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Turbocharging

Operation Manual / A155-M56

m
HT611542

.co
Document identification
Document number HZTL4032
Revision
Language ox S
English
Original Operation Manual
sb
ide

Product identification
Serial number HT611542
Customer part number IMO32002
Delivery date (yyyy-mm-dd) 2022-04-04
-gu

Weight 1800 kg

Operating limits according to rating plate

all

Speed limit in test rig operation only nMmax 458 1/s

Speed limit during operation nBmax 433 1/s
Gas inlet temperature limit in test rig operation only tMmax 650 °C
Gas inlet temperature limit during operation tBmax 620 °C
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Operation Manual / A150-M56/66/57/67 - A155-M..

Table of contents

Operation Manual / A150-M.. - A155-M..

1 Introduction............................................................................................................ 4
1.1 Purpose of the manual................................................................................................. 4
1.2 Contact information...................................................................................................... 5
1.3 Essential information.................................................................................................... 5
1.4 Layout and function of the turbocharger ................................................................ 6
1.5 Symbols, definitions..................................................................................................... 8
1.6 Storage of new turbochargers and spare parts .................................................... 10
1.7 Registered trademarks ............................................................................................... 12

2 Safety .................................................................................................................... 13
2.1 Introduction .................................................................................................................. 13
2.2 CE conformity ............................................................................................................... 13
2.3 Definition of mandatory signs .................................................................................. 14
2.4 Definition of safety instructions .............................................................................. 14
2.5 Intended use ................................................................................................................. 15
2.6 Warning plates on the turbocharger........................................................................ 16
2.7 Turbocharger rating plate.......................................................................................... 17
2.8 Periodic check of the pressure vessels.................................................................... 19
2.9 Lifting of loads ............................................................................................................ 20
2.10 Prerequisites for operation and maintenance....................................................... 21
2.11 Hazards during operation and maintenance ......................................................... 22
2.12 Safe operation ............................................................................................................. 24
2.13 Safe maintenance ....................................................................................................... 25

3 Removing and Installing...................................................................................... 29

3.1 Turbocharger weight and transportation ............................................................. 29
3.2 Removing the turbocharger...................................................................................... 30
3.3 Installing the turbocharger ....................................................................................... 34

4 Commissioning .................................................................................................... 40
4.1 Oil supply ...................................................................................................................... 40
4.2 Inspection procedures ............................................................................................... 42
4.3 Commissioning after taking out of operation...................................................... 44

5 Monitoring operation .......................................................................................... 45

5.1 Oil pressure, oil temperature.................................................................................... 45
5.2 Exhaust gas temperature before turbine .............................................................. 47
5.3 Turbocharger speed ................................................................................................... 48

6 Operation and service ......................................................................................... 51

6.1 Noise emission ............................................................................................................. 51
6.2 Service work ................................................................................................................. 53
6.3 Expected replacement intervals .............................................................................. 56

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Operation Manual / A150-M56/66/57/67 - A155-M..

Table of contents

6.4 Stopping the engine................................................................................................... 58

7 Periodic maintenance work ................................................................................ 59

7.1 Foreword to maintenance......................................................................................... 59
7.2 Cleaning the compressor during operation .......................................................... 60
7.3 Cleaning the turbine during operation................................................................... 63
7.4 Cleaning components mechanically ....................................................................... 67
7.5 Changing the absorption element .......................................................................... 80

8 Eliminating malfunctions.................................................................................... 82
8.1 Malfunctions when starting...................................................................................... 82
8.2 Malfunctions during operation ................................................................................ 83
8.3 Turbocharger is surging ............................................................................................ 86
8.4 Malfunctions when stopping.................................................................................... 87
8.5 Speed measurement system .................................................................................... 88

9 Dismantling and fitting, general........................................................................ 89

9.1 Introduction ................................................................................................................. 89
9.2 Material required......................................................................................................... 90
9.3 Disassembly and assembly concepts ..................................................................... 93
9.4 Weights of individual parts....................................................................................... 96
9.5 Table of tightening torques...................................................................................... 97

10 Dismantling and fitting with removed air inlet and gas outlet ..................... 99
10.1 Removing air inlets ..................................................................................................... 99
10.2 Removing the gas outlet casing ............................................................................. 101
10.3 Removing the gas outlet flange............................................................................. 104
10.4 Removing the cartridge group with compressor and turbine casing............ 107
10.5 Removing the compressor casing ......................................................................... 109
10.6 Removing the cartridge group ................................................................................ 111
10.7 Installing the cartridge group on the service support ....................................... 114
10.8 Removing the nozzle ring ......................................................................................... 115
10.9 Measuring clearance A and B................................................................................... 116
10.10 Nozzle ring compression PD.................................................................................... 117
10.11 Installing nozzle ring ................................................................................................. 118
10.12 Installing the cartridge group ................................................................................. 119
10.13 Installing the compressor casing ........................................................................... 122
10.14 Turning the cartridge group with compressor and turbine casing................. 124
10.15 Installing the gas outlet flange ............................................................................... 125
10.16 Radial clearances N and R......................................................................................... 126
10.17 Fitting the insulation................................................................................................. 127
10.18 Installing the cartridge group with compressor and turbine casing .............. 128
10.19 Installing the gas outlet casing............................................................................... 129
10.20 Installing air inlets ..................................................................................................... 132

11 Dismantling and fitting, cartridge concept ................................................... 134

11.1 Removing air inlets ................................................................................................... 134
11.2 Removing the compressor casing .......................................................................... 136

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Table of contents

11.3 Removing the cartridge group ................................................................................ 139

11.4 Removing the nozzle ring ......................................................................................... 142
11.5 Measuring clearance A and B.................................................................................. 143
11.6 Nozzle ring compression PD................................................................................... 144
11.7 Installing nozzle ring ................................................................................................ 145
11.8 Installing the cartridge group ................................................................................ 146
11.9 Installing the compressor casing .......................................................................... 148
11.10 Radial clearances N and R........................................................................................ 150
11.11 Fitting the insulation................................................................................................. 151
11.12 Installing air inlets ..................................................................................................... 152

12 Dismantling and fitting, special tools for fastening strips ......................... 154
12.1 Application, special tools ......................................................................................... 155

13 Removing and installing 6-nozzle turbine cleaning component (optional) ......

162
13.1 Disassembly ................................................................................................................ 162
13.2 Assembly .................................................................................................................... 165

14 Fitting the cleaning nozzles with multi-inlet turbine casings...................... 168

15 Taking out of operation at short notice ......................................................... 169

15.1 Possible emergency repairs.................................................................................... 169
15.2 Installing the replacement turbocharger ............................................................. 170
15.3 Installing the replacement cartridge group ........................................................ 170
15.4 Fitting the cover plate............................................................................................... 171
15.5 Cover plate drawing .................................................................................................. 172

16 Mothballing the turbocharger.......................................................................... 174

16.1 Taking the engine out of operation for up to 12 months .................................. 174
16.2 Taking the engine out of operation for more than 12 months ......................... 175

17 Material and Disposal........................................................................................ 176

17.1 REACH and RoHS Compliance Declaration For Products .................................. 176
17.2 Disposing of turbocharger components .............................................................. 177

18 Spare parts ......................................................................................................... 178

18.1 Ordering spare parts................................................................................................. 178
18.2 Required customer spare part set (97070)........................................................... 178
18.3 Spare part – Illustrations .......................................................................................... 179

19 Tools .................................................................................................................... 192

Figures................................................................................................................. 194

Tables .................................................................................................................. 197

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Operation Manual / A150-M56/66/57/67 - A155-M..

1 Introduction / 1.1 Purpose of the manual

1 Introduction

1.1 Purpose of the manual

m
.co
ox
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.
sb
Page 4 / 198

Operation Manual
The Operation Manual explains the turbocharger and contains instructions for safe opera-
ide

tion.
The Operation Manual is a complement to and expansion of existing national regulations for
occupational safety, accident prevention and environmental protection.

Target group
-gu

The Operation Manual is aimed at engineers and trained mechanics responsible for the
proper operation of the engine and for the turbocharger connected to it.

Availability of the Operation Manual

The Operation Manual must be available where the turbocharger is used.
all

All persons operating or working on the turbocharger must have read and fully understood
the Operation Manual.

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Operation Manual / A150-M56/66/57/67 - A155-M..

1 Introduction / 1.2 Contact information

1.2 Contact information

Contact information for the Turbo Systems service stations is available online.
u Scan the QR code to access our website.

Turbo Systems Switzerland Ltd.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland

www.abb.com/turbocharging

1.3 Essential information

Design variants

Page 5 / 198
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 Turbo Systems Service Station if you have any questions regarding a
design variant (see Contact information at www.abb.com/turbocharging).

Accuracy of illustrations
The illustrations in this document are general in nature and intended for ease of understand-
ing. Differences in detail are therefore possible.

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Operation Manual / A150-M56/66/57/67 - A155-M..

1 Introduction / 1.4 Layout and function of the turbocharger

1.4 Layout and function of the turbocharger

Page 6 / 198

Fig. 2: Layout and function of the turbocharger

01 Filter silencer / air suction branch 08 Gas outlet flange

02 Compressor casing 09 Nozzle ring
03 Diffuser 10 Turbine casing
04 Bearing casing 11 Turbine-end bearing flange
05 Axial thrust bearing 12 Compressor-end bearing flange
06 Radial plain bearing 13 Compressor wheel
07 Turbine

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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.
The exhaust gases of the internal combustion engine flow through the turbine casing (10)
and the nozzle ring (09) onto the turbine (07). The turbine (07) uses the energy contained in
the exhaust gas to drive the rotor and, hence, the compressor wheel (13). The exhaust gases
then reach the atmosphere through the exhaust gas pipe connected to the gas outlet
flange (08).
The compressor wheel (13) sucks fresh air through the air suction branch or the filter silen-
cer (01). In the compressor wheel (13), the energy required for building up the pressure is
transferred to the air. By flowing through the diffuser (03) and the compressor casing (02),
the air is compressed further and is then directed to the engine cylinders.
The rotor runs in two radial plain bearings (06) which are located in the bearing casing (04)
between the compressor and turbine. The axial thrust bearing (05) is located between the
two radial plain bearings.
The plain bearings are connected to a central lubricating oil duct which is normally supplied

Page 7 / 198
by the lubricating oil circuit of the engine. The oil outlet always lies at the deepest point of
the bearing casing (04).

Function of the compressor wheel cooling

Fig. 3: Compressor wheel cooling

Depending on the application of an A100 radial turbocharger, the turbocharger is equipped

with compressor wheel cooling. With compressor wheel cooling, after the compressor air
has cooled down by passing through the charge air cooler on the engine side, it is supplied
to the turbocharger for cooling the compressor wheel. Cooling of the compressor wheel is
compulsory to ensure the reliability and replacement intervals for the relevant operating
conditions. In the turbocharger version with compressor wheel cooling, the cooling air is
supplied through a lateral connection in the bearing casing (X).
In addition, the turbocharger version with compressor wheel cooling is indicated by the tur-
bocharger type (M6..) on the rating plate.

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Operation Manual / A150-M56/66/57/67 - A155-M..

1 Introduction / 1.5 Symbols, definitions

1.5 Symbols, definitions

Symbols
The following symbols are used in this document:
u Indicates an action step.

1. Indicates a numbered action step.

→ Refers to a page number

Definition of Note

NOTICE
Note
The note provides advice which facilitates the work.

Definition of mandatory signs

Page 8 / 198

Mandatory signs show the protective equipment to be worn for a task. The mandatory signs
are described in chapter Safety and must be complied with.

Definition of Caution / Warning

Caution and warning signs are described in chapter Safety.

Turbo Systems
Turbo Systems Switzerland Ltd is referred to in this document as Turbo Systems.

Official service stations of Turbo Systems

Official service stations are identified in this document as Turbo Systems service stations.
These Turbo Systems service stations are regularly checked and certified by Turbo Systems
Switzerland Ltd. See also chapter Contact information →5.

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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.

m
Pictogram Meaning
Tighten with specified torque

Tighten over specified tightening angle

.co
Hand-tight, tighten without tools

Oil

Apply screw locking paste (e.g. Loctite)

ox
Apply high-temperature grease

Apply other paste in accordance with specifications

Oil free, grease free and dry

sb

Page 9 / 198
Affix

Measure
ide

Note

Visually inspect

Please note text for numbered work step.

-gu

See document

Dispose of in an environmentally compatible, professional way and in compliance

with locally applicable regulations.
Table 1: Definition of pictograms
all

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Operation Manual / A150-M56/66/57/67 - A155-M..

1 Introduction / 1.6 Storage of new turbochargers and spare parts

1.6 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.
Only dry rooms in which the relative humidity is between 40…70 % and no condensation can
form are suitable for storage.

Storage of new turbochargers and spare parts for more than 6 months
As the contents of the package are adapted as required, turbochargers may also be de-
livered without a VCI label.
For parts with a VCI label on the package, the following instructions must be observed.

Fig. 4: Volatile Corrosion Inhibitor (VCI)

Page 10 / 198

WARNING
Health protection when handling VCI
VCI products are not hazardous in terms of the Ordinance on Hazardous
Substances. Nevertheless, the following points must be observed when
handling VCI:
u Observe information in material safety data sheet
u Ensure proper space ventilation.
u Do not eat, drink or store food at the workplace while working with VCI.
u Clean hands and face after working with VCI.
u For more information, see www.branopac.com.

Wear safety gloves to protect against mechanical hazards.

Every 6 months, the following mothballing measures are required:

u Open package.

u Remove VCI corrosion protection emitter from package and replace with a new VCI corro-
sion protection emitter of the same kind. New VCI corrosion protection emitters can be
obtained from www.branopac.com.
u Old VCI corrosion protection emitters must be disposed of in an environmentally compat-
ible, professional way and in compliance with locally applicable regulations.
u Close package. The more tightly the package is sealed, the longer the protection dura-
tion.

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Operation Manual / A150-M56/66/57/67 - A155-M..

1 Introduction / 1.6 Storage of new turbochargers and spare parts

Long-term storage of turbochargers

The turbochargers will be prepared for long-term storage if requested in the purchase order.
The package is equipped with a hygrometer (see illustration).

Fig. 5: Package with hygrometer

Every 6 months, the following measures are required:

u Check the hygrometer (02) in the sight-glass. There is an opening (01) in the wooden
crate which allows this check to be carried out. When the display field has changed colour
at the 70% level, the maximum permissible humidity has been exceeded. In this case, the
turbocharger must be inspected by a Turbo Systems service station and repacked.
u Inspect the package for damage. If the package is damaged, the turbocharger must be in-

Page 11 / 198
spected by a Turbo Systems service station and repacked.
After every 3 years the following work steps must be performed by a Turbo Systems service
station:
¡ Inspect the component
¡ Replace the desiccant agent
¡ Repackage the component.

NOTICE
70% field of the hygrometer has not changed colour
If the 70% field of the hygrometer (02) has not changed colour and the pack-
age is undamaged, the turbocharger can be put into operation without any
prior inspection by a Turbo Systems service station.

Unpacking the turbochargers

The corrosion protection effect ends after the material is unpacked from the VCI package.
To avoid the formation of condensation, the surroundings and the content of the package
must have the same temperature during unpacking.

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Operation Manual / A150-M56/66/57/67 - A155-M..

1 Introduction / 1.7 Registered trademarks

1.7 Registered trademarks

The trademarks of outside companies are used in this document. These are marked with the
® symbol.
Page 12 / 198

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Operation Manual / A150-M56/66/57/67 - A155-M..

2 Safety / 2.1 Introduction

2 Safety

2.1 Introduction
Turbochargers manufactured by ABB reflect the state of the art. The respective safety and
health protection requirements are met. This ensures safe operation of the turbocharger.
Nevertheless, there may be some residual risks during operation of and work on the tur-
bocharger which:
¡ are caused by the turbocharger itself or its accessories.
¡ are caused by the operating equipment used or supplies and materials.
¡ are a consequence of insufficient compliance with safety instructions.
¡ are a consequence of insufficient or inappropriate performance of maintenance and in-
spection work.
The operating company is responsible for defining measures that regulate safe access to
and safe handling of the turbocharger.
All instructions contained in this chapter must be observed for safe and trouble-free opera-
tion of the turbocharger and during all work on the turbocharger.

Page 13 / 198
All further safety instructions contained and specifically identified in every chapter of this
Operation Manual (Definition of safety instructions →14) must also be observed.

2.2 CE conformity

Information
Turbochargers from Turbo Systems comply with the Machinery Directive 2006/42/EC and
are partly completed machinery as defined by Article 2 g in this directive.

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Operation Manual / A150-M56/66/57/67 - A155-M..

2 Safety / 2.3 Definition of mandatory signs

2.3 Definition of mandatory signs

To be worn at all times
Protective clothing Safety footwear to protect

m
against mechanical hazard and
risk of falling

Table 2: Personal protective equipment to be worn at all times

.co
To be worn specific to the respective task
Safety glasses Safety goggles

Safety gloves to protect Respiratory mask to protect

against
- Mechanical hazard
- Chemical hazard
- Thermal hazard
- Electrical hazard
Safety helmet
ox against
- Dusts
- Gases

Ear protection
sb
Page 14 / 198

Table 3: Personal protective equipment to be worn specific to the respective task

ide

2.4 Definition of safety instructions

WARNING
Definition of Warning
-gu

Non-compliance or inaccurate compliance with working or operating in-

structions indicated by this symbol and the word WARNING can lead to seri-
ous injuries to personnel and even to fatal accidents.
u Warning signs must always be observed.

CAUTION
all

Definition of Caution
Non-compliance or inaccurate compliance with working or operating in-
structions indicated by this symbol and the word CAUTION can lead to seri-
ous damage to engine or property with grave consequences.
u Caution signs must always be observed.

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2 Safety / 2.5 Intended use

2.5 Intended use

Use on internal combustion engines in general

Turbo Systems turbochargers are intended for charging internal combustion engines.
To ensure compliance with the machinery directive 2006/42/EC when using on gas engines,
the turbocharger must be operated in an engine room classified as "not at risk of explosion".
This is in accordance with the position paper [2] relating to ATEX issued by EUROMOT [1].
For use on pre-mix gas engines with ignitable propellents in the gas control system, the en-
ginebuilder must implement appropriate safety measures for explosion protection [3] (such
as flame barriers in the inlet system, for example) to assure that there is no transient pres-
sure increase exceeding a maximum of 12 bar before the turbocharger in case of a deflagra-
tion.
The turbocharger supplies the engine with the air volume or air/gas mixture and the associ-
ated charging pressure required for operation.
The turbocharger is solely intended to be operated with a clockwise direction of rotation as
viewed from the turbine end.
The specific operating limits of the turbocharger were determined on the basis of informa-
tion from the enginebuilder about the intended use. These data are given on the rating

Page 15 / 198
plate.
The use of the turbocharger is limited to the specific application released at the time of de-
livery.
Turbo Systems accepts no liability and rejects all warranty claims for any non-intended ap-
plications.
[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-
tentially explosive atmospheres (ATEX) The Euromot Position as of November 2003, ATEX
Euromot Position 191103
[3]Guidelines for proper safety design of inlet systems on gas engines, RWTÜV Essen, 1991

WARNING
Unapproved operation
Any operation of the turbocharger outside of its operating limits can be haz-
ardous to personnel.
u Only operate the turbocharger within the operating limits.
u Only trained personnel must operate the turbocharger.

The intended use of the turbocharger includes compliance with all regulations and condi-
tions. In particular, the following must be observed:
¡ Operation Manual
¡ Instructions of the enginebuilder

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Operation Manual / A150-M56/66/57/67 - A155-M..

2 Safety / 2.6 Warning plates on the turbocharger

State of the art

The turbocharger is designed and manufactured according to the state of the art and is safe
to operate.

Perfect condition
The turbocharger must only be used when it is in a technically flawless condition and oper-
ated in compliance with its intended use.
Turbo Systems excludes any liability for damage resulting from unauthorized modifications
to the turbocharger or improper operation.

2.6 Warning plates on the turbocharger

Warning plates are affixed at the following locations:
Page 16 / 198

Fig. 6: Warning plate locations

If warning plates are not present in the designated locations or not readable, proceed as fol-
lows:
u Order new warning plates from Turbo Systems service stations.

u Remove any warning plates that have become unreadable.

u Clean and degrease the areas designated for the warning plates.

u Fit new warning plates and remove protective sheets.

Turbochargers supplied to the enginebuilder without insulation must be equipped later with
warning plates on the insulation. This is the responsibility of the enginebuilder.

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2 Safety / 2.7 Turbocharger rating plate

2.7 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 17 / 198
02 Turbocharger operating limits during operation

Recommended inspection and replacement intervals of turbocharger components

03 Inspection interval of plain bearings in 1000 h
04 Replacement interval of compressor in 1000 h
05 Replacement interval of turbine in 1000 h

Further data
06 Customer part number
07 Designation for special design
08 Weight of turbocharger in kg
09 Turbocharger type
10 Serial number
11 Year of construction of turbocharger
12 Manufacturing plant

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2 Safety / 2.7 Turbocharger rating plate

Explanations regarding the rating plate

The recommended inspection and replacement intervals and the corresponding operating
limits are jointly defined with the enginebuilder. This information is specific to the system.
Operation above the indicated values nBmax, tBmax can considerably shorten the recommended
replacement intervals. In such cases, we recommend contacting the nearest Turbo Systems
Service Station.
nMmax, tMmax normally apply only when running at overload (110 %) during trials on the engine
test bed. These limit values can also be permitted during operation for special applications.
Operation above nMmax and tMmax is not permitted.
Non-observance of the recommended inspection and replacement intervals increases the
risk of unpredictable component failures.
For operating limits, refer to the Operation Manual title page or the rating plate on the tur-
bocharger.

Locations of the rating plates

Page 18 / 198

Fig. 8: 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.

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2 Safety / 2.8 Periodic check of the pressure vessels

2.8 Periodic check of the pressure vessels

The pressure vessels used by Turbo Systems, such as those for wet or dry cleaning, are so-
called "simple pressure vessels".

m
¡ The locally applicable legal regulations regarding periodic checks of the pressure vessels
must be observed.
¡ The operating company is responsible for the safe operation of the pressure vessel.

.co
WARNING
Danger due to pressure vessels
The operating company must make sure the pressure vessels are in proper
working condition and monitor them. Necessary repair or maintenance work
must be performed promptly, and the required safety measures must be
taken.
ox
u Pressure equipment must not be operated if defects are present.
sb

Page 19 / 198
ide
-gu
all

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2 Safety / 2.9 Lifting of loads

2.9 Lifting of loads

WARNING
Suspended loads
Loads that are not attached according to regulations can cause injury to
personnel or fatal accidents.
u Loads must always be fastened to properly functional lifting gear with a
sufficient load limit.
u Pay attention to the correct attachment of loads on the crane hook.
u People must not stand beneath suspended loads.

Wear safety gloves to protect against mechanical hazards.

Wear safety helmet.

Page 20 / 198

Fig. 9: Attachment of loads on the crane hook

Fig. 10: Attachment angle

If there are two or more suspension points, the attachment angle of 45° must not be ex-
ceeded. This prevents excessive loading due to diagonal pull.
u Before looping around the components of the turbocharger, let them cool down (max-
imum 80 °C).
u Attach components of the turbocharger as described in the respective action steps.

u Use a suitable edge guard if there are sharp edges.

u The assembly devices must be completely screwed in and must not loosen during use.

u Use assembly devices only for the described applications.

u Put down dismantled components of the turbocharger in such a way that they cannot tip
over.

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Operation Manual / A150-M56/66/57/67 - A155-M..

2 Safety / 2.10 Prerequisites for operation and maintenance

2.10 Prerequisites for operation and maintenance

Responsibility of the operating company

In awareness of its responsibility, the operating company must ensure that only authorised
personnel work on the turbocharger, who:
¡ Are versed in the general and locally applicable regulations for occupational safety and
accident prevention
¡ Are equipped with the prescribed personal protective equipment
¡ Have read and understood the Operation Manual
¡ Have been instructed in the use of the turbocharger.
The safety-conscious work of the personnel and adherence to the Operation Manual must be
checked periodically.
Suitable working materials and personal protective equipment must be kept in a perfect
condition.
Only authorised personnel may remain in the vicinity of the turbocharger when the engine is
running.

Page 21 / 198
Competence of personnel
The turbocharger must only be operated and serviced by trained and authorised personnel.
Basic mechanical training is a prerequisite.

Modifications to the turbocharger

Modifications to the turbocharger must be approved by Turbo Systems.

WARNING
Use original parts
Operation of the turbocharger with non-original parts can impair the safety
of the turbocharger and can cause serious damage to property and injury to
personnel.
u Only use original parts from Turbo Systems.

Original parts and accessories are specially designed for Turbo Systems turbochargers.
Turbo Systems accepts no liability for any damage resulting from the use of non-original
parts and corresponding accessories.

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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.

WARNING
Noise hazards
Exposure to noise can harm the hearing system, impair health and the psy-
chological state and may lead to lack of attention and irritation.
u When the engine is running, always wear ear protection.
u Always wear ear protection if the sound pressure level exceeds 85 dB(A).

Wear ear protection.

Hazards due to hot surfaces

Page 22 / 198

Surfaces of the turbocharger, attached parts and operating fluids (lubricating oil) get hot
during operation. The surface temperature depends on the efficacy of the existing insula-
tion. The temperature may rise to a level that can cause burns.

WARNING
Danger of burns
Touching hot surfaces or contact with hot operating fluids can cause burns.
u Do not touch hot surfaces. Observe the warning plate on the turbochar-
ger.
u Wear heat-resistant safety gloves and protective clothing.
u Wait for the turbocharger to cool down before carrying out any work.

Wear safety gloves to protect against thermal hazards.

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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. If supply is without in-
sulation, the enginebuilder is responsible for providing the turbocharger
with proper insulation and for providing protection against contact with hot
surfaces.
u Compliance with the instructions and specifications given by the en-
ginebuilder to protect against hot turbocharger surfaces is compulsory.

Wear safety gloves to protect against thermal hazards.

Hazards due to rotating parts

WARNING
Hazards due to rotating parts
Contact with rotating parts can cause severe injury. The turbocharger is

Page 23 / 198
never allowed to be operated without filter silencer or air-inlet casing. With
the engine stopped, the rotor can rotate due to the stack draught alone.
u Operate the turbocharger in compliance with the specifications.
u Secure the rotor against unintentional rotation during maintenance.

Wear safety gloves to protect against mechanical hazards.

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2 Safety / 2.12 Safe operation

2.12 Safe operation

Mechanical hazards during operation

m
During standard operation, no mechanical hazards are caused by the turbocharger itself if it
has been properly installed.

.co
Safety during commissioning and operation
u Visually inspect your working environment before starting work.

u Remove any obstacles and objects littering the workplace.

u Check all pipes to and from the turbocharger for damage and leaks before commission-
ing.

ox
u Check turbocharger for recognisable damage or defects every 12 hours of operation or at
least once a day.
u Report any damage and any alterations of operational characteristics to the responsible
department immediately.
u In case of damage, take the turbocharger out of operation immediately and safeguard
sb
against accidental/unauthorised use.
Page 24 / 198

u When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay at-
tention to the risks that may occur as a consequence of this energy input.
ide
-gu
all

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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.
u When working on the turbocharger always wear safety footwear and pro-
tective clothing to protect against mechanical hazards.
u Keep personal protective equipment in perfect condition.
u Obey mandatory signs.
u Observe the general rules for occupational safety and prevention of acci-
dents.
u Only perform operations that are described in this chapter.
u Only perform operations for which you have received instruction or train-
ing.

Page 25 / 198
Wear safety footwear to protect against mechanical hazard and risk of fall-
ing.

Wear protective clothing.

WARNING
Risk of falling
When working on the turbocharger, there is a risk of falling.
u Do not climb onto the turbocharger or onto attached parts and do not
use them as climbing aids.
u Use suitable climbing aids and working platforms for work above body
height.

u Only perform work on the turbocharger when you are in a physically and psychologically
stable condition.
u Only work with suitable tools, equipment and appliances that function properly.

u Power tools must be grounded and cables must be undamaged.

u Keep the workplace clean; clear away any loose objects and obstacles on the floor.

u Keep the floor, equipment, and turbocharger clean.

u Have oil binding agents ready and provide or keep oil pans at hand.

u Clean up any spills.

u Have fire protection means and extinguishing agents available.

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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.
u Use assembly devices only for the described applications.

Welding work in the vicinity of the turbocharger

u When performing welding work in the vicinity of the turbocharger, always cover the filter
silencer to prevent the filter mat from being damaged.
u Keep flammable objects and substances out of the vicinity of flying sparks.

u Cover all connections on the turbocharger so that no foreign objects can enter the tur-
bocharger.
u Wear personal protective equipment (PPE) for welding operations.

Safety during cleaning

If cleaning agents or solvents are used for cleaning, the corresponding material safety data
sheet and the safety instructions in section Hazards due to operating materials and supplies
must be observed.
Page 26 / 198

u Observe the material safety data sheet for the cleaning agent or solvent.

u Wear personal protective equipment (PPE) according to the material safety data sheet.

u Inspect the electric cables for abrasion and damage before and after your cleaning work.

Safety during disassembly, assembly, maintenance and repair

u Observe the procedures for set-up, service and inspection work and the inspection inter-
vals.
u Inform the operating staff before starting any service or repair work. Make sure the en-
gine is not started while work is being conducted on the turbocharger.
u Before taking off any cover or removing any guard from the turbocharger, switch off the
engine and wait until the turbocharger has come to a standstill.
u Make sure that the oil supply is interrupted, especially with an external oil supply.

u Only restart the engine after all parts have been properly fitted again and oil supply is en-
sured.

CAUTION
Mechanical operations on the turbocharger
Components of the turbocharger can be damaged or destroyed as a result
of improper procedures.
u Only perform operations that are described in this chapter.
u Only perform operations for which you have received instruction or train-
ing.

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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

u Observe the material safety data sheet for the cleaning and mothballing agents.

u Wear personal protective equipment (PPE) according to the material safety data sheet.

Mechanical hazards when working on the turbocharger

WARNING
Mechanical hazard
Severe injuries to personnel or fatal accidents can be caused by mechanical
influences as a consequence of hazardous and inadequate operational pro-
cedures.
u Observe the general rules for occupational safety and prevention of acci-
dents.
u Ensure workplace safety.
u Only perform operations that are described in this chapter.
u Only perform operations for which you have previously received instruc-
tion or training.

Page 27 / 198
Hazards due to operating materials and supplies
Operating materials and supplies are substances required for the operation of the tur-
bocharger or for the performance of maintenance work. Oils, greases, coolants, detergents
and solvents, acids and similar substances can be classified as hazardous substances.

WARNING
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or con-
tact with them may be harmful to health.
u Do not breathe in these substances and avoid contact with the skin.
u Ensure proper ventilation.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Wear personal protective equipment (PPE) according to the material
safety data sheet.
u Comply with local legislation.

Wear safety goggles.

Wear safety gloves to protect against chemical hazards.

Wear a respiratory mask to protect against gases.

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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.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Comply with local legislation.
u Do not allow any exposed flame or ignition source during cleaning work.
u Carry out cleaning in the open or provide sufficient ventilation.

CAUTION
Environmental hazard
Improper handling of operating materials and supplies can lead to environ-
mental damage.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Comply with local legislation.
Page 28 / 198

Hazards due to the handling of insulation materials

WARNING
Danger from insulation materials
Dust or fibres from insulation materials can have adverse effects on the
health or cause irritations. Unsuitable and combustible insulation materials
are a fire hazard.
u Only use suitable and non-combustible insulation materials.
u Ensure good ventilation at the workplace.
u Avoid whirling up dust.
u Use dust-free tools and working methods.
u Remove package at the workplace only.
u Proceed with particular care when removing old insulation materials.
u Dispose of insulation materials properly and in an environmentally com-
patible manner in compliance with the legal regulations.

Wear safety goggles.

Wear a respiratory mask to protect against dusts.

Wear safety gloves to protect against chemical hazards.

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Operation Manual / A150-M56/66/57/67 - A155-M..

3 Removing and Installing / 3.1 Turbocharger weight and transporta-
tion

3 Removing and Installing

3.1 Turbocharger weight and transportation

m
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.
Depending on the specification, the weight specified on the rating plate may be lower than

.co
the standard value specified here.

ox
sb

Page 29 / 198
ide

Fig. 11: Suspension of complete turbocharger unit

A Complete turbocharger unit without gas outlet casing

B Complete turbocharger unit with gas outlet casing

Product Weight of complete turbocharger unit [kg]

A150-M 1200
-gu

A155-M 1800
Table 4: Weight of complete turbocharger unit
all

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3 Removing and Installing / 3.2 Removing the turbocharger

3.2 Removing the turbocharger

u Disconnect all pipes according to the instructions of the enginebuilder.

Version with turbine cleaning:

CAUTION
Turbocharger damage resulting from the cleaning nozzle breaking off
Incorrect assembly of the cleaning nozzle (51301) can damage the thread of
the turbine casing. The cleaning nozzle (51301) can be plastically deformed
when screwing in the screw connection (02) and during subsequent opera-
tion. Reuse of the cleaning nozzle after loosening the screw connection (02)
can lead to a water leak or the cleaning nozzle breaking off and thus destroy
the turbine.
u Only loosen the screw connection (02) if the cleaning nozzle (51301) needs
to be replaced.
u If the screw connection (02) has been loosened, a new cleaning
nozzle (51301) must be installed and the screw connection must be refit-
ted. Observe the specified tightening torque from the supplier of the
screw connection.
Page 30 / 198

Components (01/02) are not included in the Turbo Systems scope of delivery.

Fig. 12: Turbine cleaning nozzle

1. If present: Loosen the turbine cleaning connection (01).

The gas outlet casing (61001) can remain fitted in the exhaust gas pipe if the locking nuts
are accessible. Otherwise the complete turbocharger unit including gas outlet casing must
be removed.

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3 Removing and Installing / 3.2 Removing the turbocharger

Fig. 13: Removing the turbocharger

u Secure the lifting gear to the turbocharger (see illustration).

u If present: Loosen and remove the compressor wheel cooling connection.

Seal the compressor wheel cooling connection (01).

Page 31 / 198
u If present: Disconnect the plug to the speed sensor (86505) and secure the rolled-up
cable on the turbocharger. This protects the plug from being crushed.
u If present: Detach the support (61301) from the engine support.

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.
u Comply with the following steps for loosening the pressure screws.

CAUTION
Do not clean pressure screws
The pressure screws are equipped with a permanent sliding layer that must
not be removed. In case of non-compliance, it cannot be ensured that the
necessary tension force is reached.
u Do not clean pressure screws.
u Do not lubricate pressure screws.

If a screw jams, the previously loosened screw must be tightened again a little.

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3 Removing and Installing / 3.2 Removing the turbocharger

Fig. 14: Loosening the clamping nut

1. Working in a circle, break loose each pressure screw (≤ 20°).

2. Working in a circle, loosen each pressure screw by 45° in 4 rounds.
3. Working in a circle, loosen each pressure screw by 90° in 1…5 rounds until all of the pres-
sure screws have been relieved.
u Loosen clamping nut by hand.
Page 32 / 198

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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.
u Place the turbocharger on a clean, level support.
u Secure the turbocharger to prevent it from tipping over by using wooden
beams and wedges and by taking the centre of gravity into account.

Page 33 / 198
Fig. 15: Turbocharger centre of gravity

01 Centre of gravity
u Remove the turbocharger from the engine support.

u Remove and dispose of the O-rings (42195, 42200).

u Set down and secure the turbocharger properly at a suitable location.

u Close or cover the openings of the turbocharger and support.

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3 Removing and Installing / 3.3 Installing the turbocharger

3.3 Installing the turbocharger

3.3.1 Inserting gaskets

m
CAUTION
Inserting the gaskets
Gaskets that are forgotten, damaged or improperly inserted will lead to oil

.co
leaks.
u Always use new gaskets and insert them carefully into the slot.

ox
sb
Page 34 / 198

Fig. 16: Inserting the gasket

ide

01 Oil supply
02 Oil drain
42200 O-ring
42201 Bearing casing
42202 O-ring
-gu
all

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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

Page 35 / 198
1. Insert expansion bush (42190) into bearing casing.
2. Screw the clamping nut (42201) flush onto the threaded rod (42191). The hexagon of the
thread screw is at the top.
3. Place the thrust washer (01) of the clamping nut on the expansion bush and, with the
clamping nut screwed on, guide the threaded rod through the thrust washer, expansion
bush and bearing casing.

Step B – Preparing the positioning

u Screw the centering bush (42193) flush onto the threaded rod from below.

u Clean the surface of the bracket, the bearing casing, the centering bush and the centering
holes in the bracket.
u Make sure that the covers of the oil connections are removed.

u Make sure that the position of the oil inlet of the bracket matches the oil inlet hole in the
bearing casing.
u Make sure that the O-rings are placed correctly in the slots.

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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
Page 36 / 198

Step C – Aligning the turbocharger on the bracket

1. Lightly lubricate the hole, into which the centering bush (42193) is inserted, with screw
grease.
2. Position threaded rod with centering bush in the bracket.
3. Insert centering bush into bracket until the stop is reached.
4. Carefully lower turbocharger onto bracket and position using the centering bushes
(42193) located in the bracket.
5. Check value x.
u If value x is not reached, the turbocharger must be lifted up from the bracket and re-
aligned.

Step D – Fixing the threaded rod in place in the bracket

u Using the hexagon, screw the threaded rod into the bracket up to value L.

u If value L is not reached or the threaded rod jams while being screwed in, the threaded
rod must be loosened by no more than ½ revolution (this will loosen the centering bush
which may have jammed the rod). Then continue screwing in the threaded rod.
u If value L is not reached, undo the screw connection, carefully take the turbocharger off
the bracket and repeat the procedure starting with Step A.
u Observe the instructions for fastening the turbocharger with clamping nuts (see chapter
Fastening the turbocharger with a clamping nut →37).

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3 Removing and Installing / 3.3 Installing the turbocharger

3.3.3 Fastening the turbocharger with a clamping nut

Preparation for tightening

CAUTION
Do not clean pressure screws (04)
The pressure screws are equipped with a permanent sliding layer that must
not be removed.
Do neither clean nor lubricate the pressure screws. In case of non-compli-
ance, it cannot be ensured that the necessary tension force is reached.
u Do not clean pressure screws.
u Do not lubricate pressure screws.

In order to correctly fit the clamping nuts, the pressure screws (04) must not protrude from
the clamping nuts (03) in the direction of the thrust washer (02).
u Make sure the pressure screws do not protrude in the direction of the thrust washer.

Page 37 / 198
Fig. 19: Preparing the clamping nut for the tightening procedure

1. Clean the thread of the bolt (01) and the contact surface.
2. Lightly oil the bolt thread.
3. Position the thrust washer (02) in place.
4. Tighten clamping nut (03) by hand.
5. Unscrew clamping nut (03) by ¼ of a turn (90°).
The distance between the thrust washer and the clamping nut is now about 1 mm.

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3 Removing and Installing / 3.3 Installing the turbocharger

Tightening pressure screws

Page 38 / 198

Fig. 20: Tightening pressure screws

Product Fixing screw [mm] Tightening torques [Nm]

A150 M30 45
A155 M36 85
Table 6: Torque-controlled tightening of the pressure screws

1. Screw in pressure screws crosswise by hand until reaching the stop.

2. Tighten pressure screws crosswise to 50 % of the tightening torque specified in the
table.
3. Tighten pressure screws crosswise to 100 % of the tightening torque specified in the
table.
4. Work in a circle to tighten all pressure screws to 100 % of the tightening torque specified
in the table.
5. Tighten pressure screws to 100 % in 5 … 7 rounds until the required residual tightening
angle of < 20° is achieved.

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3 Removing and Installing / 3.3 Installing the turbocharger

3.3.4 Connecting the turbocharger

m
Fig. 21: Connecting the speed sensor

.co
u Connect cable to speed sensor (86515).

u Connect all gas, water and air lines according to the instructions of the enginebuilder.

Version with compressor wheel cooling

CAUTION ox
Failure of compressor wheel cooling
Any prolonged failure of the compressor wheel cooling will shorten the re-
placement interval of the compressor wheel.
sb
u Make sure there is an uninterrupted supply of cooling air during opera-

Page 39 / 198
tion.
ide

Fig. 22: Connecting the compressor cooling air intake

-gu

u Remove the screw plug on the connection for the compressor wheel cooling (06) and fit
the cooling air line.

3.3.5 Attaching the support

all

Fig. 23: Attaching the support

u If present: Attach support (61301) to engine support or to a connecting piece.

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4 Commissioning / 4.1 Oil supply

4 Commissioning

4.1 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.
u Comply with the enginebuilder's specifications regarding the selection of lubricating oil
and the oil change intervals.

4.1.2 Pre-lubrication
Pre-lubrication must be carried out as follows:
u Switch on the oil pump.
Page 40 / 198

u Build up oil pressure.

u Do not exceed a pre-lubrication time of 2 minutes.

u Start the engine.

u Let the oil pump run until the pump driven by the engine generates sufficient pressure.

4.1.3 Oil filtering

Filtering the lubricating oil with a filter mesh width of ≤ 0.034 mm is sufficient for this tur-
bocharger.

4.1.4 Oil pressure

Comply precisely with the oil pressure before the turbocharger for trouble-free operation.
The admissible values are specified in chapter Monitoring operation →45.

4.1.5 Oil orifice in the bearing casing

Fig. 24: Oil orifice

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4 Commissioning / 4.1 Oil supply

01 Bearing casing
02 Oil orifice
03 Circlip

With an oil inlet pressure of more than 3 bar of overpressure (with engine under load) up-
stream of the turbocharger, an oil orifice must be installed to reduce the oil pressure.

Page 41 / 198

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4 Commissioning / 4.2 Inspection procedures

4.2 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.

4.2.2 Checks before commissioning

Filter mat (if available)

u Check for damage and contamination.

Lubricating system

CAUTION
Contaminated oil
Serious damage to engine or property can be caused by dirt and solid ma-
Page 42 / 198

terial particles in the oil.

u For the initial commissioning phase and after all service work, flush the
complete lubricating system with warm oil.
u Use special running-in filters when running in the engine and after all ser-
vice work on the lubricating system.

u Check that the oil filter is clean before commissioning.

u Check the oil pressure in the oil supply pipes.

Warning plates
u Check whether warning plates are present and legible.

u Check whether the protective sheets have been removed from new warning plates.

Version with compressor wheel cooling

CAUTION
Failure of compressor wheel cooling
Any prolonged failure of the compressor wheel cooling will shorten the re-
placement interval of the compressor wheel.
u Make sure there is an uninterrupted supply of cooling air during opera-
tion.

u Check whether the compressor wheel cooling is fitted on the bearing casing.

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4 Commissioning / 4.2 Inspection procedures

4.2.3 Checks after commissioning (engine in idle mode)

Lubricating system
u Observe lubricating oil pressure at inlet upstream of turbocharger.

u Observe lubricating oil temperature at inlet upstream of turbocharger.

u For permissible values, see chapter Monitoring operation →45.

Leaktightness of pipes

WARNING
Risk of burning from hot gas
Escaping gases are hot and will lead to serious burns in the event of contact.
u Check all pipes for leaks in accordance with the enginebuilder’s instruc-
tions.

Wear safety gloves to protect against thermal hazards.

Page 43 / 198
Gas, air and oil pipes
u After starting the engine, check all gas, air and oil pipes for leaks.

4.2.4 Checks when starting up the engine

If present:
u Measure speed, oil pressure and charging pressure at various engine performances.

u Measure the exhaust gas temperature before and after the turbine.

u Measure the air temperature before and after the compressor.

u Compare the measured values with the values of the acceptance report. Different operat-
ing conditions indicate a malfunction (see chapter Eliminating malfunctions →82).
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. In
the event of a leak, contact a Turbo Systems service station.

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4 Commissioning / 4.3 Commissioning after taking out of operation

4.3 Commissioning after taking out of operation

If present

m
u Remove cover plates (blind flanges) from the compressor casing, the gas inlet and the
gas outlet.
Version with compressor wheel cooling:

.co
u Remove the locking screw on the cooling air connection and fit the cooling air line.

General
u Check the exhaust gas pipe before and after the turbine for combustion residues or wa-

ox
ter residues and clean it. Remove any foreign objects that may be present.
u Check and clean filter silencer or air supply line, and remove any foreign objects that may
be present.
u Put engine-side oil circulation to the turbocharger into operation.
sb
u Prepare the turbocharger for operation (see Checks before commissioning →42).
Page 44 / 198

u The turbocharger is now ready for operation.

ide
-gu
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5 Monitoring operation / 5.1 Oil pressure, oil temperature

5 Monitoring operation

5.1 Oil pressure, oil temperature

Lubricating oil pressure, oil inlet

To limit the oil flow rate through the turbocharger to the admissible values with the engine
at full load, an oil orifice is mandatory or already fitted at the turbocharger oil inlet if the oil
inlet pressure is > 3 bar.

CAUTION
Assuring lubricating oil pressure
Serious damage to the engine or property can result from a missing or insuf-
ficient lubricating oil supply.
u The lubricating oil pressure must be monitored during operation and the
necessary pressure assured at the oil inlet.

Status for operation Pressure at oil inlet upstream of

Page 45 / 198
the turbocharger
[bar] Overpressure
Normal operation 2.0 < poil ≤ 4.5 *)
Engine start: Cold oil, admissible for a maximum of 15 < 8.0
minutes
Engine idling, admissible for a maximum of 1 hour 0.5 < poil ≤ 2.5
Pre-lubrication and post-lubrication (engine stopped) 0.5 < poil ≤ 1.0
Warning signal: (n ≥ 0.5 x nBmax) < 1.25
Alarm signal: Not admissible. Stop the engine immedi- < 0.6
ately.
Table 7: Lubricating oil pressure at oil inlet before turbocharger

*) Depending on use of an oil orifice in accordance with the enginebuilder’s specifications.

Arrangement of temperature and pressure measuring points

01 Turbocharger contact surface
02 Oil inlet
03 Oil outlet
P Oil pressure measuring point
T Oil temperature measuring point

For monitoring the lubricating oil pressure, 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.
*) If the drain pipe is vented, the lubricating oil temperature measuring point can be installed
at the outlet in the vent tank. Otherwise the measurement should be taken in the drain pipe
as close to the turbocharger as possible.

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5 Monitoring operation / 5.1 Oil pressure, oil temperature

Lubricating oil temperature at the inlet

CAUTION
Machine damage
If the oil temperature at the oil inlet exceeds the admissible range, this may
lead to engine damage.
u Observe oil temperature at the oil inlet according to the following table.

Status for operation Oil temperature at the inlet

Toil,inlet
Admissible 30 … 90 °C
Temporarily admissible (< 1 h) → alarm > 90 °C
Not admissible → stop engine > 95 °C
Not admissible → do not start engine (before start: preheat oil) < 30 °C
Table 8: Lubricating oil temperature at the inlet

Lubricating oil temperature at the outlet

The oil temperature at the outlet is mainly dependant on:
Page 46 / 198

¡ Lubricating oil temperature and pressure at the oil inlet

¡ Engine load and turbocharger speed
¡ Exhaust gas temperature
The maximum admissible oil temperature at the outlet is listed in the following table. The
specified oil outlet temperature is to be considered as alarm value for the turbocharger op-
eration and must be monitored according to the current regulations.

Status for operation Oil temperature at the outlet

Toil,outlet
Admissible ≤ Toil,inlet + 55 K (≤ 145 °C)
Temporarily admissible → alarm > Toil,inlet + 55 K (> 145 °C)
Not admissible → stop engine > 165 °C
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, Turbo Systems recommends having the turbocharger inspected by a Turbo Systems
service station.

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5 Monitoring operation / 5.2 Exhaust gas temperature before turbine

5.2 Exhaust gas temperature before turbine

CAUTION
Factors influencing replacement intervals
Operation above the operating limits defined on the rating plate can
shorten the recommended replacement intervals considerably.
u Measure exhaust gas temperature upstream of turbine.
u Comply with operating limits on rating plate.

u For a definition and explanations concerning the rating plate, refer to chapter Safety /
Turbocharger rating plate →17.
u For operating limits, refer to the Operation Manual title page or the rating plate on the
turbocharger.

Page 47 / 198

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5 Monitoring operation / 5.3 Turbocharger speed

5.3 Turbocharger speed

5.3.1 Introduction
A speed measuring system enables the constant monitoring of the turbocharger speed.

CAUTION
Do not put the speed measurement cables under strain by pulling them
If you pull the speed measurement cables too hard, contacts can be pulled
out.
u Do not strain the speed measurement cables by pulling.

5.3.2 Layout and overview

Page 48 / 198

Fig. 25: Layout and overview of speed measurement system

86505 Speed sensor 42188 Screw plug

86515 Cable connector 42189 Gasket
86526 F/I converter 01 Plug with integrated voltage limiter
86528 Tachometer *) Alternative mounting position for speed
sensor
32109 Sealing disc with cams

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5 Monitoring operation / 5.3 Turbocharger speed

5.3.3 Speed differences with several turbochargers per engine

The speeds of all turbochargers on an engine vary only slightly from each other in standard
operation.

m
The difference between the highest and the lowest turbocharger speed must not be more
than 3 %, relative to the speed limit nBmax.
If this permissible range of difference is exceeded, the following steps must be carried out:

.co
u Reduce the engine performance immediately to the point at which the maximum tur-
bocharger speed does not exceed 70 % of nBmax.
u If the engine cannot be stopped, it can continue to be driven at this reduced engine load
or turbocharger speed.
u If a turbocharger surges continuously, the engine performance must be reduced further.

ox
u Measure the temperatures in the air lines and gas piping from and to the turbochargers
and compare with normal values. If clear deviations of temperature are found, the nearest
Turbo Systems service station has to be contacted.
u Check the pressure loss of the alternative air inlet and compare it with normal values.

If the engine can be stopped temporarily:

sb

Page 49 / 198
u Inspect air lines, gas piping and the turbochargers and remedy any malfunctions.

u In any case, contacting the nearest Turbo Systems service station is recommended.
ide

5.3.4 Malfunctions on the speed measurement system

In the case of malfunctions of the speed measurement system, refer to the chapter entitled
Troubleshooting/Speed measurement system →88.
-gu
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5 Monitoring operation / 5.3 Turbocharger speed

5.3.5 Replacing the speed sensor

WARNING
Hot speed sensor
Danger of burns. The speed sensor can reach temperatures of more than
100 °C during operation.
u Wear safety gloves when disassembling the speed sensor.

Wear safety gloves to protect against thermal hazards.

The speed sensor supplied by ABB is equipped with a sealing lip and an O-ring. No additional
gasket is required during assembly.
Page 50 / 198

Fig. 26: Replacing the speed sensor

Part number A150 A155

86505 M12 x 1.5 M12 x 1.5
15 Nm 15 Nm
Table 10: Tightening torque (86505)

u Reduce the engine performance to idling and then stop the engine. Pay attention to post-
lubrication (Stopping the engine →58).
u Switch off the lubricating oil supply to the turbocharger.

u Disconnect cable connector (86515) from speed sensor (86505).

u Unscrew and remove defective speed sensor (86505).

u Screw in new speed sensor (86505) as far as it will go and tighten.

u Connect cable connector (86515) to speed sensor (86505).

u Switch on lubricating oil supply to the turbocharger.

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6 Operation and service / 6.1 Noise emission

6 Operation and service

6.1 Noise emission

WARNING
Noise hazards
Exposure to noise can harm the hearing system, impair health and the psy-
chological state and may lead to lack of attention and irritation.
u When the engine is running, always wear ear protection.
u Always wear ear protection if the sound pressure level exceeds 85 dB(A).

Wear ear protection.

The emission sound pressure level (A-weighted) is measured at a distance of 1 meter from
the turbocharger.
The highest value of the emission sound pressure level1) reaches a maximum of 105 dB(A)
near the air inlet. The following prerequisites must be fulfilled with regard to the turbochar-

Page 51 / 198
ger to observe this limit value:
¡ Air-inlet system has been fitted
¡ All standard, noise-reducing measures2) have been fitted
¡ Bellows at the air outlet has been acoustically insulated by the enginebuilder (see Fig. 27:
Noise insulation, bellows →52).
The enginebuilder is responsible for insulating the charge air/scavenging air line and the
charge air cooler.
1) Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 :
A-weighted emission sound pressure level
2) The enginebuilder must provide acoustically equivalent measures in case of deviating in-
sulation versions

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6 Operation and service / 6.1 Noise emission

Suggestion for noise insulation, bellows

Fig. 27: Noise insulation, bellows

01 Compressor casing
02 Bellows
Page 52 / 198

03 Charge air duct / scavenging air duct

04 Insulation cushion
05 Insulation mat (at least 15 mm)
06 Sheet metal cover

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6 Operation and service / 6.2 Service work

6.2 Service work

Service work includes visual controls, monitoring, measuring and inspection as well as func-
tional checks. Service work enables the detection and rectification of changes to the tur-
bocharger and ensures full operability of the turbocharger.

CAUTION
Service intervals
Any service work on the turbocharger that is omitted or performed too late
can cause excessive contamination, wear and operating failures.
u Carry out the service work at the specified time intervals.

CAUTION
Specific service interval
Exceptional stresses such as a high number of starts and stops, harsh envir-
onmental conditions, poor fuel quality or high system vibrations can lead to
untimely machine damage even if the prescribed service intervals are ob-
served.
u Agree on a specific service interval with Turbo Systems.

Page 53 / 198
To prevent machine damage caused by ageing and downtime, we recommend having an in-
spection carried out by a Turbo Systems service station no later than 5 years after the last
service.

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6 Operation and service / 6.2 Service work

6.2.1 Service work every 25 … 50 hours

CAUTION
Unknown operational changes

m
Impairment to the degree of a possible operating failure can be the con-
sequence.
u Have any unknown causes clarified by a Turbo Systems service station.

.co
u Perform a visual control for air, exhaust gas, and oil leaks

u Record operating data and enter it in the engine logbook

u In case of deviations, determine the cause.

6.2.2
ox
Service work at 100 hours after commissioning
u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en-
gine is stopped, in accordance with the instructions of the enginebuilder.
sb
6.2.3 Service work according to instructions of enginebuilder
Page 54 / 198

u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en-
gine is stopped, in accordance with the instructions of the enginebuilder.
ide

6.2.4 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 a Turbo Systems service sta-
tion. The following work can be carried out as preparation.
-gu

u Remove turbocharger from engine, dismantle and measure clearances (see Dismantling
and fitting, general →89).
u Clean nozzle ring, turbine casing, compressor casing and diffuser, and check for cracks
and erosion/corrosion.
all

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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:
¡ Rating and speed of the engine
¡ Air intake temperature
¡ Pressure of the charge air
¡ Pressure loss in the charge-air cooler
¡ Lubricating oil pressure and lubricating oil temperature
If present:
¡ Speed of the turbocharger
¡ Air temperature after the compressor and after the charge-air cooler
¡ Exhaust gas temperature before and after the turbine
¡ Pressure loss in the filter silencer.

Page 55 / 198

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6 Operation and service / 6.3 Expected replacement intervals

6.3 Expected replacement intervals

Rotating components
The recommended replacement intervals of the compressor and turbine wheels are spe-
cified with the aid of the safety concept for rotating parts (SIKO) and dependent on the op-
erating conditions. These intervals are shown on the rating plate of the turbocharger.

Non-rotating components
Depending on the system-specific operating conditions, a differentiation must be made
between the intervals to be expected for:
¡ replacing the bearing parts and
¡ replacing the non-rotating components exposed to hot gas.
A decisive role is played by various influencing parameters which, in extreme cases, can sig-
nificantly reduce the replacement interval of these parts.
During the prescribed periodic service work, the individual parts are examined for wear and
replaced if necessary.
Page 56 / 198

Expected replacement intervals [h]

GAS / MDO HFO
Turbine casing 25000 … 50000 25000 … 50000
Nozzle ring 25000 … 50000 10000 … 25000
Gas outlet flange 25000 … 50000 25000
Heat shield 25000 … 50000 25000
Rotor components See information on rating plate
Bearing parts 12000 … 32000 12000 … 24000
Other casings 50000 50000
Table 11: Expected replacement intervals

GAS = Natural Gas

MDO = Marine Diesel Oil
HFO = Heavy Fuel Oil

The specified values are guideline values and not guaranteed values, see Influencing para-
meters.

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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:
¡ Fuel quality and fuel treatment
¡ Load profile (thermal cycling, also number of starts/stops, emergency shutdowns, oper-
ating point)
¡ Gas inlet temperature
¡ Frequency and execution of cleaning process during operation
¡ Turbocharger specification.
¡ System-specific operating conditions (combustion quality, exhaust gas composition)

For bearing parts

¡ Lubricating oil quality (oil filtering, oil condition, oil monitoring)
¡ Load profile (speed, pressure conditions, temperature)
¡ Number of starts/stops
¡ Unbalance of the rotor (degree of contamination).

Page 57 / 198

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6 Operation and service / 6.4 Stopping the engine

6.4 Stopping the engine

CAUTION
Residual heat in the turbocharger
If the residual heat in the turbocharger is not adequately dissipated, it may
damage the engine.
u Adequate cooling of the turbocharger must be ensured after stopping
the engine.

u Run the engine for 2 … 10 minutes at idling speed before stopping it.

u Observe the oil pressure specified for engine idling (see Table 7: Lubricating oil pressure
at oil inlet before turbocharger →45).
¡ For oil-cooled bearing casings, post-lubricate for 20 minutes if the turbine inlet temper-
ature (tTE) exceeds the following values when the engine is stopped:
– 550 °C with insulated casing
– 600 °C with non-insulated casing

At temperatures below the specified values, post-lubrication must be ensured until the
rotors come to a standstill. Turbo Systems recommends post-lubrication for 10 minutes.
Page 58 / 198

u Observe the oil pressure specified for post-lubrication (see Table 7: Lubricating oil pres-
sure at oil inlet before turbocharger →45).

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7 Periodic maintenance work / 7.1 Foreword to maintenance

7 Periodic maintenance work

7.1 Foreword to maintenance

m
Maintenance work includes regular visual controls and cleaning operations which are inten-
ded to ensure the trouble-free functioning of the turbocharger.

.co
To allow you to observe the standard service intervals and to maintain a high turbocharger
efficiency, Turbo Systems recommends that the cleaning procedure be carried out during
operation. This allows the thermal load of the engine to be kept low while ensuring max-
imum fuel efficiency.

Maintenance inter- Maintenance work Operating status

val
24 … 72 h 1)

50 … 200 h 1)

According to rating
plate 2)
→60
ox
Cleaning the compressor during operation

Cleaning the turbine during operation →63

Cleaning components mechanically →67

Engine load 50 … 85 %

Engine load 20 … 40 %
(guideline value)
Engine stopped
sb
12000 h Uncoupled filter silencer A155-M Engine stopped

Page 59 / 198
Changing the absorption element →80
Table 12: Maintenance table

[h] = Hours of operation

ide

1)
If the maintenance intervals are incompatible with operation of the engine, contact Turbo
Systems.
2)
Turbo Systems recommends having mechanical cleaning carried out by a Turbo Systems
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
-gu

engine.
all

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7 Periodic maintenance work / 7.2 Cleaning the compressor during op-
eration

7.2 Cleaning the compressor during operation

7.2.1 Introduction

Approval by enginebuilder
The following instructions for wet cleaning only apply to cleaning with pure water and under
the precondition that the enginebuilder approves the process.

Options and limits

Periodic cleaning during operation delays any major increase in contamination. The cleaning
method is suitable as long as the contamination has not progressed far. Very heavily con-
taminated components can no longer be cleaned using this method. In this case, Turbo Sys-
tems recommends mechanical cleaning of the contaminated components.
Periodic cleaning during operation is not a substitute for the service work during which the
turbocharger is completely dismantled and cleaned.

Cause and consequences of contamination

Page 60 / 198

The contamination of the compressor stage depends on the degree of purity of the air that
is sucked in. Deposits can form in the flow channels if salt, oil mist, exhaust gas or dust are
sucked in with the air.
Consequences of contamination:
¡ Impaired compressor efficiency
¡ Elevated exhaust gas temperatures
¡ Increased fuel consumption
¡ Increased rotor unbalance

7.2.2 Cleaning interval

The time period between the periodical cleaning cycles depends greatly on the operating
conditions. Cleaning should normally be carried out every 24 … 72 hours of operation.
If the specified cleaning intervals are incompatible with operation of the engine, contact
Turbo Systems.

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7 Periodic maintenance work / 7.2 Cleaning the compressor during op-
eration

7.2.3 Cleaning method

Cleaning method and operating state

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 Turbo Systems.

V-engines
On V-engines with several turbochargers per engine, parallel cleaning of both turbochargers
is recommended. This cleaning process is faster and reduces the risk of surging of the tur-
bocharger.

Sequential charging
With sequential charging, it must be made sure especially after operating periods in the
lower range of performance that both turbocharger compressors are cleaned.

7.2.4 Function and safety of wet cleaning

Page 61 / 198
CAUTION
Volume of water
Uncontrolled volumes of water can damage the turbocharger and the en-
gine.
u Never connect the water connection directly to a water pipe or a bigger
metering container than the one specified by Turbo Systems.

WARNING
Danger due to pressure vessels
Personal injury can occur if the locally applicable legal regulations on peri-
odic inspections of the pressure vessels are not complied with.
u The locally applicable legal regulations regarding periodic checks of the
pressure vessels must be observed.
u Do not use pressure vessels that are defective.

CAUTION
Corrosion and deposits when cleaning
Salt water and cooling water treatment substances damage and adversely
affect turbocharger parts.
u Never use salt water, but only pure water for cleaning.

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7 Periodic maintenance work / 7.2 Cleaning the compressor during op-
eration

72000 Compressor casing

27000 External water pressure vessel
27005 Sealing plug
01 Water pipe to filter silencer or air suction branch
02 Pressurized air inlet pipe
03 Valve activator

Pressurized air from the compressor casing (72000) of the turbocharger passes through the
pipe (02) to the water pressure vessel (27000). As soon as the valve activator (03) is activ-
ated, water is pressed into the pipe (01) and routed to the filter silencer or air suction
branch.
The water does not act as a solvent. The coating is removed by the mechanical action of the
impacting droplets.

7.2.5 Carrying out wet cleaning of the compressor

Page 62 / 198

Fig. 28: Carrying out wet cleaning of compressor

Engine load Filling amount of water pressure Water temperature Water injection
vessel [dm3] [°C] period [s]
50 … 85 % 0.4 5 … 30 10
Table 13: Parameters for wet cleaning of compressor

u Remove sealing plug (27005).

u Fill container with 0.4 dm3 of pure water.

u Screw in sealing plug (27005) again.

u Push the valve activator (03) against the spring and hold for 10 … 15 seconds until the en-
tire volume of water is injected.
u Continue to operate the engine for at least five minutes to ensure that all of the water is
flushed out of the system.
Not more than three cleaning cycles should be conducted consecutively. Before repeating
the process, continue to operate the engine for at least five minutes to ensure that all of the
water is flushed out of the system.

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7 Periodic maintenance work / 7.3 Cleaning the turbine during opera-
tion

7.3 Cleaning the turbine during operation

7.3.1 Introduction

Approval by enginebuilder
The following instructions for wet cleaning only apply to cleaning with pure water and under
the precondition that the enginebuilder approves the process.

Options and limits

Periodic cleaning during operation delays any major increase in contamination. The cleaning
method is suitable as long as the contamination has not progressed far. Very heavily con-
taminated components can no longer be cleaned using this method. In this case, Turbo Sys-
tems recommends mechanical cleaning of the contaminated components.
Periodic cleaning during operation is not a substitute for the service work during which the
turbocharger is completely dismantled and cleaned.

Cause and consequences of contamination

Page 63 / 198
Turbo Systems recommends the use of fuels with low ash, sulphur, sodium and vanadium
contents.
The combustion of heavy fuel oil (HFO) in diesel engines causes contamination of the tur-
bine stage. Poor quality fuel in conjunction with high exhaust gas temperatures can lead to
extremely hard deposits on turbine components. Operating states with incomplete combus-
tion also increase the tendency to form deposits and must be avoided.
Consequences of contamination:
¡ Low turbine efficiency
¡ Elevated exhaust gas temperatures
¡ Increased charging and ignition pressures with increasing turbocharger speed
¡ Lower engine performance.
Possible damage to turbocharger:
¡ After the engine is stopped the rotor may become stuck in contamination deposits.
¡ Damage to turbine heads with blade breaks.

7.3.2 Cleaning interval

The time period between the periodical cleaning cycles depends greatly on the operating
conditions. Cleaning should normally be carried out every 50 to 200 hours of operation.
If the specified cleaning intervals are incompatible with operation of the engine, contact
Turbo Systems.

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7 Periodic maintenance work / 7.3 Cleaning the turbine during opera-
tion

7.3.3 Cleaning method

The turbine components are cleaned during operation using the wet cleaning method. This
cleaning method is tested and approved by Turbo Systems.

m
The precondition for wet cleaning is that the enginebuilder approves the process and these
regulations are observed.

.co
V-engines
On V-engines with several turbochargers per engine, parallel cleaning of both turbochargers
is recommended. This cleaning process is faster and reduces the risk of surging of the tur-
bocharger.

7.3.4 Function and safety of wet cleaning

CAUTION ox
Corrosion and deposits when cleaning
Salt water and cooling water treatment substances damage and adversely
sb
affect turbocharger parts.
Page 64 / 198

u Never use salt water, but only pure water for cleaning.

To clean the turbine stage during operation, water is injected before the nozzle ring. Based
on an injection phase of 10 minutes, this cleaning procedure uses the principle of water solu-
ide

bility of dirt deposits.

To prevent corrosion of the inside surfaces of the casings, the engine must be continued to
be operated for 10 minutes after a wet cleaning. The exhaust gas temperature downstream
of the turbocharger can drop by up to 180 °C during cleaning.
-gu
all

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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.
2. Device consisting of six cleaning nozzles with connecting pipe for water and scavenging
air.
Characteristic/component Conditions

Page 65 / 198
Cleaning device one cleaning nozzle per six cleaning nozzles
gas inlet
Engine load (guideline value) 20 … 40 %
1
) Turbine inlet temperature TTE before 350 … 430 °C
water injection
Stabilisation phase after TTE has been 10 minutes
reached
Stabilisation phase after turbine clean- 10 minutes
ing
Water supply ensured
Water temperature 5 … 30 °C
Water pressure (overpressure compared 1.5 bar 2.5 bar
to atmosphere) pWT
2
) External air supply recommended recommended
External air pressure pPA relative to tur- PPA = PTE + 0.5 bar PPA = PTE + 1 bar
bine inlet pressure PTE
Table 14: Turbine wet cleaning, recommended operating state

1
) The temperature at the turbine inlet can be up to 100 °C higher than the exhaust gas tem-
perature after the cylinder. This must be taken into account when setting the operating
point before cleaning.
If necessary, the engine performance must be reduced to meet these conditions. The clean-
ing cycle can be started when the above conditions are fulfilled.
2
) External air supply for continuous blowing off of the cleaning nozzles between cleaning in-
tervals.

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7 Periodic maintenance work / 7.3 Cleaning the turbine during opera-
tion

7.3.6 Carrying out wet cleaning of the turbine

CAUTION
Inadmissible thermal stress and flooding of the turbine
Smaller amounts of water can lead to an inadequate cleaning result. Larger
amounts of water lead to inadmissible thermal stress on the turbine com-
ponents and can cause flooding of the turbine.
u It is imperative that turbine cleaning parameters are observed.

CAUTION
Maximum temperature at turbine inlet during cleaning
During cleaning, the temperature at the turbine inlet will rise and may strain
the material significantly.
u Make sure the maximum temperature at the turbine inlet is not exceeded
during cleaning.
Page 66 / 198

Fig. 30: Carrying out wet cleaning of turbine

u Fulfil prerequisites.

u Ensure that there is a supply of water (01).

u Open the stop valve (02) and set the water volume flow VW with a flowmeter (03) (see
cleaning parameters).
u Close the stop valve (02) after 10 minutes.

u Wait for 10 minutes; do not change the load during this stabilisation phase.

If the cleaning result is unsatisfactory or there is water leakage, contact a Turbo Systems
service station.

Parameter for 1-nozzle cleaning

Product Temperature be- Maximum temperature Water volume flow Injection time
fore turbine before before turbine during VW [dm3/min] 1) [min]
cleaning [°C] cleaning [°C]
A150 350 ... 430 530 14.0 10
A155 350 ... 430 530 19.0 10
Table 15: Wet cleaning of turbines, parameters for 1-nozzle cleaning

1)
Corresponds to a water pressure pWT of 1.5 bar (overpressure compared to atmosphere)
before the cleaning nozzle

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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 VW [dm3/min] 1) [min]
cleaning [°C] cleaning [°C]
A150 350 ... 430 530 18.0 10
A155 350 ... 430 530 25.0 10
Table 16: Wet cleaning of turbines, parameters for 6-nozzle cleaning

1)
Corresponds to a water pressure pWT of 2.5 bar (overpressure compared to atmosphere) at
the connection point WA/WG

7.4 Cleaning components mechanically

7.4.1 Preparation

CAUTION
Component damage and corrosion
If mechanical cleaning is carried out incorrectly, this can lead to damage and

Page 67 / 198
corrosion on the components.
u Pay attention to the specifications in this chapter pertaining to mechan-
ical cleaning.

CAUTION
Selection of cleaning tools
Turbocharger components are sensitive and easily sustain mechanical dam-
age. The use of needle descalers (for example) or other striking tools dam-
ages the components. Depending on the specification, nozzle rings or tur-
bine casings may have protective coatings which can also be damaged.
u Use only soft tools such as rags, brushes or wire brushes.
u In case of heavy contamination, the cleaning methods described in this
chapter (such as soaking, for example) can be repeated until a satisfact-
ory result is achieved.

The disassembly and assembly of the components is described in chapter Fitting and dis-
mantling.
u Contaminated water and cleaning agents must be disposed of in an environmentally
compatible, professional way and in compliance with locally applicable regulations.

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7 Periodic maintenance work / 7.4 Cleaning components mechanically

7.4.2 Cleaning the filter silencer

¡ Variant: Filter silencer with tension band →68
¡ Variant: Filter silencer with connecting rod →70 (only A155-M)

7.4.2.1 Variant: Filter silencer with tension band

Page 68 / 198

Fig. 31: Cleaning the filter silencer

81135 Filter silencer body 81266 Cover grid

81136 Absorption segment 81270 Tension band
81137 Sheet-metal covering 81271 Lock
81265 Filter ring

If present: Clean the filter ring (81265)

u Remove the filter ring.

u Clean the filter ring as required or every 500 hours of operation, and replace it after the
fifth cleaning process at the latest.
Contamination of the filter ring depends on the degree of purity of the sucked-in air.
u Rinse the filter ring with water and mild detergent or, in the case of heavy contamination,
soak and carefully push through. Rinse in cold water. Avoid high mechanical loads (water
jet).
u Let the filter ring dry completely before assembling.

u Dirty water and mild detergent must be disposed of in compliance with locally applicable
regulations.

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7 Periodic maintenance work / 7.4 Cleaning components mechanically

(see Fig. 31: Cleaning the filter silencer →68)

Dismantling and cleaning the cover grid (81266)

m
u Loosen the tension bands (81270).

u Remove and clean cover grid (81266).

.co
Cleaning the absorption segments (81136)
u Pull out and bend up the sheet-metal coverings (81137), and remove the absorption seg-
ments (81136).
u Clean the absorption segments.
When cleaning, note that the absorption segments may only be cleaned lightly with pres-
surized air, a soft brush or a moist cleaning cloth.

station.

Fitting the filter silencer

ox
u Have any heavily contaminated absorption segment replaced by a Turbo Systems service
sb
u Insert the absorption segments (81136) into the sheet-metal coverings (81137).

Page 69 / 198
u Bend the sheet-metal coverings (81137) back to their original shape and insert into the
slotted guides in the filter silencer body (81135).
u Fit the cover grid (81266).
ide

u Fit the tension bands (81270) and tighten them at the locks (81271).
Any tension bands that have become damaged must be replaced.
u Fit the filter ring (81265), if present.
-gu
all

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7 Periodic maintenance work / 7.4 Cleaning components mechanically

7.4.2.2 Variant: Filter silencer with connecting rod

Fig. 32: Cleaning the filter silencer

Page 70 / 198

81135 Filter silencer body 81266 Cover grid

81136 Absorption segment 81269 Connecting rods
81137 Sheet-metal covering 81272 Screw
81265 Filter ring (if present) 81273 Lock nut

If present: Clean the filter ring (81265)

u Remove the filter ring.

u Clean the filter ring as required or every 500 hours of operation, and replace it after the
fifth cleaning process at the latest.
Contamination of the filter ring depends on the degree of purity of the sucked-in air.
u Rinse the filter ring with water and mild detergent or, in the case of heavy contamination,
soak and carefully push through. Rinse in cold water. Avoid high mechanical loads (water
jet).
u Let the filter ring dry completely before assembling.

u Dirty water and mild detergent must be disposed of in compliance with locally applicable
regulations.

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7 Periodic maintenance work / 7.4 Cleaning components mechanically

(see Fig. 32: Cleaning the filter silencer →70)

Dismantling and cleaning the cover grid (81266)

u Loosen and remove lock nuts (81273).

u Loosen and remove screws (81272) to the connecting rods (81269).

Have damaged connecting rods replaced by a Turbo Systems service station.
u Remove connecting rods (81269).

u Remove and clean cover grid (81266).

Cleaning the absorption segments (81136)

u Pull out and bend up the sheet-metal coverings (81137), and remove the absorption seg-
ments (81136).
u Clean the absorption segments.
When cleaning, note that the absorption segments may only be cleaned lightly with pres-
surized air, a soft brush or a moist cleaning cloth.
u Have any heavily contaminated absorption segment replaced by a Turbo Systems service
station.

Page 71 / 198
Fitting the filter silencer
u Insert the absorption segments (81136) into the sheet-metal coverings (81137).

u Bend the sheet-metal coverings (81137) back to their original shape and insert into the
slotted guides in the filter silencer body (81135).
u If the cleaning container is present on the filter silencer: Reinstall the water injection pipe.

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7 Periodic maintenance work / 7.4 Cleaning components mechanically

CAUTION
Penetration of dirt and foreign particles
Any penetration of dirt and foreign particles into the compressor can dam-
age it.
u Fit the connecting rods (81269) correctly in the slots on the filter silencer
body (81135).
u It must not be possible to rotate or move the cover grid (81266) after as-
sembly.
u Check the position and alignment of the connecting rods during and after
assembly.
Page 72 / 198

Fig. 33: Cleaning the filter silencer (2)

u Place cover grids (81266) evenly and in the correct position.

u Push connecting rods (81269) through the lugs of the cover grids (81266).

u Connect the connecting rods (81269) with the screws (81272). When tightening the
screws (81272), make sure that the flattened ends of the connecting rods (81269) are cor-
rectly positioned on the edge of the filter silencer body (81135).
u Tighten screws (81272) alternately and evenly. Observe tightening torque

Screw Tightening torque [Nm]

81272 20
Table 17: Tightening torque (81272)

u Fit the lock nuts (81273) on the screw (81272). Observe tightening torque.

Lock nut Tightening torque [Nm]

81273 40
Table 18: Tightening torque (81273)

u If present: Fit the filter ring (81265) (see Fig. 32: Cleaning the filter silencer →70).

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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.
u Do not breathe in these substances and avoid contact with the skin.
u Ensure proper ventilation.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Wear personal protective equipment (PPE) according to the material
safety data sheet.
u Comply with local legislation.

Wear safety goggles.

Wear safety gloves to protect against chemical hazards.

Wear a respiratory mask to protect against gases.

Page 73 / 198
The following parts, which are relevant in terms of performance, can be cleaned in accord-
ance with the description below.

Fig. 34: Compressor-end, non-rotating parts

72000 Compressor casing

77000 Wall insert
79000 Diffuser
u Clean the above-mentioned components with steam or ultrasound. Alternatively, soak in
diesel oil or water containing household cleaning agent. After soaking, remove contamin-
ation with a brush.
u Dry components completely.

u Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the tur-
bocharger.
u Dispose of contaminated water and cleaning agents in accordance with the information
in the material safety data sheet.

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7 Periodic maintenance work / 7.4 Cleaning components mechanically

7.4.4 Turbine-end, non-rotating parts

WARNING
Handling operating materials and supplies

m
Swallowing or inhaling vapours of operating materials and supplies or con-
tact with them may be harmful to health.
u Do not breathe in these substances and avoid contact with the skin.

.co
u Ensure proper ventilation.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Wear personal protective equipment (PPE) according to the material
safety data sheet.
u Comply with local legislation.

Wear safety goggles. ox

Wear safety gloves to protect against chemical hazards.
sb
Page 74 / 198

Wear a respiratory mask to protect against gases.

Baked layers of contamination from heavy fuel oil or coked oil, for example, occur at the tur-
ide

bine end. The following parts, which are relevant in terms of performance, can be cleaned in
accordance with the description below.
-gu

Fig. 35: Turbine end, non-rotating parts

all

51000 Turbine casing 51301 Cleaning nozzle (optional)

57002 Gas outlet flange 01 Water pipe (provided by the customer)
56001 Nozzle ring 02 Screw connection (provided by the cus-
tomer)
56005 Lamellar sealing ring
u Dismantle the lamellar sealing ring (56005) in the nozzle ring.

u Place contaminated parts in hot water or in a liquid such as brake cleaner to soften the
contamination.
u Brush away the contamination or remove with a steam cleaner.

u Repeat the soaking and brushing process if necessary.

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7 Periodic maintenance work / 7.4 Cleaning components mechanically

u Use clean water to remove all traces of solvent from parts.

u Dry components completely.

u Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the tur-
bocharger.
u Dispose of contaminated water and cleaning agents in accordance with the information
in the safety data sheet.
Option with cleaning nozzle

CAUTION
Turbocharger damage resulting from the cleaning nozzle breaking off
Incorrect assembly of the cleaning nozzle (51301) can damage the thread of
the turbine casing. The cleaning nozzle (51301) can be plastically deformed
when screwing in the screw connection (02) and during subsequent opera-
tion. Reuse of the cleaning nozzle after loosening the screw connection (02)
can lead to a water leak or the cleaning nozzle breaking off and thus destroy
the turbine.
u Only loosen the screw connection (02) if the cleaning nozzle (51301) needs
to be replaced.
u If the screw connection (02) has been loosened, a new cleaning

Page 75 / 198
nozzle (51301) must be installed and the screw connection must be refit-
ted. Observe the specified tightening torque from the supplier of the
screw connection.

Water or air can be passed through the piping and into the cleaning nozzle to check whether
it is blocked. When installed, the cleaning nozzle can be mechanically cleaned with a needle.
Option with 6-nozzle cleaning
See Removing and installing 6-nozzle turbine cleaning component (optional) →162.

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.
u Immediately after cleaning, install the cartridge group and put it back
into operation.

Compressor wheels can be heavily contaminated due to poorly filtered suction air; turbines
can be heavily contaminated due to exhaust gas residues or coked oil. Cleaning during oper-
ation may not suffice to remove such contamination; instead, it may need to be cleaned
mechanically during standard service intervals (see chapter Service work).
u Remove the turbocharger from the engine (see chapter Removing and Installing →29).

u Remove the cartridge group (see chapter Dismantling and fitting, general →89).

First clean the compressor end and then the turbine end according to the following descrip-
tion.

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7 Periodic maintenance work / 7.4 Cleaning components mechanically

7.4.6 Cleaning the cartridge group on compressor end

CAUTION
Selection of the cleaning agent
Cleaning agents that contain chlorine corrode metals.
u Only use pH-neutral cleaning agents that do not corrode metals.
u Observe the material safety data sheet.
u Observe country-specific regulations regarding banned and restricted
substances.

CAUTION
Water and contamination in the cartridge group
If water or contamination penetrates the cartridge group, this can impair
the function of the turbocharger and damage parts inside the cartridge
group.
u Make sure that no water or contamination can enter into the cartridge
group.
Page 76 / 198

u Cleaning procedures should be selected that do not result in removal of the compressor
wheel material or cause damage to its surfaces. Clean the compressor wheel with a rag or
soft brush which has been soaked in water with a household cleaning agent. Do not use a
wire brush!
u Dry the compressor wheel and the gap between the compressor and the bearing casing
with low-pressure pressurized air.
u Lightly spray the compressor wheel and the gap between the compressor and the bearing
casing with penetrating oil.
u Dispose of dirty water and cleaning agents in accordance with the material safety data
sheet.

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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. The procedure for soaking the lay-
ers of contamination as well as for cleaning the turbine are described in the following.

Page 77 / 198
Fig. 36: Soaking the turbine end

Product A [mm] B [mm] C [mm]

A150 200 35 382
A155 240 40 454
Table 19: Value table for soaking

To soak the layers of contamination on the turbine, the cartridge group can be immersed
vertically in a container (02) with fluid.
u Place the container (02) inside a larger container (03) so that the overflowing fluid can be
collected.

CAUTION
Selection of the cleaning agent
Cleaning agents that contain chlorine corrode metals.
u Only use pH-neutral cleaning agents that do not corrode metals.
u Observe the material safety data sheet.
u Observe country-specific regulations regarding banned and restricted
substances.

u Fill the container (02) with soaking fluid. To shorten the soaking time, the fluid can be
heated up to a maximum of 60 ºC.

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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.
u Observe the information in the material safety data sheet.

Wear a respiratory mask according to material safety data sheet.

CAUTION
Water and contamination in the cartridge group
If water or contamination penetrates the cartridge group, this can impair
the function of the turbocharger and damage parts inside the cartridge
group.
u Place the cartridge group on suitable supports (01) made of wood or
metal.
u Observe dimension (B) for the supports (01) so that the cartridge group
is not immersed too deeply.
Page 78 / 198

u Let the layers of contamination on the turbine soak for four hours.

Removing contamination

WARNING
Health hazard due to soot particles
If soot particles enter the eyes or respiratory tract, this can be harmful to
health.
u Avoid the formation of dust.
u Vacuum up dust with a suitable vacuum cleaner.
u Wear a respiratory mask to protect against particles (P1 or P2 mask).
u Wear safety goggles.

Wear safety goggles.

Wear a respiratory mask to protect against dusts.

Wear safety gloves to protect against mechanical hazards.

u Lift up the cartridge group and align it horizontally.

u Remove contamination manually using a soft brush or a wire brush.

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7 Periodic maintenance work / 7.4 Cleaning components mechanically

CAUTION
Water and contamination in the cartridge group
If water or contamination penetrates the cartridge group, this can impair

m
the function of the turbocharger and damage parts inside the cartridge
group.
u Make sure that no water or contamination enters the gap between the
heat sheet metal and the turbine.

.co
CAUTION
Non-permissible rotor unbalance after cleaning
Unevenly distributed residual contamination deposits lead to rotor unbal-
ance. This can result in bearing or turbocharger damage.

ox
u Remove all traces of contamination from the turbine.

u After brushing off the contamination, fill the container (02) with clean water.

u Immerse the turbine of the cartridge group in clean water so that any loose contamina-
tion comes off.
sb
u Lift up the cartridge group and align it horizontally.

Page 79 / 198
u Dry the turbine and the gap between the turbine and the heat sheet metal with low-pres-
sure pressurized air.
u Lightly spray the turbine and the gap between the turbine and the heat sheet metal with
ide

penetrating oil.
u Dispose of contaminated water and cleaning agents in accordance with the information
in the safety data sheet.
-gu
all

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7 Periodic maintenance work / 7.5 Changing the absorption element

7.5 Changing the absorption element

The absorption element (81148) in uncoupled filter silencers must be replaced every 12000
hours of operation.

Disassembling the absorption element

Page 80 / 198

Fig. 37: Disassembling the absorption element

1. Remove the filter silencer (see Fig. 49: Removing the uncoupled filter silencer →100).
2. Dismantle the hexagon-head screws (81152) with washers (81153) and mounting
plate (81149).
3. Remove the socket screws (81154), roll pins (81151), flanges (81145 / 81146) and absorp-
tion element (81148).

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7 Periodic maintenance work / 7.5 Changing the absorption element

Installing the absorption element

Fig. 38: Installing the absorption element

Page 81 / 198
Product 81152 [Nm] 81154 [Nm]
A155-M 50 10
Table 20: Tightening torque (81152 / 81154)

1. Fit the new absorption element (81148) and flanges (81145 / 81146) with roll pins (81151)
and socket screws (81154).
Tighten socket screws (81154) crosswise. Observe the tightening torque.
2. Check value X = 15 mm +/- 0.1 mm along the circumference at four points (0°, 90°, 180°
and 270°).
If value X is not satisfied, unscrew the socket screws (81154) and repeat step one.
3. Fit the mounting plate (81149) with washers (81153) and hexagon-head screws (81152).
Observe the tightening torque.
4. Remove the filter silencer (see Fig. 84: Installing the uncoupled filter silencer (see
Table 57: Tightening torque (72054) →133).

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8 Eliminating malfunctions / 8.1 Malfunctions when starting

8 Eliminating malfunctions

8.1 Malfunctions when starting

Delayed start-up
Possible causes Remedy
Turbochar- Turbocharger contaminated Clean (see chapter Periodic mainten-
ger ance work →59)
Bearing damaged Contact a Turbo Systems service sta-
Rotor rubbing tion
Foreign object in the turbocharger
Table 21: Malfunctions when starting – Delayed start-up

Vibrations
Possible causes Remedy
Turbochar- Rotor unbalance Contact a Turbo Systems service sta-
ger Turbine or compressor damaged tion
Page 82 / 198

Bearing damaged
Engine Vibrations from engine Contact enginebuilder
Table 22: Malfunctions when starting – Vibrations

Rubbing of rotating parts

Normal behaviour, not a malfunction
Turbochar- A slight amount of uniform wear at the circumference of the rotor components
ger caused by slight local rubbing against adjacent components is permitted. This
causes the compressor or turbine blades to be somewhat shortened. To prevent
significant loss of efficiency, specific tolerances must be fulfilled.
¡ If there is any doubt about the extent of the rubbing, contact a Turbo Sys-
tems service station.
¡ Have a dimension check carried out by a Turbo Systems service station.
Table 23: Malfunctions when starting – Rubbing of rotating parts

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8 Eliminating malfunctions / 8.2 Malfunctions during operation

8.2 Malfunctions during operation

Lubricating oil pressure too low

WARNING
Danger of fire and explosion due to lubricating oil leaks
Leaking oil may ignite on hot surfaces. This can result in serious injuries to
personnel or fatal accidents.
u Cordon off danger area.
u Raise the alarm and, depending on the situation, stop the engine.
u Seal the oil leak.
u Soak up oil and dispose of in an environmentally compatible manner.

Wear safety gloves to protect against thermal hazards.

Possible causes Remedy

Turbochar- Axial clearance of the rotor excessive Contact a Turbo Systems service sta-
ger tion

Page 83 / 198
Engine Oil filter heavily contaminated Clean
Oil pump in lubricating system defect- Check/replace
ive
Manometer displays incorrectly Replace manometer
Table 24: Malfunctions during operation – Lubricating oil pressure too low

Speed reduces
Possible causes Remedy
Turbochar- Turbine and/or nozzle ring severely con- Clean (see chapter Periodic mainten-
ger taminated ance work →59)
Rotor components or bearing damaged Contact a Turbo Systems service sta-
tion
Engine Defects on the connected cylinders in Contact enginebuilder
pulse charging
Pipes Defects, such as leaks, in the exhaust Repair
gas pipes or charge air ducts
Table 25: Malfunctions during operation – Speed reduces

Speed increases
Possible causes Remedy
Turbochar- Light to medium contamination of the Clean (see chapter Periodic mainten-
ger turbine and/or nozzle ring (with 4- ance work →59) or contact a Turbo Sys-
stroke application) tems service station
Table 26: Malfunctions during operation – Speed increases

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8 Eliminating malfunctions / 8.2 Malfunctions during operation

Exhaust gas temperature too high

Engine performance and engine speed unchanged

Possible causes Remedy

m
Turbocharger Insufficient air, for example, when fil- Clean (see chapter Periodic mainten-
ter silencer is blocked by contamina- ance work →59)
tion
Compressor/turbine contaminated

.co
Exhaust gas back pressure too high Clean or repair boiler or exhaust gas si-
lencer
Turbine damaged or eroded Contact a Turbo Systems service sta-
tion
Engine Malfunction in the injection system Repair or contact manufacturer
Charge air Cooler contaminated Clean
cooler Cooling water volume too low Fill

too high
Insufficient ventilationox
Inlet temperature of cooling water

Table 27: Malfunctions during operation – Exhaust gas temperature too high
Check/clean cooling system

Improve ventilation
sb
Charge air pressure too low
Page 84 / 198

Engine performance and engine speed unchanged, suction condition normal

Possible causes Remedy

ide

Turbochar- Manometer display not correct Replace manometer

ger Supply pipe to manometer not sealed Repair leak
Filter silencer contaminated, therefore Clean (see chapter Periodic mainten-
pressure drop too high ance work →59)
Compressor end and/or turbine end
contaminated
Compressor/turbine damaged Contact a Turbo Systems service sta-
-gu

tion
Exhaust gas back pressure too high Clean or repair boiler or exhaust gas si-
lencer
Engine Air receiver not sealed Repair
Gas piping between engine and turbine
not sealed
Injection mistimed Set correctly
Valve control misadjusted
all

Pipes Pipes downstream to the compressor Repair.

outlet not sealed.
Table 28: Malfunctions during operation – Charge air pressure too low

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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
ger Increased speed due to contamination Clean (see chapter Periodic mainten-
of nozzle ring ance work →59) or contact a Turbo Sys-
tems service station
Engine Malfunction in the injection system Repair or contact manufacturer
Injection mistimed Set correctly
Engine performance higher than indic- Check engine performance
ated
Table 29: Malfunctions during operation – Charge air pressure too high

Reduced compressor performance/efficiency and therefore engine performance

losses

CAUTION
Compressor damage
A severely contaminated or corroded compressor wheel can reduce the com-

Page 85 / 198
pressor wheel’s fatigue endurance limit and result in the turbocharger being
damaged.
u Rectify malfunction in accordance with the following table.

Possible causes Remedy

Turbochar- Compressor components severely con- Clean (see chapter Periodic mainten-
ger taminated by the ventilation gases that ance work →59)
have been fed in Optimize oil separation
Increased blade vibration, compressor Correct the feed of ventilation gases ac-
blade damage due to the ventilation cording to instructions of engineb-
gases that have been fed in uilder.
Material of the compressor wheel cor- Correct the feed of ventilation gases ac-
roded due to the feeding in of ventila- cording to instructions of engineb-
tion gases containing corrosive com- uilder.
ponents
Material of the compressor wheel cor- Prevent exhaust gas leakages in the en-
roded due to intake air containing ex- gine space
haust gases or salt Clean (see chapter Periodic mainten-
ance work →59)
Table 30: Malfunctions during operation – Engine performance losses

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Operation Manual / A150-M56/66/57/67 - A155-M..

8 Eliminating malfunctions / 8.3 Turbocharger is surging

8.3 Turbocharger is surging

WARNING
Hot air escapes from the air inlet
A surge blow is accompanied by a loud bang and escape of hot air from the
air inlet. This may result in injury to personnel.
u While the turbocharger is pumping, keep a distance from the air inlet.

Turbocharger surges continuously or periodically

CAUTION
Continuous or periodic surging
If the turbocharger surges continuously or periodically, parts of the tur-
bocharger may be damaged.
u Gradually reduce the engine load.
u Have the cause clarified and remedied immediately by a Turbo Systems
Page 86 / 198

service station.
u Have parts assessed for damage and, if necessary, replaced by a Turbo
Systems service station.

Possible causes Remedy

Turbocharger Filter silencer or diffuser contamin- Clean (see chapter Periodic mainten-
ated ance work →59)
Heavy contamination deposits in the
turbine or in the nozzle ring
Engine Protective grating in front of the tur- Clean/replace
bocharger contaminated or damaged
Charge air Cooler contaminated Clean
cooler Charge air duct blocked
Table 31: Malfunction – Turbocharger surging

Sporadic surge blows

Possible causes Remedy
Engine Engine load reduced quickly when --
manoeuvring.
When this happens, the flow direc-
tion in the compressor is momentar-
ily reversed. Such sporadic surge
blows do not impair the safe opera-
tion of the turbocharger.
Table 32: Malfunction – Sporadic surge blows

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Operation Manual / A150-M56/66/57/67 - A155-M..

8 Eliminating malfunctions / 8.4 Malfunctions when stopping

8.4 Malfunctions when stopping

Runout noises
Possible causes Remedy
Turbochar- Turbocharger contaminated Clean (see chapter Periodic maintenance work
ger →59)
Bearing damaged Check clearances (see chapter Measuring clear-
ance A and B →116). If clearances are outside the
tolerance or if in doubt, contact a Turbo Systems
service station.
Rotor rubbing Check clearances (see chapter Radial clearances N
and R →126). If clearances are outside the toler-
ance or if in doubt, contact a Turbo Systems ser-
vice station.
Foreign object in the tur- Dismantle the turbocharger (see chapter Fitting
bocharger and dismantling). In case of damage, replace the
corresponding parts or contact a Turbo Systems
service station.
Table 33: Malfunctions when stopping – Runout noises

Runout time too short

Page 87 / 198
The runout time must be noted down as a reference. Because the runout time depends on
the oil viscosity, the runout time must always be measured at the same oil temperature.
If the runout time is significantly shorter in comparison to a previous measurement, the fol-
lowing table must be observed.

Possible causes Remedy

Turbochar- Turbocharger contaminated Clean (see chapter Periodic maintenance work
ger →59)
Bearing damaged Check clearances (see chapter Measuring clear-
ance A and B →116). If clearances are outside the
tolerance or if in doubt, contact a Turbo Systems
service station.
Rotor rubbing Check clearances (see chapter Radial clearances N
and R →126). If clearances are outside the toler-
ance or if in doubt, contact a Turbo Systems ser-
vice station.
Foreign object in the tur- Dismantle the turbocharger (see chapter Fitting
bocharger and dismantling). In case of damage, replace the
corresponding parts or contact a Turbo Systems
service station.
Table 34: Malfunctions when stopping – Runout time too short

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Operation Manual / A150-M56/66/57/67 - A155-M..

8 Eliminating malfunctions / 8.5 Speed measurement system

8.5 Speed measurement system

No signal or poor signal amplitude of the speed measurement

Possible causes Remedy
Turbochar- The speed sensor was acci- The screw plug for the sensor is fitted with an ad-
ger dentally fitted with an addi- ditional gasket (copper ring).
tional gasket. For information regarding the disassembly and as-
An enlarged distance sembly of the speed sensor, refer to chapter Re-
between the sensor tip and placing the speed sensor →50.
the signal-emitting sealing Install the speed sensor without the additional
disc reduces the voltage gasket (copper ring).
amplitude of the speed sig-
nal.
Sensor or cable defective Contact a Turbo Systems service station.
Order a new speed sensor (86505) from a Turbo
Systems service station.
Replacing the speed sensor →50.
Table 35: Malfunction of the speed measurement system – No signal or poor signal amplitude

Measured speed too high

Possible causes Remedy
Page 88 / 198

Turbochar- Sensor tip contaminated, For information regarding the disassembly and as-
ger since it is magnetic and can sembly of the speed sensor, refer to chapter Re-
attract metallic particles. placing the speed sensor →50.
This reduces the distance to Dismantle the sensor, clean the sensor tip, and fit
the signal-emitting sealing the sensor back on with the specified tightening
disc, which can lead to ampli- torque.
fication of the noise com-
ponent and therefore to false
triggering.
Table 36: Malfunction of the speed measurement system – Measured speed too high

Measured speed too low

Possible causes Remedy
Turbochar- -- Contact a Turbo Systems service station
ger
Table 37: 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 a Turbo Systems service station.

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Operation Manual / A150-M56/66/57/67 - A155-M..

9 Dismantling and fitting, general / 9.1 Introduction

9 Dismantling and fitting, general

9.1 Introduction

m
WARNING
Danger of burns

.co
Touching hot surfaces or contact with hot operating fluids can cause burns.
u Do not touch hot surfaces. Observe the warning plate on the turbochar-
ger.
u Wear heat-resistant safety gloves and protective clothing.
u Wait for the turbocharger to cool down before carrying out any work.

ox
Wear safety gloves to protect against thermal hazards.

WARNING
sb
Cutting injuries when working on the turbocharger

Page 89 / 198
Some parts on the turbocharger may have sharp edges. There is a risk of a
cutting injury.
u Wear safety gloves against mechanical risks when conducting assembly
ide

and disassembly work.

Wear safety gloves to protect against mechanical hazards.

CAUTION
-gu

Further work
This Operation Manual may be used to carry out only the work described in
it. Further work that is carried out in an incorrect way can lead to serious
damage to the machine.
u Turbo Systems recommends having further work carried out only by
trained personnel from a Turbo Systems service station.
all

Tightening torques for assembly devices

Unless otherwise described, the screws and nuts of the assembly devices supplied by Turbo
Systems must be tightened in such a way that they are tight-fitting.

Oil orifice
u When disassembling the turbocharger, an oil orifice fitted in the oil inlet must not be re-
moved (see also chapter Removing the cartridge group →111).

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Operation Manual / A150-M56/66/57/67 - A155-M..

9 Dismantling and fitting, general / 9.2 Material required

9.2 Material required

Customer spare part set

Before starting operations, make sure the required customer spare part set is available (see
chapter Spare parts →178).

Customer tool set

Before starting work, make sure the required tool set is available (see chapter Tools →192).
Not all tools are marked with a part number. Identification is guaranteed by the tool list. This
list is enclosed with the tool set.

WARNING
Servicing the tools
The tools must be checked for damage before and after use.
u Visually inspect for corrosion, cracks, deformation and wear.
u Damaged tools must no longer be used and must be replaced.
Page 90 / 198

Swivel lifting eyes

Swivel lifting eyes are required for the safe lifting of loads, which are not supplied by Turbo
Systems.

Fig. 39: Swivel lifting eye (example)

Product Thread M Length L Load limit Quantity

A150 M8 ≤ 13 mm ≥ 75 kg 3
M16 ≤ 21 mm ≥ 1000 kg 2
A155 M8 ≤ 13 mm ≥ 150 kg 3
M16 ≤ 21 mm ≥ 1400 kg 2
Table 38: Swivel lifting eyes

Press-off screws
Six press-off screws (01) are required to press off the gas outlet flange, which are not sup-
plied by Turbo Systems.

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Operation Manual / A150-M56/66/57/67 - A155-M..

9 Dismantling and fitting, general / 9.2 Material required

Fig. 40: Press-off screws

Product Thread Length Quantity

A150 M12 30 mm 3 or 6
A155 M16 30 mm 3 or 6
Table 39: 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
supplied by Turbo Systems.

Page 91 / 198
Fig. 41: Dismantling screw

Product Thread Length [mm] Quantity

A150-M M8 40 1
A155-M M10 50 1
Table 40: Dismantling screw

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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.
u Only fasten the turbocharger, assemblies or individual parts on properly
functional lifting gear with sufficient load limit.
u Pay attention to the correct attachment of loads on the crane hook.
u People must not stand beneath suspended loads.

Wear safety gloves to protect against mechanical hazards.

Wear safety helmet.

Definition of terms
¡ Suspension point
Defined loading point on a component or an assembly (blind hole thread, eyelet, lug).
Page 92 / 198

¡ Assembly device
Devices that are fitted on the turbocharger in order to obtain a suspension point. As-
sembly devices are specially constructed and designed for the defined use; they are not
commercially available products. Use assembly devices only for the described applica-
tions.
¡ Lifting gear
Equipment for the lifting and transporting of loads (ropes, chain block, crane). Lifting
gear is not supplied by ABB.

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Operation Manual / A150-M56/66/57/67 - A155-M..

9 Dismantling and fitting, general / 9.3 Disassembly and assembly con-
cepts

9.3 Disassembly and assembly concepts

Removal and installation with removed air inlet and gas outlet

Page 93 / 198
Fig. 42: Removing the cartridge group with compressor and turbine casing

When dismantling with removed air inlet and gas outlet options, the air suction branch or fil-
ter silencer, as well as the gas outlet casing are removed from the turbocharger for the time
being. The cartridge group, the turbine casing and the compressor casing can then be de-
tached from the engine and dismantled in an assembled state. Reassembly is carried out in
reverse order.
A prerequisite is that the interfaces between the alternative air inlet (filter silencer or air suc-
tion branch) and the compressor casing, as well as between the turbine casing and gas out-
let casing, are accessible at the engine side.

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9 Dismantling and fitting, general / 9.3 Disassembly and assembly con-
cepts

Cartridge concept

m
.co
Fig. 43: Cartridge concept ox
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
sb
casing and the cartridge group can be individually dismantled and fitted in the order shown
in the illustration.
Page 94 / 198

The turbine casing and optional gas outlet casing remain on the engine during the process.
In addition, the nozzle ring can also be dismantled/fitted with this concept (not shown).
ide

When employing the cartridge concept, the turbine casing and the optional gas outlet cas-
ing remain on the engine. Adequate support or suspension of these components must be
ensured.
A prerequisite is that the interfaces between the cartridge group and the turbine casing, as
well as between the cartridge group and the compressor casing, are accessible at the engine
side.
-gu
all

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Operation Manual / A150-M56/66/57/67 - A155-M..

9 Dismantling and fitting, general / 9.3 Disassembly and assembly con-
cepts

Optional spanner holder

Fig. 44: Optional spanner holder

Turbo Systems offers an optional spanner holder (90165) (see Dismantling and fitting, spe-
cial tools for fastening strips →154) which, in the event of limited accessibility, can be used
to facilitate the loosening of nuts and the application of tightening torques for the strip
connection between the cartridge group and the turbine casing.
The spanner holder (90165) should only be used for loosening the nuts and applying tighten-
ing torques for the nuts at the position shown.
Other screws or nuts on the turbocharger should not be tightened with this tool.

Page 95 / 198

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Operation Manual / A150-M56/66/57/67 - A155-M..

9 Dismantling and fitting, general / 9.4 Weights of individual parts

9.4 Weights of individual parts

The specified weights of the individual parts or assemblies are rounded-up standard values.
Page 96 / 198

Fig. 45: Weights of assemblies

Designation A150 A155

[kg] [kg]
01 Filter silencer 90 140
02 Radial air suction branch 24 40
03 Compressor casing with insulation 180 280
04 Wall insert 35 65
05 Diffuser 13 21
06 Cartridge group 220 360
07 Nozzle ring 8 13
08 Burst ring 11 17
09 Turbine casing 1 inlet * 320 500
2 inlets * 290 460
3 inlets * 300 460
10 Gas outlet flange 35 65
11 Gas outlet casing with insulation 160 240
Table 41: Weights of assemblies

* including burst protection and insulation

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Operation Manual / A150-M56/66/57/67 - A155-M..

9 Dismantling and fitting, general / 9.5 Table of tightening torques

9.5 Table of tightening torques

Fig. 46: Overview of tightening torques

Page 97 / 198
1) Only A155-M with uncoupled filter silencer
The following tightening torques must be observed for the designated screw fittings:

Position Part number A150 A155

02 72051 M16 M16
275 Nm 275 Nm
02a 72054 -- M16
275 Nm
04 79041 M6 M6
8 Nm 8 Nm
08 51007 M16 M16
175 Nm 175 Nm
51007 M16 M16
with spanner holder (90165) 85 Nm 70 Nm
09 51009 M16 M16
200 Nm 200 Nm
11 72011 M16 M18
275 Nm 370 Nm
15 86505 M12 x 1.5 M12 x 1.5
15 Nm 15 Nm
16a -- M16 M16
200 Nm 200 Nm
20 81154 -- M6
10 Nm
21 81155 -- M8
55 Nm
22 81152 -- M10
50 Nm
Table 42: Tightening torques

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Operation Manual / A150-M56/66/57/67 - A155-M..

9 Dismantling and fitting, general / 9.5 Table of tightening torques
Page 98 / 198

Fig. 47: Tightening torques for insulation

The following tightening torques must be observed for the specified screw connections:

Position Part number A150 A155

16a / 16b 1) -- M16 M16
200 Nm 200 Nm
16b 2) -- M12 M12
65 Nm 65 Nm
18 -- M6 M6
10 Nm 10 Nm
19 -- M8 M8
25 Nm 25 Nm
20 -- M10 M10
45 Nm 45 Nm
Table 43: Tightening torques for insulation

1)
Tightening torque for attaching the insulation with integrated burst protection at the tur-
bine casing
2)
Tightening torque for attaching the insulation to the burst protection.

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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

10 Dismantling and fitting with removed

air inlet and gas outlet

m
10.1 Removing air inlets

.co
u Mark the casing position for assembly.

ox
sb

Page 99 / 198
ide
-gu

Fig. 48: Removing the air inlets

1. Attach lifting gear to the filter silencer (81000) or air suction branch (82000).
all

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).

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10 Dismantling and fitting with removed air inlet and gas outlet / 10.1
Removing air inlets

A155-M Uncoupled filter silencer

Page 100 / 198

Fig. 49: Removing the uncoupled filter silencer

1. Secure lifting gear to filter silencer (81000).

2. Unscrew the hexagon-head screws (72054) and remove along with Verbus Ripp® wash-
ers (72053) and three safety plates (72055).
3. Remove the filter silencer (81000).

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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

u Mark the casing position for assembly.

Variant without support

Page 101 / 198

Fig. 50: Remove gas outlet casing without support

1. If present: Remove waste gate pipe.

2. Remove insulation ring.
3. Fit swivel lifting eyes (S) to the gas outlet casing (61001). Attach lifting gear to swivel lift-
ing eye and secure to a crane hook.
4. Loosen and remove nuts (51009).
5. Remove the gas outlet casing (61001), set it down properly in an appropriate place and
secure it.
6. Remove and dispose of the gasket (61002).

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10 Dismantling and fitting with removed air inlet and gas outlet / 10.2
Removing the gas outlet casing

Variant with support

Page 102 / 198

Fig. 51: Removing gas outlet casing with support 1

1. If present: Remove waste gate pipe.

2. Remove gas outlet casing insulation.
3. Remove insulation ring.
4. Remove fixing screws of support (61301) to bracket.
5. Fit swivel lifting eyes (S) to the gas outlet casing (61001). Attach lifting gear to swivel lift-
ing eye and secure to a crane hook.

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10 Dismantling and fitting with removed air inlet and gas outlet / 10.2
Removing the gas outlet casing

Page 103 / 198

Fig. 52: 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).

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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).

m
If the following Working Instructions are not observed, this can lead to cracks in the gas out-
let casing.
The following variants are possible:

.co
u Pressing off using 3 press-off screws.

u Pressing off using 6 press-off screws.

ox
sb
Page 104 / 198

ide
-gu
all

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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

Gas outlet flange with 3 press-off screws

CAUTION
Cracks in the gas outlet casing
Non-observance of the action steps described can lead to inadmissible
cracks on the gas outlet flange.
u Observe the maximum tightening torques when pressing off.
u Follow the action steps described.

Only dismantle the gas outlet flange if this is necessary for service work.
u If necessary: Treat the centering seat with rust remover through the press-off threads
and the clearance holes.
u Mark the casing position for assembly.

Page 105 / 198

Fig. 53: Dismantling the gas outlet flange

Product Press-off screws (strength 8.8) * Tightening torque

A150 3 x M16 x 30 ≤ 150 Nm
A155 3 x M16 x 40 ≤ 150 Nm
Table 44: 3 press-off screws

1. Evenly press off and remove the gas outlet flange (57002) with screws (01) according to
the table. If the gas outlet flange cannot be pressed off with the maximum tightening
torque, contact a Turbo Systems service station.
2. Attach swivel lifting eye (S) to the gas outlet flange. Secure lifting gear to the swivel lift-
ing eye.
3. Remove the gas outlet flange.
4. If present: Remove the metal C-ring (57003).

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10 Dismantling and fitting with removed air inlet and gas outlet / 10.3
Removing the gas outlet flange

Gas outlet flange with 6 press-off screws

CAUTION
Cracks in the gas outlet casing
Non-observance of the action steps described can lead to inadmissible
cracks on the gas outlet flange.
u Observe the maximum tightening torques when pressing off.
u Follow the action steps described.

Dismantle the gas outlet flange only if this is necessary for service work.
u With blows from a plastic tip hammer, ensure that the gas outlet flange does not cant.

u If necessary: Treat the centering seat with rust remover through the press-off threads
and the clearance holes.
u Mark the casing position for assembly.
Page 106 / 198

Fig. 54: Removing the gas outlet flange

Product Press-off screws (strength 8.8) * Tightening torque

A150 6 x M12 x 30 ≤ 65 Nm
A155 6 x M12 x 30 ≤ 150 Nm
Table 45: 6 press-off screws

* not included in the Turbo Systems scope of delivery.

1. Evenly press off and remove the gas outlet flange (57002) with screws (01) according to
the table. If the gas outlet flange cannot be pressed off with the maximum tightening
torque, contact a Turbo Systems service station.
2. Attach swivel lifting eye (S) to the gas outlet flange. Secure lifting gear to the swivel lift-
ing eye.
3. Remove the gas outlet flange.
4. If present: Remove the metal C-ring (57003).

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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. 55: Turbine cleaning nozzle

1. If present: Loosen the turbine cleaning connection.

The cleaning nozzle (51301) must be replaced after each removal procedure. If the clean-
ing nozzle is not to be replaced, the screw connection (01) must not be loosened during
disassembly.

Page 107 / 198

Fig. 56: Remove insulation

2. Remove the compressor casing insulation.

3. Remove the turbine casing insulation.

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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. 57: Removing the cartridge group with compressor and turbine casing

4. If present: Loosen and remove the compressor wheel cooling connection. Close the com-
pressor wheel cooling opening with a screw plug (01).
5. If present: Disconnect the plug to the speed sensor (86505) and secure the rolled-up
cable on the turbocharger. This protects the plug from being crushed.
Page 108 / 198

6. Attach lifting gear to the cartridge group and secure to a crane.

7. Loosen the clamping nut (see Loosening the clamping nut →31).

Fig. 58: Setting down the cartridge group with the compressor and turbine casing

8. Lift the cartridge group with the compressor and turbine casing.
9. Fit two swivel lifting eyes (S) and secure to a second set of lifting gear.
10. Turn the compressor and turbine casing and set down on suitable supports.
11. Remove lifting gear from cartridge group. Leave second lifting gear attached to com-
pressor casing for safety.
12. Remove and dispose of the O-rings (42195, 42200).

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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

m
u Mark the casing position for assembly.

.co
ox
sb

Page 109 / 198

ide

Fig. 59: Removing the compressor casing

-gu

If the compressor casing cannot be loosened, it can be pressed off against the turbine cas-
ing with the press-off tool (90042).
1. Loosen screws (72011) and remove together with fastening strips (72012).
2. Attach swivel lifting eye (S) to the compressor casing and the lifting gear.
3. Remove the compressor casing (72000) and turn it 180°.
all

4. Put the compressor casing (72000) down onto a suitable support.

5. Remove and dispose of the O-ring (42012).

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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

Page 110 / 198

Fig. 60: Dismantling the diffuser and the wall insert

1. Loosen the screws (79041) and remove with fixing discs (79040).
2. Remove diffuser (79000).
3. Fit the swivel lifting eye (S) to the wall insert (77000). Secure lifting gear to the swivel lift-
ing eye.
4. Remove the wall insert (77000). When doing this, make sure that the wall insert does not
"stick" to the compressor casing (72000).
5. Remove and dispose of the O-ring (77005).

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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

u Mark the casing position for assembly.

Fig. 61: Removing cartridge group 1

Product Position Tightening torque [Nm]

A150 01 150
A155 01 150

Page 111 / 198

Table 46: Tightening torque (90012-01)

1. Treat threads of studs (51006) with penetrating oil and leave to take effect.
2. Loosen nuts (51007) and remove Verbus Ripp® washers (51003) together with the fasten-
ing strips (51002).
3. Fit the cross-piece of the service support (90012). Observe the tightening torque.

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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. 62: Removing cartridge group 2

If the cartridge group cannot be loosened, the press-off tool (90042) can be used.
Page 112 / 198

4. Secure the first set of lifting gear to the bearing casing.

5. Secure the second set of lifting gear to the service support with a swivel lifting eye. The
length of the lifting gear must be selected in such a way that the compressor wheel is
not touched when turning the cartridge group.
6. Remove the cartridge group vertically from the turbine casing.

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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

Page 113 / 198

Fig. 63: Removing cartridge group 3

7. Place a suitable protective cover over the compressor wheel.

8. Turn the cartridge group into the horizontal rotor axis.
9. Remove lifting gear from service support and cross-piece.

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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

m
.co
ox
Fig. 64: Installing the cartridge group on the service support

1. Assemble the service support (90012) with longitudinal and cross-pieces.

sb
2. Fit service support to cartridge group.
Page 114 / 198

3. Put down cartridge group.

ide
-gu
all

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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

Page 115 / 198

Fig. 65: Removing the nozzle ring

1. Pull out the nozzle ring (56001) with the two extraction devices (90070).
2. Remove the lamellar sealing ring (56005).

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Operation Manual / A150-M56/66/57/67 - A155-M..

10 Dismantling and fitting with removed air inlet and gas outlet / 10.9
Measuring clearance A and B

10.9 Measuring clearance A and B

u Measure and record clearances A and B after the removal and before the installation of
the cartridge group.
u Attach the dial indicator and align it for the respective clearance as per the illustration.

Fig. 66: Measuring clearance A and B

Product A [mm] B [mm]

A150-M 0.12 ... 0.22 0.72 ... 1.28
A155-M 0.12 ... 0.22 0.79 ... 1.40
Table 47: Permissible clearances A and B
Page 116 / 198

1. Move the rotor to and fro up to the stop. In order to obtain a correct measurement, elev-
ate the turbine a little.
2. Measure clearance A and compare it with the permissible values in the table.
3. Raise the compressor and push the turbine down at the same time.
4. Raise the turbine and push the compressor down at the same time.
5. Measure clearance B and compare it with the permissible values in the table.

CAUTION
Clearances outside the tolerance
Serious damage to engines or property can be caused by clearances outside
the tolerance and excessively worn parts.
u Have the components assessed and, if necessary, replaced by a Turbo
Systems service station.

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Operation Manual / A150-M56/66/57/67 - A155-M..

10 Dismantling and fitting with removed air inlet and gas outlet / 10.10
Nozzle ring compression PD

10.10 Nozzle ring compression PD

In order for the nozzle ring (56001) to be fixed during operation, it must be clamped
between the heat shield (42400) and the turbine casing (51000).

Page 117 / 198

Fig. 67: Nozzle ring compression PD

42001 Bearing casing 51000 Turbine casing

42400 Heat shield 56001 Nozzle ring

Product Nozzle ring compression PD [mm]

A150-M -0.17 ... 0.17
A155-M -0.17 ... 0.17
Table 48: Nozzle ring compression PD

1. Measure dimensions A, B and S on cleaned surfaces.

2. Calculate compression (PD).
u If the calculated value (PD) lies outside the specified range, contact a Turbo Systems ser-
vice station.

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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. 68: Installing the nozzle ring

1. Fit the lamellar sealing ring (56005) (see A-A). When doing this, pay attention to correct
winding of the lamellar sealing ring (see detail B).
2. Align the cams on the nozzle ring with the recesses of the turbine casing (51000).
Page 118 / 198

3. Insert the nozzle ring (56001) into the turbine casing up to the stop.

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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

m
.co
ox
Fig. 69: 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).
sb
3. Dismantle service support.

Page 119 / 198

ide
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all

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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. 70: Turning the cartridge group

Page 120 / 198

Product Position Tightening torque [Nm]

A150 01 150
A155 01 150
Table 49: Tightening torque (90012-01)

4. Re-fit the cross-piece of the service support (90012). Observe the tightening torque.
5. Place the protective cover over the compressor wheel.
6. Secure the second set of lifting gear to the cross-piece with a swivel lifting eye. The
length of the lifting gear must be selected in such a way that the compressor wheel is
not touched.
7. Turn the cartridge group into the vertical position of the rotor axis.

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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. 71: Installing the cartridge group

Product Size Tightening torque [Nm]

A150 M16 175
A155 M16 175
Table 50: Tightening torque (51007)

Page 121 / 198

8. Coat the threads of the studs (51006) with high-temperature grease.
9. Align casing position of cartridge group with marking and lower into the turbine casing.
10. Remove lifting gear cross-piece of service support.
11. Install the fastening strips (51002) with Verbus Ripp® washers (51003) and hexagon
nuts (51007). Observe the tightening torque.

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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

Page 122 / 198

Fig. 72: Fitting the wall insert and the diffuser

Product Size Tightening torque [Nm]

A150 M6 8
A155 M6 8
Table 51: Tightening torque (79041)

1. Fit a new O-ring (77005).

2. Fit the swivel lifting eyes (S) to the wall insert (77000). Secure lifting gear to the swivel
lifting eye.
3. Install the wall insert (77000) into the compressor casing and, when doing so, pay atten-
tion to the positioning pin in the compressor casing.
4. Fit the diffuser (79000) with fixing discs (79040) and screws (79041). Observe the tight-
ening torque.

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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

Page 123 / 198

Fig. 73: Installing the compressor casing

Product Size Tightening torque [Nm]

A150 M16 275
A155 M18 370
Table 52: Tightening torque (72011)

1. Fit new O-ring (42012).

2. Thoroughly clean the fastening strips (72012) before assembly.
3. Install the compressor casing (72000).
4. Install the fastening strips (72012) with screws (72011). Observe the tightening torque.

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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

m
.co
ox
Fig. 74: Turning the cartridge group with compressor and turbine casing

1. Attach second lifting gear to bearing casing and secure to the crane hook. This lifting
gear must be attached during the entire rotating procedure.
2. Lift cartridge group with compressor and turbine casing with the first lifting gear and
sb
lower it with the second lifting gear.
Page 124 / 198

3. Remove second lifting gear and swivel lifting eye.

ide
-gu
all

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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. 75: Installing the gas outlet flange

1. If present: Insert the metal C-ring (57003) into the turbine casing (51000) and secure with
high-vacuum grease.
2. Fit swivel lifting eye (S) to the gas outlet flange (57002). Secure lifting gear to the swivel

Page 125 / 198

lifting eye.
3. Install gas outlet flange in turbine casing (51000).
4. Measure radial clearance (R) (see chapter Radial clearances N and R).

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Operation Manual / A150-M56/66/57/67 - A155-M..

10 Dismantling and fitting with removed air inlet and gas outlet / 10.16
Radial clearances N and R

10.16 Radial clearances N and R

Fig. 76: Measuring clearances N and R

Page 126 / 198

Product N [mm] R [mm]

A150-M 0.64 ... 1.09 0.71 ... 1.13
A155-M 0.78 ... 1.29 0.86 ... 1.33
Table 53: Permissible clearances N and R

1. Push the feeler gauges (01) into the gap without clearance, and measure simultaneously
at the top (N1) and the bottom (N2).
2. Calculate clearance N and compare it with the permissible values in the table.
3. Push the feeler gauges (01) into the gap without clearance, and measure simultaneously
at the top (R2) and the bottom (R1).
4. Calculate clearance R and compare it with the permissible values in the table.

CAUTION
Clearances outside the tolerance
Serious damage to engines or property can be caused by clearances outside
the tolerance and excessively worn parts.
u Have the components assessed and, if necessary, replaced by a Turbo
Systems service station.

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 All manuals and user guides at all-guidesbox.com

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

Page 127 / 198

Fig. 77: Fitting the insulation

u Fit the insulation according to the illustration. Observe tightening torques (see Table of
tightening torques →97).

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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 casing

10.18 Installing the cartridge group with compressor

and turbine casing

Fig. 78: Installing the cartridge group with compressor and turbine casing

1. Fit new O-rings (42195, 42200).

2. Remove cover from oil inlet and outlet and carefully lower cartridge group with com-
Page 128 / 198

pressor and turbine casing onto bracket.

Fig. 79: Installing the cartridge group with compressor and turbine casing

3. Mount and tighten the clamping nut (see Fastening the turbocharger with a clamping
nut →37).
4. Remove lifting gear from bearing casing.
5. If present: Remove the screw plug from the connection for the compressor wheel cooling
(01) and fit the cooling air line.
6. If present: Plug in the plug to the speed sensor (86505).
u If present: Fit connecting pipe for turbine cleaning.

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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

m
.co
ox
sb

Page 129 / 198

ide

Fig. 80: Fitting gas outlet casing without support

Product Size Tightening torque [Nm]

A150 M16 200
-gu

A155 M16 200

Table 54: Tightening torque (51009)

1. Coat thread of bolts (51008) with high-temperature grease.

2. Insert a new gasket (61002) into the gas outlet casing (61001).
3. Fit swivel lifting eyes (S) to the gas outlet casing (61001). Secure lifting gear to the swivel
lifting eye.
all

4. Place gas outlet casing at turbine casing (51000). Observe the marking.
5. Fit hexagon nuts (51009). Observe the tightening torque.
6. Fit insulation ring. Observe tightening torques (see Table of tightening torques →97).
7. If present: Attach waste gate pipe. Tighten in accordance with enginebuilder’s specifica-
tions.

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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

Page 130 / 198

Fig. 81: Installing gas outlet casing with support 1

Product Size Tightening torque [Nm]

A150 M16 200
A155 M16 200
Table 55: Tightening torque (51009)

1. Coat thread of bolts (51008) with high-temperature grease.

2. Insert a new gasket (61002) into the gas outlet casing (61001).
3. Fit swivel lifting eyes (S) to gas outlet casing (61001). Secure lifting gear to the swivel lift-
ing eye.
4. Place gas outlet casing on the turbine casing (51000). Observe the marking.
5. Fit support (61301).
6. Fit hexagon nuts (51009). Observe the tightening torque.

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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. 82: Installing gas outlet casing with support 2

Page 131 / 198

7. Fit the screws of the support. Tighten in accordance with enginebuilder’s specifications.
8. Fit insulation ring. Observe tightening torques (see Table of tightening torques →97).
9. Fit gas outlet casing insulation (see Table of tightening torques →97).
10. If present: Attach waste gate pipe. Tighten in accordance with enginebuilder’s specifica-
tions.

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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

Page 132 / 198

Fig. 83: Installing the air inlets

Product Size Tightening torque [Nm]

A150 M16 275
A155 M18 370
Table 56: Tightening torque (72051)

1. Attach lifting gear to the filter silencer (81000) or air suction branch (82000).
2. Fit a new O-ring (81010) to the filter silencer (81000) or a new O-ring (82010) to the air
suction branch (82000).
3. Install the filter silencer (81000) or air suction branch (82000).
4. Fit the fastening strips (72012) with hexagon-head screws (72051). Observe the tighten-
ing torque.

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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

Page 133 / 198

Fig. 84: Installing the uncoupled filter silencer

Product Size Tightening torque [Nm]

A155 M16 275
Table 57: Tightening torque (72054)

1. Secure lifting gear to filter silencer (81000).

2. Install the filter silencer (81000).
3. Fit the hexagon nuts (72054) together with Verbus Ripp® washers (72053) and three new
safety plates (72055) (uniformly at 120° to one another). Observe the tightening torque.

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Operation Manual / A150-M56/66/57/67 - A155-M..

11 Dismantling and fitting, cartridge concept / 11.1 Removing air inlets

11 Dismantling and fitting, cartridge

concept

m
11.1 Removing air inlets

.co
u Mark the casing position for assembly.

ox
sb
Page 134 / 198

ide
-gu

Fig. 85: Removing the air inlets

1. Attach lifting gear to the filter silencer (81000) or air suction branch (82000).
all

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).

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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

Page 135 / 198

Fig. 86: Removing the uncoupled filter silencer

1. Secure lifting gear to filter silencer (81000).

2. Unscrew the hexagon-head screws (72054) and remove along with Verbus Ripp® wash-
ers (72053) and three safety plates (72055).
3. Remove the filter silencer (81000).

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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

u Mark the casing position for assembly.
Page 136 / 198

Fig. 87: Removing the compressor casing

1. Remove the compressor casing insulation.

2. Fit swivel lifting eye (S) to the compressor casing (72000). Secure lifting gear to the
swivel lifting eye.
3. Loosen screws (72011) and remove together with fastening strips (72012).
4. Remove the compressor casing (72000).

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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).

Fig. 88: Pressing off compressor casing

Page 137 / 198

1. Remove front turbine casing insulation.
2. Press off compressor casing with press-off tool (90042).

Fig. 89: Remove the diffuser

1. Remove and dispose of the O-ring (42012).

2. Set the compressor casing (72000) down on a suitable support.

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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

Page 138 / 198

Fig. 90: Dismantling the diffuser and the wall insert

1. Loosen the screws (79041) and remove with fixing discs (79040).
2. Remove diffuser (79000).
3. Fit the swivel lifting eye (S) to the wall insert (77000). Secure lifting gear to the swivel lift-
ing eye.
4. Remove the wall insert (77000). When doing this, make sure that the wall insert does not
"stick" to the compressor casing (72000).
5. Remove and dispose of the O-ring (77005).

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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

m
.co
Fig. 91: Removing insulation sheets

u If present: Remove insulation sheets.

ox
sb

Page 139 / 198

ide

Fig. 92: Removing cartridge group 1

-gu

Product Value X [mm]

A150-M 112 ±2 mm
A155-M 144 ±2 mm
Table 58: Threaded rod, value X
all

1. Apply two marking lines (M) to the left and right of the cartridge group and the bracket.
2. Support and fix the turbine casing.
3. Loosen the clamping nut (42201) (see Loosening the clamping nut →31).
4. Screw threaded rod (42191) up to value X at the hexagon.
5. Lift the centering bush (42193) using the threaded rod (42191) and hold it firmly.
If the centering bush jams:
Remove the clamping nut and rotate the threaded rod upwards using a standard nut.
6. Rotate the clamping nut (42201) downwards until the stop is reached.

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Operation Manual / A150-M56/66/57/67 - A155-M..

11 Dismantling and fitting, cartridge concept / 11.3 Removing the cart-
ridge group

Fig. 93: Removing cartridge group 2

Page 140 / 198

If the cartridge group cannot be loosened, the press-off tool (90042) can be used.
1. Treat threads of studs (51006) with penetrating oil and leave to take effect.
2. Loosen nuts (51007) and remove Verbus Ripp® washers (51003) together with fastening
strips (51002).
3. Pull the cartridge group from the turbine casing and remove it.

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Operation Manual / A150-M56/66/57/67 - A155-M..

11 Dismantling and fitting, cartridge concept / 11.3 Removing the cart-
ridge group

Fig. 94: Removing cartridge group 2

1. Remove the centering bush (42193) and the threaded rod (42191) along with the clamping
nut (42201).
2. Remove and dispose of the O-rings (42195, 42200).

Page 141 / 198

3. Attach the cartridge group to the service support (90012).
4. If present: Remove the metal C-ring (51105).

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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

Page 142 / 198

Fig. 95: S_05180

1. Pull out the nozzle ring (56001) with the two extraction devices (90070).
2. Remove the lamellar sealing ring (56005).

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Operation Manual / A150-M56/66/57/67 - A155-M..

11 Dismantling and fitting, cartridge concept / 11.5 Measuring clear-
ance A and B

11.5 Measuring clearance A and B

u Measure and record clearances A and B after the removal and before the installation of
the cartridge group.
u Attach the dial indicator and align it for the respective clearance as per the illustration.

Fig. 96: Measuring clearance A and B

Product A [mm] B [mm]

A150-M 0.12 ... 0.22 0.72 ... 1.28
A155-M 0.12 ... 0.22 0.79 ... 1.40
Table 59: Permissible clearances A and B

Page 143 / 198

1. Move the rotor to and fro up to the stop. In order to obtain a correct measurement, elev-
ate the turbine a little.
2. Measure clearance A and compare it with the permissible values in the table.
3. Raise the compressor and push the turbine down at the same time.
4. Raise the turbine and push the compressor down at the same time.
5. Measure clearance B and compare it with the permissible values in the table.

CAUTION
Clearances outside the tolerance
Serious damage to engines or property can be caused by clearances outside
the tolerance and excessively worn parts.
u Have the components assessed and, if necessary, replaced by a Turbo
Systems service station.

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 All manuals and user guides at all-guidesbox.com

Operation Manual / A150-M56/66/57/67 - A155-M..

11 Dismantling and fitting, cartridge concept / 11.6 Nozzle ring com-
pression PD

11.6 Nozzle ring compression PD

In order for the nozzle ring (56001) to be fixed during operation, it must be clamped
between the heat shield (42400) and the turbine casing (51000).

m
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ox
sb
Page 144 / 198

ide

Fig. 97: Nozzle ring compression PD

42001 Bearing casing 51000 Turbine casing

42400 Heat shield 56001 Nozzle ring

Product Nozzle ring compression PD [mm]

A150-M -0.17 ... 0.17
-gu

A155-M -0.17 ... 0.17

Table 60: Nozzle ring compression PD

1. Measure dimensions A, B and S on cleaned surfaces.

2. Calculate compression (PD).
u If the calculated value (PD) lies outside the specified range, contact a Turbo Systems ser-
all

vice station.

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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. 98: Installing the nozzle ring

1. Fit the lamellar sealing ring (56005) (see A-A). When doing this, pay attention to correct

Page 145 / 198

winding of the lamellar sealing ring (see detail B).
2. Align the cams on the nozzle ring with the recesses of the turbine casing (51000).
3. Insert the nozzle ring (56001) into the turbine casing up to the stop.

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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. 99: Installing the cartridge group 1

1. Attach lifting gear to bearing casing.

2. Remove fixing screws.
Page 146 / 198

3. Lift the cartridge group out of the service support (90012).

4. Fit new O-rings (42195, 42200).
5. Screw the clamping nut (42201) flush onto the threaded rod (42191). The hexagon of the
thread screw is at the top.
Place the washer (01) of the clamping nut onto the expansion bush and, with the clamp-
ing nut screwed on, guide the threaded rod through the washer, expansion bush and
bearing casing.
6. Screw the centering bush (42193) flush onto the threaded rod from below.
7. Lift the centering bush (42193) using the threaded rod (42191) and hold it firmly.
8. Rotate the clamping nut (42201) downwards until the stop is reached.

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Operation Manual / A150-M56/66/57/67 - A155-M..

11 Dismantling and fitting, cartridge concept / 11.8 Installing the cart-
ridge group

Fig. 100: 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 72 ±2 mm
Table 61: Threaded rod, value X and L

Page 147 / 198

Product Size Tightening torque [Nm]
A150 M16 175
A155 M16 175
Table 62: Tightening torque (51007)

1. Lightly lubricate the hole in the bracket, into which the centering bush (42193) is inser-
ted, with screw grease.
2. If present: Insert the metal C-ring (51105).
3. Move the cartridge group into the turbine casing and align with the markings (M) made
on the bracket at the time of disassembly.
4. Screw clamping nut (42201) upwards to end of threaded rod and insert the centering
bush (42193) into the hole.
Check value X (if value X is not reached, the turbocharger must be re-aligned).
5. Screw in the threaded rod until value L is reached.
6. Tighten the pressure screws of the clamping nut (see Tightening pressure screws →38).
7. Secure fastening strips (51002) together with nuts (51007) and Verbus Ripp® wash-
ers (51003).

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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

Page 148 / 198

Fig. 101: Fitting the wall insert and the diffuser

Product Size Tightening torque [Nm]

A150 M6 8
A155 M6 8
Table 63: Tightening torque (79041)

1. Fit a new O-ring (77005).

2. Fit the swivel lifting eyes (S) to the wall insert (77000). Secure lifting gear to the swivel
lifting eye.
3. Install the wall insert (77000) into the compressor casing and, when doing so, pay atten-
tion to the positioning pin in the compressor casing.
4. Fit the diffuser (79000) with fixing discs (79040) and screws (79041). Observe the tight-
ening torque.

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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

m
.co
ox
Fig. 102: Installing the compressor casing
sb
Product Size Tightening torque [Nm]

Page 149 / 198

A150 M16 275
A155 M18 370
Table 64: Tightening torque (72011)
ide

u Thoroughly clean the fastening strips (72012) before assembly.

1. Fit a new O-ring (42012).

2. Install the compressor casing (72000).
3. Install the fastening strips (72012) with screws (72011). Observe the tightening torque.
-gu
all

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Operation Manual / A150-M56/66/57/67 - A155-M..

11 Dismantling and fitting, cartridge concept / 11.10 Radial clearances N
and R

11.10 Radial clearances N and R

Measurement of clearance R optional (only possible if gas outlet casing is dismantled).
Page 150 / 198

Fig. 103: Measuring clearances N and R

Product N [mm] R [mm]

A150-M 0.64 ... 1.09 0.71 ... 1.13
A155-M 0.78 ... 1.29 0.86 ... 1.33
Table 65: Permissible clearances N and R

1. Push the feeler gauges (01) into the gap without clearance, and measure simultaneously
at the top (N1) and the bottom (N2).
2. Calculate clearance N and compare it with the permissible values in the table.
3. Push the feeler gauges (01) into the gap without clearance, and measure simultaneously
at the top (R2) and the bottom (R1).
4. Calculate clearance R and compare it with the permissible values in the table.

CAUTION
Clearances outside the tolerance
Serious damage to engines or property can be caused by clearances outside
the tolerance and excessively worn parts.
u Have the components assessed and, if necessary, replaced by a Turbo
Systems service station.

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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

Page 151 / 198

Fig. 104: Fitting the insulation

u Fit the insulation according to the illustration. Observe tightening torques (see Table of
tightening torques →97).

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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

Page 152 / 198

Fig. 105: Installing the air inlets

Product Size Tightening torque [Nm]

A150 M16 275
A155 M18 370
Table 66: Tightening torque (72051)

1. Attach lifting gear to the filter silencer (81000) or air suction branch (82000).
2. Fit a new O-ring (81010) to the filter silencer (81000) or a new O-ring (82010) to the air
suction branch (82000).
3. Install the filter silencer (81000) or air suction branch (82000).
4. Fit the fastening strips (72012) with hexagon-head screws (72051). Observe the tighten-
ing torque.

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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

Page 153 / 198

Fig. 106: Installing the uncoupled filter silencer

Product Size Tightening torque [Nm]

A155 M16 275
Table 67: Tightening torque (72054)

1. Secure lifting gear to filter silencer (81000).

2. Install the filter silencer (81000).
3. Fit the hexagon nuts (72054) together with Verbus Ripp® washers (72053) and three new
safety plates (72055) (uniformly at 120° to one another). Observe the tightening torque.

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Operation Manual / A150-M56/66/57/67 - A155-M..

12 Dismantling and fitting, special tools for fastening strips / ​

12 Dismantling and fitting, special tools

for fastening strips

m
Turbo Systems offers an optional special tool set (90160) which, in the event of limited ac-
cessibility, 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.

.co
See also chapter Tools →192.
The spanner holder (90165) should only be used for loosening the nuts and applying tighten-
ing torques for the nuts at the position shown.
Other screws or nuts on the turbocharger should not be tightened with this tool.

ox
Customer tool (not included in the Turbo Systems scope of delivery)
sb
Page 154 / 198

ide

Fig. 107: Customer tool

Position Description Quantity

01 Collection tub 500x400x30mm 1
02 Torque spanner 40-200 Nm with 1
plug connection for holding inser-
-gu

tion tools 14x18 mm

Table 68: Customer tool

Customer tool (not included in the Turbo Systems scope of delivery)

all

Fig. 108: Customer tool

Position Description Quantity

01 Universal pliers 1
Table 69: Customer tool

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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

Page 155 / 198

Fig. 109: Positioning the collection tub

1. Position the collection tub (01) to catch any fixing elements if they fall.
2. Loosen the two nuts on one side by using the spanner holder (90165).
3. Loosen the two nuts on the other side by using the spanner holder (90166).
The cartridge group is fitted at this point in time. To enable a clear representation of the
work step, the cartridge group is not illustrated in work step 4.

Fig. 110: Removing the fastening strips

4. Remove the nuts (51007) with spanner holder (90165/90166) and attached torque span-
ner (02). Remove washers (51003) and fastening strips (51002).
Any falling screw material will be caught in the collection tub (01).
5. Loosen the nuts (51007) from the remaining fastening strips and remove the lugs (51002)
with washers (51003).

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Operation Manual / A150-M56/66/57/67 - A155-M..

12 Dismantling and fitting, special tools for fastening strips / 12.1 Ap-
plication, special tools

Fitting the fastening strips

Fig. 111: Fitting the upper fastening strips

Product Size Tightening torque [Nm]

A150 M16 175
A155 M16 175
Table 70: 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.
Page 156 / 198

Fig. 112: Fitting the bottom fastening strip

2. Position the collection tub (01) to catch any fixing elements if they fall.
3. Tighten the two nuts on one side by using the spanner holder (90165).
4. Tighten the two nuts on the other side by using the spanner holder (90166).
The cartridge group is fitted at this point in time. To enable a clear representation of the
work step, the cartridge group is not illustrated in work step 5.

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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. 113: Fitting the bottom fastening strip

Product Size Tightening torque [Nm]

A150-M M16 85
A155-M M16 70
Table 71: Tightening torque (51007) with spanner holder

5. Fit the nuts (51007) with spanner holder (90165 / 90166) and attached torque span-

Page 157 / 198

ner (02). Observe the tightening torque.

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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. 114: Fitting the cartridge group

1. Fit nuts (51007) of the (upper) fastening strips (51002) shown in the picture and tighten
with the torque spanner (02) without a spanner holder. Observe the tightening torque.
Product Size Tightening torque [Nm]
A155 M16 175
Table 72: Tightening torque (51007)
Page 158 / 198

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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.

m
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sb

Page 159 / 198

ide

Fig. 115: Positioning the fastening strip

2. Position fastening strip (51002) in the tool disassembly segment (90164).

3. Clamp the lugs (A) of the tool disassembly segment slightly using the universal pliers (03)
to fix the fastening strip.
4. Position the fastening strip with the tool disassembly segment onto the set screws.
-gu

5. Push the fastening strip with the tool disassembly segment in the direction of the tur-
bine casing as far as possible.
6. Depress the tool disassembly segment and remove it.
all

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12 Dismantling and fitting, special tools for fastening strips / 12.1 Ap-
plication, special tools
Page 160 / 198

Fig. 116: Clamping piece

7. Fix the washer (51003) with clamping device (90163) and check to ensure it is properly
seated.
8. Position the washer (51003) on the set screw.
9. Remove the clamping device.

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12 Dismantling and fitting, special tools for fastening strips / 12.1 Ap-
plication, special tools

Page 161 / 198

Fig. 117: Attach nut

Product Size Tightening torque [Nm]

A155-M M16 70
Table 73: Tightening torque (51007) with spanner holder

10. Screw nut (51007) loosely to the locking device (90162).

11. First position the cord end in the direction of the axis before winding up.
12. Wind up the cord 7-10 times around the nut and over the cord end.
13. Position the locking device (90162) with attached nut (51007) exactly onto the threaded
stud and press on.
14. Fit the nut (51007) to the set screw by pulling the cord.
15. Fit nuts (51007) with fixing washers (90165) and attached torque spanner (02). Observe
the tightening torque.

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Operation Manual / A150-M56/66/57/67 - A155-M..

13 Removing and installing 6-nozzle turbine cleaning component (op-
tional) / 13.1 Disassembly

13 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 162 / 198

Fig. 118: Initial situation

u Before disassembly, mark the positions of the elbows (51311).

Fig. 119: 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.

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13 Removing and installing 6-nozzle turbine cleaning component (op-
tional) / 13.1 Disassembly

Fig. 120: Disassembly of the elbows

u Remove the elbows (51311) from the connecting pieces (51313) in the specified order (01,
02, 03, 04, 05).

Page 163 / 198

Fig. 121: Pipe disassembly

1. Undo union nuts (51316) of pipe (51312).

2. Remove pipe.

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Operation Manual / A150-M56/66/57/67 - A155-M..

13 Removing and installing 6-nozzle turbine cleaning component (op-
tional) / 13.1 Disassembly

m
.co
Fig. 122: Disassembly of the connecting pieces

1. Unscrew hexagon-head screws (51314) from connecting pieces (51313).

2. Remove gaskets (51302).
3. Remove connecting pieces.
4. Remove gaskets from holes.
ox
sb
Page 164 / 198

ide

Fig. 123: Disassembly of the cleaning nozzle

u Remove cleaning nozzles (51301) with screw (01) in accordance with the following table.
-gu

Product Thread Length [mm] Quantity

A150-M M8 40 1
A155-M M10 50 1
Table 74: Dismantling screw
all

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13 Removing and installing 6-nozzle turbine cleaning component (op-
tional) / 13.2 Assembly

13.2 Assembly
u Clean all of the components and axial contact surfaces of the gaskets before assembling
the turbine casing.

Fig. 124: Assembly of the cleaning nozzle

Product Thread Length [mm] Quantity

A150-M M8 40 1
A155-M M10 50 1
Table 75: Dismantling screw

Page 165 / 198

1. Screw the screw (01) into the cleaning nozzle (51301) as far as it will go.
2. Insert the cleaning nozzle with screw as far as it will go.
3. Rotate the cleaning nozzle clockwise until the cleaning nozzle lowers further and is thus
correctly positioned.
u Remove the screw (01), ensuring that the cleaning nozzle remains in position.

Fig. 125: Assembly of the connecting pieces

1. Position gaskets (51302) on holes.

2. Position connecting pieces (51313).
3. Position gaskets (51302) on connecting pieces (51313).
4. Coat thread and contact surfaces of hexagon-head screws (51314) with high-temperat-
ure grease. Tighten screws by hand only.

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13 Removing and installing 6-nozzle turbine cleaning component (op-
tional) / 13.2 Assembly

Fig. 126: 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
Page 166 / 198

(51305) and tighten by hand only.

Fig. 127: Elbow 1 assembly

u Coat thread and contact surfaces of cutting ring with high-temperature grease.

u Screw union nuts (51316) of elbows (51311) in the specified order (01, 02, 03, 04, 05) to the
connecting pieces (51313).

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Operation Manual / A150-M56/66/57/67 - A155-M..

13 Removing and installing 6-nozzle turbine cleaning component (op-
tional) / 13.2 Assembly

Fig. 128: Elbow 2 assembly

Product 51314 [Nm] 51316 [Nm]

A150-M 80 70
A155-M 100 90

Page 167 / 198

Table 76: Tightening torque (51314 / 51316)

1. Tighten hexagon-head screws (51314) to tightening torque.

2. Tighten union nuts (51316) of elbows (51311) to tightening torque.

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14 Fitting the cleaning nozzles with multi-inlet turbine casings / ​

14 Fitting the cleaning nozzles with multi-

inlet turbine casings
Page 168 / 198

Fig. 129: Fit the cleaning nozzles

1. The designation (P . ) on the turbine casing must correspond with the designation (P . )
on the cleaning nozzle.
2. The edges for the defined installation position in the turbine casing and at the cleaning
nozzle must correspond.

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Operation Manual / A150-M56/66/57/67 - A155-M..

15 Taking out of operation at short notice / 15.1 Possible emergency re-
pairs

15 Taking out of operation at short notice

15.1 Possible emergency repairs

m
WARNING
Danger of fire and explosion due to lubricating oil leaks

.co
Leaking oil may ignite on hot surfaces. This can result in serious injuries to
personnel or fatal accidents.
u Cordon off danger area.
u Raise the alarm and, depending on the situation, stop the engine.
u Seal the oil leak.

ox
u Soak up oil and dispose of in an environmentally compatible manner.

Wear safety gloves to protect against thermal hazards.

sb
CAUTION

Page 169 / 198

Directives for taking out of operation
Serious damage to engine or property can be caused by non-compliance
with the directives for blanking the turbocharger off the engine.
ide

u Follow the directives of the enginebuilder.

If the engine has to be brought back into operation again as quickly as possible in the event
of a turbocharger defect, the following emergency repair options exist:
-gu

¡ If present: Installing the replacement turbocharger →170.

¡ If present: Installing the replacement cartridge group →170.
¡ If a replacement turbocharger or cartridge group is not available: Fit the cover plate
→171 and contact a Turbo Systems service station.
u Observe the following sections in connection with the emergency repairs mentioned.
all

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15 Taking out of operation at short notice / 15.2 Installing the replace-
ment turbocharger

15.2 Installing the replacement turbocharger

To enable an engine to be put back into operation quickly after a turbocharger has sustained
damage, Turbo Systems recommends having a replacement turbocharger or appropriate
spare parts available in storage. The defective turbocharger can be removed and the re-
placement turbocharger installed within a short period of time.
u Remove defective turbocharger (see chapter Removing and Installing →29).

u Install replacement turbocharger (see chapter Removing and Installing →29).

u Send the defective turbocharger to a Turbo Systems service station for inspection and re-
pair.

15.3 Installing the replacement cartridge group

WARNING
Incorrect handling of a cartridge group
Incorrect handling of a cartridge group can damage the turbocharger and
cause injuries to persons.
Page 170 / 198

u Always have repairs to the cartridge group carried out by a Turbo Sys-
tems service station.

To enable an engine to be put back into operation quickly after a turbocharger has sustained
damage, Turbo Systems recommends having a replacement cartridge group available in
storage. The defective cartridge group can be removed and the replacement cartridge group
installed within a short period of time. A replacement cartridge group is ready for use imme-
diately and includes the complete bearing casing with bearing and a balanced rotor.
The repair of a cartridge group requires special tools and the expertise of a Turbo Systems
service station. The rotating parts rotate extremely quickly, and are sensitive to unbalance.
u Remove defective cartridge group (see chapter Dismantling and fitting, general →89).

u Install replacement cartridge group (see chapter Dismantling and fitting, general →89).

u Send the defective cartridge group to a Turbo Systems service station for inspection and
repair.

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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

u Remove turbocharger (see chapter Removing and Installing →29).

¡ Gas outlet casing removed

u Fit the turbine casing with the gas outlet casing into the gas pipe again.

u Attach the cover plate (see following section).

¡ Gas outlet casing not removed

u Fit the turbine casing into the gas pipe and on the gas outlet casing again.

u Attach the cover plate (see following section).

Page 171 / 198

Fig. 130: Fitting the cover plate

u Make sure that the oil connections in the bracket are equipped with gaskets.

1. Close opening in turbine casing (51000) with cover plate (01).

2. Thoroughly clean the fastening strips (51002) before assembly.
3. Coat the threads of the studs (51006) with high-temperature grease.
4. Fasten cover plate (01) to turbine casing (51000) with fastening strips (51002), Verbus
Ripp® washers (51003) and nuts (51007) and screw to bracket.

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Operation Manual / A150-M56/66/57/67 - A155-M..

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 Turbo Systems scope of delivery and must be manufac-
tured by the operating company according to the following drawing.
Material: General structural steel, in accordance with DIN EN 10025-2.
Page 172 / 198

Fig. 131: Cover plate drawing

Product B1 B2 B3 B4 B5 B6 B7 ØD1 ØD2 R1 M

± 0.5 ± 0.2 ± 0.1 ± 0.2
A150 138.9 135 240 21.4 2.0 320 71.4 413.6 33 ≤ 196 M12
A155 164.6 160 286.5 25.5 2.0 385 84.6 492 39 ≤ 232 M16
Table 77: Cover plate dimensions [mm]

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Operation Manual / A150-M56/66/57/67 - A155-M..

15 Taking out of operation at short notice / 15.5 Cover plate drawing

Page 173 / 198

Fig. 132: Dimensions for cover plate

Product A B D1 D2 ± 0.1
A150 90 10 90 ± 0.2 28.2
A155 107 12 111 ± 0.1 37.2
Table 78: Cover plate dimensions [mm]

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Operation Manual / A150-M56/66/57/67 - A155-M..

16 Mothballing the turbocharger / 16.1 Taking the engine out of opera-
tion for up to 12 months

16 Mothballing the turbocharger

16.1 Taking the engine out of operation for up to

m
12 months

.co
State of the engine lubricating oil
The turbocharger normally remains attached to the engine. The measures to be taken for
mothballing the turbocharger depend on the state of the lubricating oil. No measures are re-
quired under the following conditions:
¡ Acid number (TAN) < 2 mg KOH/g
¡

ox
The engine lubricating oil is replaced by a preservative oil and circulated with the pre-lub-
rication pump before the engine is taken out of operation. Residues of old engine oil are
flushed away in this way and the bearing parts are largely protected against corrosion.

Preparations for mothballing

sb
Page 174 / 198

WARNING
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or con-
ide

tact with them may be harmful to health.

u Do not breathe in these substances and avoid contact with the skin.
u Ensure proper ventilation.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Wear personal protective equipment (PPE) according to the material
-gu

safety data sheet.

u Comply with local legislation.

Wear safety goggles.

Wear safety gloves to protect against chemical hazards.

all

Wear a respiratory mask to protect against gases.

If the acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures
are necessary after the engine is taken out of operation:
u Dismantle the turbocharger.

u The rotor and bearing parts must be dismantled and subsequently refitted by a Turbo
Systems service station.
u Clean all parts.

u Coat plain surfaces of steel and cast parts with anticorrosive oil.

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Operation Manual / A150-M56/66/57/67 - A155-M..

16 Mothballing the turbocharger / 16.2 Taking the engine out of opera-
tion for more than 12 months

u Fit turbocharger completely.

Rotor turning in stack draught

If the rotor turns as a result of the stack draught:
u Install a blind flange between the outlet flange of the compressor casing and the charge
air duct.

16.2 Taking the engine out of operation for more than

12 months
If the engine is taken out of operation, the following variants are possible with regard to the
turbocharger:
¡ Turbocharger remains attached to the engine
¡ The casings of the turbocharger remain attached to the engine, the rotor and bearing
parts are dismantled by a Turbo Systems service station and stored separately
¡ The turbocharger is completely removed, either as a whole unit or in individual parts

Page 175 / 198

For the measures always necessary for preparing the turbocharger parts for mothballing,
see section Taking the engine out of operation for up to 12 months, subsection Preparations
for mothballing.
If the turbocharger remains attached to the engine, see section Taking the engine out of op-
eration for up to 12 months →174, subsection Rotor turning in stack draught.
If the complete turbocharger is removed or the turbocharger is assembled again from the
individual parts:
u Seal all openings of the turbocharger with paraffin paper and wooden lids.

Only dry rooms with 40 … 70 % atmospheric humidity, in which no water condensation can
form, are suitable as storage locations.

State of the mothballed turbocharger

u Check the turbocharger parts annually for corrosion.

u If there are signs of rust: Thoroughly clean parts and renew corrosion protection.

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Operation Manual / A150-M56/66/57/67 - A155-M..

17 Material and Disposal / 17.1 REACH and RoHS Compliance Declara-
tion For Products

17 Material and Disposal

17.1 REACH and RoHS Compliance Declaration For

Products
Turbo Systems hereby confirms that all genuine products, parts and components supplied
by Turbo Systems are fully compliant with the requirements of European Union Regulation
(EC) 1907/2006 concerning the Registration, Evaluation, Authorization and Restriction of
Chemicals (REACH).

Article 33 (of requirements of European Union Regulation (EC) 1907/2006)

[in English only]
A supplier of a product composed of one or more constituent articles (products) of which
contain(s) a candidate list substance (SVHC, Substance of Very High Concern) in a concen-
tration above 0.1% wlw, shall inform the customer of the presence of such substance(s) with
sufficient information, available to the supplier.
Page 176 / 198

RoHS2 Directive 2011/65/EC

[in English only]
The EU Directive 2011/65/EC (recast) restricts the use of certain hazardous substances in
electrical and electronic equipment (RoHS2). Products and related accessories manufac-
tured by Turbo Systems Switzerland Ltd do not fall within the Scope of RoHS2 due to their
application in large scale fixed installations, means of transports for persons or goods, non-
road mobile machinery (Directive 2011/65/EC Article 2, 4.(e), (f), (g)).

Electrical or electronic equipment supplied by Turbo Systems fulfil requirements of RoHS2

Directive 2011/65/EC and fall under the exception 6a and 6c of the same Directive:
¡ 6a) Lead as an alloying element in steel for machining purposes and in galvanised steel
containing up to 0.35 % lead by weight
¡ 6c) Copper alloy containing up to 4 % lead by weight.

The maximum concentration of lead and lead compounds for our products is known to reach
max. 0.8 % (mass % in homogeneous material).

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Operation Manual / A150-M56/66/57/67 - A155-M..

17 Material and Disposal / 17.2 Disposing of turbocharger components

17.2 Disposing of turbocharger components

WARNING
Handling damaged thermal insulation
Damaged thermal insulation can lead to dust exposure. The glass fibres can
cause mechanical irritation of the eyes, skin, and respiratory tracts.
u Avoid the formation of dust.
u Vacuum up dust with a suitable vacuum cleaner.
u Wear a respiratory mask to protect against dusts (P1 or P2 mask).
u Wear safety gloves.

Wear safety goggles.

Wear a respiratory mask to protect against dusts.

Wear safety gloves to protect against mechanical hazards.

Disposal must be environmentally compatible, professional, and in compliance with locally

Page 177 / 198

applicable regulations.
The turbocharger consists largely of metal (cast iron materials, steel, nickel-steel alloys, alu-
minium and bearing brass).
Further components are: Non-metallic materials (filter components of felt and polyethylene),
lubricants (engine oil), electronic parts (speed sensor and associated components), and
thermal insulation.
u Dispose of metals as scrap metal for recycling.

u Dispose of non-metallic materials as waste.

u Dispose of residues of lubricants as waste oil.

u Dispose of electronic components as electronic waste.

u Dispose of thermal insulation as hazardous waste.

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Operation Manual / A150-M56/66/57/67 - A155-M..

18 Spare parts / 18.1 Ordering spare parts

18 Spare parts

18.1 Ordering spare parts

CAUTION
Spare part storage
All spare parts that were ordered together with the turbocharger must be
kept intact and ready for use.
u Carefully clean any rusted parts and grease them.

Please quote the following data when making queries and ordering spare parts:
¡ Turbocharger type
¡ Serial number of the turbocharger
¡ Designation and part number.
Spare parts can be ordered from any Turbo Systems Service Station.
u If different model variants are not taken into account in this document, contact an Turbo
Page 178 / 198

Systems Service Station.

u Dispose of placed and unusable parts in an environmentally-friendly and professional
manner in accordance with the local regulations.
u Dispose of the packaging of new parts in an environmentally-friendly and professional
manner in accordance with the local regulations.

18.2 Required customer spare part set (97070)

For the work described in the Operation Manual, the customer spare part set (97070) is re-
quired. These parts are only available in the complete set.

Customer spare part set

97070 Designation Quantity
42012 O-ring 1
42195 O-ring 1
42200 O-ring 1
61002 * Gasket 1
77005 O-ring 1
79041 Counter-sunk screw 2
81010 / 82010 O-ring 1
Table 79: Customer spare part set 97070

* This gasket can only be installed when a gas outlet casing from Turbo Systems is used.

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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.

m
Cartridge, oil cooled

.co
42201
42172

42190**
42170

42191

42167

42166 42172

ox 42189 42188
sb

Page 179 / 198

42194 42047

10900
ide

42200*

42012* 42197 42196 42195* 42193**

42202
** = if provided
42196
* = Available within the spare part set A150-M58/68 only HZTL443471 Mod. A

Part no. Designation

-gu

10900 Cartridge
42012* O-ring
42047 Screw plug
42166 Screw
42167 Cover
42170 Insulation
42172 Hexagon-head screw
all

42188 Hexagon-head screw

42189 Gasket
42190** Expansion bush
42191 Threaded rod
42193** Centering bush
42194 Gasket
42195* O-ring
42196 Orifice oil inlet
42197 Safety-ring
42200* O-ring
42201 Clamping nut
42202 Screw plug
Table 80: Spare parts - Cartridge, oil cooled

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 All manuals and user guides at all-guidesbox.com

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
Page 180 / 198

42008*

42302* **
42303* ** 42306*
42305*
(p) = pre-assembled
** = if provided
* = Available within the spare part set HZTL443310 Mod. D

Part no. Designation

42001 Bearing casing
42005(p) Sealing bush
42006(p) Spring-type pin
42008* Socket screw
42019* Hexagon-head screw
42020* Washer
42301 Bearing cover
42302* ** Piston ring
42303* ** Piston ring
42305* O-ring
42306* O-ring
42308* O-ring
42400 Heat shield
Table 81: Spare parts - Bearing, casing oil cooled

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Operation Manual / A150-M56/66/57/67 - A155-M..

18 Spare parts / 18.3 Spare part – Illustrations

Rotor and bearing parts

21000

32109**
42302* **
21011
32114*
32112
32103*
32104*
32113*
42002
32109

21002*
21006*
32102*
32159*

Page 181 / 198

32111*
32110
32101*
32167* **
25000

** = if provided
* = Available within the spare part set HZTL443470 Mod. B

Part no. Designation

21000 Turbine
21002* Piston ring
21006* Piston ring
21011 Sealing bush for shaft
25000 Compressor wheel
32101* Radial bearing
32102* Radial bearing
32103* Thrust ring
32104* Thrust bearing
32109** Sealing disc
32110 Bearing flange
32111* Auxiliary bearing
32112 Bearing flange
32113* Socket screw
32114* Socket screw
32159* Socket screw
32167* ** Snap ring
42002 Socket screw
42302* ** Piston ring
Table 82: Spare parts - Rotor and bearing parts

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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
56001 51101
51105**
51102
51002
Page 182 / 198

51102** TW03
51107** TW04

51500 51010**
TW03 / TW04
51102
51101

** = if provided HZTL443311 Mod. B

Part no. Designation

51000 Turbine casing
51002 Fastening strip
51003 Verbusripp washer
51006 Stud
51008 Stud
51009 Hexagon nut
51010(o) Insulation TW03 TW04
51027 Screw plug
51101 Hexagon-head screw
51102 Tension washer
51105(o) Metal C-ring
51106 Hexagon-head screw
51107(o) Tension washer
51500 Burst protection
56001 Nozzle ring
56005 Lamellar sealing ring
57002 Gas-outlet flange
57003(o) Metal C-ring
57210 Burst ring
Table 83: Spare parts – Turbine casing, 1 inlet

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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**
51002 51101

51102

Page 183 / 198

51101** TW03
51500 51106** TW04
51010**
TW03/TW04
51102

51101
** = if provided HZTL443472 Mod. A

Part no. Designation

51000 Turbine casing
51002 Fastening strip
51003 Verbusripp washer
51006 Stud
51007 Hexagon nut
51008 Stud
51009 Hexagon nut
51010** Insulation
51027 Screw plug
51101 Hexagon-head screw
51102 Tension washer
51105** Metal C-ring
51106** Hexagon-head screw
51107** Tension washer
51500 Burst protection
56001 Nozzle ring
56005 Lamellar sealing ring
57002 Gas-outlet flange
57003** Metal C-ring
57210 Burst ring
Table 84: Spare parts – Turbine casing, 2 inlets

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Operation Manual / A150-M56/66/57/67 - A155-M..

18 Spare parts / 18.3 Spare part – Illustrations

Turbine casing, 3 inlets

51027
51009
51303
51302 57002
51000 57003**
51008

m
57210
51006
51003

.co
51007

51010**
TW03/TW04

51102** TW03
51107** TW04

51002
51105**
56001
56005

51101

51102
ox
sb
Page 184 / 198

51500
51101** TW03
ide

51106** TW04
51102

51101
** = if provided HZTL443473 Mod. A

Part no. Designation

51000 Turbine casing
-gu

51002 Fastening strip

51003 Verbusripp washer
51006 Stud
51008 Stud
51009 Hexagon nut
51010** Insulation
51027 Screw plug
all

51102 Tension washer

51105** Metal C-ring
51106** Hexagon-head screw
51107** Tension washer
51302 Gasket
51303 Screw plug
51500 Burst protection
56001 Nozzle ring
56005 Lamellar sealing ring
57002 Gas-outlet flange
57003** Metal C-ring
57210 Burst ring
Table 85: Spare parts – Turbine casing, 3 inlets

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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

Page 185 / 198

51301

HZTL443336 Mod. B

Part no. Designation

51301* Cleaning nozzle
51302* Gasket
51303 Screw plug
51304 Flange
51305 Union branch
51308 Stud
51309 Expansion sleeve
51310 Hexagon nut
51311 Pipe elbow
51312 Pipe
51313 Joining piece
51314* Hexagon-head screw
51316 Cap nut
51317 Stop plug
Table 86: Spare parts - Cleaning device

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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
Page 186 / 198

61001
61301**

61002*

(p) = pre-assembled
** = if provided
* = Available within the spare part set HZTL443312 Mod. C

Part no. Designation

61001 Gas-outlet casing
61002* Gasket
61005(p) Screw plug
61100 Insulation gas-outlet casing GW03
61140 Insulation
61201 Hexagon-head screw
61202 Tension washer
61301** Support
Table 87: Spare parts - Gas outlet casing, radial

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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

Page 187 / 198

72060
77006
72012

77000
77005*
72006(p)
72005(p)
(p) = pre-assembled
* = Available within the spare part set HZTL443313 Mod. C

Part no. Designation

72000 Compressor casing
72005(p) Screw plug
72006(p) Gasket
72011 Hexagon-head screw
72012 Fastening strip
72016 Fastening strip
72060 Insulation
72061 Insulation sleeve
72062 Hexagon-head screw
72063 Tension washer
77000 Wall insert
77005* O-ring
77006 Stud
79000 Diffuser
79040 Fixing washer
79041* Counter-sunk screw
Table 88: Spare parts - Compressor casing

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Operation Manual / A150-M56/66/57/67 - A155-M..

18 Spare parts / 18.3 Spare part – Illustrations

Filter silencer

81000 81137
81136
81265**
81010*
81005
81006
Type B Type A 81135
81171
81170
81272 81266
81269
81270
81273
81266

72052
72055
72053
72054

81271
81150
81146 81149
81148 81147
81145
81000
81152
Page 188 / 198

81153
81155

81154
81151

A155-M
** = if provided Decoupled filter silencer
* = Available within the spare part set only HZTL443314 Mod. C

Part no. Designation

72052 Hexagon socket set screw
72053 Verbusripp locking disc
72054 Hexagon nut
72055 Fuse
81000 Filter silencer complete
81005 Screw plug
81006 Gasket
81010* O-ring
81135 Silencer body
81136 Absorption segment
81137 Cover sheet-metal
81145 Flange compressor-end
81146 Flange turbine-end
81147 Fixing ring
81148 Damping element
81149 Holding sheet metal
81150 Clamping strap
81151 Spring-type pin
81152 Hexagon-head screw
81153 Washer
81154 Hex socket head cap screw

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Operation Manual / A150-M56/66/57/67 - A155-M..

18 Spare parts / 18.3 Spare part – Illustrations

Part no. Designation

81155 Hexagon-head screw
81170 Screw plug
81171 Gasket

m
81265** Filter ring
81266 Cover grid
81269 Connection rod
81271 Lock

.co
81272 Hexagon-head screw
81273 Hexagon nut
Table 89: Spare parts - Filter silencer

Air suction branch axial

82007
82005

82006
ox
sb
82008

Page 189 / 198

ide
-gu

82010*
82000
all

* = Available within the spare part set HZTL443474 Mod. A

Part no. Designation

82000 Air suction branch
82005 Screw plug
82006 Gasket
82007 Screw plug
82008 Gasket
82010* O-ring
Table 90: Spare parts - Air suction branch axial

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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
Page 190 / 198

* = Available within the spare part set HZTL443315 Mod. B

Part no. Designation

82000 Air suction branch
82005 Screw plug
82006 Gasket
82007 Screw plug
82008 Gasket
82010* O-ring
Table 91: Spare parts - Air suction branch radial

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Operation Manual / A150-M56/66/57/67 - A155-M..

18 Spare parts / 18.3 Spare part – Illustrations

Speed measurement system

86258**

86526**
86515**
86505**

Page 191 / 198

** = if provided HZTL443475 Mod. A

Part no. Designation

86258** Tachometer
86505** Speed sensor
86515** Cable connector
86526** F/I-Converter
Table 92: Spare parts - Speed measurement system

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Operation Manual / A150-M56/66/57/67 - A155-M..

19 Tools / ​

19 Tools
For the work described in the Operation Manual, the customer tool set 90000 is required.

90000 Designation Quantity

90012 Service support 1
90013 Plastic insert 1
90022 (only - M58/68) Threaded insert 1
90230 Socket screw 2
90042 Press-off tool 2
90070 Extraction device 2
Table 93: Customer tool set 90000

Turbo Systems offers an optional special tool set (90160) which, in the event of limited ac-
cessibility, 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.
Special tool (90160):
Page 192 / 198

Fig. 133: Special tool

Part number Description Quantity

90160 Special tool, complete 1
90161 Bag 1
90165 Spanner holder 1
90166 Spanner holder 1
Table 94: Special tool (90160)

© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Rev.S February 2022
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Operation Manual / A150-M56/66/57/67 - A155-M..

19 Tools / ​

Extended special tool (90160) for A155:

Fig. 134: Special tool

Part number Description Quantity

90160 Special tool, complete 1
90161 Bag 1
90162 Locking device 1

Page 193 / 198

90163 Clamping piece 1
90164 Tool disassembly segment 1
90165 Spanner holder 2
Table 95: Special tool (90160)

Tool sets can be ordered from any Turbo Systems service station. The following specifica-
tions must be included in the order:
¡ Turbocharger type
¡ Designation and part number of the tool set.

© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Rev.S February 2022
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Operation Manual / A150-M56/66/57/67 - A155-M..

Figures

Figures
Fig. 1: Serial number (01) on the rating plate ........... 4 Fig. 32: Cleaning the filter silencer ............................. 70

m
Fig. 2: Layout and function of the turbocharger...... 6 Fig. 33: Cleaning the filter silencer (2) ....................... 72

Fig. 3: Compressor wheel cooling ................................ 7 Fig. 34: Compressor-end, non-rotating parts.......... 73

Fig. 4: Volatile Corrosion Inhibitor (VCI)................... 10 Fig. 35: Turbine end, non-rotating parts................... 74

.co
Fig. 5: Package with hygrometer................................ 11 Fig. 36: Soaking the turbine end................................. 77

Fig. 6: Warning plate locations ................................... 16 Fig. 37: Disassembling the absorption element...... 80

Fig. 7: Rating plate ........................................................ 17 Fig. 38: Installing the absorption element................ 81

Fig. 8: Locations of the rating plates ........................ 18 Fig. 39: Swivel lifting eye (example)........................... 90

Fig. 9: Attachment of loads on the crane hook ...... 20 Fig. 40: Press-off screws.............................................. 91

Fig. 10: Attachment angle........................................... 20

Fig. 11: Suspension of complete turbocharger unit ....

29

Fig. 12: Turbine cleaning nozzle ................................. 30

ox Fig. 41: Dismantling screw ........................................... 91

Fig. 42: Removing the cartridge group with com-

pressor and turbine casing.......................................... 93

Fig. 43: Cartridge concept ........................................... 94

sb
Fig. 13: Removing the turbocharger .......................... 31 Fig. 44: Optional spanner holder ................................ 95
Page 194 / 198

Fig. 14: Loosening the clamping nut ......................... 32 Fig. 45: Weights of assemblies ................................... 96

Fig. 15: Turbocharger centre of gravity .................... 33 Fig. 46: Overview of tightening torques ................... 97
ide

Fig. 16: Inserting the gasket....................................... 34 Fig. 47: Tightening torques for insulation................ 98

Fig. 17: Fitting the turbocharger 1............................. 35 Fig. 48: Removing the air inlets .................................. 99

Fig. 18: Fitting the turbocharger 2 ............................ 36 Fig. 49: Removing the uncoupled filter silencer .... 100

Fig. 19: Preparing the clamping nut for the tighten- Fig. 50: Remove gas outlet casing without support ...
ing procedure ................................................................ 37 101
-gu

Fig. 20: Tightening pressure screws ........................ 38 Fig. 51: Removing gas outlet casing with support 1....
102
Fig. 21: Connecting the speed sensor ...................... 39
Fig. 52: Removing gas outlet casing with support 1....
Fig. 22: Connecting the compressor cooling air in- 103
take ................................................................................. 39
Fig. 53: Dismantling the gas outlet flange ............. 105
Fig. 23: Attaching the support ................................... 39
Fig. 54: Removing the gas outlet flange ................. 106
all

Fig. 24: Oil orifice.......................................................... 40

Fig. 55: Turbine cleaning nozzle................................ 107
Fig. 25: Layout and overview of speed measurement
system ............................................................................ 48 Fig. 56: Remove insulation......................................... 107

Fig. 26: Replacing the speed sensor ......................... 50 Fig. 57: Removing the cartridge group with com-
pressor and turbine casing........................................ 108
Fig. 27: Noise insulation, bellows .............................. 52
Fig. 58: Setting down the cartridge group with the
Fig. 28: Carrying out wet cleaning of compressor. 62 compressor and turbine casing................................ 108
Fig. 29: Turbine cleaning devices .............................. 65 Fig. 59: Removing the compressor casing ............. 109
Fig. 30: Carrying out wet cleaning of turbine ......... 66 Fig. 60: Dismantling the diffuser and the wall insert ..
110
Fig. 31: Cleaning the filter silencer ............................ 68

© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Revision S February 2022
 All manuals and user guides at all-guidesbox.com

Operation Manual / A150-M56/66/57/67 - A155-M..

Figures

Fig. 61: Removing cartridge group 1........................ 111 Fig. 91: Removing insulation sheets ........................ 139

Fig. 62: Removing cartridge group 2 ....................... 112 Fig. 92: Removing cartridge group 1........................ 139

Fig. 63: Removing cartridge group 3 ....................... 113 Fig. 93: Removing cartridge group 2 ....................... 140

Fig. 64: Installing the cartridge group on the service Fig. 94: Removing cartridge group 2 ........................141
support.......................................................................... 114
Fig. 95: S_05180 ........................................................... 142
Fig. 65: Removing the nozzle ring ............................ 115
Fig. 96: Measuring clearance A and B ...................... 143
Fig. 66: Measuring clearance A and B...................... 116
Fig. 97: Nozzle ring compression PD........................ 144
Fig. 67: Nozzle ring compression PD ....................... 117
Fig. 98: Installing the nozzle ring.............................. 145
Fig. 68: Installing the nozzle ring ............................. 118
Fig. 99: Installing the cartridge group 1 .................. 146
Fig. 69: Lifting the cartridge group and rotating it
by 90° ............................................................................. 119 Fig. 100: Installing the cartridge group 2................ 147

Fig. 70: Turning the cartridge group ...................... 120 Fig. 101: Fitting the wall insert and the diffuser.... 148

Fig. 71: Installing the cartridge group ..................... 121 Fig. 102: Installing the compressor casing ............. 149

Fig. 72: Fitting the wall insert and the diffuser ..... 122 Fig. 103: Measuring clearances N and R .................. 150

Fig. 73: Installing the compressor casing............... 123 Fig. 104: Fitting the insulation ...................................151

Fig. 74: Turning the cartridge group with com- Fig. 105: Installing the air inlets ................................ 152

Page 195 / 198

pressor and turbine casing ....................................... 124
Fig. 106: Installing the uncoupled filter silencer.... 153
Fig. 75: Installing the gas outlet flange................... 125
Fig. 107: Customer tool .............................................. 154
Fig. 76: Measuring clearances N and R.................... 126
Fig. 108: Customer tool .............................................. 154
Fig. 77: Fitting the insulation .................................... 127
Fig. 109: Positioning the collection tub................... 155
Fig. 78: Installing the cartridge group with com-
pressor and turbine casing ....................................... 128 Fig. 110: Removing the fastening strips.................. 155

Fig. 79: Installing the cartridge group with com- Fig. 111: Fitting the upper fastening strips ............ 156
pressor and turbine casing ....................................... 128
Fig. 112: Fitting the bottom fastening strip ........... 156
Fig. 80: Fitting gas outlet casing without support .....
Fig. 113: Fitting the bottom fastening strip........... 157
129
Fig. 114: Fitting the cartridge group........................ 158
Fig. 81: Installing gas outlet casing with support 1.....
130 Fig. 115: Positioning the fastening strip ................. 159
Fig. 82: Installing gas outlet casing with support 2 .... Fig. 116: Clamping piece ............................................. 160
131
Fig. 117: Attach nut .......................................................161
Fig. 83: Installing the air inlets.................................. 132
Fig. 118: Initial situation ............................................. 162
Fig. 84: Installing the uncoupled filter silencer ..... 133
Fig. 119: Disassembly of the elbows ........................ 162
Fig. 85: Removing the air inlets ................................ 134
Fig. 120: Disassembly of the elbows........................ 163
Fig. 86: Removing the uncoupled filter silencer.... 135
Fig. 121: Pipe disassembly.......................................... 163
Fig. 87: Removing the compressor casing ............. 136
Fig. 122: Disassembly of the connecting pieces .... 164
Fig. 88: Pressing off compressor casing ................ 137
Fig. 123: Disassembly of the cleaning nozzle ......... 164
Fig. 89: Remove the diffuser ..................................... 137
Fig. 124: Assembly of the cleaning nozzle............... 165
Fig. 90: Dismantling the diffuser and the wall insert..
138 Fig. 125: Assembly of the connecting pieces ......... 165

© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Revision S February 2022
 All manuals and user guides at all-guidesbox.com

Operation Manual / A150-M56/66/57/67 - A155-M..

Figures

Fig. 126: Pipe assembly ............................................. 166

Fig. 127: Elbow 1 assembly........................................ 166

Fig. 128: Elbow 2 assembly ........................................ 167

Fig. 129: Fit the cleaning nozzles............................. 168

Fig. 130: Fitting the cover plate................................ 171

Fig. 131: Cover plate drawing .................................... 172

Fig. 132: Dimensions for cover plate........................ 173

Fig. 133: Special tool ................................................... 192

Fig. 134: Special tool ................................................... 193

Page 196 / 198

© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Revision S February 2022
 All manuals and user guides at all-guidesbox.com

Operation Manual / A150-M56/66/57/67 - A155-M..

Tables

Tables
Table 1: Definition of pictograms ............................... 9 Table 26: Malfunctions during operation – Speed in-
creases............................................................................. 83
Table 2: Personal protective equipment to be worn
at all times ...................................................................... 14 Table 27: Malfunctions during operation – Exhaust
gas temperature too high............................................ 84
Table 3: Personal protective equipment to be worn
specific to the respective task ................................... 14 Table 28: Malfunctions during operation – Charge air
pressure too low ............................................................ 84
Table 4: Weight of complete turbocharger unit .... 29
Table 29: Malfunctions during operation – Charge air
Table 5: Fitting the turbocharger, value X, L........... 36 pressure too high .......................................................... 85
Table 6: Torque-controlled tightening of the pres- Table 30: Malfunctions during operation – Engine
sure screws ................................................................... 38 performance losses....................................................... 85
Table 7: Lubricating oil pressure at oil inlet before Table 31: Malfunction – Turbocharger surging ........ 86
turbocharger ................................................................. 45
Table 32: Malfunction – Sporadic surge blows ........ 86
Table 8: Lubricating oil temperature at the inlet... 46
Table 33: Malfunctions when stopping – Runout
Table 9: Maximum lubricating oil temperature at the noises ............................................................................... 87
outlet .............................................................................. 46
Table 34: Malfunctions when stopping – Runout
Table 10: Tightening torque (86505)........................ 50 time too short ................................................................ 87

Page 197 / 198

Table 11: Expected replacement intervals ............... 56 Table 35: Malfunction of the speed measurement
system – No signal or poor signal amplitude .......... 88
Table 12: Maintenance table....................................... 59
Table 36: Malfunction of the speed measurement
Table 13: Parameters for wet cleaning of com- system – Measured speed too high ........................... 88
pressor ........................................................................... 62
Table 37: Malfunction of the speed measurement
Table 14: Turbine wet cleaning, recommended oper- system – Measured speed too low............................. 88
ating state ..................................................................... 65
Table 38: Swivel lifting eyes......................................... 90
Table 15: Wet cleaning of turbines, parameters for 1-
nozzle cleaning.............................................................. 66 Table 39: Press-off screws........................................... 91
Table 16: Wet cleaning of turbines, parameters for 6- Table 40: Dismantling screw ....................................... 91
nozzle cleaning.............................................................. 67
Table 41: Weights of assemblies ................................ 96
Table 17: Tightening torque (81272) .......................... 72
Table 42: Tightening torques ...................................... 97
Table 18: Tightening torque (81273) .......................... 72
Table 43: Tightening torques for insulation ............ 98
Table 19: Value table for soaking ............................... 77
Table 44: 3 press-off screws ..................................... 105
Table 20: Tightening torque (81152 / 81154) ........... 81
Table 45: 6 press-off screws ..................................... 106
Table 21: Malfunctions when starting – Delayed
start-up .......................................................................... 82 Table 46: Tightening torque (90012-01) .................. 111

Table 22: Malfunctions when starting – Vibrations 82 Table 47: Permissible clearances A and B ................116

Table 23: Malfunctions when starting – Rubbing of Table 48: Nozzle ring compression PD ..................... 117
rotating parts................................................................ 82
Table 49: Tightening torque (90012-01) ................. 120
Table 24: Malfunctions during operation – Lubricat-
ing oil pressure too low............................................... 83 Table 50: Tightening torque (51007) ........................ 121

Table 25: Malfunctions during operation – Speed re- Table 51: Tightening torque (79041)........................ 122
duces............................................................................... 83
Table 52: Tightening torque (72011) ....................... 123

Table 53: Permissible clearances N and R............... 126

© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Revision S February 2022
 All manuals and user guides at all-guidesbox.com

Operation Manual / A150-M56/66/57/67 - A155-M..

Tables

Table 54: Tightening torque (51009)....................... 129 Table 88: Spare parts - Compressor casing ........... 187

Table 55: Tightening torque (51009)...................... 130 Table 89: Spare parts - Filter silencer ...................... 189

Table 56: Tightening torque (72051) ....................... 132 Table 90: Spare parts - Air suction branch axial.... 189

Table 57: Tightening torque (72054) ....................... 133 Table 91: Spare parts - Air suction branch radial... 190

Table 58: Threaded rod, value X ............................... 139 Table 92: Spare parts - Speed measurement system..
191
Table 59: Permissible clearances A and B............... 143
Table 93: Customer tool set 90000 ......................... 192
Table 60: Nozzle ring compression PD .................. 144
Table 94: Special tool (90160)................................... 192
Table 61: Threaded rod, value X and L..................... 147
Table 95: Special tool (90160) ................................... 193
Table 62: Tightening torque (51007) ....................... 147

Table 63: Tightening torque (79041) ...................... 148

Table 64: Tightening torque (72011) ...................... 149

Table 65: Permissible clearances N and R ............. 150

Table 66: Tightening torque (72051) ....................... 152

Table 67: Tightening torque (72054) ....................... 153

Table 68: Customer tool ........................................... 154

Page 198 / 198

Table 69: Customer tool ........................................... 154

Table 70: Tightening torque (51007) ...................... 156

Table 71: Tightening torque (51007) with spanner

holder............................................................................. 157

Table 72: Tightening torque (51007) ...................... 158

Table 73: Tightening torque (51007) with spanner

holder............................................................................. 161

Table 74: Dismantling screw .................................... 164

Table 75: Dismantling screw .................................... 165

Table 76: Tightening torque (51314 / 51316).......... 167

Table 77: Cover plate dimensions [mm].................. 172

Table 78: Cover plate dimensions [mm] ................. 173

Table 79: Customer spare part set 97070 .............. 178

Table 80: Spare parts - Cartridge, oil cooled ......... 179

Table 81: Spare parts - Bearing, casing oil cooled 180

Table 82: Spare parts - Rotor and bearing parts... 181

Table 83: Spare parts – Turbine casing, 1 inlet ...... 182

Table 84: Spare parts – Turbine casing, 2 inlets.... 183

Table 85: Spare parts – Turbine casing, 3 inlets... 184

Table 86: Spare parts - Cleaning device................. 185

Table 87: Spare parts - Gas outlet casing, radial . 186

© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Revision S February 2022