Abb A135-H66 User Manual

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Page 1

Operation Manual

A135-H66

HT594610 English

Original Operation Manual

Chapter Document-ID

1 Introduction

2 Safety

3 Safety data sheet

4 Product description

HZTL4005_EN_G

HZTL4022_EN_E

HT594610

HZTL4030_EN_F

ABB Turbocharging

Page 2

Operating limits and replacement intervals

The recommended replacement intervals and the corresponding operating limits in chapter 3 are jointly defined with the enginebuilder. This information is specific to the product.

Non-observance of the recommended replacement intervals and the operating limits increases the risk of unpredictable component failures.

Page 3

Operation Manual / 1 Introduction

Table of contents

Introduction

1 Introduction............................................................................................................ 2

1.1 Purpose of the manual.................................................................................................. 2

1.2 Symbols, definitions...................................................................................................... 3

1.3 Storage of new turbochargers and spare parts...................................................... 5

1.4 Contact information...................................................................................................... 7

Page 4

Operation Manual / 1 Introduction

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

This Operation Manual belongs to the turbocharger with the identical serial number (01), see chapter 3 (Safety data sheet) and the rating plate on the turbocharger.

Operation Manual

The Operation Manual explains the turbocharger and contains instructions for safe opera-

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tion.

The Operation Manual is a complement to and expansion of existing national regulations for occupational safety, accident prevention and environmental protection.

Target group

The Operation Manual is aimed at engineers and trained mechanics responsible for the proper operation of the engine and for the turbocharger connected to it.

Availability of the Operation Manual

The Operation Manual must be available where the turbocharger is used.

All persons operating or working on the turbocharger must have read and fully understood the Operation Manual.

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Operation Manual / 1 Introduction

1 Introduction / 1.2 Symbols, definitions

1.2 Symbols, definitions

Symbols

The following symbols are used in this document:

u Indicates an action step.

1. Indicates a numbered action step.

→Refers to a page number

Definition of Note

NOTICE

Note

The note provides advice which facilitates the work.

Definition of mandatory signs

Mandatory signs show the protective equipment to be worn for a task. The mandatory signs are described in chapter Safety and must be complied with.

Definition of Caution / Warning

Caution and warning signs are described in chapter Safety.

ABB Turbocharging

ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging or as ABB Turbo Systems 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 →7.

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Page 6

Operation Manual / 1 Introduction

1 Introduction / 1.2 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

Oil free, grease free and dry

Affix

Measure

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Table1: Definition of pictograms

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.

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Operation Manual / 1 Introduction

1 Introduction / 1.3 Storage of new turbochargers and spare parts

1.3 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 sealed packaging without additional mothballing measures for up to 6months from the date of delivery (marked by the VCI label on the package).

Fig.2: Volatile Corrosion Inhibitor (VCI)

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

WARNING

Protection of health when handling VCIs

VCI products are not hazardous in the sense of the Hazardous Substances Ordinance. Nevertheless, the following points are to be observed when handling VCIs:

u Observe specifications in the safety data sheet

u Ensure good room ventilation.

u Do not eat, drink or keep food at the workplace while working with VCIs.

u Clean hands and face after working with VCIs.

u For further information refer to www.branopac.com.

Wear safety gloves to protect against mechanical hazards.

The following mothballing measures are required every 6months:

u Open the package.

u Remove the VCI corrosion protection emitter from the package and replace it with a new,

identical VCI corrosion protection emitter. New VCI corrosion protection emitters can be obtained at www.branopac.com.

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u Dispose of the old VCI corrosion protection emitter in an environmentally compatible

manner, professionally and in accordance with local regulations.

u Seal the package. The better the external seal is designed, the more permanent the pro-

tection.

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Operation Manual / 1 Introduction

1 Introduction / 1.3 Storage of new turbochargers and spare parts

Long-term storage of turbochargers

The turbochargers will be prepared for prolonged storage by ABB Turbo Systems on request. The package is equipped with a hygrometer (see illustration).

Fig.3: Package with hygrometer

The following measures are required every 6months:

u Check the hygrometer(02) in the sight-glass. There is an opening(01) in the wooden

crate which allows this check to be carried out. When the display field has changed colour at the 70% level, the maximum permissible humidity has been exceeded. In this case the turbocharger must be inspected by an ABB Turbocharging Service Station and repacked.

u Inspect the package for damage. If the package is damaged, the turbocharger must be in-

spected by an ABB Turbocharging Service Station and repacked.

After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station:

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¡ Inspect the components

¡ Replace the desiccant agent

¡ Repackage the components.

If the 70% display field of the hygrometer(02) has not changed colour and the package is undamaged, the turbocharger can be placed into operation without any prior testing by an ABB Turbocharging Service Station.

Unpacking 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.

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Operation Manual / 1 Introduction

1 Introduction / 1.4 Contact information

1.4 Contact information

Contact information for the ABB Turbocharging Service Stations is available online.

u Scan the QR code to access our website.

ABB Switzerland Ltd, Turbocharging Bruggerstrasse 71a CH-5401 Baden Switzerland

www.abb.com/turbocharging

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Page 10

Page 11

Operation Manual / 2 Safety / A130 - A155

Table of contents

Safety

1 Safety ...................................................................................................................... 2

1.1 Introduction .................................................................................................................... 2

1.2 CE conformity................................................................................................................. 2

1.3 Definition of mandatory signs .................................................................................... 3

1.4 Definition of safety instructions ................................................................................ 3

1.5 Intended use .................................................................................................................. 4

1.6 Deflagration on gas engines ....................................................................................... 5

1.7 Warning plates on the turbocharger......................................................................... 6

1.8 Turbocharger rating plate............................................................................................ 7

1.9 Periodic check of the pressure vessels..................................................................... 8

1.10 Lifting of loads .............................................................................................................. 9

1.11 Prerequisites for operation and maintenance....................................................... 10

1.12 Hazards during operation and maintenance ......................................................... 11

1.13 Safe operation.............................................................................................................. 13

1.14 Safe maintenance ........................................................................................................ 15

Page 12

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.1 Introduction

1 Safety

1.1 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 in-

spection work.

The operating company is responsible for defining measures that regulate safe access to and safe handling of the turbocharger.

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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 manual (Definition of safety instructions →3) must also be observed.

1.2 CE conformity

Information

ABB turbochargers comply with the Machinery Directive 2006/42/EC and are partly completed machinery as defined by Article 2 g in this directive.

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Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.3 Definition of mandatory signs

1.3 Definition of mandatory signs

To be worn at all times

Protective clothing Safety footwear to protect

against mechanical hazard and risk of falling

Table1: Personal protective equipment to be worn at all times

To be worn specific to the respective task

Safety glasses Safety goggles

Safety gloves to protect

against

- Mechanical hazard

- Chemical hazard

- Thermal hazard

Safety helmet Ear protection

Table2: Personal protective equipment to be worn specific to the respective task

Respiratory mask to protect against

- Dusts

- Gases

1.4 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.

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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.

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Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.5 Intended use

1.5 Intended use

Use on internal combustion engines in general

ABB turbochargers are intended for turbocharging 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.

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The turbocharger is solely intended to be operated with a clockwise direction of rotation as viewed from the turbine end.

The specific operating limits of the turbocharger were determined on the basis of information from the enginebuilder about the 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

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

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Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.6 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.

ABB excludes any liability for damage resulting from unauthorized modifications to the turbocharger or improper operation.

1.6 Deflagration on gas engines

ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12bar.

After a deflagration event ABB Turbo Systems 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. An ABB Turbocharging Service Station should be instructed to carry out this inspection.

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Page 16

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.7 Warning plates on the turbocharger

1.7 Warning plates on the turbocharger

Warning plates are attached to the turbocharger, which must be observed. The warning plates must always be present in the intended locations and must be legible.

Fig.1: Warning plate

If warning plates are not present in the intended locations or are not legible, they must be replaced with new warning plates. The necessary information can be found in the Operation Manual, Chapter 4 Product description.

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Turbochargers supplied to the enginebuilder without insulation must be equipped later with warning plates on the insulation. This is the responsibility of the enginebuilder.

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Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.8 Turbocharger rating plate

1.8 Turbocharger rating plate

Fig.2: Rating plate

Operating limits

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 Customer part number 07 Designation for special design 08 Weight of turbocharger in kg 09 Turbocharger type 10 Serial number 11 Year of construction of turbocharger 12 Manufacturing plant

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Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.9 Periodic check of the pressure vessels

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.

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Operation above the indicated values n

Bmax

, t

can considerably shorten the recommended

Bmax

replacement intervals. In such a case, we recommend that you contact the nearest official service station of ABB Turbo Systems.

, t

Mmax

normally apply only when running at overload (110%) during trials on the engine

Mmax

test bed. These limit values can also be permitted during operation for special applications. Operation above n

Mmax

and t

is not permitted.

Mmax

Non-observance of the recommended inspection and replacement intervals increases the risk of unpredictable component failures.

Locations of the rating plates

The locations of the rating plates are defined in the Operation Manual, Chapter 4 Product description.

1.9 Periodic check of the pressure vessels

The pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, are so-called "simple pressure vessels".

¡ The locally applicable legal regulations regarding periodic checks of the pressure vessels

must be observed.

¡ The operating company is responsible for the safe operation of the pressure vessel.

WARNING

Danger due to pressure vessels

The operating company must make sure the pressure vessels are in proper working condition and monitor them. Necessary repair or maintenance work must be performed promptly, and the required safety measures must be taken.

u Pressure equipment must not be operated if defects are present.

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Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.10 Lifting of loads

1.10 Lifting of loads

WARNING

Suspended loads

Loads that are not attached according to regulations can cause injury to personnel or fatal accidents.

u Loads must always be fastened to properly functional lifting gear with a

sufficient load limit.

u Pay attention to the correct attachment of loads on the crane hook. u People must not stand beneath suspended loads.

Wear safety gloves to protect against mechanical hazards.

Wear safety helmet.

Fig.3: Attachment of loads on the crane hook

Fig.4: 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 (max-

imum 80°C).

u Attach components of the turbocharger as described in the respective action steps. u Use a suitable edge guard if there are sharp edges. u The assembly devices must be completely screwed in and must not unscrew during use.

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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.

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Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.11 Prerequisites for operation and maintenance

1.11 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.

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Only authorised personnel may remain in the vicinity of the turbocharger when the engine is running.

Competence of personnel

The turbocharger must only be operated and serviced by trained and authorised personnel. Basic mechanical training is a prerequisite.

Modifications to the turbocharger

Modifications to the turbocharger must be approved by ABB 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 ABB Turbo Systems.

Original parts and accessories are specially designed by ABB Turbo Systems for the ABB turbochargers.

ABB accepts no liability for any damage resulting from the use of non-original parts and corresponding accessories.

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Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.12 Hazards during operation and maintenance

1.12 Hazards during operation and maintenance

Noise hazards

The turbocharger's noise emission during operation is influenced by its installation and operating conditions. A noise level exceeding 85 dB(A) is harmful.

WARNING

Danger due to noise

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.

Hazards due to hot surfaces

Surfaces of the turbocharger, attached parts and operating fluids (lubricating oil) get hot during operation. The surface temperature depends on the efficacy of the existing 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 turbochar-

ger.

u Wear heat-resistant safety gloves and protective clothing. u Wait for the turbocharger to cool down before carrying out any work.

Wear safety gloves to protect against thermal hazards.

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Page 22

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.12 Hazards during operation and maintenance

WARNING

Hot surfaces on the 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 en-

ginebuilder to protect against hot turbocharger surfaces is compulsory.

Wear safety gloves to protect against thermal hazards.

Hazards due to rotating parts

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WARNING

Physical hazards

Contact with rotating parts can cause severe injury. The turbocharger must never be used without the filter silencer or the air suction branch. 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.

Hazards due to electrical installations (if present)

WARNING

Dangers during work on electrical installations

Electrical installations use voltages that can lead to severe injury to personnel or accidents resulting in fatalities.

At the same time, electrical or electronic components and parts can also be damaged or destroyed.

u Only specially trained personnel should perform work on, or with, elec-

trical components.

u Observe national regulations.

Page 23

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.13 Safe operation

WARNING

Absence of grounding on electrical installations

Missing or incorrectly fitted grounding conductors can lead to severe injury to personnel or accidents resulting in fatalities.

Electric shock or elevated electromagnetic disturbances can damage or destroy electrical and electronic components.

u Ground electrical installations properly with grounding conductors. u Check the grounding connections on a regular basis and make sure they

are properly connected.

u Switch off the power supply before working on any electrical installations. u After switching off the power supply, wait for 5 minutes to allow capacitors to discharge

and hot components to cool down.

u Ensure the power supply is switched off when working on electrical installations. u Do not carry out any tests with regard to insulation resistance or voltage on the electrical

components.

1.13 Safe operation

Mechanical hazards during operation

During standard operation, no mechanical hazards are caused by the turbocharger itself if it has been properly installed.

Safety during commissioning and operation

u Visually inspect your working environment before starting work. u Remove any obstacles and objects littering the workplace. u Check all pipes to and from the turbocharger for damage and leaks before commission-

ing.

u Check turbocharger for recognisable damage or defects every 12 hours of operation or at

least once a day.

u Report any damage and any alterations of operational characteristics to the responsible

department immediately.

u In case of damage, take the turbocharger out of operation immediately and safeguard

against accidental/unauthorised use.

u When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay at-

tention to the risks that may occur as a consequence of this energy input.

Page 13 / 18

Page 24

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.13 Safe operation

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.5

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Variant A Insulation(01) with integrated burst protection from ABB Turbo Systems. Variant B Burst protection(03) and insulation (02)from ABB Turbo Systems. Variant C Burst protection(03) from ABB Turbo Systems with appropriate insulation

from the enginebuilder.

Page 25

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.14 Safe maintenance

1.14 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 pro-

tective clothing to protect against mechanical hazards.

u Keep personal protective equipment in perfect condition. u Obey mandatory signs. u Observe the general rules for occupational safety and prevention of acci-

dents.

u Only perform operations that are described in this manual. u Only perform operations for which you have received instruction or train-

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 Comply with the general accident prevention regulations. 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.

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u Keep the floor, equipment, and turbocharger clean. u Have oil binding agents ready and provide or keep oil pans at hand. u Clean up any spills. u Have fire protection means and extinguishing agents available.

Page 26

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.14 Safe maintenance

Welding work in the vicinity of the turbocharger

u When performing welding work in the vicinity of the turbocharger, always cover the filter

silencer to prevent the filter mat from being damaged.

u Keep flammable objects and substances out of the vicinity of flying sparks. u Cover all connections on the turbocharger so that no foreign objects can enter the tur-

bocharger.

u Wear personal protective equipment (PPE) for welding operations.

Safety during cleaning

If cleaning agents or solvents are used for cleaning, the corresponding material safety data sheet and the safety instructions in section Hazards due to operating materials and supplies must be observed.

u Observe the material safety data sheet for the cleaning agent or solvent. u Wear personal protective equipment (PPE) according to the material safety data sheet.

Page 16 / 18

u Inspect the electric cables for abrasion and damage before and after your cleaning work.

Safety during disassembly, assembly, maintenance and repair

u Observe the procedures for set-up, service and inspection work and the inspection inter-

vals.

u Inform the operating staff before starting any service or repair work. Make sure the en-

gine is not started while work is being conducted on the turbocharger.

u Before taking off any cover or removing any guard from the turbocharger, switch off the

engine and wait until the turbocharger has come to a standstill.

u Make sure that the oil supply is interrupted, especially with an external oil supply. u Only restart the engine after all parts have been properly fitted again and oil supply is en-

sured.

CAUTION

Mechanical operations on the turbocharger

Components of the turbocharger can be damaged or destroyed as a result of improper procedures.

u Only perform operations that are described in this manual. u Only perform operations for which you have received instruction or train-

ing.

Safety when taking out of operation or preparing for mothballing

u Secure rotor against turning. The rotor can rotate due to the stack draught alone. 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.

Page 27

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.14 Safe maintenance

Mechanical hazards when working on the turbocharger

WARNING

Physical hazards due to rotating parts

The rotor can rotate due to the stack draught alone. Contact with rotating parts can cause severe injury.

u Secure rotor against turning.

WARNING

Mechanical hazards

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 acci-

dents.

u Ensure workplace safety. u Only perform operations that are described in this chapter. u Only perform operations for which you have previously received instruc-

tion or training.

Hazards due to operating materials and supplies

Operating materials and supplies are substances required for the operation of the 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 operat-

ing materials and supplies.

u Wear personal protective equipment (PPE) according to the material

safety data sheet.

u Comply with local legislation.

Wear safety goggles.

Wear safety gloves to protect against chemical hazards.

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Wear a respiratory mask to protect against gases.

Page 28

Operation Manual / 2 Safety / A130 - A155

1 Safety / 1.14 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 operat-

ing materials and supplies.

u Comply with local legislation. u Do not allow any exposed flame or ignition source during cleaning work. u Carry out cleaning in the open or provide sufficient ventilation.

CAUTION

Environmental hazard

Improper handling of operating materials and supplies can lead to environmental damage.

u Observe the information in the material safety data sheet for the operat-

ing materials and supplies.

u Comply with local legislation.

Page 18 / 18

Hazards due to the handling of insulation materials

WARNING

Danger from insulation materials

Dust or fibres from insulation materials can have adverse effects on the health or cause irritations. Unsuitable and combustible insulation materials are a fire hazard.

u Only use suitable and non-combustible insulation materials. u Ensure good ventilation at the workplace. u Avoid whirling up dust. u Use dust-free tools and working methods. u Remove package at the workplace only. u Proceed with particular care when removing old insulation materials. u Dispose of insulation materials properly and in an environmentally com-

patible manner in compliance with the legal regulations.

Wear safety goggles.

Wear a respiratory mask to protect against dusts.

Wear safety gloves to protect against chemical hazards.

Page 29

Operation Manual / A135-H66 / Safety data sheet

Safety data sheet

A135-H66 HT594610

Page 1 / 1

864 680 844 650

X00067234

2020

270 16 50 50

Page 30

Page 31

Operation Manual / 4 Product description / A130-H.. - A140-H

Table of contents

Product description

1 Introduction............................................................................................................ 3

1.1 Essential information.................................................................................................... 3

1.2 Registered trademarks................................................................................................. 3

1.3 Related documents........................................................................................................ 3

1.4 Layout and function of the turbocharger ................................................................ 4

1.5 Warning plates on the turbocharger......................................................................... 6

1.6 Locations of the rating plates..................................................................................... 7

2 Removing and Installing........................................................................................ 8

2.1 Weight and transportation of the turbocharger.................................................... 8

2.2 Removing the turbocharger........................................................................................ 9

2.3 Installing the turbocharger........................................................................................ 13

3 Commissioning .................................................................................................... 20

3.1 Oil supply ...................................................................................................................... 20

3.2 Inspection procedures................................................................................................ 22

3.3 Commissioning after taking out of operation...................................................... 24

4 Monitoring operation .......................................................................................... 25

4.1 Oil pressure, oil temperature.................................................................................... 25

4.2 Exhaust gas temperature before turbine ............................................................... 27

4.3 Turbocharger speed................................................................................................... 28

5 Operation and service ......................................................................................... 31

5.1 Noise emission ............................................................................................................. 31

5.2 Service work ................................................................................................................. 33

5.3 Expected replacement intervals ............................................................................... 37

5.4 Stopping the engine................................................................................................... 39

6 Periodic maintenance work ................................................................................ 40

6.1 Foreword to maintenance......................................................................................... 40

6.2 Cleaning components mechanically ........................................................................ 41

7 Eliminating malfunctions.................................................................................... 51

7.1 Malfunctions when starting....................................................................................... 51

7.2 Malfunctions during operation ................................................................................ 52

7.3 Turbocharger is surging ............................................................................................ 55

7.4 Malfunctions when stopping.................................................................................... 56

7.5 Speed measurement system ..................................................................................... 57

8 Dismantling and fitting....................................................................................... 58

8.1 Introduction ................................................................................................................. 58

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Operation Manual / 4 Product description / A130-H.. - A140-H

Table of contents

8.2 Weights of individual parts....................................................................................... 60

8.3 Removing the air inlets .............................................................................................. 62

8.4 Removing the gas outlet casing .............................................................................. 63

8.5 Removing the gas outlet flange............................................................................... 63

8.6 Removing the compressor casing........................................................................... 66

8.7 Pressing off the casing .............................................................................................. 68

8.8 Removing the cartridge group................................................................................. 69

8.9 Removing the nozzle ring........................................................................................... 71

8.10 Installing the cartridge group on the service support ......................................... 72

8.11 Measuring clearance A and B..................................................................................... 73

8.12 Nozzle ring compression PD..................................................................................... 74

8.13 Installing the nozzle ring ............................................................................................ 75

8.14 Installing the cartridge group .................................................................................. 76

8.15 Installing the compressor casing ............................................................................ 78

8.16 Measuring radial clearances N and R ...................................................................... 80

8.17 Installing the air inlets ................................................................................................ 81

8.18 Installing the gas outlet flange ................................................................................ 82

8.19 Installing the gas outlet casing ................................................................................ 82

8.20 Table of tightening torques...................................................................................... 83

9 Taking out of operation at short notice ........................................................... 84

9.1 Possible emergency repairs...................................................................................... 84

9.2 Installing the replacement turbocharger............................................................... 85

9.3 Installing the replacement cartridge group .......................................................... 85

10 Mothballing the turbocharger ............................................................................ 86

10.1 Taking the engine out of operation for up to 12months ................................... 86

10.2 Taking the engine out of operation for more than 12months.......................... 87

11 Disposing of turbocharger components .......................................................... 88

12 Spare parts ........................................................................................................... 89

12.1 Ordering spare parts.................................................................................................. 89

12.2 Required customer spare part set (97070)............................................................ 89

12.3 View of turbocharger with part numbers .............................................................. 90

Figures................................................................................................................... 92

Tables .................................................................................................................... 93

Page 33

Operation Manual / 4 Product description / A130-H.. - A140-H

1 Introduction / 1.1 Essential information

1 Introduction

1.1 Essential information

Design variants

This document is valid for different design variants of turbochargers. There may be sections and descriptions of components that are not relevant for a specific turbocharger variant.

Please contact an ABB Turbocharging Service Station if you have any questions regarding a design variant (see Contact information at www.abb.com/turbocharging).

Accuracy of illustrations

The illustrations in this document are general in nature and intended for ease of understanding. Differences in detail are therefore possible.

1.2 Registered trademarks

The trademarks of outside companies are used in this document. These are marked with the ® symbol.

1.3 Related documents

Chapter Document number

Operation Manual / 1 Introduction HZTL4005 Operation Manual / 2 Safety HZTL4022 Operation Manual / 3 Safety data sheet *) Serial number of the turbocharger

Table1: Related documents

*) This chapter is only available in serialised operation manuals.

Page 3 / 93

Page 34

Operation Manual / 4 Product description / A130-H.. - A140-H

1 Introduction / 1.4 Layout and function of the turbocharger

1.4 Layout and function of the turbocharger

Page 4 / 93

Fig.1: Layout and function of the turbocharger

01 Air suction branch 08 Gas outlet flange 02 Compressor casing 09 Nozzle ring 03 Diffuser 10 Turbine casing 04 Bearing casing 11 Turbine-end bearing flange 05 Axial thrust bearing 12 Compressor-end bearing flange 06 Radial plain bearing 13 Compressor wheel 07 Turbine

Page 35

Operation Manual / 4 Product description / A130-H.. - A140-H

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.

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 in fresh air through the air suction branch (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 rotor runs in two radial plain bearings(06) which are located in the bearing casing(04) between compressor and turbine. The axial thrust bearing(05) is located between the two radial plain bearings.

The plain bearings are connected to a central lubricating oil duct which is normally supplied by the lubricating oil circuit of the engine. The oil outlet always lies at the deepest point of the bearing casing(04).

1.4.1 Function of the compressor wheel cooling

Fig.2: 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).

Page 5 / 93

In addition, the turbocharger version with compressor wheel cooling is indicated by the turbocharger type (H6..) on the rating plate.

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Operation Manual / 4 Product description / A130-H.. - A140-H

1 Introduction / 1.5 Warning plates on the turbocharger

1.5 Warning plates on the turbocharger

Warning plates are affixed at the following locations:

Page 6 / 93

Fig.3: 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 ABB Turbocharging Service Stations.

u Remove any warning plates that have become unreadable.

u Clean and degrease the areas designated for the warning plates.

u Fit new warning plates and remove protective sheets.

Turbochargers supplied to the enginebuilder without insulation must be equipped later with warning plates on the insulation. This is the responsibility of the enginebuilder.

Page 37

Operation Manual / 4 Product description / A130-H.. - A140-H

1 Introduction / 1.6 Locations of the rating plates

1.6 Locations of the rating plates

Fig.4: Locations of the rating plates

One rating plate (01) each is attached on the left and the right side of the turbocharger bearing casing.

Page 7 / 93

Page 38

Operation Manual / 4 Product description / A130-H.. - A140-H

2 Removing and Installing / 2.1 Weight and transportation of the turbocharger

2 Removing and Installing

2.1 Weight and transportation of the turbocharger

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.

Page 8 / 93

Fig.5: Transportation of the turbocharger

Product Weight of complete turbocharger unit [kg]

A130-H 190 A135-H 270 A140-H 460

Table2: Weight of complete turbocharger unit

Page 39

Operation Manual / 4 Product description / A130-H.. - A140-H

2 Removing and Installing / 2.2 Removing the turbocharger

2.2 Removing the turbocharger

u Disconnect all pipes according to the instructions of the enginebuilder.

u If present: Loosen and remove the compressor wheel cooling connection.

Seal the compressor wheel cooling connection (01).

Fig.6: Removing the turbocharger

A Position of expansion sleeves B Clamping nut C Standard nut

u Apply penetrating oil to thread of stud (02) and nut and let it work in.

Do not apply penetrating oil to the pressure screws of the clamping nut(B).

u If present: Disconnect the plug to the speed sensor (86505) and secure the rolled-up

cable on the turbocharger. This protects the plug from being crushed.

u If present: Detach the support(61301) from the engine support.

Depending on the bracket version(04), positioning pins(05) can be used for positioning and safeguarding against wrong fitting of the turbocharger. Therefore the turbocharger must always be removed from and installed on the bracket vertically.

The gas outlet casing(61001) can remain fitted in the exhaust gas pipe if the locking nuts are accessible. Otherwise the complete turbocharger unit including gas outlet casing must be removed.

Page 9 / 93

Page 40

Operation Manual / 4 Product description / A130-H.. - A140-H

2 Removing and Installing / 2.2 Removing the turbocharger

2.2.1 Fastening of the turbocharger

WARNING

Risk of scalding from hot water

If the water connections are removed immediately after taking the turbocharger out of operation, the hot cooling water that flows out can cause scalding if it comes into contact with the skin.

u Allow turbocharger to cool down before removing the water pipes.

u Wear safety gloves to protect against thermal hazards.

Wear safety gloves to protect against mechanical hazards.

CAUTION

Freezing of the cooling water in the bearing casing

Serious damage to property can be the consequence if the cooling water freezes in the pipes and in the bearing casing.

u For transport and storage of the turbocharger, drain the cooling water in

the bearing casing via two openings of the water connections.

Page 10 / 93

Manual loosening

To remove the turbocharger from the bracket, proceed as follows:

u Loosen and remove water connections. Close the openings of the water connections with

screw plugs.

u Attach lifting gear to the suspension eye.

u Loosen and remove nuts(C).

Hydraulic loosening (round special nut)

If the turbocharger was fitted by the enginebuilder using a hydraulic tool, disassembly is also done using a hydraulic tool (see instructions of the enginebuilder).

When doing this, proceed as follows:

u Attach lifting gear to the suspension eye.

u Remove the turbocharger.

u Cover the oil connections (03) at the engine side to protect against contamination.

Page 41

Operation Manual / 4 Product description / A130-H.. - A140-H

2 Removing and Installing / 2.2 Removing the turbocharger

2.2.2 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.

If a screw jams, the previously loosened screw must be tightened again a little.

Fig.7: 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.

Page 11 / 93

Page 42

Operation Manual / 4 Product description / A130-H.. - A140-H

2 Removing and Installing / 2.2 Removing the turbocharger

2.2.3 Putting down the turbocharger

WARNING

Risk of tipping

If the turbocharger is not positioned stably, it may tip over. This can result in serious personal injury.

u Place the turbocharger on a clean, level support.

u Secure the turbocharger to prevent it from tipping over by using wooden

beams and wedges and by taking the centre of gravity into account.

Page 12 / 93

Fig.8: Putting down the turbocharger

u Remove turbocharger from engine support, set it down properly in an appropriate place

and secure it.

u Close or cover the openings of the turbocharger and support.

Page 43

Operation Manual / 4 Product description / A130-H.. - A140-H

2 Removing and Installing / 2.3 Installing the turbocharger

2.3 Installing the turbocharger

2.3.1 Inserting gaskets into the bracket

CAUTION

Inserting the gaskets

Gaskets that are forgotten, damaged or improperly inserted will lead to oil leaks.

u Always use new gaskets and insert them carefully into the slot.

The oil is supplied(02) and drained(03) through the bracket (01).

The necessary sealing is provided by O-rings. The O-rings are not included in the ABB Turbo Systems scope of delivery.

Fig.9: Inserting gaskets into the bracket

01 Bracket 04 Slot for O-ring 02 Oil supply 05 O-rings 03 Oil drain 06 Pin (optional)

Pin(06) as installation safety device

Turbochargers can have an oil inlet either on their right or left side; the oil inlet position can be different for the turbocharger fitted on the left and on the right engine bank.

A pin can be installed in every support as an installation safety device to prevent inadvertent incorrect fitting. This pin fits into the respective slot on the foot of the bearing casing. Instructions of the enginebuilder must be observed.

Page 13 / 93

Page 44

Operation Manual / 4 Product description / A130-H.. - A140-H

2 Removing and Installing / 2.3 Installing the turbocharger

2.3.2 Fitting threaded rods

Fig.10: 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 14 / 93

Requirements for the threaded rods

Fig.11: Requirements for threaded rods

Product Diameter

Threaded rod

[mm]

A130-H Ø 16 / M16 10.9 / 12.9 ≥ 30 250 A135-H Ø 20 / M20 10.9 / 12.9 ≥ 30 325 A140-H Ø 24 / M24 10.9 / 12.9 ≥ 70 410 … 420

Table3: Requirements for threaded rods

Material

DIN / ISO 898

(Part 1)

Thread length

L1[mm]

Length of

threaded rod

L2 [mm]

Fastening material, scope of delivery

The threaded rods and nuts for fastening the turbocharger on the bracket are not included in the ABB Turbo Systems scope of delivery.

The clamping nuts are included in the ABB Turbo Systems scope of delivery.

Page 45

Operation Manual / 4 Product description / A130-H.. - A140-H

2 Removing and Installing / 2.3 Installing the turbocharger

2.3.3 Placing the turbocharger on the bracket

Fig.12: Placing the turbocharger on the bracket

B Clamping nut C Standard nut

u Make sure that covers of the oil and water connections are removed.

1. Make sure that the O-rings(03) are undamaged and positioned correctly in the slots.

2. Clean the expansion bushes(42190) and the contact surfaces of the expansion bushes in the bearing casing.

3. Attach the lifting gear to the suspension eye of the bearing casing(42001) and loop around the gas outlet casing.

4. Position the turbocharger on the bracket(04) and align it. If present, pay attention to the positioning pin(05) in the bracket.

5. When fixing with a standard nut (C), fit the expansion bushes in the correct position in the slot.

Safeguard against wrong fitting (only for water-cooled bearing casings)

Depending on the bracket version(04), two positioning pins(05) can be used for positioning and safeguarding against wrong fitting of the turbocharger. Therefore the turbocharger must always be removed from and installed on the bracket vertically.

u Observe the instructions for the fastening variant at hand.

Page 15 / 93

¡ Fastening the turbocharger with a standard nut →16 (A130-A140)

¡ Fastening the turbocharger with a clamping nut →17 (only A140)

Page 46

Operation Manual / 4 Product description / A130-H.. - A140-H

2 Removing and Installing / 2.3 Installing the turbocharger

2.3.4 Fastening the turbocharger with a standard nut

u Fit the nuts and tighten them according to variant 1 or 2 in the table below.

Page 16 / 93

Product Through hole in

bearing casing

[mm]

A130 Ø17 M16 280 110 A135 Ø 21 M20 560 175 A140 Ø 25 M24 960 250

Table4: Tightening torque for standard nuts

Fixing screws

[mm]

Variant 1: Tightening

torques [Nm] **)

Variant 2: Hy-

draulic pre-ten-

sioning forces [kN]

**) When the turbocharger is mounted on the engine support, the bolt threads and screw heads must be lightly oiled (assumed friction coefficient µ = 0.12 for tightening torque)

u Remove the lifting gear.

Page 47

Operation Manual / 4 Product description / A130-H.. - A140-H

2 Removing and Installing / 2.3 Installing the turbocharger

2.3.5 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).

u Make sure the pressure screws do not protrude in the direction of the thrust washer.

Fig.13: 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.

Page 17 / 93

5. Tighten clamping nut (03) by hand.

6. Unscrew clamping nut (03) by ¼ of a turn (90°).

The distance between the thrust washer and the clamping nut is now about 1 mm.

Page 48

Operation Manual / 4 Product description / A130-H.. - A140-H

2 Removing and Installing / 2.3 Installing the turbocharger

Tightening pressure screws

Page 18 / 93

Fig.14: Tightening pressure screws

Product Fixing screw [mm] Tightening torques [Nm]

A140 M24 35

Table5: Torque-controlled tightening of the pressure screws

1. Screw in pressure screws crosswise by hand until reaching the stop.

2. Tighten pressure screws crosswise to 50% of the tightening torque specified in the table.

3. Tighten pressure screws crosswise to 100% of the tightening torque specified in the table.

4. Work in a circle to tighten all pressure screws to 100% of the tightening torque specified in the table.

5. Tighten pressure screws to 100% in 5…7 rounds until the required residual tightening angle of <20° is achieved.

Page 49

Operation Manual / 4 Product description / A130-H.. - A140-H

2 Removing and Installing / 2.3 Installing the turbocharger

2.3.6 Connecting the turbocharger

u Connect the cable to the speed sensor (86515).

u Connect all exhaust gas, water and air lines according to the instructions of the engineb-

uilder.

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 opera-

tion.

Fig.15: 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.

2.3.7 Attaching the support

Fig.16: Attaching the support

Page 19 / 93

u If present: Attach support (61301) to engine support or to a connecting piece.

Page 50

Operation Manual / 4 Product description / A130-H.. - A140-H

3 Commissioning / 3.1 Oil supply

3 Commissioning

3.1 Oil supply

3.1.1 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.

3.1.2 Oil filtering

Page 20 / 93

Filtering the lubricating oil with a filter mesh width of ≤0.034mm is sufficient for this turbocharger.

3.1.3 Oil pressure

Comply precisely with the oil pressure before the turbocharger for trouble-free operation. Different oil pressures must be taken into account here for different operating states, such as, for example, idling mode and when the engine is started.

The admissible values are specified in chapter Monitoring operation →25.

3.1.4 Starting the engine for the first time after a

turbocharger or engine overhaul

When starting the engine for the first time after a turbocharger or engine overhaul, proceed as follows:

u Switch on the pre-lubrication pump.

u Build up oil pressure (see Table6: Lubricating oil pressure at oil inlet before turbocharger

→25).

u Do not exceed a pre-lubrication time of 2minutes.

u Start the engine.

u Let the pre-lubrication pump run until the pump driven by the engine generates sufficient

pressure.

Page 51

Operation Manual / 4 Product description / A130-H.. - A140-H

3 Commissioning / 3.1 Oil supply

3.1.5 Oil orifice in the bearing casing

Fig.17: Oil orifice

01 Bearing casing 02 Oil orifice 03 Circlip

With an oil inlet pressure of more than 3 bar of overpressure (with engine under load) upstream of the turbocharger, an oil orifice must be installed to reduce the oil pressure.

Page 21 / 93

Page 52

Operation Manual / 4 Product description / A130-H.. - A140-H

3 Commissioning / 3.2 Inspection procedures

3.2 Inspection procedures

3.2.1 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.

3.2.2 Checks before commissioning

Filter mat (if available)

u Check for damage and contamination.

Lubricating system

Page 22 / 93

CAUTION

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 ser-

vice work on the lubricating system.

u Check that the oil filter is clean before commissioning.

u Check the oil pressure in the oil supply pipes.

Warning plates

u Check whether warning plates are present and legible.

u Check whether the protective sheets have been removed from new warning plates.

Version with compressor wheel cooling

CAUTION

Failure of compressor wheel cooling

Any prolonged failure of the compressor wheel cooling will shorten the replacement interval of the compressor wheel.

u Make sure there is an uninterrupted supply of cooling air during opera-

tion.

u Check whether the compressor wheel cooling is fitted on the bearing casing.

Page 53

Operation Manual / 4 Product description / A130-H.. - A140-H

3 Commissioning / 3.2 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 dur-

ing operation.

u Check whether water pipes are fitted on the bearing casing.

3.2.3 Checks after commissioning (engine in idle mode)

Lubricating system

u Keep to the lubricating oil pressure at the inlet.

u Keep to the lubricating oil temperature at the inlet.

u Refer to chapter Monitoring operation →25 for admissible values.

Leaktightness of pipes

WARNING

Risk of burning from hot gas

Escaping gases are hot and will lead to serious burns in the event of contact.

u Check all pipes for leaks in accordance with the enginebuilder’s instruc-

tions.

Wear safety gloves to protect against thermal hazards.

3.2.4 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.

Page 23 / 93

u Measure the air temperature before and after the compressor.

u Compare the measured values with the values of the acceptance report. Different operat-

ing conditions indicate a malfunction (see chapter Eliminating malfunctions →51).

Lubricants and pastes used during assembly can liquefy or vaporise and escape as oily fluids during the initial hours of operation. Continual escape of an oily fluid indicates an oil leak. If there is a leak, contact an ABB Turbocharging Service Station.

Page 54

Operation Manual / 4 Product description / A130-H.. - A140-H

3 Commissioning / 3.3 Commissioning after taking out of operation

3.3 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 Remove the screw plugs on the water connections and fit the water pipe.

Version with compressor wheel cooling:

u Remove the screw plug on the cooling air connection and fit the cooling air line.

General

u Check the exhaust gas pipe before and after the turbine for combustion residues or wa-

ter residues and clean it. Remove any foreign objects that may be present.

Page 24 / 93

u Check and clean filter silencer or air supply line, and remove any foreign objects that may

be present.

u Put engine-side oil circulation to the turbocharger into operation.

u Prepare the turbocharger for operation (see Checks before commissioning →22).

u The turbocharger is now ready for operation.

Page 55

Operation Manual / 4 Product description / A130-H.. - A140-H

4 Monitoring operation / 4.1 Oil pressure, oil temperature

4 Monitoring operation

4.1 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

necessary pressure assured at the oil inlet.

Status for operation Pressure at oil inlet upstream of

the turbocharger

[bar] Overpressure

Normal operation 2.0< p Engine start: Cold oil, admissible for a maximum of 15

minutes Engine idling, admissible for a maximum of 1 hour 0.5< p Pre-lubrication and post-lubrication (engine stopped) 0.5< p Warning signal: (n ≥ 0.5 x n Alarm signal: Not admissible. Stop the engine immedi-

ately.

Table6: Lubricating oil pressure at oil inlet before turbocharger

) <1.25

Bmax

01 Turbocharger contact surface 02 Oil inlet 03 Oil outlet P Oil pressure measuring point T Oil temperature measuring point

oil

<8.0

oil

<0.5

≤ 4.5

≤ 2.5 ≤ 1.0

For monitoring the lubricating oil pressure, ABB 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.

Page 25 / 93

*) If the drain pipe is vented, the lubricating oil temperature measuring point can be installed at the outlet in the vent tank. Otherwise the measurement should be taken in the drain pipe as close to the turbocharger as possible.

Page 56

Operation Manual / 4 Product description / A130-H.. - A140-H

4 Monitoring operation / 4.1 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 Oil temperature at the inlet

oil,inlet

Admissible 30…105°C Temporarily admissible (< 1 h) → alarm >105°C Not admissible → stop engine >110°C Not admissible → do not start engine (before start: preheat

oil)

Table7: Lubricating oil temperature at the inlet

<30°C

Page 26 / 93

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

oil,outlet

Admissible ≤160°C Temporarily admissible (<0.5h) → alarm >160°C Not admissible → stop engine >180°C Admissible ≤ T Temporarily admissible → alarm > T

Table8: Lubricating oil temperature at the outlet

oil,inlet

+ 55K + 55K

If the turbocharger was operated for a longer period of time outside of the admissible range, ABB Turbo Systems recommends to have the turbocharger inspected by an ABB Turbocharging Service Station.

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Operation Manual / 4 Product description / A130-H.. - A140-H

4 Monitoring operation / 4.2 Exhaust gas temperature before turbine

4.2 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 Definition and explanations concerning rating plate: refer to chapter 2 of Operation

Manual / Safety.

u Operating limits: refer to chapter 3 of Operation Manual / Safety data sheet or examine

rating plate.

Page 27 / 93

Page 58

Operation Manual / 4 Product description / A130-H.. - A140-H

4 Monitoring operation / 4.3 Turbocharger speed

4.3 Turbocharger speed

4.3.1 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.

4.3.2 Layout and overview

Page 28 / 93

Fig.18: Layout and overview of speed measurement system

86505 Speed sensor 42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F/I converter 01 Plug with integrated voltage limiter 86528 Tachometer *) Installation variant for speed sensor 32109 Sealing disc with cams

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Operation Manual / 4 Product description / A130-H.. - A140-H

4 Monitoring operation / 4.3 Turbocharger speed

4.3.3 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 n

If this permissible range of difference is exceeded, the following steps must be carried out:

u Reduce the engine performance immediately to the point at which the maximum tur-

bocharger speed does not exceed 70 % of n

u If the engine cannot be stopped, it can continue to be driven at this reduced engine load

or turbocharger speed.

u If a turbocharger surges continuously, the engine performance must be reduced further.

u Measure the temperatures in the air lines and gas piping from and to the turbochargers

and compare with normal values. If clear deviations of temperature are found, the nearest ABB Turbocharging Service Station has to be contacted.

Bmax

u Check the pressure loss of the alternative air inlet and compare it with normal values.

If the engine can be stopped temporarily:

u Inspect air lines, gas piping and the turbochargers and remedy any malfunctions.

u In any case, contacting the nearest ABB Turbocharging Service Station is recommended.

4.3.4 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 →57.

Page 29 / 93

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Operation Manual / 4 Product description / A130-H.. - A140-H

4 Monitoring operation / 4.3 Turbocharger speed

4.3.5 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.

The speed sensor supplied by ABB is equipped with a sealing lip and an O-ring. No additional gasket is required during assembly.

Page 30 / 93

Fig.19: Replacing the speed sensor

Product Part number Tightening torque

A130 86505 M12 x 1.5

15Nm

A135 86505 M12 x 1.5

15Nm

A140 86505 M12 x 1.5

15Nm

Table9: Tightening torque(86505)

u Reduce the engine performance to idling and then stop the engine. Pay attention to post-

lubrication (Stopping the engine →39).

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.

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Operation Manual / 4 Product description / A130-H.. - A140-H

5 Operation and service / 5.1 Noise emission

5 Operation and service

5.1 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 emission sound pressure level (A-weighted) is measured at a distance of 1meter from the turbocharger.

The highest value of the emission sound pressure level1) reaches a maximum of 105dB(A) near the air inlet. The following prerequisites must be fulfilled with regard to the 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.20:

Noise insulation, bellows →32).

The enginebuilder is responsible for insulating the charge air/scavenging air line and the charge air cooler.

1) Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 : A-weighted emission sound pressure level

2) The enginebuilder must provide acoustically equivalent measures in case of deviating insulation versions

Page 31 / 93

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Operation Manual / 4 Product description / A130-H.. - A140-H

5 Operation and service / 5.1 Noise emission

Suggestion for noise insulation, bellows

Page 32 / 93

Fig.20: Noise insulation, bellows

01 Compressor casing 02 Bellows 03 Charge air duct / scavenging air duct 04 Insulation cushion 05 Insulation mat (at least 15 mm) 06 Sheet metal cover

Page 63

Operation Manual / 4 Product description / A130-H.. - A140-H

5 Operation and service / 5.2 Service work

5.2 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

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.

u Agree on a specific service interval with ABB Turbo Systems.

To prevent machine damage caused by ageing and downtime, we recommend having an inspection carried out by an ABB Turbocharging Service Station no later than 5 years after the last service.

Page 33 / 93

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Operation Manual / 4 Product description / A130-H.. - A140-H

5 Operation and service / 5.2 Service work

5.2.1 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 an ABB Turbocharging Service Sta-

tion.

u Visual check for air, exhaust gas, water and oil leaks.

u Record operating data and enter in the engine logbook.

u In case of deviations, determine the cause.

5.2.2 Service work at 100 hours after commissioning

Page 34 / 93

u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en-

gine is stopped, in accordance with the instructions of the enginebuilder.

5.2.3 Service work according to instructions of enginebuilder

u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en-

gine is stopped, in accordance with the instructions of the enginebuilder.

5.2.4 Service work according to data on the rating plate

(Usually after 8000 … 12000 operating hours)

The rotor and bearing parts must be checked and assessed by an ABB Turbocharging Service Station. The following work can be carried out as preparation.

u Remove turbocharger from engine, dismantle and measure clearance (see Dismantling

and fitting, general).

u Clean nozzle ring, turbine casing, compressor casing and diffuser, and check for cracks

and erosion/corrosion.

Application with frequent engine start/stop cycles (Peak shaving)

If the turbocharger is used for the ‘Peak shaving’ mode with frequent engine start/stop cycles, the number of successful engine start/stop cycles must be taken into account in addition to the inspection interval for the bearing parts specified on the rating plate (in operating hours).

u ABB Turbo Systems recommends having the rotor and bearing parts, as well as the casing

parts on the turbine end, including the nozzle ring, checked and maintained by an ABB Turbocharging Service Station after 5000 successful engine start cycles.

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Operation Manual / 4 Product description / A130-H.. - A140-H

5 Operation and service / 5.2 Service work

5.2.5 Other service work

If a protective grid is installed in the radial or axial gas outlet casing (61001) by ABB Turbo Systems:

Fig.21: Replacing the protective grid

u Remove the protective grid (61205) after 50000 hours and replace it with a new one.

Pre-mix gas engines

CAUTION

Replace the protective grid of pre-mix gas engines after 20000 hours

Applications on pre-mix gas engines result in a high thermo-mechanical load on the protective grid. To ensure proper functionality of the protective grid even under these conditions, the protective grid of pre-mix gas engines must be replaced after 20000 hours.

u Replace the protective grid of pre-mix gas engines after 20000 hours.

Page 35 / 93

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Operation Manual / 4 Product description / A130-H.. - A140-H

5 Operation and service / 5.2 Service work

5.2.6 Entries in the engine logbook

Monitoring the engine system makes it possible to draw conclusions on the operating behaviour of the turbocharger.

The following operating data and measured values must be entered regularly into the engine logbook of the enginebuilder:

¡ Number of times the engine is started successfully (possible aborted start cycles do not

need to be recorded)

¡ Performance and speed of the engine

¡ Air intake temperature

¡ Pressure of the charge air

¡ Pressure loss in the charge air cooler

¡ Lubricating oil pressure and lubricating oil temperature.

If present:

Page 36 / 93

¡ 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.

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Operation Manual / 4 Product description / A130-H.. - A140-H

5 Operation and service / 5.3 Expected replacement intervals

5.3 Expected replacement intervals

Fuel

The expected replacement intervals apply to engine operation with pre-mix gas and diesel oil.

Applications with frequent engine start/stop cycles (Peak shaving)

In addition to the replacement intervals specified on the rating plate for the compressor and turbine wheel (in operating hours), the number of successful engine start/stop cycles must also be taken into account.

Rotating components

The recommended replacement intervals of the compressor and turbine wheels are 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.

When employing the ‘Peak shaving’ mode, ABB Turbo Systems generally recommends replacing the compressor and turbine wheel after 20000 successful engine start/stop cycles or after reaching the number of operating hours specified on the rating plate.

Non-rotating components

Depending on the system-specific operating conditions, a differentiation must be made between the intervals to be expected for:

¡ replacing the bearing parts and

¡ replacing the non-rotating components exposed to hot gas.

A decisive role is played by various influencing parameters which, in extreme cases, can drastically reduce the replacement interval of these parts.

When utilising the ‘Peak shaving’ mode with frequent engine start/stop cycles, the turbocharger components on the exhaust gas side are subjected to high thermal loads. This load can cause thermal fatigue when the operating time and number of engine start cycles increase, thereby resulting in wear and cracking of the components. ABB Turbo Systems therefore recommends having the components periodically inspected and replaced, if necessary, by an ABB Turbocharging Service Station based on the number of successful engine start cycles specified in the following table.

The individual components will generally be examined for wear and replaced, if necessary, during the prescribed periodic service work.

Page 37 / 93

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Operation Manual / 4 Product description / A130-H.. - A140-H

5 Operation and service / 5.3 Expected replacement intervals

Expected replacement intervals

Operating hours Number of engine start

cycles (Peak shaving mode)

Turbine casing 25000…50000 5000…10000 Nozzle ring 25000…50000 5000…10000 Gas outlet flange 25000…50000 5000…10000 Heat shield 25000…50000 5000…10000 Bearing casing 25000…50000 5000…10000 Bearing parts 12000…24000 5000 Rotor components See information on rating

plate

Other casings 50000 - -

Table10: Expected replacement intervals

20000

The specified values are guideline values and not guaranteed values; see Influencing parameters.

Page 38 / 93

Influencing parameters

The specified values are guideline values and are not guaranteed. The actual values can deviate significantly from the guideline values, for example, due to the following influences:

¡ Fuel quality and fuel treatment

¡ Load profile (thermal cycling, also number of starts/stops, emergency shutdowns, oper-

ating point)

¡ Gas inlet temperature

¡ Turbocharger specification

¡ System-specific operating conditions (combustion quality, exhaust gas composition)

For bearing parts

¡ Lubricating oil quality (oil filtering, oil condition, oil monitoring)

¡ Load profile (speed, pressure conditions, temperature)

¡ Number of starts/stops

¡ Unbalance of the rotor (degree of contamination).

Page 69

Operation Manual / 4 Product description / A130-H.. - A140-H

5 Operation and service / 5.4 Stopping the engine

5.4 Stopping the engine

CAUTION

Residual heat in the turbocharger

If the residual heat in the turbocharger is not adequately dissipated, it may damage the engine.

u Adequate cooling of the turbocharger must be ensured after stopping

the engine.

Water-cooled turbocharger variant

u Post-lubricate as long as the rotor is turning.

u Observe the oil pressure while performing post-lubrication: 0.5 <p

u Switch off post-lubrication as soon as the rotor is stationary or after no more than two

≤1.0.

oil

minutes.

Deviating procedures must be coordinated with ABB Turbo Systems.

Page 39 / 93

Page 70

Operation Manual / 4 Product description / A130-H.. - A140-H

6 Periodic maintenance work / 6.1 Foreword to maintenance

6 Periodic maintenance work

6.1 Foreword to maintenance

Maintenance work includes regular visual controls and cleaning operations which are intended to ensure the trouble-free functioning of the turbocharger.

Maintenance interval Maintenance work Operating status

Similar to the service interval (usually every 8000…12000h)

Table11: Maintenance table

[h] = Hours of operation

ABB Turbo Systems recommends having mechanical cleaning carried out by an ABB Tur-

bocharging Service Station during the service work.

Cleaning components mechanically

→41

Engine stopped

Page 40 / 93

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Operation Manual / 4 Product description / A130-H.. - A140-H

6 Periodic maintenance work / 6.2 Cleaning components mechanically

6.2 Cleaning components mechanically

6.2.1 Preparation

CAUTION

Component damage and corrosion

If mechanical cleaning is carried out incorrectly, this can lead to damage and corrosion on the components.

u Pay attention to the specifications in this chapter pertaining to mechan-

ical cleaning.

CAUTION

Selection of cleaning tools

Turbocharger components are sensitive and easily sustain mechanical 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 Dismantling and

fitting →58.

u Contaminated water and cleaning agents must be disposed of in an environmentally

compatible, professional way and in compliance with locally applicable regulations.

Page 41 / 93

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Operation Manual / 4 Product description / A130-H.. - A140-H

6 Periodic maintenance work / 6.2 Cleaning components mechanically

6.2.2 Cleaning the filter silencer

Fig.22: Cleaning the filter silencer

Page 42 / 93

81135 Filter silencer body 81266 Cover grid 81136 Absorption segment 81270 Tension band 81137 Sheet-metal covering 81271 Lock 81265 Filter ring

Cleaning the filter ring (if present)

u Remove filter ring (81265).

u Clean filter ring (81265) as required or every 500 hours of operation and replace after the

fifth cleaning process at the latest. Contamination of the filter ring depends on the degree of purity of the sucked-in air.

u Rinse the filter ring (81265) with water and mild detergent or, in the case of heavy con-

tamination, soak and carefully push through. Rinse in cold water. Avoid high mechanical loads (water jet).

u Let the filter ring dry completely before assembling.

u Dirty water and mild detergent must be disposed of in compliance with locally applicable

regulations.

Page 73

Operation Manual / 4 Product description / A130-H.. - A140-H

6 Periodic maintenance work / 6.2 Cleaning components mechanically

Cleaning the absorption segments

(see Fig.22: Cleaning the filter silencer →42)

u Loosen the tension bands (81270).

u Remove the cover grid (81266).

u Pull out and bend up the sheet-metal coverings (81137), and remove the absorption seg-

ments (81136).

u Clean the absorption segments (81136).

When cleaning, note that the absorption segments (81136) must only be cleaned lightly with compressed air, a soft brush or a moist cleaning cloth.

u Have any heavily contaminated absorption segments replaced by an ABB Turbocharging

Service Station.

Fitting the filter silencer

(see Fig.22: Cleaning the filter silencer →42)

u Insert the absorption segments (81136) into the sheet-metal coverings (81137).

u Bend the sheet-metal coverings (81137) back to their original shape and insert into the

slotted guides in the filter silencer body (81135).

u Fit the cover grid (81266).

u Fit the tension bands (81270) and tighten them at the locks (81271).

u Any tension bands that have become damaged must be replaced.

u Fit the filter ring (81265), if present.

Page 43 / 93

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Operation Manual / 4 Product description / A130-H.. - A140-H

6 Periodic maintenance work / 6.2 Cleaning components mechanically

6.2.3 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 operat-

ing materials and supplies.

u Wear personal protective equipment (PPE) according to the material

safety data sheet.

u Comply with local legislation.

Wear safety goggles.

Page 44 / 93

Wear safety gloves to protect against chemical hazards.

Wear a respiratory mask to protect against gases.

The following parts, which are relevant in terms of performance, can be cleaned in accordance with the description below.

Fig.23: Compressor-end, non-rotating parts

72000 Compressor casing 77000 Wall insert 79000 Diffuser

u Clean the above-mentioned components with steam or ultrasound. Alternatively, soak in

diesel oil or water containing household cleaning agent. After soaking, remove contamination with a brush.

u Dry components completely.

u Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the tur-

bocharger.

u Dispose of contaminated water and cleaning agents in accordance with the information

in the material safety data sheet.

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Operation Manual / 4 Product description / A130-H.. - A140-H

6 Periodic maintenance work / 6.2 Cleaning components mechanically

6.2.4 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 operat-

ing materials and supplies.

u Wear personal protective equipment (PPE) according to the material

safety data sheet.

u Comply with local legislation.

Wear safety goggles.

Wear safety gloves to protect against chemical hazards.

Wear a respiratory mask to protect against gases.

Baked layers of contamination, for example, from coked oil occur at the turbine end. The following parts, which are relevant in terms of performance, can be cleaned in accordance with the description below.

Fig.24: Turbine end, non-rotating parts

51000 Turbine casing 56001 Nozzle ring 57002 Gas outlet flange 56005 Lamellar sealing ring

Page 45 / 93

u Dismantle the lamellar sealing ring (56005) in the nozzle ring.

u Place contaminated parts in hot water or in a liquid such as brake cleaner to soften the

contamination.

u Brush away the contamination or remove with a steam cleaner.

u Repeat the soaking and brushing if necessary.

u Use clean water to remove all traces of solvent from parts.

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Operation Manual / 4 Product description / A130-H.. - A140-H

6 Periodic maintenance work / 6.2 Cleaning components mechanically

u Dry components completely.

u Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the tur-

bocharger.

u Dispose of contaminated water and cleaning agents in accordance with the information

in the material safety data sheet.

6.2.5 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.

Compressor wheels can be heavily contaminated due to poorly filtered suction air; turbines can be heavily contaminated due to coked oil. Contamination such as this must be removed during the standard service intervals (see chapter Service work).

Page 46 / 93

u Remove the turbocharger from the engine (see chapter Removing and Installing →8).

u Remove the cartridge group (see chapter Dismantling and fitting →58).

First clean the compressor end and then the turbine end according to the following description.

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Operation Manual / 4 Product description / A130-H.. - A140-H

6 Periodic maintenance work / 6.2 Cleaning components mechanically

6.2.6 Cleaning the cartridge group on compressor end

CAUTION

Selection of the cleaning agent

Cleaning agents that contain chlorine corrode metals.

u Only use pH-neutral cleaning agents that do not corrode metals.

u Observe the material safety data sheet.

u Observe country-specific regulations regarding banned and restricted

substances.

CAUTION

Water and contamination in the cartridge group

If water or contamination penetrates the cartridge group, this can impair the function of the turbocharger and damage parts inside the cartridge group.

u Make sure that no water or contamination can enter into the cartridge

group.

u Cleaning procedures should be selected that do not result in removal of the compressor

wheel material or cause damage to its surfaces. Clean the compressor wheel with a rag or soft brush which has been soaked in water with a household cleaning agent. Do not use a wire brush!

u Dry the compressor wheel and the gap between the compressor and the bearing casing

with low-pressure pressurized air.

u Lightly spray the compressor wheel and the gap between the compressor and the bearing

casing with penetrating oil.

u Dispose of dirty water and cleaning agents in accordance with the material safety data

sheet.

Page 47 / 93

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Operation Manual / 4 Product description / A130-H.. - A140-H

6 Periodic maintenance work / 6.2 Cleaning components mechanically

6.2.7 Cleaning the cartridge group on turbine end

Soaking the contamination

Baked layers of contamination from coked oil occur at the turbine end. The contamination can be removed by soaking and brushing. The procedure for soaking the layers of contamination as well as for cleaning the turbine are described in the following.

Page 48 / 93

Fig.25: Soaking the turbine end

Product A[mm] B[mm] C[mm]

A130 108 17 205 A135 128 20 245 A140 157 25 300

Table12: 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.

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Operation Manual / 4 Product description / A130-H.. - A140-H

6 Periodic maintenance work / 6.2 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

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.

Page 49 / 93

u Lift up the cartridge group and align it horizontally.

u Remove contamination manually using a soft brush or a wire brush.

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Operation Manual / 4 Product description / A130-H.. - A140-H

6 Periodic maintenance work / 6.2 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.

Page 50 / 93

u Immerse the turbine of the cartridge group in clean water so that any loose contamina-

tion comes off.

u Lift up the cartridge group and align it horizontally.

u Dry the turbine and the gap between the turbine and the heat sheet metal with low-pres-

sure pressurized air.

u Lightly spray the turbine and the gap between the turbine and the heat sheet metal with

penetrating oil.

u Dispose of contaminated water and cleaning agents in accordance with the information

in the safety data sheet.

Page 81

Operation Manual / 4 Product description / A130-H.. - A140-H

7 Eliminating malfunctions / 7.1 Malfunctions when starting

7 Eliminating malfunctions

7.1 Malfunctions when starting

Delayed start-up

Possible causes Remedy

Turbocharger

Table13: Malfunctions when starting – Delayed start-up

Vibrations

Turbocharger contaminated Clean (see chapter Periodic mainten-

ance work →40)

Bearing damaged Contact ABB Turbocharging Service Rotor rubbing Foreign object in the turbocharger

Station

Possible causes Remedy

Turbocharger

Engine Vibrations from engine Contact enginebuilder

Table14: Malfunctions when starting – Vibrations

Rotor unbalance Contact ABB Turbocharging Service Turbine or compressor damaged Bearing damaged

Station

Rubbing of rotating parts

Normal behaviour, not a malfunction

Turbocharger

Table15: Malfunctions when starting – Rubbing of rotating parts

A slight amount of uniform wear at the circumference of the rotor components caused by slight local rubbing against adjacent components is permitted. This causes the compressor or turbine blades to be somewhat shortened. To prevent significant loss of efficiency, specific tolerances must be fulfilled.

¡ If there is any doubt about the extent of the rubbing, contact an ABB Tur-

bocharging Service Station.

¡ Have a dimension check carried out by an ABB Turbocharging Service Sta-

tion.

Page 51 / 93

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Operation Manual / 4 Product description / A130-H.. - A140-H

7 Eliminating malfunctions / 7.2 Malfunctions during operation

7.2 Malfunctions during operation

Lubricating oil pressure too low

WARNING

Danger of fire and explosion due to lubricating oil leaks

Leaking oil may ignite on hot surfaces. This can result in serious injuries to personnel or fatal accidents.

u Cordon off danger area.

u Raise the alarm and, depending on the situation, stop the engine.

u Seal the oil leak.

u Soak up oil and dispose of in an environmentally compatible manner.

Wear safety gloves to protect against thermal hazards.

Page 52 / 93

Possible causes Remedy

Turbocharger

Engine Oil filter heavily contaminated Clean

Table16: Malfunctions during operation – Lubricating oil pressure too low

Axial clearance of the rotor excessive Contact an ABB Turbocharging

Service Station

Oil pump in lubricating system defective

Manometer displays incorrectly Replace manometer

Check/replace

Speed reduces

Possible causes Remedy

Turbocharger

Engine Defects on the connected cylinders in

Pipes Defects, such as leaks, in the exhaust

Table17: Malfunctions during operation – Speed reduces

Turbine and/or nozzle ring severely contaminated

Rotor components or bearing damaged Contact ABB Turbocharging Service

pulse charging

gas pipes or charge air ducts

Clean (see chapter Periodic mainten-

ance work →40)

Station Contact enginebuilder

Repair

Speed increases

Possible causes Remedy

Turbocharger

Table18: Malfunctions during operation – Speed increases

Light to medium contamination of the turbine and/or nozzle ring (with 4stroke application)

Clean (see chapter Periodic mainten-

ance work →40) or contact an ABB Tur-

bocharging Service Station

Page 83

Operation Manual / 4 Product description / A130-H.. - A140-H

7 Eliminating malfunctions / 7.2 Malfunctions during operation

Exhaust gas temperature too high

Engine performance and engine speed unchanged

Possible causes Remedy

Turbocharger Insufficient air, for example, when fil-

ter silencer is blocked by contamination

Compressor/turbine contaminated Exhaust gas back pressure too high Clean or repair boiler or exhaust gas si-

Turbine damaged or eroded Contact ABB Turbocharging Service

Engine Malfunction in the injection system Repair or contact manufacturer Charge air

cooler

Table19: Malfunctions during operation – Exhaust gas temperature too high

Cooler contaminated Clean Cooling water volume too low Fill Inlet temperature of cooling water

too high Insufficient ventilation Improve ventilation

Clean (see chapter Periodic mainten-

ance work →40)

lencer

Station

Check/clean cooling system

Charge air pressure too low

Engine performance and engine speed unchanged, suction condition normal

Possible causes Remedy

Turbocharger

Engine Air receiver not sealed Repair

Pipes Pipes downstream to the compressor

Table20: Malfunctions during operation – Charge air pressure too low

Manometer display not correct Replace manometer Supply pipe to manometer not sealed Repair leak Filter silencer contaminated, therefore

pressure drop too high Compressor end and/or turbine end

contaminated Compressor/turbine damaged Contact ABB Turbocharging Service

Exhaust gas back pressure too high Clean or repair boiler or exhaust gas si-

Gas piping between engine and turbine leaking

Injection mistimed Set correctly Valve control misadjusted

outlet not sealed.

Clean (see chapter Periodic mainten-

ance work →40)

Station

lencer

Repair.

Page 53 / 93

Page 84

Operation Manual / 4 Product description / A130-H.. - A140-H

7 Eliminating malfunctions / 7.2 Malfunctions during operation

Charge air pressure too high

Engine performance and engine speed unchanged, suction condition normal

Possible causes Remedy

Turbocharger

Engine Malfunction in the injection system Repair or contact manufacturer

Table21: Malfunctions during operation – Charge air pressure too high

Manometer display not correct Replace manometer Increased speed due to contamination

of nozzle ring

Injection mistimed Set correctly Engine performance higher than indic-

ated

Clean (see chapter Periodic mainten-

ance work →40) or contact an ABB Tur-

bocharging Service Station

Check engine performance

Reduced compressor performance/efficiency and therefore engine performance losses

Page 54 / 93

CAUTION

Compressor damage

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 Remedy

Turbocharger

Table22: Malfunctions during operation – Engine performance losses

Compressor components severely contaminated 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

Clean (see chapter Periodic mainten-

ance work →40)

Optimize oil separation Correct the feed of ventilation gases ac-

cording 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 mainten-

ance work →40)

Page 85

Operation Manual / 4 Product description / A130-H.. - A140-H

7 Eliminating malfunctions / 7.3 Turbocharger is surging

7.3 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.

u Gradually reduce the engine load.

u Have the cause clarified and remedied immediately by an ABB Turbochar-

ging Service Station.

u Have parts assessed for damage and, if necessary, replaced by an ABB

Turbocharging Service Station.

Possible causes Remedy

Turbocharger Filter silencer or diffuser contamin-

ated Heavy contamination deposits in the

turbine or in the nozzle ring

Engine Protective grating in front of the tur-

bocharger contaminated or damaged

Charge air cooler

Table23: Malfunction – Turbocharger pumping

Cooler contaminated Clean Charge air duct blocked

Clean (see chapter Periodic mainten-

ance work →40)

Clean/replace

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24: Malfunction – Sporadic surge blows

- -

Page 55 / 93

Page 86

Operation Manual / 4 Product description / A130-H.. - A140-H

7 Eliminating malfunctions / 7.4 Malfunctions when stopping

7.4 Malfunctions when stopping

Runout noises

Possible causes Remedy

Turbocharger

Table25: Malfunctions when stopping – Runout noises

Turbocharger contaminated Clean (see chapter Periodic maintenance work

→40)

Bearing damaged Check clearances (see chapter Measuring clear-

ance A and B). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station.

Rotor rubbing Check clearances (see chapter Radial clearances N

and R). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station.

Foreign object in the turbocharger

Dismantle turbocharger (see chapter Dismantling

and fitting →58). In case of damage, replace the

corresponding parts or contact an ABB Turbocharging Service Station.

Page 56 / 93

Runout time too short

The runout time must be noted down as a reference. Because the runout time depends on the oil viscosity, the runout time must always be measured at the same oil temperature.

If the runout time is significantly shorter in comparison to a previous measurement, the following table must be observed.

Possible causes Remedy

Turbocharger

Table26: Malfunctions when stopping – Runout time too short

Turbocharger contaminated Clean (see chapter Periodic maintenance work

→40)

Bearing damaged Check clearances (see chapter Measuring clear-

ance A and B). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station.

Rotor rubbing Check clearances (see chapter Radial clearances N

and R). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station.

Foreign object in the turbocharger

Dismantle turbocharger (see chapter Dismantling

and fitting →58). In case of damage, replace the

corresponding parts or contact an ABB Turbocharging Service Station.

Page 87

Operation Manual / 4 Product description / A130-H.. - A140-H

7 Eliminating malfunctions / 7.5 Speed measurement system

7.5 Speed measurement system

No signal or poor signal amplitude of the speed measurement

Possible causes Remedy

Turbocharger

Table27: Malfunction of the speed measurement system – No signal or poor signal amplitude

The speed sensor was accidentally 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 Contact an ABB Turbocharging Service Station.

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. Install the speed sensor without the additional gasket (copper ring).

Order new speed sensor(86505) (refer to chapter

Ordering spare parts →89).

Replacing the speed sensor.

Measured speed too high

Possible causes Remedy

Turbocharger

Table28: Malfunction of the speed measurement system – Measured speed too high

Sensor tip contaminated, since it is magnetic and can attract metallic particles. This reduces the distance to the signal-emitting sealing disc, which can lead to amplification of the noise component and, hence, to false triggering.

For information regarding the disassembly and assembly of the speed sensor, refer to chapter Replacing the speed sensor. Dismantle the sensor, clean the sensor tip, and fit the sensor back on with the specified tightening torque.

Measured speed too low

Possible causes Remedy

Turbocharger

Table29: Malfunction of the speed measurement system – Measured speed too low

- - Contact ABB Turbocharging Service Station

If none of the measures described above remedy the malfunction, have the speed measurement system checked by an ABB Turbocharging Service Station.

Page 57 / 93

Page 88

Operation Manual / 4 Product description / A130-H.. - A140-H

8 Dismantling and fitting / 8.1 Introduction

8 Dismantling and fitting

8.1 Introduction

The precondition for the work described in the following is a turbocharger removed from the engine (see chapter Removal and installation).

WARNING

Danger of burns

Touching hot surfaces or contact with hot operating fluids can cause burns.

u Do not touch hot surfaces. Observe the warning plate on the turbochar-

ger.

u Wear heat-resistant safety gloves and protective clothing.

u Wait for the turbocharger to cool down before carrying out any work.

Page 58 / 93

Wear safety gloves to protect against thermal hazards.

WARNING

Cutting injuries when working on the turbocharger

Some parts on the turbocharger may have sharp edges. There is a risk of a cutting injury.

u Wear safety gloves against mechanical risks when conducting assembly

and disassembly work.

Wear safety gloves to protect against mechanical hazards.

WARNING

Non-observance of the work steps and further operations

Incorrectly performed work or further operations can cause injury to personnel or damage to the machine.

u Only perform operations that are described in this document.

u Only perform operations for which you have previously received instruc-

tion or training.

u Have further operations carried out only by trained personnel from an

ABB Turbocharging Service Station.

u Mark the casing position for assembly.

Identification of the assembly devices

Not all assembly devices are marked with a part number. Identification is guaranteed by the tool list. This list is enclosed with the toolbox.

Page 89

Operation Manual / 4 Product description / A130-H.. - A140-H

8 Dismantling and fitting / 8.1 Introduction

WARNING

Servicing the assembly devices

Assembly devices must be checked for damage before and after use.

u Visually inspect for corrosion, cracks, deformation and wear.

u Damaged assembly devices must no longer be used and must be re-

placed.

Customer spare part set

Before starting operations, make sure the required customer spare part set is available (see chapter Spare parts →89).

Oil orifice

u When disassembling the turbocharger, an oil orifice fitted in the oil inlet must not be re-

moved (see also chapter Removing the cartridge group).

Tightening torques for components of the turbocharger

The specified tightening torques of the screw fittings must be observed (Table of tightening torques).

Tightening torques for assembly devices

Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB must be tightened so they are tight-fitting.

WARNING

Suspended loads

Loads that are not attached according to regulations can cause injury to personnel or fatal accidents.

u Only fasten the turbocharger, assemblies or individual parts on properly

functional lifting gear with sufficient load limit.

u Pay attention to the correct attachment of loads on the crane hook.

u People must not stand beneath suspended loads.

Wear safety gloves to protect against mechanical hazards.

Page 59 / 93

Wear safety helmet.

Definition of terms

¡ Suspension point

Defined loading point on a component or an assembly (blind hole thread, eyelet, lug).

Page 90

Operation Manual / 4 Product description / A130-H.. - A140-H

8 Dismantling and fitting / 8.2 Weights of individual parts

¡ 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.

Swivel lifting eyes to be used

Swivel lifting eyes are required for the safe lifting of loads, which are not supplied by ABB.

Page 60 / 93

Fig.26: Swivel lifting eyes

Product Thread M Length L

[mm]

A130 M10 17 mm 100 kg 2 A135 M10 17 mm 150 kg 2 A140 M12 21 mm 250 kg 2

Table30: Swivel lifting eyes

Minimum load limit

[kg]

Quantity

Ring nuts to be used

Two ring nuts (M16) are required for safer lifting of the cartridge group, which are not included in the ABB Turbo Systems scope of delivery.

Fig.27: Starpoint ring nut VRM

8.2 Weights of individual parts

The specified weights of the individual parts or assemblies are rounded-up standard values.

Page 91

Operation Manual / 4 Product description / A130-H.. - A140-H

8 Dismantling and fitting / 8.2 Weights of individual parts

Fig.28: Weights of assemblies

Designation A130

[kg]

01 Filter silencer 19 30 40 02 Radial air suction branch 6 8 13 03 Axial air suction branch 4 5 6 04 Compressor casing 24 40 60 05 Wall insert 6 8 15 06 Diffuser 3 4 7 07 Cartridge group 40 60 110 08 Nozzle ring 2 2 4 09 Burst ring 2 3 5 10 Turbine casing * 45 65 120 11 Gas outlet flange 7 13 20 12 Gas outlet casing * 30 35 65

Table31: Weights of assemblies

A135

[kg]

A140

[kg]

* including burst protection

Page 61 / 93

Page 92

Operation Manual / 4 Product description / A130-H.. - A140-H

8 Dismantling and fitting / 8.3 Removing the air inlets

8.3 Removing the air inlets

u Mark the casing position for assembly.

Page 62 / 93

Fig.29: Removing the air inlets

1. Attach lifting gear to the filter silencer(81000) or air suction branch(82000).

2. Loosen and remove V-clamp(72020).

3. Remove filter silencer(81000) or air suction branch(82000), set it down properly in an appropriate place and secure it.

4. Remove and dispose of the O-ring(81010 / 82010).

Page 93

Operation Manual / 4 Product description / A130-H.. - A140-H

8 Dismantling and fitting / 8.4 Removing the gas outlet casing

8.4 Removing the gas outlet casing

u Mark the casing position for assembly.

Fig.30: 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).

8.5 Removing the gas outlet flange

Depending on the way of fixing the gas outlet flange, the appropriate Working Instruction has to be consulted (pressing off using 3 or 6 press-off screws).

If the following Working Instructions are not observed, this can lead to cracks in the gas outlet casing.

The following variants are possible:

u Pressing off using 3 press-off screws.

u Pressing off using 6 press-off screws.

Page 63 / 93

Page 94

Operation Manual / 4 Product description / A130-H.. - A140-H

8 Dismantling and fitting / 8.5 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.

u Mark the casing position for assembly.

Page 64 / 93

Fig.31: Dismantling the gas outlet flange

Product Press-off screws (strength 8.8) * Tightening torque

A130 3 x M 8 x 20 ≤ 20 Nm A135 3 x M10 x 25 ≤ 40 Nm A140 3 x M12 x 30 ≤ 65 Nm

Table32: 3 press-off screws

* not included in the ABB Turbo Systems scope of delivery

1. Press off and remove the gas outlet flange (57002) with screws(01) according to the table. If it is not possible to press off the gas outlet flange with the maximum tightening torque, contact an ABB Turbocharging Service Station.

2. If present: Remove the C-ring(57003).

Page 95

Operation Manual / 4 Product description / A130-H.. - A140-H

8 Dismantling and fitting / 8.5 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.

u Mark the casing position for assembly.

Fig.32: Removing the gas outlet flange

Product Press-off screws (strength 8.8) * Tightening torque

A130 6x M6 x 20 ≤ 10 Nm A135 6x M8 x 25 ≤ 20 Nm A140 6x M10 x 30 ≤ 40 Nm

Table33: 6 press-off screws

* not included in the ABB Turbo Systems 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 tightening torque, contact an ABB Turbo Systems Service Station.

2. If present: Remove the C-ring(57003).

Page 65 / 93

Page 96

Operation Manual / 4 Product description / A130-H.. - A140-H

8 Dismantling and fitting / 8.6 Removing the compressor casing

8.6 Removing the compressor casing

Removing the compressor casing

u Mark the casing position for assembly.

Page 66 / 93

Fig.33: Removing the compressor casing

*) In some installations a special graphite cord sealing (42126) is fitted (see also chapter

Spare parts →89).

1. Loosen screws(72011) and remove together with fastening strips(72012).

2. Attach swivel lifting eye(S) to the compressor casing and the lifting gear.

3. Remove the compressor casing(72000) and turn it 180°.

4. Remove and dispose of the O-ring(42012) or graphite cord sealing(42126).

5. Loosen screws(79041) and remove from the compressor casing(72000) with fixing discs(79040) and diffuser(79000).

If the compressor casing cannot be loosened, it can be pressed off against the turbine casing using the press-off tool(90042) (see chapter Pressing off the casing →68).

Page 97

Operation Manual / 4 Product description / A130-H.. - A140-H

8 Dismantling and fitting / 8.6 Removing the compressor casing

Dismantling the wall insert

Fig.34: 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).

8.7 Pressing off the casing

CAUTION

Axial force of the press-off tool

Using the press-off tool (90042), a high level of axial force can be generated. If the casing is pressed off with too much force on one side, the rotor can be damaged.

u Use the tool on both sides in alternation and make sure not to press off

too hard on either side.

Page 68 / 93

Fig.35: Press off the casing

Page 99

Operation Manual / 4 Product description / A130-H.. - A140-H

8 Dismantling and fitting / 8.8 Removing the cartridge group

8.8 Removing the cartridge group

u Mark the casing position for assembly.

Do not remove oil orifice (if present)

To limit the oil flow rate through the bearing casing during operation (engine under load) to the admissible values, an oil orifice is mandatory at the oil inlet of the bearing casing if the oil inlet pressure is >3bar (overpressure).

If an oil orifice is fitted in the oil inlet of the bearing casing, it must not be removed.

Fig.36: Oil orifice

01 Bearing casing 02 Oil orifice 03 Circlip

Fig.37: Removing cartridge group 1

1. Treat threads of studs(51006) with penetrating oil and leave to take effect.

Page 69 / 93

2. Undo nuts(51007) and remove Verbus Ripp® washers(51003) together with fastening strips(51002).

Page 100

Operation Manual / 4 Product description / A130-H.. - A140-H

8 Dismantling and fitting / 8.8 Removing the cartridge group

Fig.38: 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.

Page 70 / 93

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 →68).

Abb A135-H66 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.2 Symbols, definitions

1.3 Storage of new turbochargers and spare parts

1.4 Contact information

Safety

1 Safety

1.1 Introduction

1.2 CE conformity

1.3 Definition of mandatory signs

1.4 Definition of safety instructions

1.5 Intended use

1.6 Deflagration on gas engines

1.7 Warning plates on the turbocharger

1.8 Turbocharger rating plate

1.9 Periodic check of the pressure vessels

1.10 Lifting of loads

1.11 Prerequisites for operation and maintenance

1.12 Hazards during operation and maintenance

1.13 Safe operation

1.14 Safe maintenance

Product description

1 Introduction

1.1 Essential information

1.2 Registered trademarks

1.3 Related documents

1.4 Layout and function of the turbocharger

1.4.1 Function of the compressor wheel cooling

1.5 Warning plates on the turbocharger

1.6 Locations of the rating plates

2 Removing and Installing

2.1 Weight and transportation of the turbocharger

2.2 Removing the turbocharger

2.2.1 Fastening of the turbocharger

2.2.2 Loosening the clamping nut

2.2.3 Putting down the turbocharger

2.3 Installing the turbocharger

2.3.1 Inserting gaskets into the bracket

2.3.2 Fitting threaded rods

2.3.3 Placing the turbocharger on the bracket

2.3.4 Fastening the turbocharger with a standard nut

2.3.5 Fastening the turbocharger with a clamping nut

2.3.6 Connecting the turbocharger

2.3.7 Attaching the support

3 Commissioning

3.1 Oil supply

3.1.1 Introduction

3.1.2 Oil filtering

3.1.3 Oil pressure

3.1.5 Oil orifice in the bearing casing

3.2 Inspection procedures

3.2.1 Introduction

3.2.2 Checks before commissioning

3.2.3 Checks after commissioning (engine in idle mode)

3.2.4 Checks when starting up the engine

3.3 Commissioning after taking out of operation

4 Monitoring operation

4.1 Oil pressure, oil temperature

4.2 Exhaust gas temperature before turbine

4.3 Turbocharger speed

4.3.1 Introduction

4.3.2 Layout and overview

4.3.3 Speed differences with several turbochargers per engine

4.3.4 Malfunctions on the speed measurement system

4.3.5 Replacing the speed sensor

5 Operation and service

5.1 Noise emission

5.2 Service work

5.2.1 Service work every 25 … 50 hours

5.2.2 Service work at 100 hours after commissioning

5.2.3 Service work according to instructions of enginebuilder

5.2.4 Service work according to data on the rating plate

5.2.5 Other service work

5.2.6 Entries in the engine logbook

5.3 Expected replacement intervals

5.4 Stopping the engine

6 Periodic maintenance work

6.1 Foreword to maintenance