Operation Manual / A200-L - ABB

Operation Manual / A200-LTable of contents

© Copyright 2021 ABB. All rights reserved. HZTL4036_EN Rev.T December 2021

Operation Manual / A200-L1 Introduction............................................................................................................ 41.1 Essential information.................................................................................................... 51.2 Registered trademarks................................................................................................. 51.3 Layout and function of the turbocharger ................................................................ 61.4 Locations of the rating plates.................................................................................... 8

2 Safety ...................................................................................................................... 92.1 Introduction ................................................................................................................... 92.2 CE conformity................................................................................................................ 92.3 Definition of mandatory signs .................................................................................. 102.4 Definition of safety instructions .............................................................................. 102.5 Intended use ................................................................................................................. 112.6 Deflagration on gas engines ..................................................................................... 122.7 Warning plates on the turbocharger........................................................................ 132.8 Turbocharger rating plate.......................................................................................... 132.9 Periodic check of the pressure vessels.................................................................... 152.10 Lifting of loads ............................................................................................................. 162.11 Prerequisites for operation and maintenance....................................................... 172.12 Hazards during operation and maintenance ......................................................... 182.13 Safe operation ............................................................................................................. 202.14 Safe maintenance ....................................................................................................... 20

3 Removal and installation .................................................................................... 263.1 Turbocharger weight ................................................................................................. 263.2 Removing the turbocharger...................................................................................... 263.3 Installing the turbocharger ...................................................................................... 28

4 Commissioning .................................................................................................... 314.1 Oil supply ....................................................................................................................... 314.2 Inspection procedures................................................................................................ 314.3 Commissioning after taking out of operation...................................................... 33

5 Monitoring during operation.............................................................................. 345.1 Oil pressure, oil temperature.................................................................................... 345.2 Admissible air inlet temperature .............................................................................. 375.3 Turbocharger speed.................................................................................................... 375.4 Low pressure measurement at the filter silencer ................................................ 40

6 Operation and service ......................................................................................... 416.1 Noise emission ............................................................................................................. 416.2 Service work................................................................................................................. 426.3 Expected replacement intervals .............................................................................. 466.4 Flexible turbocharger cut-out .................................................................................. 47



6.5 Stopping the engine................................................................................................... 48

7 Periodic maintenance.......................................................................................... 497.1 Foreword to maintenance......................................................................................... 497.2 Cleaning the filter silencer ........................................................................................ 507.3 Changing the filter strip on the filter silencer casing.......................................... 527.4 Cleaning the compressor during operation .......................................................... 547.5 Cleaning the turbine during operation................................................................... 587.6 Draining the gas outlet casing ................................................................................. 62

8 Troubleshooting................................................................................................... 638.1 Malfunctions when starting...................................................................................... 638.2 Malfunctions during operation ................................................................................ 648.3 Surging of the turbocharger..................................................................................... 668.4 Malfunctions when stopping.................................................................................... 678.5 Speed measurement system.................................................................................... 68

9 Disassembly and assembly................................................................................. 709.1 Introduction ................................................................................................................. 709.2 Material required.......................................................................................................... 719.3 Weights of assemblies................................................................................................ 729.4 Disassembly and assembly of the filter silencer casing ...................................... 739.5 Dismantling the filter silencer .................................................................................. 789.6 Dismantling wall insert and diffuser....................................................................... 809.7 Axial clearance A prior to disassembly ................................................................... 869.8 Dismantling the insulation (≤ A275-L) .................................................................... 879.9 Dismantling the gas inlet casing (≤ A275-L) .......................................................... 889.10 Dismantling the nozzle ring (≤ A275-L)................................................................... 899.11 Dismantling the gas inlet casing (A280-L)............................................................. 909.12 Dismantling the nozzle ring (A280-L) ...................................................................... 919.13 Fitting the nozzle ring (≤ A275-L)............................................................................. 939.14 Fitting the gas inlet casing (≤ A275-L) .................................................................... 949.15 Fitting the insulation (≤ A275-L) .............................................................................. 959.16 Fitting the nozzle ring (A280-L) ............................................................................... 969.17 Fitting the gas inlet casing (A280-L)....................................................................... 989.18 Axial clearance A after assembly.............................................................................. 999.19 Fitting the diffuser ................................................................................................... 1009.20 Fitting wall insert ....................................................................................................... 1019.21 Fitting the filter silencer.......................................................................................... 1059.22 Table of tightening torques.................................................................................... 108

10 Taking a turbocharger out of operation......................................................... 11010.1 Possible emergency repairs..................................................................................... 11010.2 Taking defective turbochargers out of operation .............................................. 111

11 Mothballing the turbocharger.......................................................................... 11611.1 Taking the engine out of operation for up to 12 months .................................. 11611.2 Taking the engine out of operation for more than 12 months ......................... 117



12 Material and Disposal........................................................................................ 11812.1 REACH and RoHS Compliance Declaration For Products .................................. 11812.2 Disposing of turbocharger components .............................................................. 119

13 Spare parts ......................................................................................................... 12013.1 Ordering spare parts................................................................................................ 12013.2 Spare Part - Illustrations........................................................................................... 122

14 Tools .................................................................................................................... 140

Figures................................................................................................................. 142

Tables .................................................................................................................. 144

Operation Manual / A200-L1 Introduction /


1 Introduction

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Operation Manual / A200-L1 Introduction / 1.1 Essential information


1.1 Essential information

Design variants

This document is valid for different design variants of turbochargers. There may be sectionsand descriptions of components that are not relevant for a specific turbocharger variant.

Please contact an ABB Turbocharging Service Station if you have any questions regarding adesign 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.

1.2 Registered trademarksThe trademarks of outside companies are used in this document. These are marked with the® symbol.

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http://www.abb.com/turbocharging

Operation Manual / A200-L1 Introduction / 1.3 Layout and function of the turbocharger


1.3 Layout and function of the turbocharger

Fig. 1: Layout and function of the turbocharger

01 Filter silencer 08 Gas inlet casing02 Thrust bearing 09 Bearing casing03 Radial plain bearing 10 Diffuser04 Radial plain bearing 11 Compressor wheel05 Gas outlet casing 12 Compressor casing06 Turbine wheel 13 Air-outlet silencer (option)07 Nozzle ring

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Operation Manual / A200-L1 Introduction / 1.3 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 gas inlet casing (08)and the nozzle ring (07) onto the turbine wheel (06). The turbine wheel uses the energy con-tained in the exhaust gas to drive the rotor and, hence, the compressor wheel (11).

The exhaust gases then reach the atmosphere through the exhaust gas pipe connected tothe gas outlet casing (05).

The compressor wheel (11) sucks in fresh air and presses the compressed air into the cylin-ders.

The air passes through the filter silencer (01) to the compressor wheel (11). The air thenflows through the diffuser (10) and exits the turbocharger through the compressor cas-ing (12). An air outlet silencer (13) is optionally available. If installed, this will reduce theamount of noise generated by the components at the outlet side after the compressor cas-ing.

The rotor runs in two radial plain bearings (03/04) which are located in the bearing cas-ing (09) between the compressor and turbine. The axial thrust bearing (02) is located at thecompressor end.

The plain bearings are connected to a central lubricating oil duct which is normally suppliedby the lubricating oil circuit of the engine. The oil outlet always lies at the deepest point ofthe bearing casing (09).

The turbocharger is equipped with an oil tank which is integrated in the bearing casing (9).This oil tank supplies the bearings of the rotor with oil until standstill in the event that a mal-function of the lubrication oil system causes an emergency stop of the engine.

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Operation Manual / A200-L1 Introduction / 1.4 Locations of the rating plates


1.4 Locations of the rating plates

Fig. 2: 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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Operation Manual / A200-L2 Safety / 2.1 Introduction


2 Safety

2.1 IntroductionTurbochargers manufactured by ABB reflect the state of the art. The respective safety andhealth 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 toand 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.

All further safety instructions contained and specifically identified in every chapter of thisOperation Manual (Definition of safety instructions →10) must also be observed.

2.2 CE conformity

Information

ABB turbochargers comply with the Machinery Directive 2006/42/EC and are partly com-pleted machinery as defined by Article 2 g in this directive.

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Operation Manual / A200-L2 Safety / 2.3 Definition of mandatory signs


2.3 Definition of mandatory signs

To be worn at all timesProtective clothing Safety footwear to protect

against mechanical hazard andrisk of falling

Table 1: Personal protective equipment to be worn at all times

To be worn specific to the respective taskSafety glasses Safety goggles

Safety gloves to protectagainst- Mechanical hazard- Chemical hazard- Thermal hazard- Electrical hazard

Respiratory mask to protectagainst- Dusts- Gases

Safety helmet Ear protection

Table 2: Personal protective equipment to be worn specific to the respective task

2.4 Definition of safety instructions

WARNINGDefinition of WarningNon-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.

CAUTIONDefinition of CautionNon-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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Operation Manual / A200-L2 Safety / 2.5 Intended use


2.5 Intended use

Use on internal combustion engines in general

ABB turbochargers are intended for charging internal combustion engines.

The A100-L/A200-L turbochargers are designed for use on 2-stroke engines. These can beoperated with liquid and gaseous fuels.

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].

The turbocharger supplies the engine with the air volume and associated charging pressurerequired for operation.

The turbocharger is solely intended to be operated with a clockwise direction of rotation asviewed from the turbine end.

The turbocharger is supplied with air from the engine compartment via the filter silencer. Ifthe air is mixed with cooled exhaust gases via the low-pressure exhaust gas recirculation(EGR), it must be ensured that these are cleaned as well as possible and that no waterdroplets or exhaust gas particles enter the compressor inlet.

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 ratingplate.

The use of the turbocharger is limited to the specific application released at the time of de-livery.

ABB accepts no liability and rejects all warranty claims for any non-intended applications.

[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, ATEXEuromot Position 191103

WARNINGUnapproved operationAny 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 / A200-L2 Safety / 2.6 Deflagration on gas engines


State of the art

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

ABB excludes any liability for damage resulting from unauthorized modifications to the tur-bocharger or improper operation.

2.6 Deflagration on gas enginesABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar.

After a deflagration event ABB recommends verifying the following points on the turbochar-ger:

¡ Position of the turbine and compressor casings to the bearing casing

¡ Shifting of the bearing casing in relation to the bracket

¡ Cracks in casings

If during external inspection anomalies are found or if a particularly strong deflagrationevent has taken place, it is also recommended to check the bearings of the turbochargersbefore the next start. An ABB Turbocharging Service Station should be instructed to carryout this inspection.

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Operation Manual / A200-L2 Safety / 2.7 Warning plates on the turbocharger


2.7 Warning plates on the turbochargerWarning plates are affixed at the following locations:

Fig. 3: 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 ABB Turbocharging 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 withwarning plates on the insulation. This is the responsibility of the enginebuilder.

2.8 Turbocharger rating plate

Fig. 4: Rating plate

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Operation Manual / A200-L2 Safety / 2.8 Turbocharger rating plate


Operating limits

01 Turbocharger operating limits at engine overload (110 %). In test rig operation only, unless otherwise agreed with the en-ginebuilder.

02 Turbocharger operating limits during operation

Recommended replacement intervals of turbocharger components

03 Replacement interval of plain bearings in 1000 h04 Replacement interval of compressor in 1000 h05 Replacement interval of turbine in 1000 h

Further data

06 Customer part number07 Designation for special design08 Weight of turbocharger in kg09 Turbocharger type10 Serial number11 Year of construction of turbocharger12 Manufacturing plant

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Operation Manual / A200-L2 Safety / 2.9 Periodic check of the pressure vessels


Explanations regarding the rating plate

The recommended replacement intervals and the corresponding operating limits are jointlydefined with the enginebuilder. This information is specific to the system.

Operation above the indicated values nBmax, tBmax can considerably shorten the recommendedreplacement intervals. In such cases ABB recommends contacting the nearest ABB Tur-bocharging Service Station.

nMmax, tMmax normally apply only when running at overload (110%) during trials on the enginetest 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 replacement intervals increases the risk of unpredict-able component failures.

Locations of the rating plates

The locations of the rating plates are defined in the Operation Manual.

2.9 Periodic check of the pressure vesselsThe pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, areso-called "simple pressure vessels".

¡ The locally applicable legal regulations regarding periodic checks of the pressure vesselsmust be observed.

¡ The operating company is responsible for the safe operation of the pressure vessel.

WARNINGDanger due to pressure vesselsThe operating company must make sure the pressure vessels are in properworking condition and monitor them. Necessary repair or maintenance workmust be performed promptly, and the required safety measures must betaken.

u Pressure equipment must not be operated if defects are present.Pa

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Operation Manual / A200-L2 Safety / 2.10 Lifting of loads


2.10 Lifting of loads

WARNINGSuspended loadsLoads that are not attached according to regulations can cause injury topersonnel or fatal accidents.

u Loads must always be fastened to properly functional lifting gear with asufficient 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.

Fig. 5: Attachment of loads on the crane hook

Fig. 6: 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 tipover.

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Operation Manual / A200-L2 Safety / 2.11 Prerequisites for operation and maintenance


2.11 Prerequisites for operation and maintenance

Responsibility of the operating company

In awareness of its responsibility, the operating company must ensure that only authorisedpersonnel work on the turbocharger, who:

¡ Are versed in the general and locally applicable regulations for occupational safety andaccident 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 bechecked periodically.

Suitable working materials and personal protective equipment must be kept in a perfectcondition.

Only authorised personnel may remain in the vicinity of the turbocharger when the engine isrunning.

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 ABB.

WARNINGUse original partsOperation of the turbocharger with non-original parts can impair the safetyof the turbocharger and can cause serious damage to property and injury topersonnel.

u Only use original parts from ABB.

Original parts and accessories are specially designed for ABB turbochargers.

ABB accepts no liability for any damage resulting from the use of non-original parts and cor-responding accessories.

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Operation Manual / A200-L2 Safety / 2.12 Hazards during operation and maintenance


2.12 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.

WARNINGNoise hazardsExposure 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

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

WARNINGDanger of burnsTouching 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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Operation Manual / A200-L2 Safety / 2.12 Hazards during operation and maintenance


WARNINGHot surfaces on a non-insulated turbochargerNon-insulated turbochargers can cause serious injuries to personnel (burns).

The turbocharger is supplied with or without insulation in accordance withthe purchase order received from the enginebuilder. If supply is without in-sulation, the enginebuilder is responsible for providing the turbochargerwith proper insulation and for providing protection against contact with hotsurfaces.

u Compliance with the instructions and specifications given by the en-ginebuilder to protect against hot turbocharger surfaces is compulsory.


Hazards due to rotating parts

WARNINGHazards due to rotating partsContact with rotating parts can cause severe injury. The turbocharger isnever allowed to be operated without filter silencer or air-inlet casing. Withthe 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.


Hazards due to electrical installations (if present)

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Operation Manual / A200-L2 Safety / 2.13 Safe operation


2.13 Safe operation

Mechanical hazards during operation

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

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.

u Check turbocharger for recognisable damage or defects every 12 hours of operation or atleast once a day.

u Report any damage and any alterations of operational characteristics to the responsibledepartment immediately.

u In case of damage, take the turbocharger out of operation immediately and safeguardagainst accidental/unauthorised use.

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.

2.14 Safe maintenance

Occupational safety

WARNINGInjuries to personsSevere injuries to personnel or fatal accidents can be caused by mechanicalinfluences 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.

Wear safety footwear to protect against mechanical hazard and risk of fall-ing.

Wear protective clothing.

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Operation Manual / A200-L2 Safety / 2.14 Safe maintenance


WARNINGRisk of fallingWhen working on the turbocharger, there is a risk of falling.

u Do not climb onto the turbocharger or onto attached parts and do notuse them as climbing aids.

u Use suitable climbing aids and working platforms for work above bodyheight.

u Only perform work on the turbocharger when you are in a physically and psychologicallystable 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.

Use of assembly devices

Assembly devices are specially constructed and designed for the defined use; they are notcommercially 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 filtersilencer 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 datasheet and the safety instructions in section Hazards due to operating materials and suppliesmust be observed.

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.

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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 theengine 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.

CAUTIONMechanical operations on the turbochargerComponents of the turbocharger can be damaged or destroyed as a resultof improper procedures.


u Only perform operations for which you have received instruction or train-ing.

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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

WARNINGMechanical hazardSevere injuries to personnel or fatal accidents can be caused by mechanicalinfluences 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 for which you have previously received instruc-tion or training.

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, detergentsand solvents, acids and similar substances can be classified as hazardous substances.

WARNINGHandling operating materials and suppliesSwallowing 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 materialsafety 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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WARNINGDanger of fire or explosionFlammable and combustible operating materials and supplies can catch fireor resulting vapours can lead to an explosion.



u Do not allow any exposed flame or ignition source during cleaning work.

u Carry out cleaning in the open or provide sufficient ventilation.

CAUTIONEnvironmental hazardImproper handling of operating materials and supplies can lead to environ-mental damage.



Hazards due to the handling of insulation materials

WARNINGDanger from insulation materialsDust or fibres from insulation materials can have adverse effects on thehealth or cause irritations. Unsuitable and combustible insulation materialsare 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 a respiratory mask to protect against dusts.


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Operation Manual / A200-L3 Removal and installation / 3.1 Turbocharger weight


3 Removal and installation

3.1 Turbocharger weightLifting 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 thanthe standard value specified here.

Product Weight of complete turbocharger unit [kg]A255-L 1350A260-L 1550A265-L 2600A270-L 3800A275-L 6300A280-L 8700Table 3: Total weight

3.2 Removing the turbocharger

WARNINGRisk of tippingIf the turbocharger is not sufficiently supported or not supported at all dur-ing removal and installation, it may tip over and cause severe injury to per-sonnel or accidents resulting in fatalities.

u Support the turbocharger at a suitable location.

u Secure with lifting gear wherever possible.

u Loosen cable to speed sensor.

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

u Check lifting gear.

u Attach lifting gear to the turbocharger and tauten.

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Operation Manual / A200-L3 Removal and installation / 3.2 Removing the turbocharger


Fig. 7: Fitting the lifting gear

u Loosen fixing screws on compressor-end and turbine-end foot.

u Lift turbocharger from engine and put down in a suitable location.

u Cover oil connections.

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Operation Manual / A200-L3 Removal and installation / 3.3 Installing the turbocharger


3.3 Installing the turbocharger

3.3.1 Placing the turbocharger on the bracket

Fig. 8: Placing the turbocharger

u Remove covers from the oil connections.

u Align turbocharger and place on engine bracket.

u Tighten the fixing screws (Steps for fastening the turbocharger) while only slightlyloosening the lifting gear.

u Remove lifting gear from turbocharger.

u Connect cable to speed sensor.

u Connect all gas, air and oil pipes.

See also

2 Steps for fastening the turbocharger [} 29]

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3.3.2 Steps for fastening the turbocharger

General information

Subject Requirement / InformationTurbocharger fixing elements ISO property class ≥ 8.8Washers Hardened, thickness ≥ 15 % nominal thread dia-

meterDimension a (compressor end) a = height of turbocharger foot aDimension a (turbine end) a = height of turbocharger foot F + spacer sleeve

DDimension b Hole in bracketDimension c Thread length, ≥ 1.5 x nominal thread diameterCoefficient of friction 0.12 (lightly oiled)Table 4: General information about fastening the turbocharger

Compressor-end foot

Fig. 9: Compressor-end foot

u Tighten the foot fixing screws or nuts diagonally according to the selected tighteningmethod.

Turbine-end foot

Fig. 10: Turbine-end foot

u Tighten the foot fixing screws or nuts according to the selected tightening method.

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Torque-controlled tightening

Product Thread size Height a of foot [mm]

Tightening torque [Nm]

A255-L M27 60 830A260-L M27 60 830A265-L M22 86 440A270-L M27 100 830A275-L M30 120 1100A280-L M33 136 1500Table 5: Tightening torques (foot screws)

Angle-controlled tightening

Product Thread size Height a foot[mm]

Pre-tighteningtorque[Nm]

Tighteningangle

height a[DEG]

Additional tightening angle forevery 10 mm of ad-

ditional screwlength b

[DEG]A255-L M27 60 220 30 3.1A260-L M27 60 220 30 3.1A265-L M22 86 120 30 3.7A270-L M27 100 220 30 3.1A275-L M30 120 300 30 2.6A280-L M33 136 400 35 2.6Table 6: Tightening angle (foot screws)

Pinning of turbocharger feet with positioning pins

If the turbocharger is pinned at its feet, one pin hole per foot must be used.

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Operation Manual / A200-L4 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 oiland the oil change intervals.

For more information on the oil supply, refer to Chapter Oil pressure, oil temperature →34.

4.1.2 Oil filtering

Filtering of the lubricating oil with a filter mesh width of ≤ 0.050 mm is sufficient for the tur-bocharger.

4.1.3 Oil pressure

Comply precisely with the oil pressure before the turbocharger for trouble-free operation.

If the oil pressure at the inlet of the turbocharger is too high, it can be reduced with athrottle valve. The throttle valve is normally already fitted on the turbocharger and has beencorrectly set by the enginebuilder. This takes place either during the trial run on the enginetest bed or during the trial phase of the system.

If the oil pressure values are outside the admissible range during normal operation, youmust contact the enginebuilder.

4.2 Inspection procedures

4.2.1 Introduction

Inspection procedures include preventative visual controls, monitoring and measuring workbefore and during commissioning. Inspection procedures enable changes to the turbochar-ger to be detected. Machine damage can be prevented.

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Operation Manual / A200-L4 Commissioning / 4.2 Inspection procedures


4.2.2 Checks before commissioning

Filter mat (if available)

u Check for damage and contamination.

Lubricating system

CAUTIONContaminated oilSerious damage to engine or property can be caused by dirt and solid ma-terial particles in the oil.

u For the initial commissioning phase and after all service work, flush thecomplete 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.

4.2.3 Checks after commissioning (engine in idle mode)

Lubricating system

u Check the oil pressure in the oil supply pipes.

u Check oil inlet temperature.

The admissible values are specified in section Oil supply.

Gas, air and oil pipes

u After starting the engine, check all gas, air and oil pipes for leaks.

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Operation Manual / A200-L4 Commissioning / 4.3 Commissioning after taking out of operation


4.2.4 Checks when starting up the engine

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 Troubleshooting →63).

Escape of oily fluids

Lubricants and pastes used during assembly can liquefy or vaporise and escape as oily fluidsduring the initial hours of operation. Continual escape of an oily fluid indicates an oil leak.

u If there is a leak, contact an ABB Turbocharging Service Station.

4.3 Commissioning after taking out of operation

If present

u Remove cover plates (blind flanges) from the compressor casing, the gas inlet and thegas outlet.

General

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

u Put engine-side oil circulation to the turbocharger into operation.

u Prepare the turbocharger for operation (see Checks before commissioning →32).

u The turbocharger is now ready for operation.

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Operation Manual / A200-L5 Monitoring during operation / 5.1 Oil pressure, oil temperature


5 Monitoring during operation

5.1 Oil pressure, oil temperature

Lubricating oil pressure before turbocharger

CAUTIONAssuring lubricating oil pressureSerious 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 thenecessary pressure assured at the oil inlet.

Status for operation Oil pressure before tur-bocharger

[bar]Admissible for normal operation, with an oil temperature range at the inlet of 30 … 65 °Cwith an oil temperature range at the inlet of 65 … 80 °C

0.8 … 2.51.0 … 2.0

Admissible during engine warm-up, with an oil temperature range at the inlet of 30 … 65 °Cwith an oil temperature range at the inlet of 65 … 80 °C

0.8 … 4.01.0 … 4.0

Temporarily admissible ( < 1 h ) → alarmwith an oil temperature range at the inlet of 30 … 65 °Cwith an oil temperature range at the inlet of 65 … 85 °C

0.6 … 0.80.8 … 1.0

Not admissible → emergency stopwith an oil temperature range at the inlet of 30 … 65 °Cwith an oil temperature range at the inlet of 65 … 85 °C

< 0.6< 0.8

Admissible, during pre-lubrication and post-lubrication (enginestopped)

0.2 … 0.6

Table 7: Lubricating oil pressure, oil inlet

Lubricating oil temperature at the inlet

CAUTIONMachine damageIf the oil temperature at the oil inlet exceeds the admissible range, this maylead to engine damage.

u Observe oil temperature at the oil inlet according to the following table.

Status for operation Oil temperature at the inletToil,inlet [°C]

Admissible (see Table 7: Lubricating oil pressure, oil inlet→34)

30 … 80

Temporarily admissible (< 1 h) → alarm > 80Not admissible → stop engine > 85

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Not admissible → do not start engine (before start: preheatoil)

< 30

Table 8: Lubricating oil temperature at the inlet

Lubricating oil temperature at the outlet

The oil temperature at the outlet is mainly dependant on:

¡ 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. Thespecified oil outlet temperature is to be considered as alarm value for the turbocharger op-eration and must be monitored according to the current regulations.

Fig. 11: Oil temperature at the outlet


Oil temperature at the outletToil,outlet [°C]

Admissible 45 ≤ 110Admissible 80 ≤ 125Temporarily admissible → alarm 45 > 110Temporarily admissible → alarm 80 > 125Not admissible → stop engine 45 > 120Not admissible → stop engine 80 > 135Table 9: Lubricating oil temperature at the outlet

If the turbocharger has been operated for a longer period of time outside the admissiblerange, ABB Turbocharging recommends having the turbocharger inspected by an ABB Tur-bocharging Service Station.

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5.1.1 Pre-lubrication and post-lubrication

CAUTIONPre-lubricationSerious damage to engine or property can result if the turbocharger is notsupplied with oil from the first moment after starting the engine.

u Activate the pre-lubrication device each time before starting the engine.

The pre-lubrication time is at least 5 minutes.

The post-lubrication time is at least 10 minutes.

If the engine is operated for 5 to 10 minutes in idle mode before stopping, no additionalpost-lubrication is required.

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Operation Manual / A200-L5 Monitoring during operation / 5.2 Admissible air inlet temperature


5.2 Admissible air inlet temperatureThe permitted air inlet temperature must be between -40C°… +45C°.

5.3 Turbocharger speed

5.3.1 Introduction

The speed of the turbocharger must be permanently monitored.

CAUTIONDo not use cables as a climbing aidIf you pull the speed measurement cables too hard, contacts can be pulledout.

u Do not tension the speed measurement cables.

5.3.2 Layout and overview

Fig. 12: Layout and overview of the speed measurement system

86505 Speed sensor 86528 Tachometer86506 O-ring 42047 Screw plug86515 Cable connector 32109 Sealing disc with cams86526 F/I converter *) Alternative mounting position for speed

sensoror for the second speed sensor

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Operation Manual / A200-L5 Monitoring during 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 standardoperation.

The difference between the highest and the lowest turbocharger speed must not be morethan 3 %, relative to the speed limit nBmax.

If this permissible range of difference is exceeded, the following steps must be carried out:

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 loador turbocharger speed.

u If a turbocharger surges continuously, the engine performance must be reduced further.

u Measure the temperatures in the air lines and gas piping from and to the turbochargersand compare with normal values. If clear deviations of temperature are found, the nearestABB Turbocharging 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:

u Inspect air lines, gas piping and the turbochargers and remedy any malfunctions.

u In any case, contacting the nearest ABB Turbocharging Service Station is recommended.

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Operation Manual / A200-L5 Monitoring during operation / 5.3 Turbocharger speed


5.3.4 Replacing the speed sensor

WARNINGHot cable connector and hot speed sensorDanger of burns. The cable connector and speed sensor can reach temperat-ures in excess of 100 °C during operation.

u When disassembling the cable connector and speed sensor, wear safetygloves.


u The speed sensor is designed with a sealing lip and does not require a sealing disc for as-sembly.

Fig. 13: Replacing the speed sensor

Part number A255-L A260-L A265-L A270-L A275-L A280-L86505 M18x1.5

150 NmM18x1.5 150 Nm

M18x1.5 150 Nm

M18x1.5 150 Nm

M18x1.5 150 Nm

M27x2 320 Nm

Table 10: Tightening torques (86505)

u Reduce the engine performance to idling and then stop the engine. Pay attention to post-lubrication (Stopping the engine →48).

u Switch off the lubricating oil supply to the turbocharger.

u Disconnect the cable connector from the speed sensor.

u Unscrew the defective speed sensor.

u Screw in new speed sensor to the stop.

u Connect cable connector (86515) with the speed sensor (86505)

u Switch on lubricating oil supply to the turbocharger.

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Operation Manual / A200-L5 Monitoring during operation / 5.4 Low pressure measurement at thefilter silencer


5.3.5 Malfunction of the speed measurement system

The possible reasons for malfunction of the speed measuring system are described inchapter Troubleshooting.

5.4 Low pressure measurement at the filter silencer

5.4.1 Introduction

The low pressure measurement with a U-tube manometer is used for the following pur-poses:

¡ During acceptance test of the engine: Measurement of the correction factor for the cal-culation of the turbocharger efficiency

¡ When using a filter mat: An increased pressure loss indicates an increase in the fouling ofthe filter material.

5.4.2 U-tube manometer at the filter silencer

Fig. 14: U-tube manometer at the filter silencer

81000 Filter silencer81050 U-tube manometerA [mm H2O] Pressure loss / pressure difference

If the turbocharger is operated at maximum engine power and pressure loss (A) reaches thevalue of 200 mm H2O:

u Clean filter mat.

Reading of pressure loss

For simple reading of the pressure loss (A), the dipstick at the U-tube manometer can bepulled out to the level of the lower water level. Better readability of the U-tube manometercan be achieved by filling with slightly coloured water.

u Colour the water with food colouring or ink.

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Operation Manual / A200-L6 Operation and service / 6.1 Noise emission


6 Operation and service

6.1 Noise emission

WARNINGNoise hazardsExposure 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).


The emission sound pressure level (A-weighted) is measured at a distance of 1 meter fromthe 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-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. 15:Noise insulation, bellows →42).

The enginebuilder is responsible for insulating the charge air/scavenging air line and thecharge 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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Operation Manual / A200-L6 Operation and service / 6.2 Service work


Suggestion for noise insulation, bellows

Fig. 15: Noise insulation, bellows

01 Compressor casing02 Bellows03 Charge air duct / scavenging air duct04 Insulation cushion05 Insulation mat (at least 15 mm)06 Sheet metal cover

6.2 Service workService 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.

CAUTIONService intervalsAny service work on the turbocharger that is omitted or performed too latecan cause excessive contamination, wear and operating failures.

u Carry out the service work at the specified time intervals.

CAUTIONSpecific service intervalExceptional stresses such as a high number of starts and stops, harsh envir-onmental conditions, poor fuel quality or high system vibrations can lead tountimely machine damage even if the prescribed service intervals are ob-served.

u Agree on a specific service interval with ABB Turbocharging.

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To prevent machine damage caused by ageing and downtime, we recommend having an in-spection carried out by an ABB Turbocharging Service Station no later than 5 years after thelast service.

6.2.1 Service work every 25 … 50 hours

CAUTIONUnknown operational changesImpairment to the degree of a possible operating failure can be the con-sequence.

u Have any unknown causes clarified by an ABB Turbocharging Service Sta-tion.

u Visual check for air, exhaust gas, water and oil leaks.

u Record operating data and enter in the engine logbook.

u In case of deviations, determine the cause.

6.2.2 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.

6.2.3 Service work on turbocharger every 18000 hours

It is recommended to have this service work and these checks carried out by an ABB Tur-bocharging Service Station. Damaged and worn out parts must be replaced with originalABB parts.

Take note of correct customer spare part set (see chapter Ordering spare parts →120).

u Remove and clean the filter silencer and check for damage.

u Dismantle the wall insert.

u Check axial clearance A.

u Clean compressor wheel, diffuser, wall insert and compressor casing and check for dam-age.

u Check the nozzle ring, turbine diffuser and turbine blades for any possible contamination,damage or wear using a borescope.This checking can also be carried out after disassembling the gas inlet casing.

u Fit the wall insert.

u Install the filter silencer.

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6.2.4 Service work on turbocharger every 36000 hours

Service work on the rotor and bearing parts must be carried out by an ABB TurbochargingService Station. Damaged and worn out parts must be replaced with original ABB parts.

Take note of correct customer spare part set (see chapter Ordering spare parts →120).

u Remove the filter silencer.

u Clean filter silencer and check for damage.

u Dismantle the wall insert.

u Check axial clearance A.

u Clean wall insert, diffuser and compressor casing and check for damage.

u Remove the gas inlet casing and dismantle the nozzle ring and cover ring.

u Clean the nozzle ring and cover ring and check for damage.

u Dismantle, inspect and balance the rotor.

u Replace the plain bearing

6.2.5 Service work according to instructions of enginebuilder

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.

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6.2.6 Entries in the engine logbook

The monitoring of the engine system enables conclusions to be drawn on the behaviour ofthe turbocharger.

The following operating data and measured values must be entered regularly into the enginelogbook of the enginebuilder:

¡ Performance and speed of the engine

¡ Speed of the turbocharger

¡ Air intake temperature

¡ Exhaust gas temperature before and after the turbine

¡ Pressure of the charge air

¡ Pressure loss in the charge air cooler

¡ Lubricating oil pressure and lubricating oil temperature

¡ Pressure loss in the filter silencer

¡ Air temperature after the charge air cooler

If present:

¡ Air temperature after the compressor

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Operation Manual / A200-L6 Operation and service / 6.3 Expected replacement intervals


6.3 Expected replacement intervals

6.3.1 Replacement intervals

Expected replacement intervals [h]

Turbocharger part Operation with HFO *)Gas inlet casing 50000 … 100000

Gas outlet casing 50000 … 100000Nozzle ring 35000 … 50000Cover ring 25000 … 50000

Other casings 100000Table 11: Expected replacement intervals for turbocharger parts

*) HFO = Heavy Fuel Oil

Recommended replacement intervals [h]

Rotor components See information on rating plateBearings See information on rating plate

Table 12: Recommended replacement intervals for turbocharger parts

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

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Operation Manual / A200-L6 Operation and service / 6.4 Flexible turbocharger cut-out


6.4 Flexible turbocharger cut-outIf the load is low, an engine which is charged by multiple turbochargers can be operated withone turbocharger switched off. The flexible switch-on or switch-off of a turbocharger is re-ferred to as a "flexible turbocharger cut-out". In flexible systems, slide valves or flaps are in-stalled by the enginebuilder before the gas inlet and after the air outlet of the turbocharger.Depending on the version of the system, the turbocharger can be switched off or on manu-ally or automatically. In all cases, you must observe the enginebuilder's recommendations. The lubricating oil supply of the switched-off turbocharger must not be switched off due tothe engine vibrations. To ensure that there are no oil or gas leaks on the switched off tur-bocharger, it must be supplied with external sealing air.The turbocharger may only be switched on or off while the engine is stopped or in idle mode.

CAUTIONFlexible turbocharger cut outImproper manipulations can result in inadmissible turbocharger speedswhich can lead to serious damage to property with grave consequences.

u The air outlet flap and gas inlet flap must be completely open during nor-mal operation.

u During cut out operation, the air outlet flap and gas inlet flap must becompletely closed.

CAUTIONManual switching of the flapsIf the gas inlet flap is opened during cut-out operation or the air-outlet flapis closed during normal operation, this causes very high turbochargerspeeds. These can result in damage with serious consequences or even atotal loss of the turbocharger.

u Never open the gas inlet flap during cut-out operation.

u Never close the air-outlet flap during normal operation.

CAUTIONAutomatic switching of the flapsDuring automatic flap control, there is a risk of the turbocharger rotatingopposite the intended direction of rotation if the air-outlet flap is open fur-ther than the gas inlet flap during the switching process. This can lead todamage on the turbocharger.

u The turbocharger should only be switched on or off below charging pres-sures of 0.3 bar.

u Close the compressor outlet flap just before the gas inlet flap.

Contamination with closed flaps

To limit the contamination deposits when operating with closed flaps, we recommend youopen them at least every 500 hours of operation.

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Operation Manual / A200-L6 Operation and service / 6.5 Stopping the engine


6.5 Stopping the engineu Observe the instructions regarding post-lubrication (Pre-lubrication and post-lubrication→36)

u Stop the engine.

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Operation Manual / A200-L7 Periodic maintenance / 7.1 Foreword to maintenance


7 Periodic maintenance

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

Described maintenance points:

¡ Filter silencer

¡ Compressor

¡ Turbine and nozzle ring

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Operation Manual / A200-L7 Periodic maintenance / 7.2 Cleaning the filter silencer


7.2 Cleaning the filter silencer

Filter silencer with tension band

Fig. 16: Layout and overview of filter silencer

81126 Lock 81266 Cover grid81135 Body of filter silencer 81268 Connecting strip81136 Absorption segment 81270 Tension band81137 Sheet-metal covering 81271 Lock81265 Filter ring (if present) 81400 Water connectionE Insert unit (absorption segment / sheet-metal covering fitted)

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Operation Manual / A200-L7 Periodic maintenance / 7.2 Cleaning the filter silencer


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 thefifth 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 (waterjet).

u Let the filter ring dry completely before assembling.

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

Cleaning the absorption segments

u Loosen the tension bands (81270) at the locks (81271) and remove them along with thecover grid (81266) and connecting strips (81268) (see Fig. 16: Layout and overview of fil-ter silencer →50).

u Pull out insert units (E).

u Bend up the sheet-metal coverings (81137) and remove the absorption segments (81136).

u Clean the absorption segments (81136).When cleaning, note that the absorption segments may only be cleaned lightly with pres-surized air, with a soft brush or a moist cleaning cloth. Otherwise there is a danger ofdamage or changing of the shape.

u Replace heavily contaminated absorption segments (81136) and any damaged connectingstrips (81268) with original parts from ABB.

Fitting the filter silencer

u Insert the absorption segments (81136) into the sheet-metal coverings (81137).

u Bend the sheet-metal coverings (81137) back into the original shape.

u Insert the insert units (E) into the slotted guides in the filter silencer body (81135).

u Fit the cover grid (81266) and connecting strips (81268) on the filter silencer body (81135).

u Guide the tension bands (81270) through the eyelets of the connecting strips (81268).

u Tighten the tension bands (81270) at the locks (81271).

u Any damaged tension bands must be replaced.

u Fit filter ring (81265), if present.

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Operation Manual / A200-L7 Periodic maintenance / 7.3 Changing the filter strip on the filter silen-cer casing


7.3 Changing the filter strip on the filter silencercasing

This chapter applies only to turbochargers with filter silencer casing. The filter ring (81265) isreplaced with the filter silencer installed.

Fig. 17: Dismantling filter ring circumferential part

u Dismantle circumferential part (9).

Fig. 18: Opening filter ring lock

u Open the lock of the filter ring (81265).

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Operation Manual / A200-L7 Periodic maintenance / 7.3 Changing the filter strip on the filter silen-cer casing


Fig. 19: Attaching new filter ring

u Attach the new filter ring (81265) on the filter ring to be replaced so they overlap.

Fig. 20: Fitting new filter ring

u Pull on the old filter ring until the new filter ring is completely wrapped around the filtersilencer.

u Undo the connection between the new and the old filter ring.

u Fasten the newly installed filter ring (81265), then fit circumferential part (9).

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Operation Manual / A200-L7 Periodic maintenance / 7.4 Cleaning the compressor during operation


7.4 Cleaning the compressor during operation

7.4.1 Introduction

Approval by enginebuilder

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

The contamination of the compressor stage (compressor wheel, wall insert and diffuser) de-pends on the degree of purity of the air that is sucked in.

Deposits can form in the flow channels if salt, oil mist or dust are sucked in with the air.

Consequences of contamination:

¡ Impaired compressor efficiency

¡ Higher exhaust gas temperatures

¡ Increased fuel consumption

¡ Increased rotor unbalance

Periodic cleaning of the compressor during operation prevents or delays any major increasein contamination. But it never replaces the regular service work where the turbocharger iscompletely dismantled and the compressor is mechanically cleaned.

Cleaning interval

The interval between the cleaning cycles depends greatly on the operating conditions.Cleaning should normally be carried out every 50 hours of operation. If the specified cleaning interval is incompatible with operation of the engine, contact ABBTurbocharging.

Cleaning method and operating state

The compressor is cleaned during operation using the wet cleaning method. This cleaningmethod is tested and approved by ABB Turbocharging.

When undertaking wet cleaning, the following operating state must be ensured:

¡ engine load between 25 … 85 %.

¡ If the engine compartment temperature is below 0°C when wet cleaning the compressor,precautionary measures should be taken to prevent ice from forming.

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Principle of wet cleaning

CAUTIONRisk of ice formationWhen cleaning the compressor with water and air inlet temperatures < 0°C,there is a risk of ice formation at the turbocharger.

u Compressor cleaning with water is not recommended for air inlet temper-atures < 0°C.

CAUTIONCorrosion and deposits when cleaningSalt water and cooling water treatment substances damage and adverselyaffect turbocharger parts.

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

To clean the compressor stage during operation, water is injected upstream of the com-pressor wheel.

The water does not act as a solvent. The coating is removed by the mechanical action of theimpacting droplets. The procedure is perfectly suitable, provided that the contaminationhas not progressed too far.

Cleaning several turbochargers

If several turbochargers are installed on an engine, it is recommended to clean one com-pressor after the other.

CAUTIONVolume of water for cleaning the compressorUncontrolled volumes of water can damage the turbocharger and the en-gine.

u Do not guide water pipes to the filler openings.Pa

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7.4.2 Wet cleaning of compressor

WARNINGDamage to hearing due to high noise levelRemoving the screw plug (81126) from the filler orifice (B) may result in ahigh level of noise. Carrying out wet cleaning on the compressor without earprotection may lead to serious hearing damage.

u Always wear ear protection when carrying out wet cleaning on the com-pressor.


Fig. 21: Overview of wet cleaning of compressor

81000 Filter silencer A Can81126 Lock B Filler opening

u Remove insulation from flange of filter silencer (81000) (if present).

u Unscrew lock (81126).

u Measure volume of water according to the following table.

u Pour this water into a clean can (A).

u Carefully pour this water into the filling orifice (B) from the can.

u Screw in lock and hand-tighten.

u Fit insulation to flange of filter silencer (if present).

u After cleaning, allow the engine to continue to run for at least 5 minutes under normalload.

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Repeating the cleaning

If the cleaning is still unsuccessful after three processes, it is recommended to have the tur-bocharger checked and cleaned by an ABB Turbocharging Service Station if the engine val-ues are unsatisfactory.

Volume of water per cleaning process

Product Quantity [dm3]A255-L 1.5A260-L 1.5A265-L 2.0A270-L 2.0A275-L 3.0A280-L 3.0Table 13: Volume of water per cleaning process

The filling time is 4 ... 15 seconds.

Checking the filter plug

The filter plug only needs to be checked in the turbocharger version with a cast filter silen-cer. See chapter Design variants →78.

Fig. 22: Filter plug view

Disassembly and checking of the filter plug (81125) is required if, 20 seconds after the clean-ing process, water is still visible in filler opening B.

u Loosen and remove the filter plug (81125) with box spanner.

u Clean the drill holes of the plug.

u Fit filter plug (81125).

Part number A255-L A260-L A265-L A270-L A275-L A280-L81125 G1/2"

45 NmG1/2" 45 Nm

G1/2" 45 Nm

G1/2" 45 Nm

G1/2" 45 Nm

G1/2" 45 Nm

Table 14: Tightening torques (81125)

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Operation Manual / A200-L7 Periodic maintenance / 7.5 Cleaning the turbine during operation


7.5 Cleaning the turbine during operation

7.5.1 Introduction

Combustion of heavy fuel oil in diesel engines causes contamination of the turbine bladesand nozzle rings of the turbochargers. Contamination increases with time, which is why regular and properly carried out cleaningoperations are important to remove any deposits.

Contaminated turbine components lead to a reduction in the turbocharger efficiency. Fur-thermore, the exhaust gas temperature after the cylinders can rise and the charging pres-sure in the air receiver can drop. Contamination of the turbine also leads to rotor unbalance. A very high level of contamina-tion can lead to intolerably high rotor unbalance.

Despite periodic cleaning during operation, experience shows that overhauls during whichthe turbine and nozzle ring (or VTG) are mechanically cleaned cannot be omitted.

Cleaning method

The turbine and the nozzle ring are cleaned during operation using the dry cleaning method.This cleaning method is tested and approved by ABB Turbocharging.

Interval for dry cleaning depending on the fuel used

The interval between the cleaning cycles depends greatly on the operating conditions andfuel used.

¡ General recommendation: every 50 hours according to the cleaning instructions for thedry cleaning unit (see chapter Procedure for dry cleaning the turbine →59).

¡ For HFO applications: every 50 hours.

¡ For mixed gas / HFO applications: taking the following conditions into consideration, thecleaning interval can be increased to a maximum of 150 hours.

– Maximum 20% of operating time with HFO.– Constant exhaust gas temperatures with a constant engine load.– Provided that no excessive contamination is detected during standard inspections.

Principle of dry cleaning

During dry cleaning, the dirt coating is removed by the mechanical action of the impactingsolids (granulate).

Operating state

The dry cleaning of the turbine end components is carried out at an engine load of 5 … 85%.

Cleaning several turbochargers

If several turbochargers are installed on an engine, ABB Turbocharging recommends clean-ing one turbine after the other.

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7.5.2 Procedure for dry cleaning the turbine

Dry cleaning device

Fig. 23: Dry cleaning device

11 Granulate container (51702) 16 Protection valve [closed] (51713)12 Cover cap (51703) 17 Pressurised air valve [venting] (51704)13 Pressurised air supply [4 ... 7 bar] 18 Plate14 Piping 19 Cleaning instructions (51717)15 On-Off valve [closed] (51705) 20 Gas inlet casing, insulated

CAUTIONProtecting the pressurised air systemu Protect the pressurised air system against overpressure (> 7 bar).

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Operating the dry cleaning device

CAUTIONEscape of burnt granulate particlesCareless handling may result in incompletely burnt particles of granulateand soot particles escaping from the stack with the exhaust gas.

u Only inject the specified amount of granulate for cleaning.

u Make sure that the conditions with regard to the operating state and the maximum ex-haust gas temperature before the turbine are observed.

u Check that the protection valve (16) is closed (see Fig. 23: Dry cleaning device →59).

u Check that the on-off valve (15) is closed.

u Check that the combined pressurised air valve/pressure release valve (17) is in the neutralposition.

u Loosen and carefully remove the cover cap (12).

u Fill the specified amount of granulate into the container (11).

u Screw on and tighten the cover cap (12).

u Open the combined pressurised air valve/pressure release valve (17) (down lever posi-tion).

u Open the protection valve (16).

u Open the on-off valve (15) for cleaning the turbine for 3 ... 4 minutes.

u Close the on-off valve (15).

u Close the protection valve (16).

u Set the combined pressurised air valve/pressure release valve (17) to venting (up lever po-sition).

u Check that the exhaust gas temperature after the turbine is less than before the cleaning.

u Move the combined pressurised air valve/pressure release valve (17) to the neutral posi-tion.

Repeating the cleaning

If the cleaning is still unsuccessful after three processes, it is recommended to have the tur-bocharger checked and cleaned by an ABB Turbocharging Service Station if the engine val-ues are unsatisfactory.

Optimum cleaning effect

It is important that the specified amount of granulate is blown in for each cleaning processin order to achieve an optimum cleaning effect.

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7.5.3 Cleaning parameters for dry cleaning

Material selection

Possible suppliers of material for dry cleaning can be found on the Internet.

The following materials are suitable for dry cleaning:

¡ Hard, granulated materials (such as natural core granulates)

¡ Soft-blast media

¡ Activated carbon particles

The average grain size of the cleaning granulate must be between 1.2 and 2.0 mm.

The specific weight of the cleaning granulate must not exceed 1.2 kg/dm3.

Amount of granulate per turbocharger

Product Quantity [dm3]A255-L 0.6A260-L 0.6A265-L 1.0A270-L 1.5A275-L 2.0A280-L 2.5Table 15: Cleaning parameters

NOTICEStorage of dry cleaning materialsThe cleaning material must be stored in a dry and clean location to preventblockage of the pipes when cleaning.

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Operation Manual / A200-L7 Periodic maintenance / 7.6 Draining the gas outlet casing


7.6 Draining the gas outlet casingIf there is a boiler leak into the exhaust gas pipe or an ingress of water due to other causes,the gas outlet casing can be drained.

Fig. 24: Drain pipe diagram

01 Drain pipe A Position 102 Drain cock B Position 203 Drain04 Air line from compressor casing

u On the drain pipe (01), set the drain cock (02) to position 1 (A).

If the drain pipe (01) is blocked:

u Set the drain cock (02) to position 2 (B) and clean the drain pipe (01) with air from thecompressor casing (04).

If cleaning with air is not sufficient, the drain pipe (01) must be cleaned mechanically.

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Operation Manual / A200-L8 Troubleshooting / 8.1 Malfunctions when starting


8 Troubleshooting

8.1 Malfunctions when starting

Delayed start-up

Possible causes RemedyTurbochar-ger

Turbocharger contaminated Clean (Periodic maintenance →49)Bearing damaged Contact ABB Turbocharging Service

StationRotor rubbingForeign object in the turbocharger

Table 16: Malfunctions when starting – Delayed start-up

Vibrations


Rotor unbalance Contact ABB Turbocharging ServiceStationTurbine or compressor damaged

Bearing damagedEngine Vibrations from engine Contact enginebuilderTable 17: Malfunctions when starting – Vibrations

Rubbing of rotating parts

Normal behaviour, not a malfunctionTurbochar-ger

A slight amount of uniform wear at the circumference of the rotor componentscaused by slight local rubbing against adjacent components is permitted. Thiscauses the compressor or turbine blades to be somewhat shortened. To preventsignificant loss of efficiency, specific tolerances must be fulfilled.

¡ If there is any doubt about the extent of the rubbing, contact an ABB Tur-bocharging Service Station.

¡ Have a dimension check carried out by an ABB Turbocharging Service Sta-tion.

Table 18: Malfunctions when starting – Rubbing of rotating parts

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Operation Manual / A200-L8 Troubleshooting / 8.2 Malfunctions during operation


8.2 Malfunctions during operation

Lubricating oil pressure too low

WARNINGDanger of fire and explosion due to lubricating oil leaksLeaking oil may ignite on hot surfaces. This can result in serious injuries topersonnel 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.



Axial clearance of the rotor excessive Contact an ABB TurbochargingService Station

Engine Oil filter heavily contaminated CleanOil pump in lubricating system defect-ive

Check/replace

Manometer displays incorrectly Replace manometerTable 19: Malfunctions during operation – Lubricating oil pressure too low

Drop in speed


Heavy contamination of the turbine CleanDamaged rotor components or bearing Contact ABB Turbocharging Service

StationPipes Defects, such as leaks, in the exhaust

gas pipes or charge air ductsRepair

Table 20: Malfunctions during operation – Drop in speed

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Operation Manual / A200-L8 Troubleshooting / 8.2 Malfunctions during operation


Exhaust gas temperature too high

Engine performance and engine speed unchanged

Possible causes RemedyTurbocharger Insufficient air, for example, when fil-

ter silencer is blocked by dirtClean (Periodic maintenance →49)

Compressor/turbine contaminatedExhaust gas back pressure too high Clean or repair boiler or exhaust gas si-

lencerTurbine damaged or eroded Contact ABB Turbocharging Service

StationEngine Malfunction in the injection system Repair or contact manufacturerCharge aircooler

Cooler contaminated CleanCooling water volume too low FillInlet temperature of cooling watertoo high

Check/clean cooling system

Insufficient ventilation Improve ventilationTable 21: Malfunctions during operation – Exhaust gas temperature too high

Charge air pressure too low

Engine performance and engine speed unchanged, suction condition normal


Manometer display not correct Replace manometerSupply pipe to manometer not sealed Repair leakFilter silencer contaminated, thereforepressure drop too high

Clean (Periodic maintenance →49)

Compressor end and/or turbine endcontaminatedCompressor/turbine damaged Contact ABB Turbocharging Service

StationExhaust gas back pressure too high Clean or repair boiler or exhaust gas si-

lencerEngine Air receiver not sealed Repair

Gas pipe between engine and turbinenot sealedInjection mistimed Set correctlyValve control misadjusted

Pipes Pipes downstream to the compressoroutlet not sealed.

Repair.

Table 22: Malfunctions during operation – Charge air pressure too low

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Operation Manual / A200-L8 Troubleshooting / 8.3 Surging of the turbocharger


Charge air pressure too high

Engine performance and engine speed unchanged, suction condition normal


Manometer display not correct Replace manometer

Engine Malfunction in the injection system Repair or contact manufacturerInjection mistimed Set correctlyEngine performance higher than indic-ated

Check engine performance

Table 23: Malfunctions during operation – Charge air pressure too high

8.3 Surging of the turbocharger

Surging of the turbocharger

Possible causes RemedyTurbocharger Filter silencer or diffuser contamin-

atedClean (Periodic maintenance →49)

Heavy dirt deposits in the turbine orin the nozzle ring

Engine Protective grating in front of the tur-bocharger contaminated or damaged

Clean/replace

Charge aircooler

Cooler contaminated CleanCharge air duct blocked

Table 24: Surging of the turbocharger

CAUTIONContinuous or periodic surgingIf 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 an ABB Turbochar-ging Service Station.

u Have parts assessed for damage and, if necessary, replaced by an ABBTurbocharging Service Station.

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Operation Manual / A200-L8 Troubleshooting / 8.4 Malfunctions when stopping


Sporadic surge blows

Surging of the turbocharger can occur during certain operating states, such as when redu-cing the engine load quickly when manoeuvring. When this happens, the flow direction in thecompressor is momentarily reversed. Such sporadic surge blows do not impair the safe op-eration of the turbocharger.

¡ A surge blow is accompanied by a loud bang and escape of hot air from the filter silencer.

8.4 Malfunctions when stopping

Runout noises


Turbocharger contaminated CleanBearing damaged Contact an ABB Turbocharging

Service StationRotor rubbingForeign object in the turbocharger

Table 25: Malfunctions when stopping – Runout noises

Shortened runout time


Turbocharger contaminated CleanBearing damaged Contact an ABB Turbocharging

Service StationRotor rubbingForeign object in the turbocharger

Table 26: Malfunctions when stopping – Shortened runout time

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Operation Manual / A200-L8 Troubleshooting / 8.5 Speed measurement system


8.5 Speed measurement system

Possible causes RemedyNo signalor poorsignalamplitudepresent

Assembly fault The screw plug for the sensor is fitted with a gasket.This gasket must be removed when the speed sensor is as-sembled. If the gasket has been inadvertently fitted, the dis-tance of the sensor tip to the sealing disc giving the signal is in-creased. This reduces the voltage amplitude of the speed signalwhich can lead to problems with the evaluation electronics.This problem will be remedied by removing the gasket.

Sensor defective Contact ABB Turbocharging Service StationMeasuredspeed toohigh

Contamination ofthe sensor tip

As the sensor tip is magnetic, it can attract material particles.This reduces the distance to the auxiliary bearing, which canlead to amplification of the noise component and therefore tofalse triggering.Dismantle the sensor, clean the sensor tip, and fit the sensorback on with the specified tightening torque.

Measuredspeed toolow

- - Contact ABB Turbocharging Service Station

Othercauses ofmalfunc-tion

- - If none of the measures described above remedy the malfunc-tion, it is recommended to have the speed measurement sys-tem checked by an ABB Turbocharging Service Station.

Table 27: Malfunctions of the speed measurement system

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Operation Manual / A200-L8 Troubleshooting / 8.5 Speed measurement system


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Operation Manual / A200-L9 Disassembly and assembly / 9.1 Introduction


9 Disassembly and assembly

9.1 Introduction

CAUTIONFurther workThis Operation Manual may be used to carry out only the work described init. Further work that is carried out in an incorrect way can lead to seriousdamage to the machine.

u ABB Turbocharging recommends having further work carried out only bytrained personnel from an ABB Turbocharging Service Station.

u Mark the casing position for assembly.

Tightening torques for components

The specified tightening torques of the bolted connections must be observed.

Tightening torques for assembly devices

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

WARNINGSuspended loadsLoads that are not attached according to regulations can cause injury topersonnel or fatal accidents.

u Only fasten the turbocharger, assemblies or individual parts on properlyfunctional 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 helmet.

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Operation Manual / A200-L9 Disassembly and assembly / 9.2 Material required


9.2 Material required

Customer spare part set

Before starting work, make sure the required customer spare part set is available (seechapter Spare parts →120).

Customer tool set

Before starting work, make sure the required tool set is available (see chapter Tools →140).

Not all tools are marked with a part number. Identification is guaranteed by the tool list. Thislist is enclosed with the tool set.

WARNINGServicing the toolsThe 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.

Identification of the assembly devices

Not all assembly devices are marked with a part number. Identification is guaranteed by thetool list. This list is enclosed with the toolbox.

WARNINGServicing the assembly devicesAssembly devices must be checked for damage before and after use.

u Visually inspect for corrosion, cracks, deformation and wear.

u Damaged assembly devices must no longer be used and must be re-placed.

Definition of terms

¡ Suspension pointDefined loading point on a component or an assembly (blind hole thread, eyelet, lug).

¡ Assembly deviceDevices 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 notcommercially available products. Use assembly devices only for the described applica-tions.

¡ Lifting gearEquipment for the lifting and transporting of loads (ropes, chain block, crane). Liftinggear is not supplied by ABB.

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Operation Manual / A200-L9 Disassembly and assembly / 9.3 Weights of assemblies


9.3 Weights of assembliesThe specified weights of the individual parts or assemblies are rounded-up standard values.

Fig. 25: Weights of assemblies

Posi-tion

Assembly A255-L A260-L A265-L A270-L A275-L A280-L

01 Filter silencer 180 230 350 470 850 115002 Wall insert 130 160 300 450 760 107003 Diffuser 25 25 40 60 110 16004 Compressor cas-

ing165 215 400 620 1030 1350

05 Cover ring 15 15 30 50 75 9006 Nozzle ring 8 8 10 20 25 5007 Gas inlet casing 135 135 180 240 380 520

Table 28: Weights of assemblies [kg]

The total weight of the complete wall insert is made up of the wall insert and diffuser as-semblies.

A255-L A260-L A265-L A270-L A275-L A280-L155 185 330 510 870 1230

Table 29: Weight of wall insert [kg]

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Operation Manual / A200-L9 Disassembly and assembly / 9.4 Disassembly and assembly of the fil-ter silencer casing


9.4 Disassembly and assembly of the filter silencercasing

NOTICEDisassembly / Assembly of the filter silencer casingThis chapter applies only to turbochargers with filter silencer casing.

Only the assembly of the filter silencer casing is described in detail.

The disassembly must be carried out in reverse order of the assembly.

Fig. 26: Dismantling the filter silencer casing

01, 02 Bottom part03, 04, 07, 08 Side part05, 06, 09 Circumferential part10, 11 Flange

The complete filter silencer casing has the part number 81500.

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Assembly

NOTICEScrews on the filter silencer casingNo screws are tightened until end of filter silencer casing assembly. Onlythis way is it possible to fit all the parts.

u Do not tighten the screws during assembly.

Fig. 27: Fitting the filter silencer casing

u Fit the bottom part (01) on the filter silencer (81000) with screws (A) and (B).

NOTICEScrew (A)The location of screw (A) serves as a reference for the correct assembly ofthe filter silencer casing.

u Before disassembling the bottom part (01), mark the location ofscrew (A).

u Fit all remaining screws on the bottom part (01).

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u Fit the bottom part (02) with the screws on the filter silencer.


u Fit the side parts (03) and (04) with the screws on the filter silencer and on the bottompart.

u Fit the side parts (07) and (08) with the screws on the filter silencer, on the bottom part,and on the side parts (03, 04).

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u Insert the flanges (10) and (11) laterally between the side parts and fit the screws.


u Fit the circumferential part (05) with the screws.


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Screws for fastening the individual parts tothe filter silencer

Screws for fastening the individual parts

M1030 Nm

M825 Nm

Table 30: Tightening torques (filter silencer screws)

u Tighten all screws of the bottom parts (01) and (02).

u Tighten all screws of the side parts (03, 04, 07, 08) and the flanges (10, 11).

u Tighten all screws of the circumferential parts (05, 06, 09).

Bellows

Fig. 32: Fitting the bellows

u Fit bellows (C) with frame (F), screws (S) and nuts (N) on the filter silencer casing.Pa

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Operation Manual / A200-L9 Disassembly and assembly / 9.5 Dismantling the filter silencer


9.5 Dismantling the filter silencer

9.5.1 Design variants

The turbocharger is equipped with one of the following filter silencer variants:

¡ Welded filter silencer

¡ Cast filter silencer

The filter silencers differ in terms of the fixing eyelets for the lifting gear. The relevant vari-ant must be taken into consideration for disassembly and assembly.

9.5.2 Dismantling the filter silencer (welded)

u Dismantle the insulation if necessary.

Fig. 33: Dismantling the filter silencer

1. Attach lifting gear to the eyelets of the filter silencer (81000).

2. Loosen nuts (72004) and remove with washers (72003).

3. Remove and put down filter silencer.

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Operation Manual / A200-L9 Disassembly and assembly / 9.5 Dismantling the filter silencer


9.5.3 Dismantling the filter silencer (cast)

u Dismantle the insulation if necessary.

Fig. 34: Dismantling the filter silencer

1. Attach the lifting gear to the front lug and rear eyelet of the filter silencer (81000).

2. Loosen nuts (72004) and remove with washers (72003).

3. Remove and put down filter silencer.

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Operation Manual / A200-L9 Disassembly and assembly / 9.6 Dismantling wall insert and diffuser


9.6 Dismantling wall insert and diffuser

9.6.1 Dismantling the wall insert

A255-L.. - A260-L..

Fig. 35: Dismantling the wall insert (A255-L.. - A260-L..)

1. Secure the wall insert (77000) with a hexagon nut (72004).

2. Use the press-off screws (90900) to press off the wall insert from the compressor cas-ing (72000) until the lifting device (90190) can be fitted.

3. Remove four threaded studs (72002) at the top so that the lifting device can be fitted.

4. Fit shackle (90195) with lifting gear on P1 of lifting device.

5. Fit lifting device with crane on upper area of wall insert.

6. Change the position of the shackle with the lifting gear to P2 of the lifting device.

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Fig. 36: Moving out wall insert

7. Carefully move out the wall insert (77000) with diffuser (79000).

8. Remove O-ring (77040).

Fig. 37: Putting down wall insert

u Put down wall insert (77000) with diffuser (79000) in horizontal position and use appro-priate supports to prevent it from falling over and rolling away.

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A265-L.. - A280-L..

Fig. 38: Dismantling the wall insert (A265-L.. - A280-L..)

1. Loosen one screw (72011) and leave 2/3 of the thread length screwed into the com-pressor casing (72000).

2. Loosen and remove the remaining screws (72011).

3. Use the press-off screws (90900) to press off the wall insert (77000) from the com-pressor casing (72000) until the lifting device (90190) can be fitted.

4. Fit shackle (90195) with lifting gear on P1 of lifting device (90190).

5. Fit lifting device (90190) with crane on upper area of wall insert (77000).

6. Change the position of the shackle with the lifting gear to P2 of the lifting device (90190).

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Fig. 39: Moving out wall insert

7. Remove screw (72011).

8. Carefully move out the wall insert (77000) with diffuser (79000).

9. Remove O-ring (77040).


u Put down wall insert (77000) with diffuser (79000) in horizontal position and use appro-priate supports to prevent it from falling over and rolling away.

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9.6.2 Dismantling the diffuser

WARNINGSupport for the wall insertThe support may slip away when the wall insert is placed on flange F.

Any defective or improperly used supports can lead to serious injury to per-sonnel and even to fatal accidents.

u Check the position of the support and correct if necessary.

WARNINGRisk of tippingIf the wall insert is not tilted, it must be put down correctly. Tipping of thewall insert may lead to serious injuries to persons or even to fatal accidents.

u If the wall insert is not tilted, ensure that it is fixed correctly (see Dis-mantling wall insert).


1. Put wall insert (77000) down on suitable supports.

2. Tilt wall insert (77000) with diffuser (79000) against lifting device (90190).

3. Place wall insert with the flange (F) on the underlay.

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Fig. 42: Dismantling the diffuser

4. Loosen and remove screws (77015).

5. Remove O-rings (79020, 79021).

6. Attach lifting gear (L) to the diffuser (79000).

7. Remove and put down diffuser.

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Operation Manual / A200-L9 Disassembly and assembly / 9.7 Axial clearance A prior to disas-sembly


9.7 Axial clearance A prior to disassembly

WARNINGPhysical hazards due to sharp edges on compressor wheelThe compressor wheel has sharp edges which can result in injury.

u Wear safety gloves.


CAUTIONClearances outside the toleranceSerious damage to engines or property can be caused by clearances outsidethe tolerance and excessively worn parts.

u Have the components assessed and, if necessary, replaced by an ABB Tur-bocharging Service Station.

Fig. 43: Measuring axial clearance A

The axial clearance (A) of the rotor should always be measured before and after servicework.

Product Axial clearance A [mm]

A255-L 0.31 ... 0.55A260-L 0.31 ... 0.55A265-L 0.32 ... 0.62A270-L 0.33 ... 0.63A275-L 0.38 ... 0.68A280-L 0.41 ... 0.73Table 31: Axial clearance A

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Operation Manual / A200-L9 Disassembly and assembly / 9.8 Dismantling the insulation (≤ A275-L)


9.8 Dismantling the insulation (≤ A275-L)

NOTICEDry cleaningThe dry cleaning does not have to be removed to dismantle the insulation.

Fig. 44: Removing the insulation (A275-L and smaller).

1. Loosen and remove screws of insulation jackets (51200) from gas outlet casing (61001).

2. Loosen and remove all connecting plates of insulation jackets.

3. Remove insulation jackets.

4. Detach flange connection between gas inlet casing (51001) and bellows.

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Operation Manual / A200-L9 Disassembly and assembly / 9.9 Dismantling the gas inlet casing (≤A275-L)


9.9 Dismantling the gas inlet casing (≤ A275-L)

Fig. 45: Dismantling the gas inlet casing (275-L and smaller)

Product Maximum loosening torque [Nm]A255-L 245A260-L 245A265-L 245A270-L 350A275-L 665Table 32: Maximum admissible loosening torque (51087)

u If a threaded stud (51086) shears off when loosening, an ABB Turbocharging Service Sta-tion should be contacted.

u If a threaded stud (51086) works loose when removing the nut (51087), it should be refit-ted, after disassembling the gas outlet casing, up to the stop in the gas inlet casing untilhand-tight.

u If the nut (51087) cannot be removed with the maximum permissible loosening torque, itcan be heated or removed with an appropriate tool.

1. Treat nuts (51087) with rust remover.

2. Loosen crosswise and remove all nuts except for two opposite nuts (51087). Note max-imum admissible loosening torque.

3. Loop around the gas inlet casing (51001) with lifting gear.

4. Loosen and remove remaining nuts (51087). Note maximum admissible loosening torque.

5. Carefully move out gas inlet casing and put down.

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Operation Manual / A200-L9 Disassembly and assembly / 9.10 Dismantling the nozzle ring (≤ A275-L)


9.10 Dismantling the nozzle ring (≤ A275-L)

Fig. 46: Dismantling the nozzle ring (A275-L and smaller)

1. Loosen screws (56014) and remove with washers (56011).

2. Remove and put down nozzle ring (56001).

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Operation Manual / A200-L9 Disassembly and assembly / 9.11 Dismantling the gas inlet casing(A280-L)


9.11 Dismantling the gas inlet casing (A280-L)

Fig. 47: Dismantling the gas inlet casing (A280-L)

Part number A280-L51087 840 NmTable 33: Maximum admissible loosening torque (51087)

u If a threaded stud (51086) shears off when loosening, an ABB Turbocharging Service Sta-tion should be contacted.

u If a threaded stud (51086) works loose when removing the nut (51087), it should be refit-ted, after disassembling the gas outlet casing, up to the stop in the gas inlet casing untilhand-tight.

u If the nut (51087) cannot be removed with the maximum permissible loosening torque, itcan be heated or removed with an appropriate tool.

1. Dismantle both halves of the insulation segment (51215) and remove with all fixing ele-ments.

2. Detach flange connection between gas inlet casing (51001) and bellows.

3. Treat nuts (51087) with rust remover.

4. Loosen crosswise and remove all nuts (51087) except for two opposite nuts. Note max-imum loosening torque.

5. Loop around the gas inlet casing (51001) with lifting gear.

6. Loosen and remove remaining nuts (51087). Note maximum admissible loosening torque.

7. Fit supports (90481, 90482) on gas inlet casing and put down casing.

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Operation Manual / A200-L9 Disassembly and assembly / 9.12 Dismantling the nozzle ring (A280-L)


9.12 Dismantling the nozzle ring (A280-L)

Fig. 48: Fitting the nozzle ring holder

1. Remove screws (B2).

2. Fit the nozzle ring holder (90477) with screws (B1) at the top of the flange of the gas inletcasing (51001).

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Operation Manual / A200-L9 Disassembly and assembly / 9.12 Dismantling the nozzle ring (A280-L)


Fig. 49: Dismantling the nozzle ring

1. Loop around the nozzle ring holder (90477) with the lifting gear and secure it to thecrane.

2. Loosen screws (56014) and remove with washers (56011).

3. Pull the nozzle ring (56001) towards the front onto the nozzle ring holder.

4. Screw the screws (B2) into the nozzle ring holder.


Fig. 50: Put down the nozzle ring

u Use the crane to remove and put down the nozzle ring (56001).

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Operation Manual / A200-L9 Disassembly and assembly / 9.13 Fitting the nozzle ring (≤ A275-L)


9.13 Fitting the nozzle ring (≤ A275-L)u Coat the screw threads with high-temperature grease.

u Coat the screw threads with high-temperature grease.

Fig. 51: Fitting the nozzle ring (A275-L and smaller)

Product Size Tightening torque [Nm]A255-L M10 35A260-L M10 35A265-L M10 35A270-L M10 35A275-L M10 35Table 34: Tightening torque (56014)

1. Align the notch (A1) with the flange connection (A2) and slide the nozzle ring (56001) intothe gas inlet casing (51001).

2. Fit screws (56014) with high-temperature grease and washers (56011).

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Operation Manual / A200-L9 Disassembly and assembly / 9.14 Fitting the gas inlet casing (≤ A275-L)


9.14 Fitting the gas inlet casing (≤ A275-L)

Fig. 52: Fitting the gas outlet casing (A275-L and smaller)

Product Size Tightening torque [Nm]A255-L M16 301) / 140A260-L M16 301) / 140A265-L M16 301) / 140A270-L M18 401) / 200A275-L M22 501) / 380Table 35: Tightening torque (51087)

1) Pre-tightening torque of the nuts

1. Coat threaded stud (51086) with high-temperature grease, screw in up to the stop in thegas outlet casing (61001) and tighten hand-tight.

2. Loop around the gas inlet casing (51001) with the lifting gear and secure it to the crane.

3. Push gas inlet casing over the threaded studs up to the gas outlet casing.

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Operation Manual / A200-L9 Disassembly and assembly / 9.15 Fitting the insulation (≤ A275-L)


4. Coat two nuts with high-temperature grease and fix gas inlet casing in two opposite po-sitions.

5. Coat remaining nuts with high-temperature grease, fit and then tighten crosswise, ini-tially to the pre-tightening torque and then to the tightening torque.

6. Remove the lifting gear.

7. Connect the flange of the gas inlet casing and the bellows.

9.15 Fitting the insulation (≤ A275-L)

Fig. 53: Fitting the insulation (A275-L and smaller)

1. Fit flange connection between gas inlet casing (51001) and bellows.

2. Fit the insulation jackets (51200) on the gas inlet casing (51001) with the screws.

3. Fit connecting plates of insulation jackets with screws.

4. Fit insulation jackets with screws on gas outlet casing (61001).Pa

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Operation Manual / A200-L9 Disassembly and assembly / 9.16 Fitting the nozzle ring (A280-L)


9.16 Fitting the nozzle ring (A280-L)u Coat the screw threads with high-temperature grease.

Fig. 54: Fitting the nozzle ring (A280-L)

u Use lifting gear to secure the nozzle ring (56001) on the nozzle ring holder (90477) andtransport it.

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Operation Manual / A200-L9 Disassembly and assembly / 9.16 Fitting the nozzle ring (A280-L)


Fig. 55: Attaching the nozzle ring (A280-L)

Part number A280-L56014 M12

65 NmTable 36: Tightening torque (56014)

1. Fit the nozzle ring holder (90477) on the flange of the gas inlet casing (51001) withscrews (B1).


3. Align the notch (A1) on the cam of the nozzle ring (56001) with the flange connection (A2)and slide the nozzle ring into the gas inlet casing.

4. Coat screws (56014) with high-temperature grease and fit with washers (56011).

5. Remove screws (B1) along with the nozzle ring holder (90477).

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Operation Manual / A200-L9 Disassembly and assembly / 9.17 Fitting the gas inlet casing (A280-L)


9.17 Fitting the gas inlet casing (A280-L)

Fig. 56: Fitting the gas inlet casing (A280-L)

Part number A280-L51087 M24

801) Nm480 Nm

Table 37: Tightening torque (51087)

1) Pre-tightening torque of the screws

1. Coat threaded stud (51086) with high-temperature grease, screw in up to the stop in thegas outlet casing (61001) and tighten hand-tight.

2. Loop around the gas inlet casing (51001) with the lifting gear and secure it to the crane.

3. Dismantle and remove supports (90481, 90482) from the gas inlet casing.

4. Push gas inlet casing over the threaded studs up to the gas outlet casing.

5. Coat two nuts with high-temperature grease and fix gas outlet casing in two oppositepositions.

6. Coat remaining nuts with high-temperature grease, fit and then tighten crosswise, ini-tially to the pre-tightening torque and then to the tightening torque.

7. Remove the lifting gear.

8. Connect the flange of the gas inlet casing and the bellows.

9. Fit the insulation segments (51215).

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Operation Manual / A200-L9 Disassembly and assembly / 9.18 Axial clearance A after assembly


9.18 Axial clearance A after assembly

WARNINGPhysical hazards due to sharp edges on compressor wheelThe compressor wheel has sharp edges which can result in injury.



CAUTIONClearances outside the toleranceSerious damage to engines or property can be caused by clearances outsidethe tolerance and excessively worn parts.

u Have the components assessed and, if necessary, replaced by an ABB Tur-bocharging Service Station.

Fig. 57: Measuring axial clearance A

The axial clearance (A) of the rotor should always be measured before and after servicework.

Product Axial clearance A [mm]

A255-L 0.31 ... 0.55A260-L 0.31 ... 0.55A265-L 0.32 ... 0.62A270-L 0.33 ... 0.63A275-L 0.38 ... 0.68A280-L 0.41 ... 0.73Table 38: Axial clearance A

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Operation Manual / A200-L9 Disassembly and assembly / 9.19 Fitting the diffuser


9.19 Fitting the diffuser

Fig. 58: Fitting the diffuser

Product Size Tightening torque [Nm]A255-L M5 6A260-L M5 6A265-L M5 6A270-L M6 10A275-L M8 25A280-L M8 25Table 39: Tightening torque (77015)

1. Attach lifting gear (L) to the diffuser (79000).

2. Carefully place the diffuser on the wall insert (77000), then remove lifting gear.

3. Fit new O-rings (79020, 79021) on the diffuser.

4. Degrease screws (77015) and threaded holes in wall insert.

5. Coat threads of the screws with Loctite® 542.

6. Fit screws.

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Operation Manual / A200-L9 Disassembly and assembly / 9.20 Fitting wall insert


9.20 Fitting wall insert

Fig. 59: Positioning wall insert

u Carefully bring wall insert (77000) into vertical position with the lifting device (90190).

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A255-L.. - A260-L..

Fig. 60: Fitting the wall insert (A255-L.. - A260-L..)

Product Size Tightening torque [Nm]A255-L M16 60A260-L M16 60Table 40: Tightening torque (72002)

Product Size Tightening torque [Nm]A255-L M16 265A260-L M16 265Table 41: Tightening torque (72004)

1. Attach the new O-ring (77040) to the wall insert (77000).

2. Fit two guide studs (90320) in the upper area of the compressor casing (72000). Leavethe top threaded hole (x) in the compressor casing empty.

3. Align arrow markings of wall insert (77000) and compressor casing to one another.

4. Carefully move the wall insert with diffuser (79000) over the guide studs into the com-pressor casing. Check the correct alignment of the wall insert and the compressor cas-ing.

5. Fit a hexagon nut (72004) with a sleeve (90191) as a safety device.

6. Remove the shackle (90195) with lifting gear. Fit shackle with lifting gear on P1 of the lift-ing device (90190) and remove with the crane.

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7. Move the wall insert fully in and remove the guide studs. Fit the remaining threadedstuds. Observe tightening torque. Leave the top threaded hole (x) in the compressor cas-ing empty.

8. Check that 23 threaded studs have been fitted.

9. Press the wall insert into the compressor casing using a hexagon nut (72004) and sleeve(90191). Observe tightening torque. Remove nuts and sleeves.

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A265-L.. - A280-L..

Fig. 61: Fitting the wall insert (A265-L.. - A280-L..)

Product Size Tightening torque [Nm]A265-L M18 370A270-L M20 500A275-L M24 900A280-L M27 1300Table 42: Tightening torque (72011)

1. Attach the new O-ring (77040) to the wall insert (77000).

2. Fit two guide studs (90320) in the upper area of the compressor casing (72000).

3. Align arrow markings of wall insert (77000) and compressor casing to one another.

4. Carefully move the wall insert with diffuser (79000) over the guide studs into the com-pressor casing. Check the correct position of both casings using the marking arrows.

5. Fit a screw (72011) as a safeguard.

6. Remove the shackle (90195) with lifting gear. Change the position of the shackle with thelifting gear to P1 of the lifting device (90190) and remove with the crane.

7. Move the wall insert fully in, then remove the guide studs (90320).

8. Fit the screws (72011). Observe tightening torque.

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Operation Manual / A200-L9 Disassembly and assembly / 9.21 Fitting the filter silencer


9.21 Fitting the filter silencer

9.21.1 Design variants

The turbocharger is equipped with one of the following filter silencer variants:

¡ Welded filter silencer

¡ Cast filter silencer

The filter silencers differ in terms of the fixing eyelets for the lifting gear. The relevant vari-ant must be taken into consideration for disassembly and assembly.

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9.21.2 Fitting the filter silencer (welded)

Fig. 62: Fitting the filter silencer

Product Size Tightening torque [Nm]A255-L M16 265A260-L M16 265A265-L M14 130A270-L M16 200A275-L M18 300A280-L M20 420Table 43: Tightening torque (72004)

1. Attach lifting gear to the eyelets of the filter silencer (81000).

2. Position filter silencer on compressor casing.

3. Fit nuts (72004) with washers (72003) and tighten.

u Fit insulation as far as necessary.

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9.21.3 Fitting the filter silencer (cast)

Fig. 63: Fitting the filter silencer

Product Size Tightening torque [Nm]A265-L M14 130A270-L M16 200A275-L M18 300A280-L M20 420Table 44: Tightening torque (72004)

1. Attach the lifting gear to the front lug and rear eyelet of the filter silencer (81000).

2. Position filter silencer on compressor casing.

3. Fit nuts (72004) with washers (72003) and tighten.

u Fit insulation as far as necessary.Pa

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Operation Manual / A200-L9 Disassembly and assembly / 9.22 Table of tightening torques


9.22 Table of tightening torques

Fig. 64: Overview of tightening torques

Fig. 65: Overview of speed sensor tightening torque

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Operation Manual / A200-L9 Disassembly and assembly / 9.22 Table of tightening torques


Posi-tion

Part num-ber

A255-L A260-L A265-L A270-L A275-L A280-L

22 57005 M8 20

M8 20

M1250

M12 50

M16 80

M20 160

61 1) 51087 M16 30 140

M16 30 140

M16 302)

140

M18 40 2)

200

M22 50 2)

380

M24 80 2)

48062 1) 72011 - - - - M18

370M20 500

M24 900

M27 1300

63 1) 72004 M16 265

M16 265

M14 130

M16 200

M18 300

M20 420

63a 72002 M1660

M1660

M1440

M16 60

M18 80

M20 100

64 77015 M5 6

M5 6

M56

M6 10

M8 25

M8 25

65 56014 M10 35

M10 35

M10 35

M10 35

M10 35

M12 65

66 81125 G1/2" 45

G1/2" 45

G1/2" 45

G1/2" 45

G1/2" 45

G1/2" 45

67 86505 M18x1.5 150

M18x1.5 150

M18x1.5 150

M18x1.5 150

M18x1.5 150

M27x2 320

Table 45: Overview of tightening torques

1) Tighten crosswise

2) Pre-tightening torque of the screws

u Use hydraulic tool for tightening torques exceeding 500 Nm.

Tightening torque, insulation

Thread size Tightening torque [Nm]M8 28M10 45M12 (compressor casing insulation) 50Table 46: Tightening torque, insulation

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Operation Manual / A200-L10 Taking a turbocharger out of operation / 10.1 Possible emergencyrepairs


10 Taking a turbocharger out of operation

10.1 Possible emergency repairs

WARNINGDanger of fire and explosion due to lubricating oil leaksLeaking oil may ignite on hot surfaces. This can result in serious injuries topersonnel 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.


CAUTIONMachine damage in emergency operationThe assembly of the locking device on the turbocharger is only permissiblein emergencies. It is not permitted to lock the rotor for an engine test. Seri-ous damage to engine or property can be caused by non-compliance withthe regulations in the event of an emergency.

u The permissible turbocharger speed for the unlocked turbocharger maynot exceed nBmax. Take note of the rating plate.

u After locking the turbocharger, contact an ABB Turbocharging ServiceStation and find the nearest port.

u Observe the safety regulations.

u Follow the directives of the enginebuilder.

CAUTIONMachine damage following emergency operationImpermissible vibrations and unbalance values can cause serious damage tothe engine or property during operation. It is imperative that the followingwork is carried out after emergency operation with a locked rotor by an ABBTurbocharging Service Station:

u Remove rotor and check for unbalance

u Install rotor

u Fitting the spinner nose cone

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Operation Manual / A200-L10 Taking a turbocharger out of operation / 10.2 Taking defective tur-bochargers out of operation


CAUTIONMachine damage due to overheatingSerious damage to engine or property can be caused by the overheating ofintact turbocharger components.

u If there is a lubricating oil leak on the turbocharger, stop the oil supply.

10.2 Taking defective turbochargers out of operationIn the event of turbocharger damage, the turbocharger must be taken out of operation. Inorder to ensure that the engine can continue operation as quickly as possible, observe thefollowing instructions.

10.2.1 Procedure with one turbocharger installed per engine

u Stop the engine.

u Close off oil supply to defective turbocharger.

u Dismantle filter silencer (see chapter Dismantling the filter silencer →78).

u Lock rotor with locking device (see chapter Locking the rotor →112)

Version ProcedureWith bypass Open bypass

(see chapter Engines with bypass around the turbocharger →113)Without bypass If necessary, remove the nozzle ring

(see chapter Engines without bypass around the turbocharger→114)

Table 47: Bypass procedure

u Continue to operate engine in accordance with enginebuilder's instructions. Observe theprescribed power reduction.

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10.2.2 Procedure with two or more installed turbochargers perengine

CAUTIONMachine damage due to too high turbocharger speedThe permissible turbocharger speed for the unlocked turbocharger may notexceed nBmax. Serious damage to engine or property can be caused by ex-cessive speeds. The values provided by the enginebuilder apply to the max-imum admissible engine load.

u Observe the permissible turbocharger speed for the unlocked turbochar-ger.

u Reduce the engine load if necessary.

u Stop the engine.

u Close off oil supply to defective turbocharger.

u Blank off the inlets and outlets of the defective turbocharger (see chapter Blanking offthe inlets and outlets →115).

u Continue to operate engine in accordance with enginebuilder's instructions. Observe theprescribed power reduction.

10.2.3 Locking the rotor

Fig. 66: Locking the rotor

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Product B1 [Nm] B2 [Nm] B3 [Nm]A255-L M5

6M12

75M8 25

A260-L M8 20

M12 75

M8 25

A265-L M8 25

M12 75

M8 25

A270-L M10 45

M12 75

M8 25

A275-L M10 45

M12 75

M8 25

A280-L M12 75

M12 75

M8 25

Table 48: Tightening torque B1, B2, B3

u Dismantle the filter silencer (Dismantling the filter silencer →78).

1. If present: Loosen and remove the connecting screw at the centre of the spinner nosecone (25012). Dismantle spinner nose cone with press-off screw (90924).

2. Loosen retaining nuts (N) and remove screws (B1).

3. Loosen screws (B2) and remove with washers.

4. Align the locking device to a fin of the wall insert (77000) and align the hole circle to thedrill holes in the compressor wheel (25000).

5. Secure the locking device to the compressor wheel with the maximum possible numberof screws (B1). Observe tightening torque. Assembly with at least 6 screws is mandatory.The maximum possible number of screws to be fitted (B1) varies, as the threads in thecompressor wheel are partially occupied by set screws.

6. Align the bracket (94020) to a fin of the wall insert and fit screws (B2) with washers andscrew (B3). Observe tightening torque.

10.2.4 Engines with bypass around the turbocharger

The chapter only applies for engines with one turbocharger and for systems on which theconnections for a bypass have been prepared and the necessary pipe connections have beenprovided.

u Close the lubricating oil supply to the turbocharger.

u Open the bypass around the turbocharger.

u Observe specifications from enginebuilder.

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10.2.5 Engines without bypass around the turbocharger

To obtain a higher engine performance, the nozzle ring can be removed if required (seechapter Disassembly and assembly →70).

Securing the cover ring

If the nozzle ring is removed for emergency operation, the clamping of the cover ring (57001)to the gas outlet casing must be ensured. In this case, additional washers (01) must beprovided in accordance with the following table. These washers (01) are not supplied by ABB.

Fig. 67: Ensuring clamping of the cover ring

Product h [mm] d1 [mm] d2 [mm]A255-L 3.5 … 4.0 10 16A260-L 3.5 … 4.0 10 16A265-L 3.5 … 4.0 13 20A270-L 3.5 … 4.0 13 20A275-L 4.0 … 5.0 17 28A280-L 4.0 … 5.0 21 34Table 49: Required washers (01)

Part number A255-L A260-L A265-L A270-L A275-L A280-L57005 M8

20 NmM8

20 NmM12

50 NmM12

50 NmM16

80 NmM20

160 NmTable 50: Tightening torque (57005)

1. Remove screws (57005).

2. Fit and tighten screws (57005) with high-temperature grease and washers (01) in accord-ance with the table.

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10.2.6 Blanking off the inlets and outlets

The chapter is only applicable for engines with several turbochargers and joint air and ex-haust gas receivers. The cover plates for the compressor casing outlet, gas inlet and gasoutlet are not included in the ABB scope of delivery. The following figure shows the positions where to fit the cover plates.

Fig. 68: Position of cover plates

u Stop the engine.

u Shut off the supply of lubricating oil to the turbocharger.

u Blank off flanges of compressor casing outlet (01), gas inlet (02) and gas outlet (03) by in-stalling cover plates.

u Observe specifications from enginebuilder.

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Operation Manual / A200-L11 Mothballing the turbocharger / 11.1 Taking the engine out of opera-tion for up to 12 months


11 Mothballing the turbocharger

11.1 Taking the engine out of operation for up to12 months

State of the engine lubricating oil

The turbocharger normally remains attached to the engine. The measures to be taken formothballing 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

¡ 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 areflushed away in this way and the bearing parts are largely protected against corrosion.

Preparations for mothballing

WARNINGHandling operating materials and suppliesSwallowing 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 Wear personal protective equipment (PPE) according to the materialsafety data sheet.




Wear a respiratory mask to protect against gases.

If the acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measuresare necessary after taking the engine out of operation:

u Dismantle the turbocharger.

u The rotor and bearing parts must be dismantled and subsequently refitted by an ABB Tur-bocharging Service Station.

u Clean all parts.

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

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Operation Manual / A200-L11 Mothballing the turbocharger / 11.2 Taking the engine out of opera-tion for more than 12 months


u Fit turbocharger completely.

Rotation of the rotor in the 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 chargeair duct.

11.2 Taking the engine out of operation for more than12 months

If the engine is taken out of operation, the following variants are possible with regard to theturbocharger:

¡ Turbocharger remains attached to the engine

¡ The casings of the turbocharger remain attached to the engine, the rotor and bearingparts are dismantled by an ABB Turbocharging Service Station and stored separately

¡ The turbocharger is completely removed, either as a whole unit or in individual parts

For the measures always necessary for preparing the turbocharger parts for mothballing,see section Taking the engine out of operation for up to 12 months, subsection Preparationsfor mothballing.

If the turbocharger remains attached to the engine, see section Taking the engine out of op-eration for up to 12 months, subsection Rotor turning in stack draught.

If the complete turbocharger is removed or the turbocharger is assembled again from theindividual 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 canform, 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 / A200-L12 Material and Disposal / 12.1 REACH and RoHS Compliance Declara-tion For Products


12 Material and Disposal

12.1 REACH and RoHS Compliance Declaration ForProducts

We hereby confirm that all genuine products, parts and components supplied by ABBSwitzerland Ltd, Turbocharging are fully compliant with the requirements of EuropeanUnion Regulation (EC) 1907/2006 concerning the Registration, Evaluation, Authorization andRestriction 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 whichcontain(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) withsufficient information, available to the supplier.

RoHS2 Directive 2011/65/EC

[in English only]

The EU Directive 2011/65/EC (recast) restricts the use of certain hazardous substances inelectrical and electronic equipment (RoHS2). Products and related accessories manufac-tured by ABB Switzerland Ltd, Turbocharging do not fall within the Scope of RoHS2 due totheir 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 ABB Switzerland Ltd, Turbocharging fulfil re-quirements of RoHS2 Directive 2011/65/EC and fall under the exception 6a and 6c of thesame Directive:

¡ 6a) Lead as an alloying element in steel for machining purposes and in galvanised steelcontaining 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 reachmax. 0.8 % (mass % in homogeneous material).

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Operation Manual / A200-L12 Material and Disposal / 12.2 Disposing of turbocharger components


12.2 Disposing of turbocharger components

WARNINGHandling damaged thermal insulationDamaged thermal insulation can lead to dust exposure. The glass fibres cancause 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).



Wear a respiratory mask to protect against dusts.


Disposal must be environmentally compatible, professional, and in compliance with locallyapplicable 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), andthermal 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.Pa

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Operation Manual / A200-L13 Spare parts / 13.1 Ordering spare parts


13 Spare parts

13.1 Ordering spare parts

CAUTIONSpare part storageAll spare parts that were ordered together with the turbocharger must bekept 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 ABB Turbocharging Service Station.

u If different model variants are not taken into account in this document, contact an ABBTurbocharging Service Station.

The customer spare part sets (97070 / 97071) are available for the work described in the op-eration manual. The customer spare part set required depends on the service work beingcarried out on the turbocharger. The parts are only available in the complete set.

Customer spare part set (97070)

Customer spare part set is required for service work on the turbocharger after 36,000 hours.

Quantity Designation Part number3 Washer 560113 Hexagon-head screw 560143 Washer 720033 Hexagon nut 720042 Hexagon-head screw 770151 O-ring 770401 O-ring 790201 O-ring 790211 O-ring 86506

Table 51: Customer spare part set (97070)

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Operation Manual / A200-L13 Spare parts / 13.1 Ordering spare parts


Customer spare part set (97071)

Customer spare part set is required for service work on the turbocharger after 18,000 hours.

Quantity Designation Part number1 O-ring 770401 O-ring 790201 O-ring 79021

Table 52: Customer spare part set (97071)

u Dispose of replaced parts and parts that are not reusable in a professional and environ-mentally compatible manner.

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Operation Manual / A200-L13 Spare parts / 13.2 Spare Part - Illustrations


13.2 Spare Part - IllustrationsThe spare parts lists shown below are only available in English.

Bearing casing common parts42039

42015

42011*

42463

42464

42465

61035

42001

42461

42459

42460

42462

42307*

42306*

42305*

42300

42008

* = Available within the spare part set HZTL443382 Mod. B

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Part no. Designation42001 Bearing casing42008 Socket screw42011* O-ring42015 Sealing cover42039 Hexagon-head screw42300 Partition wall42305* O-ring42306* O-ring42307* O-ring42459 Hexagon-head screw42460 Cover42461 Gasket42462 Cover42463 Hexagon-head screw42464 Cover42465 Gasket61035 Socket screwTable 53: Spare parts – Bearing casing common parts

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Bearing casing oil tank

42186*

42064

42458

42185

42294*

42295

42041*

Bearing casing, common

42456

42047

42041* 42458

42553* **

42059

42457

42552

42557

4245542453

42452 42454

4245142450

* = Available within the spare part set HZTL443381 Mod. C** = Upgrade kit sealing air supply

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Part no. Designation42041* Gasket42047 Screw plug42059 Hexagon-head screw42064 Hexagon-head screw42185 Socket screw42186* O-ring42294* Flap with screws42295 Pressure adjusting unit42450 Socket screw42451 Cover42452 Valve sleeve42453 Orifice42454 Gasket42455 Flange plate42456 Socket screw42457 Gasket42458 Blind flange42552 Cover42553* ** Flat gasket42557 Hexagon-head screwTable 54: Spare parts – Bearing casing oil tank

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Cartridge

10900

25012

25014*

25013*

HZTL443573 Mod. A* = Available within the spare part set

Part no. Designation10900 Cartridge25012 Spinner nose cone25013* Socket screw25014* WasherTable 55: Spare parts – Cartridge

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Compressor Casing

74043**74040**

74042**

72013

79020*

72060

72000

72002

72003*

72004*

61075

77015*

79021*

79000

77040*

77000

72011

** = if providedHZTL443258 Mod. D* = Available within the spare part set

Part no. Designation61075 Hexagon-head screw72000 Compressor casing72002 Stud72003* Washer72004* Hexagon nut72011 Hexagon-head screw72013 Screw plug72060 Insulation74040** Air-outlet silencer74042** Gasket74043** Counter-sunk screw77000 Wall insert77015* Socket screw77040* O-ring79000 Diffuser

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Part no. Designation79020* O-ring79021* O-ringTable 56: Spare parts – Compressor casing

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Filter silencer

81270

81400**

81500**

81301**

81302**

81300**

81266

81271

81136 8113781135

81000

81268

81126

** = Filter silencer with low noise parts HZTL443366 Mod. D

Part no. Designation81000 Filter silencer complete81126 Lock81135 Silencer body81136 Absorption segment81137 Sheet-Metal covering81266 Cover grid81268 Connecting strip81270 Tension band81271 Lock81300** Insulation81301** Gasket81302** Insulating disk81400** Water connection81500** Silencer casingTable 57: Spare parts – Filter silencer

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Gas inlet casing axial

51200

51075

51001

51215

51087

56001

51086

51074

56011*

56014*

HZTL443515 Mod. B* = Available within the spare part set

Part no. Designation51001 Gas-inlet casing51074 Screw plug51075 Screw Plug51086 Threaded stud51087 Hexagon nut51200 Insulation51215 Insulation segment56001 Nozzle ring56011* Washer56014* Hexagon-head screwTable 58: Spare parts – Gas inlet casing axial

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Gas inlet casing radial

51200

51074

51001

51215

51087

5107556001

51086

56011*56014*

* = Available within the spare part set HZTL443256 Mod. D

Part no. Designation51001 Gas inlet casing51074 Screw plug51075 Screw plug51086 Threaded stud51087 Hexagon nut51200 Insulation51215 Insulation segment56001 Nozzle ring56011* Washer56014* Hexagon-head screwTable 59: Spare parts – Gas inlet casing radial

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Gas outlet casing

68002 5700168031 57005

61085

6103261087

61084

61086**

61083

61041

61001

61088

61100

61073

** = if providedHZTL443257 Mod. B

Part no. Designation57001 Cover ring57005 Hexagon-head screw61001 Gas outlet casing61032 Hexagon-head screw61041 Gasket61073 Screw plug61083 Pipe61084 Hexagon-head screw61085 Hexagon-head screw61086** Hexagon nut61087 Blind flange61088 Screw plug61100 Insulation68002 Foot TE68031 Distance sleeveTable 60: Spare parts – Gas outlet casing

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Rotor and bearing parts

21000

25011* **

42320*

29000

21005*

21001

21010

32102*

32101*

25008

32159*

32001*

32105*

25000

32174*

32106*

25009

32109*

* = Available within the spare part set HZTL443574 Mod. A** = only without spinner nose cone

Part no. Designation21000 Turbine21001 Turbine unbladed21005* Locking plate21010 Labyrinth sleeve25000 Compressor wheel25008 Threaded stud25009 Ring nut25011* ** O-ring29000 Turbine blade32001* Thrust bearing32101* Radial bearing32102* Radial bearing32105* Floating disc32106* Axial bearing32109* Sealing disc32159* Safety screw32174* O-ring

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Part no. Designation42320* Socket screwTable 61: Spare parts – Rotor and bearing parts

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Sealing air supply for flexible cut-out

42559**

42552

42554* **

42557

97088* **

42550 **

42553* **

42555* **42300 **

42560

42553* **

42552

42556

HZTL443339 Mod. C* = Available within the spare part set** = Upgrade kit sealing air supply

Part no. Designation42300 ** Partition wall42550 ** Sealing air pipe42552 Cover42553* ** Flat gasket42554* ** O-ring42555* ** O-ring42556 Socket screw42557 Socket screw42559** Socket screw42560 Plate sealing air97088* ** Orifice kitTable 62: Spare parts – Sealing air supply for flexible cut-out

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Speed measurement

86505**

86528**

86506* **

86515** 86526**

* = Available within the spare part set** = if provided

HZTL443252 Mod. B

Part no. Designation86505** Speed sensor86506* ** O-ring86515** Cable connector86526** F/I-converter86528** TachometerTable 63: Spare parts – Speed measurement

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U-tube manometer

81050

HZTL443260 Mod. C

Part no. Designation81050 U-tube manometerTable 64: Spare parts – U-tube manometer

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Turbine dry cleaning radial

** = if provided

51717

51723

51722

51712

51720

51705

51724

51714

51716

51700

51706

51713

51725

51719 51711

51721

51708**

51710**51710

51703 51701

5170951704

51718

HZTL443343 Mod. B

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Part no. Designation51700 Dry cleaning device51701 Container complete51703 Cover cap (with securing chain)51704 Combined air valve51705 On-off valve51706 Reducing piece51708** Screw plug51709 Reducing piece51710** Gasket51711 Connecting plate51712 Pipe51713 On-off valve51714 Union bush51716 Heat protection hose51717 Plate [on insulation of GI casing]51718 Hexagon-head screw51719 Hexagon nut51720 Stud51721 Hexagon nut51722 Sleeve51723 Heat protection hose51724 Screw-in socket51725 PipeTable 65: Spare parts – Turbine dry cleaning radial

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Operation Manual / A200-L14 Tools /


14 ToolsFor the work described in the Operation Manual, the customer tool set 90000 is required.

A255-L.. – A260-L..

90000 Designation Quantity90011 Wooden crate 190190 Lifting device 190195 Shackle 290320 Guide stud 390900 Press-off screw 690924 Press-off screw 194003 Locking device 194006 Screws 1294007 Screws 1294020 Bracket 1Table 66: Customer tool set 90000 (A255-L.. – A260-L..)

A265-L..

90000 Designation Quantity90011 Wooden crate 190190 Lifting device 190195 Shackle 290317 Guide stud 390320 Guide stud 390900 Press-off screw 390924 Press-off screw 194003 Locking device 194020 Bracket 1Table 67: Customer tool set 90000 (A265-L..)

A270-L.. – A275-L..

90000 Designation Quantity90011 Wooden crate 190190 Lifting device 190195 Shackle 290317 Guide stud 390320 Guide stud 390900 Press-off screw 690924 Press-off screw 194003 Locking device 194020 Bracket 1Table 68: Customer tool set 90000 (A270-L.. – A275-L..)

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Operation Manual / A200-L14 Tools /


A280-L..

90000 Designation Quantity90011 Wooden crate 190190 Lifting device 190195 Shackle 290317 Guide stud 390320 Guide stud 390477 Nozzle ring holder 190481 Support, left 190482 Support, right 190900 Press-off screw 690924 Press-off screw 194003 Locking device 194020 Bracket 1Table 69: Customer tool set 90000 (A280-L..)

This tool set can be ordered from any ABB Turbocharging Service Station. The following spe-cifications must be included in the order:

¡ Turbocharger type

¡ Designation and part number of the tool set

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Operation Manual / A200-LFigures

© Copyright 2021 ABB. All rights reserved. HZTL4036_EN Revision T December 2021

FiguresFig. 1: Layout and function of the turbocharger ...... 6

Fig. 2: Locations of the rating plates ......................... 8

Fig. 3: Warning plate locations ................................... 13

Fig. 4: Rating plate ........................................................ 13

Fig. 5: Attachment of loads on the crane hook ....... 16

Fig. 6: Attachment angle.............................................. 16

Fig. 7: Fitting the lifting gear ...................................... 27

Fig. 8: Placing the turbocharger................................ 28

Fig. 9: Compressor-end foot...................................... 29

Fig. 10: Turbine-end foot ............................................ 29

Fig. 11: Oil temperature at the outlet ....................... 35

Fig. 12: Layout and overview of the speed measure-ment system................................................................... 37

Fig. 13: Replacing the speed sensor ......................... 39

Fig. 14: U-tube manometer at the filter silencer .... 40

Fig. 15: Noise insulation, bellows .............................. 42

Fig. 16: Layout and overview of filter silencer ........ 50

Fig. 17: Dismantling filter ring circumferential part ....52

Fig. 18: Opening filter ring lock.................................. 52

Fig. 19: Attaching new filter ring ............................... 53

Fig. 20: Fitting new filter ring .................................... 53

Fig. 21: Overview of wet cleaning of compressor .. 56

Fig. 22: Filter plug view................................................. 57

Fig. 23: Dry cleaning device ........................................ 59

Fig. 24: Drain pipe diagram ........................................ 62

Fig. 25: Weights of assemblies .................................. 72

Fig. 26: Dismantling the filter silencer casing ......... 73

Fig. 27: Fitting the filter silencer casing .................. 74




Fig. 31: Fitting the filter silencer casing................... 76

Fig. 32: Fitting the bellows .......................................... 77

Fig. 33: Dismantling the filter silencer....................... 78

Fig. 34: Dismantling the filter silencer ...................... 79

Fig. 35: Dismantling the wall insert (A255-L.. - A260-L..) ..................................................................................... 80

Fig. 36: Moving out wall insert .................................... 81

Fig. 37: Putting down wall insert ................................ 81

Fig. 38: Dismantling the wall insert (A265-L.. - A280-L..) ..................................................................................... 82

Fig. 39: Moving out wall insert .................................... 83

Fig. 40: Putting down wall insert................................ 83

Fig. 41: Putting down wall insert ................................ 84

Fig. 42: Dismantling the diffuser ............................... 85

Fig. 43: Measuring axial clearance A .......................... 86

Fig. 44: Removing the insulation (A275-L and smal-ler)..................................................................................... 87

Fig. 45: Dismantling the gas inlet casing (275-L andsmaller) ............................................................................ 88

Fig. 46: Dismantling the nozzle ring (A275-L andsmaller) ............................................................................ 89

Fig. 47: Dismantling the gas inlet casing (A280-L) . 90

Fig. 48: Fitting the nozzle ring holder........................ 91

Fig. 49: Dismantling the nozzle ring .......................... 92

Fig. 50: Put down the nozzle ring ............................... 92

Fig. 51: Fitting the nozzle ring (A275-L and smaller)....93

Fig. 52: Fitting the gas outlet casing (A275-L andsmaller) ............................................................................ 94

Fig. 53: Fitting the insulation (A275-L and smaller) .....95

Fig. 54: Fitting the nozzle ring (A280-L) ................... 96

Fig. 55: Attaching the nozzle ring (A280-L) ............. 97

Fig. 56: Fitting the gas inlet casing (A280-L) ........... 98

Fig. 57: Measuring axial clearance A .......................... 99

Fig. 58: Fitting the diffuser........................................ 100

Fig. 59: Positioning wall insert.................................. 101

Fig. 60: Fitting the wall insert (A255-L.. - A260-L..) ......102

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Operation Manual / A200-LFigures


Fig. 61: Fitting the wall insert (A265-L.. - A280-L..) ......104

Fig. 62: Fitting the filter silencer ............................. 106

Fig. 63: Fitting the filter silencer .............................. 107

Fig. 64: Overview of tightening torques................ 108

Fig. 65: Overview of speed sensor tightening torque108

Fig. 66: Locking the rotor .......................................... 112

Fig. 67: Ensuring clamping of the cover ring ......... 114

Fig. 68: Position of cover plates............................... 115

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Operation Manual / A200-LTables


TablesTable 1: Personal protective equipment to be wornat all times ...................................................................... 10

Table 2: Personal protective equipment to be wornspecific to the respective task ................................... 10

Table 3: Total weight ................................................... 26

Table 4: General information about fastening theturbocharger ................................................................. 29

Table 5: Tightening torques (foot screws) ............. 30

Table 6: Tightening angle (foot screws).................. 30

Table 7: Lubricating oil pressure, oil inlet ............... 34

Table 8: Lubricating oil temperature at the inlet .. 35

Table 9: Lubricating oil temperature at the outlet 35

Table 10: Tightening torques (86505)...................... 39

Table 11: Expected replacement intervals for tur-bocharger parts ........................................................... 46

Table 12: Recommended replacement intervals forturbocharger parts ..................................................... 46

Table 13: Volume of water per cleaning process..... 57

Table 14: Tightening torques (81125) ........................ 57

Table 15: Cleaning parameters ................................... 61

Table 16: Malfunctions when starting – Delayedstart-up .......................................................................... 63

Table 17: Malfunctions when starting – Vibrations 63

Table 18: Malfunctions when starting – Rubbing ofrotating parts................................................................ 63

Table 19: Malfunctions during operation – Lubricat-ing oil pressure too low............................................... 64

Table 20: Malfunctions during operation – Drop inspeed ............................................................................. 64

Table 21: Malfunctions during operation – Exhaustgas temperature too high .......................................... 65

Table 22: Malfunctions during operation – Charge airpressure too low........................................................... 65

Table 23: Malfunctions during operation – Charge airpressure too high ......................................................... 66

Table 24: Surging of the turbocharger..................... 66

Table 25: Malfunctions when stopping – Runoutnoises.............................................................................. 67

Table 26: Malfunctions when stopping – Shortenedrunout time ..................................................................... 67

Table 27: Malfunctions of the speed measurementsystem ............................................................................. 68

Table 28: Weights of assemblies [kg] ........................ 72

Table 29: Weight of wall insert [kg]............................ 72

Table 30: Tightening torques (filter silencer screws) .77

Table 31: Axial clearance A............................................ 86

Table 32: Maximum admissible loosening torque(51087) ............................................................................. 88

Table 33: Maximum admissible loosening torque(51087) ............................................................................. 90

Table 34: Tightening torque (56014) ......................... 93

Table 35: Tightening torque (51087).......................... 94

Table 36: Tightening torque (56014) ......................... 97

Table 37: Tightening torque (51087).......................... 98

Table 38: Axial clearance A ........................................... 99

Table 39: Tightening torque (77015)........................ 100

Table 40: Tightening torque (72002)....................... 102

Table 41: Tightening torque (72004) ....................... 102

Table 42: Tightening torque (72011) ........................ 104



Table 45: Overview of tightening torques.............. 109

Table 46: Tightening torque, insulation.................. 109

Table 47: Bypass procedure........................................ 111

Table 48: Tightening torque B1, B2, B3........................ 113

Table 49: Required washers (01)................................ 114

Table 50: Tightening torque (57005)........................ 114

Table 51: Customer spare part set (97070) ............ 120

Table 52: Customer spare part set (97071) ............. 121

Table 53: Spare parts – Bearing casing commonparts ............................................................................... 123

Table 54: Spare parts – Bearing casing oil tank..... 125

Table 55: Spare parts – Cartridge............................. 126

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Operation Manual / A200-LTables


Table 56: Spare parts – Compressor casing .......... 128

Table 57: Spare parts – Filter silencer ..................... 129

Table 58: Spare parts – Gas inlet casing axial....... 130

Table 59: Spare parts – Gas inlet casing radial...... 131

Table 60: Spare parts – Gas outlet casing.............. 132

Table 61: Spare parts – Rotor and bearing parts .. 134

Table 62: Spare parts – Sealing air supply for flexiblecut-out........................................................................... 135

Table 63: Spare parts – Speed measurement ........ 136

Table 64: Spare parts – U-tube manometer........... 137

Table 65: Spare parts – Turbine dry cleaning radial ....139

Table 66: Customer tool set 90000 (A255-L.. – A260-L..) .................................................................................. 140

Table 67: Customer tool set 90000 (A265-L..)...... 140

Table 68: Customer tool set 90000 (A270-L.. – A275-L..) .................................................................................. 140

Table 69: Customer tool set 90000 (A280-L..) ...... 141

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Operation Manual / A200-L - ABB

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Transcript of Operation Manual / A200-L - ABB