Page 1 Operation Manual A145-M66 HT592666 English Original Operation Manual Chapter Document-ID Introduction HZTL4005_EN_F Safety HZTL4022_EN_E Safety data sheet HT592666 Product description HZTL4031_EN_H ABB Turbocharging...
Page 2 Operating limits and replacement intervals The recommended replacement intervals and the corresponding operating limits in chapter 3 are jointly defined with the enginebuilder. This information is specific to the product. Non-observance of the recommended replacement intervals and the operating limits increases the risk of unpre- dictable component failures.
Page 3: Table Of Contents
Operation Manual / 1 Introduction Table of contents Introduction Introduction......................2 Purpose of the manual....................2 Symbols, definitions...................... 3 Storage of new turbochargers and spare parts ............5 Contact information...................... 7 © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017...
Page 4: Introduction
The Operation Manual must be available where the turbocharger is used. All persons operating or working on the turbocharger must have read and fully understood the Operation Manual. © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017...
Page 5: Symbols, Definitions
ABB Turbo Systems Ltd is identified as ABB Turbo Systems in this document. Official service stations of ABB Turbo Systems Official service stations are identified in this document as ABB Turbocharging Service Sta- tions. They are regularly audited and certified by ABB Turbo Systems. Also see chapter Con- tact information →7.
Page 6 Dispose of in an environmentally ance with specifications compatible, professional way and in compliance with locally applic- Oil free, grease free and dry able regulations Table 1: Definition of pictograms © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017...
Page 7: Storage Of New Turbochargers And Spare Parts
Old VCI corrosion protection emitters must be disposed of in an environmentally compat- ible, professional way and in compliance with locally applicable regulations. Close package. The more tightly the package is sealed, the longer the protection dura- tion. © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017...
Page 8 Check the package for damage. If the package is damaged, the turbocharger or cartridge group must be checked and repackaged by an ABB Turbocharging Service Station. After every 3 years, the following steps must be carried out by an ABB Turbocharging Service Station: ¡...
Page 9: Contact Information
Operation Manual / 1 Introduction 1 Introduction / 1.4 Contact information Contact information Contact information for the ABB Turbocharging Service Stations is available online. Scan the QR code to access our website. ABB Turbo Systems Ltd Bruggerstrasse 71a CH-5401 Baden Switzerland www.abb.com/turbocharging...
Page 11 Lifting of loads ......................9 1.11 Prerequisites for operation and maintenance............10 1.12 Hazards during operation and maintenance ............11 1.13 Safe operation ......................13 1.14 Safe maintenance ......................15 © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
Page 12: Safety
Safety Introduction Turbochargers manufactured by ABB reflect the state of the art. The respective safety and health protection requirements are met. This ensures safe operation of the turbocharger. Nevertheless, there may be some residual risks during operation of and work on the tur- bocharger which: ¡...
Page 13: Definition Of Mandatory Signs
CAUTION can lead to seri- ous damage to engine or property with grave consequences. Caution signs must always be observed. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
Page 14: Intended Use
These data are given on the rating plate. ABB accepts no liability and rejects all warranty claims for any non-intended uses. [1] Euromot = The European Association of Internal Combustion Engine Manufacturers...
Page 15: Deflagration On Gas Engines
If during external inspection anomalies are found or if a particularly strong deflagration event has taken place, it is also recommended to check the bearings of the turbochargers before the next start. An ABB Turbocharging Service Station should be instructed to carry out this inspection.
Page 16: Warning Plates On The Turbocharger
Manual, Chapter 4 Product description. Turbochargers supplied to the enginebuilder without insulation must be equipped later with warning plates on the insulation. This is the responsibility of the enginebuilder. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
Page 17: Turbocharger Rating Plate
06 Customer part number 07 Designation for special design 08 Weight of turbocharger in kg 09 Turbocharger type 10 Serial number Year of construction of turbocharger 12 Manufacturing plant © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
Page 18: Periodic Check Of The Pressure Vessels
The locations of the rating plates are defined in the Operation Manual, Chapter 4 Product description. Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, are so-called "simple pressure vessels". ¡...
Page 19: Lifting Of Loads
The assembly devices must be completely screwed in and must not unscrew during use. Use assembly devices only for the described applications. Put down dismantled components of the turbocharger in such a way that they cannot tip over. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
Page 20: Prerequisites For Operation And Maintenance
Original parts and accessories are specially designed by ABB Turbo Systems for the ABB tur- bochargers. ABB accepts no liability for any damage resulting from the use of non-original parts and cor- responding accessories. © Copyright 2017 ABB. All rights reserved.
Page 21: Hazards During Operation And Maintenance
Wear heat-resistant safety gloves and protective clothing. Wait for the turbocharger to cool down before carrying out any work. Wear safety gloves to protect against thermal hazards. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
Page 22 At the same time, electrical or electronic components and parts can also be damaged or destroyed. Only specially trained personnel should perform work on, or with, elec- trical components. Observe national regulations. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
Page 23: Safe Operation
When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay at- tention to the risks that may occur as a consequence of this energy input. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
Page 24 Only operate the turbocharger with burst protection fitted and insulation fitted in one of the following, permitted variants. Fig. 5 Variant A Insulation (01) with integrated burst protection from ABB Turbo Systems. Variant B Burst protection (03) and insulation (02) from ABB Turbo Systems. Variant C Burst protection (03) from ABB Turbo Systems with appropriate insulation...
Page 25: Safe Maintenance
Keep the floor, equipment, and turbocharger clean. Have oil binding agents ready and provide or keep oil pans at hand. Clean up any spills. Have fire protection means and extinguishing agents available. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
Page 26 Secure rotor against turning. The rotor can rotate due to the stack draught alone. Observe the material safety data sheet for the cleaning and mothballing agents. Wear personal protective equipment (PPE) according to the material safety data sheet. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E...
Page 27 Wear personal protective equipment (PPE) according to the material safety data sheet. Comply with local legislation. Wear safety goggles. Wear safety gloves to protect against chemical hazards. Wear a respiratory mask to protect against gases. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
Page 28 Dispose of insulation materials properly and in an environmentally com- patible manner in compliance with the legal regulations. Wear safety goggles. Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against chemical hazards. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
Page 31 Cleaning components mechanically ............... 50 Eliminating malfunctions..................60 Malfunctions when starting..................60 Malfunctions during operation ................. 61 Turbocharger is surging .................... 64 Malfunctions when stopping..................65 Speed measurement system ..................66 © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 32 Required customer spare part set (97070)............106 12.3 View of turbocharger with part numbers ............108 12.4 View of turbine cleaning device ................110 Figures........................111 Tables ........................113 © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 33: Introduction
This document is valid for different design variants of turbochargers. There may be sections and descriptions of components that are not relevant for a specific turbocharger variant. Please contact an ABB Turbocharging Service Station if you have any questions regarding a design variant (see Contact information at www.abb.com/turbocharging).
Page 34: Layout And Function Of The Turbocharger
02 Compressor casing Nozzle ring 03 Diffuser Turbine casing 04 Bearing casing Turbine-end bearing flange 05 Axial thrust bearing Compressor-end bearing flange 06 Radial plain bearing Compressor wheel 07 Turbine © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 35: Fig. 2: Compressor Wheel Cooling
(01). In addition, the turbocharger version with compressor wheel cooling is indicated by the tur- bocharger type (M6..) on the rating plate. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H...
Page 36: Warning Plates On The Turbocharger
If warning plates are not present in the designated locations or not readable, proceed as fol- lows: Order new warning plates from ABB Turbocharging Service Stations. Remove any warning plates that have become unreadable. Clean and degrease the areas designated for the warning plates.
Page 37: Locations Of The Rating Plates
Locations of the rating plates Fig. 4: Locations of the rating plates One rating plate (01) each is attached on the left and the right side of the turbocharger bear- ing casing. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 38: Removing And Installing
B Turbocharger with water-cooled bearing casing C Complete turbocharger unit with gas outlet casing Product Weight of complete turbocharger unit [kg] A130-M A135-M A140-M A145-M Table 2: Weight of complete turbocharger unit © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 39: Removing The Turbocharger
The cleaning nozzle (51301) must be replaced after each removal procedure. If the clean- ing nozzle is not to be replaced, the screw connection (01) must not be loosened during disassembly. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H...
Page 40: Fig. 7: Removing The Turbocharger
Depending on the bracket version (04), two positioning pins (05) can be used for positioning and safeguarding against wrong fitting of the turbocharger. Therefore the turbocharger must always be removed from and installed on the bracket vertically. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H...
Page 41 Attach lifting gear to the suspension eye. Loosen the round special nut with a hydraulic tool according to the instructions of the en- ginebuilder. Positioning the turbocharger for storage →13. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 42: Fig. 8: Loosening The Clamping Nut
3. Working in a circle, loosen each pressure screw by 90° in 1...5 rounds until all of the pres- sure screws have been relieved. Loosen clamping nut by hand. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 43: Fig. 9: Turbocharger Centre Of Gravity
Centre of gravity Remove turbocharger from engine support, set it down properly in an appropriate place and secure it. Close or cover the openings of the turbocharger and support. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 44: Installing The Turbocharger
Always use new gaskets and insert them carefully into the slot. The oil is supplied (02) and drained (03) through the bracket (01). The necessary sealing is provided by O-rings. The O-rings are not included in the ABB Turbo Systems scope of delivery.
Page 45: Fig. 11: Inserting The Threaded Rods
The threaded rods and nuts for fastening the turbocharger on the bracket are not included in the ABB Turbo Systems scope of delivery. The clamping nuts are included in the ABB Turbo Systems scope of delivery. © Copyright 2019 ABB. All rights reserved.
Page 46: Fig. 13: Placing The Turbocharger On The Bracket
Depending on the bracket version (04), two positioning pins (05) can be used for positioning and safeguarding against wrong fitting of the turbocharger. Therefore the turbocharger must always be removed from and installed on the bracket vertically. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H...
Page 47: Table 4: Tightening Torque For Standard Nuts
**) When the turbocharger is mounted on the engine support, the bolt threads and screw heads must be lightly oiled (assumed friction coefficient µ = 0.12 for tightening torque) Remove the lifting gear. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H...
Page 48: Fig. 14: Preparing The Clamping Nut For The Tightening Procedure
5. Tighten clamping nut (03) by hand. 6. Unscrew clamping nut (03) by ¼ of a turn (90°). The distance between the thrust washer and the clamping nut is now about 1 mm. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H...
Page 49: Fig. 15: Tightening Pressure Screws
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 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 50: Fig. 16: Connecting The Speed Sensor
Make sure there is an uninterrupted supply of cooling air during opera- tion. Fig. 17: Connecting the compressor cooling air intake Remove the screw plug on the connection for the compressor wheel cooling (06) and fit the cooling air line. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 51: Fig. 18: Attaching The Support
2 Removing and Installing / 2.3 Installing the turbocharger 2.3.7 Attaching the support Fig. 18: Attaching the support If present: Attach support (61301) to engine support or to a connecting piece. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 52: Commissioning
Filtering the lubricating oil with a filter mesh width of ≤ 0.034 mm is sufficient for this tur- bocharger. 3.1.4 Oil pressure Comply precisely with the oil pressure before the turbocharger for trouble-free operation. The admissible values are specified in chapter Monitoring operation →27. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 53: Fig. 19: Oil Orifice
With an oil inlet pressure of more than 3 bar of overpressure (with engine under load) up- stream of the turbocharger, the bearing casings are equipped with an orifice at the oil inlet as standard. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H...
Page 54: Inspection Procedures
Make sure there is an uninterrupted supply of cooling air during opera- tion. Check whether the compressor wheel cooling is fitted on the bearing casing. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 55 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. © Copyright 2019 ABB. All rights reserved.
Page 56: Commissioning After Taking Out Of Operation
Put engine-side oil circulation to the turbocharger into operation. Prepare the turbocharger for operation (see Checks before commissioning →24). The turbocharger is now ready for operation. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 57: Monitoring Operation
Oil pressure measuring point Oil temperature measuring point For monitoring the lubricating oil pressure, ABB Turbo Systems recommends installing a "P" manometer immediately upstream of the turbocharger oil inlet before the orifice. If the pressure is controlled electronically, the relevant signals should be triggered at the warning and alarm values.
Page 58: Table 7: Lubricating Oil Temperature At The Inlet
Table 8: Lubricating oil temperature at the outlet If the turbocharger was operated for a longer period of time outside of the admissible range, ABB Turbo Systems recommends to have the turbocharger inspected by an ABB Tur- bocharging Service Station. © Copyright 2019 ABB. All rights reserved.
Page 59: Exhaust Gas Temperature Before Turbine
Definition and explanations concerning rating plate: refer to chapter 2 of Operation Manual / Safety. Operating limits: refer to chapter 3 of Operation Manual / Safety data sheet or examine rating plate. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 60: Turbocharger Speed
42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F/I converter Plug with integrated voltage limiter 86528 Tachometer Installation variant for speed sensor 32109 Sealing disc with cams © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 61 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. 4.3.4 Malfunctions on the speed measurement system...
Page 62: Fig. 21: Replacing The Speed Sensor
Wear safety gloves when disassembling the speed sensor. Wear safety gloves to protect against thermal hazards. The speed sensor supplied by ABB is equipped with a sealing lip and an O-ring. No additional gasket is required during assembly. Fig. 21: Replacing the speed sensor...
Page 63: 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 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 64: Fig. 22: Noise Insulation, Bellows
Suggestion for noise insulation, bellows Fig. 22: Noise insulation, bellows Compressor casing Bellows Charge air duct / scavenging air duct Insulation cushion Insulation mat (at least 15 mm) Sheet metal cover © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 65: Service Work
Agree on a shortened service interval with ABB Turbo Systems. 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 66 Service work according to data on the rating plate (Usually after 8000 … 12000 operating hours) The rotor and bearing parts must be checked and assessed by an ABB Turbocharging Service Station. The following work can be carried out as preparation.
Page 67: Fig. 23: Replacing The Protective Grid
5.2.5 Other service work If a protective grid is installed in the gas outlet casing (61001) by ABB Turbo Systems: Fig. 23: Replacing the protective grid Remove the protective grid (61205) after 50000 hours and replace it with a new protect- ive grid.
Page 68 Speed of the turbocharger ¡ Air temperature after the compressor and after the charge-air cooler ¡ Exhaust gas temperature before and after the turbine ¡ Pressure loss in the filter silencer. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 69: Expected Replacement Intervals
Table 10: Expected replacement intervals = Natural Gas = Marine Diesel Oil = Heavy Fuel Oil The specified values are guideline values and not guaranteed values, see Influencing para- meters. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 70 Lubricating oil quality (oil filtering, oil condition, oil monitoring) ¡ Load profile (speed, pressure conditions, temperature) ¡ Number of starts/stops ¡ Unbalance of the rotor (degree of contamination). © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 71: Stopping The Engine
– 550 °C with insulated casing – 600 °C with non-insulated casing At temperatures below the specified values, post-lubrication must be ensured until the rotors come to a standstill. ABB Turbo Systems recommends post-lubrication for 10 minutes. Observe the oil pressure specified for post-lubrication (see Table 6: Lubricating oil pres-...
Page 72: Periodic Maintenance Work
To allow you to observe the standard service intervals and to maintain a high turbocharger efficiency, ABB Turbo Systems recommends that the cleaning procedure be carried out dur- ing operation. This allows the thermal load of the engine to be kept low while ensuring max- imum fuel efficiency.
Page 73: Cleaning The Compressor During Operation
Very heavily con- taminated components can no longer be cleaned using this method. In this case, ABB Turbo Systems recommends having the contaminated components cleaned mechanically by an ABB Turbocharging Service Station.
Page 74 The compressor is cleaned during operation using the wet cleaning method. It is carried out at an engine load of 50 ... 85 %. This cleaning method has been tested and approved by ABB Turbo Systems. V-engines On V-engines with several turbochargers per engine, parallel cleaning of both turbochargers is recommended.
Page 75: Fig. 24: Carrying Out Wet Cleaning Of Compressor
Not more than three cleaning cycles should be conducted consecutively. Before repeating the process, continue to operate the engine for at least five minutes to ensure that all of the water is flushed out of the system. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H...
Page 76: Cleaning The Turbine During Operation
Very heavily con- taminated components can no longer be cleaned using this method. In this case, ABB Turbo Systems recommends having the contaminated components cleaned mechanically by an ABB Turbocharging Service Station.
Page 77 Cleaning method The turbine components are cleaned during operation using the wet cleaning method. This cleaning method is tested and approved by ABB Turbo Systems. The precondition for wet cleaning is that the enginebuilder approves the process and these regulations are observed.
Page 78: Table 13: Turbine Wet Cleaning, Recommended Operating State
During cleaning, the temperature at the turbine inlet will rise and may strain the material significantly. Make sure the maximum temperature at the turbine inlet is not exceeded during cleaning. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 79: Fig. 25: Carrying Out Wet Cleaning Of Turbine
→49). Close the stop valve (02) after 10 minutes. Wait for 10 minutes; do not change the load during this stabilisation phase. If the cleaning result is unsatisfactory or there is water leakage, contact an ABB Turbochar- ging Service Station. Product Temperature be-...
Page 80: Cleaning Components Mechanically
The disassembly and assembly of the components is described in chapter Fitting and dis- mantling. Contaminated water and cleaning agents must be disposed of in an environmentally compatible, professional way and in compliance with locally applicable regulations. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 81: Fig. 26: 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 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 82 When cleaning, note that the absorption segments (81136) must only be cleaned lightly with compressed air, a soft brush or a moist cleaning cloth. Have any heavily contaminated absorption segments replaced by an ABB Turbocharging Service Station. Fitting the filter silencer (see Fig. 26: Cleaning the filter silencer →51)
Page 83: Fig. 27: Compressor-End, Non-Rotating Parts
Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the tur- bocharger. Dispose of contaminated water and cleaning agents in accordance with the information in the material safety data sheet. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 84 Baked layers of contamination, for example, from heavy fuel oil or coked oil occur at the tur- bine end. The following parts, which are relevant in terms of performance, can be cleaned in accordance with the description below. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H...
Page 85: Fig. 28: Turbine End, Non-Rotating Parts
Water or air can be passed through the piping and into the cleaning nozzle to check whether it is blocked. When installed, the cleaning nozzle can be mechanically cleaned with a needle. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN...
Page 86 Lightly spray the compressor wheel and the gap between the compressor and the bearing casing with penetrating oil. Dispose of dirty water and cleaning agents in accordance with the material safety data sheet. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 87: Fig. 29: Soaking The Turbine End
Observe safety data sheet. Fill the container (02) with soaking fluid. To shorten the soaking time, the fluid can be heated up to a maximum of 60 ºC. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 88 Wear safety gloves to protect against mechanical hazards. Lift up the cartridge group and align it horizontally. Remove dirt manually using a soft brush or a wire brush. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 89 Lightly spray the turbine and the gap between the turbine and the partition wall with pen- etrating oil. Dispose of dirty water and cleaning agents in accordance with the information in the ma- terial safety data sheet. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 90: Eliminating Malfunctions
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 91: Malfunctions During Operation
Remedy Turbocharger Turbine and/or nozzle ring severely con- Clean (see chapter Periodic maintenance taminated work →42) Rotor components or bearing damaged Contact ABB Turbocharging Service Sta- tion Engine Defects on the connected cylinders in Contact enginebuilder pulse charging Pipes Defects, such as leaks, in the exhaust gas...
Page 92: Table 22: 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 23: Malfunctions during operation – Charge air pressure too low © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 93: Table 24: Malfunctions During Operation - Charge Air Pressure Too High
Clean (see chapter Periodic maintenance work →42) Table 25: Malfunctions during operation – Engine performance losses © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 94: Turbocharger Is Surging
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. Possible causes Remedy...
Page 95: Malfunctions When Stopping
Check clearances (see chapter Measuring clearance A and B →83). If clearances are outside the toler- ance or if in doubt, contact an ABB Turbocharging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station.
Page 96: Speed Measurement System
Table 32: Malfunction of the speed measurement system – Measured speed too low If none of the measures described above remedy the malfunction, have the speed measure- ment system checked by an ABB Turbocharging Service Station. © Copyright 2019 ABB. All rights reserved.
Page 97: Dismantling And Fitting
ABB Turbo Systems recommends having further operations carried out only by trained personnel from an ABB Turbocharging Service Station. Mark the casing position for assembly. © Copyright 2019 ABB. All rights reserved.
Page 98 (Table of tightening →97). torques Tightening torques for assembly devices Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB must be tightened so they rest firmly against the surface. WARNING Suspended loads Loads that are not attached according to regulations can cause injury to personnel or fatal accidents.
Page 99: Fig. 30: Swivel Lifting Eyes
Ring nuts to be used Two ring nuts (M16) are required for safer lifting of the cartridge group, which are not in- cluded in the ABB Turbo Systems scope of delivery. Fig. 31: Starpoint ring nut VRM © Copyright 2019 ABB. All rights reserved.
Page 100: Weights Of Individual Parts
Turbine casing * 1 inlet Turbine casing * 2 inlets Turbine casing * 3 inlets Gas outlet flange Gas outlet casing Table 34: Weights of assemblies * including burst protection © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 101: Removing The Air Inlets
3. Remove filter silencer (81000) or air suction branch (82000), set it down properly in an appropriate place and secure it. 4. Remove and dispose of the O-ring (81010 / 82010). © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 102: Removing The Gas Outlet Casing
8 Dismantling and fitting / 8.4 Removing the gas outlet casing Removing the gas outlet casing Removing the insulation Fig. 34: Removing the insulation Remove gas outlet casing insulation. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 103: Removing The Gas Outlet Flange
If the following Working Instructions are not observed, this can lead to cracks in the gas out- let casing. The following variants are possible: Pressing off using 3 press-off screws. Pressing off using 6 press-off screws. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 104: A130 A135 A140 A145
≤ 65 Nm Table 35: 3 press-off screws * not included in the ABB Turbo Systems scope of delivery 1. Press off and remove the gas outlet flange (57002) with screws (01) according to the table. If it is not possible to press off the gas outlet flange with the maximum tightening torque, contact an ABB Turbo Systems Service Station.
Page 105: Fig. 37: Removing The Gas Outlet Flange
≤ 65 Nm Table 36: 6 press-off screws * not included in the ABB Turbo Systems scope of delivery. 1. Evenly press off and remove the gas outlet flange (57002) with screws (01) according to the table. If it is not possible to press off the gas outlet flange with the maximum tight- ening torque, contact an ABB Turbo Systems Service Station.
Page 106: Removing The Compressor Casing
If the compressor casing cannot be loosened, it can be pressed off against the turbine cas- ing using the press-off tool (90042) (see chapter Pressing off the casing →78). © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 107: Wall Insert
1. Knock the wall insert (77000) out of the compressor casing (72000) with a plastic tip hammer. 2. Attach swivel lifting eye (S) to the compressor casing (72000) and the lifting gear. 3. Lift up the compressor casing (72000). 4. Remove and dispose of the O-ring (77005). © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 108: Pressing Off The Casing
If the casing is pressed off with too much force on one side, the rotor can be damaged. Use the tool on both sides in alternation and make sure not to press off too hard on either side. Fig. 40: Press off the casing © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 109: Removing The Cartridge Group
If an oil orifice is fitted in the oil inlet of the bearing casing, it must not be removed. Fig. 42: Oil orifice 01 Bearing casing 02 Oil orifice 03 Circlip © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 110: Fig. 43: Removing Cartridge Group 1
7. Turn the cartridge group into the horizontal rotor axis. If the cartridge group cannot be loosened, the press-off tool (90042) can be used (see chapter Pressing off the casing →78). © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 111: Removing The Nozzle Ring
3. Pull out the nozzle ring (56001) with the two extraction devices (90070) and the service support base (90012). 4. Remove the lamellar sealing ring (56005). 5. Remove the burst ring (57210). © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 112: Installing The Cartridge Group On The Service Support
Fig. 46: Installing the cartridge group on the service support 1. Remove ring nuts (VRM). 2. Remove service support screws. 3. Fit service support (90012) according to the illustration. 4. Insert the cartridge group. 5. Fit the nuts. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 113: Measuring Clearance A And B
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2019 ABB. All rights reserved.
Page 114: Nozzle Ring Compression Pd
Table 38: Nozzle ring compression PD 1. Measure dimensions A, B and S on cleaned surfaces. 2. Calculate compression (PD). If the calculated value (PD) lies outside the specified range, contact an ABB Turbochar- ging Service Station. © Copyright 2019 ABB. All rights reserved.
Page 115: Installing The Nozzle Ring
Align the cams on the nozzle ring with the recesses of the turbine cas- ing (51000). Do not remove the adhesive tape (01). 5. If present: Fit the metal C-ring (51105). © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H...
Page 116: Installing The Cartridge Group
4. Attach lifting gear to the ring nuts (VRM). 5. Lift cartridge group at the side of the ring nuts (VRM) and turn it into a vertical position. Installing the cartridge group Fig. 51: Installing the cartridge group © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 117: Table 39: Tightening Torque (51007)
3. Lower the cartridge group into the turbine casing. 4. Remove ring nuts and screws. 5. Fit fastening strips (51002) with Verbus Ripp® washers (51003) and hexagon nuts (51007). 6. Tighten the hexagon nuts (51007). © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 118: Fig. 52: Turbine Casing Insulation / Burst Protection
Operation Manual / 4 Product description / A130-M.. - A145-M.. 8 Dismantling and fitting / 8.14 Installing the cartridge group WARNING The turbine casing insulation supplied by ABB Turbo Systems also acts as burst protection Serious injuries or accidents resulting in fatalities can occur if the turbine casing insulation (01) supplied by ABB Turbo Systems is removed.
Page 119: Installing The Compressor Casing
2. Fit the swivel lifting eye (S) to the lifting beam. Secure lifting gear to the swivel lifting eye. 3. Fit new O-ring (77005). 4. Install the wall insert (77000) in the compressor casing. 5. Fit diffuser (79000) with fixing discs (79040) and screws (79041). Observe the tightening torque. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 120: Fig. 53: Installing The Compressor Casing
5. Install the fastening strips (72012) with screws (72011). Observe the tightening torque. If these screws do not have a Verbus Ripp® integrated, Verbus Ripp® washers (72010) must also be fitted. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 121: Measuring Radial Clearances N And R
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2019 ABB. All rights reserved.
Page 122: Installing The Air Inlets
2. Fit a new O-ring (81010) to the filter silencer (81000) or a new O-ring (82010) to the air suction branch (82000). 3. Fit the filter silencer (81000) or air suction branch (82000) with the V-clamp (72020). 4. Observe the tightening torque. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 123: Installing The Gas Outlet Flange
1. If present: Insert the metal C-ring (57003) into the turbine casing (51000) and secure with high-vacuum grease. 2. Install the gas outlet flange (57002) in the turbine casing. 3. Measure radial clearance (R) (see chapter Radial clearances N and R). © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 124: Fitting The Insulation Of The Turbine Casing
8.19 Fitting the insulation of the turbine casing Fig. 57: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see Table of tightening torques →97). © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 125: Installing The Gas Outlet Casing
3. Attach the lifting gear to the gas outlet casing (61001) and position the gas outlet casing in the correct position on the turbine casing (51000). 4. If present: Fit support (61301). 5. Fit hexagon nuts (51009). Observe the tightening torque. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 126: Fig. 59: Fitting The Insulation
8 Dismantling and fitting / 8.20 Installing the gas outlet casing Fitting the insulation Fig. 59: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see Table of tightening torques →97). © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 127: Table Of Tightening Torques
15 Nm 15 Nm 15 Nm 16a *) - - 40 Nm 40 Nm 65 Nm 65 Nm Table 45: Tightening torques *) With the variant "insulation with integrated burst protection", this position can be ig- nored. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 128: Fig. 61: Tightening Torques For Insulation
Table 46: Tightening torques for insulation Tightening torque for attaching the insulation with integrated burst protection at the tur- bine casing Tightening torque for attaching the insulation to the burst protection. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 129: Taking Out Of Operation At Short Notice
¡ If a replacement turbocharger or cartridge group is not available: Fit cover plate →101 and contact an ABB Turbocharging Service Station. Observe the following sections in connection with the emergency repairs mentioned. © Copyright 2019 ABB. All rights reserved.
Page 130: Installing The Replacement Turbocharger
The repair of a cartridge group requires special tools and the expertise of an ABB Turbochar- ging Service Station. The rotating parts rotate extremely fast, and are sensitive to unbal- ance.
Page 131: Fitting The Cover Plate
3. Coat the threads of the studs (51006) with high-temperature grease. 4. Fasten cover plate (01) to turbine casing (51000) with fastening strips (51002), Verbus Ripp® washers (51003) and nuts (51007) and screw to bracket. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H...
Page 132: Cover Plate Drawing
9 Taking out of operation at short notice / 9.5 Cover plate drawing Cover plate drawing The cover plate is not included in the ABB Turbo Systems scope of delivery and must be manufactured by the operating company according to the following drawing.
Page 133: 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 134: 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 135: Disposing Of Turbocharger Components
Dispose of non-metallic materials as waste. Dispose of residues of lubricants as waste oil. Dispose of electronic components as electronic waste. Dispose of thermal insulation as hazardous waste. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 136: Spare Parts
Counter-sunk screw 81010/ 82010 O-ring Table 48: Customer spare part set 97070 * This gasket can only be installed when a gas outlet casing from ABB Turbo Systems is used. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 137 Operation Manual / 4 Product description / A130-M.. - A145-M.. 12 Spare parts / 12.2 Required customer spare part set (97070) © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 138: View Of Turbocharger With Part Numbers
12 Spare parts / 12.3 View of turbocharger with part numbers 12.3 View of turbocharger with part numbers Fig. 64: Overview of part numbers (……) only available in customer spare part set (97070). © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 139: Table 49: Spare Parts List
82010 (in the customer spare part set) O-ring 86505* Speed sensor 86515* Cable connector 86526* F/I converter 86528* Tachometer Table 49: Spare parts list * Depending on the specification of the turbocharger © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 140: View Of Turbine Cleaning Device
51301 1 inlet = 1 cleaning nozzle 2 inlets = 2 cleaning nozzles 3 inlets = 3 cleaning nozzles 51302 Gasket 51303 Screw plug Table 50: Spare parts list © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 141: Figures
Fig. 62: Fitting the cover plate ........101 Fig. 31: Starpoint ring nut VRM........69 Fig. 63: Cover plate drawing........102 Fig. 32: Weights of assemblies ........70 Fig. 64: Overview of part numbers......108 © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 142 Operation Manual / 4 Product description / A130-M.. - A145-M.. Figures Fig. 65: Overview of part numbers......110 © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...
Page 143 Table 24: Malfunctions during operation – Charge air pressure too high ............63 Table 25: Malfunctions during operation – Engine performance losses ............. 63 Table 26: Malfunction – Turbocharger pumping..64 © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019...

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