Page 1 Turbocharging Operation Manual / A150-M66 HT604292 Document identification Document number HZTL4032 Revision Language English Original Operation Manual Product identification Serial number HT604292 Customer part number Delivery date (yyyy-mm-dd) 2021-07-05 Weight 1200 Operating limits according to rating plate Speed limit in test rig operation only Mmax Speed limit during operation Bmax...
Page 3: Table Of Contents
Operation Manual / A150-M56/66/57/67 - A155-M.. Table of contents Operation Manual / A150-M.. - A155-M.. Introduction......................4 Purpose of the manual....................4 Contact information...................... 5 Essential information....................5 Layout and function of the turbocharger ..............6 Symbols, definitions..................... 8 Storage of new turbochargers and spare parts ............ 10 Registered trademarks ....................
Page 4 Operation Manual / A150-M56/66/57/67 - A155-M.. Table of contents Expected replacement intervals ................55 Stopping the engine....................57 Periodic maintenance work ................58 Foreword to maintenance..................58 Cleaning the compressor during operation ............59 Cleaning the turbine during operation..............62 Cleaning components mechanically ...............
Page 5 Operation Manual / A150-M56/66/57/67 - A155-M.. Table of contents Dismantling and fitting, cartridge concept ........... 130 11.1 Removing air inlets ....................130 11.2 Removing the compressor casing ................132 11.3 Removing the cartridge group ................135 11.4 Removing the nozzle ring ..................138 11.5...
Page 6: Operation Manual / A150-M
Operation Manual / A150-M56/66/57/67 - A155-M.. 1 Introduction / 1.1 Purpose of the manual Introduction Purpose of the manual Fig. 1: Serial number (01) on the rating plate This Operation Manual belongs to the turbocharger with the identical serial number (01), see the Operation Manual title page and the rating plate on the turbocharger.
Page 7: Contact Information
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 8: Layout And Function Of The Turbocharger
Operation Manual / A150-M56/66/57/67 - A155-M.. 1 Introduction / 1.4 Layout and function of the turbocharger Layout and function of the turbocharger Fig. 2: Layout and function of the turbocharger 01 Filter silencer / air suction branch Gas outlet flange 02 Compressor casing...
Page 9: Fig. 3: Compressor Wheel Cooling
Operation Manual / A150-M56/66/57/67 - A155-M.. 1 Introduction / 1.4 Layout and function of the turbocharger Mode of operation The turbocharger is a turbomachine and consists of the following main components: ¡ Turbine ¡ Compressor. These components are installed on a common shaft and form the rotor.
Page 10: Symbols, Definitions
Caution and warning signs are described in chapter Safety. ABB Turbocharging ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging in this document. Official service stations of ABB Turbocharging Official service stations are regularly audited and certified by ABB Turbocharging. See also chapter Contact information →5.
Page 11: Table 1: Definition Of Pictograms
Operation Manual / A150-M56/66/57/67 - A155-M.. 1 Introduction / 1.5 Symbols, definitions Definition of pictograms The following pictograms can occur in this document. These point out actions that must be taken in accordance with the meaning of the relevant pictogram.
Page 12: Storage Of New Turbochargers And Spare Parts
Operation Manual / A150-M56/66/57/67 - A155-M.. 1 Introduction / 1.6 Storage of new turbochargers and spare parts Storage of new turbochargers and spare parts Storage of new turbochargers and spare parts up to 6 months New turbochargers and spare parts can be stored in their closed packages for 6 months from the date of delivery without additional mothballing measures.
Page 13: Fig. 5: Package With Hygrometer
Inspect the package for damage. If the package is damaged, the turbocharger must be in- spected by an ABB Turbocharging Service Station and repacked. After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station: ¡...
Page 14: Registered Trademarks
Operation Manual / A150-M56/66/57/67 - A155-M.. 1 Introduction / 1.7 Registered trademarks Registered trademarks The trademarks of outside companies are used in this document. These are marked with the ® symbol. © Copyright 2021 ABB. All rights reserved. HZTL4032_EN Rev.Q...
Page 15: 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 16: Definition Of Mandatory Signs
Operation Manual / A150-M56/66/57/67 - A155-M.. 2 Safety / 2.3 Definition of mandatory signs Definition of mandatory signs To be worn at all times Protective clothing Safety footwear to protect against mechanical hazard and risk of falling Table 2: Personal protective equipment to be worn at all times...
Page 17: Intended Use
These data are given on the rating plate. ABB accepts no liability and rejects all warranty claims for any non-intended uses. [1]Euromot = The European Association of Internal Combustion Engine Manufacturers [2]Directive 94/9/EC concerning equipment and protective systems intended for use in po-...
Page 18: Warning Plates On The Turbocharger
The turbocharger must only be used when it is in a technically flawless condition and oper- ated in compliance with its intended use. ABB excludes any liability for damage resulting from unauthorized modifications to the tur- bocharger or improper operation.
Page 19: Turbocharger Rating Plate
Operation Manual / A150-M56/66/57/67 - A155-M.. 2 Safety / 2.7 Turbocharger rating plate Turbocharger rating plate Fig. 7: Rating plate Operating limits 01 Turbocharger operating limits at engine overload (110 %). In test rig operation only, unless otherwise agreed with the en- ginebuilder.
Page 20: Fig. 8: Locations Of The Rating Plates
Operation above the indicated values n can considerably shorten the recommended Bmax Bmax replacement intervals. In such cases, we recommend contacting the nearest ABB Turbochar- ging Service Station. normally apply only when running at overload (110 %) during trials on the engine Mmax Mmax test bed.
Page 21: Periodic Check Of The Pressure Vessels
Operation Manual / A150-M56/66/57/67 - A155-M.. 2 Safety / 2.8 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". ¡...
Page 22: Lifting Of Loads
Operation Manual / A150-M56/66/57/67 - A155-M.. 2 Safety / 2.9 Lifting of loads Lifting of loads WARNING Suspended loads Loads that are not attached according to regulations can cause injury to personnel or fatal accidents. Loads must always be fastened to properly functional lifting gear with a sufficient load limit.
Page 23: Prerequisites For Operation And Maintenance
Only use original parts from ABB. Original parts and accessories are specially designed for ABB turbochargers. ABB accepts no liability for any damage resulting from the use of non-original parts and cor- responding accessories. © Copyright 2021 ABB. All rights reserved.
Page 24: Hazards During Operation And Maintenance
Operation Manual / A150-M56/66/57/67 - A155-M.. 2 Safety / 2.11 Hazards during operation and maintenance 2.11 Hazards during operation and maintenance Noise hazards The turbocharger's noise emission is influenced by its installation and operating conditions. A noise level exceeding 85 dB(A) is harmful.
Page 25 Operation Manual / A150-M56/66/57/67 - A155-M.. 2 Safety / 2.11 Hazards during operation and maintenance WARNING Hot surfaces on a non-insulated turbocharger Non-insulated turbochargers can cause serious injuries to personnel (burns). The turbocharger is supplied with or without insulation in accordance with the purchase order received from the enginebuilder.
Page 26: Safe Operation
Operation Manual / A150-M56/66/57/67 - A155-M.. 2 Safety / 2.12 Safe operation 2.12 Safe operation Mechanical hazards during operation During standard operation, no mechanical hazards are caused by the turbocharger itself if it has been properly installed. Safety during commissioning and operation Visually inspect your working environment before starting work.
Page 27: Safe Maintenance
Operation Manual / A150-M56/66/57/67 - A155-M.. 2 Safety / 2.13 Safe maintenance 2.13 Safe maintenance Occupational safety WARNING Injuries to persons Severe injuries to personnel or fatal accidents can be caused by mechanical influences as a consequence of hazardous and inadequate operational pro- cedures or non-compliance with safety and health standards.
Page 28 Operation Manual / A150-M56/66/57/67 - A155-M.. 2 Safety / 2.13 Safe maintenance Use of assembly devices Assembly devices are specially constructed and designed for the defined use; they are not commercially available products. Use assembly devices only for the described applications.
Page 29 Operation Manual / A150-M56/66/57/67 - A155-M.. 2 Safety / 2.13 Safe maintenance Safety when taking out of operation or preparing for mothballing Observe the material safety data sheet for the cleaning and mothballing agents. Wear personal protective equipment (PPE) according to the material safety data sheet.
Page 30 Operation Manual / A150-M56/66/57/67 - A155-M.. 2 Safety / 2.13 Safe maintenance WARNING Danger of fire or explosion Flammable and combustible operating materials and supplies can catch fire or resulting vapours can lead to an explosion. Observe the information in the material safety data sheet for the operat- ing materials and supplies.
Page 31: Removing And Installing
Operation Manual / A150-M56/66/57/67 - A155-M.. 3 Removing and Installing / 3.1 Turbocharger weight and transporta- tion Removing and Installing Turbocharger weight and transportation Lifting gear with a sufficient load limit must be used for removing, installing and transport- ing the turbocharger. The weight specified below applies to the heaviest variant possible.
Page 32: Removing The Turbocharger
Operation Manual / A150-M56/66/57/67 - A155-M.. 3 Removing and Installing / 3.2 Removing the turbocharger Removing the turbocharger Disconnect all pipes according to the instructions of the enginebuilder. Fig. 12: Turbine cleaning nozzle If present: Loosen the turbine cleaning connection. The cleaning nozzle (51301) must be replaced after each removal procedure. If the clean- ing nozzle is not to be replaced, the screw connection (01) must not be loosened during disassembly.
Page 33: Fig. 14: Loosening The Clamping Nut
Operation Manual / A150-M56/66/57/67 - A155-M.. 3 Removing and Installing / 3.2 Removing the turbocharger 3.2.1 Loosening the clamping nut CAUTION Incorrect procedure can make loosening impossible If individual pressure screws are fully relieved, the pressure screws can be- come compressed, making it impossible to loosen them.
Page 34: Fig. 15: Turbocharger Centre Of Gravity
Operation Manual / A150-M56/66/57/67 - A155-M.. 3 Removing and Installing / 3.2 Removing the turbocharger 3.2.2 Positioning the turbocharger for storage WARNING Risk of tipping If the turbocharger is not positioned stably, it may tip over. This can result in serious personal injury.
Page 35: Installing The Turbocharger
Operation Manual / A150-M56/66/57/67 - A155-M.. 3 Removing and Installing / 3.3 Installing the turbocharger Installing the turbocharger 3.3.1 Inserting gaskets CAUTION Inserting the gaskets Gaskets that are forgotten, damaged or improperly inserted will lead to oil leaks. Always use new gaskets and insert them carefully into the slot.
Page 36: Fig. 17: Fitting The Turbocharger 1
Operation Manual / A150-M56/66/57/67 - A155-M.. 3 Removing and Installing / 3.3 Installing the turbocharger 3.3.2 Placing the turbocharger on the bracket Fig. 17: Fitting the turbocharger 1 Step A – Preparing the fixing screws 1. Insert expansion bush (42190) into bearing casing.
Page 37: Fig. 18: Fitting The Turbocharger 2
Operation Manual / A150-M56/66/57/67 - A155-M.. 3 Removing and Installing / 3.3 Installing the turbocharger Fig. 18: Fitting the turbocharger 2 Product Value X Value L A150 112 ±2 mm 52 ±2 mm A155 144 ±2 mm 72 ±2 mm Table 5: Fitting the turbocharger, value X, L Step C –...
Page 38: Fig. 19: Preparing The Clamping Nut For The Tightening Procedure
Operation Manual / A150-M56/66/57/67 - A155-M.. 3 Removing and Installing / 3.3 Installing the turbocharger 3.3.3 Fastening the turbocharger with a clamping nut Preparations for tightening the clamping nut CAUTION Do not clean pressure screws (04) The pressure screws are equipped with a permanent sliding layer that must not be removed.
Page 39: Fig. 20: Tightening Pressure Screws
Operation Manual / A150-M56/66/57/67 - A155-M.. 3 Removing and Installing / 3.3 Installing the turbocharger Tightening pressure screws Fig. 20: Tightening pressure screws Product Fixing screw [mm] Tightening torques [Nm] A150 A155 Table 6: Torque-controlled tightening of the pressure screws 1. Screw in pressure screws crosswise by hand until reaching the stop.
Page 40: Fig. 21: Connecting The Speed Sensor
Operation Manual / A150-M56/66/57/67 - A155-M.. 3 Removing and Installing / 3.3 Installing the turbocharger 3.3.4 Connecting the turbocharger Fig. 21: Connecting the speed sensor Connect cable to speed sensor (86515). Connect all gas, water and air lines according to the instructions of the enginebuilder.
Page 41: Commissioning
Operation Manual / A150-M56/66/57/67 - A155-M.. 4 Commissioning / 4.1 Oil supply Commissioning Oil supply 4.1.1 Introduction In all operating states, a functioning and carefully executed oil supply is an important pre- requisite for trouble-free operation of the turbocharger. The lubrication of the turbocharger is usually carried out with oil from the engine oil circula- tion.
Page 42: Fig. 24: Oil Orifice
Operation Manual / A150-M56/66/57/67 - A155-M.. 4 Commissioning / 4.1 Oil supply 4.1.5 Oil orifice in the bearing casing Fig. 24: Oil orifice Bearing casing Oil orifice Circlip With an oil inlet pressure of more than 3 bar of overpressure (with engine under load) up- stream of the turbocharger, the bearing casings are equipped with an orifice at the oil inlet as standard.
Page 43: Inspection Procedures
Operation Manual / A150-M56/66/57/67 - A155-M.. 4 Commissioning / 4.2 Inspection procedures Inspection procedures 4.2.1 Introduction Inspection procedures include preventative visual controls, monitoring and measuring work before and during commissioning. Inspection procedures enable changes to the turbochar- ger to be detected. Machine damage can be prevented.
Page 44 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 2021 ABB. All rights reserved.
Page 45: Commissioning After Taking Out Of Operation
Operation Manual / A150-M56/66/57/67 - A155-M.. 4 Commissioning / 4.3 Commissioning after taking out of operation Commissioning after taking out of operation If present Remove cover plates (blind flanges) from the compressor casing, the gas inlet and the gas outlet.
Page 46: Monitoring Operation
Oil pressure measuring point Oil temperature measuring point For monitoring the lubricating oil pressure, ABB Turbocharging recommends installing a "P" manometer immediately upstream of the turbocharger oil inlet before the orifice. If the pressure is controlled electronically, the relevant signals should be triggered at the warning and alarm values.
Page 47: Table 8: Lubricating Oil Temperature At The Inlet
Table 9: Maximum lubricating oil temperature at the outlet If the turbocharger has been operated for a longer period of time outside the admissible range, ABB Turbocharging recommends having the turbocharger inspected by an ABB Tur- bocharging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 48: Exhaust Gas Temperature Before Turbine
Operation Manual / A150-M56/66/57/67 - A155-M.. 5 Monitoring operation / 5.2 Exhaust gas temperature before turbine Exhaust gas temperature before turbine CAUTION Factors influencing replacement intervals Operation above the operating limits defined on the rating plate can shorten the recommended replacement intervals considerably.
Page 49: Turbocharger Speed
Operation Manual / A150-M56/66/57/67 - A155-M.. 5 Monitoring operation / 5.3 Turbocharger speed Turbocharger speed 5.3.1 Introduction A speed measuring system enables the constant monitoring of the turbocharger speed. CAUTION Do not strain cables If you pull the speed measurement cables too hard, contacts can be pulled out.
Page 50 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. 5.3.4 Malfunctions on the speed measurement system...
Page 51: Fig. 26: 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. 26: Replacing the speed sensor...
Page 52: Operation And Service
Operation Manual / A150-M56/66/57/67 - A155-M.. 6 Operation and service / 6.1 Noise emission Operation and service Noise emission WARNING Danger due to noise Exposure to noise can harm the hearing system, impair health and the psy- chological state and may lead to lack of attention and irritation.
Page 53: Fig. 27: Noise Insulation, Bellows
Operation Manual / A150-M56/66/57/67 - A155-M.. 6 Operation and service / 6.1 Noise emission Suggestion for noise insulation, bellows Fig. 27: Noise insulation, bellows Compressor casing Bellows Charge air duct / scavenging air duct Insulation cushion Insulation mat (at least 15 mm) Sheet metal cover ©...
Page 54: Service Work
Agree on a specific service interval with ABB Turbocharging. To prevent machine damage caused by ageing and downtime, we recommend having an in- spection carried out by an ABB Turbocharging Service Station no later than 5 years after the last service.
Page 55 Service work according to data on the rating plate (Usually after 8000 … 16000 operating hours) The rotor and bearing parts must be checked and assessed by an ABB Turbocharging Service Station. The following work can be carried out as preparation.
Page 56 Operation Manual / A150-M56/66/57/67 - A155-M.. 6 Operation and service / 6.2 Service work 6.2.5 Entries in the engine logbook The monitoring of the engine system enables conclusions to be drawn on the behaviour of the turbocharger. The following operating data and measured values must be entered regularly in the engine logbook of the enginebuilder: ¡...
Page 57: Expected Replacement Intervals
Operation Manual / A150-M56/66/57/67 - A155-M.. 6 Operation and service / 6.3 Expected replacement intervals Expected replacement intervals Rotating components The recommended replacement intervals of the compressor and turbine wheels are spe- cified with the aid of the safety concept for rotating parts (SIKO) and dependent on the op- erating conditions.
Page 58 Operation Manual / A150-M56/66/57/67 - A155-M.. 6 Operation and service / 6.3 Expected replacement intervals Influencing parameters The specified values are guideline values and are not guaranteed. The actual values can devi- ate considerably from the guideline values, for example, due to the following influences: ¡...
Page 59: Stopping The Engine
– 550 °C with insulated casing – 600 °C with non-insulated casing At temperatures below the specified values, post-lubrication must be ensured until the rotors come to a standstill. ABB Turbocharging recommends post-lubrication for 10 minutes. Observe the oil pressure specified for post-lubrication (see Table 7: Lubricating oil pres-...
Page 60: Periodic Maintenance Work
Changing the absorption element →76 Table 12: Maintenance table [h] = Hours of operation If the maintenance intervals are incompatible with operation of the engine, contact ABB Turbocharging. ABB Turbocharging recommends having mechanical cleaning carried out by an ABB Tur- bocharging Service Station during the service work. Otherwise, only carry out mechanical cleaning if cleaning during operation is not sufficient to achieve the thermal load and the rating of the engine.
Page 61: Cleaning The Compressor During Operation
Periodic cleaning during operation delays any major increase in contamination. The cleaning method is suitable as long as the contamination has not progressed far. Very heavily con- taminated components can no longer be cleaned using this method. In this case, ABB Tur- bocharging recommends mechanical cleaning of the contaminated components.
Page 62 The compressor is cleaned during operation using the wet cleaning method. This is carried out at an engine load of 50 … 85%. This cleaning method is tested and approved by ABB Turbocharging. V-engines On V-engines with several turbochargers per engine, parallel cleaning of both turbochargers is recommended.
Page 63: Fig. 28: Carrying Out Wet Cleaning Of Compressor
Operation Manual / A150-M56/66/57/67 - A155-M.. 7 Periodic maintenance work / 7.2 Cleaning the compressor during op- eration 72000 Compressor casing 27000 External water pressure vessel 27005 Sealing plug Water pipe to filter silencer or air suction branch Pressurized air inlet pipe Valve activator Pressurized air from the compressor casing (72000) of the turbocharger passes through the...
Page 64: Cleaning The Turbine During Operation
Periodic cleaning during operation delays any major increase in contamination. The cleaning method is suitable as long as the contamination has not progressed far. Very heavily con- taminated components can no longer be cleaned using this method. In this case, ABB Tur- bocharging recommends mechanical cleaning of the contaminated components.
Page 65 Cleaning method The turbine components are cleaned during operation using the wet cleaning method. This cleaning method is tested and approved by ABB Turbocharging. The precondition for wet cleaning is that the enginebuilder approves the process and these regulations are observed.
Page 66: Fig. 29: Turbine Cleaning Devices
Operation Manual / A150-M56/66/57/67 - A155-M.. 7 Periodic maintenance work / 7.3 Cleaning the turbine during opera- tion 7.3.5 Prerequisites Two different turbine cleaning devices are available for turbochargers with single-inlet tur- bine casing: Fig. 29: Turbine cleaning devices 1. Device consisting of one cleaning nozzle per turbine casing gas inlet.
Page 67: Fig. 30: 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 68: Cleaning Components Mechanically
Operation Manual / A150-M56/66/57/67 - A155-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically Parameter for 6-nozzle cleaning Product Temperature be- Maximum temperature Water volume flow Injection time fore turbine before before turbine during /min] [min] cleaning [°C] cleaning [°C] A150 350 ...
Page 69: Fig. 31: Cleaning The Filter Silencer
Operation Manual / A150-M56/66/57/67 - A155-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically 7.4.2 Cleaning the filter silencer Fig. 31: Cleaning the filter silencer 81135 Filter silencer body 81266 Cover grid 81136 Absorption segment 81270 Tension band 81137 Sheet-metal covering...
Page 70 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. 31: Cleaning the filter silencer →67)
Page 71: Fig. 32: Compressor-End, Non-Rotating Parts
Operation Manual / A150-M56/66/57/67 - A155-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically 7.4.3 Compressor-end, non-rotating parts WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or con- tact with them may be harmful to health.
Page 72 Operation Manual / A150-M56/66/57/67 - A155-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically 7.4.4 Turbine-end, non-rotating parts WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or con- tact with them may be harmful to health.
Page 73: Fig. 33: Turbine End, Non-Rotating Parts
Operation Manual / A150-M56/66/57/67 - A155-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically Baked layers of contamination, for example, from heavy fuel oil or coked oil occur at the tur- bine end. The following parts, which are relevant in terms of performance, can be cleaned in accordance with the description below.
Page 74 Operation Manual / A150-M56/66/57/67 - A155-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically 7.4.5 Cartridge group, general CAUTION Corrosion If the cartridge group is not put back into operation immediately after clean- ing, parts may corrode. Immediately after cleaning, install the cartridge group and put it back into operation.
Page 75: Fig. 34: Soaking The Turbine End
Operation Manual / A150-M56/66/57/67 - A155-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically 7.4.7 Cleaning the cartridge group on turbine end Soaking the contamination Baked layers of contamination from heavy fuel oil or coked oil occur at the turbine end. The contamination can be removed by soaking and brushing.
Page 76 Operation Manual / A150-M56/66/57/67 - A155-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically WARNING Heating up of cleaning agents and operating fluids When cleaning agents or operating fluids are heated up, explosive vapours can be produced which are hazardous to health.
Page 77 Operation Manual / A150-M56/66/57/67 - A155-M.. 7 Periodic maintenance work / 7.4 Cleaning components mechanically CAUTION Water and dirt in the cartridge group If water or dirt enters the cartridge group, this can impair the function of the turbocharger and damage parts inside the cartridge group.
Page 78: Changing The Absorption Element
Operation Manual / A150-M56/66/57/67 - A155-M.. 7 Periodic maintenance work / 7.5 Changing the absorption element Changing the absorption element The absorption element (81148) in uncoupled filter silencers must be replaced every 12000 hours of operation. Disassembling the absorption element Fig. 35: Disassembling the absorption element 1.
Page 79: Fig. 36: Installing The Absorption Element
Operation Manual / A150-M56/66/57/67 - A155-M.. 7 Periodic maintenance work / 7.5 Changing the absorption element Installing the absorption element Fig. 36: Installing the absorption element Product 81152 [Nm] 81154 [Nm] A155-M Table 18: Tightening torque (81152 / 81154) 1. Fit the new absorption element (81148) and flanges (81145 / 81146) with roll pins (81151) and socket screws (81154).
Page 80: 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 81: Malfunctions During Operation
Turbochar- Turbine and/or nozzle ring severely con- Clean (see chapter Periodic mainten- taminated ance work →58) Rotor components or bearing damaged Contact ABB Turbocharging Service Station Engine Defects on the connected cylinders in Contact enginebuilder pulse charging Pipes Defects, such as leaks, in the exhaust...
Page 82: Table 25: Malfunctions During Operation - Exhaust Gas Temperature Too High
Operation Manual / A150-M56/66/57/67 - A155-M.. 8 Eliminating malfunctions / 8.2 Malfunctions during operation Exhaust gas temperature too high Engine performance and engine speed unchanged Possible causes Remedy Turbocharger Insufficient air, for example, when fil- Clean (see chapter Periodic mainten-...
Page 83: Table 27: Malfunctions During Operation - Charge Air Pressure Too High
Operation Manual / A150-M56/66/57/67 - A155-M.. 8 Eliminating malfunctions / 8.2 Malfunctions during operation Charge air pressure too high Engine performance and engine speed unchanged, suction condition normal Possible causes Remedy Turbochar- Manometer display not correct Replace manometer Increased speed due to contamination...
Page 84: 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 85: Malfunctions When Stopping
Bearing damaged Check clearances (see chapter Measuring clear- ance A and B →112). If clearances are outside the tolerance or if in doubt, contact an ABB Turbochar- ging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R →122).
Page 86: Speed Measurement System
Table 35: 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 2021 ABB. All rights reserved.
Page 87: Dismantling And Fitting, General
ABB Turbocharging recommends having further work carried out only by trained personnel from an ABB Turbocharging Service Station. Tightening torques for assembly devices Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB must be tightened so they are tight-fitting. Oil orifice...
Page 88: Material Required
Visually inspect for corrosion, cracks, deformation and wear. Damaged tools must no longer be used and must be replaced. Swivel lifting eyes Swivel lifting eyes are required for the safe lifting of loads, which are not supplied by ABB. Fig. 37: Swivel lifting eyes Product...
Page 89: Fig. 38: Press-Off Screws
Operation Manual / A150-M56/66/57/67 - A155-M.. 9 Dismantling and fitting, general / 9.2 Material required Fig. 38: Press-off screws Product Thread Length Quantity A150 30 mm 3 or 6 A155 30 mm 3 or 6 Table 37: Press-off screws Dismantling screw for the optional 6-nozzle turbine cleaning component A dismantling screw (01) is required to dismantle and fit the cleaning nozzles, which is not...
Page 90 Operation Manual / A150-M56/66/57/67 - A155-M.. 9 Dismantling and fitting, general / 9.2 Material required Lifting gear WARNING Suspended loads Loads that are not attached according to regulations can cause injury to personnel or fatal accidents. Only fasten the turbocharger, assemblies or individual parts on properly functional lifting gear with sufficient load limit.
Page 91: Disassembly And Assembly Concepts
Operation Manual / A150-M56/66/57/67 - A155-M.. 9 Dismantling and fitting, general / 9.3 Disassembly and assembly concepts Disassembly and assembly concepts Removal and installation with removed air inlet and gas outlet Fig. 40: Removing the cartridge group with compressor and turbine casing...
Page 92: Fig. 41: Cartridge Concept
Operation Manual / A150-M56/66/57/67 - A155-M.. 9 Dismantling and fitting, general / 9.3 Disassembly and assembly concepts Cartridge concept Fig. 41: Cartridge concept The cartridge concept incorporates the removal and installation of the turbocharger from/ onto the engine, whereby the air inlet (filter silencer or air suction branch), the compressor casing and the cartridge group can be individually dismantled and fitted in the order shown in the illustration.
Page 93: Fig. 42: Optional Spanner Holder
9 Dismantling and fitting, general / 9.3 Disassembly and assembly concepts Optional spanner holder Fig. 42: Optional spanner holder ABB offers an optional spanner holder (90165) (see Dismantling and fitting, special tools for fastening strips →150) 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 94: Weights Of Individual Parts
Operation Manual / A150-M56/66/57/67 - A155-M.. 9 Dismantling and fitting, general / 9.4 Weights of individual parts Weights of individual parts Fig. 43: Weights of assemblies Designation A150 A155 [kg] [kg] Filter silencer Radial air suction branch Compressor casing with insulation...
Page 95: Table Of Tightening Torques
Operation Manual / A150-M56/66/57/67 - A155-M.. 9 Dismantling and fitting, general / 9.5 Table of tightening torques Table of tightening torques Fig. 44: Overview of tightening torques 1) Only A155-M with uncoupled filter silencer The following tightening torques must be observed for the designated screw fittings:...
Page 96: Fig. 45: Tightening Torques For Insulation
Operation Manual / A150-M56/66/57/67 - A155-M.. 9 Dismantling and fitting, general / 9.5 Table of tightening torques Fig. 45: Tightening torques for insulation The following tightening torques must be observed for the specified screw connections: Position Part number A150 A155 16a / 16b 200 Nm...
Page 97: Dismantling And Fitting With Removed Air Inlet And Gas Outlet
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.1 Removing air inlets Dismantling and fitting with removed air inlet and gas outlet 10.1 Removing air inlets Fig. 46: Removing the air inlets 1.
Page 98: Fig. 47: Removing The Uncoupled Filter Silencer
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.1 Removing air inlets A155-M Uncoupled filter silencer Fig. 47: Removing the uncoupled filter silencer 1. Secure lifting gear to filter silencer (81000). 2. Unscrew the hexagon-head screws (72054) and remove along with Verbus Ripp® wash- ers (72053) and three safety plates (72055).
Page 99: Removing The Gas Outlet Casing
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.2 Removing the gas outlet casing 10.2 Removing the gas outlet casing Mark the casing position for assembly. Variant without support Fig. 48: Remove gas outlet casing without support 1.
Page 100: Fig. 49: Removing Gas Outlet Casing With Support 1
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.2 Removing the gas outlet casing Variant with support Fig. 49: Removing gas outlet casing with support 1 1. If present: Remove waste gate pipe.
Page 101: Fig. 50: Removing Gas Outlet Casing With Support 1
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.2 Removing the gas outlet casing Fig. 50: Removing gas outlet casing with support 1 6. Loosen nuts (51009) and remove together with support (61301).
Page 102: Removing The Gas Outlet Flange
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.3 Removing the gas outlet flange 10.3 Removing the gas outlet flange Depending on the way of fixing the gas outlet flange, the appropriate Working Instruction has to be consulted (pressing off using 3 or 6 press-off screws).
Page 103: Fig. 51: Dismantling The Gas Outlet Flange
If it is not possible to press off the gas outlet flange with the maximum tight- ening torque, contact an ABB Turbocharging Service Station. 2. Attach swivel lifting eye (S) to the gas outlet flange. Secure lifting gear to the swivel lift- ing eye.
Page 104: Fig. 52: Removing The Gas Outlet Flange
≤ 150 Nm Table 43: 6 press-off screws * not included in the ABB scope of delivery. 1. Evenly press off and remove the gas outlet flange (57002) with screws (01) according to the table. If it is not possible to press off the gas outlet flange with the maximum tight- ening torque, contact an ABB Turbocharging Service Station.
Page 105: Removing The Cartridge Group With Compressor And Turbine Casing
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.4 Removing the cartridge group with compressor and turbine casing 10.4 Removing the cartridge group with compressor and turbine casing Fig. 53: Turbine cleaning nozzle 1.
Page 106: Fig. 55: Removing The Cartridge Group With Compressor And Turbine Casing
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.4 Removing the cartridge group with compressor and turbine casing Fig. 55: Removing the cartridge group with compressor and turbine casing 4. If present: Loosen and remove the compressor wheel cooling connection. Close the com- pressor wheel cooling opening with a screw plug (01).
Page 107: Removing The Compressor Casing
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.5 Removing the compressor casing 10.5 Removing the compressor casing Removing the compressor casing Mark the casing position for assembly. Fig. 57: Removing the compressor casing If the compressor casing cannot be loosened, it can be pressed off against the turbine cas- ing with the press-off tool (90042).
Page 108: Fig. 58: Dismantling The Diffuser And The Wall Insert
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.5 Removing the compressor casing Dismantling the diffuser and the wall insert Fig. 58: Dismantling the diffuser and the wall insert 1. Loosen the screws (79041) and remove with fixing discs (79040).
Page 109: Removing The Cartridge Group
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.6 Removing the cartridge group 10.6 Removing the cartridge group Mark the casing position for assembly. Fig. 59: Removing cartridge group 1 Product...
Page 110: Fig. 60: Removing Cartridge Group 2
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.6 Removing the cartridge group Fig. 60: Removing cartridge group 2 If the cartridge group cannot be loosened, the press-off tool (90042) can be used.
Page 111: Fig. 61: Removing Cartridge Group 3
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.6 Removing the cartridge group Fig. 61: Removing cartridge group 3 7. Place a suitable protective cover over the compressor wheel. 8. Turn the cartridge group into the horizontal rotor axis.
Page 112: Installing The Cartridge Group On The Service Support
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.7 Installing the cartridge group on the service support 10.7 Installing the cartridge group on the service support Fig. 62: Installing the cartridge group on the service support 1.
Page 113: Removing The Nozzle Ring
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.8 Removing the nozzle ring 10.8 Removing the nozzle ring Fig. 63: Removing the nozzle ring 1. Pull out the nozzle ring (56001) with the two extraction devices (90070).
Page 114: Measuring Clearance A And B
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 115: Nozzle Ring Compression Pd
Table 46: Nozzle ring compression PD 1. Measure values A, B, and S on cleaned surfaces. 2. Calculate compression (PD). If the calculated value (PD) lies outside the specified range, contact an ABB Turbochar- ging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 116: Installing Nozzle Ring
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.11 Installing nozzle ring 10.11 Installing nozzle ring Fig. 66: Installing the nozzle ring 1. Fit the lamellar sealing ring (56005) (see A-A). When doing this, pay attention to correct winding of the lamellar sealing ring (see detail B).
Page 117: Installing The Cartridge Group
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.12 Installing the cartridge group 10.12 Installing the cartridge group Fig. 67: Lifting the cartridge group and rotating it by 90° 1. Fasten lifting gear to cartridge group and lift cartridge group.
Page 118: A150
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.12 Installing the cartridge group Fig. 68: Turning the cartridge group Product Position Tightening torque [Nm] A150 A155 Table 47: Tightening torque (90012-01) 4. Re-fit the cross-piece of the service support (90012). Observe the tightening torque.
Page 119: Fig. 69: Installing The Cartridge Group
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.12 Installing the cartridge group Fig. 69: Installing the cartridge group Product Size Tightening torque [Nm] A150 A155 Table 48: Tightening torque (51007) 8. Coat the threads of the studs (51006) with high-temperature grease.
Page 120: Installing The Compressor Casing
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.13 Installing the compressor casing 10.13 Installing the compressor casing Fitting the wall insert and the diffuser Fig. 70: Fitting the wall insert and the diffuser...
Page 121: Fig. 71: Installing The Compressor Casing
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.13 Installing the compressor casing Installing the compressor casing Fig. 71: Installing the compressor casing Product Size Tightening torque [Nm] A150 A155 Table 50: Tightening torque (72011) 1.
Page 122: Turning The Cartridge Group With Compressor And Turbine Casing
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.14 Turning the cartridge group with compressor and turbine casing 10.14 Turning the cartridge group with compressor and turbine casing Fig. 72: Turning the cartridge group with compressor and turbine casing 1.
Page 123: Installing The Gas Outlet Flange
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.15 Installing the gas outlet flange 10.15 Installing the gas outlet flange Fig. 73: Installing the gas outlet flange 1. If present: Insert the metal C-ring (57003) into the turbine casing (51000) and secure with high-vacuum grease.
Page 124: 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 2021 ABB. All rights reserved.
Page 125: Fitting The Insulation
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.17 Fitting the insulation 10.17 Fitting the insulation Fig. 75: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see...
Page 126: Installing The Cartridge Group With Compressor And Turbine Casing
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.18 Installing the cartridge group with compressor and turbine cas- 10.18 Installing the cartridge group with compressor and turbine casing Fig. 76: Installing the cartridge group with compressor and turbine casing 1.
Page 127: Installing The Gas Outlet Casing
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.19 Installing the gas outlet casing 10.19 Installing the gas outlet casing Variant without support Fig. 78: Fitting gas outlet casing without support...
Page 128: Fig. 79: Installing Gas Outlet Casing With Support 1
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.19 Installing the gas outlet casing Variant with support Fig. 79: Installing gas outlet casing with support 1 Product Size Tightening torque [Nm]...
Page 129: Fig. 80: Installing Gas Outlet Casing With Support 2
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.19 Installing the gas outlet casing Fig. 80: Installing gas outlet casing with support 2 7. Fit the screws of the support. Tighten in accordance with enginebuilder’s specifications.
Page 130: Installing Air Inlets
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.20 Installing air inlets 10.20 Installing air inlets Fig. 81: Installing the air inlets Product Size Tightening torque [Nm] A150 A155 Table 54: Tightening torque (72051) 1.
Page 131: Fig. 82: Installing The Uncoupled Filter Silencer
Operation Manual / A150-M56/66/57/67 - A155-M.. 10 Dismantling and fitting with removed air inlet and gas outlet / 10.20 Installing air inlets A155-M Uncoupled filter silencer Fig. 82: Installing the uncoupled filter silencer Product Size Tightening torque [Nm] A155 Table 55: Tightening torque (72054) 1.
Page 132: Dismantling And Fitting, Cartridge Concept
Operation Manual / A150-M56/66/57/67 - A155-M.. 11 Dismantling and fitting, cartridge concept / 11.1 Removing air inlets Dismantling and fitting, cartridge concept 11.1 Removing air inlets Fig. 83: Removing the air inlets 1. Attach lifting gear to the filter silencer (81000) or air suction branch (82000).
Page 133: Fig. 84: Removing The Uncoupled Filter Silencer
Operation Manual / A150-M56/66/57/67 - A155-M.. 11 Dismantling and fitting, cartridge concept / 11.1 Removing air inlets A155-M Uncoupled filter silencer Fig. 84: Removing the uncoupled filter silencer 1. Secure lifting gear to filter silencer (81000). 2. Unscrew the hexagon-head screws (72054) and remove along with Verbus Ripp® wash- ers (72053) and three safety plates (72055).
Page 134: Removing The Compressor Casing
Operation Manual / A150-M56/66/57/67 - A155-M.. 11 Dismantling and fitting, cartridge concept / 11.2 Removing the com- pressor casing 11.2 Removing the compressor casing Mark the casing position for assembly. Fig. 85: Removing the compressor casing 1. Remove the compressor casing insulation.
Page 135: Fig. 86: Pressing Off Compressor Casing
Operation Manual / A150-M56/66/57/67 - A155-M.. 11 Dismantling and fitting, cartridge concept / 11.2 Removing the com- pressor casing If the compressor casing cannot be loosened, it can be pressed off against the turbine cas- ing with the press-off tool (90042).
Page 136: Fig. 88: Dismantling The Diffuser And The Wall Insert
Operation Manual / A150-M56/66/57/67 - A155-M.. 11 Dismantling and fitting, cartridge concept / 11.2 Removing the com- pressor casing Dismantling the diffuser and the wall insert Fig. 88: Dismantling the diffuser and the wall insert 1. Loosen the screws (79041) and remove with fixing discs (79040).
Page 137: Removing The Cartridge Group
Operation Manual / A150-M56/66/57/67 - A155-M.. 11 Dismantling and fitting, cartridge concept / 11.3 Removing the cart- ridge group 11.3 Removing the cartridge group Fig. 89: Removing insulation sheets If present: Remove insulation sheets. Fig. 90: Removing cartridge group 1 Product Value X [mm] A150-M 112 ±2 mm...
Page 138: 1. Treat Threads Of Studs (51006) With Penetrating Oil And Leave To Take Effect
Operation Manual / A150-M56/66/57/67 - A155-M.. 11 Dismantling and fitting, cartridge concept / 11.3 Removing the cart- ridge group Fig. 91: Removing cartridge group 2 If the cartridge group cannot be loosened, the press-off tool (90042) can be used. 1. Treat threads of studs (51006) with penetrating oil and leave to take effect.
Page 139: Fig. 92: Removing Cartridge Group 2
Operation Manual / A150-M56/66/57/67 - A155-M.. 11 Dismantling and fitting, cartridge concept / 11.3 Removing the cart- ridge group Fig. 92: Removing cartridge group 2 1. Remove the centering bush (42193) and the threaded rod (42191) along with the clamping nut (42201).
Page 140: Removing The Nozzle Ring
Operation Manual / A150-M56/66/57/67 - A155-M.. 11 Dismantling and fitting, cartridge concept / 11.4 Removing the nozzle ring 11.4 Removing the nozzle ring Fig. 93: S_05180 1. Pull out the nozzle ring (56001) with the two extraction devices (90070). 2. Remove the lamellar sealing ring (56005).
Page 141: Measuring Clearance A And B
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 142: Nozzle Ring Compression Pd
Table 58: Nozzle ring compression PD 1. Measure values A, B, and S on cleaned surfaces. 2. Calculate compression (PD). If the calculated value (PD) lies outside the specified range, contact an ABB Turbochar- ging Service Station. © Copyright 2021 ABB. All rights reserved.
Page 143: Installing Nozzle Ring
Operation Manual / A150-M56/66/57/67 - A155-M.. 11 Dismantling and fitting, cartridge concept / 11.7 Installing nozzle ring 11.7 Installing nozzle ring Fig. 96: Installing the nozzle ring 1. Fit the lamellar sealing ring (56005) (see A-A). When doing this, pay attention to correct winding of the lamellar sealing ring (see detail B).
Page 144: Installing The Cartridge Group
Operation Manual / A150-M56/66/57/67 - A155-M.. 11 Dismantling and fitting, cartridge concept / 11.8 Installing the cart- ridge group 11.8 Installing the cartridge group Fig. 97: Installing the cartridge group 1 1. Attach lifting gear to bearing casing. 2. Remove fixing screws.
Page 145: Tightening Torque
Operation Manual / A150-M56/66/57/67 - A155-M.. 11 Dismantling and fitting, cartridge concept / 11.8 Installing the cart- ridge group Fig. 98: Installing the cartridge group 2 Product Value X [mm] Value L [mm] A150-M 112 ±2 mm 52 ±2 mm A155-M 144 ±2 mm...
Page 146: Installing The Compressor Casing
Operation Manual / A150-M56/66/57/67 - A155-M.. 11 Dismantling and fitting, cartridge concept / 11.9 Installing the com- pressor casing 11.9 Installing the compressor casing Fitting the wall insert and the diffuser Fig. 99: Fitting the wall insert and the diffuser Product...
Page 147: Fig. 100: Installing The Compressor Casing
Operation Manual / A150-M56/66/57/67 - A155-M.. 11 Dismantling and fitting, cartridge concept / 11.9 Installing the com- pressor casing Installing the compressor casing Fig. 100: Installing the compressor casing Product Size Tightening torque [Nm] A150 A155 Table 62: Tightening torque (72011) Thoroughly clean the fastening strips (72012) before assembly.
Page 148: 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 2021 ABB. All rights reserved.
Page 149: Fitting The Insulation
Operation Manual / A150-M56/66/57/67 - A155-M.. 11 Dismantling and fitting, cartridge concept / 11.11 Fitting the insula- tion 11.11 Fitting the insulation Fig. 102: Fitting the insulation Fit the insulation according to the illustration. Observe tightening torques (see Table of tightening torques →93).
Page 150: Installing Air Inlets
Operation Manual / A150-M56/66/57/67 - A155-M.. 11 Dismantling and fitting, cartridge concept / 11.12 Installing air inlets 11.12 Installing air inlets Fig. 103: Installing the air inlets Product Size Tightening torque [Nm] A150 A155 Table 64: Tightening torque (72051) 1. Attach lifting gear to the filter silencer (81000) or air suction branch (82000).
Page 151: Fig. 104: Installing The Uncoupled Filter Silencer
Operation Manual / A150-M56/66/57/67 - A155-M.. 11 Dismantling and fitting, cartridge concept / 11.12 Installing air inlets A155-M Uncoupled filter silencer Fig. 104: Installing the uncoupled filter silencer Product Size Tightening torque [Nm] A155 Table 65: Tightening torque (72054) 1. Secure lifting gear to filter silencer (81000).
Page 152: Dismantling And Fitting, Special Tools For Fastening Strips
Dismantling and fitting, special tools for fastening strips ABB offers an optional special tool set (90160) which, in the event of limited accessibility, can be used to facilitate the loosening of nuts and the application of tightening torques for the strip connection between the cartridge group and the turbine casing.
Page 153: Application, Special Tools
Operation Manual / A150-M56/66/57/67 - A155-M.. 12 Dismantling and fitting, special tools for fastening strips / 12.1 Ap- plication, special tools 12.1 Application, special tools Removing the fastening strips Fig. 107: Positioning the collection tub 1. Position the collection tub (01) to catch any fixing elements if they fall.
Page 154: Fig. 109: Fitting The Upper Fastening Strips
Operation Manual / A150-M56/66/57/67 - A155-M.. 12 Dismantling and fitting, special tools for fastening strips / 12.1 Ap- plication, special tools 5. Loosen the nuts (51007) from the remaining fastening strips and remove the lugs (51002) with washers (51003). Fitting the fastening strips Fig. 109: Fitting the upper fastening strips...
Page 155: Fig. 111: Fitting The Bottom Fastening Strip
Operation Manual / A150-M56/66/57/67 - A155-M.. 12 Dismantling and fitting, special tools for fastening strips / 12.1 Ap- plication, special tools 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.
Page 156: Fig. 112: Fitting The Cartridge Group
Operation Manual / A150-M56/66/57/67 - A155-M.. 12 Dismantling and fitting, special tools for fastening strips / 12.1 Ap- plication, special tools 12.1.1 A155-M Fit fastening strips with extended special tool Fig. 112: Fitting the cartridge group 1. Fit nuts (51007) of the (upper) fastening strips (51002) shown in the picture and tighten with the torque spanner (02) without a spanner holder.
Page 157: Fig. 113: Positioning The Fastening Strip
Operation Manual / A150-M56/66/57/67 - A155-M.. 12 Dismantling and fitting, special tools for fastening strips / 12.1 Ap- plication, special tools The cartridge group is already fitted at this point in time. The cartridge group is not illus- trated in the following images so that all work steps are visually clear.
Page 158: Fig. 114: Clamping Piece
Operation Manual / A150-M56/66/57/67 - A155-M.. 12 Dismantling and fitting, special tools for fastening strips / 12.1 Ap- plication, special tools Fig. 114: Clamping piece 7. Fix the washer (51003) with clamping device (90163) and check to ensure it is properly seated.
Page 159: Fig. 115: Attach Nut
Operation Manual / A150-M56/66/57/67 - A155-M.. 12 Dismantling and fitting, special tools for fastening strips / 12.1 Ap- plication, special tools Fig. 115: Attach nut Product Size Tightening torque [Nm] A155-M Table 71: Tightening torque (51007) with spanner holder 10. Screw nut (51007) loosely to the locking device (90162).
Page 160: Removing And Installing 6-Nozzle Turbine Cleaning Component (Optional)
Operation Manual / A150-M56/66/57/67 - A155-M.. 13 Removing and installing 6-nozzle turbine cleaning component (op- tional) / 13.1 Disassembly Removing and installing 6-nozzle turbine cleaning component (optional) 13.1 Disassembly The following illustration shows the initial situation before the 6-nozzle turbine cleaning component is dismantled.
Page 161: Fig. 118: Disassembly Of The Elbows
Operation Manual / A150-M56/66/57/67 - A155-M.. 13 Removing and installing 6-nozzle turbine cleaning component (op- tional) / 13.1 Disassembly Fig. 118: Disassembly of the elbows Remove the elbows (51311) from the connecting pieces (51313) in the specified order (01, 02, 03, 04, 05).
Page 162: Fig. 120: Disassembly Of The Connecting Pieces
Operation Manual / A150-M56/66/57/67 - A155-M.. 13 Removing and installing 6-nozzle turbine cleaning component (op- tional) / 13.1 Disassembly Fig. 120: Disassembly of the connecting pieces 1. Unscrew hexagon-head screws (51314) from connecting pieces (51313). 2. Remove gaskets (51302). 3. Remove connecting pieces.
Page 163: Assembly
Operation Manual / A150-M56/66/57/67 - A155-M.. 13 Removing and installing 6-nozzle turbine cleaning component (op- tional) / 13.2 Assembly 13.2 Assembly Clean all of the components and axial contact surfaces of the gaskets before assembling the turbine casing. Fig. 122: Assembly of the cleaning nozzle...
Page 164: Fig. 124: Pipe Assembly
Operation Manual / A150-M56/66/57/67 - A155-M.. 13 Removing and installing 6-nozzle turbine cleaning component (op- tional) / 13.2 Assembly Fig. 124: Pipe assembly 1. Coat thread and contact surfaces of cutting ring with high-temperature grease. 2. Position pipe (51312). 3. Position union nuts (51316) of pipe on connecting piece (51313) and screw-in fitting (51305) and tighten by hand only.
Page 165: Fig. 126: Elbow 2 Assembly
Operation Manual / A150-M56/66/57/67 - A155-M.. 13 Removing and installing 6-nozzle turbine cleaning component (op- tional) / 13.2 Assembly Fig. 126: Elbow 2 assembly Product 51314 [Nm] 51316 [Nm] A150-M A155-M Table 74: Tightening torque (51314 / 51316) 1. Tighten hexagon-head screws (51314) to tightening torque.
Page 166: Fitting The Cleaning Nozzles With Multi-Inlet Turbine Casings
Operation Manual / A150-M56/66/57/67 - A155-M.. 14 Fitting the cleaning nozzles with multi-inlet turbine casings / Fitting the cleaning nozzles with multi- inlet turbine casings Fig. 127: Fit the cleaning nozzles 1. The designation (P . ) on the turbine casing must correspond with the designation (P . ) on the cleaning nozzle.
Page 167: Taking Out Of Operation At Short Notice
Operation Manual / A150-M56/66/57/67 - A155-M.. 15 Taking out of operation at short notice / 15.1 Possible emergency repairs Taking out of operation at short notice 15.1 Possible emergency repairs WARNING Danger of fire and explosion due to lubricating oil leaks Leaking oil may ignite on hot surfaces.
Page 168: Installing The Replacement Turbocharger
The repair of a cartridge group requires special tools and the expertise of an ABB Turbochar- ging Service Station. The rotating parts rotate extremely quickly, and are sensitive to unbal- ance.
Page 169: Fitting The Cover Plate
Operation Manual / A150-M56/66/57/67 - A155-M.. 15 Taking out of operation at short notice / 15.4 Fitting the cover plate 15.4 Fitting the cover plate Remove turbocharger (see chapter Removing and Installing →29). ¡ Gas outlet casing removed Fit the turbine casing with the gas outlet casing into the gas pipe again.
Page 170: Cover Plate Drawing
15 Taking out of operation at short notice / 15.5 Cover plate drawing 15.5 Cover plate drawing The cover plate is not included in the ABB scope of delivery and must be manufactured by the operating company according to the following drawing. Material: General structural steel, in accordance with DIN EN 10025-2.
Page 171: Fig. 130: Dimensions For Cover Plate
Operation Manual / A150-M56/66/57/67 - A155-M.. 15 Taking out of operation at short notice / 15.5 Cover plate drawing Fig. 130: Dimensions for cover plate Product D2 ± 0.1 A150 90 ± 0.2 28.2 A155 111 ± 0.1 37.2 Table 76: Cover plate dimensions [mm] ©...
Page 172: 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 173: 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 174: Disposing Of Turbocharger Components
Operation Manual / A150-M56/66/57/67 - A155-M.. 17 Disposing of turbocharger components / Disposing of turbocharger components WARNING Handling damaged thermal insulation Damaged thermal insulation can lead to dust exposure. The glass fibres can cause mechanical irritation of the eyes, skin, and respiratory tracts.
Page 175: Spare Parts
79041 Counter-sunk screw 81010 / 82010 O-ring Table 77: Customer spare part set 97070 * This gasket can only be installed when a gas outlet casing from ABB is used. © Copyright 2021 ABB. All rights reserved. HZTL4032_EN Rev.Q January 2021...
Page 176: Spare Part - Illustrations
Operation Manual / A150-M56/66/57/67 - A155-M.. 18 Spare parts / 18.3 Spare part – Illustrations 18.3 Spare part – Illustrations The spare parts lists shown below are only available in English. Cartridge, oil cooled 42201 42172 42190** 42170 42191 42167...
Page 177: Table 78: Spare Parts - Cartridge, Oil Cooled
Operation Manual / A150-M56/66/57/67 - A155-M.. 18 Spare parts / 18.3 Spare part – Illustrations Part no. Designation 42194 Gasket 42195* O-ring 42196 Orifice oil inlet 42197 Safety-ring 42200* O-ring 42201 Clamping nut 42202 Screw plug Table 78: Spare parts - Cartridge, oil cooled ©...
Page 178: Table 79: Spare Parts - Bearing, Casing Oil Cooled
Operation Manual / A150-M56/66/57/67 - A155-M.. 18 Spare parts / 18.3 Spare part – Illustrations Bearing, casing oil cooled A150-M58/68 only 42305* 42306* 42308* 42020* 42019* 42400 42005(p) 42006(p) 42001 42301 42008* 42302* 42306* 42303* 42305* (p) = pre-assembled * = Available within the spare part set HZTL443310 Mod.
Page 179: Table 80: Spare Parts - Rotor And Bearing Parts
Operation Manual / A150-M56/66/57/67 - A155-M.. 18 Spare parts / 18.3 Spare part – Illustrations Rotor and bearing parts 21000 A150-M58/68 only 21011 32114* 32112 32103* 32104* 32113* 42002 32109 42302* 21002* 21006* 32102* 32159* 32111* 32110 32101* 32167* **...
Page 180: Table 81: Spare Parts - Turbine Casing, 1 Inlet
Operation Manual / A150-M56/66/57/67 - A155-M.. 18 Spare parts / 18.3 Spare part – Illustrations Turbine casing, 1 inlet 51009 57002 57003** 51008 51027 51000 51006 51003 51007 51101** TW03 51106** TW04 57210 56005 51101 56001 51105** 51102 51002 51102** TW03...
Page 181: Table 82: Spare Parts - Turbine Casing, 2 Inlets
Operation Manual / A150-M56/66/57/67 - A155-M.. 18 Spare parts / 18.3 Spare part – Illustrations Turbine casing, 2 inlets 57003** 57002 51009 51008 51027 51000 57210 51006 51003 51007 51102** TW03 51107** TW04 56005 56001 51105** 51101 51002 51102 51101** TW03...
Page 182: Table 83: Spare Parts - Turbine Casing, 3 Inlets
Operation Manual / A150-M56/66/57/67 - A155-M.. 18 Spare parts / 18.3 Spare part – Illustrations Turbine casing, 3 inlets 51027 51009 51303 57002 51302 57003** 51000 51008 57210 51006 51003 51007 51010** TW03/TW04 51102** TW03 51107** TW04 56005 56001 51105**...
Page 183: Table 84: Spare Parts - Cleaning Device
Operation Manual / A150-M56/66/57/67 - A155-M.. 18 Spare parts / 18.3 Spare part – Illustrations Cleaning device RT05...RT07 51312 51311 51310 51305 51304 51308 51313 51301 51309 51303 51302 51317 51314* RT01...RT03 51316 51303 51302 51301 HZTL443336 Mod. B Part no.
Page 184: Table 85: Spare Parts - Gas Outlet Casing, Radial
Operation Manual / A150-M56/66/57/67 - A155-M.. 18 Spare parts / 18.3 Spare part – Illustrations Gas outlet casing, radial 61100 61005(p) 61202 61201 61140 61001 61301** 61002* (p) = pre-assembled ** = if provided * = Available within the spare part set HZTL443312 Mod.
Page 185: Table 86: Spare Parts - Compressor Casing
Operation Manual / A150-M56/66/57/67 - A155-M.. 18 Spare parts / 18.3 Spare part – Illustrations Compressor casing A150-M58/68 only 72016 72061 72062 72063 72011 79041* 79040 79000 72000 72012 72051 72060 77006 72012 77000 77005* 72006(p) 72005(p) (p) = pre-assembled * = Available within the spare part set HZTL443313 Mod.
Page 186 Operation Manual / A150-M56/66/57/67 - A155-M.. 18 Spare parts / 18.3 Spare part – Illustrations Filter silencer 81000 81137 81265** 81010* 81006 81005 81136 81135 81171 81170 81266 81270 72052 72055 72053 72054 81150 81146 81149 81148 81147 81145 81000...
Page 187: Table 87: Spare Parts - Filter Silencer
Operation Manual / A150-M56/66/57/67 - A155-M.. 18 Spare parts / 18.3 Spare part – Illustrations Part no. Designation 81154 Hex socket head cap screw 81155 Hexagon-head screw 81170 Screw plug 81171 Gasket 81265** Filter ring 81266 Cover grid 81271 Lock Table 87: Spare parts - Filter silencer...
Page 188: Table 89: Spare Parts - Air Suction Branch Radial
Operation Manual / A150-M56/66/57/67 - A155-M.. 18 Spare parts / 18.3 Spare part – Illustrations Air suction branch radial 82010* 82005 82006 82000 82008 82007 * = Available within the spare part set HZTL443315 Mod. B Part no. Designation 82000...
Page 189: Table 90: Spare Parts - Speed Measurement System
Operation Manual / A150-M56/66/57/67 - A155-M.. 18 Spare parts / 18.3 Spare part – Illustrations Speed measurement system 86258** 86526** 86515** 86505** ** = if provided HZTL443475 Mod. A Part no. Designation 86258** Tachometer 86505** Speed sensor 86515** Cable connector...
Page 190: Tools
Extraction device Table 91: Customer tool set 90000 ABB offers an optional special tool set (90160) which, in the event of limited accessibility, can be used to facilitate the loosening of nuts and the application of tightening torques for the strip connection between the cartridge group and the turbine casing.
Page 191: Fig. 132: Special Tool
90164 Tool disassembly segment 90165 Spanner holder Table 93: Special tool (90160) Tool sets can be ordered from any ABB Turbocharging Service Station. The following spe- cifications must be included in the order: ¡ Turbocharger type ¡ Designation and part number of the tool set.
Page 192: Figures
Operation Manual / A150-M56/66/57/67 - A155-M.. Figures Figures Fig. 1: Serial number (01) on the rating plate ... 4 Fig. 32: Compressor-end, non-rotating parts..69 Fig. 2: Layout and function of the turbocharger..6 Fig. 33: Turbine end, non-rotating parts....71 Fig. 3: Compressor wheel cooling ........ 7 Fig. 34: Soaking the turbine end.........
Page 193 Operation Manual / A150-M56/66/57/67 - A155-M.. Figures Fig. 61: Removing cartridge group 3 ...... 109 Fig. 91: Removing cartridge group 2......136 Fig. 62: Installing the cartridge group on the service Fig. 92: Removing cartridge group 2 ......137 support................110 Fig. 93: S_05180 ............138 Fig. 63: Removing the nozzle ring ......
Page 194 Operation Manual / A150-M56/66/57/67 - A155-M.. Figures Fig. 126: Elbow 2 assembly ........163 Fig. 127: Fit the cleaning nozzles ......164 Fig. 128: Fitting the cover plate ........ 167 Fig. 129: Cover plate drawing........168 Fig. 130: Dimensions for cover plate ...... 169 Fig. 131: Special tool........... 188 Fig. 132: Special tool ..........
Page 195: Tables
Operation Manual / A150-M56/66/57/67 - A155-M.. Tables Tables Table 1: Definition of pictograms ....... 9 Table 26: Malfunctions during operation – Charge air pressure too low ............80 Table 2: Personal protective equipment to be worn at all times ..............14 Table 27: Malfunctions during operation – Charge air pressure too high ............
Page 196 Operation Manual / A150-M56/66/57/67 - A155-M.. Tables Table 55: Tightening torque (72054)....... 129 Table 89: Spare parts - Air suction branch radial .. 186 Table 56: Threaded rod, value X ....... 135 Table 90: Spare parts - Speed measurement system . Table 57: Permissible clearances A and B ....139 Table 91: Customer tool set 90000......

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Removing the Cartridge Group

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