Page 1 Operation Manual A145-M65 HT546409 English Original Operation Manual Chapter Document-ID Introduction HZTL4005_EN_E Safety HZTL4022_EN_D Safety data sheet HT546409 Product description HZTL4031_EN_E 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 ..................HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
Page 13: 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. Nev- ertheless, 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.  HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
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 accepts no liability and rejects all warranty claims for any non-intended uses. [1] Euromot = The European Association of Internal Combustion Engine Manufacturers...
Page 16: 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 inspec- tion.
Page 17: 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. HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
Page 18: Turbocharger Rating Plate
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 12 Manufacturing plant HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
Page 19: Periodic Check Of The Pressure Vessels
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".  The locally applicable legal regulations regarding periodic checks of the pressure vessels must be observed.
Page 20: 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. HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
Page 21: Prerequisites For Operation And Maintenance
WARNING personnel. Only use original parts from ABB Turbo Systems.  ABB accepts no liability for any damage resulting from the use of non-original parts and corre- sponding accessories. HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved.
Page 22: 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. HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
Page 23 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, electri-  cal components. Observe national regulations.  HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
Page 24: 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. HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
Page 25 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. HZTL4022_EN Revision D ©...
Page 26: 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.  HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
Page 27 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.  HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
Page 28  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. HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
Page 29  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. HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
Page 33: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 34: Table 19 Malfunctions During Operation
Taking the engine out of operation for up to 12 months ......111 10.2 Taking the engine out of operation for more than 12 months ...... 112 Disposing of turbocharger components ............ Spare parts ..................... © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 35 Page 3 / 121 12.1 Ordering spare parts .................. 12.2 Required customer spare part set (97070) ..........12.3 View of turbocharger with part numbers ............. Figures ....................Tables ....................© Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 37: 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. ABB Turbocharging Service Stations will be happy to provide information on questions regard- ing a design variant (see Contact information at www.abb.com/turbocharging).
Page 38: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 39 (01). In addition, the turbocharger version with compressor wheel cooling is indicated by the turbo- charger type (M6..) on the rating plate. © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 40: 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 41: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 43: Removing And Installing
Table 2: Weights of turbochargers A130-M.. – A145-M.. 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 44: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E...
Page 45 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 [➙ 15].  © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 46 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 47 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 48: Installing The Turbocharger
 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. Figure 9: Inserting gaskets into the bracket...
Page 49: 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 2017 ABB. All rights reserved.
Page 50 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E...
Page 51: Table 4 Tightening Torques For Standard
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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 52 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E...
Page 53: Table 5 Pressure Screw Tightening Tor
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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 54  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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 55: Commissioning
Filtering the lubricating oil with a filter mesh width of ≤ 0.034 mm is sufficient for this turbo- charger. 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 56 With an oil inlet pressure of more than 3 bar (with engine under load) before the turbocharger, the bearing casings are equipped as standard with an orifice at the oil inlet. © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E...
Page 57: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 59: 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 commission-  ing". The turbocharger is now ready for operation.  © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 61: 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 62: 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 Turbocharging Service Station. © Copyright 2017 ABB. All rights reserved.
Page 63: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 64: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 65 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 In the case of malfunctions of the speed measurement system, refer to the chapter entitled Troubleshooting/Speed measurement system [➙...
Page 66: Table 9 Tightening Torque
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. Figure 19: Replacing the speed sensor...
Page 67: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 68 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 69: 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 Turbocharging Service NOTICE Station no later than 5 years after the last service. © Copyright 2017 ABB. All rights reserved.
Page 70 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 71 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 72  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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 73: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 74  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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 75: 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 77: 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 during operation. This allows the thermal load of the engine to be kept low while ensuring maximum fuel efficiency.
Page 78: 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 79 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 80 (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 2017 ABB. All rights reserved. HZTL4031_EN Revision E...
Page 81: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E...
Page 82: Cleaning The Turbine During Operation
Very heavily contami- nated 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 83 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 84: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 85: 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 86: Cleaning Components Mechanically
The disassembly and assembly of the components is described in chapter Dismantling and fitting [➙ 73]. Contaminated water and cleaning agents must be disposed of in an environmentally com-  patible, professional way and in compliance with locally applicable regulations. © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 87 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 88  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 89 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 90 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 91  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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 92 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 93: Table 15 Value Table For Soaking
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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 94 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 95 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 97: 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 98: 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 99: Table 22 Malfunctions During Operation
Clean or repair boiler or exhaust gas si- lencer Pipes Pipes downstream to the compressor out- Repair. let not sealed. Table 23: Malfunctions during operation – Charge air pressure too low © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 100: 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 101: 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 102: Malfunctions When Stopping
Bearing damaged Check clearances (see chapter Axial clearance A and radial clearance B [➙ 91]). If clearances are outside the tolerance or if in doubt, contact an ABB Turbo- charging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R [➙...
Page 103: 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 2017 ABB. All rights reserved.
Page 105: 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 2017 ABB. All rights reserved.
Page 106 The specified tightening torques of the screw fittings must be observed (Table of tightening torques [➙ 105]). 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. © Copyright 2017 ABB. All rights reserved.
Page 107: Table 33 Swivel Lifting Eyes
Minimum load Quantity limit A130 17 mm 100 kg A135 17 mm 150 kg A140 21 mm 250 kg A145 21 mm 300 kg Table 33: Swivel lifting eyes © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 108: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 109: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 110: Removing 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E...
Page 111: Removing The Gas Outlet Casing
Dismantling and fitting Page 79 / 121 Removing the gas outlet casing Removing the insulation Figure 30: Removing the insulation Remove the insulation of the gas outlet casing.  © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 112 3. If present: Loosen the support (61301) from the bracket. 4. Remove the gas outlet casing (61001), set it down properly in an appropriate place and secure it. 5. Remove and dispose of the gasket (61002). © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 113: Removing The Gas Outlet Flange
If the following Working Instructions are not observed, this can lead to cracks in the gas outlet casing. The following variants are possible: Pressing off using 3 press-off screws.  Pressing off using 6 press-off screws.  © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 114: Table 36 3 Press-Off Screws
≤ 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 (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 115: Table 37 6 Press-Off Screws
≤ 65 Nm Table 37: 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 tightening torque, contact an ABB Turbo Systems Service Station.
Page 116: Removing The Compressor Casing
(79040) and diffuser (79000). If the compressor casing cannot be loosened, it can be pressed off against the turbine casing using the press-off tool (90042) (see chapter Pressing off the casing [➙ 86]). © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E...
Page 117 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E...
Page 118: Pressing Off The Casing
Use the tool on both sides in alternation and make sure not to press off  too hard on either side. Figure 36: Press off the casing © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 119: Removing The Cartridge Group
If an oil orifice is fitted in the oil inlet of the bearing casing, it must not be removed. Figure 38: Oil orifice 01 Bearing casing 02 Oil orifice 03 Circlip © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 120 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 [➙ 86]). © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E...
Page 121: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 122: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 123: 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. © Copyright 2017 ABB. All rights reserved.
Page 124: 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 2017 ABB. All rights reserved.
Page 125: Installing Nozzle Ring
Align the cams on the nozzle ring with the recesses of the turbine casing (51000). Do not remove the adhesive tape (01). 5. If present: Fit the metal C-ring (51105). © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E...
Page 126: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E...
Page 127: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 128 (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 129: Installing The Compressor Casing
3. Fit a new O-ring (77005). 4. Install the wall insert (77000) in the compressor casing. 5. Fit the diffuser (79000) with fixing discs (79040) and screws (79041). Observe the tighten- ing torque. © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 130: Table 42 Tightening Torque (72011)
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 2017 ABB. All rights reserved. HZTL4031_EN Revision E...
Page 131: 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. © Copyright 2017 ABB. All rights reserved.
Page 132: Installing 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 133: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 134 Fitting the insulation of the turbine casing Figure 53: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see Table of  tightening torques [➙ 105]). © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 135: 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 the support (61301). 5. Fit the hexagon nuts (51009). Observe the tightening torque. © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 136 Page 104 / 121 Fitting the insulation Figure 55: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see Table of  tightening torques [➙ 105]). © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 137: Table Of Tightening Torques
16a *) 40 Nm 40 Nm 65 Nm 65 Nm Table 46: Tightening torques *) With the variant "insulation with integrated burst protection", this position can be ignored. © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 138: Table 47 Tightening Torques For Insulation
Table 47: Tightening torques for insulation Tightening torque for attaching the insulation with integrated burst protection at the turbine casing Tightening torque for attaching the insulation to the burst protection. © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 139: Taking Out Of Operation At Short Notice
 If present: Installing a replacement cartridge group [➙ 108].  If a replacement turbocharger or cartridge group is not available: Fit cover plate [➙ 109] and contact an ABB Turbocharging Service Station. Observe the following sections in connection with the emergency repairs mentioned.
Page 140: Installing A Replacement Turbocharger
A replacement cartridge group is ready for use immediately and includes the complete bearing casing with bearing and a balanced rotor. 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 141: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E...
Page 142: Cover Plate Drawing
Page 110 / 121 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 143: 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 144  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...
Page 145: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 147: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E...
Page 148: View Of Turbocharger With Part Numbers
Spare parts Page 116 / 121 12.3 View of turbocharger with part numbers Figure 60: Overview of part numbers (……) only available in customer spare part set (97070). © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 149: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 151: Figures
Fig. 27 Soaking the turbine end .... Fig. 60 Overview of part numbers ..116 Fig. 28 Weights of assemblies ....Fig. 29 Removing air inlets ....Fig. 30 Removing the insulation .... © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...
Page 153: Tables
Table 23 Malfunctions during operation – Charge air pressure too low ..Table 50 Spare parts list ......117 Table 24 Malfunctions during operation – Charge air pressure too high ..© Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision E January 2017...

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