Page 1 Turbocharging Operation Manual / A135-M65 HT607857 Document identification Document number HZTL4031 Revision Language English Original Operation Manual Product identification Serial number HT607857 Customer part number 150634-18023 Delivery date (yyyy-mm-dd) 2021-11-15 Weight Operating limits according to rating plate Speed limit in test rig operation only...
Page 3: Table Of Contents
Monitoring operation ..................49 Oil pressure, oil temperature..................49 Exhaust gas temperature before turbine ............... 51 Turbocharger speed ....................52 Operation and service ..................55 Noise emission ......................55 © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 4 Taking out of operation at short notice ............121 10.1 Possible emergency repairs..................121 10.2 Installing the replacement turbocharger .............. 122 10.3 Installing the replacement cartridge group ............122 10.4 Fitting the cover plate....................123 © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 5 Ordering spare parts....................129 13.2 Required customer spare part set (97070)............129 13.3 Spare part – Illustrations ..................130 Tools ........................145 Figures......................... 146 Tables ........................148 © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 6: Operation Manual / A130-M
Availability of the Operation Manual The Operation Manual must be available where the turbocharger is used. All persons operating or working on the turbocharger must have read and fully understood the Operation Manual. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 7: Contact 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 ABB Turbocharging Service Station if you have any questions regarding a design variant (see Contact information at www.abb.com/turbocharging).
Page 8: Layout And Function Of The Turbocharger
02 Compressor casing Nozzle ring 03 Diffuser Turbine casing 04 Bearing casing Turbine-end bearing flange 05 Axial thrust bearing Compressor-end bearing flange 06 Radial plain bearing Compressor wheel 07 Turbine © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 9: Fig. 3: Compressor Wheel Cooling
(X). In addition, the turbocharger version with compressor wheel cooling is indicated by the tur- bocharger type (M6..) on the rating plate. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N...
Page 10: Symbols, Definitions
Caution and warning signs are described in chapter Safety. ABB Turbocharging ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging in this document. Official service stations of ABB Turbocharging Official service stations are regularly audited and certified by ABB Turbocharging. See also chapter Contact information →5.
Page 11: Table 1: Definition Of Pictograms
Visually inspect Please note text for numbered work step. See document Dispose of in an environmentally compatible, professional way and in compliance with locally applicable regulations. Table 1: Definition of pictograms © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 12: Storage Of New Turbochargers And Spare Parts
Old VCI corrosion protection emitters must be disposed of in an environmentally compat- ible, professional way and in compliance with locally applicable regulations. Close package. The more tightly the package is sealed, the longer the protection dura- tion. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 13: Fig. 5: Package With Hygrometer
Inspect the package for damage. If the package is damaged, the turbocharger must be in- spected by an ABB Turbocharging Service Station and repacked. After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station: ¡...
Page 14: Registered Trademarks
Operation Manual / A130-M.. - A145-M.. 1 Introduction / 1.7 Registered trademarks Registered trademarks The trademarks of outside companies are used in this document. These are marked with the ® symbol. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 15: Safety
Safety Introduction Turbochargers manufactured by ABB reflect the state of the art. The respective safety and health protection requirements are met. This ensures safe operation of the turbocharger. Nevertheless, there may be some residual risks during operation of and work on the tur- bocharger which: ¡...
Page 16: Definition Of Mandatory Signs
Non-compliance or inaccurate compliance with working or operating in- structions indicated by this symbol and the word CAUTION can lead to seri- ous damage to engine or property with grave consequences. Caution signs must always be observed. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 17: Intended Use
These data are given on the rating plate. ABB accepts no liability and rejects all warranty claims for any non-intended uses. [1]Euromot = The European Association of Internal Combustion Engine Manufacturers [2]Directive 94/9/EC concerning equipment and protective systems intended for use in po-...
Page 18: Deflagration On Gas Engines
If during external inspection anomalies are found or if a particularly strong deflagration event has taken place, it is also recommended to check the bearings of the turbochargers before the next start. An ABB Turbocharging Service Station should be instructed to carry out this inspection.
Page 19: Warning Plates On The Turbocharger
If warning plates are not present in the designated locations or not readable, proceed as fol- lows: Order new warning plates from ABB Turbocharging Service Stations. Remove any warning plates that have become unreadable. Clean and degrease the areas designated for the warning plates.
Page 20: Turbocharger Rating Plate
Further data 06 Customer part number 07 Designation for special design 08 Weight of turbocharger in kg 09 Turbocharger type 10 Serial number Year of construction of turbocharger Manufacturing plant © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 21: Fig. 8: Locations Of The Rating Plates
Operation above the indicated values n can considerably shorten the recommended Bmax Bmax replacement intervals. In such cases, we recommend contacting the nearest ABB Turbochar- ging Service Station. normally apply only when running at overload (110 %) during trials on the engine Mmax Mmax test bed.
Page 22: Periodic Check Of The Pressure Vessels
Operation Manual / A130-M.. - A145-M.. 2 Safety / 2.9 Periodic check of the pressure vessels Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, are so-called "simple pressure vessels". ¡...
Page 23: Lifting Of Loads
The assembly devices must be completely screwed in and must not loosen during use. Use assembly devices only for the described applications. Put down dismantled components of the turbocharger in such a way that they cannot tip over. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 24: Prerequisites For Operation And Maintenance
Only use original parts from ABB. Original parts and accessories are specially designed for ABB turbochargers. ABB accepts no liability for any damage resulting from the use of non-original parts and cor- responding accessories. © Copyright 2021 ABB. All rights reserved.
Page 25: Hazards During Operation And Maintenance
Do not touch hot surfaces. Observe the warning plate on the turbochar- ger. Wear heat-resistant safety gloves and protective clothing. Wait for the turbocharger to cool down before carrying out any work. Wear safety gloves to protect against thermal hazards. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 26 Operate the turbocharger in compliance with the specifications. Secure the rotor against unintentional rotation during maintenance. Wear safety gloves to protect against mechanical hazards. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 27: Safe Operation
Variant A Insulation (01) with integrated burst protection from ABB. Variant B Burst protection (03) and insulation (02) from ABB. Variant C Burst protection (03) from ABB with appropriate insulation from the enginebuilder. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 28: Safe Maintenance
Keep the floor, equipment, and turbocharger clean. Have oil binding agents ready and provide or keep oil pans at hand. Clean up any spills. Have fire protection means and extinguishing agents available. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 29 Components of the turbocharger can be damaged or destroyed as a result of improper procedures. Only perform operations that are described in this chapter. Only perform operations for which you have received instruction or train- ing. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 30 Wear personal protective equipment (PPE) according to the material safety data sheet. Comply with local legislation. Wear safety goggles. Wear safety gloves to protect against chemical hazards. Wear a respiratory mask to protect against gases. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 31 Dispose of insulation materials properly and in an environmentally com- patible manner in compliance with the legal regulations. Wear safety goggles. Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against chemical hazards. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 32: Removing And Installing
B Turbocharger with water-cooled bearing casing C Complete turbocharger unit with gas outlet casing Product Weight of complete turbocharger unit [kg] A130-M A135-M A140-M A145-M Table 4: Weight of complete turbocharger unit © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 33: Removing The Turbocharger
Observe the specified tightening torque from the supplier of the screw connection. Components (01/02) are not included in the ABB scope of delivery. Fig. 13: Turbine cleaning nozzle 1. If present: Loosen the turbine cleaning connection (01).
Page 34: Fig. 14: Removing The Turbocharger
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. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N...
Page 35 Attach lifting gear to the suspension eye. Loosen the round special nut with a hydraulic tool according to the instructions of the en- ginebuilder. Positioning the turbocharger for storage →35. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 36: Fig. 15: Loosening The Clamping Nut
3. Working in a circle, loosen each pressure screw by 90° in 1...5 rounds until all of the pres- sure screws have been relieved. Loosen clamping nut by hand. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 37: Fig. 16: Turbocharger Centre Of Gravity
Centre of gravity Remove turbocharger from engine support, set it down properly in an appropriate place and secure it. Close or cover the openings of the turbocharger and support. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 38: Installing The Turbocharger
Always use new gaskets and insert them carefully into the slot. The oil is supplied (02) and drained (03) through the bracket (01). The necessary sealing is provided by O-rings. The O-rings are not included in the ABB scope of delivery. Fig. 17: Inserting gaskets into the bracket...
Page 39: Fig. 18: Inserting The Threaded Rods
The threaded rods and nuts for fastening the turbocharger on the bracket are not included in the ABB scope of delivery. The clamping nuts are included in the ABB scope of delivery. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N...
Page 40: Fig. 20: Placing The Turbocharger On The Bracket
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. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N...
Page 41: Table 6: Tightening Torque For Standard Nuts
**) When the turbocharger is mounted on the engine support, the bolt threads and screw heads must be lightly oiled (assumed friction coefficient µ = 0.12 for tightening torque) Remove the lifting gear. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N...
Page 42: Fig. 21: Preparing The Clamping Nut For The Tightening Procedure
5. Tighten clamping nut (03) by hand. 6. Unscrew clamping nut (03) by ¼ of a turn (90°). The distance between the thrust washer and the clamping nut is now about 1 mm. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N...
Page 43: Fig. 22: Tightening Pressure Screws
4. Work in a circle to tighten all pressure screws to 100 % of the tightening torque specified in the table. 5. Tighten pressure screws to 100 % in 5 … 7 rounds until the required residual tightening angle of < 20° is achieved. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 44: Fig. 23: Connecting The Speed Sensor
Make sure there is an uninterrupted supply of cooling air during opera- tion. Fig. 24: Connecting the compressor cooling air intake Remove the screw plug on the connection for the compressor wheel cooling (06) and fit the cooling air line. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 45: Fig. 25: Attaching The Support
3 Removing and Installing / 3.3 Installing the turbocharger 3.3.7 Attaching the support Fig. 25: Attaching the support If present: Attach support (61301) to engine support or to a connecting piece. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 46: Commissioning
Filtering the lubricating oil with a filter mesh width of ≤ 0.034 mm is sufficient for this tur- bocharger. 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. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 47: Fig. 26: Oil Orifice
With an oil inlet pressure of more than 3 bar of overpressure (with engine under load) up- stream of the turbocharger, the bearing casings are equipped with an orifice at the oil inlet as standard. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N...
Page 48: Inspection Procedures
Make sure there is an uninterrupted supply of cooling air during opera- tion. Check whether the compressor wheel cooling is fitted on the bearing casing. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 49 Lubricants and pastes used during assembly can liquefy or vaporise and escape as oily fluids during the initial hours of operation. Continual escape of an oily fluid indicates an oil leak. If there is a leak, contact an ABB Turbocharging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 50: Commissioning After Taking Out Of Operation
Check and clean filter silencer or air supply line, and remove any foreign objects that may be present. Put engine-side oil circulation to the turbocharger into operation. Prepare the turbocharger for operation (see Checks before commissioning →46). The turbocharger is now ready for operation. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 51: Monitoring Operation
Oil pressure measuring point Oil temperature measuring point For monitoring the lubricating oil pressure, ABB Turbocharging recommends installing a "P" manometer immediately upstream of the turbocharger oil inlet before the orifice. If the pressure is controlled electronically, the relevant signals should be triggered at the warning and alarm values.
Page 52: Table 9: Lubricating Oil Temperature At The Inlet
Table 10: Lubricating oil temperature at the outlet If the turbocharger has been operated for a longer period of time outside the admissible range, ABB Turbocharging recommends having the turbocharger inspected by an ABB Tur- bocharging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 53: Exhaust Gas Temperature Before Turbine
Definition and explanations concerning rating plate: refer to chapter 2 of Operation Manual / Safety. Operating limits: refer to chapter 3 of Operation Manual / Safety data sheet or examine rating plate. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 54: Turbocharger Speed
86505 Speed sensor 42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F/I converter Plug with integrated voltage limiter 86528 Tachometer Installation variant for speed sensor 32109 Sealing disc with cams © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 55 Check the pressure loss of the alternative air inlet and compare it with normal values. If the engine can be stopped temporarily: Inspect air lines, gas piping and the turbochargers and remedy any malfunctions. In any case, contacting the nearest ABB Turbocharging Service Station is recommended. 5.3.4 Malfunctions on the speed measurement system...
Page 56: Fig. 28: Replacing The Speed Sensor
Wear safety gloves when disassembling the speed sensor. Wear safety gloves to protect against thermal hazards. The speed sensor supplied by ABB is equipped with a sealing lip and an O-ring. No additional gasket is required during assembly. Fig. 28: Replacing the speed sensor...
Page 57: Operation And Service
Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 : A-weighted emission sound pressure level The enginebuilder must provide acoustically equivalent measures in case of deviating in- sulation versions © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 58: Fig. 29: Noise Insulation, Bellows
Suggestion for noise insulation, bellows Fig. 29: Noise insulation, bellows Compressor casing Bellows Charge air duct / scavenging air duct Insulation cushion Insulation mat (at least 15 mm) Sheet metal cover © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 59: Service Work
Agree on a specific service interval with ABB Turbocharging. To prevent machine damage caused by ageing and downtime, we recommend having an in- spection carried out by an ABB Turbocharging Service Station no later than 5 years after the last service.
Page 60 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 an ABB Turbocharging Service Station. The following work can be carried out as preparation.
Page 61: Fig. 30: Replacing The Protective Grid
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 ABB: Fig. 30: Replacing the protective grid Remove the protective grid (61205) after 50000 hours and replace it with a new protect- ive grid.
Page 62 Speed of the turbocharger ¡ Air temperature after the compressor and after the charge-air cooler ¡ Exhaust gas temperature before and after the turbine ¡ Pressure loss in the filter silencer. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 63: Expected Replacement Intervals
Table 12: Expected replacement intervals = Natural Gas = Marine Diesel Oil = Heavy Fuel Oil The specified values are guideline values and not guaranteed values, see Influencing para- meters. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 64 ¡ Lubricating oil quality (oil filtering, oil condition, oil monitoring) ¡ Load profile (speed, pressure conditions, temperature) ¡ Number of starts/stops ¡ Unbalance of the rotor (degree of contamination). © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 65: Stopping The Engine
– 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. ABB Turbocharging recommends post-lubrication for 10 minutes. Observe the oil pressure specified for post-lubrication (see Table 8: Lubricating oil pres-...
Page 66: Periodic Maintenance Work
Table 13: Maintenance table [h] = Hours of operation If the maintenance intervals are incompatible with operation of the engine, contact ABB Turbocharging. ABB Turbocharging recommends having mechanical cleaning carried out by an ABB Tur- bocharging Service Station during the service work (see also chapter...
Page 67: Cleaning The Compressor During Operation
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 con- taminated components can no longer be cleaned using this method. In this case, ABB Tur- bocharging recommends mechanical cleaning of the contaminated components.
Page 68 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 ABB Turbocharging. V-engines On V-engines with several turbochargers per engine, parallel cleaning of both turbochargers is recommended.
Page 69: Fig. 31: Carrying Out Wet Cleaning Of Compressor
Not more than three cleaning cycles should be conducted consecutively. Before repeating the process, continue to operate the engine for at least five minutes to ensure that all of the water is flushed out of the system. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N...
Page 70: Cleaning The Turbine During Operation
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 con- taminated components can no longer be cleaned using this method. In this case, ABB Tur- bocharging recommends mechanical cleaning of the contaminated components.
Page 71 Cleaning method The turbine components are cleaned during operation using the wet cleaning method. This cleaning method is tested and approved by ABB Turbocharging. The precondition for wet cleaning is that the enginebuilder approves the process and these regulations are observed.
Page 72: Table 15: Turbine Wet Cleaning, Recommended Operating State
During cleaning, the temperature at the turbine inlet will rise and may strain the material significantly. Make sure the maximum temperature at the turbine inlet is not exceeded during cleaning. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 73: Fig. 32: Carrying Out Wet Cleaning Of Turbine
→71). Close the stop valve (02) after 10 minutes. Wait for 10 minutes; do not change the load during this stabilisation phase. If the cleaning result is unsatisfactory or there is water leakage, contact an ABB Turbochar- ging Service Station. Product Temperature be-...
Page 74: Cleaning Components Mechanically
The disassembly and assembly of the components is described in chapter Fitting and dis- mantling. Contaminated water and cleaning agents must be disposed of in an environmentally compatible, professional way and in compliance with locally applicable regulations. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 75: Fig. 33: Cleaning The Filter Silencer
Rinse in cold water. Avoid high mechanical loads (water jet). Let the filter ring dry completely before assembling. Dirty water and mild detergent must be disposed of in compliance with locally applicable regulations. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 76 When cleaning, note that the absorption segments (81136) must only be cleaned lightly with compressed air, a soft brush or a moist cleaning cloth. Have any heavily contaminated absorption segments replaced by an ABB Turbocharging Service Station. Fitting the filter silencer (see Fig. 33: Cleaning the filter silencer →73)
Page 77: Fig. 34: Compressor-End, Non-Rotating Parts
Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the tur- bocharger. Dispose of contaminated water and cleaning agents in accordance with the information in the material safety data sheet. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 78: Fig. 35: Turbine End, Non-Rotating Parts
Dismantle the lamellar sealing ring (56005) in the nozzle ring. Place contaminated parts in hot water or in a liquid such as brake cleaner to soften the contamination. Brush away the contamination or remove with a steam cleaner. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 79 Removing and Installing →30). Remove the cartridge group (see chapter Dismantling and fitting →89). First clean the compressor end and then the turbine end according to the following descrip- tion. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 80 Lightly spray the compressor wheel and the gap between the compressor and the bearing casing with penetrating oil. Dispose of dirty water and cleaning agents in accordance with the material safety data sheet. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 81: Fig. 36: Soaking The Turbine End
Use only pH-neutral cleaning agents which do not attack metals. Observe safety data sheet. 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 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 82 Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against mechanical hazards. Lift up the cartridge group and align it horizontally. Remove dirt manually using a soft brush or a wire brush. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 83 Lightly spray the turbine and the gap between the turbine and the partition wall with pen- etrating oil. Dispose of dirty water and cleaning agents in accordance with the information in the ma- terial safety data sheet. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 84: Eliminating Malfunctions
To prevent significant loss of efficiency, specific tolerances must be fulfilled. ¡ If there is any doubt about the extent of the rubbing, contact an ABB Tur- bocharging Service Station. ¡...
Page 85: Malfunctions During Operation
Turbochar- Turbine and/or nozzle ring severely con- Clean (see chapter Periodic mainten- taminated ance work →64) Rotor components or bearing damaged Contact ABB Turbocharging Service Station Engine Defects on the connected cylinders in Contact enginebuilder pulse charging Pipes Defects, such as leaks, in the exhaust...
Page 86: Table 24: Malfunctions During Operation - Exhaust Gas Temperature Too High
Gas piping between engine and turbine leaking Injection mistimed Set correctly Valve control misadjusted Pipes Pipes downstream to the compressor Repair. outlet not sealed. Table 25: Malfunctions during operation – Charge air pressure too low © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 87: Table 26: Malfunctions During Operation - Charge Air Pressure Too High
Clean (see chapter Periodic mainten- ance work →64) Table 27: Malfunctions during operation – Engine performance losses © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 88: Turbocharger Is Surging
Gradually reduce the engine load. Have the cause clarified and remedied immediately by an ABB Turbochar- ging Service Station. Have parts assessed for damage and, if necessary, replaced by an ABB Turbocharging Service Station. Possible causes Remedy...
Page 89: Malfunctions When Stopping
Check clearances (see chapter Measuring clear- ance A and B →105). If clearances are outside the tolerance or if in doubt, contact an ABB Turbochar- ging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station.
Page 90: Speed Measurement System
Table 34: Malfunction of the speed measurement system – Measured speed too low If none of the measures described above remedy the malfunction, have the speed measure- ment system checked by an ABB Turbocharging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 91: Dismantling And Fitting
ABB Turbocharging Service Station. Tightening torques for assembly devices Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB must be tightened so they are tight-fitting. © Copyright 2021 ABB. All rights reserved.
Page 92: Material Required
Visually inspect for corrosion, cracks, deformation and wear. 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 ABB. Fig. 37: Swivel lifting eyes Product...
Page 93: Fig. 38: Starpoint Ring Nut Vrm
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 in- cluded in the ABB scope of delivery. Fig. 38: Starpoint ring nut VRM Lifting gear...
Page 94: Weights Of Individual Parts
Turbine casing * 1 inlet Turbine casing * 2 inlets Turbine casing * 3 inlets Gas outlet flange Gas outlet casing Table 36: Weights of assemblies * including burst protection © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 95: Removing The Air Inlets
2. Loosen and remove V-clamp (72020). 3. Remove filter silencer (81000) or air suction branch (82000), set it down properly in an appropriate place and secure it. 4. Remove and dispose of the O-ring (81010 / 82010). © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 96: Removing The Gas Outlet Casing
Operation Manual / A130-M.. - A145-M.. 9 Dismantling and fitting / 9.5 Removing the gas outlet casing Removing the gas outlet casing Removing the insulation Fig. 41: Removing the insulation Remove gas outlet casing insulation. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 97: Removing The Gas Outlet Flange
If the following Working Instructions are not observed, this can lead to cracks in the gas out- let casing. The following variants are possible: Pressing off using 3 press-off screws. Pressing off using 6 press-off screws. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 98: A130 A135 A140 A145
≤ 65 Nm Table 37: 3 press-off screws * not included in the ABB scope of delivery 1. Press off and remove the gas outlet flange (57002) with screws (01) according to the table. If it is not possible to press off the gas outlet flange with the maximum tightening torque, contact an ABB Turbocharging Service Station.
Page 99: Fig. 44: Removing The Gas Outlet Flange
6x M12 x 30 Table 38: 6 press-off screws * not included in the ABB scope of delivery. 1. Evenly press off and remove the gas outlet flange (57002) with screws (01) according to the table. If it is not possible to press off the gas outlet flange with the maximum tight- ening torque, contact an ABB Turbocharging Service Station.
Page 100: Removing The Compressor Casing
Dispose of counter-sunk screws (79041). If the compressor casing cannot be loosened, it can be pressed off against the turbine cas- ing using the press-off tool (90042) (see chapter Pressing off the casing →100). © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 101: Wall Insert
1. Knock the wall insert (77000) out of the compressor casing (72000) with a plastic tip hammer. 2. Attach swivel lifting eye (S) to the compressor casing (72000) and the lifting gear. 3. Lift up the compressor casing (72000). 4. Remove and dispose of the O-ring (77005). © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 102: Pressing Off The Casing
If the casing is pressed off with too much force on one side, the rotor can be damaged. Use the tool on both sides in alternation and make sure not to press off too hard on either side. Fig. 47: Press off the casing © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 103: Removing The Cartridge Group
If an oil orifice is fitted in the oil inlet of the bearing casing, it must not be removed. Fig. 49: Oil orifice 01 Bearing casing 02 Oil orifice 03 Circlip © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 104: Fig. 50: Removing Cartridge Group 1
7. Turn the cartridge group into the horizontal rotor axis. If the cartridge group cannot be loosened, the press-off tool (90042) can be used (see chapter Pressing off the casing →100). © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 105: Removing The Nozzle Ring
2. Position the fastening strips (51002) in place. 3. Pull out the nozzle ring (56001) with the two extraction devices (90070) and the service support base (90012). 4. Remove the lamellar sealing ring (56005). 5. Remove the burst ring (57210). © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 106: Installing The Cartridge Group On The Service Support
Fig. 53: Installing the cartridge group on the service support 1. Remove ring nuts (VRM). 2. Remove service support screws. 3. Fit service support (90012) according to the illustration. 4. Insert the cartridge group. 5. Fit the nuts. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 107: Measuring Clearance A And B
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 108: Nozzle Ring Compression Pd
Table 40: Nozzle ring compression PD 1. Measure dimensions A, B and S on cleaned surfaces. 2. Calculate compression (PD). If the calculated value (PD) lies outside the specified range, contact an ABB Turbochar- ging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 109: Installing The Nozzle Ring
Align the cams on the nozzle ring with the recesses of the turbine cas- ing (51000). Do not remove the adhesive tape (01). 5. If present: Fit the metal C-ring (51105). © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N...
Page 110: Installing The Cartridge Group
3. Insert the screws of the service support from above and fit ring nuts (VRM) with washers. 4. Attach lifting gear to the ring nuts (VRM). 5. Lift cartridge group at the side of the ring nuts (VRM) and turn it into a vertical position. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N...
Page 111: Fig. 58: Installing The Cartridge Group
3. Lower the cartridge group into the turbine casing. 4. Remove ring nuts and screws. 5. Fit fastening strips (51002) with Verbus Ripp® washers (51003) and hexagon nuts (51007). 6. Tighten the hexagon nuts (51007). © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 112: Fig. 59: Turbine Casing Insulation / Burst Protection
9 Dismantling and fitting / 9.15 Installing the cartridge group WARNING The turbine casing insulation supplied by ABB also acts as burst protection Serious injuries or accidents resulting in fatalities can occur if the turbine casing insulation (01) supplied by ABB is removed. A burst protection is in- tegrated into this turbine casing insulation supplied by ABB.
Page 113: Installing The Compressor Casing
2. Fit the swivel lifting eye (S) to the lifting beam. Secure lifting gear to the swivel lifting eye. 3. Fit new O-ring (77005). 4. Install the wall insert (77000) in the compressor casing. 5. Fit diffuser (79000) with fixing discs (79040) and screws (79041). Observe the tightening torque. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 114: Fig. 60: Installing The Compressor Casing
4. Install the compressor casing (72000). 5. Install the fastening strips (72012) with screws (72011). Observe the tightening torque. If these screws do not have a Verbus Ripp® integrated, Verbus Ripp® washers (72010) must also be fitted. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 115: Measuring Radial Clearances N And R
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 116: Installing The Air Inlets
2. Fit a new O-ring (81010) to the filter silencer (81000) or a new O-ring (82010) to the air suction branch (82000). 3. Fit the filter silencer (81000) or air suction branch (82000) with the V-clamp (72020). 4. Observe tightening torque. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 117: Installing The Gas Outlet Flange
1. If present: Insert the metal C-ring (57003) into the turbine casing (51000) and secure with high-vacuum grease. 2. Install the gas outlet flange (57002) in the turbine casing. 3. Measure radial clearance (R) (see chapter Radial clearances N and R). © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 118: Fitting The Insulation Of The Turbine Casing
9.20 Fitting the insulation of the turbine casing Fig. 64: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see Table of tightening torques →119). © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 119: Installing The Gas Outlet Casing
3. Attach the lifting gear to the gas outlet casing (61001) and position the gas outlet casing in the correct position on the turbine casing (51000). 4. If present: Fit support (61301). 5. Fit hexagon nuts (51009). Observe the tightening torque. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 120: Fig. 66: Fitting The Insulation
9 Dismantling and fitting / 9.21 Installing the gas outlet casing Fitting the insulation Fig. 66: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see Table of tightening torques →119). © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 121: Table Of Tightening Torques
*) With the variant "insulation with integrated burst protection", this position can be ig- nored. 16d **) applies to the burst protection mounting of A130-M and A135-M turbochargers on railway applications © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 122: Fig. 68: Tightening Torques For Insulation
Table 48: Tightening torques for insulation Tightening torque for attaching the insulation with integrated burst protection at the tur- bine casing Tightening torque for attaching the insulation to the burst protection. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 123: Taking Out Of Operation At Short Notice
¡ If a replacement turbocharger or cartridge group is not available: Fit cover plate →123 and contact an ABB Turbocharging Service Station. Observe the following sections in connection with the emergency repairs mentioned. © Copyright 2021 ABB. All rights reserved.
Page 124: Installing The Replacement Turbocharger
The repair of a cartridge group requires special tools and the expertise of an ABB Turbochar- ging Service Station. The rotating parts rotate extremely quickly, and are sensitive to unbal- ance.
Page 125: Fitting The Cover Plate
3. Coat the threads of the studs (51006) with high-temperature grease. 4. Fasten cover plate (01) to turbine casing (51000) with fastening strips (51002), Verbus Ripp® washers (51003) and nuts (51007) and screw to bracket. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N...
Page 126: Cover Plate Drawing
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 ABB scope of delivery and must be manufactured by the operating company according to the following drawing. Material: General structural steel, in accordance with DIN EN 10025-2.
Page 127: Mothballing The Turbocharger
If the acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking the engine out of operation: Dismantle the turbocharger. The rotor and bearing parts must be dismantled and subsequently refitted by an ABB Tur- bocharging Service Station. Clean all parts.
Page 128: Taking The Engine Out Of Operation For More Than 12 Months
¡ The casings of the turbocharger remain attached to the engine, the rotor and bearing parts are dismantled by an ABB Turbocharging Service Station and stored separately ¡ The turbocharger is completely removed, either as a whole unit or in individual parts For the measures always necessary for preparing the turbocharger parts for mothballing, see section Taking the engine out of operation for up to 12 months, subsection Preparations...
Page 129: Disposing Of Turbocharger Components
Dispose of metals as scrap metal for recycling. Dispose of non-metallic materials as waste. Dispose of residues of lubricants as waste oil. Dispose of electronic components as electronic waste. Dispose of thermal insulation as hazardous waste. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 131: Spare Parts
O-ring 79041 Counter-sunk screw 81010/ 82010 O-ring Table 50: Customer spare part set 97070 * This gasket can only be installed when a gas outlet casing from ABB is used. © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 132: Spare Part - Illustrations
Cover 42168** Hexagon-head screw 42169** Hexagon nut 42170** Insulation 42171** Safety washer 42172** Hexagon-head screw 42188(p) Hexagon-head screw 42189(p) Gasket 42190 Expansion bush 42194(p) Gasket 42196 Orifice oil inlet © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 133: Table 51: Spare Parts - Cartridge, Oil Cooled
42167** Cover 42188(p) Hexagon-head screw 42189(p) Gasket 42190 Expansion bush 42194(p) Gasket 42196 Orifice oil inlet 42197 Safety ring 42201** Clamping nut Table 52: Spare parts - Cartridge, water cooled © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 134 51010** Insulation TW02 51027(p) Screw plug 51101** Hexagon-head screw 51102** Tension washer 51103** Hexagon-head screw 51105** Metal C-ring 51106** Hexagon-head screw 51107** Tension washer 51301** Cleaning nozzle 51302** Gasket © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 135: Table 53: Spare Parts - Turbine Casing, 1 Inlet
51500 Burst protection TW02, TW04 56001 Nozzle ring 56005 Lamellar sealing ring 57002 Gas-outlet flange 57003** Metal C-ring 57210 Burst ring Table 53: Spare parts - Turbine casing, 1 inlet © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 136 51010** Insulation TW02 51027(p) Screw plug 51101** Hexagon-head screw 51102** Tension washer 51105** Metal C-ring 51301** Cleaning nozzle 51302** Gasket 51303** Screw plug 51500 Burst protection 56001 Nozzle ring © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 137: Table 54: Spare Parts - Turbine Casing, 2 Inlets
13 Spare parts / 13.3 Spare part – Illustrations Part no. Designation 56005 Lamellar sealing ring 57002 Gas-outlet flange 57003** Metal C-ring 57210 Burst ring Table 54: Spare parts - Turbine casing, 2 inlets © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 138: Table 55: Spare Parts - Gas Outlet Casing, Axial
* = Available within the spare part set only HZTL443467 Mod.A Part no. Designation 61001 Gas-outlet casing 61001** Gas-outlet casing GHV03 61002* Gasket Table 55: Spare parts - Gas outlet casing, axial © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 139: Table 56: Spare Parts - Gas Outlet Casing, Radial
61008* ** Gasket 61100 Insulation gas-outlet casing 61200 Burst protection 61201 Hexagon-head screw 61202 Tension washer 61205** Protective grid 61301** Support Table 56: Spare parts - Gas outlet casing, radial © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 140: Table 57: Spare Parts - Compressor Casing
Insulation 72061 Insulation sleeve 72062 Hexagon-head screw 72080 Warning plate 77000 Wall insert 77005* O-ring 79000 Diffuser 79040 Fixing washer 79041* Counter-sunk screw Table 57: Spare parts - Compressor casing © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 141: Table 58: Spare Parts - Filter Silencer
Silencer body 81136 Absorption segment 81137 Cover sheet-metal 81170 Screw plug 81171 Gasket 81265** Filter ring 81266 Cover grid 81270 Tension band 81271 Lock Table 58: Spare parts - Filter silencer © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 142: Table 59: Spare Parts - Air Suction Branch Axial
HZTL443013 Mod. D Part no. Designation 82000 Air suction branch 82005 Screw plug 82006 Gasket 82007 Screw plug 82008 Gasket 82010* O-ring Table 59: Spare parts - Air suction branch axial © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 143: Table 60: Spare Parts - Air Suction Branch Radial
HZTL443012 Mod. D Part no. Designation 82000 Air suction branch 82005 Screw plug 82006 Gasket 82007 Screw plug 82008 Gasket 82010* O-ring Table 60: Spare parts - Air suction branch radial © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 144: Table 61: Spare Parts - Bearing Casing, Oil Cooled
Orifice oil inlet 42197 Safety ring 42301 Bearing cover 42302* ** Piston ring 42305* O-ring 42306* O-ring 42400 Heat shield 42401** Metal C-ring Table 61: Spare parts - Bearing casing, oil cooled © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 145: Table 62: Spare Parts - Bearing Casing, Water Cooled
42301 Bearing cover 42302* ** Piston ring 42305* O-ring 42306* O-ring 42400 Heat shield 42401** Metal C-ring 42403* ** Metal V-ring Table 62: Spare parts - Bearing casing, water cooled © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 146: Table 63: Spare Parts - Rotor And Bearing Parts
Auxiliary bearing 32112 Bearing flange TE 32113* Socket screw 32114* Socket screw 32167* Snap ring 42002 Socket screw 42302* ** Piston ring Table 63: Spare parts - Rotor and bearing parts © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021...
Page 147: Tools
90042 Press-off tool 90070 Extraction device Table 64: Customer tool set 90000 Tool sets can be ordered from any ABB Turbocharging Service Station. The following spe- cifications must be included in the order: ¡ Turbocharger type ¡ Designation and part number of the tool set.
Page 148: Figures
Fig. 61: Measuring clearances N and R ..... 113 Fig. 30: Replacing the protective grid ...... 59 Fig. 62: Installing the air inlets ........114 Fig. 31: Carrying out wet cleaning of compressor . 67 © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Revision N March 2021...
Page 149 Fig. 66: Fitting the insulation........118 Fig. 67: Tightening torques ........119 Fig. 68: Tightening torques for insulation .... 120 Fig. 69: Fitting the cover plate........123 Fig. 70: Cover plate drawing ........124 © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Revision N March 2021...
Page 150: Tables
Table 53: Spare parts - Turbine casing, 1 inlet ..133 Table 25: Malfunctions during operation – Charge air pressure too low............84 Table 54: Spare parts - Turbine casing, 2 inlets..135 © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Revision N March 2021...
Page 151 Table 61: Spare parts - Bearing casing, oil cooled 142 Table 62: Spare parts - Bearing casing, water cooled. Table 63: Spare parts - Rotor and bearing parts.. 144 Table 64: Customer tool set 90000......145 © Copyright 2021 ABB. All rights reserved. HZTL4031_EN Revision N March 2021...

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