Page 1 Turbocharging Operation Manual / A135-H65 HT610642 Document identification Document number HZTL4030 Revision Language English Original Operation Manual Product identification Serial number HT610642 Customer part number 3646534 Delivery date (yyyy-mm-dd) 2022-03-23 Weight Operating limits according to rating plate Speed limit in test rig operation only...
Page 3: Table Of Contents
Monitoring operation ..................45 Oil pressure, oil temperature..................45 Exhaust gas temperature before turbine .............. 47 Turbocharger speed ....................47 Operation and service ..................51 Noise emission ......................51 © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 4 Mothballing the turbocharger................106 11.1 Taking the engine out of operation for up to 12 months ......... 106 11.2 Taking the engine out of operation for more than 12 months ......107 © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 5 Ordering spare parts....................110 13.2 Required customer spare part set (97070)............110 13.3 Spare part – Illustrations ..................111 Tools ........................119 Figures......................... 120 Tables ........................121 © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 6: Operation Manual / A130-H
Availability of the Operation Manual 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 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 7: Contact Information
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 8: Layout And Function Of The Turbocharger
Compressor casing Gas outlet flange Diffuser Nozzle ring Bearing casing Turbine casing Axial thrust bearing Turbine-end bearing flange Radial plain bearing Compressor-end bearing flange Gas outlet casing Compressor wheel © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 9: Fig. 3: Compressor Wheel Cooling
In addition, the turbocharger version with compressor wheel cooling is indicated by the tur- bocharger type (H6..) on the rating plate. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 10: Symbols, Definitions
Caution and warning signs are described in chapter Safety. ABB Turbocharging ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging in this document. Official service stations of ABB Turbocharging Official service stations are regularly audited and certified by ABB Turbocharging. See also chapter Contact information →5.
Page 11: Table 1: Definition Of Pictograms
Visually inspect Please note text for numbered work step. See document Dispose of in an environmentally compatible, professional way and in compliance with locally applicable regulations. Table 1: Definition of pictograms © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 12: 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 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 13: Fig. 5: Package With Hygrometer
Inspect the package for damage. If the package is damaged, the turbocharger must be in- spected by an ABB Turbocharging Service Station and repacked. After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station: ¡...
Page 14: 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 15: Definition Of Mandatory Signs
Non-compliance or inaccurate compliance with working or operating in- structions indicated by this symbol and the word CAUTION can lead to seri- ous damage to engine or property with grave consequences. Caution signs must always be observed. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 16: Intended Use
The use of the turbocharger is limited to the specific application released at the time of de- livery. ABB accepts no liability and rejects all warranty claims for any non-intended uses. WARNING Unapproved operation Any operation of the turbocharger outside of its operating limits can be haz- ardous to personnel.
Page 17: Deflagration On Gas Engines
An ABB Turbocharging Service Station should be instructed to carry out this inspection. 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 18: 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 19: 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 Year of construction of turbocharger Manufacturing plant © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 20: Fig. 8: Locations Of The Rating Plates
Operation above the indicated values n can considerably shorten the recommended Bmax Bmax replacement intervals. In such cases, we recommend contacting the nearest ABB Turbochar- ging Service Station. normally apply only when running at overload (110 %) during trials on the engine Mmax Mmax test bed.
Page 21: Lifting Of Loads
The assembly devices must be completely screwed in and must not loosen 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 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 22: Prerequisites For Operation And Maintenance
Only use original parts from ABB. Original parts and accessories are specially designed for ABB turbochargers. ABB accepts no liability for any damage resulting from the use of non-original parts and cor- responding accessories. © Copyright 2021 ABB. All rights reserved.
Page 23: Hazards During Operation And Maintenance
Do not touch hot surfaces. Observe the warning plate on the turbochar- ger. 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 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 24 Operate the turbocharger in compliance with the specifications. Secure the rotor against unintentional rotation during maintenance. Wear safety gloves to protect against mechanical hazards. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 25: Safe Operation
WARNING Missing burst protection Operating the turbocharger without burst protection can result in serious injury or fatal accidents. Only operate the turbocharger with burst protection from ABB fitted. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 26: 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 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 27 Components of the turbocharger can be damaged or destroyed as a result of improper procedures. Only perform operations that are described in this chapter. Only perform operations for which you have received instruction or train- ing. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 28 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 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 29 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 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 30: Removing And Installing
Depending on the specification, the weight specified on the rating plate may be lower than the standard value specified here. Fig. 11: Transportation of the turbocharger Product Weight of complete turbocharger unit [kg] A130-H A135-H A140-H Table 4: Weight of complete turbocharger unit © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 31: Removing The Turbocharger
The gas outlet casing (61001) can remain fitted in the exhaust gas pipe if the locking nuts are accessible. Otherwise the complete turbocharger unit including gas outlet casing must be removed. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 32 When doing this, proceed as follows: Attach lifting gear to the suspension eye. Remove the turbocharger. Cover the oil connections (03) at the engine side to protect against contamination. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 33: Fig. 13: Loosening The Clamping Nut
3. Working in a circle, loosen each pressure screw by 90° in 1...5 rounds until all of the pres- sure screws have been relieved. Loosen clamping nut by hand. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 34: Fig. 14: Putting Down The Turbocharger
Fig. 14: Putting down the turbocharger 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 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 35: 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 scope of delivery. Fig. 15: Inserting gaskets into the bracket...
Page 36: Fig. 16: Fitting Threaded Rods Onto The Bracket
The threaded rods and nuts for fastening the turbocharger on the bracket are not included in the ABB scope of delivery. The clamping nuts are included in the ABB scope of delivery. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G...
Page 37: Fig. 18: Placing The Turbocharger On The Bracket
Observe the instructions for the fastening variant at hand. ¡ Fastening the turbocharger with a standard nut →36 (A130 - A140) ¡ Fastening the turbocharger with a clamping nut →37 (only A140) © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 38: Table 6: Tightening Torque For Standard Nuts
**) When the turbocharger is mounted on the engine support, the bolt threads and screw heads must be lightly oiled (assumed friction coefficient µ = 0.12 for tightening torque) Remove the lifting gear. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G...
Page 39: Fig. 19: 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 2021 ABB. All rights reserved. HZTL4030_EN Rev.G...
Page 40: Fig. 20: 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 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 41: Fig. 21: 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. 3.3.7 Attaching the support Fig. 22: Attaching the support If present: Attach support (61301) to engine support or to a connecting piece. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 42: Commissioning
Build up oil pressure. Do not exceed a pre-lubrication time of 2 minutes. Start the engine. Let the pre-lubrication pump run until the pump driven by the engine generates sufficient pressure. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 43: Fig. 23: Oil Orifice
With an oil inlet pressure of more than 3 bar of overpressure (with engine under load) up- stream of the turbocharger, an oil orifice must be installed to reduce the oil pressure. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G...
Page 44: 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 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 45 Lubricants and pastes used during assembly can liquefy or vaporise and escape as oily fluids during the initial hours of operation. Continual escape of an oily fluid indicates an oil leak. If there is a leak, contact an ABB Turbocharging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 46: Commissioning After Taking Out Of Operation
Check and clean filter silencer or air supply line, and remove any foreign objects that may be present. Put engine-side oil circulation to the turbocharger into operation. Prepare the turbocharger for operation (see Checks before commissioning →42). The turbocharger is now ready for operation. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 47: Monitoring Operation
Oil pressure measuring point Oil temperature measuring point For monitoring the lubricating oil pressure, ABB Turbocharging recommends installing a "P" manometer immediately upstream of the turbocharger oil inlet before the orifice. If the pressure is controlled electronically, the relevant signals should be triggered at the warning and alarm values.
Page 48: Table 9: Lubricating Oil Temperature At The Inlet
Table 10: Lubricating oil temperature at the outlet If the turbocharger has been operated for a longer period of time outside the admissible range, ABB Turbocharging recommends having the turbocharger inspected by an ABB Tur- bocharging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 49: Exhaust Gas Temperature Before Turbine
For a definition and explanations concerning the rating plate, refer to chapter Safety / →17. Turbocharger rating plate For operating limits, refer to the Operation Manual title page or the rating plate on the turbocharger. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 50: Fig. 24: Layout And Overview Of Speed Measurement System
86505 Speed sensor 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 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 51 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. 5.3.4 Malfunctions on the speed measurement system...
Page 52: Fig. 25: 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. 25: Replacing the speed sensor...
Page 53: 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 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 54: Fig. 26: Noise Insulation, Bellows
Suggestion for noise insulation, bellows Fig. 26: Noise insulation, bellows Compressor casing Bellows Charge air duct / scavenging air duct Insulation cushion Insulation mat (at least 15 mm) Sheet metal cover © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 55: Service Work
Agree on a specific service interval with ABB Turbocharging. To prevent machine damage caused by ageing and downtime, we recommend having an in- spection carried out by an ABB Turbocharging Service Station no later than 5 years after the last service.
Page 56 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 57: Fig. 27: Replacing The Protective Grid
6 Operation and service / 6.2 Service work 6.2.5 Other service work If a protective grid is installed in the radial or axial gas outlet casing (61001) by ABB: Fig. 27: Replacing the protective grid Remove the protective grid (61205) after 50000 hours and replace it with a new one.
Page 58 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 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 59: Expected Replacement Intervals
ABB Turbocharging therefore recommends having the components periodically inspected and replaced, if neces- sary, by an ABB Turbocharging Service Station based on the number of successful engine start cycles specified in the following table.
Page 60: Table 12: Expected Replacement Intervals
¡ 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 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 61: Stopping The Engine
Observe the oil pressure while performing post-lubrication: 0.5 < p ≤1.0. Switch off post-lubrication as soon as the rotor is stationary or after no more than two minutes. Deviating procedures must be coordinated with ABB Turbocharging. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G...
Page 62: Periodic Maintenance Work
(usually every 8000 … 12000 h) →61 Table 13: Maintenance table [h] = Hours of operation ABB Turbocharging recommends having mechanical cleaning carried out by an ABB Tur- bocharging Service Station during the service work. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G...
Page 63: Cleaning Components Mechanically
The disassembly and assembly of the components is described in chapter Dismantling and fitting →78. Contaminated water and cleaning agents must be disposed of in an environmentally compatible, professional way and in compliance with locally applicable regulations. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 64: Fig. 28: 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 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 65 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. 28: Cleaning the filter silencer →62)
Page 66: Fig. 29: Compressor-End, Non-Rotating Parts
Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the tur- bocharger. Dispose of contaminated water and cleaning agents in accordance with the information in the material safety data sheet. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 67: Fig. 30: Turbine End, Non-Rotating Parts
Brush away the contamination or remove with a steam cleaner. Repeat the soaking and brushing if necessary. Use clean water to remove all traces of solvent from parts. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 68 Removing and Installing →28). Remove the cartridge group (see chapter Dismantling and fitting →78). First clean the compressor end and then the turbine end according to the following descrip- tion. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 69 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 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 70: Fig. 31: Soaking The Turbine End
Observe country-specific regulations regarding banned and restricted substances. 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 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 71 Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against mechanical hazards. Lift up the cartridge group and align it horizontally. Remove contamination manually using a soft brush or a wire brush. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 72 Lightly spray the turbine and the gap between the turbine and the heat sheet metal with penetrating oil. Dispose of contaminated water and cleaning agents in accordance with the information in the safety data sheet. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 73: Eliminating Malfunctions
To prevent significant loss of efficiency, specific tolerances must be fulfilled. ¡ If there is any doubt about the extent of the rubbing, contact an ABB Tur- bocharging Service Station. ¡...
Page 74: Malfunctions During Operation
Turbochar- Turbine and/or nozzle ring severely con- Clean (see chapter Periodic mainten- taminated ance work →60) Rotor components or bearing damaged Contact ABB Turbocharging Service Station Engine Defects on the connected cylinders in Contact enginebuilder pulse charging Pipes Defects, such as leaks, in the exhaust...
Page 75: Table 21: Malfunctions During Operation - Exhaust Gas Temperature Too High
Gas piping between engine and turbine leaking Injection mistimed Set correctly Valve control misadjusted Pipes Pipes downstream to the compressor Repair. outlet not sealed. Table 22: Malfunctions during operation – Charge air pressure too low © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 76: Table 23: Malfunctions During Operation - Charge Air Pressure Too High
Clean (see chapter Periodic mainten- ance work →60) Table 24: Malfunctions during operation – Engine performance losses © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 77: 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 78: Malfunctions When Stopping
→60) Bearing damaged Check clearances (see chapter Measuring clear- ance A and B). If clearances are outside the toler- ance or if in doubt, contact an ABB Turbocharging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station.
Page 79: Speed Measurement System
Table 31: 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 2021 ABB. All rights reserved.
Page 80: Dismantling And Fitting
Identification of the assembly devices Not all assembly devices are marked with a part number. Identification is guaranteed by the tool list. This list is enclosed with the toolbox. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 81 The specified tightening torques of the screw fittings must be observed (Table of tightening torques). Tightening torques for assembly devices Unless otherwise described, the screws and nuts of the assembly devices supplied by ABB must be tightened in such a way that they are tight-fitting. WARNING...
Page 82: Weights Of Individual Parts
Equipment for the lifting and transporting of loads (ropes, chain block, crane). Lifting gear is not supplied by ABB. Swivel lifting eyes to be used Swivel lifting eyes are required for the safe lifting of loads, which are not supplied by ABB. Fig. 32: Swivel lifting eyes Product...
Page 83: Fig. 34: Weights Of Assemblies
06 Diffuser 07 Cartridge group 08 Nozzle ring 09 Burst ring 10 Turbine casing * Gas outlet flange Gas outlet casing * Table 33: Weights of assemblies * including burst protection © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 84: Removing The Air Inlets
2. Loosen and remove V-clamp (72020). 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 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 85: Removing The Gas Outlet Casing
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 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 86: A130 A135 A140
≤ 65 Nm Table 34: 3 press-off screws * not included in the ABB 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 Turbocharging Service Station.
Page 87: Fig. 38: Removing The Gas Outlet Flange
≤ 40 Nm Table 35: 6 press-off screws * not included in the ABB 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 Turbocharging Service Station.
Page 88: Removing The Compressor Casing
If the compressor casing cannot be loosened, it can be pressed off against the turbine cas- →88). ing using the press-off tool (90042) (see chapter Pressing off the casing © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 89: Wall Insert
1. Knock the wall insert (77000) out of the compressor casing (72000) with a plastic tip hammer. 2. Attach swivel lifting eye (S) to the compressor casing (72000) and the lifting gear. 3. Lift up the compressor casing (72000). 4. Remove and dispose of the O-ring (77005). © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 90: 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. 41: Press off the casing © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 91: Removing The Cartridge Group
Fig. 43: Removing cartridge group 1 1. Treat threads of studs (51006) with penetrating oil and leave to take effect. 2. Undo nuts (51007) and remove Verbus Ripp® washers (51003) together with fastening strips (51002). © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 92: Fig. 44: Removing Cartridge Group 2
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 →88). © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 93: Removing The Nozzle Ring
2. Position the fastening strips (51002) in place. 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 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 94: Installing The Cartridge Group On The Service Support
Fig. 46: Installing the cartridge group on the service support 1. Remove ring nuts (VRM). 2. Remove service support screws. 3. Fit service support (90012) according to the illustration. 4. Insert the cartridge group. 5. Fit the nuts. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 95: Measuring Clearance A And B
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 96: Nozzle Ring Compression Pd
Table 37: Nozzle ring compression PD 1. Measure dimensions A, B and S on cleaned surfaces. 2. Calculate compression (PD). If the calculated value (PD) lies outside the specified range, contact an ABB Turbochar- ging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 97: Installing The Nozzle Ring
Align the cams on the nozzle ring with the recesses of the turbine cas- ing (51000). Do not remove the adhesive tape (01). 5. If present: Fit the metal C-ring (51105). © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G...
Page 98: 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 2021 ABB. All rights reserved. HZTL4030_EN Rev.G...
Page 99: Fig. 52: Installing The Cartridge Group
3. Lower the cartridge group into the turbine casing. 4. Remove ring nuts and screws. 5. Fit fastening strips (51002) with Verbus Ripp® washers (51003) and hexagon nuts (51007). 6. Tighten the hexagon nuts (51007). © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 100: Installing The Compressor Casing
Required customer spare part set (97070) 2. Install the wall insert (77000) into the compressor casing. 3. Secure the diffuser (79000) with fixing discs (79040) and new screws (79041) (see chapter Required customer spare part set (97070) →110). © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 101: Fig. 54: Installing The Compressor Casing
2. Thoroughly clean the fastening strips (72012) before assembly. 3. Attach swivel lifting eyes (01) to the compressor casing (72000) and lifting gear. 4. Install the compressor casing (72000). 5. Install the fastening strips (72012) with screws (72011). © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 102: Measuring Radial Clearances N And R
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 103: Installing The Air Inlets
2. Fit a new O-ring (81010) to the filter silencer (81000) or a new O-ring (82010) to the air suction branch (82000). 3. Fit the filter silencer (81000) or air suction branch (82000) with the V-clamp (72020). 4. Observe tightening torque. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 104: Installing The Gas Outlet Flange
2. Coat the threads of the studs (51008) with high-temperature grease. 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). © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G...
Page 105: Table Of Tightening Torques
M12 x 1.5 M12 x 1.5 M12 x 1.5 15 Nm 15 Nm 15 Nm 51101 / 51103 / 20 Nm 20 Nm 40 Nm 51104 / 61201 Table 45: Tightening torques of the screw fittings © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 106: Taking Out Of Operation At Short Notice
¡ If present: Installing the replacement turbocharger →105. ¡ If present: Installing the replacement cartridge group →105. Observe the following sections in connection with the emergency repairs mentioned. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 107: Installing The Replacement Turbocharger
The repair of a cartridge group requires special tools and the expertise of an ABB Turbochar- ging Service Station. The rotating parts rotate extremely quickly, and are sensitive to unbal- ance.
Page 108: 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 109: 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 110: Material And Disposal
(RoHS2). Products and related accessories manufac- tured by ABB Switzerland Ltd, Turbocharging do not fall within the Scope of RoHS2 due to their application in large scale fixed installations, means of transports for persons or goods, non-road mobile machinery (Directive 2011/65/EC Article 2, 4.(e), (f), (g)).
Page 111: Disposing Of Turbocharger Components
Dispose of metals as scrap metal for recycling. 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 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 112: Spare Parts
O-ring 79041 Counter-sunk screw 81010/ 82010 O-ring Table 46: Customer spare part set 97070 * This gasket can only be installed when a gas outlet casing from ABB is used. © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 113: Spare Part - Illustrations
Screw plug 42126** Graphite cord sealing 42188 Hexagon-head screw 42189 Gasket 42190 Expansion bush 42194 Gasket 42196 Orifice oil inlet 42197 Safety ring 42201** Clamping nut (only for A140-H) Table 47 © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 114: Nozzle Ring 2 2
51017** Compensator sheet metal 51027(p) Screw plug 51101 Hexagon-head screw 51102 Tension washer 51105** Metal C-ring 51500 Burst protection 56001 Nozzle ring 56005 Lamellar sealing ring 57002 Gas-outlet flange © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 115: Gas Outlet Casing
** = if provided * = Available within the spare part set only HZTL443303 Mod. B Part no. Designation 61001 Gas-outlet casing 61001** Gas-outlet casing GHV03 61002* Gasket Table 49 © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 116: Table 50
* = Available within the spare part set HZTL443302 Mod. C Part no. Designation 61001 Gas-outlet casing 61002* Gasket 61005(p) Screw plug 61200** Burst protection 61201** Hexagon-head screw 61202** Tension washer 61205** Protective grid Table 50 © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 117: Table 51
Screw plug 72006(p) Gasket 72011 Hexagon-head screw 72012 Fastening strip 72020 V-clamp 72080 Warning plate 77000 Wall insert 77005* O-ring 79000 Diffuser 79040 Fixing washer 79041* Counter-sunk screw Table 51 © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 118: Fig. 60: Spi Air Suction Branch Radial
Fig. 60: SPI Air suction branch radial Part no. Designation 82000 Air suction branch 82005 Screw plug 82006 Gasket 82007 Screw plug 82008 Gasket 82010* O-ring Table 52: Spare parts - Air suction branch radial © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 119: Table 53
* = Available within the spare part set HZTL443560 Mod. A Part no. Designation 82000 Air suction branch 82005(p) Screw plug 82006(p) Gasket 82007(p) Screw plug 82008(p) Gasket 82010* O-ring Table 53 © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 120: Table 54
13 Spare parts / 13.3 Spare part – Illustrations Speed measurement system 86505** 86515** 86526** 86528** ** = if provided HZTL443468 Mod. A Part no. Designation 86505** Speed sensor 86515** Cable connector 86526** F/I-converter 86528** Tachometer Table 54 © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021...
Page 121: Tools
90042 Press-off tool 90070 Extraction device Table 55: Customer tool set 90000 Tool sets can be ordered from any ABB Turbocharging Service Station. The following spe- cifications must be included in the order: ¡ Turbocharger type ¡ Designation and part number of the tool set.
Page 122: Figures
Fig. 29: Compressor-end, non-rotating parts ..64 Fig. 60: SPI Air suction branch radial ......116 Fig. 30: Turbine end, non-rotating parts ....65 Fig. 31: Soaking the turbine end ........ 68 © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Revision G July 2021...
Page 123: Tables
Table 52: Spare parts - Air suction branch radial ... 116 Table 24: Malfunctions during operation – Engine performance losses ............. 74 Table 53 ................117 Table 25: Malfunction – Turbocharger pumping..75 Table 54 ................118 © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Revision G July 2021...

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