Page 1 Operation Manual A155-M56 HT557844 English Original Operation Manual Chapter Document-ID Introduction HZTL4005_EN_E Safety HZTL4022_EN_D Safety data sheet HT557844 Product description HZTL4032_EN_F ABB Turbocharging...
Page 2 Operating limits and replacement intervals The recommended replacement intervals and the corresponding operating limits in chapter 3 are jointly defined with the enginebuilder. This information is specific to the product. Non-observance of the recommended replacement intervals and the operating limits increases the risk of unpre- dictable component failures.
Page 3: Table Of Contents
Table of contents Page 1 / 8 Introduction Introduction .................... Purpose of the manual ................Symbols, definitions ................... Storage of new turbochargers and spare parts .......... Contact information ..................© Copyright 2016 ABB. All rights reserved. HZTL4005_EN Revision E July 2016...
Page 5: Introduction
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 2016 ABB. All rights reserved. HZTL4005_EN Revision E July 2016...
Page 6: Symbols, Definitions
Official service stations of ABB Turbo Systems Official service stations are identified in this document as ABB Turbocharging Service Sta- tions. They are regularly audited and certified by ABB Turbo Systems. Also see chapter Con- tact information [➙ 8]. © Copyright 2016 ABB. All rights reserved.
Page 7 Dispose of in an environmentally with specifications compatible, professional way and in compliance with locally applica- Oil free, grease free and dry ble regulations. Table 1: Definition of pictograms © Copyright 2016 ABB. All rights reserved. HZTL4005_EN Revision E July 2016...
Page 8: Storage Of New Turbochargers And Spare Parts
Old VCI corrosion protection emitters must be disposed of in an environmentally compati-  ble, professional way and in compliance with locally applicable regulations. Close package. The more tightly the package is sealed, the longer the protection duration.  © Copyright 2016 ABB. All rights reserved. HZTL4005_EN Revision E July 2016...
Page 9 Check the package for damage. If the package is damaged, the turbocharger or cartridge  group must be checked and repackaged by an ABB Turbocharging Service Station. After every 3 years, the following steps must be carried out by an ABB Turbocharging Service Station:  Checking the component ...
Page 10: Contact Information
Operation Manual / 1 Introduction Introduction Page 8 / 8 Contact information Contact information of the ABB Turbocharging Service Stations is available online. Scan the QR code to access our website.  ABB Turbo Systems Ltd Bruggerstrasse 71a CH-5401 Baden Switzerland www.abb.com/turbocharging...
Page 11 Periodic check of the pressure vessels ............1.10 Lifting of loads ..................... 1.11 Prerequisites for operation and maintenance ..........1.12 Hazards during operation and maintenance ..........1.13 Safe operation ..................... 1.14 Safe maintenance ..................HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
Page 13: 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. Nev- ertheless, there may be some residual risks during operation of and work on the turbocharger which: ...
Page 14: Definition Of Mandatory Signs
CAUTION can lead to serious CAUTION damage to engine or property with grave consequences. Caution signs must always be observed.  HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
Page 15: Intended Use
The specific operating limits of the turbocharger were determined on the basis of information from the enginebuilder about the intended use. These data are given on the rating plate. ABB accepts no liability and rejects all warranty claims for any non-intended uses. [1] Euromot = The European Association of Internal Combustion Engine Manufacturers...
Page 16: 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 inspec- tion.
Page 17: 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. HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
Page 18: Turbocharger Rating Plate
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 HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
Page 19: Periodic Check Of The Pressure Vessels
Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, are so-called "simple pressure vessels".  The locally applicable legal regulations regarding periodic checks of the pressure vessels must be observed.
Page 20: 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. HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
Page 21: Prerequisites For Operation And Maintenance
WARNING personnel. Only use original parts from ABB Turbo Systems.  ABB accepts no liability for any damage resulting from the use of non-original parts and corre- sponding accessories. HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved.
Page 22: 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. HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
Page 23 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, electri-  cal components. Observe national regulations.  HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
Page 24: Safe Operation
When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay  attention to the risks that may occur as a consequence of this energy input. HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
Page 25 Insulation (01) with integrated burst protection from ABB Turbo Systems. Variant B Burst protection (03) and insulation (02) from ABB Turbo Systems. Variant C Burst protection (03) from ABB Turbo Systems with appropriate insulation from the en- ginebuilder. HZTL4022_EN Revision D ©...
Page 26: Safe Maintenance
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.  HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
Page 27 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.  HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
Page 28  ty 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. HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
Page 29  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. HZTL4022_EN Revision D © Copyright 2017 ABB. All rights reserved. January 2017...
Page 33 Periodic maintenance work ..............Foreword to maintenance ................Cleaning the compressor during operation ..........Cleaning the turbine during operation ............Cleaning components mechanically ............Eliminating malfunctions ................. Malfunctions when starting ................. © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 34 Taking the engine out of operation for up to 12 months ......109 10.2 Taking the engine out of operation for more than 12 months ...... 110 Disposing of turbocharger components ............ © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 35 Spare parts ..................... 12.1 Ordering spare parts .................. 12.2 Required customer spare part set (97070) ..........12.3 View of turbocharger with part numbers ............. Figures ....................Tables ....................© Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 37: 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. ABB Turbocharging Service Stations will be happy to provide information on questions regard- ing a design variant (see Contact information at www.abb.com/turbocharging).
Page 38: 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 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 39 (01). In addition, the turbocharger version with compressor wheel cooling is indicated by the turbo- charger type (M6..) on the rating plate. © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 40: Warning Plates On The Turbocharger
Figure 3: Warning plate locations 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.
Page 41: Locations Of The Rating Plates
Locations of the rating plates Figure 4: Locations of the rating plates One rating plate (01) each is attached on the left and the right side of the turbocharger bearing casing. © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 43: Removing And Installing
Table 2: Weights of turbocharger A150-M.. – A155-M.. Figure 5: Suspension of complete turbocharger unit Complete turbocharger unit without gas outlet casing Complete turbocharger unit with gas outlet casing © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 44: Removing The Turbocharger
CAUTION possible to loosen them. Comply with the following steps for loosening the pressure screws.  © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 45 Working in a circle, loosen each of the pressure screws by about ¼ of a turn (90°).  Repeat the previous step until all pressure screws are relieved of pressure.  Loosen clamping nut by hand.  © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 46 Remove turbocharger from engine support, set it down properly in an appropriate place  and secure it. Close or cover the openings of the turbocharger and support.  © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 47: Installing The Turbocharger
The necessary sealing is performed by O-rings which are located in the slots of the bearing casing. The O-rings are supplied with the turbocharger. Figure 9: Inserting the gasket 42001 Bearing casing Oil supply 42200 O-ring Oil drain 42195 O-ring © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 48 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 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 49 Step A. Observe the instructions for fastening the turbocharger with clamping nuts (see chapter  Fastening the turbocharger with a clamping nut [➙ 18]). © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 50 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 2017 ABB. All rights reserved. HZTL4032_EN Revision F...
Page 51 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 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 52  the cooling air line. 2.3.5 Attaching the support Figure 15: Attaching the support If present: Attach support (61301) to engine support or to a connecting piece.  © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 53: Commissioning
Filtering the lubricating oil with a filter mesh width of ≤ 0.034 mm is sufficient for this turbo- charger. 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 [➙ 27]. © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 54 With an oil inlet pressure of more than 3 bar (with engine under load) before the turbocharger, the bearing casings are equipped as standard with an orifice at the oil inlet. © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F...
Page 55: Inspection Procedures
Any prolonged failure of the compressor wheel cooling will shorten the re- placement interval of the compressor wheel. CAUTION Make sure there is an uninterrupted supply of cooling air during operation.  © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 57: Commissioning After Taking Out Of Operation
Put engine-side oil circulation to the turbocharger into operation.  Prepare the turbocharger for operation according to section "Checks before commission-  ing". The turbocharger is now ready for operation.  © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 59: Monitoring Operation
Oil pressure measuring point Oil temperature measuring point For monitoring the lubricating oil pressure, ABB Turbo Systems recommends installing an "M" manometer immediately before the turbocharger. If the pressure is controlled electronically, the appropriate signals are to be triggered at the warning and alarm values.
Page 60 Table 7: Maximum lubricating oil temperature at the outlet 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 Turbocharg- ing Service Station.
Page 61: 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 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 62: 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 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 63 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 In the case of malfunctions of the speed measurement system, refer to the chapter entitled Troubleshooting/Speed measurement system [➙...
Page 64 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. Figure 18: Replacing the speed sensor...
Page 65: 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 insula- tion versions © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 66 Suggestion for noise insulation, bellows Figure 19: Noise insulation, bellows Compressor casing Bellows Charge air duct / scavenging air duct Insulation cushion Insulation mat (at least 15 mm) Sheet metal cover © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 67: Service Work
 5-year service inspection To prevent machine damage caused by ageing and downtime, we recom- mend having an inspection carried out by an ABB Turbocharging Service NOTICE Station no later than 5 years after the last service. © Copyright 2017 ABB. All rights reserved.
Page 68 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.
Page 69  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 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 70: Expected Replacement Intervals
50000 50000 Table 9: Expected replacement intervals = Marine Diesel Oil = Heavy Fuel Oil The specified values are guideline values and not guaranteed values, see Influencing parameters. © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 71  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 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 72: Stopping The Engine
– 600 °C with non-insulated casing At temperatures below the specified values, post-lubrication must be ensured until the ro- tors come to a standstill. ABB Turbo Systems recommends post-lubrication for 10 minutes. Observe the oil pressure specified for post-lubrication (see Table 5).
Page 73: Periodic Maintenance Work
8000 … 12000 h) Table 10: Maintenance table [h] = Hours of operation If the maintenance intervals are incompatible with operation of the engine, contact ABB Tur- bo Systems. ABB Turbo Systems recommends having mechanical cleaning carried out by an ABB Tur- bocharging Service Station during the service work.
Page 74: Cleaning The Compressor During Operation
Very heavily contami- nated components can no longer be cleaned using this method. In this case, ABB Turbo Sys- tems recommends having the contaminated components cleaned mechanically by an ABB Turbocharging Service Station.
Page 75 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.
Page 76 (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. © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F...
Page 77 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 2017 ABB. All rights reserved. HZTL4032_EN Revision F...
Page 78: Cleaning The Turbine During Operation
Very heavily contami- nated components can no longer be cleaned using this method. In this case, ABB Turbo Sys- tems recommends having the contaminated components cleaned mechanically by an ABB Turbocharging Service Station.
Page 79 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.
Page 80 CAUTION nents and can cause flooding of the turbine. It is imperative that turbine cleaning parameters are observed.  © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 81 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 Turbocharg- ing Service Station. Product Temperature before...
Page 82: Cleaning Components Mechanically
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 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 83  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 Figure 22) Insert the absorption segments (81136) into the sheet-metal coverings (81137).
Page 84 Spray cleaned surfaces with penetrating oil. Do not spray exterior surfaces of the turbo-  charger. Dispose of contaminated water and cleaning agents in accordance with the information in  the material safety data sheet. © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 85 Brush away the contamination or remove with a steam cleaner.  If necessary, repeat soaking and brushing.  Use clean water to completely clean parts of any solvents.  Dry components completely.  © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 86  Remove cartridge group (see chapter Dismantling and fitting [➙ 67]).  First clean the compressor end and then the turbine end according to the following descrip- tion. © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 87 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 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 88 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 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 89 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 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 90 Lightly spray the turbine and the gap between the turbine and the partition wall with pene-  trating oil. Dispose of dirty water and cleaning agents in accordance with the information in the mate-  rial safety data sheet. © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 91: Eliminating Malfunctions
To prevent significant loss of effi- ciency, specific tolerances must be fulfilled.  If there is any doubt about the extent of the rubbing, contact an ABB Turbocharging Service Station.  Have a dimension check carried out by an ABB Turbocharging Service Station.
Page 92: Malfunctions During Operation
Turbocharger Light to medium contamination of the tur- Clean (see chapter Periodic maintenance bine and/or nozzle ring (with 4-stroke ap- work [➙ 41]) or contact an ABB Turbo- plication) charging Service Station Table 21: Malfunctions during operation – Speed increases ©...
Page 93 Clean or repair boiler or exhaust gas si- lencer Pipes Pipes downstream to the compressor out- Repair. let not sealed. Table 23: Malfunctions during operation – Charge air pressure too low © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 94 Increased speed due to contamination of Clean (see chapter Periodic maintenance nozzle ring work [➙ 41]) or contact an ABB Turbo- charging Service Station Table 24: Malfunctions during operation – Charge air pressure too high Reduced compressor performance/efficiency, hence engine performance losses...
Page 95: Turbocharger Is Surging
Gradually reduce the engine load.  Have the cause clarified and remedied immediately by an ABB Turbo-  charging Service Station. Have parts assessed for damage and, if necessary, replaced by an ABB  Turbocharging Service Station. Possible causes Remedy...
Page 96: Malfunctions When Stopping
Bearing damaged Check clearances (see chapter Axial clearance A and radial clearance B [➙ 84]). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R [➙...
Page 97: Speed Measurement System
Table 32: 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 2017 ABB. All rights reserved.
Page 99: Dismantling And Fitting
ABB Turbo Systems recommends having further operations carried out  only by trained personnel from an ABB Turbocharging Service Station. Mark the casing position for assembly.  © Copyright 2017 ABB. All rights reserved.
Page 100 The specified tightening torques of the screw fittings must be observed (Table of tightening torques [➙ 101]). 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. © Copyright 2017 ABB. All rights reserved.
Page 101 Length Minimum load Quantity limit A150 13 mm 75 kg 21 mm 500 kg A155 13 mm 150 kg 21 mm 850 kg Table 33: Swivel lifting eyes © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 102: Weights Of Individual Parts
Nozzle ring Burst ring Turbine casing 1 inlet * 2 inlets 3 inlets Gas outlet flange Gas outlet casing Table 34: Weights of assemblies * Including burst protection © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 103: Removing Air Inlets
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 2017 ABB. All rights reserved. HZTL4032_EN Revision F...
Page 104: Removing The Gas Outlet Casing
Dismantling and fitting Page 72 / 120 Removing the gas outlet casing Removing the insulation Figure 28: Removing the insulation Remove the insulation of the gas outlet casing.  © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 105 3. If present: Loosen the support (61301) from the bracket. 4. Remove the gas outlet casing (61001), set it down properly in an appropriate place and secure it. 5. Remove and dispose of the gasket (61002). © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 106: Removing The Gas Outlet Flange
If the following Working Instructions are not observed, this can lead to cracks in the gas outlet casing. The following variants are possible: Pressing off using 3 press-off screws.  Pressing off using 6 press-off screws.  © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 107 ≤ 150 Nm Table 35: 3 press-off screws * not included in the ABB Turbo Systems scope of delivery. 1. Evenly press off and remove the gas outlet flange (57002) with screws (01) according to the table. If it is not possible to press off the gas outlet flange with the maximum tightening torque, contact an ABB Turbo Systems Service Station.
Page 108 ≤ 150 Nm Table 36: Press-off screws – gas outlet flange * not included in the ABB Turbo Systems scope of delivery. 1. Evenly press off and remove the gas outlet flange (57002) with screws (01) according to the table. If it is not possible to press off the gas outlet flange with the maximum tightening torque, contact an ABB Turbo Systems Service Station.
Page 109: Removing The Compressor Casing
4. Remove and dispose of the O-ring (42012). If the compressor casing cannot be loosened, it can be pressed off against the turbine casing using the press-off tool (90042) (see chapter Pressing off the casing [➙ 79]). © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F...
Page 110 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 2017 ABB. All rights reserved. HZTL4032_EN Revision F...
Page 111: Pressing Off The Casing
Use the tool on both sides in alternation and make sure not to press off  too hard on either side. Figure 34: Press off the casing © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 112: Removing The Cartridge Group
Figure 35: Oil orifice 01 Bearing casing 02 Oil orifice 03 Circlip Removing the insulation Figure 36: Removing insulation sheets Remove the insulation sheets (01, 02, 03).  © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 113 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 2017 ABB. All rights reserved. HZTL4032_EN Revision F...
Page 114 5. Remove the centering bush (42193) and the threaded rod (42191) along with the clamping nut (42201). 6. Attach the cartridge group to the service support (90012). 7. If present: Remove the metal C-ring (51105). © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 115: Removing The Nozzle Ring
Removing the nozzle ring Figure 39: 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 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 116: Axial Clearance A And Radial Clearance B
Serious damage to engines or property can be caused by clearances out- side the tolerance and excessively worn parts. CAUTION Have the components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. © Copyright 2017 ABB. All rights reserved.
Page 117: Nozzle Ring Compression Pd
Nozzle ring 1. Measure dimensions A, B, and S on cleaned surfaces. 2. Calculate compression (PD). If the calculated value (PD) lies outside the specified range, contact an ABB Turbocharging  Service Station. © Copyright 2017 ABB. All rights reserved.
Page 118: Installing Nozzle Ring
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 2017 ABB. All rights reserved. HZTL4032_EN Revision F...
Page 119: Installing The Cartridge Group
5. Screw the centering bush (42193) flush onto the threaded rod from below. 6. Lift the centering bush (42193) using the threaded rod (42191) and hold it firmly. 7. Rotate the clamping nut (42201) downwards until the stop is reached. © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F...
Page 120 6. Tighten the pressure screws of the clamping nut. (see Tightening pressure screws [➙ 19]) 7. Secure fastening strips (51002) together with nuts (51007) and Verbus Ripp® washers (51003). © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 121: Installing The Compressor Casing
3. Install the wall insert (77000) into the compressor casing and, when doing so, pay attention to the positioning pin in the compressor casing. 4. Fit the diffuser (79000) with fixing discs (79040) and screws (79041). Observe the tighten- ing torque. © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 122 5. Install the fastening strips (72012) with screws (72011). Observe the tightening torque. With the A155-M, the Verbus Ripp® washers are not integrated in the screws. Separate Verbus Ripp® washers (72010) must be fitted. © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F...
Page 123: Radial Clearances N And R
Serious damage to engines or property can be caused by clearances out- side the tolerance and excessively worn parts. CAUTION Have the components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. © Copyright 2017 ABB. All rights reserved.
Page 124: Installing Air Inlets
(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 tightening torque. © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 125: Removing The Turbine Casing
WARNING Serious injuries or accidents resulting in fatalities can occur if the turbine casing insulation supplied by ABB Turbo Systems is removed. A burst pro- tection is integrated into this turbine casing insulation supplied by ABB Turbo Systems.
Page 126 Operation Manual / 4 Product description / A150-M.. - A155-M.. Dismantling and fitting Page 94 / 120 Figure 49: Removing the insulation sheets Remove the insulation according to the illustration.  © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 127 2. Loosen nuts (51007) and remove together with Verbus Ripp® washers (51003) and fas- tening strips (51002). 3. Remove turbine casing, set it down properly in an appropriate place and secure it. 4. If present: Remove the C-ring (51105). © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 128: Installing The Turbine Casing
6. Secure the fastening strips (51002) with nuts (51007) and Verbus Ripp® washers (51003) and tighten. 7. Remove swivel lifting eye. 8. Fit screw. Observe the tightening torque. © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 129: 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 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 130 Fitting the insulation of the turbine casing Figure 53: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see Table of  tightening torques [➙ 101]). © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 131: Installing The Gas Outlet Casing
4. Position the gas outlet casing correctly on the turbine casing (51000). 5. If present: Fit the support (61301). 6. Fit the hexagon nuts (51009). Observe the tightening torque. © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 132 Page 100 / 120 Fitting the insulation Figure 55: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see Table of  tightening torques [➙ 101]). © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 133: Table Of 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 Table 48: Tightening torques © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 134 The following tightening torques must be observed for the designated screw fittings: Position Part number A150 A155 65 Nm 65 Nm 10 Nm 10 Nm 25 Nm 25 Nm 45 Nm 45 Nm Table 49: Tightening torques for insulation © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 135: Taking Out Of Operation At Short Notice
 If present: Installing a replacement cartridge group [➙ 104].  If a replacement turbocharger or cartridge group is not available: Fit cover plate [➙ 105] and contact an ABB Turbocharging Service Station. Observe the following sections in connection with the emergency repairs mentioned.
Page 136: Installing A Replacement Turbocharger
A replacement cartridge group is ready for use immediately and includes the complete bearing casing with bearing and a balanced rotor. The repair of a cartridge group requires special tools and the expertise of an ABB Turbocharg- ing Service Station. The rotating parts turn very fast and are very sensitive to unbalance.
Page 137: 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 2017 ABB. All rights reserved. HZTL4032_EN Revision F...
Page 138: Cover Plate Drawing
Page 106 / 120 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.
Page 139 Page 107 / 120 Figure 60: Dimensions for cover plate Product D2 ± 0.1 A150 90 ± 0.2 28.2 A155 111 ± 0.1 37.2 Table 51: Cover plate dimensions [mm] © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 141: 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 142: 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...
Page 143: Disposing Of Turbocharger Components
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 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 145: Spare Parts
Counter-sunk screw 81010 / 82010 O-ring Table 52: Customer spare part set 97070 * This gasket can only be installed when a gas outlet casing from ABB Turbo Systems is used. © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F...
Page 146: View Of Turbocharger With Part Numbers
Spare parts Page 114 / 120 12.3 View of turbocharger with part numbers Figure 61: Overview of part numbers (……) only available in customer spare part set (97070). © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 147 Counter-sunk screw 81000 Filter silencer 81010 (in the customer spare part set) O-ring 82000 Air suction branch 82010 (in the customer spare part set) O-ring 86505* Speed sensor © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 148 Cable connector 86526* F/I converter 86528* Tachometer 97151 (customer spare part set) 6-nozzle turbine cleaning Table 53: Spare parts list * Depending on the specification of the turbocharger © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 149: Figures
Fig. 28 Removing the insulation .... Fig. 61 Overview of part numbers ..114 Fig. 29 Removing the gas outlet casing Fig. 30 Dismantling the gas outlet flange ........© Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 151: Tables
Table 22 Malfunctions during operation R ..........91 – Exhaust gas temperature too Table 45 Tightening torque (72051) ..92 high......... Table 46 Tightening torque (51007) ..96 © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...
Page 152 Table 50 Cover plate dimensions [mm] .. 106 Table 51 Cover plate dimensions [mm] .. 107 Table 52 Customer spare part set 97070 ........113 Table 53 Spare parts list ......115 © Copyright 2017 ABB. All rights reserved. HZTL4032_EN Revision F January 2017...

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