ABB HT608279 Operation Manual

HT608279 Document identification Document number HZTL4030 Revision G Language English Original Operation Manual Product identification Serial number HT608279 Customer part number X00069277 Delivery date (yyyy-mm-dd) 2022-01-14 Weight 460 kg Operating limits according to rating plate Speed limit in test rig operation only n Mmax 728 1/s Speed limit during operation n Bmax 689 1/s Gas inlet temperature limit in test rig operation only t Mmax 680 °C Gas inlet temperature limit during operation t Bmax 650 °C

Table of contents © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 Operation Manual / A130-H.. - A140-H.. 1 Introduction............................................................................................................ 4 1.1 Purpose of the manual................................................................................................. 4 1.2 Contact information...................................................................................................... 5 1.3 Essential information.................................................................................................... 5 1.4 Registered trademarks................................................................................................. 5 1.5 Layout and function of the turbocharger ................................................................ 6 1.6 Symbols, definitions..................................................................................................... 8 1.7 Storage of new turbochargers and spare parts.................................................... 10 2 Safety .................................................................................................................... 12 2.1 Introduction .................................................................................................................. 12 2.2 CE conformity............................................................................................................... 12 2.3 Definition of mandatory signs .................................................................................. 13 2.4 Definition of safety instructions .............................................................................. 13 2.5 Intended use ................................................................................................................. 14 2.6 Deflagration on gas engines ..................................................................................... 15 2.7 Periodic check of the pressure vessels.................................................................... 15 2.8 Warning plates on the turbocharger........................................................................ 16 2.9 Turbocharger rating plate.......................................................................................... 17 2.10 Lifting of loads ............................................................................................................. 19 2.11 Prerequisites for operation and maintenance...................................................... 20 2.12 Hazards during operation and maintenance ......................................................... 21 2.13 Safe operation.............................................................................................................. 23 2.14 Safe maintenance ....................................................................................................... 24 3 Removing and Installing...................................................................................... 28 3.1 Weight and transportation of the turbocharger.................................................. 28 3.2 Removing the turbocharger...................................................................................... 29 3.3 Installing the turbocharger....................................................................................... 33 4 Commissioning .................................................................................................... 40 4.1 Oil supply ...................................................................................................................... 40 4.2 Inspection procedures............................................................................................... 42 4.3 Commissioning after taking out of operation...................................................... 44 5 Monitoring operation.......................................................................................... 45 5.1 Oil pressure, oil temperature.................................................................................... 45 5.2 Exhaust gas temperature before turbine .............................................................. 47 5.3 Turbocharger speed................................................................................................... 47 6 Operation and service ......................................................................................... 51 6.1 Noise emission ............................................................................................................. 51

Table of contents © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 6.2 Service work................................................................................................................. 53 6.3 Expected replacement intervals ............................................................................... 57 6.4 Stopping the engine................................................................................................... 59 7 Periodic maintenance work ................................................................................ 60 7.1 Foreword to maintenance......................................................................................... 60 7.2 Cleaning components mechanically ........................................................................ 61 8 Eliminating malfunctions.................................................................................... 71 8.1 Malfunctions when starting....................................................................................... 71 8.2 Malfunctions during operation ................................................................................. 72 8.3 Turbocharger is surging............................................................................................. 75 8.4 Malfunctions when stopping.................................................................................... 76 8.5 Speed measurement system..................................................................................... 77 9 Dismantling and fitting....................................................................................... 78 9.1 Introduction ................................................................................................................. 78 9.2 Weights of individual parts....................................................................................... 80 9.3 Removing the air inlets .............................................................................................. 82 9.4 Removing the gas outlet casing .............................................................................. 83 9.5 Removing the gas outlet flange............................................................................... 83 9.6 Removing the compressor casing........................................................................... 86 9.7 Pressing off the casing.............................................................................................. 88 9.8 Removing the cartridge group................................................................................. 89 9.9 Removing the nozzle ring........................................................................................... 91 9.10 Installing the cartridge group on the service support ........................................ 92 9.11 Measuring clearance A and B.................................................................................... 93 9.12 Nozzle ring compression PD..................................................................................... 94 9.13 Installing the nozzle ring ........................................................................................... 95 9.14 Installing the cartridge group .................................................................................. 96 9.15 Installing the compressor casing ............................................................................ 98 9.16 Measuring radial clearances N and R .................................................................... 100 9.17 Installing the air inlets .............................................................................................. 101 9.18 Installing the gas outlet flange .............................................................................. 102 9.19 Installing the gas outlet casing.............................................................................. 102 9.20 Table of tightening torques.................................................................................... 103 10 Taking out of operation at short notice......................................................... 104 10.1 Possible emergency repairs.................................................................................... 104 10.2 Installing the replacement turbocharger............................................................. 105 10.3 Installing the replacement cartridge group ........................................................ 105 11 Mothballing the turbocharger.......................................................................... 106 11.1 Taking the engine out of operation for up to 12 months ................................. 106 11.2 Taking the engine out of operation for more than 12 months........................ 107

Table of contents © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 12 Material and Disposal........................................................................................ 108 12.1 REACH and RoHS Compliance Declaration For Products ................................. 108 12.2 Disposing of turbocharger components ............................................................. 109 13 Spare parts ......................................................................................................... 110 13.1 Ordering spare parts................................................................................................. 110 13.2 Required customer spare part set (97070)........................................................... 110 13.3 Spare part – Illustrations.......................................................................................... 111 14 Tools .................................................................................................................... 119 Figures................................................................................................................. 120 Tables ................................................................................................................... 121

1 Introduction / 1.1 Purpose of the manual © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 1 Introduction 1.1 Purpose of the manual Fig. 1: Serial number (01) on the rating plate This Operation Manual belongs to the turbocharger with the identical serial number (01), see the Operation Manual title page and the rating plate on the turbocharger. 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. 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. Page 4 / 122

1 Introduction / 1.2 Contact information © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 1.2 Contact information Contact information for the ABB Turbocharging Service Stations is available online. u Scan the QR code to access our website. ABB Switzerland Ltd, Turbocharging Bruggerstrasse 71a CH-5401 Baden Switzerland www.abb.com/turbocharging 1.3 Essential information 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. 1.4 Registered trademarks The trademarks of outside companies are used in this document. These are marked with the ® symbol. Page 5 / 122

1 Introduction / 1.5 Layout and function of the turbocharger © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 1.5 Layout and function of the turbocharger Fig. 2: Layout and function of the turbocharger 01 Air suction branch 08 Turbine 02 Compressor casing 09 Gas outlet flange 03 Diffuser 10 Nozzle ring 04 Bearing casing 11 Turbine casing 05 Axial thrust bearing 12 Turbine-end bearing flange 06 Radial plain bearing 13 Compressor-end bearing flange 07 Gas outlet casing 14 Compressor wheel Page 6 / 122

1 Introduction / 1.5 Layout and function of the turbocharger © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 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 (11) and the nozzle ring (10) onto the turbine (08). The turbine (08) uses the energy contained in the exhaust gas to drive the rotor and thus the compressor wheel (14). The exhaust gases then reach the atmosphere through the exhaust gas pipe connected to the gas outlet cas- ing (07). The compressor wheel (14) sucks in fresh air through the air suction branch (01). In the com- pressor wheel (14), 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 the 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). Function of the compressor wheel cooling Fig. 3: Compressor wheel cooling Depending on the application of an A100 radial turbocharger, the turbocharger is equipped with compressor wheel cooling. With compressor wheel cooling, after the compressor air has cooled down by passing through the charge air cooler on the engine side, it is supplied to the turbocharger for cooling the compressor wheel. Cooling of the compressor wheel is compulsory to ensure the reliability and replacement intervals for the relevant operating conditions. In the turbocharger version with compressor wheel cooling, the cooling air is supplied through a lateral connection in the bearing casing (X). In addition, the turbocharger version with compressor wheel cooling is indicated by the tur- bocharger type (H6..) on the rating plate. Page 7 / 122

1 Introduction / 1.6 Symbols, definitions © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 1.6 Symbols, definitions Symbols The following symbols are used in this document: u Indicates an action step. 1. Indicates a numbered action step. →   Refers to a page number Definition of Note NOTICE Note The note provides advice which facilitates the work. Definition of mandatory signs Mandatory signs show the protective equipment to be worn for a task. The mandatory signs are described in chapter Safety and must be complied with. Definition of Caution / Warning Caution and warning signs are described in chapter Safety. ABB Turbocharging ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging in this document. Official service stations of ABB Turbocharging Official service stations are regularly audited and certified by ABB Turbocharging. See also chapter Contact information →5. Page 8 / 122

1 Introduction / 1.6 Symbols, definitions © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 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. Pictogram Meaning Tighten with specified torque Tighten over specified tightening angle Hand-tight, tighten without tools Oil Apply screw locking paste (e.g. Loctite) Apply high-temperature grease Apply other paste in accordance with specifications Oil free, grease free and dry Affix Measure Note 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 Page 9 / 122

1 Introduction / 1.7 Storage of new turbochargers and spare parts © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 1.7 Storage of new turbochargers and spare parts Storage of new turbochargers and spare parts up to 6 months New turbochargers and spare parts can be stored in their closed packages for 6 months from the date of delivery without additional mothballing measures. Only dry rooms in which the relative humidity is between 40…70 % and no condensation can form are suitable for storage. Storage of new turbochargers and spare parts for more than 6 months As the contents of the package are adapted as required, turbochargers may also be de- livered without a VCI label. For parts with a VCI label on the package, the following instructions must be observed. Fig. 4: Volatile Corrosion Inhibitor (VCI) WARNING Health protection when handling VCI VCI products are not hazardous in terms of the Ordinance on Hazardous 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. Wear safety gloves to protect against mechanical hazards. Every 6 months, the following mothballing measures are required: u Open package. 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. Page 10 / 122

1 Introduction / 1.7 Storage of new turbochargers and spare parts © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 Long-term storage of turbochargers The turbochargers will be prepared for long-term storage if requested in the purchase order. The package is equipped with a hygrometer (see illustration). Fig. 5: Package with hygrometer Every 6 months, the following measures are required: u Check the hygrometer (02) in the sight-glass. There is an opening (01) in the wooden crate which allows this check to be carried out. When the display field has changed colour at the 70% level, the maximum permissible humidity has been exceeded. In this case, the turbocharger must be inspected by an ABB Turbocharging Service Station and repacked. u 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: ¡ Inspect the component ¡ Replace the desiccant agent ¡ Repackage the component. NOTICE 70% field of the hygrometer has not changed colour If the 70% field of the hygrometer (02) has not changed colour and the pack- age is undamaged, the turbocharger can be put into operation without any prior inspection by an ABB Turbocharging Service Station. Unpacking the turbochargers The corrosion protection effect ends after the material is unpacked from the VCI package. To avoid the formation of condensation, the surroundings and the content of the package must have the same temperature during unpacking. Page 11 / 122

2 Safety / 2.1 Introduction © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 2 Safety 2.1 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. All further specifically identified safety instructions (Definition of safety instructions →13) must also be observed. 2.2 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. Page 12 / 122

2 Safety / 2.3 Definition of mandatory signs © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 2.3 Definition of mandatory signs To be worn at all times Protective clothing Safety footwear to protect against mechanical hazard and risk of falling Table 2: Personal protective equipment to be worn at all times To be worn specific to the respective task Safety glasses Safety goggles Safety gloves to protect against - Mechanical hazard - Chemical hazard - Thermal hazard - Electrical hazard Respiratory mask to protect against - Dusts - Gases Safety helmet Ear protection Table 3: Personal protective equipment to be worn specific to the respective task 2.4 Definition of safety instructions 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. Page 13 / 122

2 Safety / 2.5 Intended use © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 2.5 Intended use Use on internal combustion engines in general ABB turbochargers are intended for charging internal combustion engines. To ensure compliance with the machinery directive 2006/42/EC when using on gas engines, the turbocharger must be operated in an engine room classified as "not at risk of explosion". This is in accordance with the position paper [2] relating to ATEX issued by EUROMOT [1]. For use on pre-mix gas engines with ignitable propellents in the gas control system, the en- ginebuilder must implement appropriate safety measures for explosion protection [3] (such as flame barriers in the inlet system, for example) to assure that there is no transient pres- sure increase exceeding a maximum of 12 bar before the turbocharger in case of a deflagra- tion. The turbocharger supplies the engine with the air volume or air/gas mixture and the associ- ated charging pressure required for operation. The turbocharger is solely intended to be operated with a clockwise direction of rotation as viewed from the turbine end. The specific operating limits of the turbocharger were determined on the basis of informa- tion from the enginebuilder about the intended use. These data are given on the rating plate. The use of the turbocharger is limited to the specific application released at the time of de- livery. ABB accepts no liability and rejects all warranty claims for any non-intended uses. WARNING Unapproved operation Any operation of the turbocharger outside of its operating limits can be haz- ardous to personnel. 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 State of the art The turbocharger is designed and manufactured according to the state of the art and is safe to operate. Page 14 / 122

2 Safety / 2.6 Deflagration on gas engines © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 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. 2.6 Deflagration on gas engines ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar. After a deflagration event ABB recommends verifying the following points on the turbochar- ger: ¡ Position of the turbine and compressor casings to the bearing casing ¡ Shifting of the bearing casing in relation to the bracket ¡ 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. 2.7 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. Page 15 / 122

2 Safety / 2.8 Warning plates on the turbocharger © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 2.8 Warning plates on the turbocharger Warning plates are affixed at the following locations: Fig. 6: Warning plate locations 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 Remove any warning plates that have become unreadable. u Clean and degrease the areas designated for the warning plates. u Fit new warning plates and remove protective sheets. 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 16 / 122

2 Safety / 2.9 Turbocharger rating plate © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 2.9 Turbocharger rating plate Fig. 7: Rating plate Operating limits 01 Turbocharger operating limits at engine overload (110 %). In test rig operation only, unless otherwise agreed with the en- ginebuilder. 02 Turbocharger operating limits during operation Recommended inspection and replacement intervals of turbocharger components 03 Inspection interval of plain bearings in 1000 h 04 Replacement interval of compressor in 1000 h 05 Replacement interval of turbine in 1000 h 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 Page 17 / 122

2 Safety / 2.9 Turbocharger rating plate © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 Explanations regarding the rating plate The recommended inspection and replacement intervals and the corresponding operating limits are jointly defined with the enginebuilder. This information is specific to the system. Operation above the indicated values nBmax, tBmax can considerably shorten the recommended replacement intervals. In such cases, we recommend contacting the nearest ABB Turbochar- ging Service Station. nMmax, tMmax normally apply only when running at overload (110 %) during trials on the engine test bed. These limit values can also be permitted during operation for special applications. Operation above nMmax and tMmax is not permitted. Non-observance of the recommended inspection and replacement intervals increases the risk of unpredictable component failures. For operating limits, refer to the Operation Manual title page or the rating plate on the tur- bocharger. Locations of the rating plates Fig. 8: 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. Page 18 / 122

2 Safety / 2.10 Lifting of loads © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 2.10 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. Wear safety gloves to protect against mechanical hazards. Wear safety helmet. Fig. 9: Attachment of loads on the crane hook Fig. 10: Attachment angle 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 Use a suitable edge guard if there are sharp edges. u The assembly devices must be completely screwed in and must not loosen during use. u Use assembly devices only for the described applications. u Put down dismantled components of the turbocharger in such a way that they cannot tip over. Page 19 / 122

2 Safety / 2.11 Prerequisites for operation and maintenance © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 2.11 Prerequisites for operation and maintenance Responsibility of the operating company In awareness of its responsibility, the operating company must ensure that only authorised personnel work on the turbocharger, who: ¡ Are versed in the general and locally applicable regulations for occupational safety and accident prevention ¡ Are equipped with the prescribed personal protective equipment ¡ Have read and understood the Operation Manual ¡ Have been instructed in the use of the turbocharger. The safety-conscious work of the personnel and adherence to the Operation Manual must be checked periodically. Suitable working materials and personal protective equipment must be kept in a perfect condition. Only authorised personnel may remain in the vicinity of the turbocharger when the engine is running. Competence of personnel The turbocharger must only be operated and serviced by trained and authorised personnel. Basic mechanical training is a prerequisite. Modifications to the turbocharger Modifications to the turbocharger must be approved by ABB. 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. Original parts and accessories are specially designed for ABB turbochargers. ABB accepts no liability for any damage resulting from the use of non-original parts and cor- responding accessories. Page 20 / 122

2 Safety / 2.12 Hazards during operation and maintenance © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 2.12 Hazards during operation and maintenance Noise hazards The turbocharger's noise emission is influenced by its installation and operating conditions. A noise level exceeding 85 dB(A) is harmful. WARNING Noise hazards 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). Wear ear protection. Hazards due to hot surfaces Surfaces of the turbocharger, attached parts and operating fluids (lubricating oil) get hot 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. Wear safety gloves to protect against thermal hazards. Page 21 / 122

2 Safety / 2.12 Hazards during operation and maintenance © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 WARNING Hot surfaces on a 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. Wear safety gloves to protect against thermal hazards. Hazards due to rotating parts WARNING Hazards due to rotating parts Contact with rotating parts can cause severe injury. The turbocharger is never allowed to be operated without filter silencer or air-inlet casing. 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. Wear safety gloves to protect against mechanical hazards. Page 22 / 122

2 Safety / 2.13 Safe operation © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 2.13 Safe operation Mechanical hazards during operation During standard operation, no mechanical hazards are caused by the turbocharger itself if it has been properly installed. Safety during commissioning and operation u Visually inspect your working environment before starting work. u Remove any obstacles and objects littering the workplace. 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. WARNING Missing burst protection Operating the turbocharger without burst protection can result in serious injury or fatal accidents. u Only operate the turbocharger with burst protection from ABB fitted. Page 23 / 122

2 Safety / 2.14 Safe maintenance © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 2.14 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 chapter. u Only perform operations for which you have received instruction or train- ing. Wear safety footwear to protect against mechanical hazard and risk of fall- ing. Wear protective clothing. 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 Power tools must be grounded and cables must be undamaged. u Keep the workplace clean; clear away any loose objects and obstacles on the floor. u Keep the floor, equipment, and turbocharger clean. u Have oil binding agents ready and provide or keep oil pans at hand. u Clean up any spills. u Have fire protection means and extinguishing agents available. Page 24 / 122

2 Safety / 2.14 Safe maintenance © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 Use of assembly devices Assembly devices are specially constructed and designed for the defined use; they are not commercially available products. u Use assembly devices only for the described applications. Welding work in the vicinity of the turbocharger u When performing welding work in the vicinity of the turbocharger, always cover the filter silencer to prevent the filter mat from being damaged. u Keep flammable objects and substances out of the vicinity of flying sparks. 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. Safety during cleaning If cleaning agents or solvents are used for cleaning, the corresponding material safety data sheet and the safety instructions in section Hazards due to operating materials and supplies must be observed. u Observe the material safety data sheet for the cleaning agent or solvent. 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. Safety during disassembly, assembly, maintenance and repair 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 chapter. u Only perform operations for which you have received instruction or train- ing. Page 25 / 122

2 Safety / 2.14 Safe maintenance © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 Safety when taking out of operation or preparing for mothballing 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. Mechanical hazards when working on the turbocharger WARNING Mechanical hazard 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. 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. Wear safety goggles. Wear safety gloves to protect against chemical hazards. Wear a respiratory mask to protect against gases. Page 26 / 122

2 Safety / 2.14 Safe maintenance © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 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. Hazards due to the handling of insulation materials 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. Wear safety goggles. Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against chemical hazards. Page 27 / 122

3 Removing and Installing / 3.1 Weight and transportation of the tur- bocharger © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 3 Removing and Installing 3.1 Weight and transportation of the turbocharger Lifting gear with a sufficient load limit must be used for removing, installing and transport- ing the turbocharger. The weight specified below 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. Fig. 11: Transportation of the turbocharger Product Weight of complete turbocharger unit [kg] A130-H 190 A135-H 270 A140-H 460 Table 4: Weight of complete turbocharger unit Page 28 / 122

3 Removing and Installing / 3.2 Removing the turbocharger © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 3.2 Removing the turbocharger u Disconnect all pipes according to the instructions of the enginebuilder. u If present: Loosen and remove the compressor wheel cooling connection. Seal the compressor wheel cooling connection (01). Fig. 12: Removing the turbocharger A Position of expansion sleeves B Clamping nut C Standard nut u Apply penetrating oil to thread of stud (02) and nut and let it work in. Do not apply penetrating oil to the pressure screws of the clamping nut (B). 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), positioning pins (05) can be used for positioning and safeguarding against wrong fitting of the turbocharger. Therefore the turbocharger must al- ways 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. Page 29 / 122

3 Removing and Installing / 3.2 Removing the turbocharger © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 3.2.1 Fastening of 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. Wear safety gloves to protect against mechanical hazards. CAUTION Freezing of the cooling water in the bearing casing Serious damage to property can be the consequence if the cooling water freezes in the pipes and in the bearing casing. u For transport and storage of the turbocharger, drain the cooling water in the bearing casing via two openings of the water connections. Manual loosening To remove the turbocharger from the bracket, proceed as follows: u Loosen and remove water connections. Close the openings of the water connections with screw plugs. u Attach lifting gear to the suspension eye. u Loosen and remove nuts (C). Hydraulic loosening (round special nut) If the turbocharger was fitted by the enginebuilder using a hydraulic tool, disassembly is also done using a hydraulic tool (see instructions of the enginebuilder). When doing this, proceed as follows: u Attach lifting gear to the suspension eye. u Remove the turbocharger. u Cover the oil connections (03) at the engine side to protect against contamination. Page 30 / 122

3 Removing and Installing / 3.2 Removing the turbocharger © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 3.2.2 Loosening the clamping nut CAUTION Incorrect procedure can make loosening impossible If individual pressure screws are fully relieved, the pressure screws can be- come compressed, making it impossible 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. In case of non-compliance, it cannot be ensured that the necessary tension force is reached. u Do not clean pressure screws. u Do not lubricate pressure screws. If a screw jams, the previously loosened screw must be tightened again a little. Fig. 13: Loosening the clamping nut 1. Working in a circle, break loose each pressure screw (≤ 20°). 2. Working in a circle, loosen each pressure screw by 45° in 4 rounds. 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. u Loosen clamping nut by hand. Page 31 / 122

3 Removing and Installing / 3.2 Removing the turbocharger © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 3.2.3 Putting down 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. Fig. 14: Putting down the turbocharger 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. Page 32 / 122

3 Removing and Installing / 3.3 Installing the turbocharger © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 3.3 Installing the turbocharger 3.3.1 Inserting gaskets into the bracket 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. The oil is supplied (02) and drained (03) through the bracket (01). The necessary sealing is provided by O-rings. The O-rings are not included in the ABB scope of delivery. Fig. 15: Inserting gaskets into the bracket 01 Bracket 04 Slot for O-ring 02 Oil supply 05 O-rings 03 Oil drain 06 Pin (optional) Pin (06) as installation safety device Turbochargers can have an oil inlet either on their right or left side; the oil inlet position can be different for the turbocharger fitted on the left and on the right engine bank. A pin can be installed in every support as an installation safety device to prevent inadvertent incorrect fitting. This pin fits into the respective slot on the foot of the bearing casing. In- structions of the enginebuilder must be observed. Page 33 / 122

3 Removing and Installing / 3.3 Installing the turbocharger © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 3.3.2 Fitting threaded rods Fig. 16: Fitting threaded rods onto the bracket 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. Requirements for the threaded rods Fig. 17: Requirements for threaded rods Product Diameter Threaded rod [mm] Material DIN / ISO 898 (Part 1) Thread length L1 [mm] Length of threaded rod L2 [mm] A130-H Ø 16 / M16 10.9 / 12.9 ≥ 30 250 A135-H Ø 20 / M20 10.9 / 12.9 ≥ 30 325 A140-H Ø 24 / M24 10.9 / 12.9 ≥ 70 410 … 420 Table 5: Requirements for threaded rods Fastening material, scope of delivery The threaded rods and nuts for fastening the turbocharger on the bracket are not included in the ABB scope of delivery. The clamping nuts are included in the ABB scope of delivery. Page 34 / 122

3 Removing and Installing / 3.3 Installing the turbocharger © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 3.3.3 Placing the turbocharger on the bracket Fig. 18: 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. u Observe the instructions for the fastening variant at hand. ¡ Fastening the turbocharger with a standard nut →36 (A130 - A140) ¡ Fastening the turbocharger with a clamping nut →37 (only A140) Page 35 / 122

3 Removing and Installing / 3.3 Installing the turbocharger © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 3.3.4 Fastening the turbocharger with a standard nut u Fit the nuts and tighten them according to variant 1 or 2 in the table below. Product Through hole in bearing casing [mm] Fixing screws [mm] Variant 1: Tightening torques [Nm] **) Variant 2: Hy- draulic pre-ten- sioning forces [kN] A130 Ø 17 M16 280 110 A135 Ø 21 M20 560 175 A140 Ø 25 M24 960 250 Table 6: Tightening torque for standard nuts **) When the turbocharger is mounted on the engine support, the bolt threads and screw heads must be lightly oiled (assumed friction coefficient µ = 0.12 for tightening torque) u Remove the lifting gear. Page 36 / 122

3 Removing and Installing / 3.3 Installing the turbocharger © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 3.3.5 Fastening the turbocharger with a clamping nut Preparation for tightening 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. Fig. 19: 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. Page 37 / 122

3 Removing and Installing / 3.3 Installing the turbocharger © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 Tightening pressure screws Fig. 20: Tightening pressure screws Product Fixing screw [mm] Tightening torques [Nm] A140 M24 35 Table 7: Torque-controlled tightening of the pressure screws 1. Screw in pressure screws crosswise by hand until reaching the stop. 2. Tighten pressure screws crosswise to 50 % of the tightening torque specified in the 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. Page 38 / 122

3 Removing and Installing / 3.3 Installing the turbocharger © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 3.3.6 Connecting the turbocharger u Connect the cable to the speed sensor (86515). u Connect all exhaust gas, water, blow-by and air lines according to the instructions of the enginebuilder. Version with compressor wheel cooling 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. Fig. 21: 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. 3.3.7 Attaching the support Fig. 22: Attaching the support u If present: Attach support (61301) to engine support or to a connecting piece. Page 39 / 122

4 Commissioning / 4.1 Oil supply © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 4 Commissioning 4.1 Oil supply 4.1.1 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. 4.1.2 Oil filtering Filtering the lubricating oil with a filter mesh width of ≤ 0.034 mm is sufficient for this tur- bocharger. 4.1.3 Oil pressure Comply precisely with the oil pressure before the turbocharger for trouble-free operation. Different oil pressures must be taken into account here for different operating states, such as, for example, idling mode and when the engine is started. The admissible values are specified in chapter Monitoring operation →45. 4.1.4 Starting the engine for the first time after a turbocharger or engine overhaul When starting the engine for the first time after a turbocharger or engine overhaul, proceed as follows: u Switch on the pre-lubrication pump. u Build up oil pressure. u Do not exceed a pre-lubrication time of 2 minutes. u Start the engine. u Let the pre-lubrication pump run until the pump driven by the engine generates sufficient pressure. Page 40 / 122

4 Commissioning / 4.1 Oil supply © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 4.1.5 Oil orifice in the bearing casing Fig. 23: Oil orifice 01 Bearing casing 02 Oil orifice 03 Circlip 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. Page 41 / 122

4 Commissioning / 4.2 Inspection procedures © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 4.2 Inspection procedures 4.2.1 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. Machine damage can be prevented. 4.2.2 Checks before commissioning Filter mat (if available) u Check for damage and contamination. Lubricating system CAUTION Contaminated oil Serious damage to engine or property can be caused by dirt and solid ma- terial particles in the oil. u For the initial commissioning phase and after all service work, flush the complete lubricating system with warm oil. u Use special running-in filters when running in the engine and after all ser- vice work on the lubricating system. u Check that the oil filter is clean before commissioning. u Check the oil pressure in the oil supply pipes. Warning plates u Check whether warning plates are present and legible. u Check whether the protective sheets have been removed from new warning plates. Version with compressor wheel cooling 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. Page 42 / 122

4 Commissioning / 4.2 Inspection procedures © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 Water-cooled bearing casing 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 water pipes are fitted on the bearing casing. 4.2.3 Checks after commissioning (engine in idle mode) Lubricating system u Keep to the lubricating oil pressure at the inlet. u Keep to the lubricating oil temperature at the inlet. u Refer to chapter Monitoring operation →45 for admissible values. 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. Wear safety gloves to protect against thermal hazards. 4.2.4 Checks when starting up the engine If present: u Measure speed, oil pressure and charging pressure at various engine performances. u Measure the exhaust gas temperature before and after the turbine. u Measure the air temperature before and after the compressor. u Compare the measured values with the values of the acceptance report. Different operat- ing conditions indicate a malfunction (see chapter Eliminating malfunctions →71). 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. Page 43 / 122

4 Commissioning / 4.3 Commissioning after taking out of operation © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 4.3 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 Water-cooled version: Remove the screw plugs on the water connections and fit the water pipe. Version with compressor wheel cooling: u Remove the screw plug on the cooling air connection and fit the cooling air line. 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. u Prepare the turbocharger for operation (see Checks before commissioning →42). u The turbocharger is now ready for operation. Page 44 / 122

5 Monitoring operation / 5.1 Oil pressure, oil temperature © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 5 Monitoring operation 5.1 Oil pressure, oil temperature Lubricating oil pressure, oil inlet To limit the oil flow rate through the turbocharger to the admissible values with the engine at full load, an oil orifice is mandatory or already fitted at the turbocharger oil inlet if the oil inlet pressure is > 3 bar. CAUTION Assuring lubricating oil pressure Serious damage to the engine or property can result from a missing or insuf- ficient lubricating oil supply. u The lubricating oil pressure must be monitored during operation and the necessary pressure assured at the oil inlet. Status for operation Pressure at oil inlet upstream of the turbocharger [bar] Overpressure Normal operation 2.0 < poil ≤ 4.5 Engine start: Cold oil, admissible for a maximum of 15 minutes < 8.0 Engine idling, admissible for a maximum of 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- ately. < 0.5 Table 8: Lubricating oil pressure at oil inlet before turbocharger Arrangement of temperature and pressure measuring points 01 Turbocharger contact surface 02 Oil inlet 03 Oil outlet P Oil pressure measuring point T Oil temperature measuring point For monitoring the lubricating oil pressure, ABB Turbocharging recommends installing a "P" manometer immediately upstream of the turbocharger oil inlet before the orifice. If the pressure is controlled electronically, the relevant signals should be triggered at the warning and alarm values. *) If the drain pipe is vented, the lubricating oil temperature measuring point can be installed at the outlet in the vent tank. Otherwise the measurement should be taken in the drain pipe as close to the turbocharger as possible. Page 45 / 122

5 Monitoring operation / 5.1 Oil pressure, oil temperature © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 Lubricating oil temperature at the inlet 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. Status for operation Oil temperature at the inlet Toil,inlet Admissible 10 … 105 °C Temporarily admissible (< 1 h) → alarm > 105 °C Not admissible → stop engine > 110 °C Temporarily admissible when the engine is started → prior to start: generally preheat oil < 10 °C Table 9: Lubricating oil temperature at the inlet Lubricating oil temperature at the outlet The oil temperature at the outlet is mainly dependant on: ¡ Lubricating oil temperature and pressure at the oil inlet ¡ Engine load and turbocharger speed ¡ Exhaust gas temperature The maximum admissible oil temperature at the outlet is listed in the following table. The specified oil outlet temperature is to be considered as alarm value for the turbocharger op- eration and must be monitored according to the current regulations. Status for operation Oil temperature at the outlet Toil,outlet Admissible ≤ 160 °C Temporarily admissible (< 0.5 h) → alarm > 160 °C Not admissible → stop engine > 180 °C Admissible ≤ Toil,inlet + 55 K Temporarily admissible → alarm > Toil,inlet + 55 K Table 10: Lubricating oil temperature at the outlet If the turbocharger has been operated for a longer period of time outside the admissible range, ABB Turbocharging recommends having the turbocharger inspected by an ABB Tur- bocharging Service Station. Page 46 / 122

5 Monitoring operation / 5.2 Exhaust gas temperature before turbine © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 5.2 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. u For a definition and explanations concerning the rating plate, refer to chapter Safety / Turbocharger rating plate →17. u For operating limits, refer to the Operation Manual title page or the rating plate on the turbocharger. 5.3 Turbocharger speed 5.3.1 Introduction A speed measuring system enables the constant monitoring of the turbocharger speed. CAUTION Do not put the speed measurement cables under strain by pulling them If you pull the speed measurement cables too hard, contacts can be pulled out. u Do not strain the speed measurement cables by pulling. CAUTION Machine damage Operation above the operating limits defined on the rating plate can shorten the recommended replacement intervals considerably and cause machine damage. u Measure turbocharger speed. u Comply with operating limits on rating plate. u For a definition and explanations concerning the rating plate, refer to chapter Safety / Turbocharger rating plate →17. u For operating limits, refer to the Operation Manual title page or the rating plate on the turbocharger. Page 47 / 122

5 Monitoring operation / 5.3 Turbocharger speed © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 5.3.2 Layout and overview Fig. 24: Layout and overview of speed measurement system 86505 Speed sensor 42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F/I converter 01 Plug with integrated voltage limiter 86528 Tachometer *) Installation variant for speed sensor 32109 Sealing disc with cams Page 48 / 122

5 Monitoring operation / 5.3 Turbocharger speed © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 5.3.3 Speed differences with several turbochargers per engine The speeds of all turbochargers on an engine vary only slightly from each other in standard operation. The difference between the highest and the lowest turbocharger speed must not be more than 3 %, relative to the speed limit nBmax. If this permissible range of difference is exceeded, the following steps must be carried out: u Reduce the engine performance immediately to the point at which the maximum tur- bocharger speed does not exceed 70 % of nBmax. u If the engine cannot be stopped, it can continue to be driven at this reduced engine load or turbocharger speed. u If a turbocharger surges continuously, the engine performance must be reduced further. 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. If the engine can be stopped temporarily: u Inspect air lines, gas piping and the turbochargers and remedy any malfunctions. u In any case, contacting the nearest ABB Turbocharging Service Station is recommended. 5.3.4 Malfunctions on the speed measurement system In the case of malfunctions of the speed measurement system, refer to the chapter entitled Troubleshooting/Speed measurement system →77. Page 49 / 122

5 Monitoring operation / 5.3 Turbocharger speed © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 5.3.5 Replacing the speed sensor 5.3.5.1 Replacing the speed sensor 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. Wear safety gloves to protect against thermal hazards. The speed sensor supplied by ABB is equipped with a sealing lip and an O-ring. No additional gasket is required during assembly. Fig. 25: Replacing the speed sensor Part number Thread size Tightening torque 86505 M12 x 1.5 15 Nm Table 11: Tightening torque (86505) u Reduce the engine performance to idling and then stop the engine. Pay attention to post- lubrication (Stopping the engine →59). u Switch off the lubricating oil supply to the turbocharger. u Disconnect cable connector (86515) from speed sensor (86505). u Unscrew and remove defective speed sensor (86505). u Screw in new speed sensor (86505) as far as it will go and tighten. u Connect cable connector (86515) to speed sensor (86505). u Switch on lubricating oil supply to the turbocharger. Page 50 / 122

6 Operation and service / 6.1 Noise emission © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 6 Operation and service 6.1 Noise emission WARNING Noise hazards 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). Wear ear protection. 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 air inlet. The following prerequisites must be fulfilled with regard to the turbochar- ger 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. 26: Noise insulation, bellows →52). The enginebuilder is responsible for insulating the charge air/scavenging air line and the charge air cooler. 1) Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 : A-weighted emission sound pressure level 2) The enginebuilder must provide acoustically equivalent measures in case of deviating in- sulation versions Page 51 / 122

6 Operation and service / 6.1 Noise emission © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 Suggestion for noise insulation, bellows Fig. 26: Noise insulation, bellows 01 Compressor casing 02 Bellows 03 Charge air duct / scavenging air duct 04 Insulation cushion 05 Insulation mat (at least 15 mm) 06 Sheet metal cover Page 52 / 122

6 Operation and service / 6.2 Service work © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 6.2 Service work Service work includes visual controls, monitoring, measuring and inspection as well as func- tional checks. Service work enables the detection and rectification of changes to the tur- bocharger and ensures full operability of the turbocharger. 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 Specific service interval Exceptional stresses such as a high number of starts and stops, harsh envir- onmental 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 specific service interval with ABB Turbocharging. To prevent machine damage caused by ageing and downtime, we recommend having an in- spection carried out by an ABB Turbocharging Service Station no later than 5 years after the last service. Page 53 / 122

6 Operation and service / 6.2 Service work © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 6.2.1 Service work every 25 … 50 hours 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 Record operating data and enter in the engine logbook. u In case of deviations, determine the cause. 6.2.2 Service work at 100 hours after commissioning u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en- gine is stopped, in accordance with the instructions of the enginebuilder. 6.2.3 Service work according to instructions of enginebuilder u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en- gine is stopped, in accordance with the instructions of the enginebuilder. 6.2.4 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. u Remove turbocharger from engine, dismantle and measure clearances (see Dismantling and fitting →78). u Clean nozzle ring, turbine casing, compressor casing and diffuser, and check for cracks and erosion/corrosion. Application with frequent engine start/stop cycles (Peak shaving) If the turbocharger is used for the ‘Peak shaving’ mode with frequent engine start/stop cycles, the number of successful engine start/stop cycles must be taken into account in ad- dition to the inspection interval for the bearing parts specified on the rating plate (in oper- ating hours). u ABB Turbocharging recommends having the rotor and bearing parts, as well as the casing parts on the turbine end, including the nozzle ring, checked and maintained by an ABB Turbocharging Service Station after 5000 successful engine start cycles. Page 54 / 122

6 Operation and service / 6.2 Service work © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 6.2.5 Other service work If a protective grid is installed in the radial or axial gas outlet casing (61001) by ABB: Fig. 27: Replacing the protective grid u Remove the protective grid (61205) after 50000 hours and replace it with a new one. Pre-mix gas engines 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. Page 55 / 122

6 Operation and service / 6.2 Service work © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 6.2.6 Entries in the engine logbook Monitoring the engine system makes it possible to draw conclusions on the operating beha- viour of the turbocharger. The following operating data and measured values must be entered regularly into the engine logbook of the enginebuilder: ¡ Number of times the engine is started successfully (possible aborted start cycles do not need to be recorded) ¡ Performance and speed of the engine ¡ Air intake temperature ¡ Pressure of the charge air ¡ Pressure loss in the charge air cooler ¡ Lubricating oil pressure and lubricating oil temperature. If present: ¡ 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. Page 56 / 122

6 Operation and service / 6.3 Expected replacement intervals © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 6.3 Expected replacement intervals Fuel The expected replacement intervals apply to engine operation with pre-mix gas and diesel oil. Applications with frequent engine start/stop cycles (Peak shaving) In addition to the replacement intervals specified on the rating plate for the compressor and turbine wheel (in operating hours), the number of successful engine start/stop cycles must also be taken into account. Rotating components The recommended replacement intervals of the compressor and turbine wheels are spe- cified with the aid of the safety concept for rotating parts (SIKO) and dependent on the op- erating conditions. These intervals are shown on the rating plate of the turbocharger. When employing the ‘Peak shaving’ mode, ABB Turbocharging generally recommends repla- cing the compressor and turbine wheel after 20000 successful engine start/stop cycles or after reaching the number of operating hours specified on the rating plate. 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 sig- nificantly reduce the replacement interval of these parts. When utilising the ‘Peak shaving’ mode with frequent engine start/stop cycles, the tur- bocharger components on the exhaust gas side are subjected to high thermal loads. This load can cause thermal fatigue when the operating time and number of engine start cycles increase, thereby resulting in wear and cracking of the components. ABB Turbocharging therefore recommends having the components periodically inspected and replaced, if neces- sary, by an ABB Turbocharging Service Station based on the number of successful engine start cycles specified in the following table. The individual components will generally be examined for wear and replaced, if necessary, during the prescribed periodic service work. Page 57 / 122

6 Operation and service / 6.3 Expected replacement intervals © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 Expected replacement intervals Operating hours Number of engine start cycles (Peak shaving mode) Turbine casing 25000 … 50000 5000 … 10000 Nozzle ring 25000 … 50000 5000 … 10000 Gas outlet flange 25000 … 50000 5000 … 10000 Heat shield 25000 … 50000 5000 … 10000 Bearing casing 25000 … 50000 5000 … 10000 Bearing parts 12000 … 24000 5000 Rotor components See information on rating plate 20000 Other casings 50000 - - Table 12: Expected replacement intervals The specified values are guideline values and not guaranteed values; see Influencing para- meters. Influencing parameters The specified values are guideline values and are not guaranteed. The actual values can devi- ate significantly 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). Page 58 / 122

6 Operation and service / 6.4 Stopping the engine © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 6.4 Stopping the engine 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. Water-cooled turbocharger variant u Post-lubricate as long as the rotor is turning. 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 Turbocharging. Page 59 / 122

7 Periodic maintenance work / 7.1 Foreword to maintenance © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 7 Periodic maintenance work 7.1 Foreword to maintenance Maintenance work includes regular visual controls and cleaning operations which are inten- ded to ensure the trouble-free functioning of the turbocharger. Maintenance interval Maintenance work Operating status Similar to the service interval (usually every 8000 … 12000 h) Cleaning components mechanically →61 1) Engine stopped Table 13: Maintenance table [h] = Hours of operation 1) ABB Turbocharging recommends having mechanical cleaning carried out by an ABB Tur- bocharging Service Station during the service work. Page 60 / 122

7 Periodic maintenance work / 7.2 Cleaning components mechanically © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 7.2 Cleaning components mechanically 7.2.1 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. 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 →78. u Contaminated water and cleaning agents must be disposed of in an environmentally compatible, professional way and in compliance with locally applicable regulations. Page 61 / 122

7 Periodic maintenance work / 7.2 Cleaning components mechanically © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 7.2.2 Cleaning the filter silencer Fig. 28: Cleaning the filter silencer 81135 Filter silencer body 81266 Cover grid 81136 Absorption segment 81270 Tension band 81137 Sheet-metal covering 81271 Lock 81265 Filter ring Cleaning the filter ring (if present) u Remove filter ring (81265). u Clean filter ring (81265) as required or every 500 hours of operation and replace after the fifth cleaning process at the latest. The 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. Page 62 / 122

7 Periodic maintenance work / 7.2 Cleaning components mechanically © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 Cleaning the absorption segments (see Fig. 28: Cleaning the filter silencer →62) u Loosen the tension bands (81270). u Remove the cover grid (81266). 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. Fitting the filter silencer (see Fig. 28: Cleaning the filter silencer →62) u Insert the absorption segments (81136) into the sheet-metal coverings (81137). u Bend the sheet-metal coverings (81137) back to their original shape and insert into the slotted guides in the filter silencer body (81135). u Fit the cover grid (81266). u Fit the tension bands (81270) and tighten them at the locks (81271). u Any tension bands that have become damaged must be replaced. u Fit the filter ring (81265), if present. Page 63 / 122

7 Periodic maintenance work / 7.2 Cleaning components mechanically © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 7.2.3 Compressor-end, non-rotating parts 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. Wear safety goggles. Wear safety gloves to protect against chemical hazards. Wear a respiratory mask to protect against gases. The following parts, which are relevant in terms of performance, can be cleaned in accord- ance with the description below. Fig. 29: Compressor-end, non-rotating parts 72000 Compressor casing 77000 Wall insert 79000 Diffuser u Clean the above-mentioned components with steam or ultrasound. Alternatively, soak in diesel oil or water containing household cleaning agent. After soaking, remove contamin- ation with a brush. u Dry components completely. 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. Page 64 / 122

7 Periodic maintenance work / 7.2 Cleaning components mechanically © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 7.2.4 Turbine-end, non-rotating parts 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. Wear safety goggles. Wear safety gloves to protect against chemical hazards. Wear a respiratory mask to protect against gases. 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. Fig. 30: Turbine end, non-rotating parts 51000 Turbine casing 56001 Nozzle ring 57002 Gas outlet flange 56005 Lamellar sealing ring u Dismantle the lamellar sealing ring (56005) in the nozzle ring. 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. u Repeat the soaking and brushing if necessary. u Use clean water to remove all traces of solvent from parts. Page 65 / 122

7 Periodic maintenance work / 7.2 Cleaning components mechanically © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 u Dry components completely. 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. 7.2.5 Cartridge group, general 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 during the standard service intervals (see chapter Service work). u Remove the turbocharger from the engine (see chapter Removing and Installing →28). u Remove the cartridge group (see chapter Dismantling and fitting →78). First clean the compressor end and then the turbine end according to the following descrip- tion. Page 66 / 122

7 Periodic maintenance work / 7.2 Cleaning components mechanically © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 7.2.6 Cleaning the cartridge group on compressor end CAUTION Selection of the cleaning agent Cleaning agents that contain chlorine corrode metals. u Only use pH-neutral cleaning agents that do not corrode metals. u Observe the material safety data sheet. u Observe country-specific regulations regarding banned and restricted substances. 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 Cleaning procedures should be selected that do not result in removal of the compressor wheel material or cause damage to its surfaces. Clean the compressor wheel with a rag or soft brush which has been soaked in water with a household cleaning agent. Do not use a wire brush! 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. Page 67 / 122

7 Periodic maintenance work / 7.2 Cleaning components mechanically © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 7.2.7 Cleaning the cartridge group on turbine end Soaking the contamination Baked layers of contamination from coked oil occur at the turbine end. The contamination can be removed by soaking and brushing. The procedure for soaking the layers of contamin- ation as well as for cleaning the turbine are described in the following. Fig. 31: Soaking the turbine end Product A [mm] B [mm] C [mm] A130 108 17 205 A135 128 20 245 A140 157 25 300 Table 14: Value table for soaking 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 that contain chlorine corrode metals. u Only use pH-neutral cleaning agents that do not corrode metals. u Observe the material safety data sheet. u Observe country-specific regulations regarding banned and restricted substances. 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. Page 68 / 122

7 Periodic maintenance work / 7.2 Cleaning components mechanically © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 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. Wear a respiratory mask according to 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. u Let the layers of contamination on the turbine soak for four hours. Removing contamination 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. Wear safety goggles. Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against mechanical hazards. u Lift up the cartridge group and align it horizontally. u Remove contamination manually using a soft brush or a wire brush. Page 69 / 122

7 Periodic maintenance work / 7.2 Cleaning components mechanically © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 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 enters the gap between the heat sheet metal and the 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 contamination, fill the container (02) with clean water. u Immerse the turbine of the cartridge group in clean water so that any loose contamina- tion comes off. u Lift up the cartridge group and align it horizontally. u Dry the turbine and the gap between the turbine and the heat sheet metal with low-pres- sure pressurized air. u Lightly spray the turbine and the gap between the turbine and the heat sheet metal with penetrating oil. u Dispose of contaminated water and cleaning agents in accordance with the information in the safety data sheet. Page 70 / 122

8 Eliminating malfunctions / 8.1 Malfunctions when starting © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 8 Eliminating malfunctions 8.1 Malfunctions when starting Delayed start-up Possible causes Remedy Turbochar- ger Turbocharger contaminated Clean (see chapter Periodic mainten- ance work →60) Bearing damaged Contact ABB Turbocharging Service Station Rotor rubbing Foreign object in the turbocharger Table 15: Malfunctions when starting – Delayed start-up Vibrations Possible causes Remedy Turbochar- ger Rotor unbalance Contact ABB Turbocharging Service Station Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Contact enginebuilder Table 16: Malfunctions when starting – Vibrations Rubbing of rotating parts Normal behaviour, not a malfunction Turbochar- ger A slight amount of uniform wear at the circumference of the rotor components caused by slight local rubbing against adjacent components is permitted. This causes the compressor or turbine blades to be somewhat shortened. 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. ¡ Have a dimension check carried out by an ABB Turbocharging Service Sta- tion. Table 17: Malfunctions when starting – Rubbing of rotating parts Page 71 / 122

8 Eliminating malfunctions / 8.2 Malfunctions during operation © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 8.2 Malfunctions during operation Lubricating oil pressure too low 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. Wear safety gloves to protect against thermal hazards. Possible causes Remedy Turbochar- ger Axial clearance of the rotor excessive Contact an ABB Turbocharging Service Station Engine Oil filter heavily contaminated Clean Oil pump in lubricating system defect- ive Check/replace Manometer displays incorrectly Replace manometer Table 18: Malfunctions during operation – Lubricating oil pressure too low Speed reduces Possible causes Remedy Turbochar- ger Turbine and/or nozzle ring severely con- taminated Clean (see chapter Periodic mainten- ance work →60) Rotor components or bearing damaged Contact ABB Turbocharging Service Station Engine Defects on the connected cylinders in pulse charging Contact enginebuilder Pipes Defects, such as leaks, in the exhaust gas pipes or charge air ducts Repair Table 19: Malfunctions during operation – Speed reduces Speed increases Possible causes Remedy Turbochar- ger Light to medium contamination of the turbine and/or nozzle ring (with 4- stroke application) Clean (see chapter Periodic mainten- ance work →60) or contact an ABB Tur- bocharging Service Station Table 20: Malfunctions during operation – Speed increases Page 72 / 122

8 Eliminating malfunctions / 8.2 Malfunctions during operation © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 Exhaust gas temperature too high Engine performance and engine speed unchanged Possible causes Remedy Turbocharger Insufficient air, for example, when fil- ter silencer is blocked by contamina- tion Clean (see chapter Periodic mainten- ance work →60) Compressor/turbine contaminated Exhaust gas back pressure too high Clean or repair boiler or exhaust gas si- lencer Turbine damaged or eroded Contact ABB Turbocharging Service Station Engine Malfunction in the injection system Repair or contact manufacturer Charge air cooler Cooler contaminated Clean Cooling water volume too low Fill Inlet temperature of cooling water too high Check/clean cooling system Insufficient ventilation Improve ventilation Table 21: Malfunctions during operation – Exhaust gas temperature too high Charge air pressure too low Engine performance and engine speed unchanged, suction condition normal Possible causes Remedy Turbochar- ger Manometer display not correct Replace manometer Supply pipe to manometer not sealed Repair leak Filter silencer contaminated, therefore pressure drop too high Clean (see chapter Periodic mainten- ance work →60) Compressor end and/or turbine end contaminated Compressor/turbine damaged Contact ABB Turbocharging Service Station Exhaust gas back pressure too high Clean or repair boiler or exhaust gas si- lencer Engine Air receiver not sealed Repair Gas piping between engine and turbine leaking Injection mistimed Set correctly Valve control misadjusted Pipes Pipes downstream to the compressor outlet not sealed. Repair. Table 22: Malfunctions during operation – Charge air pressure too low Page 73 / 122

8 Eliminating malfunctions / 8.2 Malfunctions during operation © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 Charge air pressure too high Engine performance and engine speed unchanged, suction condition normal Possible causes Remedy Turbochar- ger Manometer display not correct Replace manometer Increased speed due to contamination of nozzle ring Clean (see chapter Periodic mainten- ance work →60) or contact an ABB Tur- bocharging Service Station Engine Malfunction in the injection system Repair or contact manufacturer Injection mistimed Set correctly Engine performance higher than indic- ated Check engine performance Table 23: Malfunctions during operation – Charge air pressure too high Reduced compressor performance/efficiency and therefore engine performance losses 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 damaged. u Rectify malfunction in accordance with the following table. Possible causes Remedy Turbochar- ger Compressor components severely con- taminated by the ventilation gases that have been fed in Clean (see chapter Periodic mainten- ance work →60) Optimize oil separation Increased blade vibration, compressor blade damage due to the ventilation gases that have been fed in Correct the feed of ventilation gases ac- cording to instructions of engineb- uilder. Material of the compressor wheel cor- roded due to the feeding in of ventila- tion gases containing corrosive com- ponents Correct the feed of ventilation gases ac- cording to instructions of engineb- uilder. Material of the compressor wheel cor- roded due to intake air containing ex- haust gases or salt Prevent exhaust gas leakages in the en- gine space Clean (see chapter Periodic mainten- ance work →60) Table 24: Malfunctions during operation – Engine performance losses Page 74 / 122

8 Eliminating malfunctions / 8.3 Turbocharger is surging © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 8.3 Turbocharger is surging WARNING Hot air escapes from the air inlet A surge blow is accompanied by a loud bang and escape of hot air from the air inlet. This may result in injury to personnel. u While the turbocharger is pumping, keep a distance from the air inlet. Turbocharger surges continuously or periodically 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 Turbocharging Service Station. Possible causes Remedy Turbocharger Filter silencer or diffuser contamin- ated Clean (see chapter Periodic mainten- ance work →60) Heavy contamination deposits in the turbine or in the nozzle ring Engine Protective grating in front of the tur- bocharger contaminated or damaged Clean/replace Charge air cooler Cooler contaminated Clean Charge air duct blocked Table 25: Malfunction – Turbocharger pumping Sporadic surge blows Possible causes Remedy Engine Engine load reduced quickly when manoeuvring. When this happens, the flow direc- tion in the compressor is momentar- ily reversed. Such sporadic surge blows do not impair the safe opera- tion of the turbocharger. - - Table 26: Malfunction – Sporadic surge blows Page 75 / 122

8 Eliminating malfunctions / 8.4 Malfunctions when stopping © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 8.4 Malfunctions when stopping Runout noises Possible causes Remedy Turbochar- ger Turbocharger contaminated Clean (see chapter Periodic maintenance work →60) Bearing damaged Check clearances (see chapter Measuring clear- ance A and B). If clearances are outside the toler- ance or if in doubt, contact an ABB Turbocharging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station. Foreign object in the tur- bocharger Dismantle turbocharger (see chapter Dismantling and fitting →78). In case of damage, replace the corresponding parts or contact an ABB Turbochar- ging Service Station. Table 27: Malfunctions when stopping – Runout noises Runout time too short The runout time must be noted down as a reference. Because the runout time depends on the oil viscosity, the runout time must always be measured at the same oil temperature. If the runout time is significantly shorter in comparison to a previous measurement, the fol- lowing table must be observed. Possible causes Remedy Turbochar- ger Turbocharger contaminated Clean (see chapter Periodic maintenance work →60) Bearing damaged Check clearances (see chapter Measuring clear- ance A and B). If clearances are outside the toler- ance or if in doubt, contact an ABB Turbocharging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station. Foreign object in the tur- bocharger Dismantle turbocharger (see chapter Dismantling and fitting →78). In case of damage, replace the corresponding parts or contact an ABB Turbochar- ging Service Station. Table 28: Malfunctions when stopping – Runout time too short Page 76 / 122

8 Eliminating malfunctions / 8.5 Speed measurement system © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 8.5 Speed measurement system No signal or poor signal amplitude of the speed measurement Possible causes Remedy Turbochar- ger The speed sensor was acci- dentally fitted with an addi- tional gasket. An enlarged distance between the sensor tip and the signal-emitting sealing disc reduces the voltage amplitude of the speed sig- nal. The screw plug for the sensor is fitted with an ad- ditional gasket (copper ring). For information regarding the disassembly and as- sembly of the speed sensor, refer to chapter Re- placing the speed sensor →50. Install the speed sensor without the additional gasket (copper ring). Sensor or cable defective Contact an ABB Turbocharging Service Station. Order a new speed sensor (86505) from an ABB Turbocharging Service Station. Replacing the speed sensor →50. Table 29: Malfunction of the speed measurement system – No signal or poor signal amplitude Measured speed too high Possible causes Remedy Turbochar- ger Sensor tip contaminated, since it is magnetic and can attract metallic particles. This reduces the distance to the signal-emitting sealing disc, which can lead to ampli- fication of the noise com- ponent and therefore to false triggering. For information regarding the disassembly and as- sembly of the speed sensor, refer to chapter Re- placing the speed sensor →50. Dismantle the sensor, clean the sensor tip, and fit the sensor back on with the specified tightening torque. Table 30: Malfunction of the speed measurement system – Measured speed too high Measured speed too low Possible causes Remedy Turbochar- ger - - Contact ABB Turbocharging Service Station Table 31: Malfunction of the speed measurement system – Measured speed too low If none of the measures described above remedy the malfunction, have the speed measure- ment system checked by an ABB Turbocharging Service Station. Page 77 / 122

9 Dismantling and fitting / 9.1 Introduction © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 9 Dismantling and fitting 9.1 Introduction The precondition for the work described in the following is a turbocharger removed from the engine (see chapter Removal and installation →28). 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. Wear safety gloves to protect against thermal hazards. 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. Wear safety gloves to protect against mechanical hazards. WARNING Non-observance of the work steps and further operations Incorrectly performed work or further operations can cause injury to person- nel or damage to the machine. u Only perform operations that are described in this document. u Only perform operations for which you have previously received instruc- tion or training. u Have further operations carried out only by trained personnel from an ABB Turbocharging Service Station. u Mark the casing position for assembly. 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. Page 78 / 122

9 Dismantling and fitting / 9.1 Introduction © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 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. Customer spare part set Before starting operations, make sure the required customer spare part set is available (see chapter Spare parts →110). 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). Tightening torques for components of the turbocharger The specified tightening torques of the screw fittings must be observed (Table of tightening torques). Tightening torques for assembly devices Unless otherwise described, the screws and nuts of the assembly devices supplied by ABB must be tightened in such a way that they are tight-fitting. WARNING 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 beneath suspended loads. Wear safety gloves to protect against mechanical hazards. Wear safety helmet. Definition of terms ¡ Suspension point Defined loading point on a component or an assembly (blind hole thread, eyelet, lug). Page 79 / 122

9 Dismantling and fitting / 9.2 Weights of individual parts © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 ¡ 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. Swivel lifting eyes to be used Swivel lifting eyes are required for the safe lifting of loads, which are not supplied by ABB. Fig. 32: Swivel lifting eyes Product Thread M Length L [mm] Minimum load limit [kg] Quantity A130 M10 17 mm 100 kg 2 A135 M10 17  mm 150  kg 2 A140 M12 21  mm 250  kg 2 Table 32: Swivel lifting eyes Ring nuts to be used Two ring nuts (M16) are required for safer lifting of the cartridge group, which are not in- cluded in the ABB scope of delivery. Fig. 33: Starpoint ring nut VRM 9.2 Weights of individual parts The specified weights of the individual parts or assemblies are rounded-up standard values. Page 80 / 122

9 Dismantling and fitting / 9.2 Weights of individual parts © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 Fig. 34: Weights of assemblies Designation A130 [kg] A135 [kg] A140 [kg] 01 Filter silencer 19 30 40 02 Radial air suction branch 6 8 13 03 Axial air suction branch 4 5 6 04 Compressor casing 24 40 60 05 Wall insert 6 8 15 06 Diffuser 3 4 7 07 Cartridge group 40 60 110 08 Nozzle ring 2 2 4 09 Burst ring 2 3 5 10 Turbine casing * 45 65 120 11 Gas outlet flange 7 13 20 12 Gas outlet casing * 30 35 65 Table 33: Weights of assemblies * including burst protection Page 81 / 122

9 Dismantling and fitting / 9.3 Removing the air inlets © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 9.3 Removing the air inlets u Mark the casing position for assembly. Fig. 35: Removing the air inlets 1. Attach lifting gear to the filter silencer (81000) or air suction branch (82000). 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). Page 82 / 122

9 Dismantling and fitting / 9.4 Removing the gas outlet casing © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 9.4 Removing the gas outlet casing u Mark the casing position for assembly. Fig. 36: Removing the gas outlet casing 1. Attach lifting gear to the gas outlet casing (61001). 2. Loosen and remove nuts (51009). 3. If present: Detach support (61301) from bracket. 4. Remove the gas outlet casing (61001), set it down properly in an appropriate place and secure it. 5. Remove and dispose of the gasket (61002). 9.5 Removing the gas outlet flange Depending on the way of fixing the gas outlet flange, the appropriate Working Instruction has to be consulted (pressing off using 3 or 6 press-off screws). If the following Working Instructions are not observed, this can lead to cracks in the gas out- let casing. The following variants are possible: u Pressing off using 3 press-off screws. u Pressing off using 6 press-off screws. Page 83 / 122

9 Dismantling and fitting / 9.5 Removing the gas outlet flange © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 Gas outlet flange with 3 press-off screws 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. Fig. 37: Dismantling the gas outlet flange Product Press-off screws (strength 8.8) * Tightening torque A130 3 x M 8 x 20 ≤ 20 Nm A135 3 x M10 x 25 ≤ 40 Nm A140 3 x M12 x 30 ≤ 65 Nm Table 34: 3 press-off screws * not included in the ABB scope of delivery 1. Press off and remove the gas outlet flange (57002) with screws (01) according to the table. If it is not possible to press off the gas outlet flange with the maximum tightening torque, contact an ABB Turbocharging Service Station. 2. If present: Remove the C-ring (57003). Page 84 / 122

9 Dismantling and fitting / 9.5 Removing the gas outlet flange © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 Gas outlet flange with 6 press-off screws 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. Dismantle the gas outlet flange only 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. Fig. 38: Removing the gas outlet flange Product Press-off screws (strength 8.8) * Tightening torque A130 6x M6 x 20 ≤ 10 Nm A135 6x M8 x 25 ≤ 20 Nm A140 6x M10 x 30 ≤ 40 Nm Table 35: 6 press-off screws * not included in the ABB scope of delivery. 1. Evenly press off and remove the gas outlet flange (57002) with screws (01) according to the table. If it is not possible to press off the gas outlet flange with the maximum tight- ening torque, contact an ABB Turbocharging Service Station. 2. If present: Remove the C-ring (57003). Page 85 / 122

9 Dismantling and fitting / 9.6 Removing the compressor casing © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 9.6 Removing the compressor casing Removing the compressor casing u Mark the casing position for assembly. Fig. 39: Removing the compressor casing *) In some installations a special graphite cord sealing (42126) is fitted (see also chapter Spare parts →110). 1. Loosen screws (72011) and remove together with fastening strips (72012). 2. Attach swivel lifting eye (S) to the compressor casing and the lifting gear. 3. Remove the compressor casing (72000) and turn it 180°. 4. Remove and dispose of the O-ring (42012) or graphite cord sealing (42126). 5. Loosen screws (79041) and remove from the compressor casing (72000) with fixing discs (79040) and diffuser (79000). If the compressor casing cannot be loosened, it can be pressed off against the turbine cas- ing using the press-off tool (90042) (see chapter Pressing off the casing →88). Page 86 / 122

9 Dismantling and fitting / 9.6 Removing the compressor casing © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 Dismantling the wall insert Fig. 40: Dismantling the wall insert 1. Knock the wall insert (77000) out of the compressor casing (72000) with a plastic tip hammer. 2. Attach swivel lifting eye (S) to the compressor casing (72000) and the lifting gear. 3. Lift up the compressor casing (72000). 4. Remove and dispose of the O-ring (77005). Page 87 / 122

9 Dismantling and fitting / 9.7 Pressing off the casing © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 9.7 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. Fig. 41: Press off the casing Page 88 / 122

9 Dismantling and fitting / 9.8 Removing the cartridge group © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 9.8 Removing the cartridge group u Mark the casing position for assembly. Do not remove oil orifice (if present) To limit the oil flow rate through the bearing casing during operation (engine under load) to the admissible values, an oil orifice is mandatory at the oil inlet of the bearing casing if the oil inlet pressure is > 3 bar (overpressure). If an oil orifice is fitted in the oil inlet of the bearing casing, it must not be removed. Fig. 42: Oil orifice 01 Bearing casing 02 Oil orifice 03 Circlip Fig. 43: Removing cartridge group 1 1. Treat threads of studs (51006) with penetrating oil and leave to take effect. 2. Undo nuts (51007) and remove Verbus Ripp® washers (51003) together with fastening strips (51002). Page 89 / 122

9 Dismantling and fitting / 9.8 Removing the cartridge group © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 Fig. 44: Removing cartridge group 2 3. Insert screws from service support into cartridge group. 4. Secure ring nuts (VRM) onto the screws with washers. 5. Secure the lifting gear to the ring nuts and suspension eye as shown. 6. Remove the cartridge group vertically from the turbine casing. 7. Turn the cartridge group into the horizontal rotor axis. If the cartridge group cannot be loosened, the press-off tool (90042) can be used (see chapter Pressing off the casing →88). Page 90 / 122

9 Dismantling and fitting / 9.9 Removing the nozzle ring © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 9.9 Removing the nozzle ring Fig. 45: Removing the nozzle ring 1. If present: Remove the metal C-ring (51105). 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). Page 91 / 122

9 Dismantling and fitting / 9.10 Installing the cartridge group on the service support © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 9.10 Installing the cartridge group on the service support Fig. 46: Installing the cartridge group on the service support 1. Remove ring nuts (VRM). 2. Remove service support screws. 3. Fit service support (90012) according to the illustration. 4. Insert the cartridge group. 5. Fit the nuts. Page 92 / 122

9 Dismantling and fitting / 9.11 Measuring clearance A and B © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 9.11 Measuring clearance A and B u Measure and record clearances A and B after the removal and before the installation of the cartridge group. u Attach the dial indicator and align it for the respective clearance as per the illustration. Fig. 47: Measuring clearance A and B Product A [mm] B [mm] A130-H 0.08 ... 0.16 0.47 ... 1.00 A135-H 0.10 ... 0.18 0.58 ... 1.16 A140-H 0.12 ... 0.21 0.70 ... 1.37 Table 36: 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. Page 93 / 122

9 Dismantling and fitting / 9.12 Nozzle ring compression PD © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 9.12 Nozzle ring compression PD In order for the nozzle ring (56001) to be fixed during operation, it must be clamped between the heat shield (42400) and the turbine casing (51000). Fig. 48: Nozzle ring compression PD 42001 Bearing casing 51000 Turbine casing 42400 Heat shield 56001 Nozzle ring Product Nozzle ring compression PD [mm] A130-H -0.15 ... 0.15 A135-H -0.16 ... 0.16 A140-H -0.16 ... 0.16 Table 37: Nozzle ring compression PD 1. Measure dimensions A, B and S on cleaned surfaces. 2. Calculate compression (PD). u If the calculated value (PD) lies outside the specified range, contact an ABB Turbochar- ging Service Station. Page 94 / 122

9 Dismantling and fitting / 9.13 Installing the nozzle ring © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 9.13 Installing the nozzle ring Fig. 49: Installing the nozzle ring *) Variant A1 or A2, depending on the nozzle ring version. 1. Fit the lamellar sealing ring (56005) in the correct slot (see detail A1/A2). When doing this, pay attention to correct winding of the lamellar sealing ring (see detail B). 2. Secure the lamellar sealing ring (56005) with adhesive tape (01). 3. Place the burst ring (57210) in the turbine casing. 4. Insert the nozzle ring (56001) (with the cams facing downwards) into the turbine casing as far as it will go. 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). Page 95 / 122

9 Dismantling and fitting / 9.14 Installing the cartridge group © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 The end position of the nozzle ring (56001) in the turbine casing (51000) can be checked via dimension H. Fig. 50: Measuring the end position of the nozzle ring Product Dimension H [mm] A130-H ≥11.00 A135-H ≥13.50 A140-H ≥16.50 Table 38: End position of the nozzle ring, control dimension H 1. Measure dimension H as shown in the illustration and compare it with the minimum di- mension H in the table. 9.14 Installing the cartridge group Lifting the cartridge group and rotating it by 90° Fig. 51: Lifting the cartridge group and rotating it by 90° 1. Loosen and remove nuts. 2. Lift the cartridge group out of the service support (90012). 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. Page 96 / 122

9 Dismantling and fitting / 9.14 Installing the cartridge group © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 Installing the cartridge group Fig. 52: Installing the cartridge group Product Size Tightening torque [Nm] A130 M8 25 A135 M10 45 A140 M12 75 Table 39: Tightening torque (51007) 1. Coat thread of studs (51006) with high-temperature grease. 2. Align the casing position of the cartridge group to the marking. 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). Page 97 / 122

9 Dismantling and fitting / 9.15 Installing the compressor casing © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 9.15 Installing the compressor casing Fitting the wall insert and the diffuser Fig. 53: Fitting the wall insert and the diffuser Product Size Tightening torque [Nm] A130 M6 8 A135 M6 8 A140 M6 8 Table 40: Tightening torque (79041) 1. Fit new O-ring (77005) (see chapter Required customer spare part set (97070) →110). 2. Install the wall insert (77000) into the compressor casing. 3. Secure the diffuser (79000) with fixing discs (79040) and new screws (79041) (see chapter Required customer spare part set (97070) →110). Page 98 / 122