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Operation Manual
A135-H66
HT604133 English
Original Operation Manual
Chapter
1
Introduction
2
Safety
3
Safety data sheet
4
Product description
ABB Switzerland Ltd, Turbocharging
Document-ID
HZTL4005_EN_G
HZTL4022_EN_E
HT604133
HZTL4030_EN_F

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Summary of Contents for ABB HT604133

  • Page 1 Operation Manual A135-H66 HT604133 English Original Operation Manual Chapter Document-ID Introduction HZTL4005_EN_G Safety HZTL4022_EN_E Safety data sheet HT604133 Product description HZTL4030_EN_F ABB Switzerland Ltd, Turbocharging...
  • Page 2 Operating limits and replacement intervals The recommended replacement intervals and the corresponding operating limits in chapter 3 are jointly defined with the enginebuilder. This information is specific to the product. Non-observance of the recommended replacement intervals and the operating limits increases the risk of unpre- dictable component failures.
  • Page 3: Table Of Contents

    Operation Manual / 1 Introduction Table of contents Introduction Introduction......................2 Purpose of the manual....................2 Symbols, definitions...................... 3 Storage of new turbochargers and spare parts ............5 Contact information...................... 7 © Copyright 2020 ABB. All rights reserved. HZTL4005_EN Rev.G March 2020...
  • Page 4: Introduction

    Availability of the Operation Manual The Operation Manual must be available where the turbocharger is used. All persons operating or working on the turbocharger must have read and fully understood the Operation Manual. © Copyright 2020 ABB. All rights reserved. HZTL4005_EN Rev.G March 2020...
  • Page 5: Symbols, Definitions

    Definition of Caution / Warning Caution and warning signs are described in chapter Safety. ABB Turbocharging ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging or as ABB Turbo Sys- tems in this document. Official service stations of ABB Turbocharging Official service stations are regularly audited and certified by ABB Turbocharging.
  • Page 6 Visually inspect Please note text for numbered work step. See document Dispose of in an environmentally compatible, professional way and in compliance with locally applicable regulations. Table 1: Definition of pictograms © Copyright 2020 ABB. All rights reserved. HZTL4005_EN Rev.G March 2020...
  • Page 7: Storage Of New Turbochargers And Spare Parts

    Dispose of the old VCI corrosion protection emitter in an environmentally compatible manner, professionally and in accordance with local regulations. Seal the package. The better the external seal is designed, the more permanent the pro- tection. © Copyright 2020 ABB. All rights reserved. HZTL4005_EN Rev.G March 2020...
  • Page 8 Inspect the package for damage. If the package is damaged, the turbocharger must be in- spected by an ABB Turbocharging Service Station and repacked. After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station: ¡...
  • Page 9: Contact Information

    Operation Manual / 1 Introduction 1 Introduction / 1.4 Contact information Contact information Contact information for the ABB Turbocharging Service Stations is available online. Scan the QR code to access our website. ABB Switzerland Ltd, Turbocharging Bruggerstrasse 71a CH-5401 Baden Switzerland www.abb.com/turbocharging...
  • Page 11 Lifting of loads ......................9 1.11 Prerequisites for operation and maintenance............10 1.12 Hazards during operation and maintenance ............11 1.13 Safe operation ......................13 1.14 Safe maintenance ......................15 © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
  • Page 12: Safety

    Safety Introduction Turbochargers manufactured by ABB reflect the state of the art. The respective safety and health protection requirements are met. This ensures safe operation of the turbocharger. Nevertheless, there may be some residual risks during operation of and work on the tur- bocharger which: ¡...
  • Page 13: Definition Of Mandatory Signs

    CAUTION can lead to seri- ous damage to engine or property with grave consequences. Caution signs must always be observed. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
  • Page 14: Intended Use

    These data are given on the rating plate. ABB accepts no liability and rejects all warranty claims for any non-intended uses. [1] Euromot = The European Association of Internal Combustion Engine Manufacturers...
  • Page 15: Deflagration On Gas Engines

    If during external inspection anomalies are found or if a particularly strong deflagration event has taken place, it is also recommended to check the bearings of the turbochargers before the next start. An ABB Turbocharging Service Station should be instructed to carry out this inspection.
  • Page 16: Warning Plates On The Turbocharger

    Manual, Chapter 4 Product description. Turbochargers supplied to the enginebuilder without insulation must be equipped later with warning plates on the insulation. This is the responsibility of the enginebuilder. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
  • Page 17: Turbocharger Rating Plate

    06 Customer part number 07 Designation for special design 08 Weight of turbocharger in kg 09 Turbocharger type 10 Serial number Year of construction of turbocharger 12 Manufacturing plant © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
  • Page 18: Periodic Check Of The Pressure Vessels

    The locations of the rating plates are defined in the Operation Manual, Chapter 4 Product description. Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, are so-called "simple pressure vessels". ¡...
  • Page 19: Lifting Of Loads

    The assembly devices must be completely screwed in and must not unscrew during use. Use assembly devices only for the described applications. Put down dismantled components of the turbocharger in such a way that they cannot tip over. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
  • Page 20: Prerequisites For Operation And Maintenance

    Original parts and accessories are specially designed by ABB Turbo Systems for the ABB tur- bochargers. ABB accepts no liability for any damage resulting from the use of non-original parts and cor- responding accessories. © Copyright 2017 ABB. All rights reserved.
  • Page 21: Hazards During Operation And Maintenance

    Wear heat-resistant safety gloves and protective clothing. Wait for the turbocharger to cool down before carrying out any work. Wear safety gloves to protect against thermal hazards. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
  • Page 22 At the same time, electrical or electronic components and parts can also be damaged or destroyed. Only specially trained personnel should perform work on, or with, elec- trical components. Observe national regulations. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
  • Page 23: Safe Operation

    When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay at- tention to the risks that may occur as a consequence of this energy input. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
  • Page 24 Only operate the turbocharger with burst protection fitted and insulation fitted in one of the following, permitted variants. Fig. 5 Variant A Insulation (01) with integrated burst protection from ABB Turbo Systems. Variant B Burst protection (03) and insulation (02) from ABB Turbo Systems. Variant C Burst protection (03) from ABB Turbo Systems with appropriate insulation...
  • Page 25: Safe Maintenance

    Keep the floor, equipment, and turbocharger clean. Have oil binding agents ready and provide or keep oil pans at hand. Clean up any spills. Have fire protection means and extinguishing agents available. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
  • Page 26 Secure rotor against turning. The rotor can rotate due to the stack draught alone. Observe the material safety data sheet for the cleaning and mothballing agents. Wear personal protective equipment (PPE) according to the material safety data sheet. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E...
  • Page 27 Wear personal protective equipment (PPE) according to the material safety data sheet. Comply with local legislation. Wear safety goggles. Wear safety gloves to protect against chemical hazards. Wear a respiratory mask to protect against gases. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
  • Page 28 Dispose of insulation materials properly and in an environmentally com- patible manner in compliance with the legal regulations. Wear safety goggles. Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against chemical hazards. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
  • Page 29 Operation Manual / A135-H66 / Safety data sheet Page 1 / 1 Safety data sheet A135-H66 HT604133 A135-H66 HT604133 X00081243 2021 © Copyright 2021 ABB. All rights reserved. HT604133 July 2021...
  • Page 31 Malfunctions when starting..................51 Malfunctions during operation ................52 Turbocharger is surging .................... 55 Malfunctions when stopping..................56 Speed measurement system ..................57 Dismantling and fitting..................58 Introduction ......................... 58 © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 32 12.1 Ordering spare parts....................89 12.2 Required customer spare part set (97070)............89 12.3 View of turbocharger with part numbers .............. 90   Figures........................92   Tables ........................93 © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 33: Introduction

    This document is valid for different design variants of turbochargers. There may be sections and descriptions of components that are not relevant for a specific turbocharger variant. Please contact an ABB Turbocharging Service Station if you have any questions regarding a design variant (see Contact information at www.abb.com/turbocharging).
  • Page 34: Layout And Function Of The Turbocharger

    09 Nozzle ring 03 Diffuser 10 Turbine casing 04 Bearing casing Turbine-end bearing flange 05 Axial thrust bearing 12 Compressor-end bearing flange 06 Radial plain bearing 13 Compressor wheel 07 Turbine © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 35: Fig. 2: Compressor Wheel Cooling

    (X). In addition, the turbocharger version with compressor wheel cooling is indicated by the tur- bocharger type (H6..) on the rating plate. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F...
  • Page 36: Warning Plates On The Turbocharger

    If warning plates are not present in the designated locations or not readable, proceed as fol- lows: Order new warning plates from ABB Turbocharging Service Stations. Remove any warning plates that have become unreadable. Clean and degrease the areas designated for the warning plates.
  • Page 37: Locations Of The Rating Plates

    Locations of the rating plates Fig. 4: Locations of the rating plates One rating plate (01) each is attached on the left and the right side of the turbocharger bear- ing casing. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 38: Removing And Installing

    Depending on the specification, the weight specified on the rating plate may be lower than the standard value specified here. Fig. 5: Transportation of the turbocharger Product Weight of complete turbocharger unit [kg] A130-H A135-H A140-H Table 2: Weight of complete turbocharger unit © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 39: Removing The Turbocharger

    The gas outlet casing (61001) can remain fitted in the exhaust gas pipe if the locking nuts are accessible. Otherwise the complete turbocharger unit including gas outlet casing must be removed. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 40 When doing this, proceed as follows: Attach lifting gear to the suspension eye. Remove the turbocharger. Cover the oil connections (03) at the engine side to protect against contamination. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 41: Fig. 7: Loosening The Clamping Nut

    3. Working in a circle, loosen each pressure screw by 90° in 1...5 rounds until all of the pres- sure screws have been relieved. Loosen clamping nut by hand. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 42: Fig. 8: Putting Down The Turbocharger

    Fig. 8: Putting down the turbocharger Remove turbocharger from engine support, set it down properly in an appropriate place and secure it. Close or cover the openings of the turbocharger and support. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 43: Installing The Turbocharger

    Always use new gaskets and insert them carefully into the slot. The oil is supplied (02) and drained (03) through the bracket (01). The necessary sealing is provided by O-rings. The O-rings are not included in the ABB Turbo Systems scope of delivery.
  • Page 44: Fig. 10: Fitting Threaded Rods Onto The Bracket

    The threaded rods and nuts for fastening the turbocharger on the bracket are not included in the ABB Turbo Systems scope of delivery. The clamping nuts are included in the ABB Turbo Systems scope of delivery. © Copyright 2020 ABB. All rights reserved.
  • Page 45: Fig. 12: Placing The Turbocharger On The Bracket

    Observe the instructions for the fastening variant at hand. ¡ Fastening the turbocharger with a standard nut →16 (A130 - A140) ¡ Fastening the turbocharger with a clamping nut →17 (only A140) © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 46: Table 4: Tightening Torque For Standard Nuts

    **) When the turbocharger is mounted on the engine support, the bolt threads and screw heads must be lightly oiled (assumed friction coefficient µ = 0.12 for tightening torque) Remove the lifting gear. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F...
  • Page 47: Fig. 13: Preparing The Clamping Nut For The Tightening Procedure

    5. Tighten clamping nut (03) by hand. 6. Unscrew clamping nut (03) by ¼ of a turn (90°). The distance between the thrust washer and the clamping nut is now about 1 mm. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F...
  • Page 48: Fig. 14: Tightening Pressure Screws

    4. Work in a circle to tighten all pressure screws to 100 % of the tightening torque specified in the table. 5. Tighten pressure screws to 100 % in 5 … 7 rounds until the required residual tightening angle of < 20° is achieved. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 49: Fig. 15: Connecting The Compressor Cooling Air Intake

    Remove the screw plug on the connection for the compressor wheel cooling (06) and fit the cooling air line. 2.3.7 Attaching the support Fig. 16: Attaching the support If present: Attach support (61301) to engine support or to a connecting piece. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 50: Commissioning

    (see Table 6: Lubricating oil pressure at oil inlet before turbocharger →25). Do not exceed a pre-lubrication time of 2 minutes. Start the engine. Let the pre-lubrication pump run until the pump driven by the engine generates sufficient pressure. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 51: Fig. 17: Oil Orifice

    With an oil inlet pressure of more than 3 bar of overpressure (with engine under load) up- stream of the turbocharger, an oil orifice must be installed to reduce the oil pressure. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F...
  • Page 52: Inspection Procedures

    Make sure there is an uninterrupted supply of cooling air during opera- tion. Check whether the compressor wheel cooling is fitted on the bearing casing. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 53 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 2020 ABB. All rights reserved.
  • Page 54: Commissioning After Taking Out Of Operation

    Check and clean filter silencer or air supply line, and remove any foreign objects that may be present. Put engine-side oil circulation to the turbocharger into operation. Prepare the turbocharger for operation (see Checks before commissioning →22). The turbocharger is now ready for operation. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 55: Monitoring Operation

    Oil pressure measuring point Oil temperature measuring point For monitoring the lubricating oil pressure, ABB Turbo Systems recommends installing a "P" manometer immediately upstream of the turbocharger oil inlet before the orifice. If the pressure is controlled electronically, the relevant signals should be triggered at the warning and alarm values.
  • Page 56: Table 7: Lubricating Oil Temperature At The Inlet

    Table 8: Lubricating oil temperature at the outlet If the turbocharger was operated for a longer period of time outside of the admissible range, ABB Turbo Systems recommends to have the turbocharger inspected by an ABB Tur- bocharging Service Station. © Copyright 2020 ABB. All rights reserved.
  • Page 57: Exhaust Gas Temperature Before Turbine

    Definition and explanations concerning rating plate: refer to chapter 2 of Operation Manual / Safety. Operating limits: refer to chapter 3 of Operation Manual / Safety data sheet or examine rating plate. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 58: Turbocharger Speed

    86505 Speed sensor 42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F/I converter Plug with integrated voltage limiter 86528 Tachometer Installation variant for speed sensor 32109 Sealing disc with cams © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 59 Check the pressure loss of the alternative air inlet and compare it with normal values. If the engine can be stopped temporarily: Inspect air lines, gas piping and the turbochargers and remedy any malfunctions. In any case, contacting the nearest ABB Turbocharging Service Station is recommended. 4.3.4 Malfunctions on the speed measurement system...
  • Page 60: Fig. 19: Replacing The Speed Sensor

    Wear safety gloves when disassembling the speed sensor. Wear safety gloves to protect against thermal hazards. The speed sensor supplied by ABB is equipped with a sealing lip and an O-ring. No additional gasket is required during assembly. Fig. 19: Replacing the speed sensor...
  • Page 61: Operation And Service

    Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 : A-weighted emission sound pressure level The enginebuilder must provide acoustically equivalent measures in case of deviating in- sulation versions © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 62: Fig. 20: Noise Insulation, Bellows

    Suggestion for noise insulation, bellows Fig. 20: Noise insulation, bellows Compressor casing Bellows Charge air duct / scavenging air duct Insulation cushion Insulation mat (at least 15 mm) Sheet metal cover © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 63: Service Work

    Agree on a specific service interval with ABB Turbo Systems. To prevent machine damage caused by ageing and downtime, we recommend having an in- spection carried out by an ABB Turbocharging Service Station no later than 5 years after the last service.
  • Page 64 Service work according to data on the rating plate (Usually after 8000 … 12000 operating hours) The rotor and bearing parts must be checked and assessed by an ABB Turbocharging Service Station. The following work can be carried out as preparation.
  • Page 65: Fig. 21: Replacing The Protective Grid

    5 Operation and service / 5.2 Service work 5.2.5 Other service work If a protective grid is installed in the radial or axial gas outlet casing (61001) by ABB Turbo Systems: Fig. 21: Replacing the protective grid Remove the protective grid (61205) after 50000 hours and replace it with a new one.
  • Page 66 Speed of the turbocharger ¡ Air temperature after the compressor and after the charge air cooler ¡ Exhaust gas temperature before and after the turbine ¡ Pressure loss in the filter silencer. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 67: Expected Replacement Intervals

    ABB Turbo Systems therefore recommends having the components periodically inspected and replaced, if neces- sary, by an ABB Turbocharging Service Station based on the number of successful engine start cycles specified in the following table.
  • Page 68: Table 10: Expected Replacement Intervals

    ¡ Lubricating oil quality (oil filtering, oil condition, oil monitoring) ¡ Load profile (speed, pressure conditions, temperature) ¡ Number of starts/stops ¡ Unbalance of the rotor (degree of contamination). © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 69: Stopping The Engine

    Observe the oil pressure while performing post-lubrication: 0.5 < p ≤1.0. Switch off post-lubrication as soon as the rotor is stationary or after no more than two minutes. Deviating procedures must be coordinated with ABB Turbo Systems. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F...
  • Page 70: Periodic Maintenance Work

    (usually every 8000 … 12000 h) →41 Table 11: Maintenance table [h] = Hours of operation ABB Turbo Systems recommends having mechanical cleaning carried out by an ABB Tur- bocharging Service Station during the service work. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F...
  • Page 71: Cleaning Components Mechanically

    The disassembly and assembly of the components is described in chapter Dismantling and fitting →58. Contaminated water and cleaning agents must be disposed of in an environmentally compatible, professional way and in compliance with locally applicable regulations. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 72: Fig. 22: Cleaning The Filter Silencer

    Rinse in cold water. Avoid high mechanical loads (water jet). Let the filter ring dry completely before assembling. Dirty water and mild detergent must be disposed of in compliance with locally applicable regulations. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 73 When cleaning, note that the absorption segments (81136) must only be cleaned lightly with compressed air, a soft brush or a moist cleaning cloth. Have any heavily contaminated absorption segments replaced by an ABB Turbocharging Service Station. Fitting the filter silencer (see Fig. 22: Cleaning the filter silencer →42)
  • Page 74: Fig. 23: Compressor-End, Non-Rotating Parts

    Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the tur- bocharger. Dispose of contaminated water and cleaning agents in accordance with the information in the material safety data sheet. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 75: Fig. 24: Turbine End, Non-Rotating Parts

    Brush away the contamination or remove with a steam cleaner. Repeat the soaking and brushing if necessary. Use clean water to remove all traces of solvent from parts. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 76 Removing and Installing →8). Remove the cartridge group (see chapter Dismantling and fitting →58). First clean the compressor end and then the turbine end according to the following descrip- tion. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 77 Lightly spray the compressor wheel and the gap between the compressor and the bearing casing with penetrating oil. Dispose of dirty water and cleaning agents in accordance with the material safety data sheet. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 78: Fig. 25: Soaking The Turbine End

    Observe country-specific regulations regarding banned and restricted substances. Fill the container (02) with soaking fluid. To shorten the soaking time, the fluid can be heated up to a maximum of 60 ºC. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 79 Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against mechanical hazards. Lift up the cartridge group and align it horizontally. Remove contamination manually using a soft brush or a wire brush. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 80 Lightly spray the turbine and the gap between the turbine and the heat sheet metal with penetrating oil. Dispose of contaminated water and cleaning agents in accordance with the information in the safety data sheet. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 81: Eliminating Malfunctions

    To prevent significant loss of efficiency, specific tolerances must be fulfilled. ¡ If there is any doubt about the extent of the rubbing, contact an ABB Tur- bocharging Service Station. ¡...
  • Page 82: Malfunctions During Operation

    Turbochar- Turbine and/or nozzle ring severely con- Clean (see chapter Periodic mainten- taminated ance work →40) Rotor components or bearing damaged Contact ABB Turbocharging Service Station Engine Defects on the connected cylinders in Contact enginebuilder pulse charging Pipes Defects, such as leaks, in the exhaust...
  • Page 83: Table 19: Malfunctions During Operation - Exhaust Gas Temperature Too High

    Gas piping between engine and turbine leaking Injection mistimed Set correctly Valve control misadjusted Pipes Pipes downstream to the compressor Repair. outlet not sealed. Table 20: Malfunctions during operation – Charge air pressure too low © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 84: Table 21: Malfunctions During Operation - Charge Air Pressure Too High

    Clean (see chapter Periodic mainten- ance work →40) Table 22: Malfunctions during operation – Engine performance losses © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 85: Turbocharger Is Surging

    Gradually reduce the engine load. Have the cause clarified and remedied immediately by an ABB Turbochar- ging Service Station. Have parts assessed for damage and, if necessary, replaced by an ABB Turbocharging Service Station. Possible causes Remedy...
  • Page 86: Malfunctions When Stopping

    →40) Bearing damaged Check clearances (see chapter Measuring clear- ance A and B). If clearances are outside the toler- ance or if in doubt, contact an ABB Turbocharging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station.
  • Page 87: Speed Measurement System

    Table 29: Malfunction of the speed measurement system – Measured speed too low If none of the measures described above remedy the malfunction, have the speed measure- ment system checked by an ABB Turbocharging Service Station. © Copyright 2020 ABB. All rights reserved.
  • Page 88: Dismantling And Fitting

    Identification of the assembly devices Not all assembly devices are marked with a part number. Identification is guaranteed by the tool list. This list is enclosed with the toolbox. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 89 The specified tightening torques of the screw fittings must be observed (Table of tightening torques). Tightening torques for assembly devices Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB must be tightened so they are tight-fitting. WARNING...
  • Page 90: Weights Of Individual Parts

    Equipment for the lifting and transporting of loads (ropes, chain block, crane). Lifting gear is not supplied by ABB. Swivel lifting eyes to be used Swivel lifting eyes are required for the safe lifting of loads, which are not supplied by ABB. Fig. 26: Swivel lifting eyes Product...
  • Page 91: Fig. 28: Weights Of Assemblies

    06 Diffuser 07 Cartridge group 08 Nozzle ring 09 Burst ring 10 Turbine casing * Gas outlet flange Gas outlet casing * Table 31: Weights of assemblies * including burst protection © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 92: Removing The Air Inlets

    2. Loosen and remove V-clamp (72020). 3. Remove filter silencer (81000) or air suction branch (82000), set it down properly in an appropriate place and secure it. 4. Remove and dispose of the O-ring (81010 / 82010). © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 93: Removing The Gas Outlet Casing

    If the following Working Instructions are not observed, this can lead to cracks in the gas out- let casing. The following variants are possible: Pressing off using 3 press-off screws. Pressing off using 6 press-off screws. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 94: Fig. 31: Dismantling The Gas Outlet Flange

    ≤ 65 Nm Table 32: 3 press-off screws * not included in the ABB Turbo Systems scope of delivery 1. Press off and remove the gas outlet flange (57002) with screws (01) according to the table. If it is not possible to press off the gas outlet flange with the maximum tightening torque, contact an ABB Turbocharging Service Station.
  • Page 95: Fig. 32: Removing The Gas Outlet Flange

    ≤ 40 Nm Table 33: 6 press-off screws * not included in the ABB Turbo Systems scope of delivery. 1. Evenly press off and remove the gas outlet flange (57002) with screws (01) according to the table. If it is not possible to press off the gas outlet flange with the maximum tight- ening torque, contact an ABB Turbo Systems Service Station.
  • Page 96: Removing The Compressor Casing

    If the compressor casing cannot be loosened, it can be pressed off against the turbine cas- →68). ing using the press-off tool (90042) (see chapter Pressing off the casing © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 97: Fig. 34: Dismantling The Wall Insert

    2. Attach swivel lifting eye (S) to the compressor casing (72000) and the lifting gear. 3. Lift up the compressor casing (72000). 4. Remove and dispose of the O-ring (77005). See also 2 View of turbocharger with part numbers [} 90] 2 Spare parts [} 89] © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 98: Pressing Off The Casing

    If the casing is pressed off with too much force on one side, the rotor can be damaged. Use the tool on both sides in alternation and make sure not to press off too hard on either side. Fig. 35: Press off the casing © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 99: Removing The Cartridge Group

    Fig. 37: Removing cartridge group 1 1. Treat threads of studs (51006) with penetrating oil and leave to take effect. 2. Undo nuts (51007) and remove Verbus Ripp® washers (51003) together with fastening strips (51002). © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 100: Fig. 38: Removing Cartridge Group 2

    7. Turn the cartridge group into the horizontal rotor axis. If the cartridge group cannot be loosened, the press-off tool (90042) can be used (see chapter Pressing off the casing →68). © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 101: Removing The Nozzle Ring

    2. Position the fastening strips (51002) in place. 3. Pull out the nozzle ring (56001) with the two extraction devices (90070) and the service support base (90012). 4. Remove the lamellar sealing ring (56005). 5. Remove the burst ring (57210). © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 102: Installing The Cartridge Group On The Service Support

    Fig. 40: Installing the cartridge group on the service support 1. Remove ring nuts (VRM). 2. Remove service support screws. 3. Fit service support (90012) according to the illustration. 4. Insert the cartridge group. 5. Fit the nuts. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 103: Measuring Clearance A And B

    Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2020 ABB. All rights reserved.
  • Page 104: Nozzle Ring Compression Pd

    Table 35: Nozzle ring compression PD 1. Measure dimensions A, B and S on cleaned surfaces. 2. Calculate compression (PD). If the calculated value (PD) lies outside the specified range, contact an ABB Turbochar- ging Service Station. © Copyright 2020 ABB. All rights reserved.
  • Page 105: Installing The Nozzle Ring

    Align the cams on the nozzle ring with the recesses of the turbine cas- ing (51000). Do not remove the adhesive tape (01). 5. If present: Fit the metal C-ring (51105). © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F...
  • Page 106: Installing The Cartridge Group

    3. Insert the screws of the service support from above and fit ring nuts (VRM) with washers. 4. Attach lifting gear to the ring nuts (VRM). 5. Lift cartridge group at the side of the ring nuts (VRM) and turn it into a vertical position. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F...
  • Page 107: Fig. 46: Installing The Cartridge Group

    3. Lower the cartridge group into the turbine casing. 4. Remove ring nuts and screws. 5. Fit fastening strips (51002) with Verbus Ripp® washers (51003) and hexagon nuts (51007). 6. Tighten the hexagon nuts (51007). © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 108: Installing The Compressor Casing

    Table 38: Tightening torque (79041) 1. Always replace the O-ring (77005) (see section Spare parts). 2. Install the wall insert (77000) into the compressor casing. 3. Secure the diffuser (79000) with fixing discs (79040) and screws (79041). © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 109: Table 39: Tightening Torque (72011)

    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 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 110: Measuring Radial Clearances N And R

    Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2020 ABB. All rights reserved.
  • Page 111: Installing The Air Inlets

    2. Fit a new O-ring (81010) to the filter silencer (81000) or a new O-ring (82010) to the air suction branch (82000). 3. Fit the filter silencer (81000) or air suction branch (82000) with the V-clamp (72020). 4. Observe tightening torque. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 112: Installing The Gas Outlet Flange

    2. Coat the threads of the studs (51008) with high-temperature grease. 3. Attach the lifting gear to the gas outlet casing (61001) and position the gas outlet casing in the correct position on the turbine casing (51000). © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F...
  • Page 113: Table Of Tightening Torques

    M12 x 1.5 M12 x 1.5 M12 x 1.5 15 Nm 15 Nm 15 Nm 51101 / 51103 / 20 Nm 20 Nm 40 Nm 51104 / 61201 Table 43: Tightening torques of the screw fittings © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 114: Taking Out Of Operation At Short Notice

    ¡ If present: Installing the replacement turbocharger →85. ¡ If present: Installing the replacement cartridge group →85. Observe the following sections in connection with the emergency repairs mentioned. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 115: Installing The Replacement Turbocharger

    The repair of a cartridge group requires special tools and the expertise of an ABB Turbochar- ging Service Station. The rotating parts rotate extremely fast, and are sensitive to unbal- ance.
  • Page 116: Mothballing The Turbocharger

    If the acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking the engine out of operation: Dismantle the turbocharger. The rotor and bearing parts must be dismantled and subsequently refitted by an ABB Tur- bocharging Service Station. Clean all parts.
  • Page 117: Taking The Engine Out Of Operation For More Than 12 Months

    ¡ The casings of the turbocharger remain attached to the engine, the rotor and bearing parts are dismantled by an ABB Turbocharging Service Station and stored separately ¡ The turbocharger is completely removed, either as a whole unit or in individual parts For the measures always necessary for preparing the turbocharger parts for mothballing, see section Taking the engine out of operation for up to 12 months, subsection Preparations...
  • Page 118: Disposing Of Turbocharger Components

    Dispose of metals as scrap metal for recycling. Dispose of non-metallic materials as waste. Dispose of residues of lubricants as waste oil. Dispose of electronic components as electronic waste. Dispose of thermal insulation as hazardous waste. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 119: Spare Parts

    Counter-sunk screw 81010/ 82010 O-ring Table 44: Customer spare part set 97070 * This gasket can only be installed when a gas outlet casing from ABB Turbo Systems is used. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 120: View Of Turbocharger With Part Numbers

    12 Spare parts / 12.3 View of turbocharger with part numbers 12.3 View of turbocharger with part numbers Fig. 54: Overview of part numbers (……) only available in customer spare part set (97070). © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F February 2020...
  • Page 121: Table 45: Spare Parts List

    ** in some installations a special graphite cord sealing is fitted or can be fitted. This is a ser- vice solution only in cases of unexpectedly high temperatures at the gasket. Please contact ABB for further instructions. © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Rev.F...
  • Page 122: Figures

    Fig. 28: Weights of assemblies ........61 Fig. 29: Removing the air inlets ......... 62 Fig. 30: Removing the gas outlet casing ....63 Fig. 31: Dismantling the gas outlet flange....64 © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Revision F February 2020...
  • Page 123 Table 23: Malfunction – Turbocharger pumping..55 Table 24: Malfunction – Sporadic surge blows..55 Table 25: Malfunctions when stopping – Runout noises................56 Table 26: Malfunctions when stopping – Runout time too short ............... 56 © Copyright 2020 ABB. All rights reserved. HZTL4030_EN Revision F February 2020...

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