Page 1 Operation Manual A150-M66 HT580635 English Original Operation Manual Chapter Document-ID Introduction HZTL4005_EN_F Safety HZTL4022_EN_E Safety data sheet HT580635 Product description HZTL4032_EN_H 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 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017...
Page 4: Purpose Of The 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 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017...
Page 5: Symbols, Definitions
ABB Turbo Systems Ltd is identified as ABB Turbo Systems in this document. 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 →7.
Page 6 Dispose of in an environmentally ance with specifications compatible, professional way and in compliance with locally applic- Oil free, grease free and dry able regulations Table 1: Definition of pictograms © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017...
Page 7: Storage Of New Turbochargers And Spare Parts
Old VCI corrosion protection emitters must be disposed of in an environmentally compat- ible, professional way and in compliance with locally applicable regulations. Close package. The more tightly the package is sealed, the longer the protection dura- tion. © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017...
Page 8 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: ¡...
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 Turbo Systems Ltd 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 Cleaning components mechanically ............... 47 Eliminating malfunctions..................57 Malfunctions when starting..................57 Malfunctions during operation ................58 Turbocharger is surging ..................... 61 Malfunctions when stopping..................62 Speed measurement system ..................63 © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 32: Introduction
Radial clearances N and R..................123 10.11 Fitting the insulation....................124 10.12 Installing air inlets ..................... 125 Dismantling and fitting, special tools for fastening strips ......126 11.1 Application, special tools ..................127 © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 33 Required customer spare part set (97151) for 6-nozzle turbine cleaning ..152 17.4 View of turbocharger with part numbers ............154 17.5 View of turbine cleaning device ................156 Figures......................... 158 Tables ........................160 © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 40: Removing And Installing
1800 Table 2: Weights of turbocharger A150-M.. – A155-M.. Fig. 5: Suspension of complete turbocharger unit Complete turbocharger unit without gas outlet casing Complete turbocharger unit with gas outlet casing © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
Page 42: Fig. 8: Loosening The Clamping Nut
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
Page 48: Fig. 14: Tightening Pressure Screws
2 Removing and Installing / 2.3 Installing the turbocharger Tightening pressure screws Fig. 14: Tightening pressure screws Torque-controlled tightening Product Fixing screw [mm] Tightening torques [Nm] A150 A155 Table 4: Pressure screw tightening torques © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
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 2018 ABB. All rights reserved.
Page 54: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 55: Monitoring Operation
Alarm signal: Not admissible. Stop the engine immediately. < 0.6 Table 5: Lubricating oil pressure at oil inlet before turbocharger *) Depending on use of an oil orifice in accordance with the enginebuilder’s specifications. © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 56: Table 6: Lubricating Oil Temperature At The Inlet
Oil pressure measuring point Oil temperature measuring point For monitoring the lubricating oil pressure, ABB Turbo Systems recommends installing a "P" manometer immediately upstream of the turbocharger oil inlet before the orifice. If the pressure is controlled electronically, the relevant signals should be triggered at the warning and alarm values.
Page 57: Exhaust Gas Temperature Before Turbine
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 Tur- bocharging Service Station.
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 63: 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 Sta- tion no later than 5 years after the last service. © Copyright 2018 ABB. All rights reserved.
Page 64 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 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
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 Turbo Systems recommends post-lubrication for 10 minutes. Observe the oil pressure specified for post-lubrication &.
Page 69: Periodic Maintenance Work
To allow you to observe the standard service intervals and to maintain a high turbocharger efficiency, ABB Turbo Systems recommends that the cleaning procedure be carried out dur- ing operation. This allows the thermal load of the engine to be kept low while ensuring max- imum fuel efficiency.
Page 70: Cleaning The Compressor During Operation
Very heavily con- taminated components can no longer be cleaned using this method. In this case, ABB Turbo Systems recommends having the contaminated components cleaned mechanically by an ABB Turbocharging Service Station.
Page 71 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 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
Page 73: Cleaning The Turbine During Operation
Very heavily con- taminated components can no longer be cleaned using this method. In this case, ABB Turbo Systems recommends having the contaminated components cleaned mechanically by an ABB Turbocharging Service Station.
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 Turbo Systems. 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 82: Fig. 27: Turbine End, Non-Rotating Parts
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) →136. © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 84: Fig. 28: Soaking The Turbine End
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 85 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 87: 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 88: Malfunctions During Operation
Remedy Turbocharger Turbine and/or nozzle ring severely con- Clean (see chapter Periodic maintenance →39) taminated work Rotor components or bearing damaged Contact ABB Turbocharging Service Sta- tion Engine Defects on the connected cylinders in Contact enginebuilder pulse charging Pipes Defects, such as leaks, in the exhaust gas...
Page 89: Table 22: Malfunctions During Operation - Exhaust Gas Temperature Too High
Injection mistimed Set correctly Valve control misadjusted Pipes Pipes downstream to the compressor Repair. outlet not sealed. Table 23: Malfunctions during operation – Charge air pressure too low © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 90: Table 24: Malfunctions During Operation - Charge Air Pressure Too High
Clean (see chapter Periodic maintenance work →39) Table 25: Malfunctions during operation – Engine performance losses © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 91: 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 92: Malfunctions When Stopping
Bearing damaged Check clearances (see chapter Axial clearance A and radial clearance B →90). If clearances are outside the tolerance or if in doubt, contact an ABB Tur- bocharging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R →100).
Page 93: 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 2018 ABB. All rights reserved.
Page 94: Dismantling And Fitting, General
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 2018 ABB. All rights reserved.
Page 95 (Table of tightening torques →72). 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 2018 ABB. All rights reserved. HZTL4032_EN...
Page 96: Table 33: Swivel Lifting Eyes
Thread Length Minimum Quantity load limit A150 13 mm 75 kg 21 mm 1000 kg A155 13 mm 150 kg 21 mm 1400 kg Table 33: Swivel lifting eyes © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 97: Table 34: Press-Off Screws
A dismantling screw (01) is required to dismantle and fit the cleaning nozzles, which is not supplied by ABB Turbo Systems. Dismantling screw Product Thread Length Quantity A150-M 40 mm A155-M 50 mm Table 35: Dismantling screw © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 98: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
Page 99: Fig. 30: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
Page 100: Fig. 31: Optional Spanner Holder
8 Dismantling and fitting, general / 8.2 Disassembly and assembly concepts Optional spanner holder Fig. 31: Optional spanner holder ABB Turbo Systems offers an optional spanner holder (90165) (see Dismantling and fitting, special tools for fastening strips →126) 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 101: Weights Of Individual Parts
Turbine casing 1 inlet * 2 inlets * 3 inlets * Gas outlet flange Gas outlet casing with insulation Table 36: Weights of assemblies * including burst protection and insulation © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 102: Table Of Tightening Torques
51007 with spanner holder 85 Nm 70 Nm (90165) 51009 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 37: Tightening torques © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 103: Fig. 34: Tightening Torques For Insulation
Table 38: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 104: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 105: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 106: Fig. 37: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
Page 107: Fig. 38: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 108: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 109: Fig. 39: Dismantling The Gas Outlet Flange
≤ 150 Nm Table 39: 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 tight- ening torque, contact an ABB Turbo Systems Service Station.
Page 110: Fig. 40: Removing The Gas Outlet Flange
≤ 150 Nm Table 40: 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 tight- ening torque, contact an ABB Turbo Systems Service Station.
Page 111: Removing The Cartridge Group With Compressor And Turbine Casing
(01) must not be loosened during disassembly. Fig. 42: Remove insulation 2. Remove the compressor casing insulation. 3. Remove the turbine casing insulation. © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 112: Fig. 43: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 113: Removing The Compressor Casing
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 114: Fig. 46: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
Page 115: Removing The Cartridge Group
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
Page 117: Fig. 49: Remove 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 118: Installing The Cartridge Group On The Service Support
Fig. 50: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 119: Removing The Nozzle Ring
Removing the nozzle ring Fig. 51: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 120: Axial Clearance A And Radial Clearance 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 2018 ABB. All rights reserved.
Page 121: Nozzle Ring Compression Pd
Table 43: Permitted nozzle ring compression PD 42001 Bearing casing 51000 Turbine casing 42400 Heat shield 56001 Nozzle ring 1. Measure dimensions A, B, and S on cleaned surfaces. 2. Calculate compression (PD). © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 122: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
Page 123: Installing The Cartridge Group
Fig. 55: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 125: Table 45: Tightening Torque (51007)
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 126: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 127: Fig. 59: Installing The Compressor Casing
1. Fit a 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 128: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 130: 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 2018 ABB. All rights reserved.
Page 131: 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. 63: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see Table of tightening torques →72). © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 132: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 133: 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 →72). 7. If present: Attach waste gate pipe. Tighten in accordance with enginebuilder’s specifica- tions. © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 134: Fig. 67: Fitting Gas Outlet Casing With Support 1
3. Fit swivel lifting eyes (S) to the gas outlet casing (61001). Secure lifting gear to the swivel lifting eye. 4. Place gas outlet casing at turbine casing (51000). Observe the marking. 5. Fit the support (61301). 6. Fit hexagon nuts (51009). Observe the tightening torque. © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 135: Fig. 68: Fitting Gas Outlet Casing With Support 2
Table of tightening torques →72). 9. Fit gas outlet casing insulation (see Table of tightening torques →72). 10. If present: Attach waste gate pipe. Tighten in accordance with enginebuilder’s specifica- tions. © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 136: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 137: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 138: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 139: Fig. 72: Pressing Off Compressor Casing
2. Press off compressor casing with press-off tool (90042). Fig. 73: Remove the diffuser 1. Remove and dispose of the O-ring (42012). 2. Set the compressor casing (72000) down on a suitable support. © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 140: Fig. 74: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
Page 141: Removing The Cartridge Group
A155-M.. 10 Dismantling and fitting, cartridge concept / 10.3 Removing the cartridge group 10.3 Removing the cartridge group Removing the insulation Fig. 75: Removing insulation sheets Remove insulation sheets. © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 142: Fig. 76: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
Page 143: Fig. 77: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 144: Fig. 78: Removing Cartridge Group 2
(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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 145: Removing The Nozzle Ring
10.4 Removing the nozzle ring Fig. 79: S_05180 1. Pull out the nozzle ring (56001) with the two extraction devices (90070). 2. Remove the lamellar sealing ring (56005). © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 146: Axial Clearance A And Radial Clearance 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 2018 ABB. All rights reserved.
Page 147: 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 Turbochar- ging Service Station. © Copyright 2018 ABB. All rights reserved.
Page 148: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
Page 149: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
Page 150: Fig. 84: Installing The Cartridge Group 2
→18) 6. Tighten the pressure screws of the clamping nut. (see Tightening pressure screws 7. Secure fastening strips (51002) together with nuts (51007) and Verbus Ripp® washers (51003). © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 151: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 152: Fig. 86: Installing The Compressor Casing
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 153: 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 2018 ABB. All rights reserved.
Page 154: Fitting The Insulation
10 Dismantling and fitting, cartridge concept / 10.11 Fitting the insula- tion 10.11 Fitting the insulation Fig. 88: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see Table of tightening torques →72). © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 155: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 156: Dismantling And Fitting, Special Tools For Fastening Strips
Dismantling and fitting, special tools for fastening strips ABB Turbo Systems offers optional special tools which, in the event of limited accessibility, can be used to facilitate the loosening of nuts and the application of tightening torques for the strip connection between the cartridge group and the turbine casing.
Page 157: Application, Special Tools
Special tools, complete 90161 90165 Spanner holder 90166 Spanner holder Table 61: Special tools (90160) Customer tool (not included in the ABB Turbo Systems scope of delivery) Fig. 91: Client tool Position Description Quantity Collection tub 500x400x30mm Torque spanner 40-200 Nm with...
Page 158: Fig. 92: Special Tools
90163 Clamping device 90164 Tool disassembly segment 90165 Spanner holder Table 63: Special tools (90160) Customer tool (not included in the ABB Turbo Systems scope of delivery) Fig. 93: Client tool Position Description Quantity Universal pliers Table 64: Client tool © Copyright 2018 ABB. All rights reserved.
Page 159: Fig. 94: Positioning The Collection Tub
Any falling screw material will be caught in the collection tub (01). 5. Loosen the nuts (51007) from the remaining fastening strips and remove the lugs (51002) with washers (51003). © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 160: Fig. 96: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
Page 161: Fig. 98: Fitting The Bottom Fastening Strip
70 Nm Table 66: Tightening torque (51007) with spanner holder 5. Fit the nuts (51007) with spanner holder (90165 / 90166) and attached torque spanner (02). Observe the tightening torque. © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 162: Fig. 99: Fitting The Cartridge Group
Table 67: Tightening torque (51007) 1. Fit the nuts (51007) of the (upper) fastening strips (51002) illustrated and tighten with a torque spanner (02) without a spanner holder. Observe the tightening torque. © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
Page 163: Fig. 100: Positioning The Fastening Strip
5. Push the fastening strip with the segment disassembly tool in the direction of the tur- bine casing as far as possible. 6. Depress the segment disassembly tool and remove it. © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
Page 164: Fig. 101: Clamping Device
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 165: Fig. 102: Attach Nut
14. Fit the nut (51007) onto the set screw by pulling the cord. 15. Fit the nuts (51007) with spanner holder (90165) and attached torque spanner (02). Ob- serve the tightening torque. © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
Page 166: Removing And Installing 6-Nozzle Turbine Cleaning Component (Optional)
Fig. 104: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
Page 167: Fig. 105: Disassembly Of The Elbows
Remove the elbows (51311) from the connecting pieces (51313) in the specified order (01, 02, 03, 04, 05). Fig. 106: Pipe disassembly 1. Undo union nuts (51316) of pipe (51312). 2. Remove pipe. © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 168: Fig. 107: Disassembly Of The Connecting Pieces
4. Remove gaskets from holes. Fig. 108: Disassembly of the cleaning nozzle Remove cleaning nozzles (51301) with screw (01) in accordance with the following table. Position A150-M A155-M M8x40 M10x50 Table 69: Dismantling screw © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 169: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 170: Fig. 111: Pipe Assembly
Coat thread and contact surfaces of cutting ring with high-temperature grease. Screw the union nuts (51316) of the elbows (51311) onto the connecting pieces (51313) in the specified order (01, 02, 03, 04, 05). © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
Page 171: Fig. 113: Assembly Of Elbows 2
100 Nm 51316 70 Nm 90 Nm Table 71: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 172: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 173: Taking Out Of Operation At Short Notice
¡ If a replacement turbocharger or cartridge group is not available: Fit cover plate →144 and contact an ABB Turbocharging Service Station. Observe the following sections in connection with the emergency repairs mentioned. © Copyright 2018 ABB. All rights reserved.
Page 174: Installing The Replacement Turbocharger
To enable you to quickly put an engine back into operation after a turbocharger has sus- tained damage, ABB Turbo Systems recommends having a replacement turbocharger or ap- propriate spare parts available in storage. The defective turbocharger can be removed and the replacement turbocharger installed within a short period of time.
Page 175: Fig. 115: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
Page 176: 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 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 177: Fig. 117: Dimensions For Cover Plate
14 Taking out of operation at short notice / 14.5 Cover plate drawing Fig. 117: Dimensions for cover plate Product D2 ± 0.1 A150 90 ± 0.2 28.2 A155 111 ± 0.1 37.2 Table 73: Cover plate dimensions [mm] © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 178: 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 179: 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 180: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 181: Spare Parts
Counter-sunk screw 81010 / 82010 O-ring Table 74: Customer spare part set 97070 * This gasket can only be installed when a gas outlet casing from ABB Turbo Systems is used. © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H...
Page 182: Required Customer Spare Part Set (97151) For 6-Nozzle Turbine Cleaning
51302 (in the customer spare Gasket part set) 51314 (in the customer spare Hexagon-head screw part set) Table 75: Customer spare part set (97151) for the optional 6-nozzle turbine cleaning component © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 183 Operation Manual / 4 Product description / A150-M56/66/57/67 - A155-M.. 17 Spare parts / 17.3 Required customer spare part set (97151) for 6- nozzle turbine cleaning 17.3.1.1 Note page © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 184: View Of Turbocharger With Part Numbers
View of turbocharger with part numbers Fig. 118: Overview of part numbers * Depending on the specification of the turbocharger (……) only available in customer spare part set (97070). © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 185: 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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 186: View Of Turbine Cleaning Device
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 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 187: Fig. 120: Overview Of Part Numbers
Hexagon-head screw 51311 Elbow 51312 Pipe 51313 Connecting piece 51314 (in the customer spare part set) Hexagon-head screw 51316 Union nut 51317 Sealing stud Table 78: Spare parts list © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 188: Figures
........68 Fig. 58: Fitting the wall insert and the diffuser ..96 Fig. 30: Cartridge concept.......... 69 Fig. 59: Installing the compressor casing....97 Fig. 31: Optional spanner holder ....... 70 © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 189 Fig. 87: Measuring clearances N and R....123 Fig. 88: Fitting the insulation........124 Fig. 89: Installing the air inlets........125 Fig. 90: Special tools........... 127 Fig. 91: Client tool............127 Fig. 92: Special tools ........... 128 © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 190: Tables
Table 24: Malfunctions during operation – Charge air pressure too high ............60 Table 53: Permissible clearances A and B ....116 Table 54: Permitted nozzle ring compression PD .. 117 © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...
Page 191 Table 75: Customer spare part set (97151) for the optional 6-nozzle turbine cleaning component ..152 Table 76: Spare parts list ........... 155 Table 77: Spare parts list........... 156 Table 78: Spare parts list ........... 157 © Copyright 2018 ABB. All rights reserved. HZTL4032_EN Revision H July 2018...

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