Page 1 Operation Manual A145-M65 HT580667 English Original Operation Manual Chapter Document-ID Introduction HZTL4005_EN_F Safety HZTL4022_EN_E Safety data sheet HT580667 Product description HZTL4031_EN_F 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 29 Operation Manual / A145-M65 / Safety data sheet Page 1 / 1 Safety data sheet A145-M65 HT580667 A145-M65 HT580667 1001965584 2018 © Copyright 2018 ABB. All rights reserved. HT580667 August 2018...
Page 31 Cleaning components mechanically ............... 49 Eliminating malfunctions..................59 Malfunctions when starting..................59 Malfunctions during operation ................60 Turbocharger is surging .................... 63 Malfunctions when stopping..................64 Speed measurement system ..................65 © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 32 Ordering spare parts....................107 12.2 Required customer spare part set (97070)............107 12.3 View of turbocharger with part numbers ............108 Figures......................... 110 Tables ........................111 © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
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
01Filter silencer / air suction branch 08Gas outlet flange 02Compressor casing 09Nozzle ring 03Diffuser 10Turbine casing 04Bearing casing 11Turbine-end bearing flange 05Axial thrust bearing 12Compressor-end bearing flange 06Radial plain bearing 13Compressor wheel 07Turbine © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
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 2017 ABB. All rights reserved. HZTL4031_EN Revision F...
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 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 38: Removing And Installing
Table 2: Weights of turbochargers A130-M.. – A145-M.. Fig. 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 F August 2017...
Page 39: 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 F...
Page 40 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 →12. © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 41: Fig. 7: Loosening The Clamping Nut
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 F...
Page 42: Fig. 8: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 43: 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 44: Fig. 10: 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 2017 ABB. All rights reserved.
Page 45: Fig. 12: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision F...
Page 46: Table 4: Tightening Torques For Standard Nuts
Hydraulic pre- [mm] torques [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 F August 2017...
Page 47: Fig. 13: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision F...
Page 48: Fig. 14: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 49: Fig. 15: 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. 2.3.7 Attaching the support Fig. 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 F August 2017...
Page 50: 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 →25. © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 51: Fig. 17: Oil Orifice
With an oil inlet pressure of more than 3 bar (with engine under load) before the turbochar- ger, the bearing casings are equipped as standard with an orifice at the oil inlet. © Copyright 2017 ABB. All rights reserved. HZTL4031_EN...
Page 52: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 53 Lubricants and pastes used during assembly can liquefy or vaporise and es- cape 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 2017 ABB. All rights reserved. HZTL4031_EN...
Page 54: 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 F August 2017...
Page 55: 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 electron- ically, the appropriate signals are to be triggered at the warning and alarm values.
Page 56: 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 2017 ABB. All rights reserved.
Page 57: 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 F August 2017...
Page 58: 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 F August 2017...
Page 59 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 60: Fig. 19: 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. 19: Replacing the speed sensor...
Page 61: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 62 Suggestion for noise insulation, bellows Fig. 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 F August 2017...
Page 63: 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 Sta- tion no later than 5 years after the last service. © Copyright 2017 ABB. All rights reserved.
Page 64 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 65: Fig. 21: 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. 21: Replacing the protective grid Remove the protective grid (61205) after 50000 hours and replace it with a new protect- ive grid.
Page 66 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 F August 2017...
Page 67: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 68 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 F August 2017...
Page 69: 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 70: 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 71: 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 72 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 73 (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 F August 2017...
Page 74: Fig. 22: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision F...
Page 75: 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 76 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 77: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 78: Fig. 23: Carrying Out Wet Cleaning Of Turbines
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...
Page 79: Cleaning Components Mechanically
The disassembly and assembly of the components is described in chapter Dismantling and fitting →66. Contaminated water and cleaning agents must be disposed of in an environmentally compatible, professional way and in compliance with locally applicable regulations. © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 80: Fig. 24: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 81 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. 24: Cleaning the filter silencer →50)
Page 82: Fig. 25: Compressor-End, Non-Rotating Parts
Spray cleaned surfaces with penetrating oil. Do not spray exterior surfaces of the tur- bocharger. 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 F August 2017...
Page 83: Fig. 26: Turbine End, Non-Rotating Parts
Place contaminated parts in hot water or in a liquid such as carbon remover to soften the contamination. 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. © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 84 Removing and Installing →8). Remove cartridge group (see chapter Dismantling and fitting →66). 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 F August 2017...
Page 85 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 F August 2017...
Page 86: Fig. 27: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 87 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 F August 2017...
Page 88 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 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 89: 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. ¡ Have a dimension check carried out by an ABB Turbocharging Service Sta- tion.
Page 90: Malfunctions During Operation
Turbocharger Turbine and/or nozzle ring severely con- Clean (see chapter Periodic maintenance taminated work →40) Rotor components or bearing damaged Contact ABB Turbocharging Service Sta- tion Pipes Defects, such as leaks, in the exhaust gas Repair pipes or charge air ducts Table 20: Malfunctions during operation –...
Page 91: Table 22: Malfunctions During Operation - Exhaust Gas Temperature Too High
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 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 92: Table 24: Malfunctions During Operation - Charge Air Pressure Too High
Clean (see chapter Periodic maintenance work →40) Table 25: Malfunctions during operation – Engine performance losses © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 93: 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 94: Malfunctions When Stopping
Bearing damaged Check clearances (see chapter Axial clearance A and radial clearance B →84). If clearances are outside the tolerance or if in doubt, contact an ABB Tur- bocharging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R →92).
Page 95: 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 96: 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 97 (Table of tightening torques →98). 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. HZTL4031_EN...
Page 98: Table 33: Swivel Lifting Eyes
Minimum Quantity load 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 F August 2017...
Page 99: Table 34: Ring Nuts To Be Used
Operation Manual / 4 Product description / A130-M.. - A145-M.. 8 Dismantling and fitting / 8.1 Introduction Two ring nuts are required for safer lifting of the cartridge group, which are not included in the ABB Turbo Systems scope of delivery. Ring nuts to be used (VRM) Product...
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 35: Weights of assemblies * including burst protection © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 101: 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 F August 2017...
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. 30: Removing the insulation Remove the insulation of the gas outlet casing. © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 103: Fig. 31: Removing The Gas Outlet Casing
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 F August 2017...
Page 104: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 105: Fig. 32: Dismantling The Gas Outlet Flange
≤ 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 106: Fig. 33: Removing The Gas Outlet Flange
≤ 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 tight- ening torque, contact an ABB Turbo Systems Service Station.
Page 107: 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 →79). © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 108: Fig. 35: Dismantling The Wall Insert
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 F August 2017...
Page 109: 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. 36: Press off the casing © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 110: Removing The Cartridge Group
If an oil orifice is fitted in the oil inlet of the bearing casing, it must not be removed. Fig. 38: Oil orifice 01 Bearing casing 02 Oil orifice 03 Circlip © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 111: Fig. 39: 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 →79). © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 112: 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 F August 2017...
Page 113: Installing The Cartridge Group On The Service Support
Fig. 42: 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 F August 2017...
Page 114: Axial Clearance A And Radial Clearance 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 2017 ABB. All rights reserved.
Page 115: 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 Turbochar- ging Service Station. © Copyright 2017 ABB. All rights reserved.
Page 116: Installing 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 2017 ABB. All rights reserved. HZTL4031_EN Revision F...
Page 117: 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 F...
Page 118: Fig. 47: Installing The Cartridge Group
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 F August 2017...
Page 119: Fig. 48: Turbine Casing Insulation / Burst Protection
(02), a separate burst protection (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 120: 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 tight- ening torque. © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 121: Fig. 49: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 122: 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 2017 ABB. All rights reserved.
Page 123: 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 F August 2017...
Page 124: 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 F August 2017...
Page 125: Fig. 53: Fitting The Insulation
8 Dismantling and fitting / 8.18 Installing the gas outlet flange Fitting the insulation of the turbine casing Fig. 53: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see Table of tightening torques →98). © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 126: 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 F August 2017...
Page 127: Fig. 55: Fitting The Insulation
8 Dismantling and fitting / 8.19 Installing the gas outlet casing Fitting the insulation Fig. 55: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see Table of tightening torques →98). © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 128: Table Of Tightening Torques
15 Nm 15 Nm 15 Nm 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 ig- nored. © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 129: Fig. 57: Tightening Torques For Insulation
Table 47: 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 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 130: Taking Out Of Operation At Short Notice
¡ If a replacement turbocharger or cartridge group is not available: Fit cover plate →102 and contact an ABB Turbocharging Service Station. Observe the following sections in connection with the emergency repairs mentioned. © Copyright 2017 ABB. All rights reserved.
Page 131: Installing A Replacement Turbocharger
The repair of a cartridge group requires special tools and the expertise of an ABB Turbochar- ging Service Station. The rotating parts turn very fast and are very sensitive to unbalance.
Page 132: 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 F...
Page 133: 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 134: 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 135: 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 136: 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 F August 2017...
Page 137: 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 F August 2017...
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. 60: Overview of part numbers (……) only available in customer spare part set (97070). © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 139: 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 F August 2017...
Page 140: Figures
Fig. 59: Cover plate drawing........103 Fig. 29: Removing air inlets ......... 71 Fig. 60: Overview of part numbers......108 Fig. 30: Removing the insulation........ 72 Fig. 31: Removing the gas outlet casing ....73 © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...
Page 141 Table 24: Malfunctions during operation – Charge air pressure too high ............62 Table 25: Malfunctions during operation – Engine performance losses ............. 62 Table 26: Malfunction – Turbocharger pumping..63 © Copyright 2017 ABB. All rights reserved. HZTL4031_EN Revision F August 2017...

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