Checking and assessment of the rotor and the bearing parts must be carried out by an ABB Turbocharging Service Station. Dismantle the turbocharger.
Page 52 Pressure loss in the charge air cooler ¡ Lubricating oil pressure and lubricating oil temperature If present: ¡ Air temperature after the compressor and after the charge-air cooler ¡ Pressure loss in the filter silencer © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 53: Expected Replacement Intervals
¡ Turbine cleaning process Influencing parameters for exhaust gas-charged, rotating components ¡ Fuel quality (gas, MDO, HFO) ¡ Frequency of turbine cleaning ¡ Turbine cleaning process ¡ Load profile © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 54: Stopping The Engine
Let the engine continue to run at idling speed for 10 minutes before stop- ping it. Post-lubrication can also be used instead of engine idling (see Pre-lubric- ation and post-lubrication →38). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 55: Periodic Maintenance
Maintenance work includes regular visual controls and cleaning operations which are inten- ded to ensure the trouble-free functioning of the turbocharger. Described maintenance points: ¡ Filter silencer ¡ Diffuser ¡ Compressor ¡ Turbine and nozzle ring © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 56: Cleaning The Filter Silencer
Rinse in cold water. Avoid high mechanical loads (water jet). Let the filter ring dry completely before assembling. Dirty water and mild detergent must be disposed of in compliance with locally applicable regulations. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 57 Have any heavily contaminated absorption segments and filter rings as well as damaged connecting rods replaced by an ABB Turbocharging Service Station. Fitting the cover grids and absorption segments (see Fig. 26: Cleaning the filter silencer →54)
Page 58: Fig. 27: Cleaning The Filter Silencer (2)
Fit lock nuts (81273) on screws (81272) and tighten with the following tightening torque: Lock nut Tightening torque [Nm] 81273 Table 16: Tightening torque (81273) Fit the filter ring (81265), if present. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 59: Cleaning The Slotted Diffuser
When cleaning, please note that this should only take place using lightly pressurized air, a brush and a moist cleaning cloth. Have any heavily contaminated or damaged diffusers replaced by an ABB Turbocharging Service Station. © Copyright 2020 ABB. All rights reserved.
Page 60: Cleaning The Compressor During Operation
The time period between the periodical cleaning cycles depends greatly on the operating conditions. Cleaning should normally be done every 25 … 100 hours of operation. If the specified cleaning intervals are incompatible with operation of the engine, contact ABB. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 61 CAUTION Volume of water Uncontrolled volumes of water can damage the turbocharger and the en- gine. Never connect the water line without the orifice specified for the tur- bocharger. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 62: Table 17: Compressor Cleaning Parameters
Cleaning parameters for each compressor Product Engine load Water pres- Water injection Cleaning interval Ø of ori- sure period fice [bar] [mm] A170-M 50 … 100 2.5 … 4.5 25 … 100 A175-M Table 17: Compressor cleaning parameters © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 63 To avoid a reduction in engine availability, the compressor stage can be cleaned at re- duced engine load during the drying time after wet cleaning of the turbine has been com- pleted (see section Cleaning turbine and nozzle ring →64). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 64: Fig. 29: Operation Of Water Pressure Vessel
On V-engines with several turbochargers per engine, parallel cleaning of both turbochargers is recommended. This cleaning process is faster and reduces the risk of surging of the tur- bocharger. To carry out the cleaning operation checked and recommended by ABB Turbocharging, the following prerequisites must be fulfilled: ¡...
Page 65: Table 18: Compressor Cleaning Parameters
After cleaning operations, a waiting period of at least 5 minutes is required for the tur- bocharger to dry. If the cleaning is unsuccessful after three attempts, we recommend having the turbocharger checked and cleaned by an ABB Turbocharging Service Station in the event of unsatisfactory engine values. Cleaning parameters for each turbocharger compressor...
Page 66: Cleaning Turbine And Nozzle Ring
The use of fuels with poor quality in conjunction with high exhaust gas temperatures can lead to extremely hard deposits on turbine components. ABB Turbocharging recommends the use of fuels with low ash, sulphur, sodium and vana- dium contents. Consequences of contamination: ¡...
Page 67 7.5.3 Cleaning method Cleaning of the turbine and the nozzle ring during operation is carried out by the cleaning method described in the following and is tested and approved by ABB Turbocharging: ¡ Wet cleaning Wet cleaning makes use of various effects. These effects are used with varying levels of in- tensity, depending on the type of contamination: ¡...
Page 68: Fig. 30: Turbine And Nozzle Ring Cleaning Cycle
Prerequisites: Procedure without automated cleaning The following operating state and the following prerequisites have been tested and ap- proved by ABB Turbocharging for cleaning operations: Set the engine load between 20 … 50 % so that the turbine inlet temperature is between 380 … 430 °C.
Page 69: Fig. 31: Cleaning Cycle Of Turbine And Nozzle Ring With Load Ramp
7 Periodic maintenance / 7.5 Cleaning turbine and nozzle ring Procedure with automated cleaning The following operating state and the following prerequisites have been tested and ap- proved by ABB Turbocharging for cleaning operations: Set the engine load as follows: ¡...
Page 70: Fig. 32: Procedure Wet Cleaning Of Turbine And Nozzle Ring
If there is no drainage system, the amount of water injected can be mon- itored with a flowmeter in the water supply. The permitted amount of water must be de- termined with the help of an ABB Turbocharging Service Station. To be observed during cleaning ¡...
Page 71: Table 19: Cleaning Parameters Wet Cleaning Of Turbine And Nozzle Ring
Table 19: Cleaning parameters Wet cleaning of turbine and nozzle ring 1) Water pressure p as guideline value: water ¡ 2.3 bar when used with an axial gas inlet casing ¡ 3 bar when used with a radial gas inlet casing © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 72: Troubleshooting
To prevent significant loss of efficiency, specific tolerances must be fulfilled. ¡ If there is any doubt about the extent of the rubbing, contact an ABB Tur- bocharging Service Station. ¡...
Page 73: Malfunctions During Operation
Turbochar- Heavy contamination of the turbine Clean (see chapter Periodic mainten- and/or nozzle ring ance →53) Damaged rotor components or bearing Contact ABB Turbocharging Service Station Engine Defect on the connected cylinders in Contact enginebuilder pulse charging Pipes Defects, such as leaks, in the exhaust...
Page 74: Table 26: Malfunctions During Operation - Exhaust Gas Temperature Too High
Injection mistimed Set correctly Valve control misadjusted Pipes Pipes downstream to the compressor Repair. outlet not sealed. Table 27: Malfunctions during operation – Charge air pressure too low © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 75: Surging Of The Turbocharger
Gradually reduce the engine load. Have the cause clarified and remedied immediately by an ABB Turbochar- ging Service Station. Have parts assessed for damage and, if necessary, replaced by an ABB Turbocharging Service Station. Surging of the turbocharger Possible causes...
Page 76: Malfunctions When Stopping
Possible causes Remedy Turbochar- Turbocharger contaminated Clean Bearing damaged Contact an ABB Turbocharging Service Station Rotor rubbing Foreign object in the turbocharger Table 31: Malfunctions when stopping – Shortened runout time © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 77: Speed Measurement System
Table 34: Malfunction, Measured speed too low NOTICE Other causes of malfunction If none of the measures described above remedy the malfunction, have the speed measurement system checked by an ABB Turbocharging Service Sta- tion. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G...
Page 78: Disassembly And Assembly
The specified tightening torques of the bolted connections must be observed. Tightening torques for assembly devices Unless otherwise described, the screws and nuts of the assembly devices supplied by ABB must be tightened in such a way that they are tight-fitting.
Page 79 Use assembly devices only for the described applica- tions. ¡ Lifting gear Equipment for the lifting and transporting of loads (ropes, chain block, crane). Lifting gear is not supplied by ABB. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 80: Weight Of Assemblies
Radial air suction branch Wall insert Diffuser Compressor casing Cartridge group 1100 Turbine diffuser Cover ring Nozzle ring Gas inlet casing, radial Gas inlet casing, axial Table 35: Assembly weights © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 81: Removing The Air Inlets
1. Loop lifting gear through the fin on the filter silencer and secure to the eyelets at the rear with shackles (90195). 2. Loosen nuts (72027) and remove with washers (72028). Remove and put down filter silencer. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 82: Fig. 35: Removing The Air Suction Branch
Fig. 35: Removing the air suction branch 1. Loop lifting gear around air suction branch. 2. Loosen and remove the nuts (72027) with washers (72028). Remove and put down the air suction branch. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 83: Axial Clearance A Prior To Disassembly
Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. Fig. 36: Axial clearance...
Page 84: Removing The Compressor Casing
Depending on the hole pattern of the wall insert (77000), the screws (90197) cannot be fitted symmetrically. 5. Put on shackle (90195) and fasten to lifting gear. 6. Remove locking screw (72011). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 85: Fig. 38: Transporting And Turning Wall Insert
1. Fit support angle (90025) with bolts and nuts. 2. Carefully turn wall insert over support angle (90025) and place on supports. Place wall insert such that lifting device (90190/90195) can be removed. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G...
Page 86: Fig. 39: Removing The Diffuser
Removing the diffuser Fig. 39: Removing the diffuser 1. Remove and dispose of the O-ring (77040). 2. Loosen and remove screws (77015). 3. Loop lifting gear around diffuser (79000) and remove diffuser. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 87: Fig. 40: Removing The Compressor Casing
(72000) and secure to crane. 2. Loosen and remove nuts (61037). 3. Use press-off nuts (61090) to fully press off and remove compressor casing (72000). 4. Remove and dispose of the O-ring (42012). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 88: Removing The Cartridge Group
Check that the oil orifices have been correctly installed. Version with compressor wheel cooling Dismantle air supply line (see Compressor wheel cooling). Separate oil inlet and outlet pipes. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 89: Fig. 42: Removing Cartridge Group 1
3. Press off the spinner nose cone (25012) using the press-off screw (90917). 4. Loosen and remove the screw (61059). 5. Loosen and remove nuts (42128). 6. Attach lifting gear to bearing casing. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 90: Fig. 43: Removing Cartridge Group 2
3. Fit supports (90450) and put down cartridge group. 4. Remove guide studs (90490). Fit and tighten the spinner nose cone (25012) together with socket screw (25013) and washer (25014) until hand-tight. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G...
Page 91: Removing The Nozzle Ring
5. Pull turbine diffuser (63000) out as far as it will go at guide plates. 6. Loop around turbine diffuser and secure to lifting gear. 7. Remove nuts (61037) and guide plates (90328). 8. Completely pull out and put down turbine diffuser. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 92: Fig. 46: Removing Cover Ring 1
Press off cover ring with the press-off screws (90916 for A170-M or 90901 for A175-M) in the provided holes. 3. Pull cover ring (57001) out as far as it will go at the guide plates. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G...
Page 93: Fig. 47: Removing Cover Ring 2
1. Bend open locking washers (56015), loosen and remove screws (56014). 2. Secure retaining plate (90338) with screws (90339) and hook guide rod (90336) into re- taining plate. 3. Fit guide plate (90328) with nuts (61037). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 94: Fig. 49: Removing Nozzle Ring 2
Blocked areas on nozzle ring If a nozzle ring is blocked in some areas or is covered by loose parts, it is recommended to appoint an ABB Turbocharging Service Station to inspect the turbine blades and carry out a crack inspection.
Page 95: Installing The Nozzle Ring
2. Using lifting gear, position nozzle ring (56001) on guide rod (90336). Do not take strain off lifting gear yet. 3. Fit guide plate (90328) with nuts (61037). 4. Remove the lifting gear. 5. Position nozzle ring (56001) in gas outlet casing. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 96: Fig. 51: Installing Nozzle Ring 2
9. Fit the nozzle ring (56001) on the gas inlet casing (51001) using the screws (56014) and locking washers (56015). 10. Bend over locking washers (56015). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 97: Fig. 52: Installing Cover Ring
4. Slide in cover ring as far as it will go. 5. Remove guide plates (90328) and nuts (61037). 6. Coat threads of screws (57005) with high-temperature grease. 7. Fit and tighten screws (57005). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 98: Fig. 53: Installing Turbine Diffuser 1
2. Fit guide plates (90328) with nuts (61037). 3. Remove the lifting gear. 4. Slide in turbine diffuser as far as it will go. 5. Remove nuts (61037), guide plates (90328) and guide studs (90802). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 99: Fig. 54: Installing Turbine Diffuser 2
Fig. 54: Installing turbine diffuser 2 Product Size Tightening torque [Nm] A170-M A175-M Table 39: Tightening torque (61069) 6. Coat threads of screws (61069) with high-temperature grease. 7. Fit and tighten screws (61069). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 100: Installing The Cartridge Group
1. Fasten lifting gear to bearing casing and lift cartridge group slightly. 2. Remove support (90450). 3. Using two guide rods (90490), carefully move in cartridge group. 4. Remove guide rods (90490). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 101: Fig. 56: Installing The Cartridge Group 2
1. Coat thread of screw (61059) and two bolts for the nuts (42128) with high-temperature grease. 2. Secure cartridge group with screw (61059) and nuts (42128). 3. Remove the lifting gear. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 102: Fig. 57: Installing The Cartridge Group 3
Check that the oil orifices have been correctly installed. Remove temporary covers on oil connections. Fit all oil pipes according to instructions of enginebuilder. Version with compressor wheel cooling Fit air supply line (see Compressor wheel cooling). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 103: Fitting The Spinner Nose Cone
9 Disassembly and assembly / 9.10 Fitting the spinner nose cone 9.10 Fitting the spinner nose cone If present: The spinner nose cone (25012) and Loctite®542 are supplied by the ABB service station to- gether with the overhauled cartridge group. CAUTION Total failure of turbocharger...
Page 104: Fig. 59: Fitting The Spinner Nose Cone (25012)
6. Measure and note down distance Z between spinner nose cone and compressor wheel at no less than three points around the circumference. Permissible distance Z: 0.1 – 0.7 mm Permissible difference of the measurements: ± 0.1 mm © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 105: Installing The Compressor Casing
1. Distributed evenly around the circumference, screw the press-off nuts (61090) onto the studs of the bearing casing and turn them by hand until they are at the end of the thread. 2. Grease the new O-ring (42012) and fit it. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G...
Page 106: Fig. 61: Installing Diffuser
1. Loop around diffuser (79000) with lifting gear and position it on the wall insert (77000). 2. Attach diffuser with screws (77015). 3. Grease the new O-ring (77040) and fit it. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G...
Page 107: Fig. 62: Turning And Moving In Wall Insert
2. Remove support angle (90025), screws and nuts. 3. Fit guide studs (90319). 4. Carefully install the wall insert (77000) in the compressor casing. Make sure both mark- ings are in the correct position. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 108: Fig. 63: Fitting Wall Insert
2. Slide wall insert (77000) into compressor casing up to stop and remove guide stud (90319). 3. Secure wall insert with screws (72011) and washers (72008). For assembly of the alternative air inlet, see section Installing air inlets. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 109: Axial Clearance A After Assembly
Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. Fig. 64: Axial clearance...
Page 110: Installing The Air Inlets
2. Fit air suction branch together with nuts (72027) and washer (72028). Observe tightening torque. Disconnect all air lines according to the instructions of the enginebuilder. Dismantle insulation as far as necessary. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 111: Fig. 66: Installing The Filter Silencer
2. Fit filter silencer together with nuts (72027) and washers (72028). Observe tightening torque. Tighten nuts that are difficult to access with a fork/ring spanner. Fit insulation. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 112: Removing And Installing Turbine-End Nozzle Ring
Blocked areas on nozzle ring If a nozzle ring is blocked in some areas or is covered by loose parts, it is re- commended to appoint an ABB Turbocharging Service Station to inspect the turbine blades and carry out a crack inspection.
Page 113: Fig. 67: Removing The Nozzle Ring At The Turbine End (Radial Gas Inlet Casing)
3. Loosen screws (61009) and move out gas inlet casing with nozzle ring. 4. Bend open locking washers (56015), loosen and remove screws (56014). 5. Pull out nozzle ring (56001). 6. Remove spiral-wound gasket (61050) and provide new one. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 114: Fig. 69: Installing The Nozzle Ring At The Turbine End (Radial Gas Inlet Casing)
Installing the nozzle ring Fig. 69: Installing the nozzle ring at the turbine end (radial gas inlet casing) Fig. 70: Installing the nozzle ring at the turbine end (axial gas inlet casing) © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 115: Table 52: Tightening Torque (56014)
6. Remove the guide studs (90321). 7. Fit remaining screws (61009), then crosswise tighten all screws (61009). Observe tight- ening torque. 8. If present: Fit connecting pipe for turbine cleaning Refit dismantled insulation. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 116: Table Of Tightening Torques
Operation Manual / A170-M.. - A175-M.. 9 Disassembly and assembly / 9.15 Table of tightening torques 9.15 Table of tightening torques Fig. 71: Tightening torques 1 Fig. 72: Tightening torques 2 © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 117: Table 54: Tightening Torques
56014 61009 57005 42059 72011 1000 72027 72026 25013 86505 M18x1.5 M18x1.5 Table 54: Tightening torques 1) Tighten screws (61009) crosswise in four steps (see Table 55: Tightening torques 61009 →116). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 118: Fig. 73: Flange Tightening Sequence
9 Disassembly and assembly / 9.15 Table of tightening torques Tightening sequence Fig. 73: Flange tightening sequence Product Tightening torque (61009) [Nm] Step 1 Step 2 Step 3 Step 4 A170-M hand-tight A175-M hand-tight Table 55: Tightening torques 61009 © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 119: Taking A Turbocharger Out Of Operation
The permissible turbocharger speed for the unlocked turbocharger may not exceed n . Take note of the rating plate. Bmax After locking the turbocharger, contact an ABB Turbocharging Service Station and find the nearest port. Observe the safety regulations. Follow the directives of the enginebuilder.
Page 120: Locking The Rotor
A locked rotor must be removed after emergency operation and checked for unbalance (see chapter Removing the cartridge group). The unbalance check must be carried out by an ABB Turbocharging Service Station. Exception The exception concerns customer requirements for test bed runs of new engines at a max- imum engine load of up to 25 %.
Page 121: Fig. 74: Fitting The Locking Device
Rotate compressor wheel in such a way that the holes in the lifting spigot (90427) corres- pond with the holes in the assembly/disassembly device (94003). 5. Secure assembly/disassembly device (94003) to the lifting spigot (90427) with screws (94006). © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 122 In pulse charging (2 to 4 gas inlets), the engine can be operated at a maximum engine load of up to 20 %. The pressure in the charge air receiver must not exceed 0.5 bar over- pressure. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G...
Page 123: Fitting The Cover Plate
Table 58: Cover plate dimensions 2 ⍺ 1 ⍺ 2 ⍺ 3 Product A170-M 4 x 90° 37.5° 24 x 15° A175-M 4 x 90° 37.5° 24 x 15° Table 59: Cover plate dimensions 3 © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 124 In engines with separate air and exhaust gas receivers, no further measures are necessary. The engine can be operated as a suction engine according to the instructions of the en- ginebuilder. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G...
Page 125: Blanking Off The Inlets And Outlets
Close the lubricating oil supply to the turbocharger. Open the bypass around the turbocharger. Observe specifications from enginebuilder. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 126: Mothballing The Turbocharger
If the acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking the engine out of operation: Dismantle the turbocharger. The rotor and bearing parts must be dismantled and subsequently refitted by an ABB Tur- bocharging Service Station. Clean all parts.
Page 127: Taking The Engine Out Of Operation For More Than 12 Months
¡ The casings of the turbocharger remain attached to the engine, the rotor and bearing parts are dismantled by an ABB Turbocharging Service Station and stored separately ¡ The turbocharger is completely removed, either as a whole unit or in individual parts For the measures always necessary for preparing the turbocharger parts for mothballing, see section Taking the engine out of operation for up to 12 months, subsection Preparations...
Page 128: Disposing Of Turbocharger Components
Dispose of metals as scrap metal for recycling. Dispose of non-metallic materials as waste. Dispose of residues of lubricants as waste oil. Dispose of electronic components as electronic waste. Dispose of thermal insulation as hazardous waste. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 129: Spare Parts
Designation and part number. Spare parts can be ordered from any ABB Turbocharging Service Station. If different model variants are not taken into account in this document, contact an ABB Turbocharging Service Station. Dispose of placed and unusable parts in an environmentally-friendly and professional manner in accordance with the local regulations.
Page 130: Spare Part - Illustrations
Socket screw 77040 O-ring 86506 O-ring (speed sensor) Table 60: Customer spare part set (97070) 13.2 Spare part – Illustrations The spare parts lists shown below are only available in English. © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 131: Table 61: Spare Parts - Cartridge
42040 Oil outlet flange 42041* Gasket 42044 Flange 42045* Gasket 42058 Verbusripp washer 42059* Hexagon-head screw 42063 Verbusripp washer 42064* Hexagon-head screw 42170 Insulation Table 61: Spare parts - Cartridge © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 132: Table 62: Spare Parts - Bearing Casing
42015 Sealing cover 42016 Screw 42043 Orifice 42049 Locking ring 42099 Socket screw 42300 Partition wall 42305* O-ring 42306* O-ring 42400 Heat shield Table 62: Spare parts - Bearing casing © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 133 Turbine blade 32001* Thrust bearing 32003* O-ring 32101* Radial bearing compressor end 32102* Radial bearing turbine end 32105* Floating disc 32106* Axial bearing 32107 Bearing bush 32118* Auxiliary bearing © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 134: Table 63: Spare Parts - Rotor And Bearing Parts
Table 63: Spare parts - Rotor and bearing parts Water vessel 27005(p) 27000 (p) = pre-assembled Part no. Designation 27000 Water vessel 27005(p) Plug Table 64: Spare parts - Water vessel © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 135: Table 65: Spare Parts - Gas Inlet Casing Axial
Screw plug 51256 Union nut 51258 Pressure plate 51259 Hexalobular-head screw 52208 Nozzle 56001 Nozzle ring 56014* Hexagon-head screw 56015* Locking disc Table 65: Spare parts - Gas inlet casing axial © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 136: Table 66: Spare Parts - Gas Inlet Casing Radial
Verbusripp washer 51064 Screw 51077 Blind flange 51078 Gasket 51169 Screw plug 56001 Nozzle ring 56014* Hexagon-head screw 56015* Locking disc Table 66: Spare parts - Gas inlet casing radial © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 137: Table 67: Spare Parts - Cleaning Device For Gas Inlet Casing
51322 Hexagon-head screw 51323 Gasket 51324 Flange 51325 Union bush 51327 Pipe 51328 Hexagon socket head pipe 51329 Gasket Table 67: Spare parts - Cleaning device for gas inlet casing © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 138: Table 68: Spare Parts - Compressor Casing
Washer 72011 Hexagon-head screw 72026 Stud 72027 Hexagon nut 72028 Washer 72060 Insulation 77000 Wall insert 77015* Socket screw 77040* O-ring 79000 Diffuser Table 68: Spare parts - Compressor casing © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 139: Table 69: Spare Parts - Filter Silencer
Cover sheet-metal 81140** Cleaning nozzle 81141** Pressure spring 81265** Filter ring 81266 Cover grid 81269 Connection rod 81272 Hexagon-head screw 81273 Hexagon nut Table 69: Spare parts - Filter silencer © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 140: Table 70: Spare Parts - Air Suction Branch Radial
Screw plug 82006 Gasket 82007 Screw plug 82008 Gasket 82140** Cleaning nozzle 82141** Pressure spring 82143 Screw plug 82170 Screw plug Table 70: Spare parts - Air suction branch radial © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Rev.G December 2020...
Page 141: Tools
94007 Hexagon-head screw 90321 Guide stud Table 71: Customer tool set 90009 This tool set can be ordered from any ABB Turbocharging Service Station. The following spe- cifications must be included in the order: ¡ Turbocharger type ¡ Designation and part number of the tool set.
Page 142: Figures
Fig. 31: Cleaning cycle of turbine and nozzle ring Fig. 62: Turning and moving in wall insert....105 with load ramp.............. 67 Fig. 63: Fitting wall insert........... 106 Fig. 64: Axial clearance ..........107 © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Revision G December 2020...
Page 143 Fig. 73: Flange tightening sequence......116 Fig. 74: Fitting the locking device ......119 Fig. 75: Cover plate (01) / spacer sleeves (02) dimen- sions................121 Fig. 76: Fitting the cover plate........122 © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Revision G December 2020...
Page 144: Tables
................71 Table 54: Tightening torques........115 Table 26: Malfunctions during operation – Exhaust gas temperature too high ........... 72 Table 55: Tightening torques 61009......116 Table 56: Locking device tightening torque.... 119 © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Revision G December 2020...
Page 145 Table 68: Spare parts - Compressor casing... 136 Table 69: Spare parts - Filter silencer...... 137 Table 70: Spare parts - Air suction branch radial.. 138 Table 71: Customer tool set 90009......139 © Copyright 2020 ABB. All rights reserved. HZTL4033_EN Revision G December 2020...

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