Operation Manual: HT575708 English
Operation Manual: HT575708 English
A135-H65
HT575708 English
Original Operation Manual
Chapter Document-ID
1 Introduction HZTL4005_EN_F
2 Safety HZTL4022_EN_E
ABB Turbocharging
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.
Operation Manual / 1 Introduction
Table of contents
Introduction
1 Introduction............................................................................................................ 2
1.1 Purpose of the manual.................................................................................................. 2
1.2 Symbols, definitions...................................................................................................... 3
1.3 Storage of new turbochargers and spare parts ...................................................... 5
1.4 Contact information...................................................................................................... 7
© Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017
Operation Manual / 1 Introduction
1 Introduction / 1.1 Purpose of the manual
1 Introduction
This Operation Manual belongs to the turbocharger with the identical serial number (01), see
chapter 3 (Safety data sheet) and the rating plate on the turbocharger.
Page 2 / 7
Operation Manual
The Operation Manual explains the turbocharger and contains instructions for safe opera-
tion.
The Operation Manual is a complement to and expansion of existing national regulations for
occupational safety, accident prevention and environmental protection.
Target group
The Operation Manual is aimed at engineers and trained mechanics responsible for the
proper operation of the engine and for the turbocharger connected to it.
© Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017
Operation Manual / 1 Introduction
1 Introduction / 1.2 Symbols, definitions
Symbols
The following symbols are used in this document:
u Indicates an action step.
Definition of Note
NOTICE
Note
The note provides advice which facilitates the work.
Page 3 / 7
are described in chapter Safety and must be complied with.
© Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017
Operation Manual / 1 Introduction
1 Introduction / 1.2 Symbols, definitions
Definition of pictograms
The following pictograms can occur in this document. These point out actions that must be
taken in accordance with the meaning of the relevant pictogram.
Apply screw locking paste (e.g. Please note text for numbered
Loctite) work step
Apply high-temperature grease See document
© Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017
Operation Manual / 1 Introduction
1 Introduction / 1.3 Storage of new turbochargers and spare parts
Only dry rooms with 40...70 % atmospheric humidity, in which no water condensation can
form, are suitable as storage locations.
Storage of new turbochargers and spare parts for more than 6 months
WARNING
Health protection when handling VCI
VCI products are not hazardous in terms of the Ordinance on Hazardous
Page 5 / 7
Substances. Nevertheless, the following points must be observed when
handling VCI:
u Observe information in material safety data sheet
u Ensure proper space ventilation.
u Do not eat, drink or store food at the workplace while working with VCI.
u Clean hands and face after working with VCI.
u For more information, see www.branopac.com.
u Remove VCI corrosion protection emitter from package and replace with a new VCI corro-
sion protection emitter of the same kind. New VCI corrosion protection emitters can be
obtained from www.branopac.com.
u Old VCI corrosion protection emitters must be disposed of in an environmentally compat-
ible, professional way and in compliance with locally applicable regulations.
u 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
Operation Manual / 1 Introduction
1 Introduction / 1.3 Storage of new turbochargers and spare parts
After every 3 years, the following steps must be carried out by an ABB Turbocharging Service
Station:
¡ Checking the component
¡ Replacing the desiccant
¡ Repackaging the component.
NOTICE
Replacement components which are ready for operation
If the 70% field of the hygrometer (02) has not changed colour and the pack-
age is not damaged, the replacement turbocharger or replacement cartridge
group can be put into operation without previously having been checked by
an ABB Turbocharging Service Station.
© Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017
Operation Manual / 1 Introduction
1 Introduction / 1.4 Contact information
www.abb.com/turbocharging
Page 7 / 7
© Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017
Operation Manual / 2 Safety / A130 - A155
Table of contents
Safety
1 Safety ...................................................................................................................... 2
1.1 Introduction .................................................................................................................... 2
1.2 CE conformity ................................................................................................................. 2
1.3 Definition of mandatory signs .................................................................................... 3
1.4 Definition of safety instructions ................................................................................ 3
1.5 Intended use .................................................................................................................. 4
1.6 Deflagration on gas engines ....................................................................................... 5
1.7 Warning plates on the turbocharger......................................................................... 6
1.8 Turbocharger rating plate............................................................................................ 7
1.9 Periodic check of the pressure vessels..................................................................... 8
1.10 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
Operation Manual / 2 Safety / A130 - A155
1 Safety / 1.1 Introduction
1 Safety
1.1 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:
¡ Are caused by the turbocharger itself or its accessories.
¡ Are caused by the operating equipment used or supplies and materials.
¡ Are a consequence of insufficient compliance with safety instructions.
¡ Are a consequence of insufficient or inappropriate performance of maintenance and in-
spection work.
The operating company is responsible for defining measures that regulate safe access to
and safe handling of the turbocharger.
All instructions contained in this chapter must be observed for safe and trouble-free opera-
tion of the turbocharger and during all work on the turbocharger.
Page 2 / 18
All further safety instructions contained and specifically identified in every chapter of this
manual (Definition of safety instructions →3) must also be observed.
1.2 CE conformity
Information
ABB turbochargers comply with the Machinery Directive 2006/42/EC and are partly com-
pleted machinery as defined by Article 2 g in this directive.
© Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017
Operation Manual / 2 Safety / A130 - A155
1 Safety / 1.3 Definition of mandatory signs
Page 3 / 18
Table 2: Personal protective equipment to be worn specific to the respective task
WARNING
Definition of Warning
Non-compliance or inaccurate compliance with working or operating in-
structions indicated by this symbol and the word WARNING can lead to seri-
ous injuries to personnel and even to fatal accidents.
u Warning signs must always be observed.
CAUTION
Definition of Caution
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.
u Caution signs must always be observed.
© Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017
Operation Manual / 2 Safety / A130 - A155
1 Safety / 1.5 Intended use
plate.
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.
u Only operate the turbocharger within the operating limits.
u Only trained personnel must operate the turbocharger.
The intended use of the turbocharger includes compliance with all regulations and condi-
tions. In particular, the following must be observed:
¡ Operation Manual
¡ Instructions of the enginebuilder
© Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017
Operation Manual / 2 Safety / A130 - A155
1 Safety / 1.6 Deflagration on gas engines
Perfect condition
The turbocharger must only be used when it is in a technically flawless condition and oper-
ated in compliance with its intended use.
ABB excludes any liability for damage resulting from unauthorized modifications to the tur-
bocharger or improper operation.
Page 5 / 18
¡ Cracks in casings
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.
© Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017
Operation Manual / 2 Safety / A130 - A155
1 Safety / 1.7 Warning plates on the turbocharger
If warning plates are not present in the intended locations or are not legible, they must be
replaced with new warning plates. The necessary information can be found in the Operation
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.
Page 6 / 18
© Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017
Operation Manual / 2 Safety / A130 - A155
1 Safety / 1.8 Turbocharger rating plate
Operating limits
01 Turbocharger operating limits at engine overload (110 %).
In test rig operation only, unless otherwise agreed with the en-
ginebuilder.
Page 7 / 18
02 Turbocharger operating limits during operation
Further data
06 Customer part number
07 Designation for special design
08 Weight of turbocharger in kg
09 Turbocharger type
10 Serial number
11 Year of construction of turbocharger
12 Manufacturing plant
© Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017
Operation Manual / 2 Safety / A130 - A155
1 Safety / 1.9 Periodic check of the pressure vessels
The pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, are
so-called "simple pressure vessels".
¡ The locally applicable legal regulations regarding periodic checks of the pressure vessels
must be observed.
¡ The operating company is responsible for the safe operation of the pressure vessel.
WARNING
Danger due to pressure vessels
The operating company must make sure the pressure vessels are in proper
working condition and monitor them. Necessary repair or maintenance work
must be performed promptly, and the required safety measures must be
taken.
u Pressure equipment must not be operated if defects are present.
© Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017
Operation Manual / 2 Safety / A130 - A155
1 Safety / 1.10 Lifting of loads
WARNING
Suspended loads
Loads that are not attached according to regulations can cause injury to
personnel or fatal accidents.
u Loads must always be fastened to properly functional lifting gear with a
sufficient load limit.
u Pay attention to the correct attachment of loads on the crane hook.
u People must not stand beneath suspended loads.
Page 9 / 18
Fig. 3: Attachment of loads on the crane hook
If there are two or more suspension points, the attachment angle of 45° must not be ex-
ceeded. This prevents excessive loading due to diagonal pull.
u Before looping around the components of the turbocharger, let them cool down (max-
imum 80 °C).
u Attach components of the turbocharger as described in the respective action steps.
u The assembly devices must be completely screwed in and must not unscrew during use.
u 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
Operation Manual / 2 Safety / A130 - A155
1 Safety / 1.11 Prerequisites for operation and maintenance
Competence of personnel
The turbocharger must only be operated and serviced by trained and authorised personnel.
Basic mechanical training is a prerequisite.
WARNING
Use original parts
Operation of the turbocharger with non-original parts can impair the safety
of the turbocharger and can cause serious damage to property and injury to
personnel.
u Only use original parts from ABB Turbo Systems.
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. HZTL4022_EN Revision E May 2017
Operation Manual / 2 Safety / A130 - A155
1 Safety / 1.12 Hazards during operation and maintenance
Noise hazards
The turbocharger's noise emission during operation is influenced by its installation and op-
erating conditions. A noise level exceeding 85 dB(A) is harmful.
WARNING
Danger due to noise
Exposure to noise can harm the hearing system, impair health and the psy-
chological state and may lead to lack of attention and irritation.
u When the engine is running, always wear ear protection.
u Always wear ear protection if the sound pressure level exceeds 85 dB(A).
Page 11 / 18
during operation. The surface temperature depends on the efficacy of the existing insula-
tion. The temperature may rise to a level that can cause burns.
WARNING
Danger of burns
Touching hot surfaces or contact with hot operating fluids can cause burns.
u Do not touch hot surfaces. Observe the warning plate on the turbochar-
ger.
u Wear heat-resistant safety gloves and protective clothing.
u Wait for the turbocharger to cool down before carrying out any work.
© Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017
Operation Manual / 2 Safety / A130 - A155
1 Safety / 1.12 Hazards during operation and maintenance
WARNING
Hot surfaces on the non-insulated turbocharger
Non-insulated turbochargers can cause serious injuries to personnel (burns).
The turbocharger is supplied with or without insulation in accordance with
the purchase order received from the enginebuilder. If supply is without in-
sulation, the enginebuilder is responsible for providing the turbocharger
with proper insulation and for providing protection against contact with hot
surfaces.
u Compliance with the instructions and specifications given by the en-
ginebuilder to protect against hot turbocharger surfaces is compulsory.
WARNING
Physical hazards
Contact with rotating parts can cause severe injury. The turbocharger must
Page 12 / 18
never be used without the filter silencer or the air suction branch. With the
engine stopped, the rotor can rotate due to the stack draught alone.
u Operate the turbocharger in compliance with the specifications.
u Secure the rotor against unintentional rotation during maintenance.
WARNING
Dangers during work on electrical installations
Electrical installations use voltages that can lead to severe injury to person-
nel or accidents resulting in fatalities.
At the same time, electrical or electronic components and parts can also be
damaged or destroyed.
u Only specially trained personnel should perform work on, or with, elec-
trical components.
u Observe national regulations.
© Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017
Operation Manual / 2 Safety / A130 - A155
1 Safety / 1.13 Safe operation
WARNING
Absence of grounding on electrical installations
Missing or incorrectly fitted grounding conductors can lead to severe injury
to personnel or accidents resulting in fatalities.
Electric shock or elevated electromagnetic disturbances can damage or des-
troy electrical and electronic components.
u Ground electrical installations properly with grounding conductors.
u Check the grounding connections on a regular basis and make sure they
are properly connected.
u Switch off the power supply before working on any electrical installations.
u After switching off the power supply, wait for 5 minutes to allow capacitors to discharge
and hot components to cool down.
u Ensure the power supply is switched off when working on electrical installations.
u Do not carry out any tests with regard to insulation resistance or voltage on the electrical
components.
Page 13 / 18
Mechanical hazards during operation
During standard operation, no mechanical hazards are caused by the turbocharger itself if it
has been properly installed.
u Check all pipes to and from the turbocharger for damage and leaks before commission-
ing.
u Check turbocharger for recognisable damage or defects every 12 hours of operation or at
least once a day.
u Report any damage and any alterations of operational characteristics to the responsible
department immediately.
u In case of damage, take the turbocharger out of operation immediately and safeguard
against accidental/unauthorised use.
u 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
Operation Manual / 2 Safety / A130 - A155
1 Safety / 1.13 Safe operation
WARNING
Burst protection and insulation
Operation without burst protection and insulation or with the wrong com-
bination of burst protection and insulation can cause serious injuries to per-
sons or even fatal accidents.
u 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 14 / 18
© Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017
Operation Manual / 2 Safety / A130 - A155
1 Safety / 1.14 Safe maintenance
Occupational safety
WARNING
Injuries to persons
Severe injuries to personnel or fatal accidents can be caused by mechanical
influences as a consequence of hazardous and inadequate operational pro-
cedures or non-compliance with safety and health standards.
u When working on the turbocharger always wear safety footwear and pro-
tective clothing to protect against mechanical hazards.
u Keep personal protective equipment in perfect condition.
u Obey mandatory signs.
u Observe the general rules for occupational safety and prevention of acci-
dents.
u Only perform operations that are described in this manual.
u Only perform operations for which you have received instruction or train-
ing.
Page 15 / 18
Wear safety footwear to protect against mechanical hazard and risk of fall-
ing.
WARNING
Risk of falling
When working on the turbocharger, there is a risk of falling.
u Do not climb onto the turbocharger or onto attached parts and do not
use them as climbing aids.
u Use suitable climbing aids and working platforms for work above body
height.
u Only perform work on the turbocharger when you are in a physically and psychologically
stable condition.
u Only work with suitable tools, equipment and appliances that function properly.
u Keep the workplace clean; clear away any loose objects and obstacles on the floor.
u Have oil binding agents ready and provide or keep oil pans at hand.
© Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017
Operation Manual / 2 Safety / A130 - A155
1 Safety / 1.14 Safe maintenance
u Cover all connections on the turbocharger so that no foreign objects can enter the tur-
bocharger.
u Wear personal protective equipment (PPE) for welding operations.
u Wear personal protective equipment (PPE) according to the material safety data sheet.
u Inspect the electric cables for abrasion and damage before and after your cleaning work.
u Observe the procedures for set-up, service and inspection work and the inspection inter-
vals.
u Inform the operating staff before starting any service or repair work. Make sure the en-
gine is not started while work is being conducted on the turbocharger.
u Before taking off any cover or removing any guard from the turbocharger, switch off the
engine and wait until the turbocharger has come to a standstill.
u Make sure that the oil supply is interrupted, especially with an external oil supply.
u Only restart the engine after all parts have been properly fitted again and oil supply is en-
sured.
CAUTION
Mechanical operations on the turbocharger
Components of the turbocharger can be damaged or destroyed as a result
of improper procedures.
u Only perform operations that are described in this manual.
u Only perform operations for which you have received instruction or train-
ing.
u Observe the material safety data sheet for the cleaning and mothballing agents.
u Wear personal protective equipment (PPE) according to the material safety data sheet.
© Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017
Operation Manual / 2 Safety / A130 - A155
1 Safety / 1.14 Safe maintenance
WARNING
Physical hazards due to rotating parts
The rotor can rotate due to the stack draught alone. Contact with rotating
parts can cause severe injury.
u Secure rotor against turning.
WARNING
Mechanical hazards
Severe injuries to personnel or fatal accidents can be caused by mechanical
influences as a consequence of hazardous and inadequate operational pro-
cedures.
u Observe the general rules for occupational safety and prevention of acci-
dents.
u Ensure workplace safety.
u Only perform operations that are described in this chapter.
u Only perform operations for which you have previously received instruc-
tion or training.
Page 17 / 18
Hazards due to operating materials and supplies
Operating materials and supplies are substances required for the operation of the tur-
bocharger or for the performance of maintenance work. Oils, greases, coolants, detergents
and solvents, acids and similar substances can be classified as hazardous substances.
WARNING
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or con-
tact with them may be harmful to health.
u Do not breathe in these substances and avoid contact with the skin.
u Ensure proper ventilation.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Wear personal protective equipment (PPE) according to the material
safety data sheet.
u Comply with local legislation.
© Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017
Operation Manual / 2 Safety / A130 - A155
1 Safety / 1.14 Safe maintenance
WARNING
Danger of fire or explosion
Flammable and combustible operating materials and supplies can catch fire
or resulting vapours can lead to an explosion.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Comply with local legislation.
u Do not allow any exposed flame or ignition source during cleaning work.
u Carry out cleaning in the open or provide sufficient ventilation.
CAUTION
Environmental hazard
Improper handling of operating materials and supplies can lead to environ-
mental damage.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Comply with local legislation.
Page 18 / 18
WARNING
Danger from insulation materials
Dust or fibres from insulation materials can have adverse effects on the
health or cause irritations. Unsuitable and combustible insulation materials
are a fire hazard.
u Only use suitable and non-combustible insulation materials.
u Ensure good ventilation at the workplace.
u Avoid whirling up dust.
u Use dust-free tools and working methods.
u Remove package at the workplace only.
u Proceed with particular care when removing old insulation materials.
u Dispose of insulation materials properly and in an environmentally com-
patible manner in compliance with the legal regulations.
© Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017
Operation Manual / A135-H65 / Safety data sheet
Page 1 / 1
A135-H65 HT575708
A135-H65 HT575708
908 680
888 650
3646534
270 16 50 50
2018
Product description
1 Introduction............................................................................................................ 3
1.1 Essential information.................................................................................................... 3
1.2 Registered trademarks ................................................................................................. 3
1.3 Related documents........................................................................................................ 3
1.4 Layout and function of the turbocharger ................................................................ 4
1.5 Warning plates on the turbocharger......................................................................... 6
1.6 Locations of the rating plates..................................................................................... 7
3 Commissioning .................................................................................................... 20
3.1 Oil supply ...................................................................................................................... 20
3.2 Inspection procedures ................................................................................................ 22
3.3 Commissioning after taking out of operation...................................................... 24
7 Eliminating malfunctions.................................................................................... 49
7.1 Malfunctions when starting...................................................................................... 49
7.2 Malfunctions during operation ................................................................................ 50
7.3 Turbocharger is surging ............................................................................................ 53
7.4 Malfunctions when stopping.................................................................................... 54
7.5 Speed measurement system .................................................................................... 55
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
Table of contents
Figures................................................................................................................... 90
Tables .................................................................................................................... 91
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
1 Introduction / 1.1 Essential information
1 Introduction
Design variants
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).
Accuracy of illustrations
The illustrations in this document are general in nature and intended for ease of understand-
ing. Differences in detail are therefore possible.
Page 3 / 91
The trademarks of outside companies are used in this document. These are marked with the
® symbol.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
1 Introduction / 1.4 Layout and function of the turbocharger
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
1 Introduction / 1.4 Layout and function of the turbocharger
Mode of operation
The turbocharger is a turbomachine and consists of the following main components:
¡ Turbine
¡ Compressor.
The exhaust gases of the internal combustion engine flow through the turbine casing (10)
and the nozzle ring (09) onto the turbine (07). The turbine (07) uses the energy contained in
the exhaust gas to drive the rotor and, hence, the compressor wheel (13). The exhaust gases
then reach the atmosphere through the exhaust gas pipe connected to the gas outlet
flange (08).
The compressor wheel (13) sucks in fresh air through the air suction branch (01). In the com-
pressor wheel (13), the energy required for building up the pressure is transferred to the air.
By flowing through the diffuser (03) and the compressor casing (02), the air is compressed
further and is then directed to the engine cylinders.
The rotor runs in two radial plain bearings (06) which are located in the bearing casing (04)
between compressor and turbine. The axial thrust bearing (05) is located between the two
radial plain bearings.
The plain bearings are connected to a central lubricating oil duct which is normally supplied
by the lubricating oil circuit of the engine. The oil outlet always lies at the deepest point of
the bearing casing (04).
Page 5 / 91
Turbocharger version with compressor wheel cooling
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
1 Introduction / 1.5 Warning plates on the turbocharger
If warning plates are not present in the designated locations or not readable, proceed as fol-
lows:
u Order new warning plates from ABB Turbocharging Service Stations.
u Clean and degrease the areas designated for the warning plates.
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. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
1 Introduction / 1.6 Locations of the rating plates
Page 7 / 91
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. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
2 Removing and Installing / 2.1 Turbocharger weight and transporta-
tion
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
2 Removing and Installing / 2.2 Removing the turbocharger
u If present: Loosen and remove the compressor wheel cooling connection. Close the com-
pressor wheel cooling opening with a screw plug (01).
Page 9 / 91
Fig. 6: Removing the turbocharger
u If present: Disconnect the plug to the speed sensor (86505) and secure the rolled-up
cable on the turbocharger. This protects the plug from being crushed.
u If present: Detach the support (61301) from the engine support.
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.
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 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
2 Removing and Installing / 2.2 Removing the turbocharger
WARNING
Risk of scalding from hot water
If the water connections are removed immediately after taking the tur-
bocharger out of operation, the hot cooling water that flows out can cause
scalding if it comes into contact with the skin.
u Allow turbocharger to cool down before removing the water pipes.
u Wear safety gloves to protect against thermal hazards.
CAUTION
Freezing of cooling water in bearing casing
Serious property damage can result from cooling water freezing in the pipes
and the bearing casing.
u Drain cooling water from bearing casing through two screw plugs before
turbocharger transport and storage.
Manual loosening
Page 10 / 91
u Cover the oil connections (03) at the engine side to protect against contamination.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
2 Removing and Installing / 2.2 Removing the turbocharger
CAUTION
Incorrect procedure can make loosening impossible
Never relieve individual pressure screws completely. If this procedure is not
complied with, the pressure screws can get compressed, thus making it im-
possible to loosen them.
u Comply with the following steps for loosening the pressure screws.
CAUTION
Do not clean pressure screws
The pressure screws are equipped with a permanent sliding layer that must
not be removed.
Do neither clean nor lubricate the pressure screws. In case of non-compli-
ance, it cannot be ensured that the necessary tension force is reached.
u Do not clean pressure screws.
u Do not lubricate pressure screws.
Page 11 / 91
Fig. 7: Loosening the clamping nut
u Working in a circle, break loose all pressure screws of the clamping nut.
u Working in a circle, loosen each of the pressure screws by about ¼ of a turn (90°).
u Repeat the previous step until all pressure screws are relieved of pressure.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
2 Removing and Installing / 2.2 Removing the turbocharger
WARNING
Risk of tipping
If the turbocharger is not positioned stably, it may tip over. This can result in
serious personal injury.
u Place the turbocharger on a clean, level support.
u Secure the turbocharger to prevent it from tipping over by using wooden
beams and wedges and by taking the centre of gravity into account.
Page 12 / 91
u Remove turbocharger from engine support, set it down properly in an appropriate place
and secure it.
u Close or cover the openings of the turbocharger and support.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
2 Removing and Installing / 2.3 Installing the turbocharger
CAUTION
Inserting the gaskets
Gaskets that are forgotten, damaged or improperly inserted will lead to oil
leaks.
u Always use new gaskets and insert them carefully into the slot.
Page 13 / 91
Fig. 9: Inserting gaskets into the bracket
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Operation Manual / 4 Product description / A130-H.. - A140-H
2 Removing and Installing / 2.3 Installing the turbocharger
1. Lightly oil the surfaces of the threaded rods (02) to be screwed in.
2. Screw the threaded rods into the bracket with the aid of locknuts (01).
3. Remove nuts (01) again.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
2 Removing and Installing / 2.3 Installing the turbocharger
Page 15 / 91
Fig. 12: Placing the turbocharger on the bracket
B Clamping nut
C Standard nut
u Make sure that covers of the oil and water connections are removed.
1. Make sure that the O-rings (03) are undamaged and positioned correctly in the slots.
2. Clean the expansion bushes (42190) and the contact surfaces of the expansion bushes in
the bearing casing.
3. Attach the lifting gear to the suspension eye of the bearing casing (42001) and loop
around the gas outlet casing.
4. Position the turbocharger on the bracket (04) and align it. If present, pay attention to the
positioning pin (05) in the bracket.
5. When fixing with a standard nut (C), fit the expansion bushes in the correct position in
the slot .
Safeguard against wrong fitting (only for water-cooled bearing casings)
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. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
2 Removing and Installing / 2.3 Installing the turbocharger
**) 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)
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
2 Removing and Installing / 2.3 Installing the turbocharger
CAUTION
Do not clean pressure screws (04)
The pressure screws are equipped with a permanent sliding layer that must
not be removed.
Do neither clean nor lubricate the pressure screws. In case of non-compli-
ance, it cannot be ensured that the necessary tension force is reached.
u Do not clean pressure screws.
u Do not lubricate pressure screws.
In order to correctly fit the clamping nuts, the pressure screws (04) must not protrude from
the clamping nuts (03) in the direction of the thrust washer (02).
u Make sure the pressure screws do not protrude in the direction of the thrust washer.
Page 17 / 91
Fig. 13: Preparing the clamping nut for the tightening procedure
1. Check whether the expansion bushes (42190) with recess are correctly positioned and do
not touch the flange of the core hole cover (A).
2. Clean the thread of the bolt (01) and the contact surface.
3. Lightly oil the bolt thread.
4. Position the thrust washer (02) in place.
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. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
2 Removing and Installing / 2.3 Installing the turbocharger
Torque-controlled tightening
Product Fixing screw [mm] Tightening torques [Nm]
A140 M24 35
Table 5: Pressure screw tightening torque
table.
3. Tighten pressure screws crosswise to 100 % of the tightening torque specified in the
table.
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. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
2 Removing and Installing / 2.3 Installing the turbocharger
u Connect all exhaust gas, water and air lines according to the instructions of the engineb-
uilder.
CAUTION
Failure of compressor wheel cooling
Any prolonged failure of the compressor wheel cooling will shorten the re-
placement interval of the compressor wheel.
u Make sure there is an uninterrupted supply of cooling air during opera-
tion.
Page 19 / 91
Fig. 15: Connecting the compressor cooling air intake
u Remove the screw plug on the connection for the compressor wheel cooling (06) and fit
the cooling air line.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
3 Commissioning / 3.1 Oil supply
3 Commissioning
3.1.1 Introduction
In all operating states, a functioning and carefully executed oil supply is an important pre-
requisite for trouble-free operation of the turbocharger.
The lubrication of the turbocharger is usually carried out with oil from the engine oil circula-
tion.
u Comply with the enginebuilder's specifications regarding the selection of lubricating oil
and the oil change intervals.
3.1.2 Pre-lubrication
Pre-lubrication must be carried out as follows:
u Switch on the oil pump.
Page 20 / 91
u Build up oil pressure (see Table 6: Lubricating oil pressure at oil inlet before turbocharger
→25).
u Do not exceed a pre-lubrication time of 2 minutes.
u Let the oil pump run until the pump driven by the engine generates sufficient pressure.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
3 Commissioning / 3.1 Oil supply
01 Bearing casing
02 Oil orifice
03 Circlip
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.
Page 21 / 91
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
3 Commissioning / 3.2 Inspection procedures
3.2.1 Introduction
Inspection procedures include preventative visual controls, monitoring and measuring work
before and during commissioning. Inspection procedures enable changes to the turbochar-
ger to be detected. Engine damage can be prevented.
Lubricating system
CAUTION
Contaminated oil
Serious damage to engine or property can be caused by dirt and solid ma-
Page 22 / 91
Warning plates
u Check whether warning plates are present and legible.
CAUTION
Failure of compressor wheel cooling
Any prolonged failure of the compressor wheel cooling will shorten the re-
placement interval of the compressor wheel.
u Make sure there is an uninterrupted supply of cooling air during opera-
tion.
u Check whether the compressor wheel cooling is fitted on the bearing casing.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
3 Commissioning / 3.2 Inspection procedures
CAUTION
Failure of bearing casing cooling
Any prolonged failure of the water cooling will shorten the lifetime of the
turbocharger.
u Make sure that an uninterrupted supply of cooling water is provided dur-
ing operation.
u Check whether the water pipes are fitted on the bearing casing.
Lubricating system
u Keep to the lubricating oil pressure at the inlet.
Page 23 / 91
Leaktightness of pipes
WARNING
Risk of burning from hot gas
Escaping gases are hot and will lead to serious burns in the event of contact.
u Check all pipes for leaks in accordance with the enginebuilder’s instruc-
tions.
u Measure the exhaust gas temperature before and after the turbine.
u Compare the measured values with the values of the acceptance report. Different operat-
ing conditions indicate a malfunction (see chapter Eliminating malfunctions →49).
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 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
3 Commissioning / 3.3 Commissioning after taking out of operation
If present
u Remove cover plates (blind flanges) from the compressor casing, the gas inlet and the
gas outlet.
u Remove the screw plugs on the water connections and fit the water pipe.
General
u Check the exhaust gas pipe before and after the turbine for combustion residues or wa-
ter residues and clean it. Remove any foreign objects that may be present.
u Check and clean filter silencer or air supply line, and remove any foreign objects that may
be present.
u Put engine-side oil circulation to the turbocharger into operation.
Page 24 / 91
u Prepare the turbocharger for operation according to section "Checks before commission-
ing".
u The turbocharger is now ready for operation.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
4 Monitoring operation / 4.1 Oil pressure, oil temperature
4 Monitoring operation
CAUTION
Assuring lubricating oil pressure
Serious damage to engine or property can result from missing or insuffi-
cient lubricating oil supply.
u The lubricating oil pressure must be monitored during operation and the
necessary pressure assured at the oil inlet.
Page 25 / 91
Normal operation 2.0 < poil ≤ 4.5
Engine start: Cold oil, admissible for maximal 15 < 8.0
minutes
Engine idling, admissible for maximal 1 hour 0.5 < poil ≤ 2.5
Pre-lubrication and post-lubrication (engine stopped) 0.5 < poil ≤ 1.0
Warning signal: (n ≥ 0.5 x nBmax) < 1.25
Alarm signal: Not admissible. Stop the engine immedi- < 0.5
ately.
Table 6: Lubricating oil pressure at oil inlet before turbocharger
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.
*) If the drain pipe is vented, the measuring point for lubricating oil temperature can be in-
stalled at the outlet in the vent tank. Otherwise the measurement should be taken in the
drain pipe as close to the turbocharger as possible.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
4 Monitoring operation / 4.1 Oil pressure, oil temperature
CAUTION
Machine damage
If the oil temperature at the oil inlet exceeds the admissible range, this may
lead to engine damage.
u Observe oil temperature at the oil inlet according to the following table.
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. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
4 Monitoring operation / 4.2 Exhaust gas temperature before turbine
CAUTION
Factors influencing replacement intervals
Operation above the operating limits defined on the rating plate can
shorten the recommended replacement intervals considerably.
u Measure exhaust gas temperature upstream of turbine.
u Comply with operating limits on rating plate.
Page 27 / 91
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
4 Monitoring operation / 4.3 Turbocharger speed
4.3.1 Introduction
A speed measuring system enables the constant monitoring of the turbocharger speed.
CAUTION
Do not strain cables
If you pull the speed measurement cables too hard, contacts can be pulled
out.
u Do not strain the speed measurement cables by pulling.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
4 Monitoring operation / 4.3 Turbocharger speed
u Measure the temperatures in the air lines and gas piping from and to the turbochargers
and compare with normal values. If clear deviations of temperature are found, the nearest
ABB Turbocharging Service Station has to be contacted.
u Check the pressure loss of the alternative air inlet and compare it with normal values.
Page 29 / 91
u In any case, contacting the nearest ABB Turbocharging Service Station is recommended.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
4 Monitoring operation / 4.3 Turbocharger speed
WARNING
Hot speed sensor
Danger of burns. The speed sensor can reach temperatures of more than
100 °C during operation.
u Wear safety gloves when disassembling the speed sensor.
The speed sensor supplied by ABB is equipped with a sealing lip and an O-ring. No additional
gasket is required during assembly.
Page 30 / 91
u Reduce the engine performance to idling and then stop the engine. Pay attention to post-
lubrication (Stopping the engine →38).
u Switch off the lubricating oil supply to the turbocharger.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
5 Operation and service / 5.1 Noise emission
WARNING
Danger due to noise
Exposure to noise can harm the hearing system, impair health and the psy-
chological state and may lead to lack of attention and irritation.
u When the engine is running, always wear ear protection.
u Always wear ear protection if the sound pressure level exceeds 85 dB(A).
The emission sound pressure level (A-weighted) is measured at a distance of 1 meter from
the turbocharger.
The highest value of the emission sound pressure level1) reaches a maximum of 105 dB(A)
near the filter silencer. The following prerequisites must be fulfilled with regard to the tur-
Page 31 / 91
bocharger to observe this limit value:
¡ Air-inlet system has been fitted
¡ All standard, noise-reducing measures2) have been fitted
¡ Bellows at the air-outlet has been acoustically insulated by the enginebuilder (see
Fig. 20: Noise insulation, bellows →32).
The enginebuilder is responsible for insulating the charge air/scavenging air line and the
charge air cooler.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
5 Operation and service / 5.1 Noise emission
01 Compressor casing
02 Bellows
Page 32 / 91
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
5 Operation and service / 5.2 Service work
CAUTION
Service intervals
Any service work on the turbocharger that is omitted or performed too late
can cause excessive contamination, wear and operating failures.
u Carry out the service work at the specified time intervals.
CAUTION
Shortened service intervals
Exceptional stresses such as several starts/stops per day, harsh environ-
mental conditions, poor fuel quality or high system vibrations can lead to
untimely machine damage even if the prescribed service intervals are ob-
served.
u Agree on a shortened service interval with ABB Turbo Systems.
Page 33 / 91
NOTICE
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. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
5 Operation and service / 5.2 Service work
CAUTION
Unknown operational changes
Impairment to the degree of a possible operating failure can be the con-
sequence.
u Have any unknown causes clarified by an ABB Turbocharging Service Sta-
tion.
u Visual check for air, exhaust gas, water and oil leaks.
u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en-
gine is stopped.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
5 Operation and service / 5.2 Service work
u Remove the protective grid (61205) after 50000 hours and replace it with a new one.
Page 35 / 91
CAUTION
Replace the protective grid of pre-mix gas engines after 20000 hours
Applications on pre-mix gas engines result in a high thermo-mechanical load
on the protective grid. To ensure proper functionality of the protective grid
even under these conditions, the protective grid of pre-mix gas engines
must be replaced after 20000 hours.
u Replace the protective grid of pre-mix gas engines after 20000 hours.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
5 Operation and service / 5.2 Service work
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Operation Manual / 4 Product description / A130-H.. - A140-H
5 Operation and service / 5.3 Expected replacement intervals
Rotating components
The recommended replacement intervals for compressor and turbine wheels are specified
based on the safety concept for rotating parts (SIKO) and dependent on the operating con-
ditions. These intervals are shown on the rating plate of the turbocharger.
Non-rotating components
Depending on the system-specific operating conditions, a differentiation must be made
between the intervals to be expected for:
¡ replacing the bearing parts and
¡ replacing the non-rotating components exposed to hot gas.
A decisive role is played by various influencing parameters which, in extreme cases, can
drastically shorten the replacement interval of these parts.
During the prescribed periodic service work, the individual parts are examined for wear and
replaced if necessary.
Page 37 / 91
Expected replacement intervals [h]
Pre-mix GAS GAS / MDO
Turbine casing 25000 … 50000 25000 … 50000
Nozzle ring 25000 … 50000 25000 … 50000
Gas outlet flange 25000 … 50000 25000 … 50000
Heat shield 25000 … 50000 25000 … 50000
Protective grid in gas outlet 40000 50000
casing
Rotor components See rating plate information
Bearing parts 12000 … 24000 12000 … 24000
Other casings 50000 50000
Table 10: Expected replacement intervals
The specified values are guideline values and not guaranteed values, see Influencing para-
meters.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
5 Operation and service / 5.4 Stopping the engine
Influencing parameters
The specified values are guideline values and are not guaranteed. The actual values can devi-
ate considerably from the guideline values, for example, due to the following influences:
¡ Fuel quality and fuel treatment
¡ Load profile (thermal cycling, also number of starts/stops, emergency shutdowns, oper-
ating point)
¡ Gas inlet temperature
¡ Turbocharger specification.
¡ System-specific operating conditions (combustion quality, exhaust gas composition)
For bearing parts
¡ 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).
CAUTION
Residual heat in the turbocharger
If the residual heat in the turbocharger is not adequately dissipated, it may
damage the engine.
u Adequate cooling of the turbocharger must be ensured after stopping
the engine.
u Observe the oil pressure while performing post-lubrication: 0.5 < poil ≤1.0.
u 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 Turbo Systems.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
6 Periodic maintenance work / 6.1 Foreword to maintenance
6.2.1 Preparation
CAUTION
Component damage and corrosion
If mechanical cleaning is carried out incorrectly, this can lead to damage and
corrosion on the components.
u Pay attention to the specifications in this chapter pertaining to mechan-
ical cleaning.
Page 39 / 91
CAUTION
Selection of cleaning tools
Turbocharger components are sensitive and easily sustain mechanical dam-
age. The use of needle descalers (for example) or other striking tools dam-
ages the components. Depending on the specification, nozzle rings or tur-
bine casings may have protective coatings which can also be damaged.
u Use only soft tools such as rags, brushes or wire brushes.
u In case of heavy contamination, the cleaning methods described in this
chapter (such as soaking, for example) can be repeated until a satisfact-
ory result is achieved.
The disassembly and assembly of the components is described in chapter Dismantling and
fitting →56.
u 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. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
6 Periodic maintenance work / 6.2 Cleaning components mechanically
u Clean filter ring (81265) as required or every 500 hours of operation and replace after the
fifth cleaning process at the latest.
Contamination of the filter ring depends on the degree of purity of the sucked-in air.
u Rinse the filter ring (81265) with water and mild detergent or, in the case of heavy con-
tamination, soak and carefully push through. Rinse in cold water. Avoid high mechanical
loads (water jet).
u Let the filter ring dry completely before assembling.
u Dirty water and mild detergent must be disposed of in compliance with locally applicable
regulations.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
6 Periodic maintenance work / 6.2 Cleaning components mechanically
u Pull out and bend up the sheet-metal coverings (81137), and remove the absorption seg-
ments (81136).
u Clean the absorption segments (81136).
When cleaning, note that the absorption segments (81136) must only be cleaned lightly
with compressed air, a soft brush or a moist cleaning cloth.
u Have any heavily contaminated absorption segments replaced by an ABB Turbocharging
Service Station.
u Bend the sheet-metal coverings (81137) back to their original shape and insert into the
slotted guides in the filter silencer body (81135).
Page 41 / 91
u Fit the cover grid (81266).
u Fit the tension bands (81270) and tighten them at the locks (81271).
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
6 Periodic maintenance work / 6.2 Cleaning components mechanically
WARNING
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or con-
tact with them may be harmful to health.
u Do not breathe in these substances and avoid contact with the skin.
u Ensure proper ventilation.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Wear personal protective equipment (PPE) according to the material
safety data sheet.
u Comply with local legislation.
The following parts, which are relevant in terms of performance, can be cleaned in accord-
ance with the description below.
u Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the tur-
bocharger.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
6 Periodic maintenance work / 6.2 Cleaning components mechanically
u Dispose of contaminated water and cleaning agents in accordance with the information
in the material safety data sheet.
WARNING
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or con-
tact with them may be harmful to health.
u Do not breathe in these substances and avoid contact with the skin.
u Ensure proper ventilation.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Wear personal protective equipment (PPE) according to the material
safety data sheet.
u Comply with local legislation.
Page 43 / 91
Wear safety gloves to protect against chemical hazards.
Baked layers of contamination, for example, from coked oil occur at the turbine end. The fol-
lowing parts, which are relevant in terms of performance, can be cleaned in accordance with
the description below.
u Place contaminated parts in hot water or in a liquid such as brake cleaner to soften the
contamination.
u Brush away the contamination or remove with a steam cleaner.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
6 Periodic maintenance work / 6.2 Cleaning components mechanically
u Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the tur-
bocharger.
u Dispose of contaminated water and cleaning agents in accordance with the information
in the material safety data sheet.
CAUTION
Corrosion
If the cartridge group is not put back into operation immediately after clean-
ing, parts may corrode.
u Immediately after cleaning, install the cartridge group and put it back
into operation.
Compressor wheels can be heavily contaminated due to poorly filtered suction air; turbines
can be heavily contaminated due to coked oil. Contamination such as this must be removed
Page 44 / 91
First clean the compressor end and then the turbine end according to the following descrip-
tion.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
6 Periodic maintenance work / 6.2 Cleaning components mechanically
CAUTION
Selection of the cleaning agent
Cleaning agents which contain chlorine attack metals.
u Use only pH-neutral cleaning agents which do not attack metals.
u Observe safety data sheet.
CAUTION
Water and contamination in the cartridge group
If water or contamination penetrates the cartridge group, this can impair
the function of the turbocharger and damage parts inside the cartridge
group.
u Make sure that no water or contamination can enter into the cartridge
group.
u Clean the compressor wheel with a rag or soft brush which has been soaked in water with
a household cleaning agent. Do not use wire brushes!
Page 45 / 91
u Dry the compressor wheel and the gap between the compressor and the bearing casing
with low-pressure pressurized air.
u Lightly spray the compressor wheel and the gap between the compressor and the bearing
casing with penetrating oil.
u Dispose of dirty water and cleaning agents in accordance with the material safety data
sheet.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
6 Periodic maintenance work / 6.2 Cleaning components mechanically
To soak the layers of contamination on the turbine, the cartridge group can be immersed
vertically in a container (02) with fluid.
u Place the container (02) inside a larger container (03) so that the overflowing fluid can be
collected.
CAUTION
Selection of the cleaning agent
Cleaning agents which contain chlorine attack metals.
u Use only pH-neutral cleaning agents which do not attack metals.
u Observe safety data sheet.
u 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. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
6 Periodic maintenance work / 6.2 Cleaning components mechanically
WARNING
Heating up of cleaning agents and operating fluids
When cleaning agents or operating fluids are heated up, explosive vapours
can be produced which are hazardous to health.
u Observe the information in the material safety data sheet.
CAUTION
Water and contamination in the cartridge group
If water or contamination penetrates the cartridge group, this can impair
the function of the turbocharger and damage parts inside the cartridge
group.
u Place the cartridge group on suitable supports (01) made of wood or
metal.
u Observe dimension (B) for the supports (01) so that the cartridge group
is not immersed too deeply.
Page 47 / 91
u Let the layers of contamination on the turbine soak for four hours.
Removing dirt
WARNING
Health hazard due to soot particles
If soot particles enter the eyes or respiratory tract, this can be harmful to
health.
u Avoid the formation of dust.
u Vacuum up dust with a suitable vacuum cleaner.
u Wear a respiratory mask to protect against particles (P1 or P2 mask).
u Wear safety goggles.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
6 Periodic maintenance work / 6.2 Cleaning components mechanically
CAUTION
Water and dirt in the cartridge group
If water or dirt enters the cartridge group, this can impair the function of
the turbocharger and damage parts inside the cartridge group.
u Make sure that no water or dirt enters the gap between partition wall and
turbine.
CAUTION
Non-permissible rotor unbalance after cleaning
Unevenly distributed residual contamination deposits lead to rotor unbal-
ance. This can result in bearing or turbocharger damage.
u Remove all traces of contamination from the turbine.
u After brushing off the dirt, fill the container (02) with clean water and not with salt water .
u Immerse the turbine of the cartridge group in clean water so that any loose dirt comes
off.
u Lift up the cartridge group and align it horizontally.
u Dry the turbine and the gap between the turbine and the partition wall with low-pressure
compressed air.
u Lightly spray the turbine and the gap between the turbine and the partition wall with pen-
etrating oil.
u 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. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
7 Eliminating malfunctions / 7.1 Malfunctions when starting
7 Eliminating malfunctions
Delayed start-up
Possible causes Remedy
Turbochar- Turbocharger contaminated Clean (see chapter Periodic mainten-
ger ance work →39)
Bearing damaged Contact ABB Turbocharging Service
Rotor rubbing Station
Foreign object in the turbocharger
Table 12: Malfunctions when starting – Delayed start-up
Vibrations
Possible causes Remedy
Turbochar- Rotor unbalance Contact ABB Turbocharging Service
ger Turbine or compressor damaged Station
Page 49 / 91
Bearing damaged
Engine Vibrations from engine Contact enginebuilder
Table 13: Malfunctions when starting – Vibrations
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
7 Eliminating malfunctions / 7.2 Malfunctions during operation
WARNING
Danger of fire and explosion due to lubricating oil leaks
Leaking oil may ignite on hot surfaces. This can result in serious injuries to
personnel or fatal accidents.
u Cordon off danger area.
u Raise the alarm and, depending on the situation, stop the engine.
u Seal the oil leak.
u Soak up oil and dispose of in an environmentally compatible manner.
Speed reduces
Possible causes Remedy
Turbochar- Turbine and/or nozzle ring severely Clean (see chapter Periodic mainten-
ger contaminated ance work →39)
Rotor components or bearing dam- Contact ABB Turbocharging Service
aged Station
Engine Defects on the connected cylinders in Contact enginebuilder
pulse charging
Pipes Defects, such as leaks, in the exhaust Repair
gas pipes or charge air ducts
Table 16: Malfunctions during operation – Speed reduces
Speed increases
Possible causes Remedy
Turbochar- Light to medium contamination of the Clean (see chapter Periodic mainten-
ger turbine and/or nozzle ring (with 4- ance work →39) or contact an ABB Tur-
stroke application) bocharging Service Station
Table 17: Malfunctions during operation – Speed increases
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
7 Eliminating malfunctions / 7.2 Malfunctions during operation
Page 51 / 91
Charge air pressure too low
Engine performance and engine speed unchanged, suction condition normal
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
7 Eliminating malfunctions / 7.2 Malfunctions during operation
CAUTION
Compressor damage
A severely contaminated or corroded compressor wheel can reduce the com-
pressor wheel’s fatigue endurance limit and result in the turbocharger being
Page 52 / 91
damaged.
u Rectify malfunction in accordance with the following table.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
7 Eliminating malfunctions / 7.3 Turbocharger is surging
WARNING
Hot air escapes from the filter silencer
A surge blow is accompanied by a loud bang and escape of hot air from the
filter silencer. Personal injury can result.
u Keep distance from the filter silencer while the turbocharger is surging.
CAUTION
Continuous or periodic surging
If the turbocharger surges continuously or periodically, parts of the tur-
bocharger may be damaged.
u Gradually reduce the engine load.
u Have the cause clarified and remedied immediately by an ABB Turbochar-
ging Service Station.
u Have parts assessed for damage and, if necessary, replaced by an ABB
Page 53 / 91
Turbocharging Service Station.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
7 Eliminating malfunctions / 7.4 Malfunctions when stopping
Runout noises
Possible causes Remedy
Turbochar- Turbocharger contaminated Clean (see chapter Periodic maintenance work
ger →39)
Bearing damaged Check clearances (see chapter Axial clearance A
and radial clearance B →71). 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 →78). If clearances are outside the tol-
erance or if in doubt, contact an ABB Turbochar-
ging Service Station.
Foreign object in the tur- Dismantle turbocharger (see chapter Dismant-
bocharger ling and fitting →56). In case of damage, re-
place the corresponding parts or contact an ABB
Turbocharging Service Station.
Table 24: Malfunctions when stopping – Runout noises
Page 54 / 91
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
7 Eliminating malfunctions / 7.5 Speed measurement system
Page 55 / 91
Possible causes Remedy
Turbochar- Sensor tip contaminated, For information regarding the disassembly and
ger since it is magnetic and can assembly of the speed sensor, refer to chapter
attract metallic particles. Replacing the speed sensor →30.
This reduces the distance to Dismantle the sensor, clean the sensor tip, and
the signal-emitting sealing fit the sensor back on with the specified tighten-
disc, which can lead to amp- ing torque.
lification of the noise com-
ponent and, hence, to false
triggering.
Table 27: Malfunction of the speed measurement system – Measured speed too high
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. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.1 Introduction
8.1 Introduction
The precondition for the work described in the following is a turbocharger removed from the
engine (see chapter Removal and installation).
WARNING
Danger of burns
Touching hot surfaces or contact with hot operating fluids can cause burns.
u Do not touch hot surfaces. Observe the warning plate on the turbochar-
ger.
u Wear heat-resistant safety gloves and protective clothing.
u Wait for the turbocharger to cool down before carrying out any work.
WARNING
Cutting injuries when working on the turbocharger
Some parts on the turbocharger may have sharp edges. There is a risk of a
cutting injury.
u Wear safety gloves against mechanical risks when conducting assembly
and disassembly work.
CAUTION
Further operations
This Operation Manual may be used to carry out only those operations that
are described in it. Further operations that are executed in an incorrect way
can lead to serious damage to the machine.
u ABB Turbo Systems recommends having further operations carried out
only by trained personnel from an ABB Turbocharging Service Station.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.1 Introduction
WARNING
Servicing the assembly devices
Assembly devices must be checked for damage before and after use.
u Visually inspect for corrosion, cracks, deformation and wear.
u Damaged assembly devices must no longer be used and must be re-
placed.
Oil orifice
u When disassembling the turbocharger, an oil orifice fitted in the oil inlet must not be re-
moved (see also chapter Removing the cartridge group →67).
Page 57 / 91
The specified tightening torques of the screw fittings must be observed (Table of tightening
torques →81).
WARNING
Suspended loads
Loads that are not attached according to regulations can cause injury to
personnel or fatal accidents.
u Only fasten the turbocharger, assemblies or individual parts on properly
functional lifting gear with sufficient load limit.
u Pay attention to the correct attachment of loads on the crane hook.
u People must not stand under suspended loads.
Definition of terms
¡ Suspension point
Defined loading point on a component or an assembly (blind hole thread, eyelet, lug).
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.1 Introduction
¡ Assembly device
Devices that are fitted on the turbocharger in order to obtain a suspension point. As-
sembly devices are specially constructed and designed for the defined use; they are not
commercially available products. Use assembly devices only for the described applica-
tions.
¡ Lifting gear
Equipment for the lifting and transporting of loads (ropes, chain block, crane). Lifting
gear is not supplied by ABB.
Two ring nuts are required for safer lifting of the cartridge group, which are not included in
the ABB Turbo Systems scope of delivery.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.2 Weights of individual parts
Page 59 / 91
Fig. 26: Weights of assemblies
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.3 Removing air inlets
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.4 Removing the gas outlet casing
Page 61 / 91
Fig. 28: Removing the gas outlet casing
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.5 Removing the gas outlet flange
CAUTION
Cracks in the gas outlet casing
Non-observance of the action steps described can lead to inadmissible
cracks on the gas outlet flange.
Page 62 / 91
Only dismantle the gas outlet flange if this is necessary for service work.
u If necessary: Treat the centering seat with rust remover through the press-off threads
and the clearance holes.
u Mark the casing position for assembly.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.5 Removing the gas outlet flange
CAUTION
Cracks in the gas outlet casing
Non-observance of the action steps described can lead to inadmissible
cracks on the gas outlet flange.
u Observe the maximum tightening torques when pressing off.
u Follow the action steps described.
Only dismantle the gas outlet flange if this is necessary for service work.
u If necessary: Treat the centering seat with rust remover through the press-off threads
and the clearance holes.
u Mark the casing position for assembly.
Page 63 / 91
Fig. 29: Removing the gas outlet flange
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.6 Removing the compressor casing
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.6 Removing the compressor casing
Page 65 / 91
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 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.7 Pressing off the casing
CAUTION
Axial force of the press-off tool
Using the press-off tool (90042), a high level of axial force can be generated.
If the casing is pressed off with too much force on one side, the rotor can be
damaged.
u Use the tool on both sides in alternation and make sure not to press off
too hard on either side.
Page 66 / 91
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.8 Removing the cartridge group
Page 67 / 91
Fig. 34: Oil orifice
01 Bearing casing
02 Oil orifice
03 Circlip
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.8 Removing the cartridge group
1. Treat threads of studs (51006) with penetrating oil and leave to take effect.
2. Loosen nuts (51007) and remove Verbus Ripp® washers (51003) together with the fasten-
ing strips (51002).
Page 68 / 91
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.9 Removing the nozzle ring
Page 69 / 91
Fig. 37: Removing the nozzle ring
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.10 Installing the cartridge group on the
service support
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.11 Axial clearance A and radial clearance B
Page 71 / 91
Table 34: Permissible clearances A and B
1. Move the rotor to and fro up to the stop. In order to obtain a correct measurement, elev-
ate the turbine a little.
2. Measure clearance A and compare it with the permissible values in the table.
3. Raise the compressor and push the turbine down at the same time.
4. Raise the turbine and push the compressor down at the same time.
5. Measure clearance B and compare it with the permissible values in the table.
CAUTION
Clearances outside the tolerance
Serious damage to engines or property can be caused by clearances outside
the tolerance and excessively worn parts.
u Have the components assessed and, if necessary, replaced by an ABB Tur-
bocharging Service Station.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.12 Nozzle ring compression PD
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.13 Installing nozzle ring
Page 73 / 91
Fig. 41: Installing the nozzle ring
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.14 Installing the cartridge group
The end position of the nozzle ring (56001) in the turbine casing (51000) can be checked via
dimension H.
1. Measure dimension H as shown in the illustration and compare it with the minimum di-
mension H in the table.
Page 74 / 91
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.14 Installing the cartridge group
Page 75 / 91
Table 37: Tightening torque (51007)
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.15 Installing the compressor casing
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.15 Installing the compressor casing
Page 77 / 91
Part number A130 A135 A140
72011 M8 M10 M12
35 Nm 70 Nm 105 Nm
Table 39: Tightening torque (72011)
1. Fit a new, high temperature-resisting O-ring (42012, red or green) (see chapter Required
customer spare part set (97070) →87).
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 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.16 Radial clearances N and R
1. Push the feeler gauges (01) into the gap such that there is no clearance. The upper direc-
tion (N1) and lower direction (N2) must be covered simultaneously.
2. Calculate clearance N and compare it with the permissible values in the table.
3. Push the feeler gauges (01) into the gap such that there is no clearance. The upper direc-
tion (R2) and lower direction (R1) must be covered simultaneously.
4. Calculate clearance R and compare it with the permissible values in the table.
CAUTION
Clearances outside the tolerance
Serious damage to engines or property can be caused by clearances outside
the tolerance and excessively worn parts.
u Have the components assessed and, if necessary, replaced by an ABB Tur-
bocharging Service Station.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.17 Installing air inlets
Page 79 / 91
Fig. 48: Installing the air inlets
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.18 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).
1. Insert a new gasket (61002) into the gas outlet casing (61001).
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).
4. If present: Fit the support (61301).
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
8 Dismantling and fitting / 8.20 Table of tightening torques
Page 81 / 91
Fig. 51: Tightening torques
The following tightening torques must be observed for the designated screw fittings:
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
9 Taking out of operation at short notice / 9.1 Possible emergency re-
pairs
WARNING
Danger of fire and explosion due to lubricating oil leaks
Leaking oil may ignite on hot surfaces. This can result in serious injuries to
personnel or fatal accidents.
u Cordon off danger area.
u Raise the alarm and, depending on the situation, stop the engine.
u Seal the oil leak.
u Soak up oil and dispose of in an environmentally compatible manner.
CAUTION
Page 82 / 91
If the engine has to be brought back into operation again as quickly as possible in the event
of a turbocharger defect, the following emergency repair options exist:
¡ If present: Installing a replacement turbocharger →83.
¡ If present: Installing a replacement cartridge group →83.
u Observe the following sections in connection with the emergency repairs mentioned.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
9 Taking out of operation at short notice / 9.2 Installing a replacement
turbocharger
u Send the defective turbocharger to an ABB Turbocharging Service Station for inspection
and repair.
WARNING
Incorrect handling of a cartridge group
Incorrect handling of a cartridge group can damage the turbocharger and
cause injuries to persons.
Page 83 / 91
u Have repairs to the cartridge group carried out by an ABB Turbocharging
Service Station only.
To enable you to quickly put an engine back into operation after a turbocharger has sus-
tained damage, ABB Turbo Systems recommends having a replacement cartridge group
available in storage (see chapter Storage of new turbochargers and spare parts). The defect-
ive cartridge group can be removed and the replacement cartridge group installed within a
short period of time. A replacement cartridge group is ready for use immediately and in-
cludes the complete bearing casing with bearing and a balanced rotor.
The repair of a cartridge group requires special tools and the expertise of an ABB Turbochar-
ging Service Station. The rotating parts turn very fast and are very sensitive to unbalance.
u Remove defective cartridge group (see chapter Dismantling and fitting →56).
u Install replacement cartridge group (see chapter Dismantling and fitting →56).
u Send the defective cartridge group to an ABB Turbocharging Service Station for inspec-
tion and repair.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
10 Mothballing the turbocharger / 10.1 Taking the engine out of opera-
tion for up to 12 months
WARNING
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or con-
tact with them may be harmful to health.
u Do not breathe in these substances and avoid contact with the skin.
u Ensure proper ventilation.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Wear personal protective equipment (PPE) according to the material
safety data sheet.
u Comply with local legislation.
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:
u Dismantle the turbocharger.
u The rotor and bearing parts must be dismantled and subsequently refitted by an ABB Tur-
bocharging Service Station.
u Clean all parts.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
10 Mothballing the turbocharger / 10.2 Taking the engine out of oper-
ation for more than 12 months
u Coat plain surfaces of steel and cast parts with anticorrosive oil.
Page 85 / 91
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
for mothballing.
If the turbocharger remains attached to the engine, see section Taking the engine out of op-
eration for up to 12 months, subsection Rotation of the rotor in the stack draught.
If the complete turbocharger is removed or the turbocharger is assembled again from the
individual parts:
u Seal all openings of the turbocharger with paraffin paper and wooden lids.
Only dry rooms with 40 ... 70 % atmospheric humidity, in which no water condensation can
form, are suitable as storage locations.
u If there are signs of rust: Thoroughly clean parts and renew corrosion protection.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
11 Disposing of turbocharger components / 10.2 Taking the engine
out of operation for more than 12 months
applicable regulations.
The turbocharger consists largely of metal (cast iron materials, steel, nickel-steel alloys, alu-
minium and bearing brass).
Further components are: Non-metallic materials (filter components of felt and polyethylene),
lubricants (engine oil), electronic parts (speed sensor and associated components), and
thermal insulation.
u Dispose of metals as scrap metal for recycling.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
12 Spare parts / 12.1 Ordering spare parts
12 Spare parts
CAUTION
Spare part storage
All spare parts that were ordered together with the turbocharger must be
kept intact and ready for use.
u Carefully clean any rusted parts and grease them.
Please quote the following data when making queries and ordering spare parts:
¡ Turbocharger type
¡ Serial number of the turbocharger
¡ Designation and part number
Spare parts can be ordered from any ABB Turbocharging Service Station.
u If different model variants are not taken into account in this document, contact an ABB
Page 87 / 91
Turbocharging Service Station.
u Dispose of placed and unusable parts in an environmentally-friendly and professional
manner in accordance with the local regulations.
u Dispose of the packaging of new parts in an environmentally-friendly and professional
manner in accordance with the local regulations.
* This gasket can only be installed when a gas outlet casing from ABB Turbo Systems is used.
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
12 Spare parts / 12.3 View of turbocharger with part numbers
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
12 Spare parts / 12.3 View of turbocharger with part numbers
Page 89 / 91
72000 Compressor casing
72011 Hexagon-head screw
72012 Fastening strip
72020 V-clamp
77000 Wall insert
77005 (in customer spare part set) O-ring
79000 Diffuser
79041 (in the customer spare part set) Counter-sunk screw
81000 Filter silencer
81010 (in the customer spare part set) O-ring
82000 Air suction branch
82010 (in the customer spare part set) O-ring
86505* Speed sensor
86515* Cable connector
86526* F/I converter
86528* Tachometer
Table 45: Spare parts list
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
Figures
Figures
Fig. 1: Layout and function of the turbocharger ...... 4 Fig. 32: Press off the casing......................................... 66
Fig. 2: Compressor wheel cooling ................................ 5 Fig. 33: Removing insulation sheets .......................... 67
Fig. 4: Locations of the rating plates .......................... 7 Fig. 35: Removing cartridge group 1.......................... 68
Fig. 5: Suspension of complete turbocharger unit.. 8 Fig. 36: Removing cartridge group 2 ......................... 68
Fig. 6: Removing the turbocharger............................. 9 Fig. 37: Removing the nozzle ring ............................... 69
Fig. 7: Loosening the clamping nut............................ 11 Fig. 38: Installing the cartridge group on the service
support ............................................................................ 70
Fig. 8: Putting down the turbocharger ..................... 12
Fig. 39: Measuring clearance A and B .........................71
Fig. 9: Inserting gaskets into the bracket ................ 13
Fig. 40: Nozzle ring compression PD ......................... 72
Fig. 10: Inserting the threaded rods .......................... 14
Fig. 41: Installing the nozzle ring ................................ 73
Fig. 11: Requirements for threaded rods .................. 14
Fig. 42: Measuring the end position of the nozzle
Fig. 12: Placing the turbocharger on the bracket.... 15 ring ................................................................................... 74
Fig. 13: Preparing the clamping nut for the tighten- Fig. 43: Lifting the cartridge group and rotating it
ing procedure ................................................................ 17 by 90° ............................................................................... 74
Page 90 / 91
Fig. 19: Replacing the speed sensor ......................... 30 Fig. 50: Installing the gas outlet casing .................... 80
Fig. 21: Replacing the protective grid....................... 35 Fig. 52: Overview of part numbers ............................. 88
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017
Operation Manual / 4 Product description / A130-H.. - A140-H
Tables
Tables
Table 1: Related documents .......................................... 3 Table 26: Malfunction of the speed measurement
system – No signal or poor signal amplitude .......... 55
Table 2: Weights of turbochargers A130-H.. – A140-
H......................................................................................... 8 Table 27: Malfunction of the speed measurement
system – Measured speed too high ........................... 55
Table 3: Requirements for threaded rods ................ 14
Table 28: Malfunction of the speed measurement
Table 4: Tightening torques for standard nuts....... 16 system – Measured speed too low............................. 55
Table 5: Pressure screw tightening torque.............. 18 Table 29: Swivel lifting eyes......................................... 58
Table 6: Lubricating oil pressure at oil inlet before Table 30: Ring nuts to be used.................................... 58
turbocharger ................................................................. 25
Table 31: Weights of assemblies................................. 59
Table 7: Lubricating oil temperature at the inlet ... 26
Table 32: 3 press-off screws ........................................ 62
Table 8: Lubricating oil temperature at the outlet 26
Table 33: 6 press-off screws – gas outlet flange..... 63
Table 9: Tightening torque (86505).......................... 30
Table 34: Permissible clearances A and B ..................71
Table 10: Expected replacement intervals ............... 37
Table 35: Permitted nozzle ring compression PD ... 72
Table 11: Value table for soaking.............................. 46
Table 36: End position of the nozzle ring, control di-
Table 12: Malfunctions when starting – Delayed mension H ....................................................................... 74
start-up .......................................................................... 49
Page 91 / 91
Table 37: Tightening torque (51007).......................... 75
Table 13: Malfunctions when starting – Vibrations 49
Table 38: Tightening torque (79041) ......................... 76
Table 14: Malfunctions when starting – Rubbing of
rotating parts................................................................ 49 Table 39: Tightening torque (72011) .......................... 77
Table 15: Malfunctions during operation – Lubricat- Table 40: Permissible clearances N and R ................ 78
ing oil pressure too low............................................... 50
Table 41: Tightening torque (72020).......................... 79
Table 16: Malfunctions during operation – Speed re-
duces............................................................................... 50 Table 42: Tightening torque (51009) ......................... 80
Table 17: Malfunctions during operation – Speed in- Table 43: Tightening torques of the screw fittings 81
creases ........................................................................... 50
Table 44: Customer spare part set 97070 ................ 87
Table 18: Malfunctions during operation – Exhaust
gas temperature too high ........................................... 51 Table 45: Spare parts list ............................................. 89
© Copyright 2017 ABB. All rights reserved. HZTL4030_EN Revision D May 2017