Page 1 Turbo Systems Switzerland Ltd Operation Manual / A145-M66 HT612770 Document identification Document number HZTL4031 Revision Language English Original Operation Manual Product identification Serial number HT612770 Customer part number Delivery date (yyyy-mm-dd) 2022-05-06 Weight Operating limits according to rating plate Speed limit in test rig operation only...
Page 3: Table Of Contents
Oil pressure, oil temperature..................49 Exhaust gas temperature before turbine ............... 51 Turbocharger speed ....................52 Operation and service ..................55 Noise emission ......................55 Service work ........................57 © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 4 Installing the replacement turbocharger .............. 122 10.3 Installing the replacement cartridge group ............122 10.4 Fitting the cover plate....................123 10.5 Cover plate drawing ....................124 Mothballing the turbocharger................125 © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 5 Ordering spare parts....................129 13.2 Required customer spare part set (97070)............129 13.3 Spare part – Illustrations ..................130 Tools ........................145 Figures......................... 146 Tables ........................148 © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 6: Operation Manual / A130-M
Availability of the Operation Manual The Operation Manual must be available where the turbocharger is used. All persons operating or working on the turbocharger must have read and fully understood the Operation Manual. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 7: Contact Information
Please contact an Turbo Systems 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.
Page 8: Layout And Function Of The Turbocharger
02 Compressor casing Nozzle ring 03 Diffuser Turbine casing 04 Bearing casing Turbine-end bearing flange 05 Axial thrust bearing Compressor-end bearing flange 06 Radial plain bearing Compressor wheel 07 Turbine © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 9: Fig. 3: Compressor Wheel Cooling
In addition, the turbocharger version with compressor wheel cooling is indicated by the tur- bocharger type (M6..) on the rating plate. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 10: Symbols, Definitions
Official service stations are identified in this document as Turbo Systems service stations. These Turbo Systems service stations are regularly checked and certified by Turbo Systems Switzerland Ltd. See also chapter Contact information →5. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 11: Table 1: Definition Of Pictograms
Visually inspect Please note text for numbered work step. See document Dispose of in an environmentally compatible, professional way and in compliance with locally applicable regulations. Table 1: Definition of pictograms © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 12: Storage Of New Turbochargers And Spare Parts
Old VCI corrosion protection emitters must be disposed of in an environmentally compat- ible, professional way and in compliance with locally applicable regulations. Close package. The more tightly the package is sealed, the longer the protection dura- tion. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 13: Fig. 5: Package With Hygrometer
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. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P...
Page 14: Registered Trademarks
Operation Manual / A130-M.. - A145-M.. 1 Introduction / 1.7 Registered trademarks Registered trademarks The trademarks of outside companies are used in this document. These are marked with the ® symbol. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 15: Safety
Safety Introduction Turbochargers manufactured by ABB reflect the state of the art. The respective safety and health protection requirements are met. This ensures safe operation of the turbocharger. Nevertheless, there may be some residual risks during operation of and work on the tur- bocharger which: ¡...
Page 16: Definition Of Mandatory Signs
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. Caution signs must always be observed. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 17: Intended Use
The intended use of the turbocharger includes compliance with all regulations and condi- tions. In particular, the following must be observed: ¡ Operation Manual ¡ Instructions of the enginebuilder © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 18: Deflagration On Gas Engines
Turbo Systems excludes any liability for damage resulting from unauthorized modifications to the turbocharger or improper operation. 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: ¡...
Page 19: Warning Plates On The Turbocharger
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. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P...
Page 20: Turbocharger Rating Plate
Further data 06 Customer part number 07 Designation for special design 08 Weight of turbocharger in kg 09 Turbocharger type 10 Serial number Year of construction of turbocharger Manufacturing plant © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 21: Fig. 8: Locations Of The Rating Plates
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. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 22: Periodic Check Of The Pressure Vessels
Necessary repair or maintenance work must be performed promptly, and the required safety measures must be taken. Pressure equipment must not be operated if defects are present. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 23: Lifting Of Loads
The assembly devices must be completely screwed in and must not loosen during use. Use assembly devices only for the described applications. Put down dismantled components of the turbocharger in such a way that they cannot tip over. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 24: Prerequisites For Operation And Maintenance
Original parts and accessories are specially designed for Turbo Systems turbochargers. Turbo Systems accepts no liability for any damage resulting from the use of non-original parts and corresponding accessories. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 25: Hazards During Operation And Maintenance
Do not touch hot surfaces. Observe the warning plate on the turbochar- ger. Wear heat-resistant safety gloves and protective clothing. Wait for the turbocharger to cool down before carrying out any work. Wear safety gloves to protect against thermal hazards. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 26 Operate the turbocharger in compliance with the specifications. Secure the rotor against unintentional rotation during maintenance. Wear safety gloves to protect against mechanical hazards. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 27: Safe Operation
Insulation (01) with integrated burst protection from Turbo Systems. Variant B Burst protection (03) and insulation (02) from Turbo Systems. Variant C Burst protection (03) from Turbo Systems with appropriate insulation from the en- ginebuilder. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 28: Safe Maintenance
Keep the floor, equipment, and turbocharger clean. Have oil binding agents ready and provide or keep oil pans at hand. Clean up any spills. Have fire protection means and extinguishing agents available. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 29 Components of the turbocharger can be damaged or destroyed as a result of improper procedures. Only perform operations that are described in this chapter. Only perform operations for which you have received instruction or train- ing. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 30 Wear personal protective equipment (PPE) according to the material safety data sheet. Comply with local legislation. Wear safety goggles. Wear safety gloves to protect against chemical hazards. Wear a respiratory mask to protect against gases. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 31 Dispose of insulation materials properly and in an environmentally com- patible manner in compliance with the legal regulations. Wear safety goggles. Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against chemical hazards. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 32: Removing And Installing
B Turbocharger with water-cooled bearing casing C Complete turbocharger unit with gas outlet casing Product Weight of complete turbocharger unit [kg] A130-M A135-M A140-M A145-M Table 4: Weight of complete turbocharger unit © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 33: Removing The Turbocharger
Observe the specified tightening torque from the supplier of the screw connection. Components (01/02) are not included in the Turbo Systems scope of delivery. Fig. 13: Turbine cleaning nozzle 1. If present: Loosen the turbine cleaning connection (01). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 34: Fig. 14: Removing The Turbocharger
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. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P...
Page 35 Attach lifting gear to the suspension eye. Loosen the round special nut with a hydraulic tool according to the instructions of the en- ginebuilder. Positioning the turbocharger for storage →35. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 36: Fig. 15: Loosening The Clamping Nut
3. Working in a circle, loosen each pressure screw by 90° in 1…5 rounds until all of the pres- sure screws have been relieved. Loosen clamping nut by hand. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 37: Fig. 16: Turbocharger Centre Of Gravity
Centre of gravity Remove turbocharger from engine support, set it down properly in an appropriate place and secure it. Close or cover the openings of the turbocharger and support. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 38: Installing The Turbocharger
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. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P...
Page 39: Fig. 18: Fitting Threaded Rods Onto The Bracket
The threaded rods and nuts for fastening the turbocharger on the bracket are not included in the Turbo Systems scope of delivery. The clamping nuts are included in the Turbo Systems scope of delivery. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P...
Page 40: Fig. 20: Placing The Turbocharger On The Bracket
Observe the instructions for the fastening variant at hand. ¡ Fastening the turbocharger with a standard nut →39 ¡ Fastening the turbocharger with a clamping nut →40 © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 41: 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) Remove the lifting gear. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P...
Page 42: Fig. 21: Preparing The Clamping Nut For The Tightening Procedure
5. Tighten clamping nut (03) by hand. 6. Unscrew clamping nut (03) by ¼ of a turn (90°). The distance between the thrust washer and the clamping nut is now about 1 mm. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P...
Page 43: Fig. 22: Tightening Pressure Screws
4. Work in a circle to tighten all pressure screws to 100 % of the tightening torque specified in the table. 5. Tighten pressure screws to 100 % in 5 … 7 rounds until the required residual tightening angle of < 20° is achieved. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 44: Fig. 23: Connecting The Speed Sensor
Make sure there is an uninterrupted supply of cooling air during opera- tion. Fig. 24: Connecting the compressor cooling air intake Remove the screw plug on the connection for the compressor wheel cooling (06) and fit the cooling air line. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 45: Fig. 25: Attaching The Support
3 Removing and Installing / 3.3 Installing the turbocharger 3.3.7 Attaching the support Fig. 25: Attaching the support If present: Attach support (61301) to engine support or to a connecting piece. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 46: Commissioning
Comply precisely with the oil pressure before the turbocharger for trouble-free operation. The admissible values are specified in chapter Monitoring operation →49. 4.1.5 Oil orifice in the bearing casing Fig. 26: Oil orifice © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 47 With an oil inlet pressure of more than 3 bar of overpressure (with engine under load) up- stream of the turbocharger, an oil orifice must be installed to reduce the oil pressure. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P...
Page 48: Inspection Procedures
Make sure there is an uninterrupted supply of cooling air during opera- tion. Check whether the compressor wheel cooling is fitted on the bearing casing. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 49 Lubricants and pastes used during assembly can liquefy or vaporise and escape as oily fluids during the initial hours of operation. Continual escape of an oily fluid indicates an oil leak. In the event of a leak, contact a Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P...
Page 50: Commissioning After Taking Out Of Operation
Check and clean filter silencer or air supply line, and remove any foreign objects that may be present. Put engine-side oil circulation to the turbocharger into operation. Prepare the turbocharger for operation (see Checks before commissioning →46). The turbocharger is now ready for operation. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 51: Monitoring Operation
*) 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. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P...
Page 52: Table 9: Lubricating Oil Temperature At The Inlet
If the turbocharger has been operated for a longer period of time outside the admissible range, Turbo Systems recommends having the turbocharger inspected by a Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 53: Exhaust Gas Temperature Before Turbine
For a definition and explanations concerning the rating plate, refer to chapter Safety / Turbocharger rating plate →18. For operating limits, refer to the Operation Manual title page or the rating plate on the turbocharger. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 54: Turbocharger Speed
86505 Speed sensor 42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F/I converter Plug with integrated voltage limiter 86528 Tachometer Installation variant for speed sensor 32109 Sealing disc with cams © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 55 In any case, contacting the nearest Turbo Systems 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 →88. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 56: Fig. 28: Replacing The Speed Sensor
Wear safety gloves when disassembling the speed sensor. Wear safety gloves to protect against thermal hazards. The speed sensor supplied by ABB is equipped with a sealing lip and an O-ring. No additional gasket is required during assembly. Fig. 28: Replacing the speed sensor...
Page 57: Operation And Service
Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 : A-weighted emission sound pressure level The enginebuilder must provide acoustically equivalent measures in case of deviating in- sulation versions © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 58: Fig. 29: Noise Insulation, Bellows
Suggestion for noise insulation, bellows Fig. 29: Noise insulation, bellows Compressor casing Bellows Charge air duct / scavenging air duct Insulation cushion Insulation mat (at least 15 mm) Sheet metal cover © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 59: Service Work
To prevent machine damage caused by ageing and downtime, we recommend having an in- spection carried out by a Turbo Systems service station no later than 5 years after the last service. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P...
Page 60 The following work can be carried out as preparation. Remove turbocharger from engine, dismantle and measure clearances (see Dismantling and fitting, general). Clean nozzle ring, turbine casing, compressor casing and diffuser, and check for cracks and erosion/corrosion. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 61: Fig. 30: Replacing The Protective Grid
If a protective grid is installed in the gas outlet casing (61001) by Turbo Systems: Fig. 30: Replacing the protective grid Remove the protective grid (61205) after 50000 hours and replace it with a new protect- ive grid. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 62 Speed of the turbocharger ¡ Air temperature after the compressor and after the charge-air cooler ¡ Exhaust gas temperature before and after the turbine ¡ Pressure loss in the filter silencer. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 63: Expected Replacement Intervals
Table 12: Expected replacement intervals = Natural Gas = Marine Diesel Oil = Heavy Fuel Oil The specified values are guideline values and not guaranteed values, see Influencing para- meters. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 64 ¡ Lubricating oil quality (oil filtering, oil condition, oil monitoring) ¡ Load profile (speed, pressure conditions, temperature) ¡ Number of starts/stops ¡ Unbalance of the rotor (degree of contamination). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 65: Stopping The Engine
Turbo Systems recommends post-lubrication for 10 minutes. Observe the oil pressure specified for post-lubrication (see Table 8: Lubricating oil pres- sure at oil inlet before turbocharger →49). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 66: Periodic Maintenance Work
→58). Otherwise, only carry out mechanical cleaning if cleaning during opera- tion is not sufficient to achieve the thermal load and the rating of the engine. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 67: Cleaning The Compressor During Operation
The time period between the periodical cleaning cycles depends greatly on the operating conditions. Cleaning should normally be carried out every 24 … 72 hours of operation. If the specified cleaning intervals are incompatible with operation of the engine, contact Turbo Systems. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 68 CAUTION Corrosion and deposits when cleaning Salt water and cooling water treatment substances damage and adversely affect turbocharger parts. Never use salt water, but only pure water for cleaning. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 69: Fig. 31: Carrying Out Wet Cleaning Of Compressor
Not more than three cleaning cycles should be conducted consecutively. Before repeating the process, continue to operate the engine for at least five minutes to ensure that all of the water is flushed out of the system. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P...
Page 70: Cleaning The Turbine During Operation
Cleaning should normally be carried out every 50 to 200 hours of operation. If the specified cleaning intervals are incompatible with operation of the engine, contact Turbo Systems. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 71 To prevent corrosion of the inside surfaces of the casings, the engine must be continued to be operated for 10 minutes after a wet cleaning. The exhaust gas temperature downstream of the turbocharger can drop by up to 180 °C during cleaning. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P...
Page 72: Table 15: Turbine Wet Cleaning, Recommended Operating State
During cleaning, the temperature at the turbine inlet will rise and may strain the material significantly. Make sure the maximum temperature at the turbine inlet is not exceeded during cleaning. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 73: Fig. 32: Carrying Out Wet Cleaning Of Turbine
350 ... 430 A140 350 ... 430 A145 350 ... 430 12.0 Table 16: Wet cleaning of turbine, parameters Corresponds to a water pressure p of 1.5 bar (overpressure compared to atmosphere) © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 74: Cleaning Components Mechanically
The disassembly and assembly of the components is described in chapter Fitting and dis- mantling. Contaminated water and cleaning agents must be disposed of in an environmentally compatible, professional way and in compliance with locally applicable regulations. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 75: Fig. 33: Cleaning The Filter Silencer
Rinse in cold water. Avoid high mechanical loads (water jet). Let the filter ring dry completely before assembling. Dirty water and mild detergent must be disposed of in compliance with locally applicable regulations. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 76 Fit the cover grid (81266). Fit the tension bands (81270) and tighten them at the locks (81271). Any tension bands that have become damaged must be replaced. Fit the filter ring (81265), if present. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 77: Fig. 34: Compressor-End, Non-Rotating Parts
Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the tur- bocharger. Dispose of contaminated water and cleaning agents in accordance with the information in the material safety data sheet. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 78: Fig. 35: Turbine End, Non-Rotating Parts
Place contaminated parts in hot water or in a liquid such as brake cleaner to soften the contamination. Brush away the contamination or remove with a steam cleaner. Repeat the soaking and brushing process if necessary. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 80 Lightly spray the compressor wheel and the gap between the compressor and the bearing casing with penetrating oil. Dispose of dirty water and cleaning agents in accordance with the material safety data sheet. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 81: Fig. 36: Soaking The Turbine End
Observe country-specific regulations regarding banned and restricted substances. Fill the container (02) with soaking fluid. To shorten the soaking time, the fluid can be heated up to a maximum of 60 ºC. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 82 Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against mechanical hazards. Lift up the cartridge group and align it horizontally. Remove contamination manually using a soft brush or a wire brush. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 83 Lightly spray the turbine and the gap between the turbine and the heat sheet metal with penetrating oil. Dispose of contaminated water and cleaning agents in accordance with the information in the safety data sheet. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 84: Eliminating Malfunctions
If there is any doubt about the extent of the rubbing, contact a Turbo Sys- tems service station. ¡ Have a dimension check carried out by a Turbo Systems service station. Table 20: Malfunctions when starting – Rubbing of rotating parts © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 85: Malfunctions During Operation
Clean (see chapter Periodic mainten- turbine and/or nozzle ring (with 4- ance work →64) or contact a Turbo Sys- stroke application) tems service station Table 23: Malfunctions during operation – Speed increases © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 86: Table 24: Malfunctions During Operation - Exhaust Gas Temperature Too High
Injection mistimed Set correctly Valve control misadjusted Pipes Pipes downstream to the compressor Repair. outlet not sealed. Table 25: Malfunctions during operation – Charge air pressure too low © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 87: Table 26: Malfunctions During Operation - Charge Air Pressure Too High
Clean (see chapter Periodic mainten- ance work →64) Table 27: Malfunctions during operation – Engine performance losses © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 88: Turbocharger Is Surging
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 29: Malfunction – Sporadic surge blows © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 89: Malfunctions When Stopping
Dismantle the turbocharger (see chapter Fitting bocharger and dismantling). In case of damage, replace the corresponding parts or contact a Turbo Systems service station. Table 31: Malfunctions when stopping – Runout time too short © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 90: Speed Measurement System
Table 34: 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 a Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P...
Page 91: Dismantling And Fitting
Systems must be tightened in such a way that they are tight-fitting. Oil orifice When disassembling the turbocharger, an oil orifice fitted in the oil inlet must not be re- moved (see also chapter Removing the cartridge group). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 92: Material Required
Fig. 37: Swivel lifting eye (example) Product Thread M Length L Load limit Quantity A130 ≤ 17 mm ≥ 100 kg A135 ≤ 17 mm ≥ 150 kg A140 ≤ 21 mm ≥ 250 kg A145 ≤ 21 mm ≥ 300 kg Table 35: Swivel lifting eyes © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 93: Fig. 38: Starpoint Ring Nut Vrm
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. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 94: Weights Of Individual Parts
Turbine casing * 1 inlet Turbine casing * 2 inlets Turbine casing * 3 inlets Gas outlet flange Gas outlet casing Table 36: Weights of assemblies * including burst protection © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 95: Removing The Air Inlets
2. Loosen and remove V-clamp (72020). 3. Remove filter silencer (81000) or air suction branch (82000), set it down properly in an appropriate place and secure it. 4. Remove and dispose of the O-ring (81010 / 82010). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 96: Removing The Gas Outlet Casing
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.5 Removing the gas outlet casing Removing the gas outlet casing Removing the insulation Fig. 41: Removing the insulation Remove gas outlet casing insulation. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 97: Removing The Gas Outlet Flange
If the following Working Instructions are not observed, this can lead to cracks in the gas out- let casing. The following variants are possible: Pressing off using 3 press-off screws. Pressing off using 6 press-off screws. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 98: A130 A135 A140 A145
1. Press off and remove the gas outlet flange (57002) with screws (01) according to the table. If the gas outlet flange cannot be pressed off with the maximum tightening torque, contact a Turbo Systems service station. 2. If present: Remove the C-ring (57003). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 99: Fig. 44: Removing The Gas Outlet Flange
1. Evenly press off and remove the gas outlet flange (57002) with screws (01) according to the table. If the gas outlet flange cannot be pressed off with the maximum tightening torque, contact a Turbo Systems service station. 2. If present: Remove the C-ring (57003). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 100: Removing The Compressor Casing
Dispose of counter-sunk screws (79041). 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 →100). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 101: 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). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 102: Pressing Off The Casing
If the casing is pressed off with too much force on one side, the rotor can be damaged. Use the tool on both sides in alternation and make sure not to press off too hard on either side. Fig. 47: Press off the casing © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 103: Removing The Cartridge Group
If an oil orifice is fitted in the oil inlet of the bearing casing, it must not be removed. Fig. 49: Oil orifice 01 Bearing casing 02 Oil orifice 03 Circlip © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 104: Fig. 50: Removing Cartridge Group 1
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 →100). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 105: Removing The Nozzle Ring
2. Position the fastening strips (51002) in place. 3. Pull out the nozzle ring (56001) with the two extraction devices (90070) and the service support base (90012). 4. Remove the lamellar sealing ring (56005). 5. Remove the burst ring (57210). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 106: Installing The Cartridge Group On The Service Support
Fig. 53: Installing the cartridge group on the service support 1. Remove ring nuts (VRM). 2. Remove service support screws. 3. Fit service support (90012) according to the illustration. 4. Insert the cartridge group. 5. Fit the nuts. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 107: Measuring Clearance A And B
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by a Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 108: Nozzle Ring Compression Pd
1. Measure dimensions A, B and S on cleaned surfaces. 2. Calculate compression (PD). If the calculated value (PD) lies outside the specified range, contact a Turbo Systems ser- vice station. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 109: Installing The Nozzle Ring
Align the cams on the nozzle ring with the recesses of the turbine cas- ing (51000). Do not remove the adhesive tape (01). 5. If present: Fit the metal C-ring (51105). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P...
Page 110: Installing The Cartridge Group
3. Insert the screws of the service support from above and fit ring nuts (VRM) with washers. 4. Attach lifting gear to the ring nuts (VRM). 5. Lift cartridge group at the side of the ring nuts (VRM) and turn it into a vertical position. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P...
Page 111: Fig. 58: Installing The Cartridge Group
3. Lower the cartridge group into the turbine casing. 4. Remove ring nuts and screws. 5. Fit fastening strips (51002) with Verbus Ripp® washers (51003) and hexagon nuts (51007). 6. Tighten the hexagon nuts (51007). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 112: Fig. 59: Turbine Casing Insulation / Burst Protection
Never operate a turbocharger without burst protection and insulation. Fig. 59: Turbine casing insulation / Burst protection © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 113: Installing The Compressor Casing
2. Fit the swivel lifting eye (S) to the lifting beam. Secure lifting gear to the swivel lifting eye. 3. Fit new O-ring (77005). 4. Install the wall insert (77000) in the compressor casing. 5. Fit diffuser (79000) with fixing discs (79040) and screws (79041). Observe the tightening torque. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 114: Fig. 60: Installing The Compressor Casing
4. Install the compressor casing (72000). 5. Install the fastening strips (72012) with screws (72011). Observe the tightening torque. If these screws do not have a Verbus Ripp® integrated, Verbus Ripp® washers (72010) must also be fitted. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 115: Measuring Radial Clearances N And R
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by a Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 116: Installing The Air Inlets
2. Fit a new O-ring (81010) to the filter silencer (81000) or a new O-ring (82010) to the air suction branch (82000). 3. Fit the filter silencer (81000) or air suction branch (82000) with the V-clamp (72020). 4. Observe tightening torque. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 117: Installing The Gas Outlet Flange
1. If present: Insert the metal C-ring (57003) into the turbine casing (51000) and secure with high-vacuum grease. 2. Install the gas outlet flange (57002) in the turbine casing. 3. Measure radial clearance (R) (see chapter Radial clearances N and R). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 118: Fitting The Insulation Of The Turbine Casing
9.20 Fitting the insulation of the turbine casing Fig. 64: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see Table of tightening torques →119). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 119: Installing The Gas Outlet Casing
3. Attach the lifting gear to the gas outlet casing (61001) and position the gas outlet casing in the correct position on the turbine casing (51000). 4. If present: Fit support (61301). 5. Fit hexagon nuts (51009). Observe the tightening torque. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 120: Fig. 66: Fitting The Insulation
Fitting the insulation Fig. 66: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see Table of tightening torques →119). See also 2 Table of tightening torques [} 119] © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 121: Table Of Tightening Torques
*) With the variant "insulation with integrated burst protection", this position can be ig- nored. 16d **) applies to the burst protection mounting of A130-M and A135-M turbochargers on railway applications © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 122: Fig. 68: Tightening Torques For Insulation
Table 48: Tightening torques for insulation Tightening torque for attaching the insulation with integrated burst protection at the tur- bine casing Tightening torque for attaching the insulation to the burst protection. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 123: Taking Out Of Operation At Short Notice
If a replacement turbocharger or cartridge group is not available: Fit the cover plate →123 and contact a Turbo Systems service station. Observe the following sections in connection with the emergency repairs mentioned. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 124: Installing The Replacement Turbocharger
Dismantling and fitting →89). Install replacement cartridge group (see chapter Dismantling and fitting →89). Send the defective cartridge group to a Turbo Systems service station for inspection and repair. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 125: Fitting The Cover Plate
3. Coat the threads of the studs (51006) with high-temperature grease. 4. Fasten cover plate (01) to turbine casing (51000) with fastening strips (51002), Verbus Ripp® washers (51003) and nuts (51007) and screw to bracket. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P...
Page 126: Cover Plate Drawing
A130 65.7 11.7 35.7 227.7 ≤ 105 A135 79.6 14.2 39.6 271.7 ≤ 125 A140 98.2 17.2 48.2 332.5 ≤ 153 A145 116.8 20.5 56.8 395.9 ≤ 182 Table 49: Cover plate dimensions [mm] © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 127: Mothballing The Turbocharger
The rotor and bearing parts must be dismantled and subsequently refitted by a Turbo Systems service station. Clean all parts. Coat plain surfaces of steel and cast parts with anticorrosive oil. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 128: Taking The Engine Out Of Operation For More Than 12 Months
State of the mothballed turbocharger Check the turbocharger parts annually for corrosion. If there are signs of rust: Thoroughly clean parts and renew corrosion protection. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 129: Material And Disposal
6c) Copper alloy containing up to 4 % lead by weight. The maximum concentration of lead and lead compounds for our products is known to reach max. 0.8 % (mass % in homogeneous material). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P...
Page 130: Disposing Of Turbocharger Components
Dispose of metals as scrap metal for recycling. Dispose of non-metallic materials as waste. Dispose of residues of lubricants as waste oil. Dispose of electronic components as electronic waste. Dispose of thermal insulation as hazardous waste. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 131: Spare Parts
79041 Counter-sunk screw 81010/ 82010 O-ring Table 50: Customer spare part set 97070 * This gasket can only be installed when a gas outlet casing from Turbo Systems is used. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 132: Spare Part - Illustrations
Hexagon-head screw 42188(p) Hexagon-head screw 42189(p) Gasket 42190 Expansion bush 42194(p) Gasket 42196 Orifice oil inlet 42197 Safety ring 42201** Clamping nut Table 51: Spare parts - Cartridge, oil cooled © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 133: Table 52: Spare Parts - Cartridge, Water Cooled
42167** Cover 42188(p) Hexagon-head screw 42189(p) Gasket 42190 Expansion bush 42194(p) Gasket 42196 Orifice oil inlet 42197 Safety ring 42201** Clamping nut Table 52: Spare parts - Cartridge, water cooled © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 134 Hexagon-head screw 51102** Tension washer 51103** Hexagon-head screw 51105** Metal C-ring 51106** Hexagon-head screw 51107** Tension washer 51301** Cleaning nozzle 51302** Gasket 51303** Screw plug 51500 Burst protection TW02, TW04 © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 135: Table 53: Spare Parts - Turbine Casing, 1 Inlet
13 Spare parts / 13.3 Spare part – Illustrations Part no. Designation 56001 Nozzle ring 56005 Lamellar sealing ring 57002 Gas-outlet flange 57003** Metal C-ring 57210 Burst ring Table 53: Spare parts - Turbine casing, 1 inlet © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 136 Hexagon-head screw 51102** Tension washer 51105** Metal C-ring 51301** Cleaning nozzle 51302** Gasket 51303** Screw plug 51500 Burst protection 56001 Nozzle ring 56005 Lamellar sealing ring 57002 Gas-outlet flange © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 137: Table 54: Spare Parts - Turbine Casing, 2 Inlets
Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Part no. Designation 57003** Metal C-ring 57210 Burst ring Table 54: Spare parts - Turbine casing, 2 inlets © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 138: Table 55: Spare Parts - Gas Outlet Casing, Axial
* = Available within the spare part set only HZTL443467 Mod.A Part no. Designation 61001 Gas-outlet casing 61001** Gas-outlet casing GHV03 61002* Gasket Table 55: Spare parts - Gas outlet casing, axial © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 139: Table 56: Spare Parts - Gas Outlet Casing, Radial
61008* ** Gasket 61100 Insulation gas-outlet casing 61200 Burst protection 61201 Hexagon-head screw 61202 Tension washer 61205** Protective grid 61301** Support Table 56: Spare parts - Gas outlet casing, radial © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 140: Table 57: Spare Parts - Compressor Casing
Insulation 72061 Insulation sleeve 72062 Hexagon-head screw 72080 Warning plate 77000 Wall insert 77005* O-ring 79000 Diffuser 79040 Fixing washer 79041* Counter-sunk screw Table 57: Spare parts - Compressor casing © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 141: Table 58: Spare Parts - Filter Silencer
Silencer body 81136 Absorption segment 81137 Cover sheet-metal 81170 Screw plug 81171 Gasket 81265** Filter ring 81266 Cover grid 81270 Tension band 81271 Lock Table 58: Spare parts - Filter silencer © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 142: Table 59: Spare Parts - Air Suction Branch Axial
HZTL443013 Mod. D Part no. Designation 82000 Air suction branch 82005 Screw plug 82006 Gasket 82007 Screw plug 82008 Gasket 82010* O-ring Table 59: Spare parts - Air suction branch axial © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 143: Table 60: Spare Parts - Air Suction Branch Radial
HZTL443012 Mod. D Part no. Designation 82000 Air suction branch 82005 Screw plug 82006 Gasket 82007 Screw plug 82008 Gasket 82010* O-ring Table 60: Spare parts - Air suction branch radial © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 144: Table 61: Spare Parts - Bearing Casing, Oil Cooled
Orifice oil inlet 42197 Safety ring 42301 Bearing cover 42302* ** Piston ring 42305* O-ring 42306* O-ring 42400 Heat shield 42401** Metal C-ring Table 61: Spare parts - Bearing casing, oil cooled © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 145: Table 62: Spare Parts - Bearing Casing, Water Cooled
42301 Bearing cover 42302* ** Piston ring 42305* O-ring 42306* O-ring 42400 Heat shield 42401** Metal C-ring 42403* ** Metal V-ring Table 62: Spare parts - Bearing casing, water cooled © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 146: Table 63: Spare Parts - Rotor And Bearing Parts
Auxiliary bearing 32112 Bearing flange TE 32113* Socket screw 32114* Socket screw 32167* Snap ring 42002 Socket screw 42302* ** Piston ring Table 63: Spare parts - Rotor and bearing parts © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 147: Tools
Tool sets can be ordered from any Turbo Systems service station. The following specifica- tions must be included in the order: ¡ Turbocharger type ¡ Designation and part number of the tool set. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022...
Page 148: Figures
Fig. 61: Measuring clearances N and R ..... 113 Fig. 30: Replacing the protective grid ...... 59 Fig. 62: Installing the air inlets ........114 Fig. 31: Carrying out wet cleaning of compressor . 67 © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Revision P February 2022...
Page 149 Fig. 66: Fitting the insulation........118 Fig. 67: Tightening torques ........119 Fig. 68: Tightening torques for insulation .... 120 Fig. 69: Fitting the cover plate........123 Fig. 70: Cover plate drawing ........124 © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Revision P February 2022...
Page 150: Tables
Table 53: Spare parts - Turbine casing, 1 inlet ..133 Table 25: Malfunctions during operation – Charge air pressure too low............84 Table 54: Spare parts - Turbine casing, 2 inlets..135 © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Revision P February 2022...
Page 151 Table 61: Spare parts - Bearing casing, oil cooled 142 Table 62: Spare parts - Bearing casing, water cooled. Table 63: Spare parts - Rotor and bearing parts.. 144 Table 64: Customer tool set 90000......145 © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Revision P February 2022...

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ABB HT612770 Operation Manual

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