Page 1 Operation Manual A150-M56 HT595183 English Original Operation Manual Chapter Document-ID Introduction HZTL4005_EN_G Safety HZTL4022_EN_E Safety data sheet HT595183 Product description HZTL4032_EN_P ABB Turbocharging...
Page 2 Operating limits and replacement intervals The recommended replacement intervals and the corresponding operating limits in chapter 3 are jointly defined with the enginebuilder. This information is specific to the product. Non-observance of the recommended replacement intervals and the operating limits increases the risk of unpre- dictable component failures.
Page 3: Table Of Contents
Operation Manual / 1 Introduction Table of contents Introduction Introduction......................2 Purpose of the manual....................2 Symbols, definitions...................... 3 Storage of new turbochargers and spare parts ............5 Contact information...................... 7 © Copyright 2020 ABB. All rights reserved. HZTL4005_EN Rev.G March 2020...
Page 4: Purpose Of The Manual
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...
Page 5: Symbols, Definitions
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.
Page 6 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...
Page 7: Storage Of New Turbochargers And Spare Parts
Dispose of the old VCI corrosion protection emitter in an environmentally compatible manner, professionally and in accordance with local regulations. 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...
Page 8 Inspect the package for damage. If the package is damaged, the turbocharger must be in- spected by an ABB Turbocharging Service Station and repacked. After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station: ¡...
Page 9: Contact Information
Operation Manual / 1 Introduction 1 Introduction / 1.4 Contact information Contact information Contact information for the ABB Turbocharging Service Stations is available online. Scan the QR code to access our website. ABB Switzerland Ltd, Turbocharging Bruggerstrasse 71a CH-5401 Baden Switzerland www.abb.com/turbocharging...
Page 11 Lifting of loads ......................9 1.11 Prerequisites for operation and maintenance............10 1.12 Hazards during operation and maintenance ............11 1.13 Safe operation ......................13 1.14 Safe maintenance ......................15 © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
Page 12: Safety
Safety Introduction Turbochargers manufactured by ABB reflect the state of the art. The respective safety and health protection requirements are met. This ensures safe operation of the turbocharger. Nevertheless, there may be some residual risks during operation of and work on the tur- bocharger which: ¡...
Page 13: Definition Of Mandatory Signs
CAUTION can lead to seri- ous damage to engine or property with grave consequences. Caution signs must always be observed. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
Page 14: 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...
Page 15: Deflagration On Gas Engines
If during external inspection anomalies are found or if a particularly strong deflagration event has taken place, it is also recommended to check the bearings of the turbochargers before the next start. An ABB Turbocharging Service Station should be instructed to carry out this inspection.
Page 16: Warning Plates On The Turbocharger
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. HZTL4022_EN Revision E May 2017...
Page 17: Turbocharger Rating Plate
06 Customer part number 07 Designation for special design 08 Weight of turbocharger in kg 09 Turbocharger type 10 Serial number Year of construction of turbocharger 12 Manufacturing plant © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
Page 18: Periodic Check Of The Pressure Vessels
The locations of the rating plates are defined in the Operation Manual, Chapter 4 Product description. Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, are so-called "simple pressure vessels". ¡...
Page 19: Lifting Of Loads
The assembly devices must be completely screwed in and must not unscrew during use. Use assembly devices only for the described applications. Put down dismantled components of the turbocharger in such a way that they cannot tip over. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
Page 20: Prerequisites For Operation And Maintenance
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.
Page 21: Hazards During Operation And Maintenance
Wear heat-resistant safety gloves and protective clothing. Wait for the turbocharger to cool down before carrying out any work. Wear safety gloves to protect against thermal hazards. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
Page 22 At the same time, electrical or electronic components and parts can also be damaged or destroyed. Only specially trained personnel should perform work on, or with, elec- trical components. Observe national regulations. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
Page 23: Safe Operation
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...
Page 24 Only operate the turbocharger with burst protection fitted and insulation fitted in one of the following, permitted variants. Fig. 5 Variant A Insulation (01) with integrated burst protection from ABB Turbo Systems. Variant B Burst protection (03) and insulation (02) from ABB Turbo Systems. Variant C Burst protection (03) from ABB Turbo Systems with appropriate insulation...
Page 25: Safe Maintenance
Keep the floor, equipment, and turbocharger clean. Have oil binding agents ready and provide or keep oil pans at hand. Clean up any spills. Have fire protection means and extinguishing agents available. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
Page 26 Secure rotor against turning. The rotor can rotate due to the stack draught alone. Observe the material safety data sheet for the cleaning and mothballing agents. Wear personal protective equipment (PPE) according to the material safety data sheet. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E...
Page 27 Wear personal protective equipment (PPE) according to the material safety data sheet. Comply with local legislation. Wear safety goggles. Wear safety gloves to protect against chemical hazards. Wear a respiratory mask to protect against gases. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017...
Page 28 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...
Page 31 Changing the absorption element ................57 Eliminating malfunctions..................59 Malfunctions when starting..................59 Malfunctions during operation ................60 Turbocharger is surging .................... 63 Malfunctions when stopping..................64 Speed measurement system ..................65 © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 32: Introduction
Radial clearances N and R..................129 10.11 Fitting the insulation....................130 10.12 Installing air inlets ..................... 131 Dismantling and fitting, special tools for fastening strips ......133 11.1 Application, special tools ..................135 © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 33 View of turbocharger with part numbers ............160 17.4 View of turbine cleaning device ................162 17.5 View of uncoupled filter silencer A155..............164 Tools ........................165 Figures......................... 167 Tables ........................170 © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 34: Introduction
This document is valid for different design variants of turbochargers. There may be sections and descriptions of components that are not relevant for a specific turbocharger variant. Please contact an ABB Turbocharging Service Station if you have any questions regarding a design variant (see Contact information at www.abb.com/turbocharging).
Page 35: Related Documents
Operation Manual / 2 Safety HZTL4022 Operation Manual / 3 Safety data sheet *) Serial number of the turbocharger Table 1: Related documents *) This chapter is only available in serialised operation manuals. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 36: Layout And Function Of The Turbocharger
02 Compressor casing Nozzle ring 03 Diffuser Turbine casing 04 Bearing casing Turbine-end bearing flange 05 Axial thrust bearing Compressor-end bearing flange 06 Radial plain bearing Compressor wheel 07 Turbine © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 37: Fig. 2: Compressor Wheel Cooling
(01). In addition, the turbocharger version with compressor wheel cooling is indicated by the tur- bocharger type (M6..) on the rating plate. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P...
Page 38: Warning Plates On The Turbocharger
If warning plates are not present in the designated locations or not readable, proceed as fol- lows: Order new warning plates from ABB Turbocharging Service Stations. Remove any warning plates that have become unreadable. Clean and degrease the areas designated for the warning plates.
Page 39: Locations Of The Rating Plates
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 40: Removing And Installing
Complete turbocharger unit without gas outlet casing Complete turbocharger unit with gas outlet casing Product Weight of complete turbocharger unit [kg] A150-M 1200 A155-M 1800 Table 2: Weight of complete turbocharger unit © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 41: Removing The Turbocharger
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. If present: Detach the support (61301) from the engine support. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P...
Page 42: Fig. 8: Loosening The Clamping Nut
3. Working in a circle, loosen each pressure screw by 90° in 1...5 rounds until all of the pres- sure screws have been relieved. Loosen clamping nut by hand. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 43: Fig. 9: Turbocharger Centre Of Gravity
Remove and dispose of the O-rings (42195, 42200). Set down and secure the turbocharger properly at a suitable location. Close or cover the openings of the turbocharger and support. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 44: Installing The Turbocharger
Gaskets that are forgotten, damaged or improperly inserted will lead to oil leaks. Always use new gaskets and insert them carefully into the slot. Fig. 10: Inserting the gasket Oil supply Oil drain 42200 O-ring 42201 Bearing casing 42202 O-ring © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 45: Fig. 11: Fitting The Turbocharger 1
Make sure that the position of the oil inlet of the bracket matches the oil inlet hole in the bearing casing. Make sure that the O-rings are placed correctly in the slots. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P...
Page 46: Fig. 12: Fitting The Turbocharger 2
Step A. Observe the instructions for fastening the turbocharger with clamping nuts (see chapter Fastening the turbocharger with a clamping nut →17). © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 47: Fig. 13: Preparing The Clamping Nut For The Tightening Procedure
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P...
Page 48: Fig. 14: Tightening Pressure Screws
4. Work in a circle to tighten all pressure screws to 100 % of the tightening torque specified in the table. 5. Tighten pressure screws to 100 % in 5 … 7 rounds until the required residual tightening angle of < 20° is achieved. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 49: Fig. 15: Connecting The Speed Sensor
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 If present: Attach support (61301) to engine support or to a connecting piece. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 50: Commissioning
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. The admissible values are specified in chapter Monitoring operation →25. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 51: Fig. 18: Oil Orifice
With an oil inlet pressure of more than 3 bar of overpressure (with engine under load) up- stream of the turbocharger, the bearing casings are equipped with an orifice at the oil inlet as standard. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P...
Page 52: Inspection Procedures
Make sure there is an uninterrupted supply of cooling air during opera- tion. Check whether the compressor wheel cooling is fitted on the bearing casing. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 53 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 2020 ABB. All rights reserved.
Page 54: Commissioning After Taking Out Of Operation
Check and clean filter silencer or air supply line, and remove any foreign objects that may be present. Put engine-side oil circulation to the turbocharger into operation. Prepare the turbocharger for operation (see Checks before commissioning →22). The turbocharger is now ready for operation. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 55: Monitoring Operation
Oil pressure measuring point Oil temperature measuring point For monitoring the lubricating oil pressure, ABB Turbocharging recommends installing a "P" manometer immediately upstream of the turbocharger oil inlet before the orifice. If the pressure is controlled electronically, the relevant signals should be triggered at the warning and alarm values.
Page 56: Table 6: Lubricating Oil Temperature At The Inlet
Table 7: Maximum lubricating oil temperature at the outlet If the turbocharger has been operated for a longer period of time outside the admissible range, ABB Turbocharging recommends having the turbocharger inspected by an ABB Tur- bocharging Service Station. © Copyright 2020 ABB. All rights reserved.
Page 57: Exhaust Gas Temperature Before Turbine
Definition and explanations concerning rating plate: refer to chapter 2 of Operation Manual / Safety. Operating limits: refer to chapter 3 of Operation Manual / Safety data sheet or examine rating plate. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 58: Turbocharger Speed
42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F/I converter Plug with integrated voltage limiter 86528 Tachometer Alternative mounting position for speed sensor 32109 Sealing disc with cams © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 59 Check the pressure loss of the alternative air inlet and compare it with normal values. If the engine can be stopped temporarily: Inspect air lines, gas piping and the turbochargers and remedy any malfunctions. In any case, contacting the nearest ABB Turbocharging Service Station is recommended. 4.3.4 Malfunctions on the speed measurement system...
Page 60: Fig. 20: Replacing The Speed Sensor
Wear safety gloves when disassembling the speed sensor. Wear safety gloves to protect against thermal hazards. The speed sensor supplied by ABB is equipped with a sealing lip and an O-ring. No additional gasket is required during assembly. Fig. 20: Replacing the speed sensor...
Page 61: Operation And Service
Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 : A-weighted emission sound pressure level The enginebuilder must provide acoustically equivalent measures in case of deviating in- sulation versions © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 62: Fig. 21: Noise Insulation, Bellows
Suggestion for noise insulation, bellows Fig. 21: Noise insulation, bellows Compressor casing Bellows Charge air duct / scavenging air duct Insulation cushion Insulation mat (at least 15 mm) Sheet metal cover © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 63: Service Work
Agree on a specific service interval with ABB Turbocharging. To prevent machine damage caused by ageing and downtime, we recommend having an in- spection carried out by an ABB Turbocharging Service Station no later than 5 years after the last service.
Page 64 Service work according to data on the rating plate (Usually after 8000 … 16000 operating hours) The rotor and bearing parts must be checked and assessed by an ABB Turbocharging Service Station. The following work can be carried out as preparation.
Page 65 Speed of the turbocharger ¡ Air temperature after the compressor and after the charge-air cooler ¡ Exhaust gas temperature before and after the turbine ¡ Pressure loss in the filter silencer. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 66: Expected Replacement Intervals
Table 9: Expected replacement intervals = Natural Gas = Marine Diesel Oil = Heavy Fuel Oil The specified values are guideline values and not guaranteed values, see Influencing para- meters. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 67 ¡ Lubricating oil quality (oil filtering, oil condition, oil monitoring) ¡ Load profile (speed, pressure conditions, temperature) ¡ Number of starts/stops ¡ Unbalance of the rotor (degree of contamination). © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 68: Stopping The Engine
– 550 °C with insulated casing – 600 °C with non-insulated casing At temperatures below the specified values, post-lubrication must be ensured until the rotors come to a standstill. ABB Turbocharging recommends post-lubrication for 10 minutes. Observe the oil pressure specified for post-lubrication (see Table 5: Lubricating oil pres-...
Page 69: Periodic Maintenance Work
Changing the absorption element →57 Table 10: Maintenance table [h] = Hours of operation If the maintenance intervals are incompatible with operation of the engine, contact ABB Turbocharging. ABB Turbocharging recommends having mechanical cleaning carried out by an ABB Tur- bocharging Service Station during the service work. Otherwise, only carry out mechanical cleaning if cleaning during operation is not sufficient to achieve the thermal load and the rating of the engine.
Page 70: Cleaning The Compressor During Operation
Periodic cleaning during operation delays any major increase in contamination. The cleaning method is suitable as long as the contamination has not progressed far. Very heavily con- taminated components can no longer be cleaned using this method. In this case, ABB Tur- bocharging recommends mechanical cleaning of the contaminated components.
Page 71 The compressor is cleaned during operation using the wet cleaning method. This is carried out at an engine load of 50 … 85%. This cleaning method is tested and approved by ABB Turbocharging. V-engines On V-engines with several turbochargers per engine, parallel cleaning of both turbochargers is recommended.
Page 72: Fig. 22: Carrying Out Wet Cleaning Of Compressor
Not more than three cleaning cycles should be conducted consecutively. Before repeating the process, continue to operate the engine for at least five minutes to ensure that all of the water is flushed out of the system. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P...
Page 73: Cleaning The Turbine During Operation
Periodic cleaning during operation delays any major increase in contamination. The cleaning method is suitable as long as the contamination has not progressed far. Very heavily con- taminated components can no longer be cleaned using this method. In this case, ABB Tur- bocharging recommends mechanical cleaning of the contaminated components.
Page 74 Cleaning method The turbine components are cleaned during operation using the wet cleaning method. This cleaning method is tested and approved by ABB Turbocharging. The precondition for wet cleaning is that the enginebuilder approves the process and these regulations are observed.
Page 75: Fig. 23: Turbine Cleaning Devices
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. ) External air supply for continuous blowing off of the cleaning nozzles between cleaning in- tervals. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 76: Fig. 24: Carrying Out Wet Cleaning Of Turbines
Close the stop valve (02) after 10 minutes. Wait for 10 minutes; do not change the load during this stabilisation phase. If the cleaning result is unsatisfactory or there is water leakage, contact an ABB Turbochar- ging Service Station. Parameter for 1-nozzle cleaning...
Page 77: Cleaning Components Mechanically
The disassembly and assembly of the parts is described in the respective Disassembly and Assembly chapters. Contaminated water and cleaning agents must be disposed of in an environmentally compatible, professional way and in compliance with locally applicable regulations. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 78: Fig. 25: Cleaning The Filter Silencer
Rinse in cold water. Avoid high mechanical loads (water jet). Let the filter ring dry completely before assembling. Dirty water and mild detergent must be disposed of in compliance with locally applicable regulations. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 79 When cleaning, note that the absorption segments (81136) must only be cleaned lightly with compressed air, a soft brush or a moist cleaning cloth. Have any heavily contaminated absorption segments replaced by an ABB Turbocharging Service Station. Fitting the filter silencer (see Fig. 25: Cleaning the filter silencer →48)
Page 80: Fig. 26: Compressor-End, Non-Rotating Parts
Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the tur- bocharger. Dispose of contaminated water and cleaning agents in accordance with the information in the material safety data sheet. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 81 Wear personal protective equipment (PPE) according to the material safety data sheet. Comply with local legislation. Wear safety goggles. Wear safety gloves to protect against chemical hazards. Wear a respiratory mask to protect against gases. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 82: Fig. 27: Turbine End, Non-Rotating Parts
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 Removing and installing 6-nozzle turbine cleaning component (optional) →143. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 83 Lightly spray the compressor wheel and the gap between the compressor and the bearing casing with penetrating oil. Dispose of dirty water and cleaning agents in accordance with the material safety data sheet. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 84: Fig. 28: Soaking The Turbine End
Use only pH-neutral cleaning agents which do not attack metals. Observe safety data sheet. Fill the container (02) with soaking fluid. To shorten the soaking time, the fluid can be heated up to a maximum of 60 ºC. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 85 Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against mechanical hazards. Lift up the cartridge group and align it horizontally. Remove dirt manually using a soft brush or a wire brush. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 86 Lightly spray the turbine and the gap between the turbine and the partition wall with pen- etrating oil. Dispose of dirty water and cleaning agents in accordance with the information in the ma- terial safety data sheet. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 87: Changing The Absorption Element
(see Fig. 41: Removing the uncoupled filter silencer →78). 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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 88: Fig. 30: Installing The Absorption Element
3. Fit the mounting plate (81149) with washers (81153) and hexagon-head screws (81152). Observe the tightening torque. 4. Remove the filter silencer (see Fig. 76: Installing the uncoupled filter silencer (see →111). Table 53: Tightening torque (72054) © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 89: Eliminating Malfunctions
To prevent significant loss of efficiency, specific tolerances must be fulfilled. ¡ If there is any doubt about the extent of the rubbing, contact an ABB Tur- bocharging Service Station. ¡...
Page 90: Malfunctions During Operation
Turbochar- Turbine and/or nozzle ring severely con- Clean (see chapter Periodic mainten- taminated ance work →39) Rotor components or bearing damaged Contact ABB Turbocharging Service Station Engine Defects on the connected cylinders in Contact enginebuilder pulse charging Pipes Defects, such as leaks, in the exhaust...
Page 91: Table 23: Malfunctions During Operation - Exhaust Gas Temperature Too High
Gas piping between engine and turbine leaking Injection mistimed Set correctly Valve control misadjusted Pipes Pipes downstream to the compressor Repair. outlet not sealed. Table 24: Malfunctions during operation – Charge air pressure too low © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 92: Table 25: Malfunctions During Operation - Charge Air Pressure Too High
Clean (see chapter Periodic mainten- ance work →39) Table 26: Malfunctions during operation – Engine performance losses © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 93: Turbocharger Is Surging
Gradually reduce the engine load. Have the cause clarified and remedied immediately by an ABB Turbochar- ging Service Station. Have parts assessed for damage and, if necessary, replaced by an ABB Turbocharging Service Station. Possible causes Remedy...
Page 94: Malfunctions When Stopping
Bearing damaged Check clearances (see chapter Measuring clear- ance A and B →94). If clearances are outside the tolerance or if in doubt, contact an ABB Turbochar- ging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R →104).
Page 95: Speed Measurement System
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 2020 ABB. All rights reserved.
Page 96: Dismantling And Fitting, General
ABB Turbocharging recommends having further work carried out only by trained personnel from an ABB Turbocharging Service Station. Tightening torques for assembly devices Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB must be tightened so they are tight-fitting. Oil orifice When disassembling the turbocharger, an oil orifice fitted in the oil inlet must not be re- →89).
Page 97: Material Required
Visually inspect for corrosion, cracks, deformation and wear. Damaged tools must no longer be used and must be replaced. Swivel lifting eyes Swivel lifting eyes are required for the safe lifting of loads, which are not supplied by ABB. Fig. 31: Swivel lifting eyes Product...
Page 98: Fig. 32: Press-Off Screws
A dismantling screw (01) is required to dismantle and fit the cleaning nozzles, which is not supplied by ABB. Fig. 33: Dismantling screw Product Thread Length [mm] Quantity A150-M A155-M Table 36: Dismantling screw © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 99 Use assembly devices only for the described applica- tions. ¡ Lifting gear Equipment for the lifting and transporting of loads (ropes, chain block, crane). Lifting gear is not supplied by ABB. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 100: Disassembly And Assembly Concepts
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P...
Page 101: Fig. 35: Cartridge Concept
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P...
Page 102: Fig. 36: Optional Spanner Holder
8 Dismantling and fitting, general / 8.3 Disassembly and assembly concepts Optional spanner holder Fig. 36: Optional spanner holder ABB offers an optional spanner holder (90165) (see Dismantling and fitting, special tools for fastening strips →133) 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.
Page 103: Weights Of Individual Parts
Turbine casing 1 inlet * 2 inlets * 3 inlets * Gas outlet flange Gas outlet casing with insulation Table 37: Weights of assemblies * including burst protection and insulation © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 104: Table Of Tightening Torques
Operation Manual / 4 Product description / A150-M56/66/57/67 - A155-M.. 8 Dismantling and fitting, general / 8.5 Table of tightening torques Table of tightening torques Fig. 38: Overview of tightening torques 1) Only A155-M with uncoupled filter silencer © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 105: Table 38: Tightening Torques
200 Nm 200 Nm 72011 275 Nm 370 Nm 86505 M12 x 1.5 M12 x 1.5 15 Nm 15 Nm 200 Nm 200 Nm 81154 10 Nm 81155 - - 55 Nm 81152 50 Nm Table 38: Tightening torques © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 106: Fig. 39: Tightening Torques For Insulation
Table 39: Tightening torques for insulation Tightening torque for attaching the insulation with integrated burst protection at the tur- bine casing Tightening torque for attaching the insulation to the burst protection. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 107: Dismantling And Fitting With Removed Air Inlet And Gas Outlet
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 108: 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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 109: Removing The Gas Outlet Casing
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 110: Fig. 43: Removing Gas Outlet Casing With Support 1
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P...
Page 111: 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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 112: Removing The Gas Outlet Flange
If the following Working Instructions are not observed, this can lead to cracks in the gas out- let casing. The following variants are possible: Pressing off using 3 press-off screws. Pressing off using 6 press-off screws. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 113: Fig. 45: Dismantling The Gas Outlet Flange
If it is not possible to press off the gas outlet flange with the maximum tight- ening torque, contact an ABB Turbocharging Service Station. 2. Attach swivel lifting eye (S) to the gas outlet flange. Secure lifting gear to the swivel lift- ing eye.
Page 114: Fig. 46: Removing The Gas Outlet Flange
≤ 150 Nm Table 41: 6 press-off screws * not included in the ABB scope of delivery. 1. Evenly press off and remove the gas outlet flange (57002) with screws (01) according to the table. If it is not possible to press off the gas outlet flange with the maximum tight- ening torque, contact an ABB Turbocharging Service Station.
Page 115: Removing The Cartridge Group With Compressor And Turbine Casing
(01) must not be loosened during disassembly. Fig. 48: Remove insulation 2. Remove the compressor casing insulation. 3. Remove the turbine casing insulation. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 116: Fig. 49: Removing The Cartridge Group With Compressor And Turbine Casing
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 117: Removing The Compressor Casing
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 118: Fig. 52: Dismantling The Diffuser And The Wall Insert
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P...
Page 119: Removing The Cartridge Group
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 121: 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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 122: 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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 123: Removing The Nozzle Ring
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 124: Measuring Clearance A And B
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2020 ABB. All rights reserved.
Page 125: Nozzle Ring Compression Pd
Table 44: Nozzle ring compression PD 1. Measure values A, B, and S on cleaned surfaces. 2. Calculate compression (PD). If the calculated value (PD) lies outside the specified range, contact an ABB Turbochar- ging Service Station. © Copyright 2020 ABB. All rights reserved.
Page 126: Installing Nozzle 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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P...
Page 127: 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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 129: Fig. 63: Installing The Cartridge Group
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 130: Installing The Compressor Casing
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 131: Fig. 65: Installing The Compressor Casing
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 132: Turning The Cartridge Group With Compressor And Turbine Casing
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P...
Page 133: Installing The Gas Outlet Flange
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 134: Radial Clearances N And R
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2020 ABB. All rights reserved.
Page 135: Fitting The Insulation
9 Dismantling and fitting with removed air inlet and gas outlet / 9.17 Fitting the insulation 9.17 Fitting the insulation Fig. 69: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see Table of tightening torques →74). © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 136: Installing The Cartridge Group With Compressor And Turbine 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). If present: Fit connecting pipe for turbine cleaning. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 137: Installing The Gas Outlet Casing
5. Fit hexagon nuts (51009). Observe the tightening torque. 6. Fit insulation ring. Observe tightening torques (see Table of tightening torques →74). 7. If present: Attach waste gate pipe. Tighten in accordance with enginebuilder’s specifica- tions. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 138: Fig. 73: Installing Gas Outlet Casing With Support 1
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 139: Fig. 74: Installing Gas Outlet Casing With Support 2
Table of tightening torques →74). 9. Fit gas outlet casing insulation (see Table of tightening torques →74). 10. If present: Attach waste gate pipe. Tighten in accordance with enginebuilder’s specifica- tions. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 140: Installing Air Inlets
2. Fit a new O-ring (81010) to the filter silencer (81000) or a new O-ring (82010) to the air suction branch (82000). 3. 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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 141: Fig. 76: Installing The Uncoupled Filter Silencer
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 142: Dismantling And Fitting, Cartridge Concept
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 143: 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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 144: Removing The Compressor Casing
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 145: Fig. 80: Pressing Off Compressor Casing
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 146: Fig. 82: Dismantling The Diffuser And The Wall Insert
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P...
Page 147: Removing The Cartridge Group
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 Remove insulation sheets. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 148: Fig. 84: Removing Cartridge Group 1
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 149: Fig. 85: Removing Cartridge Group 2
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 150: 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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 151: 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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 152: Measuring Clearance A And B
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2020 ABB. All rights reserved.
Page 153: Nozzle Ring Compression Pd
Table 56: Nozzle ring compression PD 1. Measure values A, B, and S on cleaned surfaces. 2. Calculate compression (PD). If the calculated value (PD) lies outside the specified range, contact an ABB Turbochar- ging Service Station. © Copyright 2020 ABB. All rights reserved.
Page 154: Installing Nozzle 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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P...
Page 155: Installing The Cartridge Group
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P...
Page 156: Fig. 92: Installing The Cartridge Group 2
5. Screw in the threaded rod until value L is reached. 6. Tighten the pressure screws of the clamping nut (see Tightening pressure screws →18). 7. Secure fastening strips (51002) together with nuts (51007) and Verbus Ripp® wash- ers (51003). © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 157: Installing The Compressor Casing
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 158: Fig. 94: Installing The Compressor Casing
Table 60: Tightening torque (72011) 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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 159: Radial Clearances N And R
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2020 ABB. All rights reserved.
Page 160: Fitting The Insulation
10 Dismantling and fitting, cartridge concept / 10.11 Fitting the insula- tion 10.11 Fitting the insulation Fig. 96: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see Table of tightening torques →74). © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 161: Installing Air Inlets
2. Fit a new O-ring (81010) to the filter silencer (81000) or a new O-ring (82010) to the air suction branch (82000). 3. 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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 162: Fig. 98: Installing The Uncoupled Filter Silencer
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 163: Dismantling And Fitting, Special Tools For Fastening Strips
Dismantling and fitting, special tools for fastening strips ABB offers an optional special tool set (90160) 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.
Page 164: Fig. 99: Customer Tool
Operation Manual / 4 Product description / A150-M56/66/57/67 - A155-M.. 11 Dismantling and fitting, special tools for fastening strips / Customer tool (not included in the ABB scope of delivery) Fig. 99: Customer tool Position Description Quantity Collection tub 500x400x30mm...
Page 165: Application, Special Tools
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). © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P...
Page 166 11 Dismantling and fitting, special tools for fastening strips / 11.1 Ap- plication, special tools 5. Loosen the nuts (51007) from the remaining fastening strips and remove the lugs (51002) with washers (51003). © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 167: Fig. 103: Fitting The Upper Fastening Strips
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P...
Page 168: Fig. 105: Fitting The Bottom Fastening Strip
A150-M A155-M Table 67: 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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 169: Fig. 106: 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 Table 68: Tightening torque (51007) © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 170: Fig. 107: Positioning The Fastening Strip
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P...
Page 171: Fig. 108: 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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 172: Fig. 109: Attach Nut
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 173: Removing And Installing 6-Nozzle Turbine Cleaning Component (Optional)
Fig. 111: 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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P...
Page 174: Fig. 112: Disassembly Of The Elbows
Remove the elbows (51311) from the connecting pieces (51313) in the specified order (01, 02, 03, 04, 05). Fig. 113: Pipe disassembly 1. Undo union nuts (51316) of pipe (51312). 2. Remove pipe. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 175: Fig. 114: Disassembly Of The Connecting Pieces
Fig. 115: Disassembly of the cleaning nozzle Remove cleaning nozzles (51301) with screw (01) in accordance with the following table. Product Thread Length [mm] Quantity A150-M A155-M Table 70: Dismantling screw © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 176: Assembly
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 177: Fig. 118: Pipe Assembly
Coat thread and contact surfaces of cutting ring with high-temperature grease. Screw union nuts (51316) of elbows (51311) in the specified order (01, 02, 03, 04, 05) to the connecting pieces (51313). © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P...
Page 178: Fig. 120: Elbow 2 Assembly
Product 51314 [Nm] 51316 [Nm] A150-M A155-M Table 72: 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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 179: Fitting The Cleaning Nozzles With Multi-Inlet Turbine Casings
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 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 180: Taking Out Of Operation At Short Notice
¡ If a replacement turbocharger or cartridge group is not available: Fit cover plate →152 and contact an ABB Turbocharging Service Station. Observe the following sections in connection with the emergency repairs mentioned. © Copyright 2020 ABB. All rights reserved.
Page 181: Installing The Replacement Turbocharger
The repair of a cartridge group requires special tools and the expertise of an ABB Turbochar- ging Service Station. The rotating parts rotate extremely quickly, and are sensitive to unbal- ance.
Page 182: Fitting The Cover Plate
3. Coat the threads of the studs (51006) with high-temperature grease. 4. Fasten cover plate (01) to turbine casing (51000) with fastening strips (51002), Verbus Ripp® washers (51003) and nuts (51007) and screw to bracket. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P...
Page 183: Cover Plate Drawing
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 scope of delivery and must be manufactured by the operating company according to the following drawing. Material: General structural steel, in accordance with DIN EN 10025-2.
Page 184: Fig. 124: Dimensions For Cover Plate
14 Taking out of operation at short notice / 14.5 Cover plate drawing Fig. 124: Dimensions for cover plate Product D2 ± 0.1 A150 90 ± 0.2 28.2 A155 111 ± 0.1 37.2 Table 74: Cover plate dimensions [mm] © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 185: Mothballing The Turbocharger
If the acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking the engine out of operation: Dismantle the turbocharger. The rotor and bearing parts must be dismantled and subsequently refitted by an ABB Tur- bocharging Service Station. Clean all parts.
Page 186: Taking The Engine Out Of Operation For More Than 12 Months
¡ The casings of the turbocharger remain attached to the engine, the rotor and bearing parts are dismantled by an ABB Turbocharging Service Station and stored separately ¡ The turbocharger is completely removed, either as a whole unit or in individual parts For the measures always necessary for preparing the turbocharger parts for mothballing, see section Taking the engine out of operation for up to 12 months, subsection Preparations...
Page 187: Disposing Of Turbocharger Components
Dispose of metals as scrap metal for recycling. Dispose of non-metallic materials as waste. Dispose of residues of lubricants as waste oil. Dispose of electronic components as electronic waste. Dispose of thermal insulation as hazardous waste. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 188: Spare Parts
79041 Counter-sunk screw 81010 / 82010 O-ring Table 75: Customer spare part set 97070 * This gasket can only be installed when a gas outlet casing from ABB is used. © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 189 Operation Manual / 4 Product description / A150-M56/66/57/67 - A155-M.. 17 Spare parts / 17.2 Required customer spare part set (97070) © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 190: View Of Turbocharger With Part Numbers
17.3 View of turbocharger with part numbers Fig. 125: Overview of part numbers * Depending on the specification of the turbocharger (……) only available in customer spare part set (97070). © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 191: Table 76: Spare Parts List
82010 (in the customer spare part set) O-ring 86505* Speed sensor 86515* Cable connector 86526* F/I converter 86528* Tachometer Table 76: Spare parts list * Depending on the specification of the turbocharger © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 192: View Of Turbine Cleaning Device
Designation 51301 1 inlet = 1 cleaning nozzle 2 inlets = 2 cleaning nozzles 3 inlets = 3 cleaning nozzles 51302 Gasket 51303 Screw plug Table 77: Spare parts list © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 193: Fig. 127: Overview Of Part Numbers
Screw-in fitting 51308 Stud 51309 Expansion sleeve 51310 Hexagon-head screw 51311 Elbow 51312 Pipe 51313 Connecting piece 51314 Hexagon-head screw 51316 Union nut 51317 Sealing stud Table 78: Spare parts list © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 194: View Of Uncoupled Filter Silencer A155
Fixing ring 81148 Absorption element 81149 Mounting plate 81150 Fastening strips 81151 Roll pin 81152 Hexagon-head screw 81153 Washer 81154 Socket screw 81155 Hexagon-head screw Table 79: Spare parts list © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Rev.P March 2020...
Page 195: Tools
Extraction device Table 80: Customer tool set 90000 ABB offers an optional special tool set (90160) 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.
Page 196: Fig. 130: Special Tool
90164 Tool disassembly segment 90165 Spanner holder Table 82: Special tool (90160) Tool sets can be ordered from any ABB Turbocharging Service Station. The following spe- cifications must be included in the order: ¡ Turbocharger type ¡ Designation and part number of the tool set.
Page 197: Figures
Fig. 58: Measuring clearance A and B ......94 Fig. 30: Installing the absorption element ....58 Fig. 59: Nozzle ring compression PD ......95 Fig. 31: Swivel lifting eyes ........... 67 Fig. 60: Installing the nozzle ring........ 96 © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Revision P March 2020...
Page 198 Fig. 123: Cover plate drawing ........153 Fig. 89: Nozzle ring compression PD ....... 123 Fig. 124: Dimensions for cover plate......154 Fig. 90: Installing the nozzle ring ......124 Fig. 125: Overview of part numbers ......160 © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Revision P March 2020...
Page 199 Fig. 126: Overview of part numbers......162 Fig. 127: Overview of part numbers ......163 Fig. 128: Overview of part numbers......164 Fig. 129: Special tool ..........165 Fig. 130: Special tool ..........166 © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Revision P March 2020...
Page 200: Tables
61 Table 54: Threaded rod, value X......... 118 Table 25: Malfunctions during operation – Charge air pressure too high ............62 Table 55: Permissible clearances A and B ....122 © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Revision P March 2020...
Page 201 Table 78: Spare parts list ........... 163 Table 79: Spare parts list .......... 164 Table 80: Customer tool set 90000......165 Table 81: Special tool (90160) ........165 Table 82: Special tool (90160)........166 © Copyright 2020 ABB. All rights reserved. HZTL4032_EN Revision P March 2020...

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