Page 1 Operation Manual A140-H56 Type A140-H56 HT846941 Mmax Mmax °C Bmax Bmax 00460 Application according to Year 2022 the Operation Manual ABB Turbocharging...
Page 2 In case the operation conditions differs signiﬁ cantly from what is considered to be normal for the cur- rent application, it is recommended to contact ABB for a re-calculation of replacement intervals. Frequent load alterations, high temperatures and high speed lower the life of components.
Page 3: Table Of Contents
Warning plates on the turbocharger ............Safe operation and maintenance ............... Hazards during operation and maintenance ..........Periodic check of the pressure vessels ............Use of ABB turbochargers on gas engines..........Lifting of loads .................... Introduction .................... Essential information ..................
Page 4 12.1 Taking the engine out of operation for up to 12 months ......109 12.2 Taking the engine out of operation for more than 12 months ...... 110 © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 5 Operation Manual / A130-H.. - A140-H.. Contents Page 3 / 115 Disposing of turbocharger components ............ Spare parts ..................... 14.1 Ordering spare parts .................. 14.2 View of turbocharger with part numbers ............. © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 7: Preliminary Remarks
Operation Manual cover sheet and the turbocharger rating plate. Operation Manual This Operation Manual will familiarise you with the turbocharger of ABB Turbo Systems and provides information on how to use it in compliance with its intended purpose. The Operation Manual explains what is important to know in order to operate the turbocharger safely, appropriately and profitably.
Page 8: Symbols, Definitions, Contact Address
Caution and warning signs are described in chapter Safety. ABB Turbo Systems ABB Turbo Systems Ltd is identified as ABB Turbo Systems in this document. Official service stations of ABB Turbo Systems Official service stations are identified in this document as ABB Turbocharging Service Sta- tions.
Page 9: Safety
Safety Introduction Turbochargers manufactured by ABB Turbo Systems are state of the art and comply with the respective health and safety standards in effect at the time the turbocharger was built. This ensures safe operation of the turbocharger. Nevertheless, there may be some residual risks during operation of and work on the turbocharger which: ...
Page 10: Warning Plates On The Turbocharger
Warning plates are affixed at the following locations on the turbocharger: Figure 2: ≤ A145 If warning plates are not present in the designated locations or not readable, proceed as follows: Order new warning plates from ABB Turbocharging Service Stations.  Remove any warning plates that have become unreadable. ...
Page 11 Keep flammable objects and substances out of the vicinity of flying sparks.  Cover all connections on the turbocharger so that no foreign objects can enter the tur-  bocharger. © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 12 (3) is fitted. Never operate a turbocharger without burst protection and insulation.  If the insulation from ABB Turbo Systems (1) is not installed, the separate  burst protection (3) plus either the insulation (2) or an appropriate insulati- on supplied by the enginebuilder must be installed for operation.
Page 13 Safety when taking out of operation at short notice or preparing for mothballing Secure rotor against turning. The rotor can rotate due to the stack draught alone.  Clean the turbocharger prior to mothballing.  Wear appropriate protective clothing.  © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 14: Hazards During Operation And Maintenance
Ensure workplace safety.  Only perform operations that are described in this manual.  Only perform operations for which you have previously received instruc-  tion or training. © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 15 Unfallverhütungsvorschriften für Unternehmen der Seefahrt (UVV See) [Accident Prevention Regulations for Enterprises engaged in Seafaring]): Figure 4 Noise level [dB(A)] Maximum duration of exposure [min] per working day © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 16  Hot surfaces on the non-insulated turbocharger Non-insulated turbochargers can cause serious injuries to personnel (burns). ABB Turbo Systems supplies the turbocharger with or without insulation in WARNING accordance with the purchase order received from the enginebuilder. If supply is without insulation, the enginebuilder is responsible for providing the turbocharger with proper insulation and for providing protection against contact with hot surfaces.
Page 17 Wear suitable work clothing (safety goggles, dust mask).  Avoid whirling up dust.  Use dust-free tools and working methods.  Remove package at the workplace only.  © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 18: Periodic Check Of The Pressure Vessels
 Periodic check of the pressure vessels The pressure vessels used by ABB Turbo Systems, for example, in the wet or dry cleaning process, are so-called simple pressure vessels.  The locally applicable legal regulations regarding periodic checks of the pressure vessels must be observed.
Page 19: Use Of Abb Turbochargers On Gas Engines
Page 17 / 115 Use of ABB turbochargers on gas engines ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar. In deflagration tests on engines with flame barriers, a maximum of 11 bar was measured. This value is supported by the practical experience in operation gained by renowned gas engine manufacturers.
Page 20: 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 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 21: 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. The ABB Turbocharging Service Stations will be happy to provide information on questions regarding a design variant.
Page 22: Layout And Function Of The Turbocharger
3 Diffuser 10 Turbine casing 4 Bearing casing 11 Turbine-end bearing flange 5 Axial thrust bearing 12 Compressor-end bearing flange 6 Radial plain bearing 13 Compressor wheel 7 Turbine © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 23 (1). In addition, the turbocharger version with compressor wheel cooling is indicated by the tur- bocharger type (H6..) on the rating plate. © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 24: Storage Of New Turbochargers And Cartridge Groups
Storage of new turbochargers and cartridge groups for up to 6 months New turbochargers and cartridge groups from ABB Turbo Systems can be stored in their closed packages for 6 months from the date of delivery without additional mothballing mea- sures (indicated by VCI label on package).
Page 25: Intended Use
Check the package for damage. If the package is damaged, the turbocharger or cartridge  group must be checked and repackaged by an ABB Turbocharging Service Station. After every 3 years, the following steps must be carried out by an ABB Turbocharging Service Station:  Checking the component ...
Page 26 The specific operating limits of the turbocharger were determined on the basis of information from the enginebuilder about the intended use. These data are given on the rating plate. ABB Turbo Systems accepts no liability and rejects all warranty claims for any non-intended uses.
Page 27: Prerequisites For Operation
The responsible body must be notified of the malfunction.  Original parts and safety Original parts and accessories are specially designed by ABB Turbo Systems for the ABB turbochargers. Use original parts Operation of the turbocharger with non-original parts can impair the safety of...
Page 28: Turbocharger Rating Plate
Operation Manual / A130-H.. - A140-H.. Introduction Page 26 / 115 ABB Turbo Systems accepts no liability for any damage resulting from the use of non-original parts and associated accessories. Turbocharger rating plate Figure 11 Operating limits 1 Turbocharger operating limits at engine overload (110 %).
Page 29: Ce Conformity
One rating plate (1) each is attached on the left and the right side of the turbocharger bearing casing. CE conformity Information ABB turbochargers comply with the Machinery Directive 2006/42/EC and are incomplete ma- chines as defined by Article 2 g. © Copyright 2013 ABB. All rights reserved. HZTL2414_EN...
Page 31: Removal And Installation
The following weight specification applies to the heaviest variant possible. Depending on the specification, the weight specified on the rating plate may be lower than the standard value specified here. Complete turbocharger Weights [kg] A130 A135 A140 Table 1 © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 32: Removing The Turbocharger
Depending on the bracket version (4), two positioning pins (5) can be used for positioning and safeguarding against wrong fitting of the turbocharger. NOTICE Therefore the turbocharger must always be removed from and installed on the bracket vertically. © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 33 (see instructions of the enginebuilder). Remove the turbocharger.  Cover the oil connections (3) on the engine side to protect against dirt.  © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 34 In case of non-compliance, it cannot be ensured that the neces- sary tension force is reached. Do not clean pressure screws.  Do not lubricate pressure screws.  © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 35: Installing The Turbocharger
The oil is supplied (2) and drained (3) through the bracket (1). The necessary sealing is performed by O-rings which are located in the slots of the bracket. The gaskets are not included in the ABB Turbo Systems scope of delivery and must be provi- ded by the enginebuilder.
Page 36 Fixing material scope of delivery The threaded rods and nuts for fastening the turbocharger on the bracket are not included in the ABB Turbo Systems scope of delivery. These parts depend on the version of the engine- side bracket. The clamping nuts are included in the ABB Turbo Systems scope of delivery.
Page 37 Depending on the bracket version (4), two positioning pins (5) can be used for positioning and safeguarding against wrong fitting of the turbocharger. NOTICE Therefore the turbocharger must always be removed from and installed on the bracket vertically. © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 38 Fit the nuts and tighten them according to variant 1 or 2 in the table below.  Product Fixing screws [mm] Variant 1: Variant 2: Tightening torques [Nm] Hydraulic pre-tensioning forces [kN] A130 A135 A140 Table 3 Remove lifting gear.  © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 39 Tighten the clamping nut (3) by hand and then unscrew it again by ¼ of a turn (90°).  The distance between the thrust washer and the clamping nut is now about 1 mm. © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B...
Page 40 Tighten pressure screws to 100 % in 5 … 7 rounds until the required residual tightening  angle of < 20° is achieved. Torque-controlled tightening Product Fixing screw [mm] Tightening torques [Nm] A140 Table 4 © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 41 Ensure the supply of cooling air.  Figure 21 Remove the screw plug on the connection for the compressor wheel cooling (6) and fit the  cooling air line. © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 43: Commissioning
– 600 °C with non-insulated casing At temperatures below the specified values, post-lubrication for 10 minutes is recom- mended. Observe the oil pressure specified for post-lubrication (see Table 5).  © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 44: Inspection Procedures
5.2.2 Checks before commissioning Air filter mat (if present) Check for damage and contamination.  Lubricating system Check that the oil filter is clean before commissioning.  © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 45 Failure of bearing casing cooling Any prolonged failure of the water cooling will negatively affect the operatio- nal safety of the turbocharger. CAUTION Ensure the supply of the water pipes.  © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 46 Continual escape of NOTICE an oily fluid indicates a possible oil leak. If there is a leak, contact an ABB Turbocharging Service Station. © Copyright 2013 ABB. All rights reserved. HZTL2414_EN...
Page 47: Commissioning After Taking Out Of Operation
Put engine-side oil circulation to the turbocharger into operation.  Prepare the turbocharger for operation according to section "Checks before commission-  ing". Start the engine and put the turbocharger into operation.  © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 49: Monitoring During Operation
M Oil pressure measuring point T Oil temperature measuring point Monitoring of the lubricating oil pressure For monitoring the lubricating oil pressure, ABB Turbo Systems recommends installing an "M" manometer immediately before the turbocharger. If the NOTICE pressure is controlled electronically, the appropriate signals are to be trigge- red at the warning and alarm values.
Page 50 Table 7 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 2013 ABB. All rights reserved.
Page 51: Turbocharger Speed
42188 Locking screw 86515 Cable connector 42189 Gasket 86526 F/I converter 1 Plug with integrated voltage limiter 86528 Tachometer *) Installation variant for speed sensor 32109 Sealing disc with cams © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 52 If the engine can be stopped temporarily: Inspect air lines, exhaust gas pipes and the turbochargers and remedy any malfunctions.  In any case, contacting the nearest ABB Turbocharging Service Station is recommended.  6.2.4 Replacing the speed sensor Hot cable connector and hot speed sensor Danger of burns.
Page 53 Switch on lubricating oil supply to the turbocharger.  6.2.5 Malfunction of the speed measurement system The possible reasons for failure of the speed measurement system are described in chapter "Troubleshooting" (see Table 27). © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 55: 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 insula- tion versions © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 56: Service Work
Service work on the turbocharger that is omitted or performed too late can cause excessive contamination and wear as well as operating failures. CAUTION Carry out the service work at the specified time intervals.  © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 57  Unknown operational changes Impairment to the degree of a possible operating failure can be the conse- quence. CAUTION Unknown causes must be clarified by an ABB Turbocharging Service Sta-  tion. 7.2.2 Service work at 100 hours after commissioning Clean or replace the oil filter located in the supply pipe to the turbocharger while the engine ...
Page 58 Operation and service Page 56 / 115 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. Remove the turbocharger from the engine and disassemble according to chapter Disas- ...
Page 59  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 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 60: Expected Replacement Intervals
Influencing parameters The specified values are guideline values and are not guaranteed. The actual values can de- viate considerably from the guideline values, for example, due to the following influences: © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B...
Page 61: Stopping The Engine
– 600 °C with non-insulated casing At temperatures below the specified values, post-lubrication for 10 minutes is recom- mended. Observe the oil pressure specified for post-lubrication (see Table 5).  © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 63: Periodic Maintenance
– Cartridge group: Compressor, turbine Cleaning method To allow you to observe the standard service intervals and to maintain a high turbocharger efficiency, ABB Turbo Systems recommends that compressor NOTICE and turbine be cleaned during operation. This allows the thermal load of the engine to be kept low while ensuring maximum fuel efficiency.
Page 64: Cleaning The Compressor During Operation
If the specified cleaning intervals are incompatible with operation of the engine, please contact ABB Turbo Systems. Cleaning method The compressor is cleaned during operation using the wet cleaning method. This cleaning method has been tested and approved by ABB Turbo Systems. © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B...
Page 65 CAUTION Never connect injection tubes directly to a water pipe or a larger metering  container other than that specified by ABB Turbo Systems. V-engines On V-engines with several turbochargers per engine, parallel cleaning of both turbochargers is recommended. This cleaning process is faster and reduces the risk of surging of the tur- bocharger.
Page 66 8.2.2 Prerequisites To carry out the cleaning operation checked and recommended by ABB Turbo Systems, the engine load must be 50 % to 85 %. 8.2.3 Procedure for wet-cleaning the compressor...
Page 67: Cleaning The Turbine During Operation
If the cleaning is still unsuccessful after three processes and the engine values are unsatisfac- tory, it is recommended to have the turbocharger checked and cleaned by an ABB Tur- bocharging Service Station. Cleaning the turbine during operation...
Page 68 Cleaning method The turbine components are cleaned during operation using the wet cleaning method. This cleaning method is tested and approved by ABB Turbo Systems. The precondition for wet cleaning is that the enginebuilder approves the process and these regulations are observed.
Page 69 Periodic maintenance Page 67 / 115 8.3.2 Procedure for wet-cleaning the turbine If the cleaning result is unsatisfactory or there is water leakage, contact an ABB Tur- bocharging Service Station. Fulfil prerequisites.  Inadmissible thermal stress and flooding of the turbine Smaller amounts of water can lead to an inadequate cleaning result.
Page 70: Cleaning Components Mechanically
A turbine cleaning procedure with multiple short injection periods is recom- mended only under certain circumstances. If such a procedure is to be used, CAUTION this must be coordinated with ABB Turbo Systems. Contact ABB Turbo Systems.  Cleaning components mechanically 8.4.1...
Page 71 Rinse the filter ring (81265) with water and mild detergent or, in the case of heavy contami-  nation, soak and carefully push through. Rinse in cold water. Avoid high mechanical loads (water jet). Let the filter ring dry completely before assembling.  © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 72  When cleaning, note that the absorption segments (81136) must only be cleaned lightly with pressurized air, with a soft brush or a moist cleaning cloth. Have any heavily contaminated absorption segments replaced by an ABB Turbocharging  Service Station.
Page 73 Use clean water to completely clean parts of any solvents.  Dry components completely.  Spray cleaned surfaces with penetrating oil. Do not spray exterior surfaces of the tur-  bocharger. © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 74 Dry the compressor wheel and the gap between the compressor and the bearing casing  with low-pressure pressurized air. Lightly spray the compressor wheel and the gap between the compressor and the bearing  casing with penetrating oil. © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 75 Cleaning agents containing chlorine will corrode the aluminium alloy of the compressor wheel. CAUTION Only use chemically neutral cleaning agents that do not corrode metals.  Fill the container (2) with soaking fluid.  © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 76 Dry the turbine and the gap between the turbine and the partition wall with low-pressure  pressurized air. Lightly spray the turbine and the gap between the turbine and the partition wall with penet-  rating oil. © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 77: Troubleshooting
To prevent significant loss of effi- ciency, specific tolerances must be fulfilled.  If there is any doubt about the extent of the rubbing, contact an ABB Turbocharging Service Station.  Have a dimension check carried out by an ABB Turbocharging Service Station.
Page 78: Malfunctions During Operation
Remedy Turbocharger Light to medium contamination of the tur- Clean (see chapter Periodic maintenance bine and/or nozzle ring (with 4-stroke ap- [➙ 61]) or contact an ABB Turbocharging plication) Service Station Table 18 © Copyright 2013 ABB. All rights reserved.
Page 79 Compressor end and/or turbine end contaminated Compressor/turbine damaged Contact ABB Turbocharging Service Stati- Exhaust gas back pressure too high Clean or repair boiler or exhaust gas silencer Table 20 © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 80 Prevent exhaust gas leakages in the engi- ded due to intake air containing exhaust ne space gases or salt Clean (see chapter Periodic maintenance [➙ 61]) Table 23 © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 81: Surging Of The Turbocharger
CAUTION Have the cause clarified and remedied immediately by an ABB Tur-  bocharging Service Station. Have parts assessed for damage and, if necessary, replaced by an ABB  Turbocharging Service Station. Sporadic surge blows Surging of the turbocharger can occur during certain operating states, such as when reducing the engine load quickly when manoeuvring.
Page 82: Malfunctions When Stopping
Bearing damaged Check clearances (see chapter Axial clearance A and radial clearance B [➙ 102]). If clearances are outside the tolerance or if in doubt, contact an ABB Tur- bocharging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R [➙...
Page 83: Speed Measurement System
Other causes of If none of the measures described above remedy the malfunction malfunction, it is recommended to have the speed mea- surement system checked by an ABB Turbocharging Service Station. Table 27 © Copyright 2013 ABB. All rights reserved.
Page 85: Disassembly And Assembly
ABB Turbo Systems recommends having further operations carried out  only by trained staff or an ABB Turbocharging Service Station. Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to di- sassembly. NOTICE Identification of the assembly devices Not all assembly devices are marked with a part number.
Page 86 The specified tightening torques of the screw fittings must be observed (Table of tightening torques [➙ 103]). Tightening torques for assembly devices from ABB Turbo Systems Unless described otherwise, the screws and nuts of the assembly devices must be tightened so they rest firmly against the surface.
Page 87: Weights Of Assemblies
10 Turbine casing * 1 inlet Turbine casing * 2 inlets Turbine casing * 3 inlets 11 Gas outlet flange 12 Gas outlet casing * Table 29 * Including burst protection © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 88: Removing / Installing Air-Inlets
(82000) with O-ring (82010). Installing air-inlets Fit the filter silencer (81000) or air suction branch (82000) with the V-clamp (72020).  (Table of tightening torques [➙ 103]) © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 89: Removing / Installing Compressor Casing
(pressing off with too much force on one side), this may CAUTION result in damage to the rotor. Use the tool on both sides alternatingly and make sure not to press off too  hard on either side. © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 90 Knock the wall insert (77000) out of the compressor casing (72000) with a nylon hammer.  Attach swivel lifting eyes (a) to the compressor casing (72000) and lifting gear.  Lift up the compressor casing (72000).  Remove O-ring (77005).  © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 91 Install the wall insert (77000) in the compressor casing.  Secure the diffuser (79000) with fixing discs (79040) and screws (79041).  (Table of tightening torques [➙ 103]) © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 92 Attach swivel lifting eyes (a) to the compressor casing (72000) and lifting gear.  Install the compressor casing (72000).  Install the fastening strips (72012) with screws (72011).  (Table of tightening torques [➙ 103]) © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 93: Removing The Cartridge Group
(2), a separate burst pro- tection (3) is fitted. If the insulation from ABB Turbo Systems (1) is not installed, the separate burst protection (3) plus either the insulation (2) or an appropriate insulation supplied by the enginebuilder must be installed for operation.
Page 94 If an oil orifice is fitted in the oil inlet of the bearing casing, it must not be removed. Figure 35 1 Bearing casing 2 Oil orifice 3 Circlip © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 95 Loosening the cartridge group with a press-off tool If the cartridge group cannot be loosened, it can be pressed off against the turbine casing with the press-off tool (90042). NOTICE © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 96 Pull out the nozzle ring (56001) with the two extraction devices (90070) and the service  support base (90012). Remove the labyrinth sealing ring (56005).  Remove the burst ring (57210).  © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 97 Page 95 / 115 Fixing the cartridge group in place Figure 38 Fit service support (90012) according to the illustration.  Fasten the cartridge group on the service support (90012).  © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 98: Installing The Cartridge Group
PD [mm] -0.15 ... 0.15 -0.16 ... 0.16 -0.16 ... 0.16 Table 30 If the calculated value (PD) lies outside the specified range, contact an ABB Turbocharging  Service Station. © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B...
Page 99 (51000). Insert the nozzle ring (56001) into the turbine casing up to the stop. Do not remove the ad-  hesive tape (1). © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 100 Carefully lower the cartridge group into the turbine casing.  Secure fastening strips (51002) along with nuts (51007) and Verbusripp washers (51003).  (Table of tightening torques [➙ 103]) © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 101: Removing / Installing Gas Outlet Casing
6x M8 6x M10 Table 31 *Not included in the ABB Turbo Systems scope of delivery. Installing the gas outlet casing and gas outlet flange If present: Insert metal C-ring (57003) into the turbine casing and secure with high-vacuum ...
Page 102: Radial Clearances N And R
To measure R1 and R2, the feeler gauges must be inserted without clearance between gas outlet flange and turbine, one each above and below. © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 103 Serious damage to engines or property can be caused by clearances outsi- de the tolerance and excessively worn parts. CAUTION Have the components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. © Copyright 2013 ABB. All rights reserved.
Page 104: Axial Clearance A And Radial Clearance B
Serious damage to engines or property can be caused by clearances outsi- de the tolerance and excessively worn parts. CAUTION Have the components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. © Copyright 2013 ABB. All rights reserved.
Page 105: Table Of Tightening Torques
Part number A130 A135 A140 72020 79041 51007 51009 72011 86505 M12 x 1.5 M12 x 1.5 M12 x 1.5 51101 / 51103 / 51104 / 61201 Table 34 © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 106 Page 104 / 115 Figure 47 The following tightening torques must be observed for the designated screw fittings: Tightening torques [Nm] Item Part number A130 A135 A140 Table 35 © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 107: Taking Out Of Operation At Short Notice
 If present: Installing a replacement cartridge group [➙ 106].  If a replacement turbocharger or cartridge group is not available: Fitting the cover plate [➙ 107] and contact an ABB Turbocharging Service Station. Observe the following sections in connection with the emergency repairs mentioned.
Page 108: Installing A Replacement Turbocharger
11.3 Installing a replacement cartridge group The repair of a cartridge group requires special tools and the expertise of an ABB Tur- bocharging Service Station. The rotating parts turn very fast and are very sensitive to unba- lance.
Page 109: Fitting The Cover Plate
Fasten the cover plate (A) on the turbine casing (51000) with fastening strips (51002), Ver-  busripp washers (51003) and nuts (51007) and screw it onto the bracket. © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 110 11.4.1 Cover plate drawing The cover is not included in the ABB Turbo Systems scope of delivery and must be manufac- tured by the operating company according to the following drawing. Material: General structural steel, in compliance with DIN EN 10025-2.
Page 111: 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 112: 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.
Page 113: Disposing Of Turbocharger Components
Wear respirator mask for particles (P1 or P2 mask)  Wear work gloves made of leather  Wear tightly fitting protective goggles.  Dispose of thermal insulation as hazardous waste.  © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 115: Spare Parts
81010/ 82010 O-ring Table 37 * This gasket can only be installed when a gas outlet casing from ABB Turbo Systems is used. Spare part storage All spare parts that were ordered together with the turbocharger must be kept intact and ready for use.
Page 116: View Of Turbocharger With Part Numbers
Operation Manual / A130-H.. - A140-H.. Spare parts Page 114 / 115 14.2 View of turbocharger with part numbers Figure 50 © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 117 82010 (in the customer spare part set) O-ring 86505* Speed sensor 86515* Cable connector 86526* F/I converter 86528* Tachometer Table 38 * Depending on the specification of the turbocharger © Copyright 2013 ABB. All rights reserved. HZTL2414_EN Revision B March 2013...
Page 118  ABB Switzerland Ltd Turbocharging Bruggerstrasse 71a CH-5401 Baden Switzerland...

This manual is also suitable for:

Ht846941

ABB A140-H56 Operation Manual

Quick Links

Related Manuals for ABB A140-H56

Summary of Contents for ABB A140-H56

This manual is also suitable for:

Table of Contents