Operation Manual
A155-M66
HT594556 English
Original Operation Manual
Chapter
Document-ID
HZTL4005_EN_G
HZTL4022_EN_E
HT594556
1
2
3
4
Introduction
Safety
Safety data sheet
Product description
HZTL4032_EN_N
ABB Turbocharging
Operation Manual / 1 Introduction
Table of contents
Introduction
Storage of new turbochargers and spare parts...................................................... 5
© Copyright 2020 ABB. All rights reserved.
HZTL4005_EN
Rev.G
March 2020
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-
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.
© Copyright 2020 ABB. All rights reserved.
HZTL4005_EN
Rev.G
March 2020
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 Sys-
tems in this document.
Official service stations of ABB Turbocharging
Official service stations are regularly audited and certified by ABB Turbocharging. See also
© Copyright 2020 ABB. All rights reserved.
HZTL4005_EN
Rev.G
March 2020
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
Note
Visually inspect
Please note text for numbered work step.
See document
Dispose of in an environmentally compatible, professional way and in compliance
with locally applicable regulations.
Table 1: Definition of pictograms
© Copyright 2020 ABB. All rights reserved.
HZTL4005_EN
Rev.G
March 2020
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.
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
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.
© Copyright 2020 ABB. All rights reserved.
HZTL4005_EN
Rev.G
March 2020
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 re-
quest. 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:
¡
¡
¡
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.
© Copyright 2020 ABB. All rights reserved.
HZTL4005_EN
Rev.G
March 2020
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
© Copyright 2020 ABB. All rights reserved.
HZTL4005_EN
Rev.G
March 2020
Operation Manual / 2 Safety / A130 - A155
Table of contents
Safety
Safety ...................................................................................................................... 2
CE conformity................................................................................................................. 2
Intended use .................................................................................................................. 4
Warning plates on the turbocharger......................................................................... 6
Periodic check of the pressure vessels..................................................................... 8
Lifting of loads .............................................................................................................. 9
Hazards during operation and maintenance ......................................................... 11
Safe operation.............................................................................................................. 13
© Copyright 2017 ABB. All rights reserved.
HZTL4022_EN
Revision E
May 2017
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 tur-
bocharger which:
¡
¡
¡
¡
Are caused by the turbocharger itself or its accessories.
Are caused by the operating equipment used or supplies and materials.
Are a consequence of insufficient compliance with safety instructions.
Are a consequence of insufficient or inappropriate performance of maintenance and in-
spection work.
The operating company is responsible for defining measures that regulate safe access to
and safe handling of the turbocharger.
All instructions contained in this chapter must be observed for safe and trouble-free opera-
tion of the turbocharger and during all work on the turbocharger.
All further safety instructions contained and specifically identified in every chapter of this
1.2
CE conformity
Information
ABB turbochargers comply with the Machinery Directive 2006/42/EC and are partly com-
pleted machinery as defined by Article 2 g in this directive.
© Copyright 2017 ABB. All rights reserved.
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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
Respiratory mask to protect
against
- Dusts
- Gases
Safety helmet
Ear protection
Table 2: Personal protective equipment to be worn specific to the respective task
1.4
Definition of safety instructions
WARNING
Definition of Warning
Non-compliance or inaccurate compliance with working or operating in-
structions indicated by this symbol and the word WARNING can lead to seri-
ous injuries to personnel and even to fatal accidents.
u Warning signs must always be observed.
CAUTION
Definition of Caution
Non-compliance or inaccurate compliance with working or operating in-
structions indicated by this symbol and the word CAUTION can lead to seri-
ous damage to engine or property with grave consequences.
u Caution signs must always be observed.
© Copyright 2017 ABB. All rights reserved.
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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 en-
ginebuilder must implement appropriate safety measures for explosion protection [3] (such
as flame barriers in the inlet system, for example) to assure that there is no transient pres-
sure increase exceeding a maximum of 12 bar before the turbocharger in case of a deflagra-
tion.
The turbocharger supplies the engine with the air volume or air/gas mixture and the associ-
ated charging pressure required for operation.
The turbocharger is solely intended to be operated with a clockwise direction of rotation as
viewed from the turbine end.
The specific operating limits of the turbocharger were determined on the basis of informa-
tion from the enginebuilder about the intended use. These data are given on the rating
plate.
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 haz-
ardous to personnel.
u Only operate the turbocharger within the operating limits.
u Only trained personnel must operate the turbocharger.
The intended use of the turbocharger includes compliance with all regulations and condi-
tions. In particular, the following must be observed:
¡
¡
Operation Manual
Instructions of the enginebuilder
© Copyright 2017 ABB. All rights reserved.
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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 oper-
ated in compliance with its intended use.
ABB excludes any liability for damage resulting from unauthorized modifications to the tur-
bocharger or improper operation.
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.
© Copyright 2017 ABB. All rights reserved.
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Revision E
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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.
Turbochargers supplied to the enginebuilder without insulation must be equipped later with
warning plates on the insulation. This is the responsibility of the enginebuilder.
© Copyright 2017 ABB. All rights reserved.
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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 en-
ginebuilder.
02 Turbocharger operating limits during operation
Recommended inspection and replacement intervals of turbocharger components
03 Inspection interval of plain bearings in 1000 h
04 Replacement interval of compressor in 1000 h
05 Replacement interval of turbine in 1000 h
Further data
06 Customer part number
07 Designation for special design
08 Weight of turbocharger in kg
09 Turbocharger type
10 Serial number
11 Year of construction of turbocharger
12 Manufacturing plant
© Copyright 2017 ABB. All rights reserved.
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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.
Operation above the indicated values nBmax, tBmax can considerably shorten the recommended
replacement intervals. In such a case, we recommend that you contact the nearest official
service station of ABB Turbo Systems.
nMmax, tMmax normally apply only when running at overload (110 %) during trials on the engine
test bed. These limit values can also be permitted during operation for special applications.
Operation above nMmax and tMmax is not permitted.
Non-observance of the recommended inspection and replacement intervals increases the
risk of unpredictable component failures.
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.
© Copyright 2017 ABB. All rights reserved.
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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 ex-
ceeded. This prevents excessive loading due to diagonal pull.
u Before looping around the components of the turbocharger, let them cool down (max-
imum 80 °C).
u Attach components of the turbocharger as described in the respective action steps.
u Use a suitable edge guard if there are sharp edges.
u The assembly devices must be completely screwed in and must not unscrew during use.
u Use assembly devices only for the described applications.
u Put down dismantled components of the turbocharger in such a way that they cannot tip
over.
© Copyright 2017 ABB. All rights reserved.
HZTL4022_EN
Revision E
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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.
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 tur-
bochargers.
ABB accepts no liability for any damage resulting from the use of non-original parts and cor-
responding accessories.
© Copyright 2017 ABB. All rights reserved.
HZTL4022_EN
Revision E
May 2017
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 op-
erating 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 psy-
chological state and may lead to lack of attention and irritation.
u When the engine is running, always wear ear protection.
u Always wear ear protection if the sound pressure level exceeds 85 dB(A).
Wear ear protection.
Hazards due to hot surfaces
Surfaces of the turbocharger, attached parts and operating fluids (lubricating oil) get hot
during operation. The surface temperature depends on the efficacy of the existing insula-
tion. The temperature may rise to a level that can cause burns.
WARNING
Danger of burns
Touching hot surfaces or contact with hot operating fluids can cause burns.
u Do not touch hot surfaces. Observe the warning plate on the turbochar-
ger.
u Wear heat-resistant safety gloves and protective clothing.
u Wait for the turbocharger to cool down before carrying out any work.
Wear safety gloves to protect against thermal hazards.
© Copyright 2017 ABB. All rights reserved.
HZTL4022_EN
Revision E
May 2017
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 in-
sulation, the enginebuilder is responsible for providing the turbocharger
with proper insulation and for providing protection against contact with hot
surfaces.
u Compliance with the instructions and specifications given by the en-
ginebuilder to protect against hot turbocharger surfaces is compulsory.
Wear safety gloves to protect against thermal hazards.
Hazards due to rotating parts
WARNING
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 person-
nel 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.
© Copyright 2017 ABB. All rights reserved.
HZTL4022_EN
Revision E
May 2017
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 des-
troy 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.
© Copyright 2017 ABB. All rights reserved.
HZTL4022_EN
Revision E
May 2017
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 com-
bination of burst protection and insulation can cause serious injuries to per-
sons 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
Variant A
Variant B
Variant C
Insulation (01) with integrated burst protection from ABB Turbo Systems.
Burst protection (03) and insulation (02) from ABB Turbo Systems.
Burst protection (03) from ABB Turbo Systems with appropriate insulation
from the enginebuilder.
© Copyright 2017 ABB. All rights reserved.
HZTL4022_EN
Revision E
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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 pro-
cedures or non-compliance with safety and health standards.
u When working on the turbocharger always wear safety footwear and pro-
tective clothing to protect against mechanical hazards.
u Keep personal protective equipment in perfect condition.
u Obey mandatory signs.
u Observe the general rules for occupational safety and prevention of acci-
dents.
u Only perform operations that are described in this 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 fall-
ing.
Wear protective clothing.
WARNING
Risk of falling
When working on the turbocharger, there is a risk of falling.
u Do not climb onto the turbocharger or onto attached parts and do not
use them as climbing aids.
u Use suitable climbing aids and working platforms for work above body
height.
u 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.
u Keep the floor, equipment, and turbocharger clean.
u Have oil binding agents ready and provide or keep oil pans at hand.
u Clean up any spills.
u Have fire protection means and extinguishing agents available.
© Copyright 2017 ABB. All rights reserved.
HZTL4022_EN
Revision E
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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.
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.
© Copyright 2017 ABB. All rights reserved.
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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 pro-
cedures.
u Observe the general rules for occupational safety and prevention of acci-
dents.
u Ensure workplace safety.
u Only perform operations that are described in this chapter.
u Only perform operations for which you have previously received instruc-
tion or training.
Hazards due to operating materials and supplies
Operating materials and supplies are substances required for the operation of the tur-
bocharger or for the performance of maintenance work. Oils, greases, coolants, detergents
and solvents, acids and similar substances can be classified as hazardous substances.
WARNING
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or con-
tact with them may be harmful to health.
u Do not breathe in these substances and avoid contact with the skin.
u Ensure proper ventilation.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Wear personal protective equipment (PPE) according to the material
safety data sheet.
u Comply with local legislation.
Wear safety goggles.
Wear safety gloves to protect against chemical hazards.
Wear a respiratory mask to protect against gases.
© Copyright 2017 ABB. All rights reserved.
HZTL4022_EN
Revision E
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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 environ-
mental damage.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Comply with local legislation.
Hazards due to the handling of insulation materials
WARNING
Danger from insulation materials
Dust or fibres from insulation materials can have adverse effects on the
health or cause irritations. Unsuitable and combustible insulation materials
are a fire hazard.
u Only use suitable and non-combustible insulation materials.
u Ensure good ventilation at the workplace.
u Avoid whirling up dust.
u Use dust-free tools and working methods.
u Remove package at the workplace only.
u Proceed with particular care when removing old insulation materials.
u Dispose of insulation materials properly and in an environmentally com-
patible manner in compliance with the legal regulations.
Wear safety goggles.
Wear a respiratory mask to protect against dusts.
Wear safety gloves to protect against chemical hazards.
© Copyright 2017 ABB. All rights reserved.
HZTL4022_EN
Revision E
May 2017
Operation Manual / A155-M66 / Safety data sheet
Page 1 / 1
Safety data sheet
A155-M66
HT594556
A155-M66
466
HT594556
630
466
600
1800
16
50
50
2020
© Copyright 2020 ABB. All rights reserved.
HT594556
March 2020
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
Table of contents
Product description
Essential information................................................................................................... 4
Registered trademarks................................................................................................ 4
Layout and function of the turbocharger ................................................................ 6
Warning plates on the turbocharger......................................................................... 8
Locations of the rating plates.................................................................................... 9
Removing and Installing...................................................................................... 10
Removing the turbocharger....................................................................................... 11
Installing the turbocharger........................................................................................ 14
Oil supply ...................................................................................................................... 20
Inspection procedures................................................................................................ 22
Commissioning after taking out of operation...................................................... 24
Monitoring operation.......................................................................................... 25
Oil pressure, oil temperature.................................................................................... 25
Turbocharger speed................................................................................................... 28
Operation and service ......................................................................................... 31
Service work................................................................................................................. 33
Expected replacement intervals .............................................................................. 36
Stopping the engine................................................................................................... 38
Periodic maintenance work ................................................................................ 39
Foreword to maintenance......................................................................................... 39
Cleaning the compressor during operation .......................................................... 40
Cleaning the turbine during operation................................................................... 43
Cleaning components mechanically ....................................................................... 47
Malfunctions when starting...................................................................................... 59
Malfunctions during operation ................................................................................ 60
Turbocharger is surging............................................................................................ 63
Malfunctions when stopping.................................................................................... 64
Speed measurement system.................................................................................... 65
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
Table of contents
Introduction ................................................................................................................. 66
Disassembly and assembly concepts ..................................................................... 70
Table of tightening torques...................................................................................... 74
Removing the gas outlet casing .............................................................................. 79
Removing the gas outlet flange............................................................................... 82
Removing the compressor casing........................................................................... 87
Removing the cartridge group................................................................................. 89
Removing the nozzle ring .......................................................................................... 93
Measuring clearance A and B.................................................................................... 94
Nozzle ring compression PD..................................................................................... 95
Installing nozzle ring .................................................................................................. 96
Installing the cartridge group ................................................................................. 97
Installing the compressor casing .......................................................................... 100
Installing the gas outlet flange .............................................................................. 103
Radial clearances N and R........................................................................................ 104
Fitting the insulation................................................................................................ 105
Installing the gas outlet casing.............................................................................. 107
Removing air inlets .................................................................................................... 112
Removing the compressor casing.......................................................................... 114
Removing the cartridge group................................................................................ 117
Removing the nozzle ring ......................................................................................... 121
Nozzle ring compression PD.................................................................................... 123
Installing the cartridge group ................................................................................ 125
Fitting the insulation................................................................................................ 130
Installing air inlets ..................................................................................................... 131
Application, special tools ........................................................................................ 134
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
Table of contents
Disassembly............................................................................................................... 143
Assembly .................................................................................................................... 146
Taking out of operation at short notice......................................................... 150
Possible emergency repairs.................................................................................... 150
Installing the replacement turbocharger.............................................................. 151
Mothballing the turbocharger.......................................................................... 155
Spare parts ......................................................................................................... 158
Ordering spare parts................................................................................................ 158
Required customer spare part set (97070).......................................................... 158
View of turbocharger with part numbers ............................................................ 160
View of uncoupled filter silencer A155.................................................................. 164
Tables .................................................................................................................. 168
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
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
Accuracy of illustrations
The illustrations in this document are general in nature and intended for ease of understand-
ing. Differences in detail are therefore possible.
1.2
Registered trademarks
The trademarks of outside companies are used in this document. These are marked with the
® symbol.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
1 Introduction / 1.3 Related documents
1.3
Related documents
Chapter
Operation Manual / 1 Introduction
Operation Manual / 2 Safety
Document number
HZTL4005
HZTL4022
Operation Manual / 3 Safety data sheet *)
Table 1: Related documents
Serial number of the turbocharger
*) This chapter is only available in serialised operation manuals.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
1 Introduction / 1.4 Layout and function of the turbocharger
1.4
Layout and function of the turbocharger
Fig. 1: Layout and function of the turbocharger
01 Filter silencer / air suction branch
02 Compressor casing
03 Diffuser
08
09
10
11
12
13
Gas outlet flange
Nozzle ring
Turbine casing
Turbine-end bearing flange
Compressor-end bearing flange
Compressor wheel
04 Bearing casing
05 Axial thrust bearing
06 Radial plain bearing
07 Turbine
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
1 Introduction / 1.4 Layout and function of the turbocharger
Mode of operation
The turbocharger is a turbomachine and consists of the following main components:
¡
¡
Turbine
Compressor.
These components are installed on a common shaft and form the rotor.
The exhaust gases of the internal combustion engine flow through the turbine casing (10)
and the nozzle ring (09) onto the turbine (07). The turbine (07) uses the energy contained in
the exhaust gas to drive the rotor and, hence, the compressor wheel (13). The exhaust gases
then reach the atmosphere through the exhaust gas pipe connected to the gas outlet
flange (08).
The compressor wheel (13) sucks fresh air through the air suction branch or the filter silen-
cer (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 the compressor and turbine. The axial thrust bearing (05) is located between the
two radial plain bearings.
The plain bearings are connected to a central lubricating oil duct which is normally supplied
by the lubricating oil circuit of the engine. The oil outlet always lies at the deepest point of
the bearing casing (04).
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 (01).
In addition, the turbocharger version with compressor wheel cooling is indicated by the tur-
bocharger type (M6..) on the rating plate.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
1 Introduction / 1.5 Warning plates on the turbocharger
1.5
Warning plates on the turbocharger
Warning plates are affixed at the following locations:
Fig. 3: Warning plate locations
If warning plates are not present in the designated locations or not readable, proceed as fol-
lows:
u Order new warning plates from ABB Turbocharging Service Stations.
u Remove any warning plates that have become unreadable.
u Clean and degrease the areas designated for the warning plates.
u Fit new warning plates and remove protective sheets.
Turbochargers supplied to the enginebuilder without insulation must be equipped later with
warning plates on the insulation. This is the responsibility of the enginebuilder.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
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Operation Manual / 4 Product description / A150-M56/66/57/67 -
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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 bear-
ing casing.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
2 Removing and Installing / 2.1 Turbocharger weight and transporta-
tion
2
Removing and Installing
2.1
Turbocharger weight and transportation
Lifting gear with a sufficient load limit must be used for transporting the turbocharger. The
weight specified below applies to the heaviest variant possible. Depending on the specifica-
tion, the weight specified on the rating plate may be lower than the standard value specified
here.
Fig. 5: Suspension of complete turbocharger unit
A
B
Complete turbocharger unit without gas outlet casing
Complete turbocharger unit with gas outlet casing
Product
Weight of complete turbocharger unit [kg]
A150-M
A155-M
1200
1800
Table 2: Weight of complete turbocharger unit
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
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.
Fig. 6: Turbine cleaning nozzle
u If present: Loosen the turbine cleaning connection.
The cleaning nozzle (51301) must be replaced after each removal procedure. If the clean-
ing nozzle is not to be replaced, the screw connection (01) must not be loosened during
disassembly.
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.
Fig. 7: Removing the turbocharger
u Secure the lifting gear to the turbocharger (see illustration).
u If present: Loosen and remove the compressor wheel cooling connection. Close the com-
pressor wheel cooling opening with a screw plug (01).
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.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
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2 Removing and Installing / 2.2 Removing the turbocharger
2.2.1
Loosening the clamping nut
CAUTION
Incorrect procedure can make loosening impossible
If individual pressure screws are fully relieved, the pressure screws can be-
come compressed, making it impossible to loosen them.
u Comply with the following steps for loosening the pressure screws.
CAUTION
Do not clean pressure screws
The pressure screws are equipped with a permanent sliding layer that must
not be removed. In case of non-compliance, it cannot be ensured that the
necessary tension force is reached.
u Do not clean pressure screws.
u Do not lubricate pressure screws.
If a screw jams, the previously loosened screw must be tightened again a little.
Fig. 8: Loosening the clamping nut
1. Working in a circle, break loose each pressure screw (≤ 20°).
2. Working in a circle, loosen each pressure screw by 45° in 4 rounds.
3. Working in a circle, loosen each pressure screw by 90° in 1...5 rounds until all of the pres-
sure screws have been relieved.
u Loosen clamping nut by hand.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
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2 Removing and Installing / 2.2 Removing the turbocharger
2.2.2
Positioning the turbocharger for storage
WARNING
Risk of tipping
If the turbocharger is not positioned stably, it may tip over. This can result in
serious personal injury.
u Place the turbocharger on a clean, level support.
u Secure the turbocharger to prevent it from tipping over by using wooden
beams and wedges and by taking the centre of gravity into account.
Fig. 9: Turbocharger centre of gravity
01
Centre of gravity
u Remove the turbocharger from the engine support.
u Remove and dispose of the O-rings (42195, 42200).
u Set down and secure the turbocharger properly at a suitable location.
u Close or cover the openings of the turbocharger and support.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
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2 Removing and Installing / 2.3 Installing the turbocharger
2.3
Installing the turbocharger
2.3.1
Inserting gaskets
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.
Fig. 10: Inserting the gasket
01
02
42200
42201
42202
Oil supply
Oil drain
O-ring
Bearing casing
O-ring
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
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2 Removing and Installing / 2.3 Installing the turbocharger
2.3.2
Placing the turbocharger on the bracket
Fig. 11: Fitting the turbocharger 1
Step A – Preparing the fixing screws
1. Insert expansion bush (42190) into bearing casing.
2. Screw the clamping nut (42201) flush onto the threaded rod (42191). The hexagon of the
thread screw is at the top.
3. Place the thrust washer (01) of the clamping nut on the expansion bush and, with the
clamping nut screwed on, guide the threaded rod through the thrust washer, expansion
bush and bearing casing.
Step B – Preparing the positioning
u Screw the centering bush (42193) flush onto the threaded rod from below.
u Clean the surface of the bracket, the bearing casing, the centering bush and the centering
holes in the bracket.
u Make sure that the covers of the oil connections are removed.
u Make sure that the position of the oil inlet of the bracket matches the oil inlet hole in the
bearing casing.
u Make sure that the O-rings are placed correctly in the slots.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
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2 Removing and Installing / 2.3 Installing the turbocharger
Fig. 12: Fitting the turbocharger 2
Product
A150
A155
Value X
112 ±2 mm
144 ±2 mm
Value L
52 ±2 mm
72 ±2 mm
Table 3: Fitting the turbocharger, value X, L
Step C – Aligning the turbocharger on the bracket
1. Lightly lubricate the hole, into which the centering bush (42193) is inserted, with screw
grease.
2. Position threaded rod with centering bush in the bracket.
3. Insert centering bush into bracket until the stop is reached.
4. Carefully lower turbocharger onto bracket and position using the centering bushes
(42193) located in the bracket.
5. Check value x.
u If value x is not reached, the turbocharger must be lifted up from the bracket and re-
aligned.
Step D – Fixing the threaded rod in place in the bracket
u Using the hexagon, screw the threaded rod into the bracket up to value L.
u If value L is not reached or the threaded rod jams while being screwed in, the threaded
rod must be loosened by no more than ½ revolution (this will loosen the centering bush
which may have jammed the rod). Then continue screwing in the threaded rod.
u If value L is not reached, undo the screw connection, carefully take the turbocharger off
the bracket and repeat the procedure starting with Step A.
u Observe the instructions for fastening the turbocharger with clamping nuts (see chapter
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
2 Removing and Installing / 2.3 Installing the turbocharger
2.3.3
Fastening the turbocharger with a clamping nut
Preparations for tightening the clamping nut
CAUTION
Do not clean pressure screws (04)
The pressure screws are equipped with a permanent sliding layer that must
not be removed.
Do neither clean nor lubricate the pressure screws. In case of non-compli-
ance, it cannot be ensured that the necessary tension force is reached.
u Do not clean pressure screws.
u Do not lubricate pressure screws.
In order to correctly fit the clamping nuts, the pressure screws (04) must not protrude from
the clamping nuts (03) in the direction of the thrust washer (02).
u Make sure the pressure screws do not protrude in the direction of the thrust washer.
Fig. 13: Preparing the clamping nut for the tightening procedure
1. Clean the thread of the bolt (01) and the contact surface.
2. Lightly oil the bolt thread.
3. Position the thrust washer (02) in place.
4. Tighten clamping nut (03) by hand.
5. Unscrew clamping nut (03) by ¼ of a turn (90°).
The distance between the thrust washer and the clamping nut is now about 1 mm.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
2 Removing and Installing / 2.3 Installing the turbocharger
Tightening pressure screws
Fig. 14: Tightening pressure screws
Product
A150
A155
Fixing screw [mm]
Tightening torques [Nm]
M30
M36
45
85
Table 4: Torque-controlled tightening of the pressure screws
1. Screw in pressure screws crosswise by hand until reaching the stop.
2. Tighten pressure screws crosswise to 50 % of the tightening torque specified in the
table.
3. Tighten pressure screws crosswise to 100 % of the tightening torque specified in the
table.
4. Work in a circle to tighten all pressure screws to 100 % of the tightening torque specified
in the table.
5. Tighten pressure screws to 100 % in 5 … 7 rounds until the required residual tightening
angle of < 20° is achieved.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
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2 Removing and Installing / 2.3 Installing the turbocharger
2.3.4
Connecting the turbocharger
Fig. 15: Connecting the speed sensor
u Connect cable to speed sensor (86515).
u Connect all gas, water and air lines according to the instructions of the enginebuilder.
Version with compressor wheel cooling
CAUTION
Failure of compressor wheel cooling
Any prolonged failure of the compressor wheel cooling will shorten the re-
placement interval of the compressor wheel.
u Make sure there is an uninterrupted supply of cooling air during opera-
tion.
Fig. 16: 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.
2.3.5
Attaching the support
Fig. 17: Attaching the support
u If present: Attach support (61301) to engine support or to a connecting piece.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
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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 pre-
requisite for trouble-free operation of the turbocharger.
The lubrication of the turbocharger is usually carried out with oil from the engine oil circula-
tion.
u Comply with the enginebuilder's specifications regarding the selection of lubricating oil
and the oil change intervals.
3.1.2
Pre-lubrication
Pre-lubrication must be carried out as follows:
u Switch on the oil pump.
u Build up oil pressure &.
u Do not exceed a pre-lubrication time of 2 minutes.
u Start the engine.
u Let the oil pump run until the pump driven by the engine generates sufficient pressure.
3.1.3
Oil filtering
Filtering the lubricating oil with a filter mesh width of ≤ 0.034 mm is sufficient for this tur-
bocharger.
3.1.4
Oil pressure
Comply precisely with the oil pressure before the turbocharger for trouble-free operation.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
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3 Commissioning / 3.1 Oil supply
3.1.5
Oil orifice in the bearing casing
Fig. 18: Oil orifice
01
02
03
Bearing casing
Oil orifice
Circlip
With an oil inlet pressure of more than 3 bar of overpressure (with engine under load) up-
stream of the turbocharger, the bearing casings are equipped with an orifice at the oil inlet
as standard.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
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 turbochar-
ger 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
CAUTION
Contaminated oil
Serious damage to engine or property can be caused by dirt and solid ma-
terial particles in the oil.
u For the initial commissioning phase and after all service work, flush the
complete lubricating system with warm oil.
u Use special running-in filters when running in the engine and after all ser-
vice work on the lubricating system.
u Check that the oil filter is clean before commissioning.
u Check the oil pressure in the oil supply pipes.
Warning plates
u Check whether warning plates are present and legible.
u Check whether the protective sheets have been removed from new warning plates.
Version with compressor wheel cooling:
CAUTION
Failure of compressor wheel cooling
Any prolonged failure of the compressor wheel cooling will shorten the re-
placement interval of the compressor wheel.
u Make sure there is an uninterrupted supply of cooling air during opera-
tion.
u Check whether the compressor wheel cooling is fitted on the bearing casing.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
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3 Commissioning / 3.2 Inspection procedures
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.
Gas, air and oil pipes
u After starting the engine, check all gas, air and oil pipes for leaks.
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.
u Measure the air temperature before and after the compressor.
u Compare the measured values with the values of the acceptance report. Different operat-
Lubricants and pastes used during assembly can liquefy or vaporise and escape as oily fluids
during the initial hours of operation. Continual escape of an oily fluid indicates an oil leak. If
there is a leak, contact an ABB Turbocharging Service Station.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
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Operation Manual / 4 Product description / A150-M56/66/57/67 -
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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.
Version with compressor wheel cooling:
u Remove the locking screw on the cooling air connection and fit the cooling air line.
General
u Check the exhaust gas pipe before and after the turbine for combustion residues or wa-
ter residues and clean it. Remove any foreign objects that may be present.
u Check and clean filter silencer or air supply line, and remove any foreign objects that may
be present.
u Put engine-side oil circulation to the turbocharger into operation.
u The turbocharger is now ready for operation.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
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Operation Manual / 4 Product description / A150-M56/66/57/67 -
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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 insuf-
ficient lubricating oil supply.
u The lubricating oil pressure must be monitored during operation and the
necessary pressure assured at the oil inlet.
Status for operation
Pressure at oil inlet upstream of
the turbocharger
[bar] Overpressure
Normal operation
2.0 < poil ≤ 4.5 *)
Engine start: Cold oil, admissible for a maximum of 15
< 8.0
minutes
Engine idling, admissible for a maximum of 1 hour
Pre-lubrication and post-lubrication (engine stopped)
0.5 < poil ≤ 2.5
0.5 < poil ≤ 1.0
< 1.25
Warning signal: (n ≥ 0.5 x nBmax
)
Alarm signal: Not admissible. Stop the engine immedi-
< 0.6
ately.
Table 5: Lubricating oil pressure at oil inlet before turbocharger
*) Depending on use of an oil orifice in accordance with the enginebuilder’s specifications.
01 Turbocharger contact surface
02 Oil inlet
03 Oil outlet
P
T
Oil pressure measuring point
Oil temperature measuring point
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.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
4 Monitoring operation / 4.1 Oil pressure, oil temperature
*) 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.
Lubricating oil temperature at the inlet
CAUTION
Machine damage
If the oil temperature at the oil inlet exceeds the admissible range, this may
lead to engine damage.
u Observe oil temperature at the oil inlet according to the following table.
Status for operation
Oil temperature at the inlet
Toil,inlet
30 … 90 °C
> 90 °C
Admissible
Temporarily admissible (< 1 h) → alarm
Not admissible → stop engine
> 95 °C
Not admissible → do not start engine (before start: preheat oil)
Table 6: Lubricating oil temperature at the inlet
< 30 °C
Lubricating oil temperature at the outlet
The oil temperature at the outlet is mainly dependant on:
¡
¡
¡
Lubricating oil temperature and pressure at the oil inlet
Engine load and turbocharger speed
Exhaust gas temperature
The maximum admissible oil temperature at the outlet is listed in the following table. The
specified oil outlet temperature is to be considered as alarm value for the turbocharger op-
eration and must be monitored according to the current regulations.
Status for operation
Oil temperature at the outlet
Toil,outlet
Admissible
≤ Toil,inlet + 55 K
(≤ 145 °C)
Temporarily admissible → alarm
Not admissible → stop engine
Table 7: Maximum lubricating oil temperature at the outlet
> Toil,inlet + 55 K
(> 145 °C)
> 165 °C
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 Tur-
bocharging Service Station.
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Operation Manual / 4 Product description / A150-M56/66/57/67 -
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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.
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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 strain cables
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
Fig. 19: Layout and overview of speed measurement system
86505 Speed sensor
86515 Cable connector
86526 F/I converter
86528 Tachometer
42188 Screw plug
42189 Gasket
01
*)
Plug with integrated voltage limiter
Alternative mounting position for speed
sensor
32109 Sealing disc with cams
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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 nBmax
.
If this permissible range of difference is exceeded, the following steps must be carried out:
u Reduce the engine performance immediately to the point at which the maximum tur-
bocharger speed does not exceed 70 % of nBmax
.
u If the engine cannot be stopped, it can continue to be driven at this reduced engine load
or turbocharger speed.
u If a turbocharger surges continuously, the engine performance must be reduced further.
u Measure the temperatures in the air lines and gas piping from and to the turbochargers
and compare with normal values. If clear deviations of temperature are found, the nearest
ABB Turbocharging Service Station has to be contacted.
u Check the pressure loss of the alternative air inlet and compare it with normal values.
If the engine can be stopped temporarily:
u Inspect air lines, gas piping and the turbochargers and remedy any malfunctions.
u In any case, contacting the nearest ABB Turbocharging Service Station is recommended.
4.3.4
Malfunctions on the speed measurement system
In the case of malfunctions of the speed measurement system, refer to the chapter entitled
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Operation Manual / 4 Product description / A150-M56/66/57/67 -
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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.
Fig. 20: Replacing the speed sensor
Part number
A150
A155
86505
M12 x 1.5
15 Nm
M12 x 1.5
15 Nm
Table 8: Tightening torque (86505)
u Reduce the engine performance to idling and then stop the engine. Pay attention to post-
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 / A150-M56/66/57/67 -
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5 Operation and service / 5.1 Noise emission
5
Operation and service
5.1
Noise emission
WARNING
Danger due to noise
Exposure to noise can harm the hearing system, impair health and the psy-
chological state and may lead to lack of attention and irritation.
u When the engine is running, always wear ear protection.
u Always wear ear protection if the sound pressure level exceeds 85 dB(A).
Wear ear protection.
The emission sound pressure level (A-weighted) is measured at a distance of 1 meter from
the turbocharger.
The highest value of the emission sound pressure level1) reaches a maximum of 105 dB(A)
near the filter silencer. The following prerequisites must be fulfilled with regard to the tur-
bocharger to observe this limit value:
¡
¡
¡
Air-inlet system has been fitted
All standard, noise-reducing measures2) have been fitted
The enginebuilder is responsible for insulating the charge air/scavenging air line and the
charge air cooler.
1)
2)
Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 :
A-weighted emission sound pressure level
The enginebuilder must provide acoustically equivalent measures in case of deviating in-
sulation versions
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Operation Manual / 4 Product description / A150-M56/66/57/67 -
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5 Operation and service / 5.1 Noise emission
Suggestion for noise insulation, bellows
Fig. 21: Noise insulation, bellows
01
02
03
04
05
06
Compressor casing
Bellows
Charge air duct / scavenging air duct
Insulation cushion
Insulation mat (at least 15 mm)
Sheet metal cover
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5 Operation and service / 5.2 Service work
5.2
Service work
Service work includes visual controls, monitoring, measuring and inspection as well as func-
tional checks. Service work enables the detection and rectification of changes to the tur-
bocharger and ensures full operability of the turbocharger.
CAUTION
Service intervals
Any service work on the turbocharger that is omitted or performed too late
can cause excessive contamination, wear and operating failures.
u Carry out the service work at the specified time intervals.
CAUTION
Shortened service intervals
Exceptional stresses such as several starts/stops per day, harsh environ-
mental conditions, poor fuel quality or high system vibrations can lead to
untimely machine damage even if the prescribed service intervals are ob-
served.
u Agree on a shortened service interval with ABB Turbo Systems.
To prevent machine damage caused by ageing and downtime, we recommend having an in-
spection carried out by an ABB Turbocharging Service Station no later than 5 years after the
last service.
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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 con-
sequence.
u Have any unknown causes clarified by an ABB Turbocharging Service Sta-
tion.
u Perform a visual control for air, exhaust gas, and oil leaks
u Record operating data and enter it in the engine logbook
u In case of deviations, determine the cause.
5.2.2
Service work at 100 hours after commissioning
u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en-
gine is stopped.
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.
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 Clean nozzle ring, turbine casing, compressor casing and diffuser, and check for cracks
and erosion/corrosion.
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5 Operation and service / 5.2 Service work
5.2.5
Entries in the engine logbook
The monitoring of the engine system enables conclusions to be drawn on the behaviour of
the turbocharger.
The following operating data and measured values must be entered regularly in the engine
logbook of the enginebuilder:
¡
¡
¡
¡
¡
Rating and speed of the engine
Air intake temperature
Pressure of the charge air
Pressure loss in the charge-air cooler
Lubricating oil pressure and lubricating oil temperature
If present:
¡
¡
¡
¡
Speed of the turbocharger
Air temperature after the compressor and after the charge-air cooler
Exhaust gas temperature before and after the turbine
Pressure loss in the filter silencer.
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5 Operation and service / 5.3 Expected replacement intervals
5.3
Expected replacement intervals
Rotating components
The recommended replacement intervals of the compressor and turbine wheels are spe-
cified with the aid of the safety concept for rotating parts (SIKO) and dependent on the op-
erating conditions. These intervals are shown on the rating plate of the turbocharger.
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.
During the prescribed periodic service work, the individual parts are examined for wear and
replaced if necessary.
Expected replacement intervals [h]
GAS / MDO
25000 … 50000
25000 … 50000
25000 … 50000
25000 … 50000
HFO
25000 … 50000
10000 … 25000
25000
Turbine casing
Nozzle ring
Gas outlet flange
Heat shield
25000
Rotor components
Bearing parts
Other casings
See rating plate data
12000 … 24000
50000
12000 … 24000
50000
Table 9: Expected replacement intervals
GAS
MDO = Marine Diesel Oil
HFO = Heavy Fuel Oil
= Natural Gas
The specified values are guideline values and not guaranteed values, see Influencing para-
meters.
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Operation Manual / 4 Product description / A150-M56/66/57/67 -
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5 Operation and service / 5.3 Expected replacement intervals
Influencing parameters
The specified values are guideline values and are not guaranteed. The actual values can devi-
ate considerably from the guideline values, for example, due to the following influences:
¡
¡
Fuel quality and fuel treatment
Load profile (thermal cycling, also number of starts/stops, emergency shutdowns, oper-
ating point)
¡
¡
¡
¡
Gas inlet temperature
Frequency and execution of cleaning process during operation
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).
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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.
u Run the engine for 5 ... 10 minutes at idling speed before stopping it.
¡
For oil-cooled bearing casings, post-lubricate for 20 minutes if the turbine inlet temper-
ature (tTE) exceeds the following values when the engine is stopped:
– 550 °C with insulated casing
– 600 °C with non-insulated casing
At temperatures below the specified values, post-lubrication must be ensured until the
rotors come to a standstill. ABB Turbo Systems recommends post-lubrication for
10 minutes.
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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 inten-
ded to ensure the trouble-free functioning of the turbocharger.
To allow you to observe the standard service intervals and to maintain a high turbocharger
efficiency, ABB Turbo Systems recommends that the cleaning procedure be carried out dur-
ing operation. This allows the thermal load of the engine to be kept low while ensuring max-
imum fuel efficiency.
Maintenance inter- Maintenance work
val
Operating status
24 … 72 h 1)
Engine load 50 … 85 %
50 … 200 h 1)
Engine load 20 … 40%
(guideline value)
Engine stopped
interval (usually
every
8000 … 12000 h) 2)
12000 h
Uncoupled filter silencer A155-M
Engine stopped
Table 10: Maintenance table
[h] = Hours of operation
1) If the maintenance intervals are incompatible with operation of the engine, contact ABB
Turbo Systems.
2) ABB Turbo Systems recommends having mechanical cleaning carried out by an ABB Tur-
bocharging Service Station during the service work. Otherwise, only carry out mechanical
cleaning if cleaning during operation is not sufficient to achieve the thermal load and the
rating of the engine.
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6 Periodic maintenance work / 6.2 Cleaning the compressor during
operation
6.2
Cleaning the compressor during operation
6.2.1
Introduction
Approval by enginebuilder
The following instructions for wet cleaning only apply to cleaning with pure water and under
the precondition that the enginebuilder approves the process.
Options and limits
Periodic cleaning during operation delays any major increase in contamination. The cleaning
method is suitable as long as the contamination has not progressed far. Very heavily con-
taminated components can no longer be cleaned using this method. In this case, ABB Turbo
Systems recommends having the contaminated components cleaned mechanically by an
ABB Turbocharging Service Station.
Periodic cleaning during operation is not a substitute for the service work during which the
turbocharger is completely dismantled and cleaned.
Cause and consequences of contamination
The contamination of the compressor stage depends on the degree of purity of the air that
is sucked in. Deposits can form in the flow channels if salt, oil mist, exhaust gas or dust are
sucked in with the air.
Consequences of contamination:
¡
¡
¡
¡
Impaired compressor efficiency
Elevated exhaust gas temperatures
Increased fuel consumption
Increased rotor unbalance
6.2.2
Cleaning interval
The time period between the periodical cleaning cycles depends greatly on the operating
conditions. Cleaning should normally be done every 24 ... 72 hours of operation.
If the specified cleaning intervals are incompatible with operation of the engine, contact
ABB Turbo Systems.
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6 Periodic maintenance work / 6.2 Cleaning the compressor during
operation
6.2.3
Cleaning method
Cleaning method and operating state
The compressor is cleaned during operation using the wet cleaning method. It is carried out
at an engine load of 50 ... 85 %.
This cleaning method has been tested and approved by ABB Turbo Systems.
V-engines
On V-engines with several turbochargers per engine, parallel cleaning of both turbochargers
is recommended. This cleaning process is faster and reduces the risk of surging of the tur-
bocharger.
Sequential charging
With sequential charging, it must be made sure especially after operating periods in the
lower range of performance that both turbocharger compressors are cleaned.
6.2.4
Function and safety of wet cleaning
CAUTION
Volume of water
Uncontrolled volumes of water can damage the turbocharger and the en-
gine.
u Never connect the water connection directly to a water pipe or a bigger
metering container than the one specified by ABB Turbo Systems.
WARNING
Danger due to pressure vessels
Personal injury can occur if the locally applicable legal regulations on peri-
odic inspections of the pressure vessels are not complied with.
u The locally applicable legal regulations regarding periodic checks of the
pressure vessels must be observed.
u Do not use pressure vessels that are defective.
CAUTION
Corrosion and deposits when cleaning
Salt water and cooling water treatment substances damage and adversely
affect turbocharger parts.
u Never use salt water, but only pure water for cleaning.
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6 Periodic maintenance work / 6.2 Cleaning the compressor during
operation
72000 Compressor casing
27000 External water pressure vessel
27005 Sealing plug
01
02
03
Water pipe to filter silencer or air suction branch
Pressurized air inlet pipe
Valve activator
Pressurized air from the compressor casing (72000) of the turbocharger passes through the
pipe (02) to the water pressure vessel (27000). As soon as the valve activator (03) is activ-
ated, water is pressed into the pipe (01) and routed to the filter silencer or air suction
branch.
The water does not act as a solvent. The coating is removed by the mechanical action of the
impacting droplets.
6.2.5
Carrying out wet cleaning of the compressor
Fig. 22: Carrying out wet cleaning of compressor
Engine load Filling amount of water pressure Water temperature
Water injection
period [s]
vessel [dm3]
[°C]
50 … 85 %
0.4
5 … 30
10
Table 11: Parameters for wet cleaning of compressor
u Remove sealing plug (27005).
u Fill container with 0.4 dm3 of pure water.
u Screw in sealing plug (27005) again.
u Push the valve activator (03) against the spring and hold for 10 … 15 seconds until the en-
tire volume of water is injected.
u Continue to operate the engine for at least five minutes to ensure that all of the water is
flushed out of the system.
Not more than three cleaning cycles should be conducted consecutively. Before repeating
the process, continue to operate the engine for at least five minutes to ensure that all of the
water is flushed out of the system.
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6 Periodic maintenance work / 6.3 Cleaning the turbine during opera-
tion
6.3
Cleaning the turbine during operation
6.3.1
Introduction
Approval by enginebuilder
The following instructions for wet cleaning only apply to cleaning with pure water and under
the precondition that the enginebuilder approves the process.
Options and limits
Periodic cleaning during operation delays any major increase in contamination. The cleaning
method is suitable as long as the contamination has not progressed far. Very heavily con-
taminated components can no longer be cleaned using this method. In this case, ABB Turbo
Systems recommends having the contaminated components cleaned mechanically by an
ABB Turbocharging Service Station.
Periodic cleaning during operation is not a substitute for the service work during which the
turbocharger is completely dismantled and cleaned.
Cause and consequences of contamination
ABB Turbo Systems recommends the use of fuels with low ash, sulphur, sodium and vana-
dium contents. Operating states with incomplete combustion also increase the tendency to
form deposits and must be avoided.
The combustion of heavy fuel oil (HFO) in diesel engines causes contamination of the tur-
bine stage. Poor quality fuel in conjunction with high exhaust gas temperatures can lead to
extremely hard deposits on turbine components.
Consequences of contamination:
¡
¡
¡
¡
Low turbine efficiency
Elevated exhaust gas temperatures
Increased charging and ignition pressures with increasing turbocharger speed
Lower engine performance.
Possible damage to turbocharger:
¡
¡
After the engine is stopped the rotor may become stuck in contamination deposits
Damage to turbine heads with blade breaks.
6.3.2
Cleaning interval
The time period between the periodical cleaning cycles depends greatly on the operating
conditions. Cleaning should normally be done every 50 to 200 hours of operation.
If the specified cleaning intervals are incompatible with operation of the engine, contact
ABB Turbo Systems.
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6 Periodic maintenance work / 6.3 Cleaning the turbine during opera-
tion
6.3.3
Cleaning method
The turbine components are cleaned during operation using the wet cleaning method. This
cleaning method is tested and approved by ABB Turbo Systems.
The precondition for wet cleaning is that the enginebuilder approves the process and these
regulations are observed.
V-engines
On V-engines with several turbochargers per engine, parallel cleaning of both turbochargers
is recommended. This cleaning process is faster and reduces the risk of surging of the tur-
bocharger.
6.3.4
Function and safety of wet cleaning
CAUTION
Corrosion and deposits when cleaning
Salt water and cooling water treatment substances damage and adversely
affect turbocharger parts.
u Never use salt water, but only pure water for cleaning.
To clean the turbine stage during operation, water is injected before the nozzle ring. Based
on an injection phase of 10 minutes, this cleaning procedure uses the principle of water solu-
bility of dirt deposits.
To prevent corrosion of the inside surfaces of the casings, the engine must be continued to
be operated for 10 minutes after a wet cleaning. The exhaust gas temperature downstream
of the turbocharger can drop by up to 180 °C during cleaning.
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6 Periodic maintenance work / 6.3 Cleaning the turbine during opera-
tion
6.3.5
Prerequisites
Two different turbine cleaning devices are available for turbochargers with single-inlet tur-
bine casing:
Fig. 23: Turbine cleaning devices
1. Device consisting of one cleaning nozzle per turbine casing gas inlet.
2. Device consisting of six cleaning nozzles with connecting pipe for water and scavenging
air.
Characteristic/component
Cleaning device
Conditions
one cleaning nozzle per six cleaning nozzles
gas inlet
Engine load (guideline value)
20 … 40 %
1) Turbine inlet temperature TTE before
water injection
350 … 430 °C
10 minutes
10 minutes
Stabilisation phase after TTE has been
reached
Stabilisation phase after turbine clean-
ing
Water supply
ensured
Water temperature
5 … 30 °C
Water pressure (overpressure compared
1.5 bar
2.5 bar
to atmosphere) pWT
2) External air supply
recommended
PPA = PTE + 0.5 bar
recommended
PPA = PTE + 1 bar
External air pressure pPA relative to tur-
bine inlet pressure PTE
Table 12: Turbine wet cleaning, recommended operating state
1) The temperature at the turbine inlet can be up to 100 °C higher than the exhaust gas tem-
perature after the cylinder. This must be taken into account when setting the operating
point before cleaning.
If necessary, the engine performance must be reduced to meet these conditions. The clean-
ing cycle can be started when the above conditions are fulfilled.
2) External air supply for continuous blowing off of the cleaning nozzles between cleaning in-
tervals.
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6 Periodic maintenance work / 6.3 Cleaning the turbine during opera-
tion
6.3.6
Carrying out wet cleaning of the turbine
CAUTION
Inadmissible thermal stress and flooding of the turbine
Smaller amounts of water can lead to an inadequate cleaning result. Larger
amounts of water lead to inadmissible thermal stress on the turbine com-
ponents and can cause flooding of the turbine.
u It is imperative that turbine cleaning parameters are observed.
CAUTION
Maximum temperature at turbine inlet during cleaning
During cleaning, the temperature at the turbine inlet will rise and may strain
the material significantly.
u Make sure the maximum temperature at the turbine inlet is not exceeded
during cleaning.
Fig. 24: Carrying out wet cleaning of turbines
u Fulfil prerequisites.
u Ensure that the water supply (01) is guaranteed.
u Open the stop valve (02) and set the water volume flow VW with a flowmeter (03) (see
cleaning parameters).
u Close the stop valve (02) after 10 minutes.
u Wait for 10 minutes; do not change the load during this stabilisation phase.
If the cleaning result is unsatisfactory or there is water leakage, contact an ABB Turbochar-
ging Service Station.
Parameter for 1-nozzle cleaning
Product
Temperature be- Maximum temperature Water volume flow Injection time
VW [dm3/min] 1)
[min]
fore turbine before before turbine during
cleaning [°C]
350 ... 430
cleaning [°C]
A150
A155
530
530
14.0
19.0
10
10
350 ... 430
Table 13: Wet cleaning of turbines, parameters for 1-nozzle cleaning
1) Corresponds to a water pressure pWT of 1.5 bar (overpressure compared to atmosphere)
before the cleaning nozzle
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6 Periodic maintenance work / 6.4 Cleaning components mechanically
Parameter for 6-nozzle cleaning
Product
Temperature be- Maximum temperature Water volume flow Injection time
VW [dm3/min] 1)
[min]
fore turbine before before turbine during
cleaning [°C]
350 ... 430
cleaning [°C]
A150
A155
530
530
18.0
25.0
10
10
350 ... 430
Table 14: Wet cleaning of turbines, parameters for 6-nozzle cleaning
1) Corresponds to a water pressure pWT of 2.5 bar (overpressure compared to atmosphere) at
the connection point WA/WG
6.4
Cleaning components mechanically
6.4.1
Preparation
CAUTION
Component damage and corrosion
If mechanical cleaning is carried out incorrectly, this can lead to damage and
corrosion on the components.
u Pay attention to the specifications in this chapter pertaining to mechan-
ical cleaning.
CAUTION
Selection of cleaning tools
Turbocharger components are sensitive and easily sustain mechanical dam-
age. The use of needle descalers (for example) or other striking tools dam-
ages the components. Depending on the specification, nozzle rings or tur-
bine casings may have protective coatings which can also be damaged.
u Use only soft tools such as rags, brushes or wire brushes.
u In case of heavy contamination, the cleaning methods described in this
chapter (such as soaking, for example) can be repeated until a satisfact-
ory result is achieved.
The disassembly and assembly of the parts is described in the respective Disassembly and
Assembly chapters.
u Contaminated water and cleaning agents must be disposed of in an environmentally
compatible, professional way and in compliance with locally applicable regulations.
© Copyright 2019 ABB. All rights reserved.
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Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
6 Periodic maintenance work / 6.4 Cleaning components mechanically
6.4.2
Cleaning the filter silencer
Fig. 25: Cleaning the filter silencer
81135 Filter silencer body
81136 Absorption segment
81266 Cover grid
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.
© Copyright 2019 ABB. All rights reserved.
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Operation Manual / 4 Product description / A150-M56/66/57/67 -
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6 Periodic maintenance work / 6.4 Cleaning components mechanically
Cleaning the absorption segments
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
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.
© Copyright 2019 ABB. All rights reserved.
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Rev.N
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Operation Manual / 4 Product description / A150-M56/66/57/67 -
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6 Periodic maintenance work / 6.4 Cleaning components mechanically
6.4.3
Compressor-end, non-rotating parts
WARNING
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or con-
tact with them may be harmful to health.
u Do not breathe in these substances and avoid contact with the skin.
u Ensure proper ventilation.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Wear personal protective equipment (PPE) according to the material
safety data sheet.
u Comply with local legislation.
Wear safety goggles.
Wear safety gloves to protect against chemical hazards.
Wear a respiratory mask to protect against gases.
The following parts, which are relevant in terms of performance, can be cleaned in accord-
ance with the description below.
Fig. 26: Compressor-end, non-rotating parts
72000
77000
79000
Compressor casing
Wall insert
Diffuser
u Clean the above-mentioned components with steam or ultrasound. Alternatively, soak in
diesel oil or water containing household cleaning agent. After soaking, remove contamin-
ation with a brush.
u Dry components completely.
u Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the tur-
bocharger.
u Dispose of contaminated water and cleaning agents in accordance with the information
in the material safety data sheet.
© Copyright 2019 ABB. All rights reserved.
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Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
6 Periodic maintenance work / 6.4 Cleaning components mechanically
6.4.4
Turbine-end, non-rotating parts
WARNING
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or con-
tact with them may be harmful to health.
u Do not breathe in these substances and avoid contact with the skin.
u Ensure proper ventilation.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Wear personal protective equipment (PPE) according to the material
safety data sheet.
u Comply with local legislation.
Wear safety goggles.
Wear safety gloves to protect against chemical hazards.
Wear a respiratory mask to protect against gases.
© Copyright 2019 ABB. All rights reserved.
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Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
6 Periodic maintenance work / 6.4 Cleaning components mechanically
Baked layers of contamination, for example, from heavy fuel oil or coked oil occur at the tur-
bine end. The following parts, which are relevant in terms of performance, can be cleaned in
accordance with the description below.
Fig. 27: Turbine end, non-rotating parts
51000 Turbine casing
51301 Cleaning nozzle (optional)
57002 Gas outlet flange
01
Screw connection (provided by the cus-
tomer)
56001 Nozzle ring
56005 Lamellar sealing ring
u Dismantle the lamellar sealing ring (56005) in the nozzle ring.
u Place contaminated parts in hot water or in a liquid such as brake cleaner to soften the
contamination.
u Brush away the contamination or remove with a steam cleaner.
u Repeat the soaking and brushing process if necessary.
u Use clean water to remove all traces of solvent from parts.
u Dry components completely.
u Spray cleaned surfaces with penetrating oil. Do not spray exterior surfaces of the tur-
bocharger.
u Dispose of dirty water and cleaning agents in accordance with the information in the ma-
terial safety data sheet.
Option with cleaning nozzle
u The cleaning nozzle (51301) must be replaced after each removal procedure. If the clean-
ing nozzle is not to be replaced, the screw connection (01) must not be loosened during
disassembly.
Water or air can be passed through the piping and into the cleaning nozzle to check whether
it is blocked. When installed, the cleaning nozzle can be mechanically cleaned with a needle.
Option with 6-nozzle cleaning
© Copyright 2019 ABB. All rights reserved.
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Rev.N
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Operation Manual / 4 Product description / A150-M56/66/57/67 -
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6 Periodic maintenance work / 6.4 Cleaning components mechanically
6.4.5
Cartridge group, general
CAUTION
Corrosion
If the cartridge group is not put back into operation immediately after clean-
ing, parts may corrode.
u Immediately after cleaning, install the cartridge group and put it back
into operation.
Compressor wheels can be heavily contaminated due to poorly filtered suction air; turbines
can be heavily contaminated due to exhaust gas residues or coked oil. Cleaning during oper-
ation may not suffice to remove such contamination; instead, it may need to be cleaned
mechanically during standard service intervals (see the Service work chapter).
First clean compressor end and then turbine end according to the following description.
6.4.6
Cleaning the cartridge group on compressor end
CAUTION
Selection of the cleaning agent
Cleaning agents which contain chlorine attack metals.
u Use only pH-neutral cleaning agents which do not attack metals.
u Observe 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 Make sure that no water or contamination can enter into the cartridge
group.
u Cleaning procedures should be selected that do not result in removal of the compressor
wheel material or cause damage to its surfaces. Clean the compressor wheel with a rag or
soft brush which has been soaked in water with a household cleaning agent. Do not use a
wire brush!
u Dry the compressor wheel and the gap between the compressor and the bearing casing
with low-pressure pressurized air.
u Lightly spray the compressor wheel and the gap between the compressor and the bearing
casing with penetrating oil.
u Dispose of dirty water and cleaning agents in accordance with the material safety data
sheet.
© Copyright 2019 ABB. All rights reserved.
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Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
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6 Periodic maintenance work / 6.4 Cleaning components mechanically
6.4.7
Cleaning the cartridge group on turbine end
Soaking the contamination
Baked layers of contamination from heavy fuel oil or coked oil occur at the turbine end. The
contamination can be removed by soaking and brushing. The procedure for soaking the lay-
ers of contamination as well as for cleaning the turbine are described in the following.
Fig. 28: Soaking the turbine end
Product
A150
A [mm]
200
B [mm]
35
C [mm]
382
A155
240
40
454
Table 15: 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 which contain chlorine attack metals.
u Use only pH-neutral cleaning agents which do not attack metals.
u Observe safety data sheet.
u Fill the container (02) with soaking fluid. To shorten the soaking time, the fluid can be
heated up to a maximum of 60 ºC.
© Copyright 2019 ABB. All rights reserved.
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Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
6 Periodic maintenance work / 6.4 Cleaning components mechanically
WARNING
Heating up of cleaning agents and operating fluids
When cleaning agents or operating fluids are heated up, explosive vapours
can be produced which are hazardous to health.
u Observe the information in the material safety data sheet.
Wear a respiratory mask according to material safety data sheet.
CAUTION
Water and contamination in the cartridge group
If water or contamination penetrates the cartridge group, this can impair
the function of the turbocharger and damage parts inside the cartridge
group.
u Place the cartridge group on suitable supports (01) made of wood or
metal.
u Observe dimension (B) for the supports (01) so that the cartridge group
is not immersed too deeply.
u Let the layers of contamination on the turbine soak for four hours.
Removing dirt
WARNING
Health hazard due to soot particles
If soot particles enter the eyes or respiratory tract, this can be harmful to
health.
u Avoid the formation of dust.
u Vacuum up dust with a suitable vacuum cleaner.
u Wear a respiratory mask to protect against particles (P1 or P2 mask).
u Wear safety goggles.
Wear safety goggles.
Wear a respiratory mask to protect against dusts.
Wear safety gloves to protect against mechanical hazards.
u Lift up the cartridge group and align it horizontally.
u Remove dirt manually using a soft brush or a wire brush.
© Copyright 2019 ABB. All rights reserved.
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Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
6 Periodic maintenance work / 6.4 Cleaning components mechanically
CAUTION
Water and dirt in the cartridge group
If water or dirt enters 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 dirt enters the gap between partition wall and
turbine.
CAUTION
Non-permissible rotor unbalance after cleaning
Unevenly distributed residual contamination deposits lead to rotor unbal-
ance. This can result in bearing or turbocharger damage.
u Remove all traces of contamination from the turbine.
u After brushing off the dirt, fill the container (02) with clean water and not with salt water .
u Immerse the turbine of the cartridge group in clean water so that any loose dirt comes
off.
u Lift up the cartridge group and align it horizontally.
u Clamp the partition wall to the bearing casing.
u Dry the turbine and the gap between the turbine and the partition wall with low-pressure
compressed air.
u Lightly spray the turbine and the gap between the turbine and the partition wall with pen-
etrating oil.
u Dispose of dirty water and cleaning agents in accordance with the information in the ma-
terial safety data sheet.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
6 Periodic maintenance work / 6.5 Changing the absorption element
6.5
Changing the absorption element
The absorption element (81148) in uncoupled filter silencers must be replaced every 12000
hours of operation.
Disassembling the absorption element
Fig. 29: Disassembling the absorption element
2. Dismantle the hexagon-head screws (81152) with washers (81153) and mounting
plate (81149).
3. Remove the socket screws (81154), roll pins (81151), flanges (81145 / 81146) and absorp-
tion element (81148).
© Copyright 2019 ABB. All rights reserved.
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Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
6 Periodic maintenance work / 6.5 Changing the absorption element
Installing the absorption element
Fig. 30: Installing the absorption element
Product
81152 [Nm]
81154 [Nm]
A155-M
50
10
Table 16: Tightening torque (81152 / 81154)
1. Fit the new absorption element (81148) and flanges (81145 / 81146) with roll pins (81151)
and socket screws (81154).
Tighten socket screws (81154) crosswise. Observe the tightening torque.
2. Check value X = 15 mm +/- 0.1 mm along the circumference at four points (0°, 90°, 180°
and 270°).
If value X is not satisfied, unscrew the socket screws (81154) and repeat step one.
3. Fit the mounting plate (81149) with washers (81153) and hexagon-head screws (81152).
Observe the tightening torque.
© Copyright 2019 ABB. All rights reserved.
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Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
7 Eliminating malfunctions / 7.1 Malfunctions when starting
7
Eliminating malfunctions
7.1
Malfunctions when starting
Delayed start-up
Possible causes
Remedy
Turbochar-
ger
Turbocharger contaminated
Clean (see chapter Periodic mainten-
Bearing damaged
Rotor rubbing
Contact ABB Turbocharging Service
Station
Foreign object in the turbocharger
Table 17: Malfunctions when starting – Delayed start-up
Vibrations
Possible causes
Remedy
Turbochar-
ger
Rotor unbalance
Turbine or compressor damaged
Bearing damaged
Contact ABB Turbocharging Service
Station
Engine
Vibrations from engine
Contact enginebuilder
Table 18: Malfunctions when starting – Vibrations
Rubbing of rotating parts
Normal behaviour, not a malfunction
Turbochar-
ger
A slight amount of uniform wear at the circumference of the rotor components
caused by slight local rubbing against adjacent components is permitted. This
causes the compressor or turbine blades to be somewhat shortened. To prevent
significant loss of efficiency, specific tolerances must be fulfilled.
¡
If there is any doubt about the extent of the rubbing, contact an ABB Tur-
bocharging Service Station.
¡
Have a dimension check carried out by an ABB Turbocharging Service Sta-
tion.
Table 19: Malfunctions when starting – Rubbing of rotating parts
© Copyright 2019 ABB. All rights reserved.
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October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
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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.
Possible causes
Remedy
Turbochar-
Axial clearance of the rotor excessive
Contact an ABB Turbocharging
ger
Service Station
Engine
Oil filter heavily contaminated
Clean
Oil pump in lubricating system defect- Check/replace
ive
Manometer displays incorrectly
Replace manometer
Table 20: Malfunctions during operation – Lubricating oil pressure too low
Speed reduces
Possible causes
Turbochar-
ger
Remedy
Rotor components or bearing damaged Contact ABB Turbocharging Service
Station
Engine
Pipes
Defects on the connected cylinders in
pulse charging
Contact enginebuilder
Repair
Defects, such as leaks, in the exhaust
gas pipes or charge air ducts
Table 21: Malfunctions during operation – Speed reduces
Speed increases
Possible causes
Remedy
Turbochar-
ger
turbine and/or nozzle ring (with 4-
stroke application)
bocharging Service Station
Table 22: Malfunctions during operation – Speed increases
© Copyright 2019 ABB. All rights reserved.
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October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
7 Eliminating malfunctions / 7.2 Malfunctions during operation
Exhaust gas temperature too high
Engine performance and engine speed unchanged
Possible causes
Remedy
Turbocharger
tion
Compressor/turbine contaminated
Exhaust gas back pressure too high
Clean or repair boiler or exhaust gas si-
lencer
Turbine damaged or eroded
Contact ABB Turbocharging Service
Station
Engine
Malfunction in the injection system
Cooler contaminated
Cooling water volume too low
Repair or contact manufacturer
Clean
Fill
Charge air
cooler
Inlet temperature of cooling water
Check/clean cooling system
too high
Insufficient ventilation
Improve ventilation
Table 23: Malfunctions during operation – Exhaust gas temperature too high
Charge air pressure too low
Engine performance and engine speed unchanged, suction condition normal
Possible causes
Remedy
Turbochar-
ger
Manometer display not correct
Supply pipe to manometer not sealed
Replace manometer
Repair leak
pressure drop too high
Compressor end and/or turbine end
contaminated
Compressor/turbine damaged
Exhaust gas back pressure too high
Air receiver not sealed
Contact ABB Turbocharging Service
Station
Clean or repair boiler or exhaust gas si-
lencer
Repair
Engine
Pipes
Gas piping between engine and turbine
leaking
Injection mistimed
Valve control misadjusted
Set correctly
Repair.
Pipes downstream to the compressor
outlet not sealed.
Table 24: Malfunctions during operation – Charge air pressure too low
© Copyright 2019 ABB. All rights reserved.
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Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
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
Replace manometer
Turbochar-
ger
Manometer display not correct
of nozzle ring
bocharging Service Station
Engine
Malfunction in the injection system
Injection mistimed
Repair or contact manufacturer
Set correctly
Engine performance higher than indic- Check engine performance
ated
Table 25: Malfunctions during operation – Charge air pressure too high
Reduced compressor performance/efficiency and therefore engine performance
losses
CAUTION
Compressor damage
A severely contaminated or corroded compressor wheel can reduce the com-
pressor wheel’s fatigue endurance limit and result in the turbocharger being
damaged.
u Rectify malfunction in accordance with the following table.
Possible causes
Remedy
Turbochar-
ger
have been fed in
Optimize oil separation
Increased blade vibration, compressor Correct the feed of ventilation gases ac-
blade damage due to the ventilation
gases that have been fed in
cording to instructions of engineb-
uilder.
Material of the compressor wheel cor-
roded due to the feeding in of ventila-
tion gases containing corrosive com-
ponents
Correct the feed of ventilation gases ac-
cording to instructions of engineb-
uilder.
Material of the compressor wheel cor-
roded due to intake air containing ex-
haust gases or salt
Prevent exhaust gas leakages in the en-
gine space
Clean (see chapter Periodic mainten-
Table 26: Malfunctions during operation – Engine performance losses
© Copyright 2019 ABB. All rights reserved.
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Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
7 Eliminating malfunctions / 7.3 Turbocharger is surging
7.3
Turbocharger is surging
WARNING
Hot air escapes from the filter silencer
A surge blow is accompanied by a loud bang and escape of hot air from the
filter silencer. This may result in injury to personnel.
u Keep a distance from the filter silencer while the turbocharger is surging.
Turbocharger surges continuously or periodically
CAUTION
Continuous or periodic surging
If the turbocharger surges continuously or periodically, parts of the tur-
bocharger may be damaged.
u Gradually reduce the engine load.
u Have the cause clarified and remedied immediately by an ABB Turbochar-
ging Service Station.
u Have parts assessed for damage and, if necessary, replaced by an ABB
Turbocharging Service Station.
Possible causes
Remedy
Turbocharger
Filter silencer or diffuser contamin-
ated
Clean (see chapter Periodic mainten-
Heavy contamination deposits in the
turbine or in the nozzle ring
Engine
Protective grating in front of the tur- Clean/replace
bocharger contaminated or damaged
Charge air
cooler
Cooler contaminated
Charge air duct blocked
Clean
Table 27: Malfunction – Turbocharger pumping
Sporadic surge blows
Possible causes
Remedy
Engine
Engine load reduced quickly when
- -
manoeuvring.
When this happens, the flow direc-
tion in the compressor is momentar-
ily reversed. Such sporadic surge
blows do not impair the safe opera-
tion of the turbocharger.
Table 28: Malfunction – Sporadic surge blows
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
7 Eliminating malfunctions / 7.4 Malfunctions when stopping
7.4
Malfunctions when stopping
Runout noises
Possible causes
Remedy
Turbochar-
ger
Bearing damaged
Rotor rubbing
Check clearances (see chapter Measuring clear-
tolerance or if in doubt, contact an ABB Turbochar-
ging Service Station.
Check clearances (see chapter Radial clearances N
ance or if in doubt, contact an ABB Turbocharging
Service Station.
Foreign object in the tur-
bocharger
Dismantle turbocharger (see chapter Fitting and
dismantling). In case of damage, replace the cor-
responding parts or contact an ABB Turbochar-
ging Service Station.
Table 29: Malfunctions when stopping – Runout noises
Runout time too short
The runout time must be noted down as a reference. Because the runout time depends on
the oil viscosity, the runout time must always be measured at the same oil temperature.
If the runout time is significantly shorter in comparison to a previous measurement, the fol-
lowing table must be observed.
Possible causes
Remedy
Turbochar-
ger
Bearing damaged
Rotor rubbing
Check clearances (see chapter Measuring clear-
tolerance or if in doubt, contact an ABB Turbochar-
ging Service Station.
Check clearances (see chapter Radial clearances N
ance or if in doubt, contact an ABB Turbocharging
Service Station.
Foreign object in the tur-
bocharger
Dismantle turbocharger (see chapter Fitting and
dismantling). In case of damage, replace the cor-
responding parts or contact an ABB Turbochar-
ging Service Station.
Table 30: Malfunctions when stopping – Runout time too short
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
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
Turbochar-
ger
The speed sensor was acci-
The screw plug for the sensor is fitted with an ad-
dentally fitted with an addi- ditional gasket (copper ring).
tional gasket.
For information regarding the disassembly and as-
sembly of the speed sensor, refer to chapter Re-
An enlarged distance
between the sensor tip and
the signal-emitting sealing
disc reduces the voltage
amplitude of the speed sig-
nal.
Install the speed sensor without the additional
gasket (copper ring).
Sensor or cable defective
Contact an ABB Turbocharging Service Station.
Order new speed sensor (86505) (refer to chapter
Table 31: Malfunction of the speed measurement system – No signal or poor signal amplitude
Measured speed too high
Possible causes
Remedy
Turbochar-
ger
Sensor tip contaminated,
For information regarding the disassembly and as-
attract metallic particles.
This reduces the distance to Dismantle the sensor, clean the sensor tip, and fit
the signal-emitting sealing
the sensor back on with the specified tightening
disc, which can lead to ampli- torque.
fication of the noise com-
ponent and, hence, to false
triggering.
Table 32: Malfunction of the speed measurement system – Measured speed too high
Measured speed too low
Possible causes
Remedy
Turbochar-
- -
Contact ABB Turbocharging Service Station
ger
Table 33: Malfunction of the speed measurement system – Measured speed too low
If none of the measures described above remedy the malfunction, have the speed measure-
ment system checked by an ABB Turbocharging Service Station.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
8 Dismantling and fitting, general / 8.1 Introduction
8
Dismantling and fitting, general
8.1
Introduction
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
Danger of burns
Touching hot surfaces can cause severe burns.
u Do not touch hot surfaces.
u Wear heat-resistant safety gloves.
u Clearly designate hot parts and assemblies when leaving the workplace.
Wear safety gloves to protect against thermal hazards.
CAUTION
Further operations
This Operation Manual may be used to carry out only those operations that
are described in it. Further operations that are executed in an incorrect way
can lead to serious damage to the machine.
u ABB Turbo Systems recommends having further operations carried out
only by trained personnel from an ABB Turbocharging Service Station.
u Mark the casing position for assembly.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
8 Dismantling and fitting, general / 8.1 Introduction
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.
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
Oil orifice
u When disassembling the turbocharger, an oil orifice fitted in the oil inlet must not be re-
Tightening torques for components of the turbocharger
The specified tightening torques of the screw fittings must be observed (Table of tightening
Tightening torques for assembly devices
Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB
must be tightened so they rest firmly against the surface.
WARNING
Suspended loads
Loads that are not attached according to regulations can cause injury to
personnel or fatal accidents.
u Only fasten the turbocharger, assemblies or individual parts on properly
functional lifting gear with sufficient load limit.
u Pay attention to the correct attachment of loads on the crane hook.
u People must not stand beneath suspended loads.
Wear safety gloves to protect against mechanical hazards.
Wear safety helmet.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
8 Dismantling and fitting, general / 8.1 Introduction
Definition of terms
¡
Suspension point
Defined loading point on a component or an assembly (blind hole thread, eyelet, lug).
¡
Assembly device
Devices that are fitted on the turbocharger in order to obtain a suspension point. As-
sembly devices are specially constructed and designed for the defined use; they are not
commercially available products. Use assembly devices only for the described applica-
tions.
¡
Lifting gear
Equipment for the lifting and transporting of loads (ropes, chain block, crane). Lifting
gear is not supplied by ABB.
Swivel lifting eyes to be used
Two swivel lifting eyes are required for the safe lifting of loads, these are not supplied by
ABB Turbo Systems.
Fig. 31: Swivel lifting eyes
Product
Thread M
Length L
[mm]
Minimum load limit
[kg]
Quantity
A150
A155
M8
13 mm
75 kg
3
2
M16
21 mm
1000 kg
M8
13 mm
21 mm
150 kg
3
M16
1400 kg
2
Table 34: Swivel lifting eyes
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
8 Dismantling and fitting, general / 8.1 Introduction
Press-off screws to be used
Six press-off screws (01) are required to press off the gas outlet flange, which are not sup-
plied by ABB Turbo Systems.
Fig. 32: Press-off screws
Product
A150
A155
Thread
M12
M16
Length
30 mm
30 mm
Quantity
3 or 6
3 or 6
Table 35: Press-off screws
Dismantling screw to be used for the optional 6-nozzle turbine cleaning component
A dismantling screw (01) is required to dismantle and fit the cleaning nozzles, which is not
supplied by ABB Turbo Systems
Fig. 33: Dismantling screw
Product
A150-M
A155-M
Thread
M8
M10
Length [mm]
Quantity
40
50
1
1
Table 36: Dismantling screw
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
8 Dismantling and fitting, general / 8.2 Disassembly and assembly
concepts
8.2
Disassembly and assembly concepts
Removal and installation with removed air inlet and gas outlet
Fig. 34: Removing the cartridge group with compressor and turbine casing
When dismantling with removed air inlet and gas outlet options, the air suction branch or fil-
ter silencer, as well as the gas outlet casing are removed from the turbocharger for the time
being. The cartridge group, the turbine casing and the compressor casing can then be de-
tached from the engine and dismantled in an assembled state. Reassembly is carried out in
reverse order.
A prerequisite is that the interfaces between the alternative air inlet (filter silencer or air suc-
tion branch) and the compressor casing, as well as between the turbine casing and gas out-
let casing, are accessible at the engine side.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
8 Dismantling and fitting, general / 8.2 Disassembly and assembly
concepts
Cartridge concept
Fig. 35: Cartridge concept
The cartridge concept incorporates the removal and installation of the turbocharger from/
onto the engine, whereby the air inlet (filter silencer or air suction branch), the compressor
casing and the cartridge group can be individually dismantled and fitted in the order shown
in the illustration.
The turbine casing and optional gas outlet casing remain on the engine during the process.
In addition, the nozzle ring can also be dismantled/fitted with this concept (not shown).
When employing the cartridge concept, the turbine casing and the optional gas outlet cas-
ing remain on the engine. Adequate support or suspension of these components must be
ensured.
A prerequisite is that the interfaces between the cartridge group and the turbine casing, as
well as between the cartridge group and the compressor casing, are accessible at the engine
side.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
8 Dismantling and fitting, general / 8.2 Disassembly and assembly
concepts
Optional spanner holder
Fig. 36: Optional spanner holder
ABB Turbo Systems offers an optional spanner holder (90165) (see Dismantling and fitting,
used to facilitate the loosening of nuts and the application of tightening torques for the
strip connection between the cartridge group and the turbine casing.
The spanner holder (90165) should only be used for loosening the nuts and applying tighten-
ing torques for the nuts at the position shown.
Other screws or nuts on the turbocharger should not be tightened with this tool.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
8 Dismantling and fitting, general / 8.3 Weights of individual parts
8.3
Weights of individual parts
Fig. 37: Weights of assemblies
Designation
A150
[kg]
A155
[kg]
01
02
03
04
05
06
07
08
09
Filter silencer
90
24
180
35
13
220
8
140
40
280
65
21
360
13
Radial air suction branch
Compressor casing with insulation
Wall insert
Diffuser
Cartridge group
Nozzle ring
Burst ring
Turbine casing
11
17
1 inlet *
2 inlets *
3 inlets *
320
290
300
35
500
460
460
65
10
11
Gas outlet flange
Gas outlet casing with insulation
160
240
Table 37: Weights of assemblies
* including burst protection and insulation
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
8 Dismantling and fitting, general / 8.4 Table of tightening torques
8.4
Table of tightening torques
Fig. 38: Overview of tightening torques
1) Only A155-M with uncoupled filter silencer
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
8 Dismantling and fitting, general / 8.4 Table of tightening torques
The following tightening torques must be observed for the designated screw fittings:
Position
Part number
A150
A155
02
72051
M16
M16
275 Nm
275 Nm
02a
04
72054
79041
51007
- -
M16
275 Nm
M6
M6
8 Nm
8 Nm
08
M16
M16
175 Nm
175 Nm
51007
M16
M16
with spanner
holder (90165)
85 Nm
70 Nm
09
11
51009
72011
86505
- -
M16
M16
200 Nm
200 Nm
M16
M18
275 Nm
370 Nm
15
M12 x 1.5
M12 x 1.5
15 Nm
15 Nm
16a
20
21
M16
M16
200 Nm
200 Nm
81154
81155
81152
- -
- -
- -
M6
10 Nm
M8
55 Nm
22
M10
50 Nm
Table 38: Tightening torques
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
8 Dismantling and fitting, general / 8.4 Table of tightening torques
Fig. 39: Tightening torques for insulation
The following tightening torques must be observed for the specified screw connections:
Position
Part number
A150
A155
16a / 16b 1)
- -
M16
M16
200 Nm
200 Nm
16b 2)
18
- -
- -
- -
- -
M12
M12
65 Nm
65 Nm
M6
M6
10 Nm
10 Nm
19
M8
M8
25 Nm
25 Nm
20
M10
M10
45 Nm
45 Nm
Table 39: Tightening torques for insulation
1) Tightening torque for attaching the insulation with integrated burst protection at the tur-
bine casing
2) Tightening torque for attaching the insulation to the burst protection.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.1
Removing air inlets
9
Dismantling and fitting with removed
air inlet and gas outlet
9.1
Removing air inlets
Fig. 40: Removing the air inlets
1. Attach lifting gear to the filter silencer (81000) or air suction branch (82000).
2. Loosen the hexagon-head screws (72051) and remove them with fastening strips (72012).
3. Remove the filter silencer (81000) or air suction branch (82000).
4. Remove and dispose of the O-ring (81010 or 82010).
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.1
Removing air inlets
A155-M Uncoupled filter silencer
Fig. 41: Removing the uncoupled filter silencer
1. Secure lifting gear to filter silencer (81000).
2. Unscrew the hexagon-head screws (72054) and remove along with Verbus Ripp® wash-
ers (72053) and three safety plates (72055).
3. Remove the filter silencer (81000).
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.2
Removing the gas outlet casing
9.2
Removing the gas outlet casing
u Mark the casing position for assembly.
Variant without support
Fig. 42: Remove gas outlet casing without support
1. If present: Remove waste gate pipe.
2. Remove insulation ring.
3. Fit swivel lifting eyes (S) to the gas outlet casing (61001). Attach lifting gear to swivel lift-
ing eye and secure to a crane hook.
4. Loosen and remove nuts (51009).
5. Remove the gas outlet casing (61001), set it down properly in an appropriate place and
secure it.
6. Remove and dispose of the gasket (61002).
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.2
Removing the gas outlet casing
Variant with support
Fig. 43: Removing gas outlet casing with support 1
1. If present: Remove waste gate pipe.
2. Remove gas outlet casing insulation.
3. Remove insulation ring.
4. Remove fixing screws of support (61301) to bracket.
5. Fit swivel lifting eyes (S) to the gas outlet casing (61001). Attach lifting gear to swivel lift-
ing eye and secure to a crane hook.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.2
Removing the gas outlet casing
Fig. 44: Removing gas outlet casing with support 1
6. Loosen nuts (51009) and remove together with support (61301).
7. Remove the gas outlet casing (61001), set it down properly in an appropriate place and
secure it.
8. Remove and dispose of the gasket (61002).
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.3
Removing the gas outlet flange
9.3
Removing the gas outlet flange
Depending on the way of fixing the gas outlet flange, the appropriate Working Instruction
has to be consulted (pressing off using 3 or 6 press-off screws).
If the following Working Instructions are not observed, this can lead to cracks in the gas out-
let casing.
The following variants are possible:
u Pressing off using 3 press-off screws.
u Pressing off using 6 press-off screws.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.3
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.
Fig. 45: Dismantling the gas outlet flange
Product
A150
Press-off screws (strength 8.8) *
3 x M12 x 30
Tightening torque
≤ 65 Nm
A155
3 x M12 x 30
≤ 150 Nm
Table 40: 3 press-off screws
1. Evenly press off and remove the gas outlet flange (57002) with screws (01) according to
the table. If it is not possible to press off the gas outlet flange with the maximum tight-
ening torque, contact an ABB Turbo Systems Service Station.
2. Attach swivel lifting eye (S) to the gas outlet flange. Secure lifting gear to the swivel lift-
ing eye.
3. Remove the gas outlet flange.
4. If present: Remove the metal C-ring (57003).
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.3
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.
Only dismantle the gas outlet flange if this is necessary for service work.
u With blows from a plastic tip hammer, ensure that the gas outlet flange does not cant.
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. 46: Removing the gas outlet flange
Product
A150
Press-off screws (strength 8.8) *
6 x M12 x 30
Tightening torque
≤ 65 Nm
A155
6 x M12 x 30
≤ 150 Nm
Table 41: 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 tight-
ening torque, contact an ABB Turbo Systems Service Station.
2. Attach swivel lifting eye (S) to the gas outlet flange. Secure lifting gear to the swivel lift-
ing eye.
3. Remove the gas outlet flange.
4. If present: Remove the metal C-ring (57003).
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.4
Removing the cartridge group with compressor and turbine casing
9.4
Removing the cartridge group with compressor
and turbine casing
Fig. 47: Turbine cleaning nozzle
1. If present: Loosen the turbine cleaning connection.
The cleaning nozzle (51301) must be replaced after each removal procedure. If the clean-
ing nozzle is not to be replaced, the screw connection (01) must not be loosened during
disassembly.
Fig. 48: Remove insulation
2. Remove the compressor casing insulation.
3. Remove the turbine casing insulation.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.4
Removing the cartridge group with compressor and turbine casing
Fig. 49: Removing the cartridge group with compressor and turbine casing
4. If present: Loosen and remove the compressor wheel cooling connection. Close the com-
pressor wheel cooling opening with a screw plug (01).
5. 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.
6. Attach lifting gear to the cartridge group and secure to a crane.
Fig. 50: Set down the cartridge group with the compressor and turbine casing
8. Lift the cartridge group with the compressor and turbine casing.
9. Fit two swivel lifting eyes (S) and secure to a second set of lifting gear.
10. Turn the compressor and turbine casing and set down on suitable supports.
11. Remove lifting gear from cartridge group. Leave second lifting gear attached to com-
pressor casing for safety.
12. Remove and dispose of the O-rings (42195, 42200).
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.5
Removing the compressor casing
9.5
Removing the compressor casing
Removing the compressor casing
u Mark the casing position for assembly.
Fig. 51: Removing the compressor casing
If the compressor casing cannot be loosened, it can be pressed off against the turbine cas-
ing with the press-off tool (90042).
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. Put the compressor casing (72000) down onto a suitable support.
5. Remove and dispose of the O-ring (42012).
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.5
Removing the compressor casing
Dismantling the diffuser and the wall insert
Fig. 52: Dismantling the diffuser and the wall insert
1. Loosen the screws (79041) and remove with fixing discs (79040).
2. Remove diffuser (79000).
3. Fit the swivel lifting eye (S) to the wall insert (77000). Secure lifting gear to the swivel lift-
ing eye.
4. Remove the wall insert (77000). When doing this, make sure that the wall insert does not
"stick" to the compressor casing (72000).
5. Remove and dispose of the O-ring (77005).
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.6
Removing the cartridge group
9.6
Removing the cartridge group
u Mark the casing position for assembly.
Fig. 53: Removing cartridge group 1
Product
Position
Tightening torque [Nm]
A150
A155
01
01
150
150
Table 42: Tightening torque (90012-01)
1. Treat threads of studs (51006) with penetrating oil and leave to take effect.
2. Loosen nuts (51007) and remove Verbus Ripp® washers (51003) together with the fasten-
ing strips (51002).
3. Fit the cross-piece of the service support (90012). Observe the tightening torque.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.6
Removing the cartridge group
Fig. 54: Removing cartridge group 2
If the cartridge group cannot be loosened, the press-off tool (90042) can be used.
4. Secure the first set of lifting gear to the bearing casing.
5. Secure the second set of lifting gear to the service support with a swivel lifting eye. The
length of the lifting gear must be selected in such a way that the compressor wheel is
not touched when turning the cartridge group.
6. Remove the cartridge group vertically from the turbine casing.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.6
Removing the cartridge group
Fig. 55: Removing cartridge group 3
7. Place a suitable protective cover over the compressor wheel.
8. Turn the cartridge group into the horizontal rotor axis.
9. Remove lifting gear from service support and cross-piece.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.7 In-
stalling the cartridge group on the service support
9.7
Installing the cartridge group on the service
support
Fig. 56: Installing the cartridge group on the service support
1. Assemble the service support (90012) with longitudinal and cross-pieces.
2. Fit service support to cartridge group.
3. Put down cartridge group.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.8
Removing the nozzle ring
9.8
Removing the nozzle ring
Fig. 57: Removing the nozzle ring
1. Pull out the nozzle ring (56001) with the two extraction devices (90070).
2. Remove the lamellar sealing ring (56005).
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.9
Measuring clearance A and B
9.9
Measuring clearance A and B
u Measure and record clearances A and B after the removal and before the installation of
the cartridge group.
u Attach the dial indicator and align it for the respective clearance as per the illustration.
Fig. 58: Measuring clearance A and B
Product
A150-M
A155-M
A [mm]
0.12 ... 0.22
0.12 ... 0.22
B [mm]
0.72 ... 1.28
0.79 ... 1.40
Table 43: Permissible clearances A and B
1. Move the rotor to and fro up to the stop. In order to obtain a correct measurement, elev-
ate the turbine a little.
2. Measure clearance A and compare it with the permissible values in the table.
3. Raise the compressor and push the turbine down at the same time.
4. Raise the turbine and push the compressor down at the same time.
5. Measure clearance B and compare it with the permissible values in the table.
CAUTION
Clearances outside the tolerance
Serious damage to engines or property can be caused by clearances outside
the tolerance and excessively worn parts.
u Have the components assessed and, if necessary, replaced by an ABB Tur-
bocharging Service Station.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.10
Nozzle ring compression PD
9.10
Nozzle ring compression PD
For the nozzle ring (56001) to be fixed during operation, it must be clamped between the
heat shield (42400) and the turbine casing (51000).
Fig. 59: Nozzle ring compression PD
42001
42400
Bearing casing
Heat shield
51000
56001
Turbine casing
Nozzle ring
Product
A150-M
A155-M
Nozzle ring compression PD [mm]
-0.17 ... 0.17
-0.17 ... 0.17
Table 44: Nozzle ring compression PD
1. Measure values A, B, and S on cleaned surfaces.
2. Calculate compression (PD).
u If the calculated value (PD) lies outside the specified range, contact an ABB Turbochar-
ging Service Station.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.11
Installing nozzle ring
9.11
Installing nozzle ring
Fig. 60: Installing the nozzle ring
1. Fit the lamellar sealing ring (56005) (see A-A). When doing this, pay attention to correct
winding of the lamellar sealing ring (see detail B).
2. Align the cams on the nozzle ring with the recesses of the turbine casing (51000).
3. Insert the nozzle ring (56001) into the turbine casing up to the stop.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.12
Installing the cartridge group
9.12
Installing the cartridge group
Fig. 61: Lifting the cartridge group and rotating it by 90°
1. Fasten lifting gear to cartridge group and lift cartridge group.
2. Remove service support (90012).
3. Dismantle service support.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.12
Installing the cartridge group
Fig. 62: Turning the cartridge group
Product
Position
Tightening torque [Nm]
A150
A155
01
01
150
150
Table 45: Tightening torque (90012-01)
4. Re-fit the cross-piece of the service support (90012). Observe the tightening torque.
5. Place the protective cover over the compressor wheel.
6. Secure the second set of lifting gear to the cross-piece with a swivel lifting eye. The
length of the lifting gear must be selected in such a way that the compressor wheel is
not touched.
7. Turn the cartridge group into the vertical position of the rotor axis.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.12
Installing the cartridge group
Fig. 63: Installing the cartridge group
Product
A150
A155
Size
M16
M16
Tightening torque [Nm]
175
175
Table 46: Tightening torque (51007)
8. Coat the threads of the studs (51006) with high-temperature grease.
9. Align casing position of cartridge group with marking and lower into the turbine casing.
10. Remove lifting gear cross-piece of service support.
11. Install the fastening strips (51002) with Verbus Ripp® washers (51003) and hexagon
nuts (51007). Observe the tightening torque.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.13
Installing the compressor casing
9.13
Installing the compressor casing
Fitting the wall insert and the diffuser
Fig. 64: Fitting the wall insert and the diffuser
Product
A150
A155
Size
M6
M6
Tightening torque [Nm]
8
8
Table 47: Tightening torque (79041)
1. Fit a new O-ring (77005).
2. Fit the swivel lifting eyes (S) to the wall insert (77000). Secure lifting gear to the swivel
lifting eye.
3. Install the wall insert (77000) into the compressor casing and, when doing so, pay atten-
tion to the positioning pin in the compressor casing.
4. Fit the diffuser (79000) with fixing discs (79040) and screws (79041). Observe the tight-
ening torque.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.13
Installing the compressor casing
Installing the compressor casing
Fig. 65: Installing the compressor casing
Product
A150
A155
Size
M16
M18
Tightening torque [Nm]
275
370
Table 48: Tightening torque (72011)
1. Fit new O-ring (42012).
2. Thoroughly clean the fastening strips (72012) before assembly.
3. Install the compressor casing (72000).
4. Install the fastening strips (72012) with screws (72011). Observe the tightening torque.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.14
Turning the cartridge group with compressor and turbine casing
9.14
Turning the cartridge group with compressor and
turbine casing
Fig. 66: Turning the cartridge group with compressor and turbine casing
1. Attach second lifting gear to bearing casing and secure to the crane hook. This lifting
gear must be attached during the entire rotating procedure.
2. Lift cartridge group with compressor and turbine casing with the first lifting gear and
lower it with the second lifting gear.
3. Remove second lifting gear and swivel lifting eye.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.15
Installing the gas outlet flange
9.15
Installing the gas outlet flange
Fig. 67: Installing the gas outlet flange
1. If present: Insert the metal C-ring (57003) into the turbine casing (51000) and secure with
high-vacuum grease.
2. Fit swivel lifting eye (S) to the gas outlet flange (57002). Secure lifting gear to the swivel
lifting eye.
3. Install gas outlet flange in turbine casing (51000).
4. Measure radial clearance (R) (see chapter Radial clearances N and R).
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.16
Radial clearances N and R
9.16
Radial clearances N and R
Fig. 68: Measuring clearances N and R
Product
A150-M
A155-M
N [mm]
0.64 ... 1.09
0.78 ... 1.29
R [mm]
0.71 ... 1.13
0.86 ... 1.33
Table 49: Permissible clearances N and R
1. Push the feeler gauges (01) into the gap without clearance simultaneously at the top (N1)
and the bottom (N2).
2. Calculate clearance N and compare it with the permissible values in the table.
3. Push the feeler gauges (01) into the gap without clearance simultaneously at the top (R2)
and the bottom (R1).
4. Calculate clearance R and compare it with the permissible values in the table.
CAUTION
Clearances outside the tolerance
Serious damage to engines or property can be caused by clearances outside
the tolerance and excessively worn parts.
u Have the components assessed and, if necessary, replaced by an ABB Tur-
bocharging Service Station.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.18
Installing the cartridge group with compressor and turbine casing
9.18
Installing the cartridge group with compressor
and turbine casing
Fig. 70: Installing the cartridge group with compressor and turbine casing
1. Fit new O-rings (42195, 42200).
2. Remove cover from oil inlet and outlet and carefully lower cartridge group with com-
pressor and turbine casing onto bracket.
Fig. 71: Installing the cartridge group with compressor and turbine casing
4. Remove lifting gear from bearing casing.
5. If present: Remove the screw plug from the connection for the compressor wheel cooling
(01) and fit the cooling air line.
6. If present: Plug in the plug to the speed sensor (86505).
u If present: Fit connecting pipe for turbine cleaning.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.19
Installing the gas outlet casing
9.19
Installing the gas outlet casing
Variant without support
Fig. 72: Fitting gas outlet casing without support
Product
A150
A155
Size
M16
M16
Tightening torque [Nm]
200
200
Table 50: Tightening torque (51009)
1. Coat thread of bolts (51008) with high-temperature grease.
2. Insert a new gasket (61002) into the gas outlet casing (61001).
3. Fit swivel lifting eyes (S) to the gas outlet casing (61001). Secure lifting gear to the swivel
lifting eye.
4. Place gas outlet casing at turbine casing (51000). Observe the marking.
5. Fit hexagon nuts (51009). Observe the tightening torque.
7. If present: Attach waste gate pipe. Tighten in accordance with enginebuilder’s specifica-
tions.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.19
Installing the gas outlet casing
Variant with support
Fig. 73: Installing gas outlet casing with support 1
Product
A150
A155
Size
M16
M16
Tightening torque [Nm]
200
200
Table 51: Tightening torque (51009)
1. Coat thread of bolts (51008) with high-temperature grease.
2. Insert a new gasket (61002) into the gas outlet casing (61001).
3. Fit swivel lifting eyes (S) to gas outlet casing (61001). Secure lifting gear to the swivel lift-
ing eye.
4. Place gas outlet casing on the turbine casing (51000). Observe the marking.
5. Fit support (61301).
6. Fit hexagon nuts (51009). Observe the tightening torque.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.19
Installing the gas outlet casing
Fig. 74: Installing gas outlet casing with support 2
7. Fit the screws of the support. Tighten in accordance with enginebuilder’s specifications.
10. If present: Attach waste gate pipe. Tighten in accordance with enginebuilder’s specifica-
tions.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.20
Installing air inlets
9.20
Installing air inlets
Fig. 75: Installing the air inlets
Product
A150
A155
Size
M16
M18
Tightening torque [Nm]
275
370
Table 52: Tightening torque (72051)
1. Attach lifting gear to the filter silencer (81000) or air suction branch (82000).
2. Fit a new O-ring (81010) to the filter silencer (81000) or a new O-ring (82010) to the air
suction branch (82000).
3. Install the filter silencer (81000) or air suction branch (82000).
4. Fit the fastening strips (72012) with hexagon-head screws (72051). Observe the tighten-
ing torque.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
9 Dismantling and fitting with removed air inlet and gas outlet / 9.20
Installing air inlets
A155-M Uncoupled filter silencer
Fig. 76: Installing the uncoupled filter silencer
Product
Size
Tightening torque [Nm]
A155
M16
275
Table 53: Tightening torque (72054)
1. Secure lifting gear to filter silencer (81000).
2. Install the filter silencer (81000).
3. Fit the hexagon nuts (72054) together with Verbus Ripp® washers (72053) and three new
safety plates (72055) (uniformly at 120° to one another). Observe the tightening torque.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
10 Dismantling and fitting, cartridge concept / 10.1 Removing air in-
lets
10
Dismantling and fitting, cartridge
concept
10.1
Removing air inlets
Fig. 77: Removing the air inlets
1. Attach lifting gear to the filter silencer (81000) or air suction branch (82000).
2. Loosen the hexagon-head screws (72051) and remove them with fastening strips (72012).
3. Remove the filter silencer (81000) or air suction branch (82000).
4. Remove and dispose of the O-ring (81010 or 82010).
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
10 Dismantling and fitting, cartridge concept / 10.1 Removing air in-
lets
A155-M Uncoupled filter silencer
Fig. 78: Removing the uncoupled filter silencer
1. Secure lifting gear to filter silencer (81000).
2. Unscrew the hexagon-head screws (72054) and remove along with Verbus Ripp® wash-
ers (72053) and three safety plates (72055).
3. Remove the filter silencer (81000).
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
10 Dismantling and fitting, cartridge concept / 10.2 Removing the
compressor casing
10.2
Removing the compressor casing
u Mark the casing position for assembly.
Fig. 79: Removing the compressor casing
1. Remove the compressor casing insulation.
2. Fit swivel lifting eye (S) to the compressor casing (72000). Secure lifting gear to the
swivel lifting eye.
3. Loosen screws (72011) and remove together with fastening strips (72012).
4. Remove the compressor casing (72000).
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
10 Dismantling and fitting, cartridge concept / 10.2 Removing the
compressor casing
If the compressor casing cannot be loosened, it can be pressed off against the turbine cas-
ing with the press-off tool (90042).
Fig. 80: Pressing off compressor casing
1. Remove front turbine casing insulation.
2. Press off compressor casing with press-off tool (90042).
Fig. 81: Remove the diffuser
1. Remove and dispose of the O-ring (42012).
2. Set the compressor casing (72000) down on a suitable support.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
10 Dismantling and fitting, cartridge concept / 10.2 Removing the
compressor casing
Dismantling the diffuser and the wall insert
Fig. 82: Dismantling the diffuser and the wall insert
1. Loosen the screws (79041) and remove with fixing discs (79040).
2. Remove diffuser (79000).
3. Fit the swivel lifting eye (S) to the wall insert (77000). Secure lifting gear to the swivel lift-
ing eye.
4. Remove the wall insert (77000). When doing this, make sure that the wall insert does not
"stick" to the compressor casing (72000).
5. Remove and dispose of the O-ring (77005).
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
10 Dismantling and fitting, cartridge concept / 10.3 Removing the
cartridge group
10.3
Removing the cartridge group
Removing the insulation
Fig. 83: Removing insulation sheets
u Remove insulation sheets.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
10 Dismantling and fitting, cartridge concept / 10.3 Removing the
cartridge group
Removing the cartridge group
Fig. 84: Removing cartridge group 1
Product
Value X [mm]
A150-M
A155-M
112 ±2 mm
144 ±2 mm
Table 54: Threaded rod, value X
1. Apply two marking lines (M) to the left and right of the cartridge group and the bracket.
2. Support and fix the turbine casing.
4. Screw threaded rod (42191) up to value X at the hexagon.
5. Lift the centering bush (42193) using the threaded rod (42191) and hold it firmly.
If the centering bush jams:
Remove the clamping nut and rotate the threaded rod upwards using a standard nut.
6. Rotate the clamping nut (42201) downwards until the stop is reached.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
10 Dismantling and fitting, cartridge concept / 10.3 Removing the
cartridge group
Fig. 85: Removing cartridge group 2
If the cartridge group cannot be loosened, the press-off tool (90042) can be used.
1. Treat threads of studs (51006) with penetrating oil and leave to take effect.
2. Loosen nuts (51007) and remove Verbus Ripp® washers (51003) together with fastening
strips (51002).
3. Pull the cartridge group from the turbine casing and remove it.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
10 Dismantling and fitting, cartridge concept / 10.3 Removing the
cartridge group
Fig. 86: Removing cartridge group 2
1. Remove the centering bush (42193) and the threaded rod (42191) along with the clamping
nut (42201).
2. Remove and dispose of the O-rings (42195, 42200).
3. Attach the cartridge group to the service support (90012).
4. If present: Remove the metal C-ring (51105).
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
10 Dismantling and fitting, cartridge concept / 10.4 Removing the
nozzle ring
10.4
Removing the nozzle ring
Fig. 87: S_05180
1. Pull out the nozzle ring (56001) with the two extraction devices (90070).
2. Remove the lamellar sealing ring (56005).
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
10 Dismantling and fitting, cartridge concept / 10.5 Measuring clear-
ance A and B
10.5
Measuring clearance A and B
u Measure and record clearances A and B after the removal and before the installation of
the cartridge group.
u Attach the dial indicator and align it for the respective clearance as per the illustration.
Fig. 88: Measuring clearance A and B
Product
A150-M
A155-M
A [mm]
0.12 ... 0.22
0.12 ... 0.22
B [mm]
0.72 ... 1.28
0.79 ... 1.40
Table 55: Permissible clearances A and B
1. Move the rotor to and fro up to the stop. In order to obtain a correct measurement, elev-
ate the turbine a little.
2. Measure clearance A and compare it with the permissible values in the table.
3. Raise the compressor and push the turbine down at the same time.
4. Raise the turbine and push the compressor down at the same time.
5. Measure clearance B and compare it with the permissible values in the table.
CAUTION
Clearances outside the tolerance
Serious damage to engines or property can be caused by clearances outside
the tolerance and excessively worn parts.
u Have the components assessed and, if necessary, replaced by an ABB Tur-
bocharging Service Station.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
10 Dismantling and fitting, cartridge concept / 10.6 Nozzle ring com-
pression PD
10.6
Nozzle ring compression PD
For the nozzle ring (56001) to be fixed during operation, it must be clamped between the
heat shield (42400) and the turbine casing (51000).
Fig. 89: Nozzle ring compression PD
42001
42400
Bearing casing
Heat shield
51000
56001
Turbine casing
Nozzle ring
Product
A150-M
A155-M
Nozzle ring compression PD [mm]
-0.17 ... 0.17
-0.17 ... 0.17
Table 56: Nozzle ring compression PD
1. Measure values A, B, and S on cleaned surfaces.
2. Calculate compression (PD).
u If the calculated value (PD) lies outside the specified range, contact an ABB Turbochar-
ging Service Station.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
10 Dismantling and fitting, cartridge concept / 10.7 Installing nozzle
ring
10.7
Installing nozzle ring
Fig. 90: Installing the nozzle ring
1. Fit the lamellar sealing ring (56005) (see A-A). When doing this, pay attention to correct
winding of the lamellar sealing ring (see detail B).
2. Align the cams on the nozzle ring with the recesses of the turbine casing (51000).
3. Insert the nozzle ring (56001) into the turbine casing up to the stop.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
10 Dismantling and fitting, cartridge concept / 10.8 Installing the cart-
ridge group
10.8
Installing the cartridge group
Fig. 91: Installing the cartridge group 1
1. Attach lifting gear to bearing casing.
2. Remove fixing screws.
3. Lift the cartridge group out of the service support (90012).
4. Fit new O-rings (42195, 42200).
5. Screw the clamping nut (42201) flush onto the threaded rod (42191). The hexagon of the
thread screw is at the top.
Place the washer (01) of the clamping nut onto the expansion bush and, with the clamp-
ing nut screwed on, guide the threaded rod through the washer, expansion bush and
bearing casing.
6. Screw the centering bush (42193) flush onto the threaded rod from below.
7. Lift the centering bush (42193) using the threaded rod (42191) and hold it firmly.
8. Rotate the clamping nut (42201) downwards until the stop is reached.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
10 Dismantling and fitting, cartridge concept / 10.8 Installing the cart-
ridge group
Fig. 92: Installing the cartridge group 2
Product
A150-M
Value X [mm]
112 ±2 mm
Value L [mm]
52 ±2 mm
A155-M
144 ±2 mm
72 ±2 mm
Table 57: Threaded rod, value X and L
Product
A150-M
A155-M
Size
M16
M16
Tightening torque [Nm]
175
175
Table 58: Tightening torque (51007)
1. Lightly lubricate the hole in the bracket, into which the centering bush (42193) is inser-
ted, with screw grease.
2. If present: Insert the metal C-ring (51105).
3. Move the cartridge group into the turbine casing and align with the markings (M) made
on the bracket at the time of disassembly.
4. Screw clamping nut (42201) upwards to end of threaded rod and insert the centering
bush (42193) into the hole.
Check value X (if value X is not reached, the turbocharger must be re-aligned).
5. Screw in the threaded rod until value L is reached.
7. Secure fastening strips (51002) together with nuts (51007) and Verbus Ripp® wash-
ers (51003).
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
10 Dismantling and fitting, cartridge concept / 10.9 Installing the com-
pressor casing
10.9
Installing the compressor casing
Fitting the wall insert and the diffuser
Fig. 93: Fitting the wall insert and the diffuser
Product
A150
A155
Size
M6
M6
Tightening torque [Nm]
8
8
Table 59: Tightening torque (79041)
1. Fit a new O-ring (77005).
2. Fit the swivel lifting eyes (S) to the wall insert (77000). Secure lifting gear to the swivel
lifting eye.
3. Install the wall insert (77000) into the compressor casing and, when doing so, pay atten-
tion to the positioning pin in the compressor casing.
4. Fit the diffuser (79000) with fixing discs (79040) and screws (79041). Observe the tight-
ening torque.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
10 Dismantling and fitting, cartridge concept / 10.9 Installing the com-
pressor casing
Installing the compressor casing
Fig. 94: Installing the compressor casing
Product
A150
A155
Size
M16
M18
Tightening torque [Nm]
275
370
Table 60: Tightening torque (72011)
u Thoroughly clean the fastening strips (72012) before assembly.
1. Fit a new O-ring (42012).
2. Install the compressor casing (72000).
3. Install the fastening strips (72012) with screws (72011). Observe the tightening torque.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
10 Dismantling and fitting, cartridge concept / 10.10 Radial clearances
N and R
10.10
Radial clearances N and R
Measurement of clearance R optional (only possible if gas outlet casing is dismantled).
Fig. 95: Measuring clearances N and R
Product
A150-M
A155-M
N [mm]
0.64 ... 1.09
0.78 ... 1.29
R [mm]
0.71 ... 1.13
0.86 ... 1.33
Table 61: Permissible clearances N and R
1. Push the feeler gauges (01) into the gap without clearance simultaneously at the top (N1)
and the bottom (N2).
2. Calculate clearance N and compare it with the permissible values in the table.
3. Push the feeler gauges (01) into the gap without clearance simultaneously at the top (R2)
and the bottom (R1).
4. Calculate clearance R and compare it with the permissible values in the table.
CAUTION
Clearances outside the tolerance
Serious damage to engines or property can be caused by clearances outside
the tolerance and excessively worn parts.
u Have the components assessed and, if necessary, replaced by an ABB Tur-
bocharging Service Station.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
10 Dismantling and fitting, cartridge concept / 10.12 Installing air in-
lets
10.12
Installing air inlets
Fig. 97: Installing the air inlets
Product
A150
A155
Size
M16
M18
Tightening torque [Nm]
275
370
Table 62: Tightening torque (72051)
1. Attach lifting gear to the filter silencer (81000) or air suction branch (82000).
2. Fit a new O-ring (81010) to the filter silencer (81000) or a new O-ring (82010) to the air
suction branch (82000).
3. Install the filter silencer (81000) or air suction branch (82000).
4. Fit the fastening strips (72012) with hexagon-head screws (72051). Observe the tighten-
ing torque.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
10 Dismantling and fitting, cartridge concept / 10.12 Installing air in-
lets
A155-M Uncoupled filter silencer
Fig. 98: Installing the uncoupled filter silencer
Product
Size
Tightening torque [Nm]
A155
M16
275
Table 63: Tightening torque (72054)
1. Secure lifting gear to filter silencer (81000).
2. Install the filter silencer (81000).
3. Fit the hexagon nuts (72054) together with Verbus Ripp® washers (72053) and three new
safety plates (72055) (uniformly at 120° to one another). Observe the tightening torque.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
11 Dismantling and fitting, special tools for fastening strips /
11
Dismantling and fitting, special tools
for fastening strips
ABB Turbo Systems offers optional special tools which, in the event of limited accessibility,
can be used to facilitate the loosening of nuts and the application of tightening torques for
the strip connection between the cartridge group and the turbine casing.
The spanner holder (90165) should only be used for loosening the nuts and applying tighten-
ing torques for the nuts at the position shown.
Other screws or nuts on the turbocharger should not be tightened with this tool.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
11 Dismantling and fitting, special tools for fastening strips / 11.1 Ap-
plication, special tools
11.1
Application, special tools
Special tools (90160)
Fig. 99: Special tools
Part number
90160
Description
Special tools, complete
Bag
Spanner holder
Spanner holder
Quantity
1
1
1
1
90161
90165
90166
Table 64: Special tools (90160)
Customer tool (not included in the ABB Turbo Systems scope of delivery)
Fig. 100: Client tool
Position
Description
Quantity
01
02
Collection tub 500x400x30mm
1
1
Torque spanner 40-200 Nm with
plug connection for holding inser-
tion tools 14x18 mm
Table 65: Client tool
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
11 Dismantling and fitting, special tools for fastening strips / 11.1 Ap-
plication, special tools
A155-M Extended special tools (90160)
Fig. 101: Special tools
Part number
90160
Description
Special tools, complete
Bag
Locking device
Clamping device
Tool disassembly segment
Spanner holder
Quantity
1
1
1
1
1
2
90161
90162
90163
90164
90165
Table 66: Special tools (90160)
Customer tool (not included in the ABB Turbo Systems scope of delivery)
Fig. 102: Client tool
Position
01
Description
Universal pliers
Quantity
1
Table 67: Client tool
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
11 Dismantling and fitting, special tools for fastening strips / 11.1 Ap-
plication, special tools
Removing the fastening strips
Fig. 103: Positioning the collection tub
1. Position the collection tub (01) to catch any fixing elements if they fall.
2. Loosen the two nuts on one side by using the spanner holder (90165).
3. Loosen the two nuts on the other side by using the spanner holder (90166).
The cartridge group is fitted at this point in time. To enable a clear representation of the
work step, the cartridge group is not illustrated in work step 4.
Fig. 104: Removing the fastening strips
4. Remove the nuts (51007) with spanner holder (90165/90166) and attached torque span-
ner (02). Remove washers (51003) and fastening strips (51002).
Any falling screw material will be caught in the collection tub (01).
5. Loosen the nuts (51007) from the remaining fastening strips and remove the lugs (51002)
with washers (51003).
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
11 Dismantling and fitting, special tools for fastening strips / 11.1 Ap-
plication, special tools
Fitting the fastening strips
Fig. 105: Fitting the upper fastening strips
Product
A150
A155
Size
M16
M16
Tightening torque [Nm]
175
175
Table 68: Tightening torque (51007)
1. Fit the nuts (51007) of the (upper) fastening strips (51002) illustrated and tighten with a
torque spanner (02) without a spanner holder. Observe the tightening torque.
Fig. 106: Fitting the bottom fastening strip
2. Position the collection tub (01) to catch any fixing elements if they fall.
3. Tighten the two nuts on one side by using the spanner holder (90165).
4. Tighten the two nuts on the other side by using the spanner holder (90166).
The cartridge group is fitted at this point in time. To enable a clear representation of the
work step, the cartridge group is not illustrated in work step 5.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
11 Dismantling and fitting, special tools for fastening strips / 11.1 Ap-
plication, special tools
Fig. 107: Fitting the bottom fastening strip
Product
A150-M
A155-M
Size
M16
M16
Tightening torque [Nm]
85
70
Table 69: Tightening torque (51007) with spanner holder
5. Fit the nuts (51007) with spanner holder (90165 / 90166) and attached torque span-
ner (02). Observe the tightening torque.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
11 Dismantling and fitting, special tools for fastening strips / 11.1 Ap-
plication, special tools
11.1.1
A155-M Fit fastening strips with extended special tool
Fig. 108: Fitting the cartridge group
1. Fit nuts (51007) of the (upper) fastening strips (51002) shown in the picture and tighten
with the torque spanner (02) without a spanner holder. Observe the tightening torque.
Product
Size
Tightening torque [Nm]
A155
M16
175
Table 70: Tightening torque (51007)
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
11 Dismantling and fitting, special tools for fastening strips / 11.1 Ap-
plication, special tools
The cartridge group is already fitted at this point in time. The cartridge group is not illus-
trated in the following images so that all work steps are visually clear.
Fig. 109: Positioning the fastening strip
2. Position fastening strip (51002) in the tool disassembly segment (90164).
3. Clamp the lugs (A) of the tool disassembly segment slightly using the universal pliers (03)
to fix the fastening strip.
4. Position the fastening strip with the tool disassembly segment onto the set screws.
5. Push the fastening strip with the tool disassembly segment in the direction of the tur-
bine casing as far as possible.
6. Depress the tool disassembly segment and remove it.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
11 Dismantling and fitting, special tools for fastening strips / 11.1 Ap-
plication, special tools
Fig. 110: Clamping piece
7. Fix the washer (51003) with clamping device (90163) and check to ensure it is properly
seated.
8. Position the washer (51003) on the set screw.
9. Remove the clamping device.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
11 Dismantling and fitting, special tools for fastening strips / 11.1 Ap-
plication, special tools
Fig. 111: Attach nut
Product
Size
Tightening torque [Nm]
A155-M
M16
70
Table 71: Tightening torque (51007) with spanner holder
10. Screw nut (51007) loosely to the locking device (90162).
11. First position the cord end in the direction of the axis before winding up.
12. Wind up the cord 7-10 times around the nut and over the cord end.
13. Position the locking device (90162) with attached nut (51007) exactly onto the threaded
stud and press on.
14. Fit the nut (51007) to the set screw by pulling the cord.
15. Fit nuts (51007) with fixing washers (90165) and attached torque spanner (02). Observe
the tightening torque.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
12 Removing and installing 6-nozzle turbine cleaning component (op-
tional) / 12.1 Disassembly
12
Removing and installing 6-nozzle
turbine cleaning component (optional)
12.1
Disassembly
The following illustration shows the initial situation before the 6-nozzle turbine cleaning
component is dismantled.
Fig. 112: Initial situation
u Before disassembly, mark the positions of the elbows (51311).
Fig. 113: Disassembly of the elbows
1. Just loosen the union nuts (51316) of the elbows (51311). Do not remove them yet.
2. Just loosen the screws (51314). Do not remove them yet.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
12 Removing and installing 6-nozzle turbine cleaning component (op-
tional) / 12.1 Disassembly
Fig. 114: Disassembly of the elbows
u Remove the elbows (51311) from the connecting pieces (51313) in the specified order (01,
02, 03, 04, 05).
Fig. 115: Pipe disassembly
1. Undo union nuts (51316) of pipe (51312).
2. Remove pipe.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
12 Removing and installing 6-nozzle turbine cleaning component (op-
tional) / 12.1 Disassembly
Fig. 116: Disassembly of the connecting pieces
1. Unscrew hexagon-head screws (51314) from connecting pieces (51313).
2. Remove gaskets (51302).
3. Remove connecting pieces.
4. Remove gaskets from holes.
Fig. 117: Disassembly of the cleaning nozzle
u Remove cleaning nozzles (51301) with screw (01) in accordance with the following table.
Product
A150-M
A155-M
Thread
M8
M10
Length [mm]
Quantity
40
50
1
1
Table 72: Dismantling screw
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
12 Removing and installing 6-nozzle turbine cleaning component (op-
tional) / 12.2 Assembly
12.2
Assembly
u Clean all of the components and axial contact surfaces of the gaskets before assembling
the turbine casing.
Fig. 118: Assembly of the cleaning nozzle
Product
A150-M
A155-M
Thread
M8
M10
Length [mm]
Quantity
40
50
1
1
Table 73: Dismantling screw
1. Screw the screw (01) into the cleaning nozzle (51301) as far as it will go.
2. Insert the cleaning nozzle with screw as far as it will go.
3. Rotate the cleaning nozzle clockwise until the cleaning nozzle lowers further and is thus
correctly positioned.
u Remove the screw (01), ensuring that the cleaning nozzle remains in position.
Fig. 119: Assembly of the connecting pieces
1. Position gaskets (51302) on holes.
2. Position connecting pieces (51313).
3. Position gaskets (51302) on connecting pieces (51313).
4. Coat thread and contact surfaces of hexagon-head screws (51314) with high-temperat-
ure grease. Tighten screws by hand only.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
12 Removing and installing 6-nozzle turbine cleaning component (op-
tional) / 12.2 Assembly
Fig. 120: Pipe assembly
1. Coat thread and contact surfaces of cutting ring with high-temperature grease.
2. Position pipe (51312).
3. Position union nuts (51316) of pipe on connecting piece (51313) and screw-in fitting
(51305) and tighten by hand only.
Fig. 121: Elbow 1 assembly
u Coat thread and contact surfaces of cutting ring with high-temperature grease.
u Screw union nuts (51316) of elbows (51311) in the specified order (01, 02, 03, 04, 05) to the
connecting pieces (51313).
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
12 Removing and installing 6-nozzle turbine cleaning component (op-
tional) / 12.2 Assembly
Fig. 122: Elbow 2 assembly
Product
A150-M
A155-M
51314 [Nm]
51316 [Nm]
80
100
70
90
Table 74: Tightening torque (51314 / 51316)
1. Tighten hexagon-head screws (51314) to tightening torque.
2. Tighten union nuts (51316) of elbows (51311) to tightening torque.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
13 Fitting the cleaning nozzles with multi-inlet turbine casings /
13
Fitting the cleaning nozzles with multi-
inlet turbine casings
Fig. 123: Fit the cleaning nozzles
1. The designation (P . ) on the turbine casing must correspond with the designation (P . )
on the cleaning nozzle.
2. The edges for the defined installation position in the turbine casing and at the cleaning
nozzle must correspond.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
14 Taking out of operation at short notice / 14.1 Possible emergency
repairs
14
Taking out of operation at short notice
14.1
Possible emergency repairs
WARNING
Danger of fire and explosion due to lubricating oil leaks
Leaking oil may ignite on hot surfaces. This can result in serious injuries to
personnel or fatal accidents.
u Cordon off danger area.
u Raise the alarm and, depending on the situation, stop the engine.
u Seal the oil leak.
u Soak up oil and dispose of in an environmentally compatible manner.
Wear safety gloves to protect against thermal hazards.
CAUTION
Directives for taking out of operation
Serious damage to engine or property can be caused by non-compliance
with the directives for blanking the turbocharger off the engine.
u Follow the directives of the enginebuilder.
If the engine has to be operated again as quickly as possible following a turbocharger de-
fect, then the following options are available for emergency repairs:
¡
¡
¡
and contact an ABB Turbocharging Service Station.
u Observe the following sections in connection with the emergency repairs mentioned.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
14 Taking out of operation at short notice / 14.2 Installing the replace-
ment turbocharger
14.2
Installing the replacement turbocharger
To enable you to quickly put an engine back into operation after a turbocharger has sus-
tained damage, ABB Turbo Systems recommends having a replacement turbocharger or ap-
propriate spare parts available in storage. The defective turbocharger can be removed and
the replacement turbocharger installed within a short period of time.
u Send the defective turbocharger to an ABB Turbocharging Service Station for inspection
and repair.
14.3
14.4
Installing the replacement cartridge group
Fitting the cover plate
¡
Gas outlet casing removed
u Fit the turbine casing with the gas outlet casing into the gas pipe again.
u Attach the cover plate (see following section).
¡
Gas outlet casing not removed
u Fit the turbine casing into the gas pipe and on the gas outlet casing again.
u Attach the cover plate (see following section).
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
14 Taking out of operation at short notice / 14.4 Fitting the cover
plate
Fig. 124: Fitting the cover plate
u Make sure that the oil connections in the bracket are equipped with gaskets.
1. Close opening in turbine casing (51000) with cover plate (01).
2. Thoroughly clean the fastening strips (51002) before assembly.
3. Coat the threads of the studs (51006) with high-temperature grease.
4. Fasten cover plate (01) to turbine casing (51000) with fastening strips (51002), Verbus
Ripp® washers (51003) and nuts (51007) and screw to bracket.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
14 Taking out of operation at short notice / 14.5 Cover plate drawing
14.5
Cover plate drawing
The cover plate is not included in the ABB Turbo Systems scope of delivery and must be
manufactured by the operating company according to the following drawing.
Material: General structural steel, in compliance with DIN EN 10025-2.
Fig. 125: Cover plate drawing
Product
B1
± 0.5
138.9
B2
B3
B4
± 0.2
21.4
B5
B6
± 0.1
320
B7
ØD1
± 0.2
413.6
492
ØD2
R1
M
A150
A155
135
240
2.0
2.0
71.4
84.6
33
39
≤ 196
≤ 232
M12
M16
164.6 160 286.5 25.5
385
Table 75: Cover plate dimensions [mm]
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
14 Taking out of operation at short notice / 14.5 Cover plate drawing
Fig. 126: Dimensions for cover plate
Product
A150
A155
A
90
107
B
10
12
D1
90 ± 0.2
111 ± 0.1
D2 ± 0.1
28.2
37.2
Table 76: Cover plate dimensions [mm]
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
15 Mothballing the turbocharger / 15.1 Taking the engine out of opera-
tion for up to 12 months
15
Mothballing the turbocharger
15.1
Taking the engine out of operation for up to
12 months
State of the engine lubricating oil
The turbocharger normally remains attached to the engine. The measures to be taken for
mothballing the turbocharger depend on the state of the lubricating oil. No measures are re-
quired under the following conditions:
¡
¡
Acid number (TAN) < 2 mg KOH/g
The engine lubricating oil is replaced by a preservative oil and circulated with the pre-lub-
rication pump before the engine is taken out of operation. Residues of old engine oil are
flushed away in this way and the bearing parts are largely protected against corrosion.
Preparations for mothballing
WARNING
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or con-
tact with them may be harmful to health.
u Do not breathe in these substances and avoid contact with the skin.
u Ensure proper ventilation.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Wear personal protective equipment (PPE) according to the material
safety data sheet.
u Comply with local legislation.
Wear safety goggles.
Wear safety gloves to protect against chemical hazards.
Wear a respiratory mask to protect against gases.
If the acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures
are necessary after taking the engine out of operation:
u Dismantle the turbocharger.
u The rotor and bearing parts must be dismantled and subsequently refitted by an ABB Tur-
bocharging Service Station.
u Clean all parts.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
15 Mothballing the turbocharger / 15.2 Taking the engine out of opera-
tion for more than 12 months
u Coat plain surfaces of steel and cast parts with anticorrosive oil.
u Fit turbocharger completely.
Rotation of the rotor in the stack draught
If the rotor turns as a result of the stack draught:
u Install a blind flange between the outlet flange of the compressor casing and the charge
air duct.
15.2
Taking the engine out of operation for more than
12 months
If the engine is taken out of operation, the following variants are possible with regard to the
turbocharger:
¡
¡
Turbocharger remains attached to the engine
The casings of the turbocharger remain attached to the engine, the rotor and bearing
parts are dismantled by an ABB Turbocharging Service Station and stored separately
¡
The turbocharger is completely removed, either as a whole unit or in individual parts
For the measures always necessary for preparing the turbocharger parts for mothballing,
see section Taking the engine out of operation for up to 12 months, subsection Preparations
for mothballing.
If the turbocharger remains attached to the engine, see section Taking the engine out of op-
If the complete turbocharger is removed or the turbocharger is assembled again from the
individual parts:
u Seal all openings of the turbocharger with paraffin paper and wooden lids.
Only dry rooms with 40 ... 70 % atmospheric humidity, in which no water condensation can
form, are suitable as storage locations.
State of the mothballed turbocharger
u Check the turbocharger parts annually for corrosion.
u If there are signs of rust: Thoroughly clean parts and renew corrosion protection.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
16 Disposing of turbocharger components /
16
Disposing of turbocharger components
WARNING
Handling damaged thermal insulation
Damaged thermal insulation can lead to dust exposure. The glass fibres can
cause mechanical irritation of the eyes, skin, and respiratory tracts.
u Avoid the formation of dust.
u Vacuum up dust with a suitable vacuum cleaner.
u Wear a respiratory mask to protect against dusts (P1 or P2 mask).
u Wear work gloves made of leather.
Wear safety goggles.
Wear a respiratory mask to protect against dusts.
Wear safety gloves to protect against mechanical hazards.
Disposal must be environmentally compatible, professional, and in compliance with locally
applicable regulations.
The turbocharger consists largely of metal (cast iron materials, steel, nickel-steel alloys, alu-
minium and bearing brass).
Further components are: Non-metallic materials (filter components of felt and polyethylene),
lubricants (engine oil), electronic parts (speed sensor and associated components), and
thermal insulation.
u Dispose of metals as scrap metal for recycling.
u Dispose of non-metallic materials as waste.
u Dispose of residues of lubricants as waste oil.
u Dispose of electronic components as electronic waste.
u Dispose of thermal insulation as hazardous waste.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
17 Spare parts / 17.1 Ordering spare parts
17
Spare parts
17.1
Ordering spare parts
CAUTION
Spare part storage
All spare parts that were ordered together with the turbocharger must be
kept intact and ready for use.
u Carefully clean any rusted parts and grease them.
Please quote the following data when making queries and ordering spare parts:
¡
¡
¡
Turbocharger type
Serial number of the turbocharger
Designation and part number
Spare parts can be ordered from any ABB Turbocharging Service Station.
u If different model variants are not taken into account in this document, contact an ABB
Turbocharging Service Station.
u Dispose of placed and unusable parts in an environmentally-friendly and professional
manner in accordance with the local regulations.
u Dispose of the packaging of new parts in an environmentally-friendly and professional
manner in accordance with the local regulations.
17.2
Required customer spare part set (97070)
For the operations described in the Operation Manual, the customer spare part set (97070)
is required. These parts are only available in the complete set.
Part number
42012
42195
42200
61002 *
77005
Designation
O-ring
O-ring
O-ring
Gasket
O-ring
Counter-sunk screw
O-ring
Quantity
1
1
1
1
1
2
1
79041
81010 / 82010
Table 77: Customer spare part set 97070
* This gasket can only be installed when a gas outlet casing from ABB Turbo Systems is used.
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
17 Spare parts / 17.2 Required customer spare part set (97070)
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
17 Spare parts / 17.3 View of turbocharger with part numbers
17.3
View of turbocharger with part numbers
Fig. 127: Overview of part numbers
* Depending on the specification of the turbocharger
(……) only available in customer spare part set (97070).
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
17 Spare parts / 17.3 View of turbocharger with part numbers
Part number
- -
42012 (in customer spare part set)
Designation
Cartridge group
O-ring
42167
Orifice
42170 (option)
42190
42191
42193
Bearing casing insulation
Expansion sleeve
Threaded rod
Centering bush
O-ring
42195 (in the customer spare part set)
42196
Oil orifice
42200 (in the customer spare part set)
O-ring
42201
51000
51002
51010
51105*
51500
56001
Clamping nut
Turbine casing
Fastening strip
Bearing casing insulation
Metal C-ring
Burst protection
Nozzle ring
56005
57002
57003*
57210
Lamellar sealing ring
Gas outlet flange
Metal C-ring
Burst ring
61001
Gas outlet casing
Gasket
61002 (in the customer spare part set)
61301*
Support
72000
72011
72012
72060
Compressor casing
Hexagon-head screw
Fastening strip
Hood
72061
77000
Insulating bush
Wall insert
77005 (in customer spare part set)
O-ring
79000
Diffuser
79040
Fixing disc
79041 (in the customer spare part set)
81000
81010 (in the customer spare part set)
Counter-sunk screw
Filter silencer
O-ring
82000
Air suction branch
O-ring
82010 (in the customer spare part set)
86505*
86515*
86526*
86528*
Speed sensor
Cable connector
F/I converter
Tachometer
Table 78: Spare parts list
* Depending on the specification of the turbocharger
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
17 Spare parts / 17.4 View of turbine cleaning device
17.4
View of turbine cleaning device
17.4.1
One cleaning nozzle per turbine inlet
Fig. 128: Overview of part numbers
Part number
Designation
51301
1 inlet = 1 cleaning nozzle
2 inlets = 2 cleaning nozzles
3 inlets = 3 cleaning nozzles
Gasket
51302
51303
Screw plug
Table 79: Spare parts list
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
17 Spare parts / 17.4 View of turbine cleaning device
17.4.2
6-nozzle turbine cleaning
Fig. 129: Overview of part numbers
Part number
51301
51302
Designation
Cleaning nozzle
Gasket
51303
Screw plug
51304
Flange
51305
51308
Screw-in fitting
Stud
51309
51310
51311
Expansion sleeve
Hexagon-head screw
Elbow
51312
Pipe
51313
51314
51316
Connecting piece
Hexagon-head screw
Union nut
51317
Sealing stud
Table 80: Spare parts list
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
17 Spare parts / 17.5 View of uncoupled filter silencer A155
17.5
View of uncoupled filter silencer A155
Fig. 130: Overview of part numbers
Part number
72052
Designation
Set screw
72053
72054
Verbus Ripp® washer
Hexagon nut
72055
Safety plate
81000
Filter silencer
81145
81146
81147
Flange, compressor end
Flange, turbine end
Fixing ring
81148
81149
81150
81151
Absorption element
Mounting plate
Fastening strips
Roll pin
81152
81153
Hexagon-head screw
Washer
81154
Socket screw
81155
Hexagon-head screw
Table 81: Spare parts list
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Rev.N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
ꢀFigures
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Revision N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
ꢀFigures
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Revision N
October 2019
Operation Manual / 4 Product description / A150-M56/66/57/67 -
A155-M..
ꢀTables
© Copyright 2019 ABB. All rights reserved.
HZTL4032_EN
Revision N
October 2019
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