10 Disassembly and assembly
10.1 Introduction
The precondition for the work described in the following is a turbocharger removed from the engine (see chapter Removal and installation).
Further operations
Further operations that are not described here must only be carried out by trained staff of an ABB Turbocharger service station.
Only perform operations that are described in this chapter.
Marking casing position for assembly
ABB Turbo Systems recommends marking casing positions prior to disas-sembly.
Identification of the assembly devices
Not all assembly devices are marked with a part number. Identification is guaranteed by the tool list. This list is enclosed in the toolbox.
Servicing the assembly devices
Assembly devices must be checked for damage before and after use.
Visual inspection for corrosion, cracks, deformation and wear.
Damaged assembly devices must no longer be used and must be re-placed.
Customer spare part kit
Before starting operations, make sure the required customer spare part kits are available.
See chapter Reserve and spare parts.
Oil orifice
When disassembling the turbocharger, a fitted oil orifice must not be removed.
CAUTION
NOTICE
WARNING
10 Disassembly and assembly Page 72 / 95 Tightening torques for components of the turbocharger
The specified tightening torques of the screw fittings must be observed (see chapter Disas-sembly and asDisas-sembly, section Table of tightening torques).
Tightening torques for assembly devices from ABB Turbo Systems
Unless described otherwise, the screws and nuts of the assembly devices must be tightened so they rest firmly against the surface.
Definition of terms
Attachment point
Defined loading point on a component or an assembly (blind hole thread, eyelet, lug).
Assembly device
Devices that are fitted on the turbocharger in order to obtain an attachment point. Assem-bly devices are specially constructed and designed for the defined use, they are not trad-ing goods. Use assembly devices only for the described applications.
Lifting gear
Equipment for the lifting and transporting of loads (ropes, chain hoist, crane). Lifting gear is not supplied by ABB Turbo Systems AG.
Swivel lifting eyes to be used
Two swivel lifting eyes are required for the safe lifting of loads, which are not supplied by ABB Turbo Systems.
Swivel lifting eye
Turbochar-ger type Thread
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10.2 Weights of assemblies
The specified weights of the individual parts or assemblies are rounded-up standard values.
1
* Including burst protection
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10.3 Removing / Installing air-inlets
81000 81010
82000
82010
72020
82000
82010 51002 A150...A155
A130...A145
Figure 23
A130 to A145
Loosen V-clamp (72020) and remove filter silencer (81000) with O-ring (81010) or air suc-tion branch (82000) with O-ring (82010).
A150 to A155
Undo the fastening strip connection (51002) and remove filter silencer (81000) with O-ring (81010) or air suction branch (82000) with O-ring (82010).
Installing air-inlets A130 to A145
Fit the filter silencer (81000) or air suction branch (82000) with the V-clamp (72020).
A150 to A155
Fit the filter silencer (81000) or air suction branch (82000) with the fastening strip connec-tion (51002).
Observe tightening torque (See Table 33).
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10.4 Removing / Installing compressor casing
72000
79000 79040 79041 72012
72011 77005
77000 90042
a
Figure 24
Loosen screws (72011) and remove with the fastening strips (72012).
Attach swivel lifting eyes (a) to the compressor casing and lifting gear.
Remove the compressor casing (72000) together with the wall insert (77000).
Loosening the compressor casing with press-off tool
If the compressor casing cannot be loosened, it can be pressed off against the turbine casing with the press-off tool (90042).
Axial force of the press-off tool
A high axial force can be generated with the press-off tool. If this tool is han-dled improperly (pressing off with too much force on one side), this may re-sult in damage to the rotor.
Use the tool on both sides alternatingly and make sure not to press off too hard on either side.
NOTICE
CAUTION
10 Disassembly and assembly Page 76 / 95 Disassembly of wall insert A145 to A155
77005 77000 90258 a
Figure 25
A145
Attach the lifting beam (90258) to the wall insert (77000).
Attach swivel lifting eye (a) to the lifting beam.
Remove wall insert (77000) using lifting gear.
A150 to A155
Attach the swivel lifting eye M8 to the wall insert (77000).
Remove the wall insert (77000).
Installing the compressor casing To be observed:
Install the compressor casing in reverse order accordingly (See Figure 24)
Always replace O-rings (see section Reserve and spare parts).
Thoroughly clean the fastening strips (72012) before assembly.
Observe tightening torques (See Table 33).
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10.5 Removing the cartridge group
51006 51007 51003 51002 90042
a
Figure 26
a Oil-cooled bearing casing
Treat the threads of the studs (51006) with penetrating oil and leave it on.
Loosen nuts (51007) and remove Verbusripp washers (51003) together with the fastening strips (51002).
Attach the lifting gear to the frame and loop around the bearing casing as shown.
Looping around the cartridge group
The loop can slip off and lead to serious injuries to persons or even to fatal accidents.
Make sure that the surface for the loop on the cartridge group and the ro-pe are free from oil.
Remove the cartridge group. After the nozzle ring has been removed, the cartridge group can be placed on the service support (90012).
Axial force of the press-off tool
A high axial force can be generated with the press-off tool. If this tool is han-dled improperly (pressing off with too much force on one side), this may re-sult in damage to the rotor.
Use the tool on both sides alternatingly and make sure not to press off too hard on either side.
CAUTION
CAUTION
10 Disassembly and assembly Page 78 / 95 Removing the nozzle ring
56005 56001 90012
51000 90070
51002
Figure 27
Place the fastening strips (51002) under the nozzle ring.
Pull out the nozzle ring (56001) with the two extraction devices (90070) and the service support base (90012).
Remove the labyrinth sealing ring (56005).
a
90012
Figure 28
Place the cartridge group on the service support (90012).
Measure axial clearance A and radial flexibility B (See Table 32).
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10.6 Installing the cartridge group
Nozzle ring compression
For the nozzle ring (56001) to be fixed during operation, it must be clamped between the heat shield (42400) and the turbine casing (51000).
Measure dimensions A, B and S on cleaned surfaces.
Calculate compression (PD).
56001 A
B S PD = A + B - S
42001 42400
51000
Figure 29
42001 Bearing casing 51000 Turbine casing
42400 Heat shield 56001 Nozzle ring
A130 A135 A140 A145 A150 A155
PD [mm] -0.15 ... 0.15 -0.16 ... 0.16 -0.16 ... 0.16 -0.16 ... 0.16 - - - - Table 30
If the calculated value (PD) lies outside the specified range, contact an ABB Turbocharger service station.
10 Disassembly and assembly Page 80 / 95 Installing the nozzle ring
56005 56001
51000
1 A
Figure 30
Fit the labyrinth sealing ring (56005) and, for type A130 to A145, secure it with adhesive tape (1). At the same time, ensure correct winding of the labyrinth sealing ring (see detail A).
Align the cams on the nozzle ring to the recesses of the turbine casing (51000).
Insert the nozzle ring (56001) into the turbine casing up to the stop. Do not remove the ad-hesive tape (1).
Installing the cartridge group
51006 51007 51003 51002
a a
90012 Figure 31
Attach the lifting gear to the suspension lug / eye of the cartridge group. For an oil-cooled cartridge group, see detail a.
Lift the cartridge group out of the service support (90012).
Additionally, loop the lifting gear around the cartridge group as shown.
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Looping around the cartridge group
The loop can slip off and lead to serious injuries to persons or even to fatal accidents.
Make sure that the surface for the loop on the cartridge group and the ro-pe are free from oil.
Fasten fastening strips (51002) together with nuts (51007) and Verbusripp washers (51003).
Observe tightening torque (See Table 33).
10.7 Radial clearances N and R
N2N1
N
R2R1
R
Figure 32
N and R
These are theoretical values for the radial clearance between the compressor wheel and the wall insert or between the turbine wheel and the gas-outlet flange.
The minimum and maximum values result from the manufacturing tolerances of the compres-sor and turbine wheel or the wall insert and the gas-outlet flange.
N1, R1, N2, R2
The clearances in the bearings and casing centrings are not distributed evenly because of the rotor weight.
CAUTION
10 Disassembly and assembly Page 82 / 95 Feeler gauge
N1/N2 or R1/R2, respectively, are always measured at the same time using two feeler gauges.
The feeler gauges must be inserted without clear-ance between wall insert/compressor wheel or gas outlet flange/turbine wheel.
Measurement of N and R
N1 + N2
2 = N R1 + R2
2 = R
Figure 33
The measured average values must lie within the admissible values of radial clearance N and R.
Radial clearances N and R [mm]
A130 A135 A140 A145 A150 A155
N 0.26 ... 0.60 0.34 ... 0.70 0.45 ... 0.90 0.56 ... 0.95 - - - - R 0.45 ... 0.70 0.51 ... 0.85 0.64 ... 1.00 0.76 ... 1.20 - - - - Table 31
Clearances outside the tolerance
Serious damage to engines or property can be caused by unauthorised clea-rance values and excessively worn parts.
Have the components assessed and, if necessary, replaced by an ABB Turbocharger service station.
CAUTION
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10.8 Axial clearance A and radial flexibility B
A
B
Figure 34
After the removal and the installation of the cartridge group axial clearance A and radial flexibility B must be measured and recorded.
For correct measurement of axial clearance A the turbine must be lifted slightly.
Axial clearance and radial flexibility [mm]
A130 A135 A140 A145 A150 A155
A 0.08 ... 0.16 0.10 ... 0.18 0.12 ... 0.21 0.15 ... 0.25 - - - - B 0.47 ... 1.00 0.58 ... 1.16 0.70 ... 1.37 0.88 ... 1.56 - - - - Table 32
Clearances outside the tolerance
Serious damage to engines or property can be caused by unauthorised clea-rance values and excessively worn parts.
Have the components assessed and, if necessary, replaced by an ABB Turbocharger service station.
CAUTION
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10.9 Table of tightening torques
02 04
11
08 09
15
Figure 35 16
The following tightening torques must be observed for the designated screw fittings:
Tightening torques [Nm]
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