Page 1 ABB Turbocharging Operation Manual A135-M65 HT562595 English Original Operation Manual Chapter Document-ID Introduction HZTL4005_EN_D Safety HZTL4022_EN_B Safety data sheet HT562595 Product description HZTL4031_EN_C ABB Turbo Systems Ltd...
Page 2 We herewith confirm that this Operation Manual has been drawn up in compliance with the "EU Product Liability Directive" 85/374/EEC as well as with the "EU Machinery Directive" 2006/42/EC. © Copyright 2016 ABB. All rights reserved. Design and specifications are subject to change without notice.
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 ..................HZTL4005_EN Revision D © Copyright 2015 ABB. All rights reserved. September 2015...
Page 5: Introduction
3 (Safety data sheet) and the rating plate on the turbocharger. Operation Manual The Operation Manual explains the turbocharger from ABB Turbo Systems and contains instructions for safe operation. The Operation Manual is a complement to and expansion of existing national regulations for occupational safety, accident prevention and environmental protection.
Page 6: 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 Stations. They are regularly audited and certified by ABB Turbo Systems. Also see chapter Contact information [➙ 8]. HZTL4005_EN Revision D ©...
Page 7 Dispose of in an environmentally with specifications compatible, professional way and in compliance with locally Oil free, grease free and dry applicable regulations. Table 1: Definition of pictograms HZTL4005_EN Revision D © Copyright 2015 ABB. All rights reserved. September 2015...
Page 8: Storage Of New Turbochargers And Spare Parts
Storage of new turbochargers and spare parts Storage of new turbochargers and spare parts up to 6 months New turbochargers and spare parts from ABB Turbo Systems can be stored in sealed packaging without additional mothballing measures for up to 6 months from the date of delivery (marked by the VCI label on the package).
Page 9 Inspect the package for damage. If the package is damaged, the turbocharger or cartridge  group must be inspected 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:  Inspect the components ...
Page 10: Contact Information
Operation Manual / 1 Introduction Introduction Page 8 / 8 Contact information Contact information for the official service stations of ABB Turbo Systems is available online. Scan the QR code to access our website.  ABB Turbo Systems AG Bruggerstrasse 71a...
Page 11 Periodic check of the pressure vessels ............1.10 Lifting of loads .................... 1.11 Prerequisites for operation and maintenance ..........1.12 Hazards during operation and maintenance ..........1.13 Safe operation ................... 1.14 Safe maintenance ..................© Copyright 2015 ABB. All rights reserved. HZTL4022_EN Revision B April 2015...
Page 13: Safety
Safety Introduction Turbochargers manufactured by ABB Turbo Systems are state of the art and comply with the respective health and safety standards in effect at the time the turbocharger was built. This ensures safe operation of the turbocharger. Nevertheless, there may be some residual risks during operation of and work on the turbocharger which: ...
Page 14: Definition Of Mandatory Signs
CAUTION can lead to CAUTION serious damage to engine or property with grave consequences. Caution signs must always be observed.  © Copyright 2015 ABB. All rights reserved. HZTL4022_EN Revision B April 2015...
Page 15: Intended Use
The specific operating limits of the turbocharger were determined on the basis of information from the enginebuilder about the intended use. These data are given on the rating plate. ABB Turbo Systems accepts no liability and rejects all warranty claims for any non-intended uses.
Page 16: Deflagration On Gas Engines
Deflagration on gas engines ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar. ABB Turbo Systems recommends subjecting the turbocharger to a visual inspection after a deflagration event. As part of the inspection, the position of the turbine casing and the position of the compressor casing to the bearing casing must be checked, and the bearing casing must be examined to see if it has shifted in relation to the bracket.
Page 17: Turbocharger Rating Plate
Replacement interval of turbine in 1000 h Further data Customer part number Designation for special design Weight of turbocharger in kg Turbocharger type 10 Serial number 11 Year of construction of turbocharger © Copyright 2015 ABB. All rights reserved. HZTL4022_EN Revision B April 2015...
Page 18: Periodic Check Of The Pressure Vessels
The locations of the rating plates are defined in the Operation Manual / Product description. Periodic check of the pressure vessels The pressure vessels used by ABB Turbo Systems, for example, in the wet or dry cleaning process, are so-called simple pressure vessels.
Page 19: Lifting Of Loads
The assembly devices must be completely screwed in and must not unscrew during use.  Use assembly devices only for the described applications.  Put down dismantled components of the turbocharger in such a way that they cannot tip  over. © Copyright 2015 ABB. All rights reserved. HZTL4022_EN Revision B April 2015...
Page 20: Prerequisites For Operation And Maintenance
WARNING personnel. Only use original parts from ABB Turbo Systems.  ABB Turbo Systems accepts no liability for any damage resulting from the use of non-original parts and associated accessories. © Copyright 2015 ABB. All rights reserved. HZTL4022_EN Revision B...
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 against thermal risks. © Copyright 2015 ABB. All rights reserved. HZTL4022_EN Revision B April 2015...
Page 22 Page 12 / 18 Hot surfaces on the non-insulated turbocharger Non-insulated turbochargers can cause serious injuries to personnel (burns). ABB Turbo Systems supplies the turbocharger with or without insulation in WARNING accordance with the purchase order received from the enginebuilder. If...
Page 23: Safe Operation
When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay  attention to the risks that may occur as a consequence of this energy input. © Copyright 2015 ABB. All rights reserved. HZTL4022_EN Revision B April 2015...
Page 24 Insulation (01) with integrated burst protection from ABB Turbo Systems. Variant B Burst protection (03) and insulation (02) from ABB Turbo Systems. Variant C Burst protection (03) from ABB Turbo Systems with appropriate insulation from the enginebuilder. © Copyright 2015 ABB. All rights reserved. HZTL4022_EN...
Page 25: Safe Maintenance
Have oil binding agents ready and provide or keep oil pans at hand.  Clean up any spills.  Have fire protection means and extinguishing agents available.  © Copyright 2015 ABB. All rights reserved. HZTL4022_EN Revision B April 2015...
Page 26 Secure rotor against turning. The rotor can rotate due to the stack draught alone.  Wear appropriate protective clothing.  Observe the material safety data sheet for the cleaning and mothballing agents.  © Copyright 2015 ABB. All rights reserved. HZTL4022_EN Revision B April 2015...
Page 27 Observe the information in the material safety data sheet for the operating  materials and supplies. Comply with local legislation.  Wear safety goggles. Wear safety gloves against mechanical risks. Wear a respiratory mask to protect against gases. © Copyright 2015 ABB. All rights reserved. HZTL4022_EN Revision B April 2015...
Page 28 Dispose of insulation materials properly and in an environmentally  compatible manner in compliance with the legal regulations. Wear safety goggles. Wear a respiratory mask to protect against particles. Wear safety gloves against chemical risks. © Copyright 2015 ABB. All rights reserved. HZTL4022_EN Revision B April 2015...
Page 31: Table 10 Expected Replacement Intervals
Periodic maintenance work ..............Foreword to maintenance ................Cleaning the compressor during operation ..........Cleaning the turbine during operation ............Cleaning components mechanically ............Eliminating malfunctions ................. Malfunctions when starting ................. © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 32: Table 19 Malfunctions During Operation
Taking the engine out of operation for up to 12 months ......105 10.2 Taking the engine out of operation for more than 12 months ...... 106 Disposing of turbocharger components ............ Spare parts ..................... © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 33 Page 3 / 115 12.1 Ordering spare parts .................. 12.2 Required customer spare part set (97070) ..........12.3 View of turbocharger with part numbers ............. Figures ....................Tables ....................© Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 35: 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 regarding a design variant (see Operation Manual / 1 Introduction / Customer Service).
Page 36: Layout And Function Of The Turbocharger
03 Diffuser 10 Turbine casing 04 Bearing casing 11 Turbine-end bearing flange 05 Axial thrust bearing 12 Compressor-end bearing flange 06 Radial plain bearing 13 Compressor wheel 07 Turbine © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 37 (01). In addition, the turbocharger version with compressor wheel cooling is indicated by the turbocharger type (M6..) on the rating plate. © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C...
Page 38: Warning Plates On The Turbocharger
Figure 3: Warning plate locations If warning plates are not present in the designated locations or not readable, proceed as follows: Order new warning plates from ABB Turbocharging Service Stations.  Remove any warning plates that have become unreadable. ...
Page 39: Locations Of The Rating Plates
Locations of the rating plates Figure 4: Locations of the rating plates One rating plate (01) each is attached on the left and the right side of the turbocharger bearing casing. © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 41: Removing And Installing
Table 2: Turbocharger weights Figure 5: Suspension of complete turbocharger unit A Turbocharger with water-cooled bearing casing B Turbocharger with oil-cooled bearing casing C Complete turbocharger unit with gas outlet casing © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 42: 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 NOTICE turbocharger. Therefore the turbocharger must always be removed from and installed on the bracket vertically. © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 43 (see instructions of the enginebuilder). Remove the turbocharger.  Cover the oil connections (03) at the engine side to protect against contamination.  © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 44 Working in a circle, loosen each of the pressure screws by about ¼ of a turn (90°).  Repeat the previous step until all pressure screws are relieved of pressure.  Loosen clamping nut by hand.  © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 46: Installing The Turbocharger
The oil is supplied (02) and drained (03) through the bracket (01). The necessary sealing is by means of O-rings which are located in the slots of the bracket. The gaskets are not included in the ABB Turbo Systems scope of delivery and must be provided by the enginebuilder.
Page 47: Table 3 Requirements For Threaded Rods
Fixing material scope of delivery The threaded rods and nuts for fastening the turbocharger on the bracket are not included in the ABB Turbo Systems scope of delivery. These parts depend on the version of the engine- side bracket. The clamping nuts are included in the ABB Turbo Systems scope of delivery.
Page 48 Depending on the bracket version (04), two positioning pins (05) can be used for positioning and safeguarding against wrong fitting of the NOTICE turbocharger. Therefore the turbocharger must always be removed from and installed on the bracket vertically. © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 49: 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 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 50 4. Tighten clamping nut (03) by hand. 5. Unscrew clamping nut (03) by ¼ of a turn (90°). The distance between the thrust washer and the clamping nut is now about 1 mm. © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C...
Page 51: Table 5 Pressure Screw Tightening
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 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 52 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 Figure 16: Attaching the support If present: Attach support (61301) to the engine support.  © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 53: Commissioning
Lubricating oil filtering with a filter mesh width of ≤ 0.034 mm is sufficient for this turbocharger. 3.1.4 Oil pressure Comply precisely with the oil pressure before the turbocharger for trouble-free operation. The admissible values are specified in chapter Monitoring operation [➙ 29]. © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 54 With an oil inlet pressure of more than 3 bar (when engine under load) before the turbocharger, the bearing casings are equipped as standard with an orifice at the oil inlet. © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C...
Page 55: Inspection Procedures
Any prolonged failure of the compressor wheel cooling will shorten the replacement interval of the compressor wheel. CAUTION Make sure there is an uninterrupted supply of cooling air during operation.  © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 57: Commissioning After Taking Out Of Operation
Put engine-side oil circulation to the turbocharger into operation.  Prepare the turbocharger for operation according to section "Checks before  commissioning". The turbocharger is now ready for operation.  © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 59: Monitoring Operation
Oil pressure measuring point Oil temperature measuring point For monitoring the lubricating oil pressure, ABB Turbo Systems recommends installing an "M" manometer immediately before the turbocharger. If the pressure is controlled electronically, the appropriate signals are to be triggered at the warning and alarm values.
Page 60: Table 7 Lubricating Oil Temperature At 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 2015 ABB. All rights reserved.
Page 61: Exhaust Gas Temperature Before Turbine
Definition and explanations concerning rating plate: refer to chapter 2 of Operation  Manual / Safety. Operating limits: refer to chapter 3 of Operation Manual / Safety data sheet or examine  rating plate. © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 62: Turbocharger Speed
42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F/I converter Plug with integrated voltage limiter 86528 Tachometer Installation variant for speed sensor 32109 Sealing disc with cams © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 63  If the engine can be stopped temporarily: Inspect air lines, exhaust gas pipes and the turbochargers and remedy any malfunctions.  ABB Turbo Systems recommends contacting the nearest ABB Turbocharging Service  Station. 4.3.4 Malfunctions on the speed measurement system In the case of malfunctions of the speed measurement system, refer to the chapter entitled Troubleshooting/Speed measurement system [➙...
Page 64: Table 9 Tightening Torque
Screw in new speed sensor (86505) as far as it will go and tighten.  Connect cable connector (86515) to speed sensor (86505).  Switch on lubricating oil supply to the turbocharger.  © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 65: Operation And Service
Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7: A-weighted emission sound pressure level The enginebuilder must provide acoustically equivalent measures in case of deviating insulation versions © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 66 Suggestion for noise insulation, bellows Figure 20: Noise insulation, bellows Compressor casing Bellows Charge air duct / scavenging air duct Insulation cushion Insulation mat (at least 15 mm) Sheet metal cover © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 67: Service Work
CAUTION lead to untimely machine damage even if the prescribed service intervals are observed. Agree on a shortened service interval with ABB Turbo Systems.  5-year service inspection To prevent machine damage caused by ageing and downtime, we...
Page 68 Service work according to data on the rating plate (Usually after 8000 … 12000 operating hours) The rotor and bearing parts must be checked and assessed by an ABB Turbocharging Service Station. The following work can be carried out as preparation.
Page 69 5.2.5 Other service work If a protective grid is installed in the gas outlet casing (61001) by ABB Turbo Systems: Figure 21: Replacing the protective grid Remove the protective grid (61205) after 50000 hours and replace it with a new one.
Page 70  Speed of the turbocharger  Air temperature after the compressor and after the charge-air cooler  Exhaust gas temperature before and after the turbine  Pressure loss in the filter silencer. © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 71: Expected Replacement Intervals
Table 10: Expected replacement intervals = Natural Gas = Marine Diesel Oil = Heavy Fuel Oil The specified values are guideline values and not guaranteed values, see Influencing parameters. © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 72  Lubricating oil quality (oil filtering, oil condition, oil monitoring)  Load profile (speed, pressure conditions, temperature)  Number of starts/stops  Imbalance of the rotor (degree of contamination). © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 73: Stopping The Engine
– 600 °C with non-insulated casing At temperatures below the specified values, post-lubrication must be ensured until the 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).
Page 75: Periodic Maintenance Work
8000 … 12000 h) Table 11: Maintenance table [h] = Hours of operation If the maintenance intervals are incompatible with operation of the engine, contact ABB Turbo Systems. ABB Turbo Systems recommends having mechanical cleaning carried out by an ABB Turbocharging Service Station during the service work.
Page 76: Cleaning The Compressor During Operation
In this case, ABB Turbo Systems recommends having the contaminated components cleaned mechanically by an ABB Turbocharging Service Station. Periodic cleaning in operation is no replacement for service work in which an ABB Turbocharging Service Station completely dismantles and maintains the turbocharger.
Page 77 The compressor is cleaned during operation using the wet cleaning method. It is carried out at an engine load of 50 ... 85 %. This cleaning method has been tested and approved by ABB Turbo Systems. V-engines On V-engines with several turbochargers per engine, parallel cleaning of both turbochargers is recommended.
Page 78 (01) and routed to the filter silencer or air suction branch. The water does not act as a solvent. The coating is removed by the mechanical action of the impacting droplets. © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 79: Table 12 Parameters For Wet Cleaning Of
The success of the cleaning can be recognised based on the charging pressure or the exhaust gas temperature. If the engine values are still unsatisfactory after carrying out the process three times, ABB Turbo Systems recommends having the turbocharger checked and cleaned by an ABB Turbocharging Service Station.
Page 80: Cleaning The Turbine During Operation
In this case, ABB Turbo Systems recommends having the contaminated components cleaned mechanically by an ABB Turbocharging Service Station. Periodic cleaning in operation is no replacement for service work in which an ABB Turbocharging Service Station completely dismantles and maintains the turbocharger.
Page 81 Cleaning method The turbine components are cleaned during operation using the wet cleaning method. This cleaning method is tested and approved by ABB Turbo Systems. The precondition for wet cleaning is that the enginebuilder approves the process and these regulations are observed.
Page 82: Table 13 Turbine Wet Cleaning, Recommended Operating State
During cleaning, the temperature at the turbine inlet will rise and may strain the material significantly. CAUTION Make sure the maximum temperature at the turbine inlet is not exceeded  during cleaning. © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 83: Table 14 Wet Cleaning Of Turbines, Parameters
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 Turbocharging Service Station. Product Temperature before...
Page 84: Cleaning Components Mechanically
Dismantling and fitting [➙ 73]. NOTICE Contaminated water and cleaning agents must be disposed of in an environmentally  compatible, professional way and in compliance with locally applicable regulations. © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 85 (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 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 86  When cleaning, note that the absorption segments (81136) must only be cleaned lightly with compressed air, a soft brush or a moist cleaning cloth. Have any heavily contaminated absorption segments replaced by an ABB Turbocharging  Service Station. Fitting the filter silencer (see Figure 24) Insert the absorption segments (81136) into the sheet-metal coverings (81137).
Page 87 Spray cleaned surfaces with penetrating oil. Do not spray exterior surfaces of the  turbocharger. Dispose of contaminated water and cleaning agents in accordance with the information in  the material safety data sheet. © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 88 Use clean water to completely clean parts of any solvents.  Dry components completely.  Spray cleaned surfaces with penetrating oil. Do not spray exterior surfaces of the  turbocharger. © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 89 Remove turbocharger from engine (see chapter Removing and Installing [➙ 11]).  Remove cartridge group (see chapter Dismantling and fitting [➙ 73]).  First clean the compressor end and then the turbine end according to the following description. © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 90 Lightly spray the compressor wheel and the gap between the compressor and the bearing  casing with penetrating oil. Dispose of dirty water and cleaning agents in accordance with the material safety data  sheet. © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 91: Table 15 Value Table For Soaking
Cleaning agents which contain chlorine attack metals. Use only pH-neutral cleaning agents which do not attack metals.  CAUTION Observe safety data sheet.  Fill the container (02) with soaking fluid.  © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 92 Wear safety gloves against mechanical risks. Lift up the cartridge group and align it horizontally.  Remove dirt manually using a soft brush or a wire brush.  © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 93 Lightly spray the turbine and the gap between the turbine and the partition wall with  penetrating oil. Dispose of dirty water and cleaning agents in accordance with the information in the  material safety data sheet. © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 95: 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 Turbocharging Service Station.  Have a dimension check carried out by an ABB Turbocharging Service Station.
Page 96: Malfunctions During Operation
Remedy Turbocharger Light to medium contamination of the Clean (see chapter Periodic maintenance turbine and/or nozzle ring (with 4-stroke work [➙ 45]) or contact an ABB application) Turbocharging Service Station Table 21: Malfunctions during operation – Speed increases © Copyright 2015 ABB. All rights reserved.
Page 97: Table 22 Malfunctions During Operation
Clean or repair boiler or exhaust gas silencer Pipes Pipes downstream to the compressor Repair. outlet not sealed. Table 23: Malfunctions during operation – Charge air pressure too low © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 98: Table 24 Malfunctions During Operation - Charge Air Pressure Too High
Increased speed due to contamination of Clean (see chapter Periodic maintenance nozzle ring work [➙ 45]) or contact an ABB Turbocharging Service Station Table 24: Malfunctions during operation – Charge air pressure too high Reduced compressor performance/efficiency, hence engine performance losses...
Page 99: Turbocharger Is Surging
Gradually reduce the engine load.  Have the cause clarified and remedied immediately by an ABB  Turbocharging Service Station. Have parts assessed for damage and, if necessary, replaced by an ABB  Turbocharging Service Station. Possible causes Remedy Engine...
Page 100: Malfunctions When Stopping
Bearing damaged Check clearances (see chapter Axial clearance A and radial clearance B [➙ 87]). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R [➙...
Page 101: Speed Measurement System
Table 32: Malfunction of the speed measurement system – Measured speed too low Other causes of malfunction If none of the measures described above remedy the malfunction, have the speed measurement system checked by an ABB Turbocharging Service NOTICE Station.
Page 103: Dismantling And Fitting
ABB Turbo Systems recommends having further operations carried out  only by trained staff or an ABB Turbocharging Service Station. Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to disassembly.
Page 104 [➙ 98]). Tightening torques for assembly devices Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB Turbo Systems must be tightened so they rest firmly against the surface. © Copyright 2015 ABB. All rights reserved.
Page 105: Table 33 Swivel Lifting Eyes
 Lifting gear Equipment for the lifting and transporting of loads (ropes, chain block, crane). Lifting gear is not supplied by ABB Turbo Systems. Swivel lifting eyes to be used Two swivel lifting eyes are required for the safe lifting of loads, which are not supplied by ABB Turbo Systems.
Page 106: Table 34 Ring Nuts To Be Used
ABB Turbo Systems scope of delivery. Ring nuts to be used (VRM) Product Thread A130 A135 A140 A145 Starpoint ring nut VRM Table 34: Ring nuts to be used © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 107: Weights Of Individual Parts
Turbine casing * 1 inlet Turbine casing * 2 inlets Turbine casing * 3 inlets Gas outlet flange Gas outlet casing Table 35: Weights of assemblies * Including burst protection © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 108: Removing Air Inlets
Dismantling and fitting Page 78 / 115 Removing air inlets Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to disassembly. NOTICE Figure 29: Removing the air inlets 1. Loop around the filter silencer (81000) with lifting gear.
Page 109: Removing The Gas Outlet Casing
Dismantling and fitting Page 79 / 115 Removing the gas outlet casing Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to disassembly. NOTICE Figure 30: Removing the gas outlet casing 1. Loosen and remove nuts (51009).
Page 110: Removing The Gas Outlet Flange
Operation Manual / 4 Product description / A130-M.. - A145-M.. Dismantling and fitting Page 80 / 115 Removing the gas outlet flange Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to disassembly. NOTICE Figure 31: Removing the gas outlet flange Product Press-off screws to be used (strength 8.8)*...
Page 111: Removing The Compressor Casing
Page 81 / 115 Removing the compressor casing Removing the compressor casing Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to disassembly. NOTICE Loosening the compressor casing with press-off tool If the compressor casing cannot be loosened, it can be pressed off against...
Page 112: Pressing Off The Casing
If the casing is pressed off with too much force on one side, the rotor can be CAUTION damaged. Use the tool on both sides in alternation and make sure not to press off  too hard on either side. © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 113: Removing The Cartridge Group
Figure 34: Removing insulation sheets If present: Remove the insulation sheets (01, 02, 03).  Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to disassembly. NOTICE Do not remove oil orifice (if present) To limit the oil flow rate through the bearing casing during operation (engine under load) to the admissible values, an oil orifice is mandatory at the oil inlet of the bearing casing if the oil inlet pressure is >...
Page 114 5. Secure the lifting gear to the ring nuts and suspension eye as shown. 6. Remove the cartridge group vertically from the turbine casing. 7. Place the cartridge group on a soft underlay. © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C...
Page 115: Removing The Nozzle Ring
2. Pull out the nozzle ring (56001) with the two extraction devices (90070) and the service support base (90012). 3. Remove the lamellar sealing ring (56005). 4. Remove the burst ring (57210). © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 116: Rotating And Fixing The Cartridge Group
2. Remove the ring nuts (VRM) and screws from the service support. 3. Insert the service support (90012) into the cartridge group. 4. Fit the nuts. 5. Rotate the cartridge group on the service support (90012). © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 117: 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. CAUTION Have the components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. Measure and record clearances A and B after the removal and before the installation of the ...
Page 118: 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 2015 ABB. All rights reserved.
Page 119: Installing Nozzle Ring
(51000). 3. Insert the nozzle ring (56001) into the turbine casing up to the stop. Do not remove the adhesive tape (01). © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C...
Page 120: Installing The Cartridge Group
2. Secure ring nuts (VRM) onto the screws with washers. 3. Secure the lifting gear to the ring nuts and suspension eye as shown. 4. Lift the cartridge group vertically. © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C...
Page 121: Table 39 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 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 122 (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 insulation supplied by the enginebuilder must be installed for operation.
Page 123: Installing The Compressor Casing
3. Fit a new O-ring (77005). 4. Install the wall insert (77000) in the compressor casing. 5. Secure the diffuser (79000) with fixing discs (79040) and screws (79041). © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 124: Table 41 Tightening Torque (72011)
2. Attach swivel lifting eyes (01) to the compressor casing (72000) and lifting gear. 3. Install the compressor casing (72000). 4. Install the fastening strips (72012) with screws (72011). © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 125: Radial Clearances N And R
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. CAUTION Have the components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. Figure 48: Measuring clearances N and R...
Page 126: Installing Air Inlets
2. Fit the filter silencer (81000) with the O-ring (81010) or the air suction branch (82000) with the O-ring (82010) and V-clamp (72020). 3. Tighten the V-clamp (72020). © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 127: Installing The Gas Outlet Flange
2. Attach the lifting gear to the gas outlet casing (61001) and position the gas outlet casing in the correct position on the turbine casing (51000). 3. If present: Fit the support (61301). 4. Fit and tighten the hexagon nuts (51009). © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 128: Table Of Tightening Torques
15 Nm 15 Nm 15 Nm 51101 / 51103 / 40 Nm 40 Nm 65 Nm 65 Nm 51104 / 61201 Table 45: Tightening torques of the screw fittings © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 129: Table 46 Tightening Torques For Insulation
10 Nm 10 Nm 10 Nm 25 Nm 25 Nm 25 Nm 25 Nm 45 Nm 45 Nm 45 Nm 45 Nm Table 46: Tightening torques for insulation © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 131: Taking Out Of Operation At Short Notice
 If present: Installing a replacement cartridge group [➙ 102].  If a replacement turbocharger or cartridge group is not available: Fit cover plate [➙ 103] and contact an ABB Turbocharging Service Station. Observe the following sections in connection with the emergency repairs mentioned.
Page 132: Installing A Replacement Turbocharger
The repair of a cartridge group requires special tools and the expertise of an ABB Turbocharging Service Station. The rotating parts turn very fast and are very sensitive to unbalance.
Page 133: 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 2015 ABB. All rights reserved. HZTL4031_EN Revision C...
Page 134: Cover Plate Drawing
Page 104 / 115 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 135: Mothballing The Turbocharger
If the total acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking an engine out of operation: Dismantle the turbocharger.  The rotor and the bearing parts must be removed by an official ABB Turbocharging service  station and refitted afterwards. Clean all parts.
Page 136: Taking The Engine Out Of Operation For More Than 12 Months
 The casings of the turbocharger remain attached to the engine, the rotor and bearing parts are dismantled by an ABB Turbocharging Service Station and stored separately  The turbocharger has been completely removed, either as a whole unit or in individual...
Page 137: 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 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 139: Spare Parts
Counter-sunk screw 81010/ 82010 O-ring Table 48: Customer spare part set 97070 * This gasket can only be installed when a gas outlet casing from ABB Turbo Systems is used. © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C...
Page 140: View Of Turbocharger With Part Numbers
Operation Manual / 4 Product description / A130-M.. - A145-M.. Spare parts Page 110 / 115 12.3 View of turbocharger with part numbers Figure 56: Overview of part numbers © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 141: Table 49 Spare Parts List
82010 (in the customer spare part set) O-ring 86505* Speed sensor 86515* Cable connector 86526* F/I converter 86528* Tachometer Table 49: Spare parts list * Depending on the specification of the turbocharger © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 143: Figures
Fig. 26 Turbine end, non-rotating parts . Fig. 27 Soaking the turbine end .... Fig. 28 Weights of assemblies ....Fig. 29 Removing the air inlets ....Fig. 30 Removing the gas outlet casing © Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...
Page 145: Tables
Table 48 Customer spare part set 97070 . 109 Table 24 Malfunctions during operation – Table 49 Spare parts list ......111 Charge air pressure too high ..© Copyright 2015 ABB. All rights reserved. HZTL4031_EN Revision C February 2016...

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