Page 1 Operation Manual A145-M66 HT564839 English Original Operation Manual Chapter Document-ID Introduction HZTL4005_EN_E Safety HZTL4022_EN_C Safety data sheet HT564839 Product description HZTL4031_EN_D 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
Table of contents Page 1 / 8 Introduction Introduction .................... Purpose of the manual ................Symbols, definitions ................... Storage of new turbochargers and spare parts .......... Contact information ..................© Copyright 2016 ABB. All rights reserved. HZTL4005_EN Revision E July 2016...
Page 5: 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 2016 ABB. All rights reserved. HZTL4005_EN Revision E July 2016...
Page 6: Symbols, Definitions
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 [➙ 8]. © Copyright 2016 ABB. All rights reserved.
Page 7 Dispose of in an environmentally with specifications compatible, professional way and in compliance with locally applica- Oil free, grease free and dry ble regulations. Table 1: Definition of pictograms © Copyright 2016 ABB. All rights reserved. HZTL4005_EN Revision E July 2016...
Page 8: Storage Of New Turbochargers And Spare Parts
Old VCI corrosion protection emitters must be disposed of in an environmentally compati-  ble, professional way and in compliance with locally applicable regulations. Close package. The more tightly the package is sealed, the longer the protection duration.  © Copyright 2016 ABB. All rights reserved. HZTL4005_EN Revision E July 2016...
Page 9 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:  Checking the component ...
Page 10: Contact Information
Operation Manual / 1 Introduction Introduction Page 8 / 8 Contact information Contact information of 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 Periodic check of the pressure vessels ............1.10 Lifting of loads .................... 1.11 Prerequisites for operation and maintenance ..........1.12 Hazards during operation and maintenance ..........1.13 Safe operation ................... 1.14 Safe maintenance ..................© Copyright 2016 ABB. All rights reserved. HZTL4022_EN Revision C May 2016...
Page 13: Safety
Safety Introduction Turbochargers manufactured by ABB Turbo Systems are state of the art and comply with the respective health and safety standards in effect at the time the turbocharger was built. This ensures safe operation of the turbocharger. Nevertheless, there may be some residual risks during operation of and work on the turbocharger which: ...
Page 14: Definition Of Mandatory Signs
CAUTION can lead to serious CAUTION damage to engine or property with grave consequences. Caution signs must always be observed.  © Copyright 2016 ABB. All rights reserved. HZTL4022_EN Revision C May 2016...
Page 15: Intended Use
The specific operating limits of the turbocharger were determined on the basis of information from the enginebuilder about the intended use. These data are given on the rating plate. ABB Turbo Systems accepts no liability and rejects all warranty claims for any non-intended uses.
Page 16: Deflagration On Gas Engines
Deflagration on gas engines ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar. ABB Turbo Systems recommends subjecting the turbocharger to a visual inspection after a deflagration event. As part of the inspection, the position of the turbine casing and the position of the compressor casing to the bearing casing must be checked, and the bearing casing must be examined to see if it has shifted in relation to the bracket.
Page 17: 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 11 Year of construction of turbocharger © Copyright 2016 ABB. All rights reserved. HZTL4022_EN Revision C May 2016...
Page 18: Periodic Check Of The Pressure Vessels
The locations of the rating plates are defined in the Operation Manual / Product description. Periodic check of the pressure vessels The pressure vessels used by ABB Turbo Systems, for example, in the wet or dry cleaning process, 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 2016 ABB. All rights reserved. HZTL4022_EN Revision C May 2016...
Page 20: Prerequisites For Operation And Maintenance
WARNING personnel. Only use original parts from ABB Turbo Systems.  ABB Turbo Systems accepts no liability for any damage resulting from the use of non-original parts and associated accessories. © Copyright 2016 ABB. All rights reserved. HZTL4022_EN Revision C...
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 2016 ABB. All rights reserved. HZTL4022_EN Revision C May 2016...
Page 22 Page 12 / 18 Hot surfaces on the non-insulated turbocharger Non-insulated turbochargers can cause serious injuries to personnel (burns). ABB Turbo Systems supplies the turbocharger with or without insulation in WARNING accordance with the purchase order received from the enginebuilder. If sup-...
Page 23: Safe Operation
When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay  attention to the risks that may occur as a consequence of this energy input. © Copyright 2016 ABB. All rights reserved. HZTL4022_EN Revision C May 2016...
Page 24 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 from the en- ginebuilder. © Copyright 2016 ABB. All rights reserved. HZTL4022_EN...
Page 25: Safe Maintenance
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 2016 ABB. All rights reserved. HZTL4022_EN Revision C May 2016...
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 2016 ABB. All rights reserved. HZTL4022_EN Revision C May 2016...
Page 27  ty 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 2016 ABB. All rights reserved. HZTL4022_EN Revision C May 2016...
Page 28  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 2016 ABB. All rights reserved. HZTL4022_EN Revision C May 2016...
Page 31: Table 10 Expected Replacement Intervals
Periodic maintenance work ..............Foreword to maintenance ................Cleaning the compressor during operation ..........Cleaning the turbine during operation ............Cleaning components mechanically ............Eliminating malfunctions ................. Malfunctions when starting ................. © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 32: Table 19 Malfunctions During Operation
Taking the engine out of operation for up to 12 months ......107 10.2 Taking the engine out of operation for more than 12 months ...... 108 Disposing of turbocharger components ............ Spare parts ..................... © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 33 Page 3 / 117 12.1 Ordering spare parts .................. 12.2 Required customer spare part set (97070) ..........12.3 View of turbocharger with part numbers ............. Figures ....................Tables ....................© Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 35: Introduction
This document is valid for different turbocharger design variants. As a result, it might contain sections and descriptions of components that do not apply to a certain turbocharger. If you have any queries about a design variant, ABB Turbocharging Service Stations will be pleased to provide information (see Contact information at www.abb.com/turbocharging).
Page 36: Layout And Function Of The Turbocharger
03 Diffuser 10 Turbine casing 04 Bearing casing 11 Turbine-end bearing flange 05 Axial thrust bearing 12 Compressor-end bearing flange 06 Radial plain bearing 13 Compressor wheel 07 Turbine © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 37 (01). In addition, the turbocharger version with compressor wheel cooling is indicated by the turbo- charger type (M6..) on the rating plate. © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 38: Warning Plates On The Turbocharger
Figure 3: Warning plate locations 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.
Page 39: Locations Of The Rating Plates
Locations of the rating plates Figure 4: Locations of the rating plates One rating plate (01) each is attached on the left and the right side of the turbocharger bearing casing. © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 41: Removing And Installing
Table 2: Turbocharger weights Figure 5: Suspension of complete turbocharger unit A Turbocharger with oil-cooled bearing casing B Turbocharger with water-cooled bearing casing C Complete turbocharger unit with gas outlet casing © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 42: Removing The Turbocharger
NOTICE charger. Therefore the turbocharger must always be removed from and in- stalled on the bracket vertically. © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 43 (see instructions of the enginebuilder). Remove the turbocharger.  Cover the oil connections (03) at the engine side to protect against contamination.  © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 44 Working in a circle, loosen each of the pressure screws by about ¼ of a turn (90°).  Repeat the previous step until all pressure screws are relieved of pressure.  Loosen clamping nut by hand.  © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 46: Installing The Turbocharger
CAUTION The oil is supplied (02) and drained (03) through the bracket (01). The necessary sealing is provided by O-rings. The gaskets are not included in the ABB Turbo Systems scope of delivery and must be provided by the enginebuilder.
Page 47: Table 3 Requirements For 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 2016 ABB. All rights reserved.
Page 49: Table 4 Tightening Torques For Stand
Hydraulic pre- [mm] [Nm] **) tensioning forces [kN] A130 Ø 17 A135 Ø 21 A140 Ø 25 Table 4: Tightening torques for standard nuts Remove the lifting gear.  © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 50 4. Tighten clamping nut (03) by hand. 5. 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 2016 ABB. All rights reserved. HZTL4031_EN Revision D...
Page 51: Table 5 Pressure Screw Tightening Torques
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 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 52  the cooling air line. 2.3.7 Attaching the support Figure 16: Attaching the support If present: Attach support (61301) to engine support or to a connecting piece.  © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 53: Commissioning
Lubricating oil filtering with a filter mesh width of ≤ 0.034 mm is sufficient for this turbocharger. 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 [➙ 29]. © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 54 With an oil inlet pressure of more than 3 bar (when engine under load) before the turbo- charger, the bearing casings are equipped as standard with an orifice at the oil inlet. © Copyright 2016 ABB. All rights reserved. HZTL4031_EN...
Page 55: Inspection Procedures
Any prolonged failure of the compressor wheel cooling will shorten the re- placement interval of the compressor wheel. CAUTION Make sure there is an uninterrupted supply of cooling air during operation.  © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 57: Commissioning After Taking Out Of Operation
Put engine-side oil circulation to the turbocharger into operation.  Prepare the turbocharger for operation according to section "Checks before commissioning".  The turbocharger is now ready for operation.  © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 59: Monitoring Operation
Oil pressure measuring point Oil temperature measuring point For monitoring the lubricating oil pressure, ABB Turbo Systems recommends installing an "M" manometer immediately before the turbocharger. If the pressure is controlled electronically, the appropriate signals are to be triggered at the warning and alarm values.
Page 60: Table 7 Lubricating Oil Temperature At
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 Turbocharg- ing Service Station.
Page 61: 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 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 62: 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 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 63  If the engine can be stopped temporarily: Inspect air lines, exhaust gas pipes and the turbochargers and remedy any malfunctions.  ABB Turbo Systems recommends contacting the nearest ABB Turbocharging Service Sta-  tion. 4.3.4 Malfunctions on the speed measurement system In the case of malfunctions of the speed measurement system, refer to the chapter entitled Troubleshooting/Speed measurement system [➙...
Page 64 Screw in new speed sensor (86505) as far as it will go and tighten.  Connect cable connector (86515) to speed sensor (86505).  Switch on lubricating oil supply to the turbocharger.  © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 65: 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 insula- tion versions © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 66 Suggestion for noise insulation, bellows Figure 20: Noise insulation, bellows Compressor casing Bellows Charge air duct / scavenging air duct Insulation cushion Insulation mat (at least 15 mm) Sheet metal cover © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 67: Service Work
 5-year service inspection To prevent machine damage caused by ageing and downtime, we recom- mend having an inspection carried out by an ABB Turbocharger Service Sta- NOTICE tion no later than 5 years after the last service. © Copyright 2016 ABB. All rights reserved.
Page 68 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 69 5.2.5 Other service work If a protective grid is installed in the gas outlet casing (61001) by ABB Turbo Systems: Figure 21: Replacing the protective grid Remove the protective grid (61205) after 50000 hours and replace it with a new protective ...
Page 70  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 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 71: 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 parame- ters. © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 72  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 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 73: Stopping The Engine
– 600 °C with non-insulated casing At temperatures below the specified values, post-lubrication must be ensured until the ro- tors come to a standstill. ABB Turbo Systems recommends post-lubrication for 10 minutes. Observe the oil pressure specified for post-lubrication (see Table 6).
Page 75: Periodic Maintenance Work
8000 … 12000 h) Table 11: Maintenance table [h] = Hours of operation If the maintenance intervals are incompatible with operation of the engine, contact ABB Turbo Systems. ABB Turbo Systems recommends having mechanical cleaning carried out by an ABB Turbocharging Service Station during the service work.
Page 76: Cleaning The Compressor During Operation
Very heavily contami- nated components can no longer be cleaned using this method. In this case, ABB Turbo Sys- tems recommends having the contaminated components cleaned mechanically by an ABB Turbocharging Service Station.
Page 77 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 78 (01) and routed to the filter silencer or air suction branch. The water does not act as a solvent. The coating is removed by the mechanical action of the impacting droplets. © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D...
Page 79: Table 12 Parameters For Wet Cleaning Of
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 2016 ABB. All rights reserved. HZTL4031_EN Revision D...
Page 80: Cleaning The Turbine During Operation
Very heavily contami- nated components can no longer be cleaned using this method. In this case, ABB Turbo Sys- tems recommends having the contaminated components cleaned mechanically by an ABB Turbocharging Service Station.
Page 81 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 82: Table 13: Turbine Wet Cleaning, Recommended Operating State
During cleaning, the temperature at the turbine inlet will rise and may strain the material significantly. CAUTION Make sure the maximum temperature at the turbine inlet is not exceeded  during cleaning. © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 83: Table 14 Wet Cleaning Of Turbines, Pa
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 Turbocharg- ing Service Station. Product Temperature before...
Page 84: Cleaning Components Mechanically
Dismantling and fitting [➙ 73]. NOTICE Contaminated water and cleaning agents must be disposed of in an environmentally com-  patible, professional way and in compliance with locally applicable regulations. © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 85 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 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 86  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 Figure 24) Insert the absorption segments (81136) into the sheet-metal coverings (81137).
Page 87 Spray cleaned surfaces with penetrating oil. Do not spray exterior surfaces of the turbo-  charger. Dispose of contaminated water and cleaning agents in accordance with the information in  the material safety data sheet. © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 88 Brush away the contamination or remove with a steam cleaner.  If necessary, repeat soaking and brushing.  Use clean water to completely clean parts of any solvents.  Dry components completely.  © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 89  Remove cartridge group (see chapter Dismantling and fitting [➙ 73]).  First clean the compressor end and then the turbine end according to the following descrip- tion. © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 90 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 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 91: Table 15 Value Table For Soaking
Cleaning agents which contain chlorine attack metals. Use only pH-neutral cleaning agents which do not attack metals.  CAUTION Observe safety data sheet.  Fill the container (02) with soaking fluid.  © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 92 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 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 93 Lightly spray the turbine and the gap between the turbine and the partition wall with pene-  trating oil. Dispose of dirty water and cleaning agents in accordance with the information in the mate-  rial safety data sheet. © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 95: Eliminating Malfunctions
To prevent significant loss of effi- ciency, specific tolerances must be fulfilled.  If there is any doubt about the extent of the rubbing, contact an ABB Turbocharging Service Station.  Have a dimension check carried out by an ABB Turbocharging Service Station.
Page 96: Malfunctions During Operation
Turbocharger Light to medium contamination of the tur- Clean (see chapter Periodic maintenance bine and/or nozzle ring (with 4-stroke ap- work [➙ 45]) or contact an ABB Turbo- plication) charging Service Station Table 21: Malfunctions during operation – Speed increases ©...
Page 97: Table 22 Malfunctions During Operation
Clean or repair boiler or exhaust gas si- lencer Pipes Pipes downstream to the compressor Repair. outlet not sealed. Table 23: Malfunctions during operation – Charge air pressure too low © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 98: Table 24 Malfunctions During Operation - Charge Air Pressure Too High
Increased speed due to contamination of Clean (see chapter Periodic maintenance nozzle ring work [➙ 45]) or contact an ABB Turbo- charging Service Station Table 24: Malfunctions during operation – Charge air pressure too high Reduced compressor performance/efficiency, hence engine performance losses...
Page 99: Turbocharger Is Surging
Gradually reduce the engine load.  Have the cause clarified and remedied immediately by an ABB Turbo-  charging Service Station. Have parts assessed for damage and, if necessary, replaced by an ABB  Turbocharging Service Station. Possible causes Remedy...
Page 100: Malfunctions When Stopping
Bearing damaged Check clearances (see chapter Axial clearance A and radial clearance B [➙ 89]). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R [➙...
Page 101: Speed Measurement System
Table 32: Malfunction of the speed measurement system – Measured speed too low 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- NOTICE tion.
Page 103: Dismantling And Fitting
ABB Turbo Systems recommends having further operations carried out  only by trained personnel from an ABB Turbocharging Service Station. Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to dis- assembly. NOTICE © Copyright 2016 ABB. All rights reserved.
Page 104 [➙ 100]). Tightening torques for assembly devices Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB Turbo Systems must be tightened so they rest firmly against the surface. © Copyright 2016 ABB. All rights reserved.
Page 105: Table 33 Swivel Lifting Eyes
 Lifting gear Equipment for the lifting and transporting of loads (ropes, chain block, crane). Lifting gear is not supplied by ABB Turbo Systems. 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.
Page 106: Table 34 Ring Nuts To Be Used
ABB Turbo Systems scope of delivery. Ring nuts to be used (VRM) Product Thread A130 A135 A140 A145 Starpoint ring nut VRM Table 34: Ring nuts to be used © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 107: Weights Of Individual Parts
Turbine casing * 1 inlet Turbine casing * 2 inlets Turbine casing * 3 inlets Gas outlet flange Gas outlet casing Table 35: Weights of assemblies * Including burst protection © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 108: Removing Air Inlets
Dismantling and fitting Page 78 / 117 Removing air inlets Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to dis- assembly. NOTICE Figure 29: Removing the air inlets 1. Loop around the filter silencer (81000) with lifting gear.
Page 109: Removing The Gas Outlet Casing
Dismantling and fitting Page 79 / 117 Removing the gas outlet casing Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to dis- assembly. NOTICE Figure 30: Removing the gas outlet casing 1. Loosen and remove nuts (51009).
Page 110: Removing The Gas Outlet Flange
Pressing off using 3 press-off screws.  Pressing off using 6 press-off screws.  Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to dis- assembly. NOTICE © Copyright 2016 ABB. All rights reserved. HZTL4031_EN...
Page 111: Table 9 Tightening Torque
≤ 65 Nm Table 36: 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 (S) according to the table. If it is not possible to press off the gas outlet flange with the maximum tightening torque, ...
Page 112: Table 37 6 Press-Off Screws - Gas Outlet
≤ 65 Nm Table 37: 6 press-off screws – gas outlet flange *Not included in the ABB Turbo Systems scope of delivery. 1. Evenly press off and remove the gas outlet flange (57002) with screws (S) according to the table.
Page 113: Removing The Compressor Casing
Page 83 / 117 Removing the compressor casing Removing the compressor casing Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to dis- assembly. NOTICE Loosening the compressor casing with press-off tool If the compressor casing cannot be loosened, it can be pressed off against...
Page 114: Pressing Off The Casing
If the casing is pressed off with too much force on one side, the rotor can be CAUTION damaged. Use the tool on both sides in alternation and make sure not to press off  too hard on either side. © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 115: Removing The Cartridge Group
Figure 35: Removing insulation sheets If present: Remove the insulation sheets (01, 02, 03).  Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to dis- assembly. NOTICE Do not remove oil orifice (if present)
Page 116 5. Secure the lifting gear to the ring nuts and suspension eye as shown. 6. Remove the cartridge group vertically from the turbine casing. 7. Turn the cartridge group into the horizontal rotor axis. © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D...
Page 117: Removing The Nozzle Ring
2. Pull out the nozzle ring (56001) with the two extraction devices (90070) and the service support base (90012). 3. Remove the lamellar sealing ring (56005). 4. Remove the burst ring (57210). © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 118: 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 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 119: Axial Clearance A And Radial Clearance B
Serious damage to engines or property can be caused by clearances out- side the tolerance and excessively worn parts. CAUTION Have the components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. Measure and record clearances A and B after the removal and before the installation of the ...
Page 120: Nozzle Ring Compression Pd
Nozzle ring 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 Turbocharging  Service Station. © Copyright 2016 ABB. All rights reserved.
Page 121: Installing Nozzle Ring
3. Insert the nozzle ring (56001) (with the cams facing downwards) into the turbine casing as far as it will go. Align the cams on the nozzle ring with the recesses of the turbine casing (51000). Do not remove the adhesive tape (01). © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D...
Page 122: Installing The Cartridge Group
3. Insert the screws of the service support from above and fit ring nuts (VRM) with washers. 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. © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D...
Page 123: Table 40 Tightening Torque (51007)
3. Lower the cartridge group into the turbine casing. 4. Remove ring nuts and screws. 5. Install the fastening strips (51002) with Verbus Ripp®discs (51003) and hexagon nuts (51007). 6. Tighten the hexagon nuts (51007). © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 124 (02), a separate burst pro- tection (03) is fitted. If the insulation from ABB Turbo Systems (01) is not installed, the separate burst protection (03) plus either the insulation (02) or an appropriate insula- tion supplied by the enginebuilder must be installed for operation.
Page 125: Installing The Compressor Casing
3. Fit a new O-ring (77005). 4. Install the wall insert (77000) in the compressor casing. 5. Secure the diffuser (79000) with fixing discs (79040) and screws (79041). © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 126: Table 42 Tightening Torque (72011)
2. Attach swivel lifting eyes (01) to the compressor casing (72000) and lifting gear. 3. Install the compressor casing (72000). 4. Install the fastening strips (72012) with screws (72011). © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 127: Radial Clearances N And R
Serious damage to engines or property can be caused by clearances out- side the tolerance and excessively worn parts. CAUTION Have the components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. Figure 48: Measuring clearances N and R...
Page 128: Installing Air Inlets
2. Fit the filter silencer (81000) with the O-ring (81010) or the air suction branch (82000) with the O-ring (82010) and V-clamp (72020). 3. Tighten the V-clamp (72020). © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 129: Installing The Gas Outlet Flange
2. 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). 3. If present: Fit the support (61301). 4. Fit and tighten the hexagon nuts (51009). © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 130: Table Of Tightening Torques
15 Nm 15 Nm 15 Nm 51101 / 51103 / 40 Nm 40 Nm 65 Nm 65 Nm 51104 / 61201 Table 46: Tightening torques of the screw fittings © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 131: Table 47 Tightening Torques For Insulation
10 Nm 10 Nm 10 Nm 25 Nm 25 Nm 25 Nm 25 Nm 45 Nm 45 Nm 45 Nm 45 Nm Table 47: Tightening torques for insulation © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 133: Taking Out Of Operation At Short Notice
 If present: Installing a replacement cartridge group [➙ 104].  If a replacement turbocharger or cartridge group is not available: Fit cover plate [➙ 105] and contact an ABB Turbocharging Service Station. Observe the following sections in connection with the emergency repairs mentioned.
Page 134: Installing A Replacement Turbocharger
The repair of a cartridge group requires special tools and the expertise of an ABB Turbocharg- ing Service Station. The rotating parts turn very fast and are very sensitive to unbalance.
Page 135: 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 2016 ABB. All rights reserved. HZTL4031_EN Revision D...
Page 136: Cover Plate Drawing
Page 106 / 117 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. Material: General structural steel, in compliance with DIN EN 10025-2.
Page 137: Mothballing The Turbocharger
If the total acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking an engine out of operation: Dismantle the turbocharger.  The rotor and the bearing parts must be removed by an official ABB Turbocharging service  station and refitted afterwards. Clean all parts.
Page 138: 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 has been completely removed, either as a whole unit or in individual...
Page 139: 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 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 141: Spare Parts
Counter-sunk screw 81010/ 82010 O-ring Table 49: Customer spare part set 97070 * This gasket can only be installed when a gas outlet casing from ABB Turbo Systems is used. © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D...
Page 142: View Of Turbocharger With Part Numbers
Operation Manual / 4 Product description / A130-M.. - A145-M.. Spare parts Page 112 / 117 12.3 View of turbocharger with part numbers Figure 56: Overview of part numbers © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 143: Table 50 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 50: Spare parts list * Depending on the specification of the turbocharger © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 145: Figures
Fig. 26 Turbine end, non-rotating parts . Fig. 27 Soaking the turbine end .... Fig. 28 Weights of assemblies ....Fig. 29 Removing the air inlets ....Fig. 30 Removing the gas outlet casing © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...
Page 147: Tables
– Charge air pressure too low . Table 49 Customer spare part set 97070 . 111 Table 24 Malfunctions during operation Table 50 Spare parts list ......113 – Charge air pressure too high © Copyright 2016 ABB. All rights reserved. HZTL4031_EN Revision D June 2016...

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