ABB 151893-18111 Operation Manual

Turbo Systems Switzerland Ltd Operation Manual / A145-M65 HT606348 Document identification Document number HZTL4031 Revision P Language English Original Operation Manual Product identification Serial number HT606348 Customer part number 151893-18111 Delivery date (yyyy-mm-dd) 2021-09-08 Weight 850 kg Operating limits according to rating plate Speed limit in test rig operation only nMmax 613 1/s Speed limit during operation nBmax 599 1/s Gas inlet temperature limit in test rig operation only tMmax 630 °C Gas inlet temperature limit during operation tBmax °C 600 Operation Manual / A130-M.. - A145-M.. Table of contents Operation Manual / A130-M.. - A145-M.. 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Introduction............................................................................................................ 4 Purpose of the manual................................................................................................. 4 Contact information...................................................................................................... 5 Essential information.................................................................................................... 5 Layout and function of the turbocharger ................................................................ 6 Symbols, definitions..................................................................................................... 8 Storage of new turbochargers and spare parts .................................................... 10 Registered trademarks ............................................................................................... 12 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 Safety .................................................................................................................... 13 Introduction .................................................................................................................. 13 CE conformity ............................................................................................................... 13 Definition of mandatory signs .................................................................................. 14 Definition of safety instructions .............................................................................. 14 Intended use ................................................................................................................. 15 Deflagration on gas engines ..................................................................................... 16 Warning plates on the turbocharger........................................................................ 17 Turbocharger rating plate.......................................................................................... 18 Periodic check of the pressure vessels................................................................... 20 Lifting of loads ............................................................................................................. 21 Prerequisites for operation and maintenance....................................................... 22 Hazards during operation and maintenance ......................................................... 23 Safe operation ............................................................................................................. 25 Safe maintenance ....................................................................................................... 26 3 3.1 3.2 3.3 Removing and Installing...................................................................................... 30 Turbocharger weight and transportation ............................................................. 30 Removing the turbocharger....................................................................................... 31 Installing the turbocharger ....................................................................................... 36 4 4.1 4.2 4.3 Commissioning .................................................................................................... 44 Oil supply ...................................................................................................................... 44 Inspection procedures ............................................................................................... 46 Commissioning after taking out of operation...................................................... 48 5 5.1 5.2 5.3 Monitoring operation .......................................................................................... 49 Oil pressure, oil temperature.................................................................................... 49 Exhaust gas temperature before turbine ............................................................... 51 Turbocharger speed ................................................................................................... 52 6 6.1 6.2 Operation and service ......................................................................................... 55 Noise emission ............................................................................................................ 55 Service work .................................................................................................................. 57 © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. Table of contents 6.3 6.4 Expected replacement intervals ............................................................................... 61 Stopping the engine................................................................................................... 63 7 7.1 7.2 7.3 7.4 Periodic maintenance work ................................................................................ 64 Foreword to maintenance......................................................................................... 64 Cleaning the compressor during operation .......................................................... 65 Cleaning the turbine during operation................................................................... 68 Cleaning components mechanically ........................................................................ 72 8 8.1 8.2 8.3 8.4 8.5 Eliminating malfunctions.................................................................................... Malfunctions when starting...................................................................................... Malfunctions during operation ................................................................................ Turbocharger is surging ............................................................................................ Malfunctions when stopping.................................................................................... Speed measurement system .................................................................................... 9 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 9.13 9.14 9.15 9.16 9.17 9.18 9.19 9.20 9.21 9.22 Dismantling and fitting....................................................................................... 89 Introduction ................................................................................................................. 89 Material required......................................................................................................... 90 Weights of individual parts....................................................................................... 92 Removing the air inlets .............................................................................................. 93 Removing the gas outlet casing .............................................................................. 94 Removing the gas outlet flange............................................................................... 95 Removing the compressor casing ........................................................................... 98 Pressing off the casing ............................................................................................ 100 Removing the cartridge group ................................................................................ 101 Removing the nozzle ring ........................................................................................ 103 Installing the cartridge group on the service support ...................................... 104 Measuring clearance A and B.................................................................................. 105 Nozzle ring compression PD................................................................................... 106 Installing the nozzle ring ......................................................................................... 107 Installing the cartridge group ................................................................................ 108 Installing the compressor casing ........................................................................... 111 Measuring radial clearances N and R ..................................................................... 113 Installing the air inlets .............................................................................................. 114 Installing the gas outlet flange ............................................................................... 115 Fitting the insulation of the turbine casing ......................................................... 116 Installing the gas outlet casing............................................................................... 117 Table of tightening torques..................................................................................... 119 10 10.1 10.2 10.3 10.4 10.5 Taking out of operation at short notice .......................................................... 121 Possible emergency repairs..................................................................................... 121 Installing the replacement turbocharger .............................................................. 122 Installing the replacement cartridge group ......................................................... 122 Fitting the cover plate............................................................................................... 123 Cover plate drawing .................................................................................................. 124 11 Mothballing the turbocharger.......................................................................... 125 © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P 82 82 83 86 87 88 February 2022 Operation Manual / A130-M.. - A145-M.. Table of contents 11.1 11.2 Taking the engine out of operation for up to 12 months .................................. 125 Taking the engine out of operation for more than 12 months ......................... 126 12 12.1 12.2 Material and Disposal........................................................................................ 127 REACH and RoHS Compliance Declaration For Products .................................. 127 Disposing of turbocharger components .............................................................. 128 13 13.1 13.2 13.3 Spare parts ......................................................................................................... 129 Ordering spare parts................................................................................................. 129 Required customer spare part set (97070)........................................................... 129 Spare part – Illustrations ......................................................................................... 130 14 Tools .................................................................................................................... 145 Figures................................................................................................................. 146 Tables .................................................................................................................. 148 © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 1 Introduction / 1.1 Purpose of the manual 1 Introduction 1.1 Purpose of the manual Fig. 1: Serial number (01) on the rating plate Page 4 / 149 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 operation. 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. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 1 Introduction / 1.2 Contact information 1.2 Contact information Contact information for the Turbo Systems service stations is available online. u Scan the QR code to access our website. Turbo Systems Switzerland Ltd. Bruggerstrasse 71a CH-5401 Baden Switzerland www.abb.com/turbocharging 1.3 Essential information 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 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 understanding. Differences in detail are therefore possible. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 5 / 149 Design variants Operation Manual / A130-M.. - A145-M.. 1 Introduction / 1.4 Layout and function of the turbocharger Layout and function of the turbocharger Page 6 / 149 1.4 Fig. 2: Layout and function of the turbocharger 01 02 03 04 05 06 07 Filter silencer / air suction branch Compressor casing Diffuser Bearing casing Axial thrust bearing Radial plain bearing Turbine © Copyright 2022 ABB. All rights reserved. 08 09 10 11 12 13 Gas outlet flange Nozzle ring Turbine casing Turbine-end bearing flange Compressor-end bearing flange Compressor wheel HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 1 Introduction / 1.4 Layout and function of the turbocharger Mode of operation The turbocharger is a turbomachine and consists of the following main components: ¡ Turbine ¡ Compressor. These components are installed on a common shaft and form the rotor. The exhaust gases of the internal combustion engine flow through the turbine casing (10) and the nozzle ring (09) onto the turbine (07). The turbine (07) uses the energy contained in the exhaust gas to drive the rotor and, hence, the compressor wheel (13). The exhaust gases then reach the atmosphere through the exhaust gas pipe connected to the gas outlet flange (08). The compressor wheel (13) sucks fresh air through the air suction branch or the filter silencer (01). In the compressor wheel (13), the energy required for building up the pressure is transferred to the air. By flowing through the diffuser (03) and the compressor casing (02), the air is compressed further and is then directed to the engine cylinders. The 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 turbocharger type (M6..) on the rating plate. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 7 / 149 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. Operation Manual / A130-M.. - A145-M.. 1 Introduction / 1.5 Symbols, definitions 1.5 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. Page 8 / 149 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. Turbo Systems Turbo Systems Switzerland Ltd is referred to in this document as Turbo Systems. Official service stations of Turbo Systems 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 Operation Manual / A130-M.. - A145-M.. 1 Introduction / 1.5 Symbols, definitions Definition of pictograms The following pictograms can occur in this document. These point out actions that must be taken in accordance with the meaning of the relevant pictogram. 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 Page 9 / 149 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 © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 1 Introduction / 1.6 Storage of new turbochargers and spare parts 1.6 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 delivered without a VCI label. For parts with a VCI label on the package, the following instructions must be observed. Page 10 / 149 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 corrosion 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 compatible, professional way and in compliance with locally applicable regulations. u Close package. The more tightly the package is sealed, the longer the protection dura- tion. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 1 Introduction / 1.6 Storage of new turbochargers and spare parts 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 a Turbo Systems service station and repacked. spected by a Turbo Systems service station and repacked. After every 3 years the following work steps must be performed by a Turbo Systems 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 package is undamaged, the turbocharger can be put into operation without any prior inspection by a Turbo Systems 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. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 11 / 149 u Inspect the package for damage. If the package is damaged, the turbocharger must be in- Operation Manual / A130-M.. - A145-M.. 1 Introduction / 1.7 Registered trademarks 1.7 Registered trademarks Page 12 / 149 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 Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.1 Introduction 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 turbocharger 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 inspection work. All instructions contained in this chapter must be observed for safe and trouble-free operation of the turbocharger and during all work on the turbocharger. All further safety instructions contained and specifically identified in every chapter of this Operation Manual (Definition of safety instructions →14) must also be observed. 2.2 CE conformity Information Turbochargers from Turbo Systems comply with the Machinery Directive 2006/42/EC and are partly completed machinery as defined by Article 2 g in this directive. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 13 / 149 The operating company is responsible for defining measures that regulate safe access to and safe handling of the turbocharger. Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.3 Definition of mandatory signs 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 Page 14 / 149 Safety gloves to protect against - Mechanical hazard - Chemical hazard - Thermal hazard - Electrical hazard Safety helmet Respiratory mask to protect against - Dusts - Gases 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 instructions indicated by this symbol and the word WARNING can lead to serious 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 instructions indicated by this symbol and the word CAUTION can lead to serious damage to engine or property with grave consequences. u Caution signs must always be observed. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.5 Intended use 2.5 Intended use Use on internal combustion engines in general Turbo Systems 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 enginebuilder 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 pressure increase exceeding a maximum of 12 bar before the turbocharger in case of a deflagration. The turbocharger supplies the engine with the air volume or air/gas mixture and the associated charging pressure required for operation. The specific operating limits of the turbocharger were determined on the basis of information from the enginebuilder about the intended use. These data are given on the rating plate. The use of the turbocharger is limited to the specific application released at the time of delivery. Turbo Systems accepts no liability and rejects all warranty claims for any non-intended applications. [1]Euromot = The European Association of Internal Combustion Engine Manufacturers [2]Directive 94/9/EC concerning equipment and protective systems intended for use in potentially explosive atmospheres (ATEX) The Euromot Position as of November 2003, ATEX Euromot Position 191103 [3]Guidelines for proper safety design of inlet systems on gas engines, RWTÜV Essen, 1991 WARNING Unapproved operation Any operation of the turbocharger outside of its operating limits can be hazardous 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 conditions. 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 15 / 149 The turbocharger is solely intended to be operated with a clockwise direction of rotation as viewed from the turbine end. Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.6 Deflagration on gas engines State of the art The turbocharger is designed and manufactured according to the state of the art and is safe to operate. Perfect condition The turbocharger must only be used when it is in a technically flawless condition and operated in compliance with its intended use. Turbo Systems excludes any liability for damage resulting from unauthorized modifications to the turbocharger or improper operation. 2.6 Deflagration on gas engines ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar. Page 16 / 149 After a deflagration event ABB recommends verifying the following points on the turbocharger: ¡ 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. A Turbo Systems service station should be instructed to carry out this inspection. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.7 Warning plates on the turbocharger 2.7 Warning plates on the turbocharger Fig. 6: Warning plate locations If warning plates are not present in the designated locations or not readable, proceed as follows: u Order new warning plates from Turbo Systems 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. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 17 / 149 Warning plates are affixed at the following locations: Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.8 Turbocharger rating plate 2.8 Turbocharger rating plate Fig. 7: Rating plate Operating limits Page 18 / 149 01 Turbocharger operating limits at engine overload (110 %). In test rig operation only, unless otherwise agreed with the enginebuilder. 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 07 08 09 10 11 12 Customer part number Designation for special design Weight of turbocharger in kg Turbocharger type Serial number Year of construction of turbocharger Manufacturing plant © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.8 Turbocharger rating plate 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 Turbo Systems 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 turbocharger. Page 19 / 149 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 bearing casing. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.9 Periodic check of the pressure vessels 2.9 Periodic check of the pressure vessels The pressure vessels used by Turbo Systems, such as those for wet or dry cleaning, are socalled "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. Page 20 / 149 u Pressure equipment must not be operated if defects are present. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.10 Lifting of loads 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. Page 21 / 149 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 exceeded. This prevents excessive loading due to diagonal pull. u Before looping around the components of the turbocharger, let them cool down (maximum 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. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.11 Prerequisites for operation and maintenance 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. Page 22 / 149 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 Turbo Systems. 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 Turbo Systems. 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 Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.12 Hazards during operation and maintenance 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 psychological 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. 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 insulation. 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 turbocharger. 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. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 23 / 149 Hazards due to hot surfaces Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.12 Hazards during operation and maintenance 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 insulation, 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 enginebuilder to protect against hot turbocharger surfaces is compulsory. Wear safety gloves to protect against thermal hazards. Hazards due to rotating parts WARNING Page 24 / 149 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. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.13 Safe operation 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 commissioning. 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. against accidental/unauthorised use. u When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay attention to the risks that may occur as a consequence of this energy input. WARNING Burst protection and insulation Operation without burst protection and insulation or with the wrong combination of burst protection and insulation can cause serious injuries to persons or even fatal accidents. u Only operate the turbocharger with burst protection fitted and insulation fitted in one of the following, permitted variants. Fig. 11 Variant A Variant B Variant C Insulation (01) with integrated burst protection from Turbo Systems. Burst protection (03) and insulation (02) from Turbo Systems. Burst protection (03) from Turbo Systems with appropriate insulation from the enginebuilder. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 25 / 149 u In case of damage, take the turbocharger out of operation immediately and safeguard Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.14 Safe maintenance 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 procedures or non-compliance with safety and health standards. u When working on the turbocharger always wear safety footwear and protective 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 accidents. u Only perform operations that are described in this chapter. u Only perform operations for which you have received instruction or train- Page 26 / 149 ing. Wear safety footwear to protect against mechanical hazard and risk of falling. 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. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.14 Safe maintenance 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 turbocharger. u Wear personal protective equipment (PPE) for welding operations. 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 intervals. u Inform the operating staff before starting any service or repair work. Make sure the engine 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 ensured. 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 training. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 27 / 149 Safety during cleaning Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.14 Safe maintenance 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 procedures. u Observe the general rules for occupational safety and prevention of accidents. 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- Page 28 / 149 tion or training. Hazards due to operating materials and supplies Operating materials and supplies are substances required for the operation of the turbocharger 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 contact 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 operating 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. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.14 Safe maintenance WARNING Danger of fire or explosion Flammable and combustible operating materials and supplies can catch fire or resulting vapours can lead to an explosion. u Observe the information in the material safety data sheet for the operating 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 environmental damage. u Observe the information in the material safety data sheet for the operating materials and supplies. Page 29 / 149 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 compatible 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 Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.1 Turbocharger weight and transportation 3 Removing and Installing 3.1 Turbocharger weight and transportation Page 30 / 149 Lifting gear with a sufficient load limit must be used for removing, installing and transporting 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. 12: Suspension of complete turbocharger unit A Turbocharger with oil-cooled bearing casing B Turbocharger with water-cooled bearing casing C Complete turbocharger unit with gas outlet casing Product A130-M A135-M A140-M A145-M Weight of complete turbocharger unit [kg] 210 300 500 850 Table 4: Weight of complete turbocharger unit © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.2 Removing the turbocharger 3.2 Removing the turbocharger u Disconnect all pipes according to the instructions of the enginebuilder. Version with turbine cleaning: CAUTION Turbocharger damage resulting from the cleaning nozzle breaking off Incorrect assembly of the cleaning nozzle (51301) can damage the thread of the turbine casing. The cleaning nozzle (51301) can be plastically deformed when screwing in the screw connection (02) and during subsequent operation. Reuse of the cleaning nozzle after loosening the screw connection (02) can lead to a water leak or the cleaning nozzle breaking off and thus destroy the turbine. u Only loosen the screw connection (02) if the cleaning nozzle (51301) needs to be replaced. u If the screw connection (02) has been loosened, a new cleaning Page 31 / 149 nozzle (51301) must be installed and the screw connection must be refitted. 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 Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.2 Removing the turbocharger The gas outlet casing (61001) can remain fitted in the exhaust gas pipe if the locking nuts are accessible. Otherwise the complete turbocharger unit including gas outlet casing must be removed. u If present: Loosen and remove the compressor wheel cooling connection. Seal the compressor wheel cooling connection (01). u If present: Disconnect the plug to the speed sensor (86505) and secure the rolled-up Page 32 / 149 cable on the turbocharger. This protects the plug from being crushed. Fig. 14: Removing the turbocharger A B C Oil-cooled bearing casing Water-cooled bearing casing Position of expansion sleeves D Clamping nut E Standard nut u Apply penetrating oil to thread of stud (02) and nut and let it work in. Do not oil the pressure screws of the clamping nut (D). 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 always be removed from and installed on the bracket vertically. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.2 Removing the turbocharger Version with water cooling CAUTION Freezing of the cooling water in the bearing casing If cooling water freezes in the bearing casing, this can lead to severe damage. u For transport and storage of the turbocharger, drain the cooling water from the bearing casing via one of the two bottom openings of the water connections. 3.2.1 Fastening of the turbocharger Depending on the type and version, the turbocharger can be fastened in different ways. The appropriate procedure must be chosen to undo the connection. Oil-cooled bearing casing (A) u Attach lifting gear to the suspension eye. Page 33 / 149 u Loosen and remove nuts (E). If clamping nut (D) is present: Loosen in accordance with chapter Loosening the clamping nut →34. u Positioning the turbocharger for storage →35. Water-cooled bearing casing (B) 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 (E). If clamping nut (D) is present: Loosen in accordance with chapter Loosening the clamping nut →34. u Positioning the turbocharger for storage →35. Hydraulic loosening (round special nut) u Attach lifting gear to the suspension eye. u Loosen the round special nut with a hydraulic tool according to the instructions of the enginebuilder. u Positioning the turbocharger for storage →35. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.2 Removing the turbocharger 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 become 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. Page 34 / 149 If a screw jams, the previously loosened screw must be tightened again a little. Fig. 15: 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 pressure screws have been relieved. u Loosen clamping nut by hand. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.2 Removing the turbocharger 3.2.3 Positioning the turbocharger for storage 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 Fig. 16: Turbocharger centre of gravity 01 Centre of gravity u Remove turbocharger from engine support, set it down properly in an appropriate place and secure it. u Close or cover the openings of the turbocharger and support. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 35 / 149 beams and wedges and by taking the centre of gravity into account. Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.3 Installing the turbocharger 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). Page 36 / 149 The necessary sealing is provided by O-rings. The O-rings are not included in the Turbo Systems scope of delivery. Fig. 17: Inserting gaskets into the bracket 01 02 03 Bracket Oil supply Oil drain 04 05 06 Slot for O-ring O-rings 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. Instructions of the enginebuilder must be observed. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.3 Installing the turbocharger 3.3.2 Fitting threaded rods Fig. 18: 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. Page 37 / 149 Requirements for the threaded rods Fig. 19: Requirements for threaded rods Product A130 A135 A140 A145 Diameter Threaded rod [mm] Ø 16 / M16 Ø 20 / M20 Ø 24 / M24 Ø 30 / M30 Material Thread length DIN / ISO 898 L1 [mm] (Part 1) 10.9 / 12.9 10.9 / 12.9 10.9 / 12.9 10.9 / 12.9 ≥ 30 ≥ 30 ≥ 70 ≥ 80 Oil-cooled L2 [mm] Water-cooled L2 [mm] 250 270 350 … 360 415 … 425 250 325 410 … 420 -- Table 5: Requirements for threaded rods 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 February 2022 Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.3 Installing the turbocharger Page 38 / 149 3.3.3 Placing the turbocharger on the bracket Fig. 20: Placing the turbocharger on the bracket A B Oil-cooled bearing casing Water-cooled bearing casing C Fixing with clamping nut D Fixing with standard nut u Make sure that covers of the oil and water connections are removed. 1. Make sure that the gaskets (03) are not damaged and are positioned correctly in the slots. 2. Clean the contact surfaces of the expansion bushes (42190) in the bearing casing. 3. Clean the expansion bushes (42190). 4. Attach the lifting gear to the suspension eye of the bearing casing (A/B) and loop around the gas outlet casing (61001). If the gas outlet casing is already fitted in the exhaust gas pipe, the attachment of the lifting gear on the bearing casing is sufficient. 5. Position the turbocharger on the bracket (04) and align it. Pay attention to the positioning pins (05) in the bracket. 6. When fixing with a standard nut (D), fit expansion bushes (42190) in the correct position in the slot (only relevant for older, water-cooled versions). 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 →39 ¡ Fastening the turbocharger with a clamping nut →40 © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.3 Installing the turbocharger u Observe the instructions for the fastening variant at hand. ¡ Fastening the turbocharger with a standard nut →39 (A130 - A140) ¡ Fastening the turbocharger with a clamping nut →40 (A140 and A145) 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 A130 A135 A140 Through hole in bearing casing [mm] Ø 17 Ø 21 Ø 25 Fixing screws [mm] Variant 1: Tightening torques [Nm] **) M16 M20 M24 280 560 960 Variant 2: Hydraulic pre-tensioning forces [kN] 110 175 250 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) © Copyright 2022 ABB. All rights reserved. Page 39 / 149 u Remove the lifting gear. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.3 Installing the turbocharger 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-compliance, 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). Page 40 / 149 u Make sure the pressure screws do not protrude in the direction of the thrust washer. Fig. 21: Preparing the clamping nut for the tightening procedure 1. Check whether the expansion bushes (42190) with recess are correctly positioned and do not touch the flange of the core hole cover (A). 2. Clean the thread of the bolt (01) and the contact surface. 3. Lightly oil the bolt thread. 4. Position the thrust washer (02) in place. 5. Tighten clamping nut (03) by hand. 6. Unscrew clamping nut (03) by ¼ of a turn (90°). The distance between the thrust washer and the clamping nut is now about 1 mm. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.3 Installing the turbocharger Fig. 22: Tightening pressure screws Product A140 A145 Fixing screw [mm] M24 M30 Tightening torques [Nm] 35 45 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. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 41 / 149 Tightening pressure screws Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.3 Installing the turbocharger 3.3.6 Connecting the turbocharger Fig. 23: Connecting the speed sensor u Connect cable to speed sensor (86515). u Connect all gas, water and air lines according to the instructions of the enginebuilder. Version with water-cooled bearing casing u Fit the water pipes according to the instructions of the enginebuilder. Version with compressor wheel cooling Page 42 / 149 CAUTION Failure of compressor wheel cooling Any prolonged failure of the compressor wheel cooling will shorten the replacement interval of the compressor wheel. u Make sure there is an uninterrupted supply of cooling air during operation. Fig. 24: Connecting the compressor cooling air intake u Remove the screw plug on the connection for the compressor wheel cooling (06) and fit the cooling air line. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 3 Removing and Installing / 3.3 Installing the turbocharger 3.3.7 Attaching the support Fig. 25: Attaching the support Page 43 / 149 u 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 Operation Manual / A130-M.. - A145-M.. 4 Commissioning / 4.1 Oil supply 4 Commissioning 4.1 Oil supply 4.1.1 Introduction In all operating states, a functioning and carefully executed oil supply is an important prerequisite for trouble-free operation of the turbocharger. The lubrication of the turbocharger is usually carried out with oil from the engine oil circulation. u Comply with the enginebuilder's specifications regarding the selection of lubricating oil and the oil change intervals. 4.1.2 Pre-lubrication Page 44 / 149 Pre-lubrication must be carried out as follows: u Switch on the oil pump. u Build up oil pressure. u Do not exceed a pre-lubrication time of 2 minutes. u Start the engine. u Let the oil pump run until the pump driven by the engine generates sufficient pressure. 4.1.3 Oil filtering Filtering the lubricating oil with a filter mesh width of ≤ 0.034 mm is sufficient for this turbocharger. 4.1.4 Oil pressure 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 Operation Manual / A130-M.. - A145-M.. 4 Commissioning / 4.1 Oil supply 01 02 03 Bearing casing Oil orifice Circlip Page 45 / 149 With an oil inlet pressure of more than 3 bar of overpressure (with engine under load) upstream of the turbocharger, an oil orifice must be installed to reduce the oil pressure. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 4 Commissioning / 4.2 Inspection procedures 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 turbocharger 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 Page 46 / 149 Contaminated oil Serious damage to engine or property can be caused by dirt and solid material 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 service 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 replacement interval of the compressor wheel. u Make sure there is an uninterrupted supply of cooling air during operation. u Check whether the compressor wheel cooling is fitted on the bearing casing. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 4 Commissioning / 4.2 Inspection procedures 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 during 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 Observe lubricating oil pressure at inlet upstream of turbocharger. u Observe lubricating oil temperature at inlet upstream of turbocharger. Page 47 / 149 u For permissible values, see chapter Monitoring operation →49. 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 instructions. 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 operating conditions indicate a malfunction (see chapter Eliminating malfunctions →82). 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 February 2022 Operation Manual / A130-M.. - A145-M.. 4 Commissioning / 4.3 Commissioning after taking out of operation 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 water 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 Page 48 / 149 be present. u Put engine-side oil circulation to the turbocharger into operation. u Prepare the turbocharger for operation (see Checks before commissioning →46). u The turbocharger is now ready for operation. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 5 Monitoring operation / 5.1 Oil pressure, oil temperature 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 insufficient lubricating oil supply. u The lubricating oil pressure must be monitored during operation and the Status for operation Normal operation Engine start: Cold oil, admissible for a maximum of 15 minutes Engine idling, admissible for a maximum of 1 hour Pre-lubrication and post-lubrication (engine stopped) Warning signal: (n ≥ 0.5 x nBmax) Alarm signal: Not admissible. Stop the engine immediately. Pressure at oil inlet upstream of the turbocharger [bar] Overpressure 2.0 < poil ≤ 4.5 *) < 8.0 0.5 < poil ≤ 2.5 0.5 < poil ≤ 1.0 < 1.25 < 0.6 Table 8: Lubricating oil pressure at oil inlet before turbocharger *) Depending on use of an oil orifice in accordance with the enginebuilder’s specifications. Arrangement of temperature and pressure measuring points 01 02 03 P T Turbocharger contact surface Oil inlet Oil outlet Oil pressure measuring point Oil temperature measuring point For monitoring the lubricating oil pressure, Turbo Systems recommends installing a "P" manometer immediately upstream of the turbocharger oil inlet before the orifice. If the pressure is controlled electronically, the relevant signals should be triggered at the warning and alarm values. *) 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 February 2022 Page 49 / 149 necessary pressure assured at the oil inlet. Operation Manual / A130-M.. - A145-M.. 5 Monitoring operation / 5.1 Oil pressure, oil temperature 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 Admissible Temporarily admissible (< 1 h) → alarm Not admissible → stop engine Not admissible → do not start engine (before start: preheat oil) Oil temperature at the inlet Toil,inlet 30 … 105 °C > 105 °C > 110 °C < 30 °C Table 9: Lubricating oil temperature at the inlet Page 50 / 149 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 operation and must be monitored according to the current regulations. Status for operation Oil temperature at the outlet Toil,outlet ≤ 160 °C > 160 °C > 180 °C ≤ Toil,inlet + 55 K > Toil,inlet + 55 K Admissible Temporarily admissible (< 0.5 h) → alarm Not admissible → stop engine Admissible Temporarily admissible → alarm Table 10: Lubricating oil temperature at the outlet 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 Operation Manual / A130-M.. - A145-M.. 5 Monitoring operation / 5.2 Exhaust gas temperature before turbine 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 →18. u For operating limits, refer to the Operation Manual title page or the rating plate on the Page 51 / 149 turbocharger. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 5 Monitoring operation / 5.3 Turbocharger speed 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. Layout and overview Page 52 / 149 5.3.2 Fig. 27: Layout and overview of speed measurement system 86505 86515 86526 86528 32109 Speed sensor Cable connector F/I converter Tachometer Sealing disc with cams © Copyright 2022 ABB. All rights reserved. 42188 42189 01 *) Screw plug Gasket Plug with integrated voltage limiter Installation variant for speed sensor HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 5 Monitoring operation / 5.3 Turbocharger speed 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 turbocharger 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 Turbo Systems service station has to be contacted. u Check the pressure loss of the alternative air inlet and compare it with normal values. u Inspect air lines, gas piping and the turbochargers and remedy any malfunctions. u 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 53 / 149 If the engine can be stopped temporarily: Operation Manual / A130-M.. - A145-M.. 5 Monitoring operation / 5.3 Turbocharger speed 5.3.5 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. Page 54 / 149 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 Part number 86505 A130 M12 x 1.5 15 Nm A135 M12 x 1.5 15 Nm A140 M12 x 1.5 15 Nm A145 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 →63). 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. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 6 Operation and service / 6.1 Noise emission 6 Operation and service 6.1 Noise emission WARNING Noise hazards Exposure to noise can harm the hearing system, impair health and the psychological 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 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 turbocharger 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. 29: Noise insulation, bellows →56). The enginebuilder is responsible for insulating the charge air/scavenging air line and the charge air cooler. 1) 2) 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 insulation versions © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 55 / 149 The emission sound pressure level (A-weighted) is measured at a distance of 1 meter from the turbocharger. Operation Manual / A130-M.. - A145-M.. 6 Operation and service / 6.1 Noise emission Suggestion for noise insulation, bellows Page 56 / 149 Fig. 29: Noise insulation, bellows 01 02 03 04 05 06 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 Operation Manual / A130-M.. - A145-M.. 6 Operation and service / 6.2 Service work 6.2 Service work Service work includes visual controls, monitoring, measuring and inspection as well as functional checks. Service work enables the detection and rectification of changes to the turbocharger 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 u Agree on a specific service interval with Turbo Systems. To prevent machine damage caused by ageing and downtime, we recommend having an inspection 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 February 2022 Page 57 / 149 Exceptional stresses such as a high number of starts and stops, harsh environmental conditions, poor fuel quality or high system vibrations can lead to untimely machine damage even if the prescribed service intervals are observed. Operation Manual / A130-M.. - A145-M.. 6 Operation and service / 6.2 Service work 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 consequence. u Have any unknown causes clarified by a Turbo Systems service station. 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 engine is stopped, in accordance with the instructions of the enginebuilder. Page 58 / 149 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 engine 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 … 16000 operating hours) The rotor and bearing parts must be checked and assessed by a Turbo Systems service station. The following work can be carried out as preparation. u Remove turbocharger from engine, dismantle and measure clearances (see Dismantling and fitting, general). u 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 Operation Manual / A130-M.. - A145-M.. 6 Operation and service / 6.2 Service work 6.2.5 Other service work If a protective grid is installed in the gas outlet casing (61001) by Turbo Systems: Fig. 30: Replacing the protective grid u Remove the protective grid (61205) after 50000 hours and replace it with a new protect- Page 59 / 149 ive grid. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 6 Operation and service / 6.2 Service work 6.2.6 Entries in the engine logbook The monitoring of the engine system enables conclusions to be drawn on the behaviour of the turbocharger. The following operating data and measured values must be entered regularly in the engine logbook of the enginebuilder: ¡ Rating 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 60 / 149 ¡ © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 6 Operation and service / 6.3 Expected replacement intervals 6.3 Expected replacement intervals Rotating components The recommended replacement intervals of the compressor and turbine wheels are specified with the aid of the safety concept for rotating parts (SIKO) and dependent on the operating conditions. These intervals are shown on the rating plate of the turbocharger. Non-rotating components Depending on the system-specific operating conditions, a differentiation must be made between the intervals to be expected for: ¡ replacing the bearing parts and ¡ replacing the non-rotating components exposed to hot gas. A decisive role is played by various influencing parameters which, in extreme cases, can significantly reduce the replacement interval of these parts. Expected replacement intervals [h] GAS / MDO Turbine casing Nozzle ring Gas outlet flange Heat shield Rotor components Bearing parts Other casings HFO 25000 … 50000 25000 … 50000 25000 … 50000 10000 … 25000 25000 … 50000 25000 25000 … 50000 25000 See information on rating plate 12000 … 32000 12000 … 24000 50000 50000 Table 12: Expected replacement intervals GAS MDO HFO = Natural Gas = Marine Diesel Oil = Heavy Fuel Oil The specified values are guideline values and not guaranteed values, see Influencing parameters. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 61 / 149 During the prescribed periodic service work, the individual parts are examined for wear and replaced if necessary. Operation Manual / A130-M.. - A145-M.. 6 Operation and service / 6.3 Expected replacement intervals Influencing parameters The specified values are guideline values and are not guaranteed. The actual values can deviate considerably from the guideline values, for example, due to the following influences: ¡ Fuel quality and fuel treatment ¡ Load profile (thermal cycling, also number of starts/stops, emergency shutdowns, operating point) ¡ Gas inlet temperature ¡ Frequency and execution of cleaning process during operation ¡ Turbocharger specification. ¡ System-specific operating conditions (combustion quality, exhaust gas composition) Page 62 / 149 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). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 6 Operation and service / 6.4 Stopping the engine 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. u Run the engine for 2 … 10 minutes at idling speed before stopping it. u Observe the oil pressure specified for engine idling (see Table 8: Lubricating oil pressure ¡ Post-lubricate water-cooled bearing casings until the rotors come to a standstill. Deactivate post-lubrication as soon as the rotor comes to a standstill. Deviating procedures must be coordinated with Turbo Systems. ¡ For oil-cooled bearing casings, post-lubricate for 20 minutes if the turbine inlet temperature (tTE) exceeds the following values when the engine is stopped: – 550 °C with insulated casing – 600 °C with non-insulated casing At temperatures below the specified values, post-lubrication must be ensured until the rotors come to a standstill. Turbo Systems recommends post-lubrication for 10 minutes. u Observe the oil pressure specified for post-lubrication (see Table 8: Lubricating oil pressure at oil inlet before turbocharger →49). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 63 / 149 at oil inlet before turbocharger →49). Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.1 Foreword to maintenance 7 Periodic maintenance work 7.1 Foreword to maintenance Maintenance work includes regular visual controls and cleaning operations which are intended to ensure the trouble-free functioning of the turbocharger. To allow you to observe the standard service intervals and to maintain a high turbocharger efficiency, Turbo Systems recommends that the cleaning procedure be carried out during operation. This allows the thermal load of the engine to be kept low while ensuring maximum fuel efficiency. Maintenance interval 24 … 72 h 1) 50 … 200 h 1) Page 64 / 149 According to rating plate 2) Maintenance work Operating status Cleaning the compressor during operation →65 Cleaning the turbine during operation →68 Engine load 50 … 85 % Cleaning components mechanically →72 Engine load 20 … 40 % (guideline value) Engine stopped Table 13: Maintenance table [h] = Hours of operation 1) If the maintenance intervals are incompatible with operation of the engine, contact Turbo Systems. 2) Turbo Systems recommends having mechanical cleaning carried out by a Turbo Systems service station during the service work (see also chapter Service work according to data on the rating plate →58). Otherwise, only carry out mechanical cleaning if cleaning during operation 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 Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.2 Cleaning the compressor during operation 7.2 Cleaning the compressor during operation 7.2.1 Introduction Approval by enginebuilder The following instructions for wet cleaning only apply to cleaning with pure water and under the precondition that the enginebuilder approves the process. Options and limits Periodic cleaning during operation delays any major increase in contamination. The cleaning method is suitable as long as the contamination has not progressed far. Very heavily contaminated components can no longer be cleaned using this method. In this case, Turbo Systems recommends mechanical cleaning of the contaminated components. Cause and consequences of contamination The contamination of the compressor stage depends on the degree of purity of the air that is sucked in. Deposits can form in the flow channels if salt, oil mist, exhaust gas or dust are sucked in with the air. Consequences of contamination: ¡ Impaired compressor efficiency ¡ Elevated exhaust gas temperatures ¡ Increased fuel consumption ¡ Increased rotor unbalance 7.2.2 Cleaning interval 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 65 / 149 Periodic cleaning during operation is not a substitute for the service work during which the turbocharger is completely dismantled and cleaned. Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.2 Cleaning the compressor during operation 7.2.3 Cleaning method Cleaning method and operating state The compressor is cleaned during operation using the wet cleaning method. This is carried out at an engine load of 50 … 85%. This cleaning method is tested and approved by Turbo Systems. V-engines On V-engines with several turbochargers per engine, parallel cleaning of both turbochargers is recommended. This cleaning process is faster and reduces the risk of surging of the turbocharger. Sequential charging Page 66 / 149 With sequential charging, it must be made sure especially after operating periods in the lower range of performance that both turbocharger compressors are cleaned. 7.2.4 Function and safety of wet cleaning CAUTION Volume of water Uncontrolled volumes of water can damage the turbocharger and the engine. u Never connect the water connection directly to a water pipe or a bigger metering container than the one specified by Turbo Systems. WARNING Danger due to pressure vessels Personal injury can occur if the locally applicable legal regulations on periodic inspections of the pressure vessels are not complied with. u The locally applicable legal regulations regarding periodic checks of the pressure vessels must be observed. u Do not use pressure vessels that are defective. CAUTION Corrosion and deposits when cleaning Salt water and cooling water treatment substances damage and adversely affect turbocharger parts. u Never use salt water, but only pure water for cleaning. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.2 Cleaning the compressor during operation 72000 27000 27005 01 02 03 Compressor casing External water pressure vessel Sealing plug Water pipe to filter silencer or air suction branch Pressurized air inlet pipe Valve activator Pressurized air from the compressor casing (72000) of the turbocharger passes through the pipe (02) to the water pressure vessel (27000). As soon as the valve activator (03) is activated, water is pressed into the pipe (01) and routed to the filter silencer or air suction branch. The water does not act as a solvent. The coating is removed by the mechanical action of the impacting droplets. Carrying out wet cleaning of the compressor Page 67 / 149 7.2.5 Fig. 31: Carrying out wet cleaning of compressor Engine load Filling amount of water pressure vessel [dm3] 50 … 85 % 0.4 Water temperature [°C] 5 … 30 Water injection period [s] 10 Table 14: Parameters for wet cleaning of compressor u Remove sealing plug (27005). u Fill container with 0.4 dm3 of pure water. u Screw in sealing plug (27005) again. u Push the valve activator (03) against the spring and hold for 10 … 15 seconds until the en- tire volume of water is injected. u Continue to operate the engine for at least five minutes to ensure that all of the water is flushed out of the system. 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 February 2022 Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.3 Cleaning the turbine during operation 7.3 Cleaning the turbine during operation 7.3.1 Introduction Approval by enginebuilder The following instructions for wet cleaning only apply to cleaning with pure water and under the precondition that the enginebuilder approves the process. Options and limits Periodic cleaning during operation delays any major increase in contamination. The cleaning method is suitable as long as the contamination has not progressed far. Very heavily contaminated components can no longer be cleaned using this method. In this case, Turbo Systems recommends mechanical cleaning of the contaminated components. Page 68 / 149 Periodic cleaning during operation is not a substitute for the service work during which the turbocharger is completely dismantled and cleaned. Cause and consequences of contamination Turbo Systems recommends the use of fuels with low ash, sulphur, sodium and vanadium contents. The combustion of heavy fuel oil (HFO) in diesel engines causes contamination of the turbine stage. Poor quality fuel in conjunction with high exhaust gas temperatures can lead to extremely hard deposits on turbine components. Operating states with incomplete combustion also increase the tendency to form deposits and must be avoided. Consequences of contamination: ¡ Low turbine efficiency ¡ Elevated exhaust gas temperatures ¡ Increased charging and ignition pressures with increasing turbocharger speed ¡ Lower engine performance. Possible damage to turbocharger: ¡ After the engine is stopped the rotor may become stuck in contamination deposits. ¡ Damage to turbine heads with blade breaks. 7.3.2 Cleaning interval The time period between the periodical cleaning cycles depends greatly on the operating conditions. 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 Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.3 Cleaning the turbine during operation 7.3.3 Cleaning method The turbine components are cleaned during operation using the wet cleaning method. This cleaning method is tested and approved by Turbo Systems. The precondition for wet cleaning is that the enginebuilder approves the process and these regulations are observed. V-engines On V-engines with several turbochargers per engine, parallel cleaning of both turbochargers is recommended. This cleaning process is faster and reduces the risk of surging of the turbocharger. 7.3.4 Function and safety of wet cleaning CAUTION Corrosion and deposits when cleaning u Never use salt water, but only pure water for cleaning. To clean the turbine stage during operation, water is injected before the nozzle ring. Based on an injection phase of 10 minutes, this cleaning procedure uses the principle of water solubility of dirt deposits. 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 February 2022 Page 69 / 149 Salt water and cooling water treatment substances damage and adversely affect turbocharger parts. Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.3 Cleaning the turbine during operation 7.3.5 Prerequisites Characteristic/component Engine load (guideline value) *) Turbine inlet temperature TTE before water injection Stabilisation phase after TTE has been reached Stabilisation phase after turbine cleaning Water supply Water pressure (overpressure compared to atmosphere) pWT Water temperature Conditions 20 … 40 % 350 … 430 °C 10 minutes 10 minutes ensured 1.5 bar 5 … 30 °C Table 15: Turbine wet cleaning, recommended operating state *) The temperature at the turbine inlet can be up to 100 °C higher than the exhaust gas temperature after the cylinder. This must be taken into account when setting the operating point before cleaning. If necessary, the engine performance must be reduced to meet these conditions. The cleaning cycle can be started when the above conditions are fulfilled. Page 70 / 149 The water mass flow to be set can be found in the Operation Manual. 7.3.6 Carrying out wet cleaning of the turbine CAUTION Inadmissible thermal stress and flooding of the turbine Smaller amounts of water can lead to an inadequate cleaning result. Larger amounts of water lead to inadmissible thermal stress on the turbine components and can cause flooding of the turbine. u It is imperative that turbine cleaning parameters are observed. CAUTION Maximum temperature at turbine inlet during cleaning During cleaning, the temperature at the turbine inlet will rise and may strain the material significantly. u 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 Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.3 Cleaning the turbine during operation Fig. 32: Carrying out wet cleaning of turbine u Fulfil prerequisites. u Ensure that the water supply (01) is guaranteed. u Open the stop valve (02) and set the required water pressure at the manometer (3) (see cleaning parameters in the table (see Table 15: Turbine wet cleaning, recommended operating state →70)). If an optional flowmeter (04) is present, set the water volume flow VW on the basis of the cleaning parameters in the table (see Table 16: Wet cleaning of turbine, parameters →71). u Close the stop valve (02) after 10 minutes. u Wait for 10 minutes; do not change the load during this stabilisation phase. Product A130 A135 A140 A145 Temperature be- Maximum temper- Water volume flow fore turbine before ature before turVW [dm3/min] 1) cleaning [°C] bine during cleaning [°C] 350 ... 430 530 4.0 350 ... 430 530 5.5 350 ... 430 530 8.5 350 ... 430 530 12.0 Injection time [min] 10 10 10 10 Table 16: Wet cleaning of turbine, parameters 1) Corresponds to a water pressure pWT of 1.5 bar (overpressure compared to atmosphere) © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 71 / 149 If the cleaning result is unsatisfactory or there is water leakage, contact a Turbo Systems service station. Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically 7.4 Cleaning components mechanically 7.4.1 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 mechanical cleaning. CAUTION Selection of cleaning tools Page 72 / 149 Turbocharger components are sensitive and easily sustain mechanical damage. The use of needle descalers (for example) or other striking tools damages the components. Depending on the specification, nozzle rings or turbine 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 satisfactory result is achieved. The disassembly and assembly of the components is described in chapter Fitting and dismantling. u 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 Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically 7.4.2 Cleaning the filter silencer 81135 81136 81137 81265 Filter silencer body Absorption segment Sheet-metal covering Filter ring 81266 81270 81271 Page 73 / 149 Fig. 33: Cleaning the filter silencer Cover grid Tension band Lock If present: Clean the filter ring (81265) u Remove the filter ring. u Clean the filter ring as required or every 500 hours of operation, and replace it after the fifth cleaning process at the latest. Contamination of the filter ring depends on the degree of purity of the sucked-in air. u Rinse the filter ring with water and mild detergent or, in the case of heavy contamination, soak and carefully push through. Rinse in cold water. Avoid high mechanical loads (water jet). u Let the filter ring dry completely before assembling. u Dirty water and mild detergent must be disposed of in compliance with locally applicable regulations. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically (see Fig. 33: Cleaning the filter silencer →73) Dismantling and cleaning the cover grid (81266) u Loosen the tension bands (81270). u Remove and clean cover grid (81266). Cleaning the absorption segments (81136) u Pull out and bend up the sheet-metal coverings (81137), and remove the absorption segments (81136). u Clean the absorption segments. When cleaning, note that the absorption segments may only be cleaned lightly with pressurized air, a soft brush or a moist cleaning cloth. u Have any heavily contaminated absorption segment replaced by a Turbo Systems service station. Fitting the filter silencer Page 74 / 149 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). Any tension bands that have become damaged must be replaced. u Fit the filter ring (81265), if present. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically 7.4.3 Compressor-end, non-rotating parts WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or contact 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 operating 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 a respiratory mask to protect against gases. The following parts, which are relevant in terms of performance, can be cleaned in accordance with the description below. Fig. 34: Compressor-end, non-rotating parts 72000 77000 79000 Compressor casing Wall insert 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 contamination with a brush. u Dry components completely. u Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the turbocharger. u 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 75 / 149 Wear safety gloves to protect against chemical hazards. Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically 7.4.4 Turbine-end, non-rotating parts WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or contact 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 operating materials and supplies. u Wear personal protective equipment (PPE) according to the material safety data sheet. u Comply with local legislation. Wear safety goggles. Page 76 / 149 Wear safety gloves to protect against chemical hazards. Wear a respiratory mask to protect against gases. Baked layers of contamination from heavy fuel oil or coked oil, for example, occur at the turbine end. The following parts, which are relevant in terms of performance, can be cleaned in accordance with the description below. Fig. 35: Turbine end, non-rotating parts 51000 Turbine casing 57002 Gas outlet flange 56001 Nozzle ring 51301 01 02 Cleaning nozzle (optional) Water pipe (provided by the customer) Screw connection (provided by the customer) 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 process if necessary. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically u Use clean water to remove all traces of solvent from parts. u Dry components completely. u Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the turbocharger. u Dispose of contaminated water and cleaning agents in accordance with the information in the safety data sheet. Option with cleaning nozzle CAUTION Turbocharger damage resulting from the cleaning nozzle breaking off Incorrect assembly of the cleaning nozzle (51301) can damage the thread of the turbine casing. The cleaning nozzle (51301) can be plastically deformed when screwing in the screw connection (02) and during subsequent operation. Reuse of the cleaning nozzle after loosening the screw connection (02) can lead to a water leak or the cleaning nozzle breaking off and thus destroy the turbine. u Only loosen the screw connection (02) if the cleaning nozzle (51301) needs u If the screw connection (02) has been loosened, a new cleaning nozzle (51301) must be installed and the screw connection must be refitted. Observe the specified tightening torque from the supplier of the screw connection. Water or air can be passed through the piping and into the cleaning nozzle to check whether it is blocked. When installed, the cleaning nozzle can be mechanically cleaned with a needle. 7.4.5 Cartridge group, general CAUTION Corrosion If the cartridge group is not put back into operation immediately after cleaning, parts may corrode. u Immediately after cleaning, install the cartridge group and put it back into operation. CAUTION Oil leak Damage to the O-ring grooves on the bearing casing can lead to oil leakage. u Sandblasting is not permitted for cleaning the bearing casing. Compressor wheels can be heavily contaminated due to poorly filtered suction air; turbines can be heavily contaminated due to exhaust gas residues or coked oil. Cleaning during operation may not suffice to remove such contamination; instead, it may need to be cleaned mechanically during standard service intervals (see chapter Service work). u Remove the turbocharger from the engine (see chapter Removing and Installing →30). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 77 / 149 to be replaced. Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically u Remove the cartridge group (see chapter Dismantling and fitting →89). First clean the compressor end and then the turbine end according to the following description. 7.4.6 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 Page 78 / 149 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. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically 7.4.7 Cleaning the cartridge group on turbine end Soaking the contamination Fig. 36: Soaking the turbine end Product A130 A135 A140 A145 A [mm] 108 128 157 187 B [mm] 17 20 25 30 C [mm] 205 245 300 357 Table 17: 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. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 79 / 149 Baked layers of contamination from heavy fuel oil or coked oil occur at the turbine end. The contamination can be removed by soaking and brushing. The procedure for soaking the layers of contamination as well as for cleaning the turbine are described in the following. Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically WARNING Heating up of cleaning agents and operating fluids When cleaning agents or operating fluids are heated up, explosive vapours can be produced which are hazardous to health. u Observe the information in the material safety data sheet. 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 Page 80 / 149 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. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically 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 unbalance. 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 contaminau 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-pressure 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. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 81 / 149 tion comes off. Operation Manual / A130-M.. - A145-M.. 8 Eliminating malfunctions / 8.1 Malfunctions when starting 8 Eliminating malfunctions 8.1 Malfunctions when starting Delayed start-up Possible causes TurbocharTurbocharger contaminated ger Bearing damaged Rotor rubbing Foreign object in the turbocharger Remedy Clean (see chapter Periodic maintenance work →64) Contact a Turbo Systems service station Table 18: Malfunctions when starting – Delayed start-up Page 82 / 149 Vibrations Possible causes TurbocharRotor unbalance ger Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Remedy Contact a Turbo Systems service station Contact enginebuilder Table 19: Malfunctions when starting – Vibrations Rubbing of rotating parts Normal behaviour, not a malfunction TurbocharA slight amount of uniform wear at the circumference of the rotor components ger 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 a Turbo Systems 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 Operation Manual / A130-M.. - A145-M.. 8 Eliminating malfunctions / 8.2 Malfunctions during operation 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. Possible causes TurbocharAxial clearance of the rotor excessive ger Remedy Contact a Turbo Systems service station Engine Clean Check/replace Oil filter heavily contaminated Oil pump in lubricating system defective Manometer displays incorrectly Replace manometer Table 21: Malfunctions during operation – Lubricating oil pressure too low Speed reduces Possible causes TurbocharTurbine and/or nozzle ring severely conger taminated Rotor components or bearing damaged Engine Pipes Defects on the connected cylinders in pulse charging Defects, such as leaks, in the exhaust gas pipes or charge air ducts Remedy Clean (see chapter Periodic maintenance work →64) Contact a Turbo Systems service station Contact enginebuilder Repair Table 22: Malfunctions during operation – Speed reduces Speed increases Possible causes TurbocharLight to medium contamination of the ger turbine and/or nozzle ring (with 4stroke application) Remedy Clean (see chapter Periodic maintenance work →64) or contact a Turbo Systems service station Table 23: Malfunctions during operation – Speed increases © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 83 / 149 Wear safety gloves to protect against thermal hazards. Operation Manual / A130-M.. - A145-M.. 8 Eliminating malfunctions / 8.2 Malfunctions during operation Exhaust gas temperature too high Engine performance and engine speed unchanged Possible causes Turbocharger Insufficient air, for example, when filter silencer is blocked by contamination Compressor/turbine contaminated Exhaust gas back pressure too high Turbine damaged or eroded Engine Charge air cooler Malfunction in the injection system Cooler contaminated Cooling water volume too low Inlet temperature of cooling water too high Insufficient ventilation Remedy Clean (see chapter Periodic maintenance work →64) Clean or repair boiler or exhaust gas silencer Contact a Turbo Systems service station Repair or contact manufacturer Clean Fill Check/clean cooling system Improve ventilation Page 84 / 149 Table 24: Malfunctions during operation – Exhaust gas temperature too high Charge air pressure too low Engine performance and engine speed unchanged, suction condition normal Possible causes TurbocharManometer display not correct ger Supply pipe to manometer not sealed Filter silencer contaminated, therefore pressure drop too high Compressor end and/or turbine end contaminated Compressor/turbine damaged Exhaust gas back pressure too high Engine Pipes Air receiver not sealed Gas piping between engine and turbine not sealed Injection mistimed Valve control misadjusted Pipes downstream to the compressor outlet not sealed. Remedy Replace manometer Repair leak Clean (see chapter Periodic maintenance work →64) Contact a Turbo Systems service station Clean or repair boiler or exhaust gas silencer Repair Set correctly Repair. Table 25: Malfunctions during operation – Charge air pressure too low © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 8 Eliminating malfunctions / 8.2 Malfunctions during operation Charge air pressure too high Engine performance and engine speed unchanged, suction condition normal Possible causes TurbocharManometer display not correct ger Increased speed due to contamination of nozzle ring Engine Malfunction in the injection system Injection mistimed Engine performance higher than indicated Remedy Replace manometer Clean (see chapter Periodic maintenance work →64) or contact a Turbo Systems service station Repair or contact manufacturer Set correctly Check engine performance Table 26: Malfunctions during operation – Charge air pressure too high Reduced compressor performance/efficiency and therefore engine performance losses CAUTION A severely contaminated or corroded compressor wheel can reduce the compressor wheel’s fatigue endurance limit and result in the turbocharger being damaged. u Rectify malfunction in accordance with the following table. Possible causes TurbocharCompressor components severely conger taminated by the ventilation gases that have been fed in Increased blade vibration, compressor blade damage due to the ventilation gases that have been fed in Material of the compressor wheel corroded due to the feeding in of ventilation gases containing corrosive components Material of the compressor wheel corroded due to intake air containing exhaust gases or salt Remedy Clean (see chapter Periodic maintenance work →64) Optimize oil separation Correct the feed of ventilation gases according to instructions of enginebuilder. Correct the feed of ventilation gases according to instructions of enginebuilder. Prevent exhaust gas leakages in the engine space Clean (see chapter Periodic maintenance work →64) Table 27: Malfunctions during operation – Engine performance losses © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 85 / 149 Compressor damage Operation Manual / A130-M.. - A145-M.. 8 Eliminating malfunctions / 8.3 Turbocharger is surging 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 turbocharger may be damaged. Page 86 / 149 u Gradually reduce the engine load. u Have the cause clarified and remedied immediately by a Turbo Systems service station. u Have parts assessed for damage and, if necessary, replaced by a Turbo Systems service station. Possible causes Turbocharger Filter silencer or diffuser contaminated Heavy contamination deposits in the turbine or in the nozzle ring Engine Protective grating in front of the turbocharger contaminated or damaged Charge air Cooler contaminated cooler Charge air duct blocked Remedy Clean (see chapter Periodic maintenance work →64) Clean/replace Clean Table 28: Malfunction – Turbocharger surging Sporadic surge blows Possible causes Remedy Engine Engine load reduced quickly when -manoeuvring. When this happens, the flow direction in the compressor is momentarily reversed. Such sporadic surge blows do not impair the safe operation of the turbocharger. Table 29: Malfunction – Sporadic surge blows © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 8 Eliminating malfunctions / 8.4 Malfunctions when stopping 8.4 Malfunctions when stopping Runout noises Possible causes TurbocharTurbocharger contaminated ger Bearing damaged Rotor rubbing Foreign object in the turbocharger Remedy Clean (see chapter Periodic maintenance work →64) Check clearances (see chapter Measuring clearance A and B →105). If clearances are outside the tolerance or if in doubt, contact a Turbo Systems service station. Check clearances (see chapter Radial clearances N and R). If clearances are outside the tolerance or if in doubt, contact a Turbo Systems service station. Dismantle the turbocharger (see chapter Fitting and dismantling). In case of damage, replace the corresponding parts or contact a Turbo Systems service station. Table 30: Malfunctions when stopping – Runout noises 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 following table must be observed. Possible causes TurbocharTurbocharger contaminated ger Bearing damaged Rotor rubbing Foreign object in the turbocharger Remedy Clean (see chapter Periodic maintenance work →64) Check clearances (see chapter Measuring clearance A and B →105). If clearances are outside the tolerance or if in doubt, contact a Turbo Systems service station. Check clearances (see chapter Radial clearances N and R). If clearances are outside the tolerance or if in doubt, contact a Turbo Systems service station. Dismantle the turbocharger (see chapter Fitting 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 87 / 149 Runout time too short Operation Manual / A130-M.. - A145-M.. 8 Eliminating malfunctions / 8.5 Speed measurement system 8.5 Speed measurement system No signal or poor signal amplitude of the speed measurement Possible causes TurbocharThe speed sensor was acciger dentally fitted with an additional gasket. An enlarged distance between the sensor tip and the signal-emitting sealing disc reduces the voltage amplitude of the speed signal. Sensor or cable defective Remedy The screw plug for the sensor is fitted with an additional gasket (copper ring). For information regarding the disassembly and assembly of the speed sensor, refer to chapter Replacing the speed sensor →54. Install the speed sensor without the additional gasket (copper ring). Contact a Turbo Systems service station. Order a new speed sensor (86505) from a Turbo Systems service station. Replacing the speed sensor →54. Table 32: Malfunction of the speed measurement system – No signal or poor signal amplitude Page 88 / 149 Measured speed too high Possible causes TurbocharSensor tip contaminated, ger since it is magnetic and can attract metallic particles. This reduces the distance to the signal-emitting sealing disc, which can lead to amplification of the noise component and therefore to false triggering. Remedy For information regarding the disassembly and assembly of the speed sensor, refer to chapter Replacing the speed sensor →54. Dismantle the sensor, clean the sensor tip, and fit the sensor back on with the specified tightening torque. Table 33: Malfunction of the speed measurement system – Measured speed too high Measured speed too low Possible causes Turbochar-ger Remedy Contact a Turbo Systems service station 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 measurement system checked by a Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.1 Introduction 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 →30). 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 turbocharger. u Wear heat-resistant safety gloves and protective clothing. u Wait for the turbocharger to cool down before carrying out any work. WARNING Cutting injuries when working on the turbocharger Some parts on the turbocharger may have sharp edges. There is a risk of a cutting injury. u Wear safety gloves against mechanical risks when conducting assembly and disassembly work. Wear safety gloves to protect against mechanical hazards. CAUTION Further work This Operation Manual may be used to carry out only the work described in it. Further work that is carried out in an incorrect way can lead to serious damage to the machine. u Turbo Systems recommends having further work carried out only by trained personnel from a Turbo Systems service station. Tightening torques for assembly devices Unless otherwise described, the screws and nuts of the assembly devices supplied by Turbo Systems must be tightened in such a way that they are tight-fitting. Oil orifice u When disassembling the turbocharger, an oil orifice fitted in the oil inlet must not be removed (see also chapter Removing the cartridge group). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 89 / 149 Wear safety gloves to protect against thermal hazards. Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.2 Material required 9.2 Material required Customer spare part set Before starting operations, make sure the required customer spare part set is available (see chapter Spare parts →129). Customer tool set Before starting work, make sure the required tool set is available (see chapter Tools →145). Not all tools are marked with a part number. Identification is guaranteed by the tool list. This list is enclosed with the tool set. WARNING Servicing the tools The tools must be checked for damage before and after use. u Visually inspect for corrosion, cracks, deformation and wear. Page 90 / 149 u Damaged tools must no longer be used and must be replaced. Swivel lifting eyes Swivel lifting eyes are required for the safe lifting of loads, which are not supplied by Turbo Systems. Fig. 37: Swivel lifting eye (example) Product A130 A135 A140 A145 Thread M M10 M10 M12 M12 Length L ≤ 17 mm ≤ 17 mm ≤ 21 mm ≤ 21 mm Load limit ≥ 100 kg ≥ 150 kg ≥ 250 kg ≥ 300 kg Quantity 2 2 2 2 Table 35: Swivel lifting eyes © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.2 Material required Starpoint ring nuts Two ring nuts (M16) are required for safer lifting of the cartridge group, which are not included in the Turbo Systems scope of delivery. Fig. 38: Starpoint ring nut VRM Lifting gear WARNING Suspended loads 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). ¡ Assembly device Devices that are fitted on the turbocharger in order to obtain a suspension point. Assembly devices are specially constructed and designed for the defined use; they are not commercially available products. Use assembly devices only for the described applications. ¡ 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 91 / 149 Loads that are not attached according to regulations can cause injury to personnel or fatal accidents. Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.3 Weights of individual parts 9.3 Weights of individual parts Page 92 / 149 The specified weights of the individual parts or assemblies are rounded-up standard values. Fig. 39: Weights of assemblies Designation 01 02 03 04 05 06 07 08 09 10 11 12 Filter silencer Radial air suction branch Axial air suction branch Compressor casing Wall insert Diffuser Cartridge group Nozzle ring Burst ring Turbine casing * 1 inlet Turbine casing * 2 inlets Turbine casing * 3 inlets Gas outlet flange Gas outlet casing A130 [kg] 19 6 4 24 6 3 40 2 2 50 45 -7 30 A135 [kg] 30 8 5 40 8 4 60 2 3 75 65 -13 35 A140 [kg] 40 13 6 60 15 7 110 4 5 135 125 125 20 65 A145 [kg] 65 21 9 95 24 11 180 6 12 210 190 190 23 120 Table 36: Weights of assemblies * including burst protection © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.4 Removing the air inlets 9.4 Removing the air inlets Fig. 40: 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). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 93 / 149 u Mark the casing position for assembly. Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.5 Removing the gas outlet casing 9.5 Removing the gas outlet casing Page 94 / 149 Removing the insulation Fig. 41: Removing the insulation u Remove gas outlet casing insulation. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.6 Removing the gas outlet flange Removing the gas outlet casing Page 95 / 149 u Mark the casing position for assembly. Fig. 42: 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). 9.6 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 outlet casing. The following variants are possible: u Pressing off using 3 press-off screws. u Pressing off using 6 press-off screws. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.6 Removing the gas outlet flange 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. Page 96 / 149 u Mark the casing position for assembly. Fig. 43: Dismantling the gas outlet flange Product A130 A135 A140 A145 Press-off screws (strength 8.8) * 3 x M 8 x 20 3 x M10 x 25 3 x M12 x 30 3 x M12 x 30 Tightening torque ≤ 20 Nm ≤ 40 Nm ≤ 65 Nm ≤ 65 Nm Table 37: 3 press-off screws * not included in the Turbo Systems scope of delivery 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 Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.6 Removing the gas outlet flange 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. Page 97 / 149 u Mark the casing position for assembly. Fig. 44: Removing the gas outlet flange Product A130 A135 A140 A145 Press-off screws (strength 8.8) * 6x M6 x 20 6x M8 x 25 6x M10 x 30 6x M12 x 30 Tightening torque ≤ 10 Nm ≤ 20 Nm ≤ 40 Nm ≤ 65 Nm Table 38: 6 press-off screws * not included in the Turbo Systems scope of delivery. 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 Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.7 Removing the compressor casing 9.7 Removing the compressor casing Removing the compressor casing Page 98 / 149 u Mark the casing position for assembly. Fig. 45: Removing the compressor casing 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). 5. Loosen counter-sunk screws (79041) and remove from the compressor casing (72000) with fixing discs (79040) and diffuser (79000). Dispose of counter-sunk screws (79041). If the compressor casing cannot be loosened, it can be pressed off against the turbine casing 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 Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.7 Removing the compressor casing Fig. 46: 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). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 99 / 149 Dismantling the wall insert Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.8 Pressing off the casing 9.8 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 Page 100 / 149 too hard on either side. Fig. 47: Press off the casing © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.9 Removing the cartridge group 9.9 Removing the cartridge group Fig. 48: Removing insulation sheets u If present: Remove the insulation sheets (01, 02, 03). u Mark the casing position for assembly. Do not remove oil orifice (if present) 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 101 / 149 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). Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.9 Removing the cartridge group Fig. 50: Removing cartridge group 1 1. Treat threads of studs (51006) with penetrating oil and leave to take effect. Page 102 / 149 2. Loosen nuts (51007) and remove Verbus Ripp® washers (51003) together with fastening strips (51002). Fig. 51: 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 →100). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.10 Removing the nozzle ring Removing the nozzle ring Page 103 / 149 9.10 Fig. 52: 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). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.11 Installing the cartridge group on the service support 9.11 Installing the cartridge group on the service support Page 104 / 149 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 Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.12 Measuring clearance A and B 9.12 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. Product A130-M A135-M A140-M A145-M A [mm] B [mm] 0.08 ... 0.16 0.10 ... 0.18 0.12 ... 0.21 0.15 ... 0.25 0.47 ... 1.00 0.58 ... 1.16 0.70 ... 1.37 0.88 ... 1.56 Table 39: Permissible clearances A and B 1. Move the rotor to and fro up to the stop. In order to obtain a correct measurement, elevate 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 a Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 105 / 149 Fig. 54: Measuring clearance A and B Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.13 Nozzle ring compression PD 9.13 Nozzle ring compression PD Page 106 / 149 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. 55: Nozzle ring compression PD 42001 42400 Bearing casing Heat shield Product A130-M A135-M A140-M A145-M 51000 56001 Turbine casing Nozzle ring Nozzle ring compression PD [mm] -0.15 ... 0.15 -0.16 ... 0.16 -0.16 ... 0.16 -0.16 ... 0.16 Table 40: 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 a Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.14 Installing the nozzle ring Installing the nozzle ring Fig. 56: 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 casing (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 February 2022 Page 107 / 149 9.14 Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.15 Installing the cartridge group 9.15 Installing the cartridge group Lifting the cartridge group and rotating it by 90° Fig. 57: Lifting the cartridge group and rotating it by 90° Page 108 / 149 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. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.15 Installing the cartridge group Fig. 58: Installing the cartridge group Product A130 A135 A140 A145 Size M8 M10 M12 M12 Tightening torque [Nm] 25 45 75 75 Table 41: Tightening torque (51007) 1. Coat the threads of the 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). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 109 / 149 Installing the cartridge group Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.15 Installing the cartridge group WARNING The turbine casing insulation supplied by Turbo Systems also acts as burst protection Serious injuries or accidents resulting in fatalities can occur if the turbine casing insulation (01) supplied by Turbo Systems is removed. A burst protection is integrated into this turbine casing insulation supplied by Turbo Systems. For turbochargers which were ordered from Turbo Systems without insulation or which are equipped with the insulation (02), separate burst protection (03) is fitted. If the insulation from Turbo Systems (01) is not installed, the separate burst protection (03) plus either the insulation (02) or an appropriate insulation supplied by the enginebuilder must be installed for operation. Page 110 / 149 u 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 Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.16 Installing the compressor casing 9.16 Installing the compressor casing A130 - A140 Product A130 A135 A140 A145 A145 Size M6 M6 M6 M6 Tightening torque [Nm] 8 8 8 8 Table 42: Tightening torque (79041) u Always replace the O-ring (77005) (see section Spare parts). A130 - A140 1. Fit new O-ring (77005). 2. Install the wall insert (77000) in the compressor casing. 3. Fit diffuser (79000) with fixing discs (79040) and screws (79041). Observe the tightening torque. A145 1. Fit the lifting beam (90258) to the wall insert (77000). 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 111 / 149 Fitting the wall insert and the diffuser Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.16 Installing the compressor casing Installing the compressor casing Page 112 / 149 Fig. 60: Installing the compressor casing Product A130 A135 A140 A145 Size M8 M10 M12 M14 Tightening torque [Nm] 35 70 105 170 Table 43: Tightening torque (72011) 1. Fit a new O-ring (42012). 2. Thoroughly clean the fastening strips (72012) before assembly. 3. Attach swivel lifting eyes (S) to compressor casing (72000). Secure lifting gear to the swivel lifting eyes. 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 Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.17 Measuring radial clearances N and R Measuring radial clearances N and R Fig. 61: Measuring clearances N and R Product A130-M A135-M A140-M A145-M N [mm] 0.26 ... 0.60 0.34 ... 0.70 0.45 ... 0.90 0.56 ... 0.95 R [mm] 0.45 ... 0.70 0.51 ... 0.85 0.64 ... 1.00 0.76 ... 1.20 Table 44: Permissible clearances N and R 1. Push the feeler gauges (01) into the gap without clearance, and measure simultaneously at the top (N1) and the bottom (N2). 2. Calculate clearance N and compare it with the permissible values in the table. 3. Push the feeler gauges (01) into the gap without clearance, and measure simultaneously at the top (R2) and the bottom (R1). 4. Calculate clearance R and compare it with the permissible values in the table. CAUTION Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. u Have the components assessed and, if necessary, replaced by a Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 113 / 149 9.17 Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.18 Installing the air inlets 9.18 Installing the air inlets Page 114 / 149 Fig. 62: Installing the air inlets Product A130 A135 A140 A145 Size M12 M12 M12 M12 Tightening torque [Nm] 60 60 60 60 Table 45: Tightening torque (72020) 1. Secure lifting gear to filter silencer (81000). 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 Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.19 Installing the gas outlet flange 9.19 Installing the gas outlet flange Fig. 63: 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. Page 115 / 149 3. Measure radial clearance (R) (see chapter Radial clearances N and R). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.20 Fitting the insulation of the turbine casing Page 116 / 149 9.20 Fitting the insulation of the turbine casing Fig. 64: Fitting the insulation u Fit the insulation according to the illustration. u Observe tightening torques (see Table of tightening torques →119). © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.21 Installing the gas outlet casing 9.21 Installing the gas outlet casing Product A130 A135 A140 A145 Size M8 M10 M12 M12 Tightening torque [Nm] 20 40 65 65 Table 46: Tightening torque (51009) 1. Insert a new gasket (61002) into the gas outlet casing (61001). 2. Coat the threads of the studs (51008) with high-temperature grease. 3. Attach the lifting gear to the gas outlet casing (61001) and position the gas outlet casing in the correct position on the turbine casing (51000). 4. If present: Fit support (61301). 5. Fit hexagon nuts (51009). Observe the tightening torque. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 117 / 149 Fig. 65: Installing the gas outlet casing Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.21 Installing the gas outlet casing Page 118 / 149 Fitting the insulation Fig. 66: Fitting the insulation u 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 Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.22 Table of tightening torques 9.22 Table of tightening torques The following tightening torques must be observed for the specified bolted connections: Position 02 Part number 72020 04 79041 08 51007 09 51009 11 72011 15 86505 16a *) 61201 16c *) 51101 16d **) 51101 A130 M12 60 Nm M6 8 Nm M8 25 Nm M8 20 Nm M8 35 Nm M12 x 1.5 15 Nm M10 40 Nm M10 40 Nm M10 50 Nm A135 M12 60 Nm M6 8 Nm M10 45 Nm M10 40 Nm M10 70 Nm M12 x 1.5 15 Nm M10 40 Nm M10 40 Nm M10 50 Nm A140 M12 60 Nm M6 8 Nm M12 75 Nm M12 65 Nm M12 105 Nm M12 x 1.5 15 Nm M12 65 Nm M12 65 Nm -- A145 M12 60 Nm M6 8 Nm M12 75 Nm M12 65 Nm M14 170 Nm M12 x 1.5 15 Nm M12 65 Nm M12 85 Nm -- Table 47: Tightening torques *) With the variant "insulation with integrated burst protection", this position can be ignored. 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 119 / 149 Fig. 67: Tightening torques Page 120 / 149 Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.22 Table of tightening torques Fig. 68: Tightening torques for insulation The following tightening torques must be observed for the specified screw connections: Position 16a / 16b 1) 16b 2) Part number -- 18 -- 19 -- 20 -- -- A130 M10 40 Nm M8 20 Nm M6 10 Nm M8 25 Nm M10 45 Nm A135 M10 40 Nm M8 20 Nm M6 10 Nm M8 25 Nm M10 45 Nm A140 M12 65 Nm M10 40 Nm M6 10 Nm M8 25 Nm M10 45 Nm A145 M12 65 Nm M10 40 Nm M6 10 Nm M8 25 Nm M10 45 Nm Table 48: Tightening torques for insulation 1) Tightening torque for attaching the insulation with integrated burst protection at the turbine casing 2) Tightening torque for attaching the insulation to the burst protection. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 10 Taking out of operation at short notice / 10.1 Possible emergency repairs 10 Taking out of operation at short notice 10.1 Possible emergency repairs WARNING Danger of fire and explosion due to lubricating oil leaks Leaking oil may ignite on hot surfaces. This can result in serious injuries to personnel or fatal accidents. u Cordon off danger area. u Raise the alarm and, depending on the situation, stop the engine. u Seal the oil leak. u Soak up oil and dispose of in an environmentally compatible manner. CAUTION Directives for taking out of operation Serious damage to engine or property can be caused by non-compliance with the directives for blanking the turbocharger off the engine. u Follow the directives of the enginebuilder. If the engine has to be brought back into operation again as quickly as possible in the event of a turbocharger defect, the following emergency repair options exist: ¡ If present: Installing the replacement turbocharger →122. ¡ If present: Installing the replacement cartridge group →122. ¡ If a replacement turbocharger or cartridge group is not available: Fit the cover plate →123 and contact a Turbo Systems service station. u Observe the following sections in connection with the emergency repairs mentioned. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 121 / 149 Wear safety gloves to protect against thermal hazards. Operation Manual / A130-M.. - A145-M.. 10 Taking out of operation at short notice / 10.2 Installing the replacement turbocharger 10.2 Installing the replacement turbocharger To enable an engine to be put back into operation quickly after a turbocharger has sustained damage, Turbo Systems recommends having a replacement turbocharger or appropriate spare parts available in storage. The defective turbocharger can be removed and the replacement turbocharger installed within a short period of time. u Remove defective turbocharger (see chapter Removing and Installing →30). u Install replacement turbocharger (see chapter Removing and Installing →30). u Send the defective turbocharger to a Turbo Systems service station for inspection and repair. 10.3 Installing the replacement cartridge group WARNING Incorrect handling of a cartridge group Page 122 / 149 Incorrect handling of a cartridge group can damage the turbocharger and cause injuries to persons. u Always have repairs to the cartridge group carried out by a Turbo Sys- tems service station. To enable an engine to be put back into operation quickly after a turbocharger has sustained damage, Turbo Systems recommends having a replacement cartridge group available in storage. The defective cartridge group can be removed and the replacement cartridge group installed within a short period of time. A replacement cartridge group is ready for use immediately and includes the complete bearing casing with bearing and a balanced rotor. The repair of a cartridge group requires special tools and the expertise of a Turbo Systems service station. The rotating parts rotate extremely quickly, and are sensitive to unbalance. u Remove defective cartridge group (see chapter Dismantling and fitting →89). u Install replacement cartridge group (see chapter Dismantling and fitting →89). u 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 Operation Manual / A130-M.. - A145-M.. 10 Taking out of operation at short notice / 10.4 Fitting the cover plate 10.4 Fitting the cover plate u Remove turbocharger (see chapter Removing and Installing →30). ¡ Gas outlet casing removed u Fit the turbine casing with the gas outlet casing into the gas pipe again. u Attach the cover plate (see following section). ¡ Gas outlet casing not removed u Fit the turbine casing into the gas pipe and on the gas outlet casing again. Page 123 / 149 u Attach the cover plate (see following section). Fig. 69: Fitting the cover plate u Make sure that the oil connections in the bracket are equipped with gaskets. 1. Close opening in turbine casing (51000) with cover plate (01). 2. Thoroughly clean the fastening strips (51002) before assembly. 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 February 2022 Operation Manual / A130-M.. - A145-M.. 10 Taking out of operation at short notice / 10.5 Cover plate drawing 10.5 Cover plate drawing The cover plate is not included in the Turbo Systems scope of delivery and must be manufactured by the operating company according to the following drawing. Page 124 / 149 Material: General structural steel, in accordance with DIN EN 10025-2. Fig. 70: Cover plate drawing Product A130 A135 A140 A145 B1 B2 ± 0.5 65.7 60 79.6 80 98.2 102 116.8 120 B3 130 155 190 226 B4 ± 0.2 11.7 14.2 17.2 20.5 B5 B6 B7 1.4 1.6 2.0 2.4 150 180 220 260 35.7 39.6 48.2 56.8 ØD1 ± 0.2 227.7 271.7 332.5 395.9 ØD2 R1 M 17 21 25 31 ≤ 105 ≤ 125 ≤ 153 ≤ 182 M8 M8 M10 M10 Table 49: Cover plate dimensions [mm] © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 11 Mothballing the turbocharger / 11.1 Taking the engine out of operation for up to 12 months 11 Mothballing the turbocharger 11.1 Taking the engine out of operation for up to 12 months State of the engine lubricating oil The turbocharger normally remains attached to the engine. The measures to be taken for mothballing the turbocharger depend on the state of the lubricating oil. No measures are required under the following conditions: ¡ Acid number (TAN) < 2 mg KOH/g ¡ The engine lubricating oil is replaced by a preservative oil and circulated with the pre-lubrication pump before the engine is taken out of operation. Residues of old engine oil are flushed away in this way and the bearing parts are largely protected against corrosion. WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or contact 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 operating 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. If the acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after the engine is taken out of operation: u Dismantle the turbocharger. u The rotor and bearing parts must be dismantled and subsequently refitted by a Turbo Systems service station. u Clean all parts. u Coat plain surfaces of steel and cast parts with anticorrosive oil. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 125 / 149 Preparations for mothballing Operation Manual / A130-M.. - A145-M.. 11 Mothballing the turbocharger / 11.2 Taking the engine out of operation for more than 12 months u Fit turbocharger completely. Rotor turning in stack draught If the rotor turns as a result of the stack draught: u Install a blind flange between the outlet flange of the compressor casing and the charge air duct. 11.2 Taking the engine out of operation for more than 12 months Page 126 / 149 If the engine is taken out of operation, the following variants are possible with regard to the turbocharger: ¡ Turbocharger remains attached to the engine ¡ The casings of the turbocharger remain attached to the engine, the rotor and bearing parts are dismantled by a Turbo Systems service station and stored separately ¡ The turbocharger is completely removed, either as a whole unit or in individual parts For the measures always necessary for preparing the turbocharger parts for mothballing, see section Taking the engine out of operation for up to 12 months, subsection Preparations for mothballing. If the turbocharger remains attached to the engine, see section Taking the engine out of operation for up to 12 months →125, subsection Rotor turning in stack draught. If the complete turbocharger is removed or the turbocharger is assembled again from the individual parts: u Seal all openings of the turbocharger with paraffin paper and wooden lids. Only dry rooms with 40 … 70 % atmospheric humidity, in which no water condensation can form, are suitable as storage locations. State of the mothballed turbocharger u Check the turbocharger parts annually for corrosion. u 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 Operation Manual / A130-M.. - A145-M.. 12 Material and Disposal / 12.1 REACH and RoHS Compliance Declaration For Products 12 Material and Disposal 12.1 REACH and RoHS Compliance Declaration For Products Turbo Systems hereby confirms that all genuine products, parts and components supplied by Turbo Systems are fully compliant with the requirements of European Union Regulation (EC) 1907/2006 concerning the Registration, Evaluation, Authorization and Restriction of Chemicals (REACH). Article 33 (of requirements of European Union Regulation (EC) 1907/2006) A supplier of a product composed of one or more constituent articles (products) of which contain(s) a candidate list substance (SVHC, Substance of Very High Concern) in a concentration above 0.1% wlw, shall inform the customer of the presence of such substance(s) with sufficient information, available to the supplier. RoHS2 Directive 2011/65/EC [in English only] The EU Directive 2011/65/EC (recast) restricts the use of certain hazardous substances in electrical and electronic equipment (RoHS2). Products and related accessories manufactured by Turbo Systems Switzerland Ltd do not fall within the Scope of RoHS2 due to their application in large scale fixed installations, means of transports for persons or goods, nonroad mobile machinery (Directive 2011/65/EC Article 2, 4.(e), (f), (g)). Electrical or electronic equipment supplied by Turbo Systems fulfil requirements of RoHS2 Directive 2011/65/EC and fall under the exception 6a and 6c of the same Directive: ¡ 6a) Lead as an alloying element in steel for machining purposes and in galvanised steel containing up to 0.35 % lead by weight ¡ 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 February 2022 Page 127 / 149 [in English only] Operation Manual / A130-M.. - A145-M.. 12 Material and Disposal / 12.2 Disposing of turbocharger components 12.2 Disposing of turbocharger components WARNING Handling damaged thermal insulation Damaged thermal insulation can lead to dust exposure. The glass fibres can cause mechanical irritation of the eyes, skin, and respiratory tracts. u Avoid the formation of dust. u Vacuum up dust with a suitable vacuum cleaner. u Wear a respiratory mask to protect against dusts (P1 or P2 mask). u Wear safety gloves. Wear safety goggles. Wear a respiratory mask to protect against dusts. Page 128 / 149 Wear safety gloves to protect against mechanical hazards. Disposal must be environmentally compatible, professional, and in compliance with locally applicable regulations. The turbocharger consists largely of metal (cast iron materials, steel, nickel-steel alloys, aluminium and bearing brass). Further components are: Non-metallic materials (filter components of felt and polyethylene), lubricants (engine oil), electronic parts (speed sensor and associated components), and thermal insulation. u Dispose of metals as scrap metal for recycling. u Dispose of non-metallic materials as waste. u Dispose of residues of lubricants as waste oil. u Dispose of electronic components as electronic waste. u Dispose of thermal insulation as hazardous waste. © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.1 Ordering spare parts 13 Spare parts 13.1 Ordering spare parts CAUTION Spare part storage All spare parts that were ordered together with the turbocharger must be kept intact and ready for use. u Carefully clean any rusted parts and grease them. Please quote the following data when making queries and ordering spare parts: ¡ Turbocharger type ¡ Serial number of the turbocharger ¡ Designation and part number. u If different model variants are not taken into account in this document, contact an Turbo Systems Service Station. u Dispose of placed and unusable parts in an environmentally-friendly and professional manner in accordance with the local regulations. u Dispose of the packaging of new parts in an environmentally-friendly and professional manner in accordance with the local regulations. 13.2 Required customer spare part set (97070) For the work described in the Operation Manual, the customer spare part set (97070) is required. These parts are only available in the complete set. Customer spare part set 97070 42012 61002 * 61008 * 77005 79041 81010/ 82010 Designation O-ring Gasket Gasket O-ring Counter-sunk screw O-ring Quantity 1 1 1 1 2 1 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 129 / 149 Spare parts can be ordered from any Turbo Systems Service Station. Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations 13.3 Spare part – Illustrations The spare parts lists shown below are only available in English. Cartridge, oil cooled 42167** 42169** 42170** 42171** 42201** 42168** 42190 Page 130 / 149 42166** 42172** 42194(p) 42047(p) 42012* 42189(p) 10900 42188(p) (p) = pre-assembled 42197 ** = if provided * = Available within the spare part set Part no. 10900 42012* 42047(p) 42166** 42167** 42168** 42169** 42170** 42171** 42172** 42188(p) 42189(p) 42190 42194(p) 42196 42197 42201** 42196 HZTL443463 Mod. A Designation Cartridge complete O-ring Screw plug Screw Cover Hexagon-head screw Hexagon nut Insulation Safety washer Hexagon-head screw Hexagon-head screw Gasket Expansion bush Gasket Orifice oil inlet Safety ring Clamping nut Table 51: Spare parts - Cartridge, oil cooled © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Cartridge, water cooled 42167** 42201** 42190 42166** 42047(p) 42012* 42189(p) 10900 42188(p) (p) = pre-assembled ** = if provided 42197 * = Available within the spare part set Part no. 10900 42012* 42047(p) 42166** 42167** 42188(p) 42189(p) 42190 42194(p) 42196 42197 42201** 42196 HZTL443464 Mod. A Designation Cartidge complete O-ring Screw plug Screw Cover Hexagon-head screw Gasket Expansion bush Gasket Orifice oil inlet Safety ring Clamping nut Table 52: Spare parts - Cartridge, water cooled © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Page 131 / 149 42194(p) Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Turbine casing, 1 inlet 51302** 51303** 51301** 51027(p) 51008 51007 51003 51002 57003** 51009 51006 57002 51102** TW03 51107** TW04 51000 57210 Page 132 / 149 51105* ** 56001 51101 56005 51102 51103** 51010** TW02 51010** TW03/TW04 (p) = pre-assembled 51500 ** = if provided TW02/TW04 * = Available within the spare part set Part no. 51000 51002 51003 51006 51007 51008 51009 51010** 51027(p) 51101** 51102** 51103** 51105** 51106** 51107** 51301** 51302** 51303** 51500 51101** TW03 51106** TW04 HZTL443204 Mod. L Designation Turbine casing Fastening strip Verbusripp washer Stud Hexagon nut Stud Hexagon nut Insulation TW02 Screw plug Hexagon-head screw Tension washer Hexagon-head screw Metal C-ring Hexagon-head screw Tension washer Cleaning nozzle Gasket Screw plug Burst protection TW02, TW04 © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Part no. 56001 56005 57002 57003** 57210 Designation Nozzle ring Lamellar sealing ring Gas-outlet flange Metal C-ring Burst ring Page 133 / 149 Table 53: Spare parts - Turbine casing, 1 inlet © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Turbine casing, 2 inlets 51027(p) 51301** 51302** 51303** 51009 51008 51006 51002 51003 57002 51007 57003** 57210 56005 Page 134 / 149 51105* ** 51010** TW03 51000 51101 51102 56001 51101 51010** TW02 51500 (p) = pre-assembled 51101** TW02 ** = if provided * = Available within the spare part set Part no. 51000 51002 51003 51006 51007 51008 51009 51010** 51027(p) 51101** 51102** 51105** 51301** 51302** 51303** 51500 56001 56005 57002 51102** HZTL443220 Mod. H Designation Turbine casing Fastening strip Verbusripp washer Stud Hexagon nut Stud Hexagon nut Insulation TW02 Screw plug Hexagon-head screw Tension washer Metal C-ring Cleaning nozzle Gasket Screw plug Burst protection Nozzle ring Lamellar sealing ring Gas-outlet flange © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Part no. 57003** 57210 Designation Metal C-ring Burst ring Page 135 / 149 Table 54: Spare parts - Turbine casing, 2 inlets © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Gas outlet casing, axial 61001 61002* GH02 Page 136 / 149 61001** GH02 GHV03 61001** GH02 GHV08 ** = if provided * = Available within the spare part set only Part no. 61001 61001** 61002* HZTL443467 Mod.A Designation Gas-outlet casing Gas-outlet casing GHV03 Gasket Table 55: Spare parts - Gas outlet casing, axial © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Gas outlet casing, radial 61100 GW03 61205** 61202 61008* ** 61201 61005(p) Page 137 / 149 61200 61202 61201 (p) = pre-assembled 61002* 61001 61301** 61100 ** = if provided * = Available within the spare part set Part no. 61001 61002* 61005(p) 61008* ** 61100 61200 61201 61202 61205** 61301** HZTL443466 Mod. B Designation Gas-outlet casing Gasket Screw plug Gasket Insulation gas-outlet casing Burst protection Hexagon-head screw Tension washer Protective grid Support Table 56: Spare parts - Gas outlet casing, radial © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Compressor casing 72060 72062 72061 72012 79040 79041* 72010** (A145 only) 79000 77000 77005* 72011 Page 138 / 149 72080 72000 72020 (p) = pre-assembled 72006(p) ** = if provided 72005(p) * = Available within the spare part set Part no. 72000 72005(p) 72006(p) 72010** 72011 72012 72020 72060 72061 72062 72080 77000 77005* 79000 79040 79041* HZTL443201 Mod. E Designation Compressor casing Screw plug Gasket Verbus. locking disc Hexagon-head screw Fastening strip V-clamp Insulation Insulation sleeve Hexagon-head screw Warning plate Wall insert O-ring Diffuser Fixing washer Counter-sunk screw Table 57: Spare parts - Compressor casing © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Filter silencer 81000 81137 81136 81005 81006 81170 81171 81135 81266 81010* Page 139 / 149 81270 81265** 81271 (p) = pre-assembled * = Available within the spare part set Part no. 81000 81005 81006 81010* 81135 81136 81137 81170 81171 81265** 81266 81270 81271 HZTL443469 Mod. A Designation Filter silencer complete Screw plug Gasket O-ring Silencer body Absorption segment Cover sheet-metal Screw plug Gasket Filter ring Cover grid Tension band Lock Table 58: Spare parts - Filter silencer © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Air suction branch axial 82005 82008 82007 82010* 82006 Page 140 / 149 82000 * = Available within the spare part set Part no. 82000 82005 82006 82007 82008 82010* HZTL443013 Mod. D Designation Air suction branch Screw plug Gasket Screw plug Gasket O-ring Table 59: Spare parts - Air suction branch axial © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Air suction branch radial 82007 82008 Page 141 / 149 82000 82010* 82006 82005 * = Available within the spare part set Part no. 82000 82005 82006 82007 82008 82010* HZTL443012 Mod. D Designation Air suction branch Screw plug Gasket Screw plug Gasket O-ring Table 60: Spare parts - Air suction branch radial © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Bearing casing, oil cooled 42006** 42001 42005** 42401** 42400 42008* Page 142 / 149 42047(p) 42194(p) 42302* ** 42189(p) 42188(p) 42301 42305* 42306* 42197 42196 (p) = pre-assembled ** = if provided * = Available within the spare part set Part no. 42001 42005** 42006** 42008* 42047(p) 42188(p) 42189(p) 42194(p) 42196 42197 42301 42302* ** 42305* 42306* 42400 42401** HZTL443373 Mod. E Designation Bearing casing Sealing bush Spring-type pin Socket screw Screw plug Hexagon-head screw Gasket Gasket Orifice oil inlet Safety ring Bearing cover Piston ring O-ring O-ring Heat shield Metal C-ring Table 61: Spare parts - Bearing casing, oil cooled © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Bearing casing, water cooled Railway and Traction Application 42142*(p) 42141*(p) 42140*(p) 42001 42056** 42403* ** 42006** 42005** 42006** 42008* 42401** 42400 42047(p) 42194(p) 42302* ** 42189(p) 42301 42305* 42306* 42197 Page 143 / 149 42188(p) 42196 (p) = pre-assembled ** = if provided * = Available within the spare part set Part no. 42001 42005** 42006** 42008* 42047(p) 42056** 42140*(p) 42141*(p) 42172*(p) 42188(p) 42189(p) 42194(p) 42196 42197 42301 42302* ** 42305* 42306* 42400 42401** 42403* ** HZTL443374 Mod. E Designation Bearing casing Sealing bush Spring-type pin Socket screw Screw plug Wear protection ring Gasket Core hole cover Socket screw Hexagon-head screw Gasket Gasket Orifice oil inlet Safety ring Bearing cover Piston ring O-ring O-ring Heat shield Metal C-ring Metal V-ring Table 62: Spare parts - Bearing casing, water cooled © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 13 Spare parts / 13.3 Spare part – Illustrations Rotor and bearing parts 32109** 42302* ** 21000 21000 21011** 21006* ** 32103* 21002* 32104* 32111* 32167* 42002 Page 144 / 149 32109 32102* 32114* 32112 32113* 32110 32101* 25000 ** = if provided * = Available within the spare part set Part no. 21000 21002* 21006* ** 21011 25000 32101* 32102* 32103* 32104* 32109 32110 32111* 32112 32113* 32114* 32167* 42002 42302* ** HZTL443465 Mod. D Designation Turbine Piston riing Piston ring Sealing bush for shaft Compressor wheel Radial bearing CE Radial bearing TE Thrust ring Thrust bearing Sealing disc Bearing flange CE Auxiliary bearing Bearing flange TE Socket screw Socket screw Snap ring Socket screw Piston ring Table 63: Spare parts - Rotor and bearing parts © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. 14 Tools / 14 Tools For the work described in the Operation Manual, the customer tool set 90000 is required. 90000 90012 90013 90258 (≥A145) 90230 90042 90070 Designation Service support Plastic insert Lifting beam Socket screw Press-off tool Extraction device Quantity 1 1 1 2 1 1 Table 64: Customer tool set 90000 Tool sets can be ordered from any Turbo Systems service station. The following specifications must be included in the order: Turbocharger type ¡ Designation and part number of the tool set. Page 145 / 149 ¡ © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Rev.P February 2022 Operation Manual / A130-M.. - A145-M.. Figures Page 146 / 149 Figures Fig. 1: Serial number (01) on the rating plate ........... 4 Fig. 32: Carrying out wet cleaning of turbine............71 Fig. 2: Layout and function of the turbocharger...... 6 Fig. 33: Cleaning the filter silencer ............................. 73 Fig. 3: Compressor wheel cooling ................................ 7 Fig. 34: Compressor-end, non-rotating parts.......... 75 Fig. 4: Volatile Corrosion Inhibitor (VCI)................... 10 Fig. 35: Turbine end, non-rotating parts................... 76 Fig. 5: Package with hygrometer................................ 11 Fig. 36: Soaking the turbine end................................. 79 Fig. 6: Warning plate locations ................................... 17 Fig. 37: Swivel lifting eye (example) ........................... 90 Fig. 7: Rating plate ........................................................ 18 Fig. 38: Starpoint ring nut VRM................................... 91 Fig. 8: Locations of the rating plates ........................ 19 Fig. 39: Weights of assemblies ................................... 92 Fig. 9: Attachment of loads on the crane hook ....... 21 Fig. 40: Removing the air inlets .................................. 93 Fig. 10: Attachment angle............................................ 21 Fig. 41: Removing the insulation................................. 94 Fig. 11 .............................................................................. 25 Fig. 42: Removing the gas outlet casing ................... 95 Fig. 12: Suspension of complete turbocharger unit .... 30 Fig. 43: Dismantling the gas outlet flange ............... 96 Fig. 13: Turbine cleaning nozzle .................................. 31 Fig. 14: Removing the turbocharger .......................... 32 Fig. 15: Loosening the clamping nut......................... 34 Fig. 16: Turbocharger centre of gravity ................... 35 Fig. 17: Inserting gaskets into the bracket.............. 36 Fig. 18: Fitting threaded rods onto the bracket...... 37 Fig. 19: Requirements for threaded rods.................. 37 Fig. 20: Placing the turbocharger on the bracket . 38 Fig. 21: Preparing the clamping nut for the tightening procedure ............................................................... 40 Fig. 22: Tightening pressure screws.......................... 41 Fig. 23: Connecting the speed sensor ...................... 42 Fig. 44: Removing the gas outlet flange ................... 97 Fig. 45: Removing the compressor casing ............... 98 Fig. 46: Dismantling the wall insert ........................... 99 Fig. 47: Press off the casing ...................................... 100 Fig. 48: Removing insulation sheets........................ 101 Fig. 49: Oil orifice......................................................... 101 Fig. 50: Removing cartridge group 1........................ 102 Fig. 51: Removing cartridge group 2........................ 102 Fig. 52: Removing the nozzle ring............................. 103 Fig. 53: Installing the cartridge group on the service support .......................................................................... 104 Fig. 54: Measuring clearance A and B ...................... 105 Fig. 55: Nozzle ring compression PD ....................... 106 Fig. 24: Connecting the compressor cooling air intake ................................................................................. 42 Fig. 56: Installing the nozzle ring .............................. 107 Fig. 25: Attaching the support................................... 43 Fig. 57: Lifting the cartridge group and rotating it by 90°................................................................................... 108 Fig. 26: Oil orifice.......................................................... 44 Fig. 27: Layout and overview of speed measurement system ............................................................................ 52 Fig. 28: Replacing the speed sensor ......................... 54 Fig. 29: Noise insulation, bellows.............................. 56 Fig. 30: Replacing the protective grid ...................... 59 Fig. 58: Installing the cartridge group..................... 109 Fig. 59: Turbine casing insulation / Burst protection . 110 Fig. 60: Installing the compressor casing................ 112 Fig. 61: Measuring clearances N and R ..................... 113 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 Operation Manual / A130-M.. - A145-M.. Figures Fig. 63: Installing the gas outlet flange .................. 115 Fig. 64: Fitting the insulation.................................... 116 Fig. 65: Installing the gas outlet casing .................. 117 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 Page 147 / 149 Fig. 70: Cover plate drawing ..................................... 124 © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Revision P February 2022 Operation Manual / A130-M.. - A145-M.. Tables Tables Table 1: Definition of pictograms ............................... 9 Table 2: Personal protective equipment to be worn at all times ...................................................................... 14 Table 3: Personal protective equipment to be worn specific to the respective task ................................... 14 Table 27: Malfunctions during operation – Engine performance losses....................................................... 85 Table 28: Malfunction – Turbocharger surging........ 86 Table 4: Weight of complete turbocharger unit .... 30 Table 29: Malfunction – Sporadic surge blows ........ 86 Table 5: Requirements for threaded rods ................ 37 Table 30: Malfunctions when stopping – Runout noises ............................................................................... 87 Table 6: Tightening torque for standard nuts........ 39 Table 7: Torque-controlled tightening of the pressure screws .................................................................... 41 Table 8: Lubricating oil pressure at oil inlet before turbocharger ................................................................. 49 Page 148 / 149 Table 26: Malfunctions during operation – Charge air pressure too high .......................................................... 85 Table 31: Malfunctions when stopping – Runout time too short.......................................................................... 87 Table 32: Malfunction of the speed measurement system – No signal or poor signal amplitude .......... 88 Table 9: Lubricating oil temperature at the inlet... 50 Table 33: Malfunction of the speed measurement system – Measured speed too high ........................... 88 Table 10: Lubricating oil temperature at the outlet .... 50 Table 34: Malfunction of the speed measurement system – Measured speed too low............................. 88 Table 11: Tightening torque (86505) ........................ 54 Table 35: Swivel lifting eyes......................................... 90 Table 12: Expected replacement intervals................ 61 Table 36: Weights of assemblies ................................ 92 Table 13: Maintenance table....................................... 64 Table 37: 3 press-off screws ........................................ 96 Table 14: Parameters for wet cleaning of compressor ........................................................................... 67 Table 38: 6 press-off screws........................................ 97 Table 15: Turbine wet cleaning, recommended operating state ..................................................................... 70 Table 39: Permissible clearances A and B ............... 105 Table 40: Nozzle ring compression PD.................... 106 Table 16: Wet cleaning of turbine, parameters ....... 71 Table 41: Tightening torque (51007)........................ 109 Table 17: Value table for soaking............................... 79 Table 42: Tightening torque (79041) ........................ 111 Table 18: Malfunctions when starting – Delayed start-up .......................................................................... 82 Table 43: Tightening torque (72011) ........................ 112 Table 19: Malfunctions when starting – Vibrations 82 Table 20: Malfunctions when starting – Rubbing of rotating parts................................................................ 82 Table 21: Malfunctions during operation – Lubricating oil pressure too low............................................... 83 Table 22: Malfunctions during operation – Speed reduces............................................................................... 83 Table 23: Malfunctions during operation – Speed increases ........................................................................... 83 Table 24: Malfunctions during operation – Exhaust gas temperature too high .......................................... 84 Table 25: Malfunctions during operation – Charge air pressure too low........................................................... 84 © Copyright 2022 ABB. All rights reserved. Table 44: Permissible clearances N and R ............... 113 Table 45: Tightening torque (72020) ........................114 Table 46: Tightening torque (51009)........................ 117 Table 47: Tightening torques .....................................119 Table 48: Tightening torques for insulation .......... 120 Table 49: Cover plate dimensions [mm] ................. 124 Table 50: Customer spare part set 97070 .............. 129 Table 51: Spare parts - Cartridge, oil cooled .......... 130 Table 52: Spare parts - Cartridge, water cooled..... 131 Table 53: Spare parts - Turbine casing, 1 inlet ....... 133 Table 54: Spare parts - Turbine casing, 2 inlets..... 135 HZTL4031_EN Revision P February 2022 Operation Manual / A130-M.. - A145-M.. Tables Table 55: Spare parts - Gas outlet casing, axial .... 136 Table 56: Spare parts - Gas outlet casing, radial .. 137 Table 57: Spare parts - Compressor casing ........... 138 Table 58: Spare parts - Filter silencer...................... 139 Table 59: Spare parts - Air suction branch axial... 140 Table 60: Spare parts - Air suction branch radial.. 141 Table 61: Spare parts - Bearing casing, oil cooled 142 Table 62: Spare parts - Bearing casing, water cooled. 143 Table 63: Spare parts - Rotor and bearing parts.. 144 Page 149 / 149 Table 64: Customer tool set 90000........................ 145 © Copyright 2022 ABB. All rights reserved. HZTL4031_EN Revision P February 2022

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