ABB TPS52 F33 User Manual

Operation Manual

TPS52-F33

ABB Turbo Systems Ltd

CH 5401 Baden

Type TPS52-F33

n_Mmax843

HT845348

680

650

Mmax

Bmax

1/s

°C

n_Bmax801

SOLD06

00250 kg 20

Application according to

the Operation Manual

Year 2020

made in Switzerland

ABB Turbocharging

ꢀꢁꢁ

Operation Manual / TPS44-F.. - TPS61-F..

Table of contents

Operation Manual

Preliminary remarks................................................................................................. 3

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

Purpose of this manual.................................................................................................. 3

Layout and function........................................................................................................ 4

Intended use of the turbocharger .............................................................................. 6

Storage of new turbochargers and spare parts ....................................................... 7

Essential information..................................................................................................... 9

Symbols and definitions.............................................................................................. 11

Turbocharger rating plate........................................................................................... 12

Contact information..................................................................................................... 13

Safety...................................................................................................................... 14

Introduction ................................................................................................................... 14

CE conformity ................................................................................................................ 14

Definition of mandatory signs ................................................................................... 15

Definition of Safety instructions ............................................................................... 15

Warning plates on the turbocharger......................................................................... 16

Safe operation and maintenance............................................................................... 16

Hazards during operation and maintenance........................................................... 20

Deflagration on gas engines....................................................................................... 25

Periodic checking of the pressure vessel................................................................. 26

Lifting loads ................................................................................................................... 26

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

2.10

Start-up ................................................................................................................. 28

Oil supply ........................................................................................................................ 28

Inspection work............................................................................................................. 32

Commissioning after taking out of operation........................................................ 34

3.1

3.2

3.3

Operation ............................................................................................................... 35

Noise emissions ............................................................................................................ 35

Servicing work ............................................................................................................... 36

Expected exchange intervals ...................................................................................... 39

Speed measurement .................................................................................................... 41

Stopping the engine.................................................................................................... 44

4.1

4.2

4.3

4.4

4.5

Maintenance .......................................................................................................... 45

Foreword to Maintenance .......................................................................................... 45

Cleaning the compressor during operation ........................................................... 46

Turbine cleaning during operation........................................................................... 50

Cleaning components mechanically.......................................................................... 56

5.1

5.2

5.3

5.4

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Table of contents

Troubleshooting.................................................................................................... 67

6.1

6.2

6.3

6.4

6.5

Malfunctions when starting........................................................................................ 67

Surging of the turbocharger...................................................................................... 68

Malfunctions during operation ................................................................................. 69

Malfunctions when stopping...................................................................................... 72

Speed measurement system ...................................................................................... 73

Removal and installation...................................................................................... 74

Transport ........................................................................................................................ 74

Turbocharger weights.................................................................................................. 75

Removing the turbocharger........................................................................................ 75

Installing the turbocharger ......................................................................................... 76

7.1

7.2

7.3

7.4

Disassembly and assembly.................................................................................. 78

Introduction ................................................................................................................... 78

Module weights ............................................................................................................. 81

Disassembling and assembling turbocharger ........................................................ 82

Axial clearance A and radial clearance B.................................................................. 96

Radial clearances N and R........................................................................................... 98

Table of tightening torques..................................................................................... 100

8.1

8.2

8.3

8.4

8.5

8.6

Taking out of operation .................................................................................... 101

9.1

Shutting down the turbocharger ............................................................................ 101

10.1

10.2

Mothballing the turbocharger........................................................................... 105

Taking the engine out of operation for up to 12 months.................................... 105

Taking the engine out of operation for more than 12 months ......................... 106

Disposing of turbocharger components.......................................................... 108

Spare parts........................................................................................................... 109

Ordering spare parts.................................................................................................. 109

View of turbocharger showing part numbers....................................................... 110

View of cartridge group showing part numbers .................................................. 112

12.1

12.2

12.3

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1 Preliminary remarks / 1.1 Purpose of this manual

1 Preliminary remarks

1.1 Purpose of this manual

This Operation Manual belongs to the turbocharger with the identical

serial number (01), see the cover sheet of the Operation Manual and the

turbocharger rating plate.

Operation Manual

This Operation Manual helps familiarise the user with the turbocharger

from ABB Turbocharging and how to use it as intended.

It provides important information in order that the turbocharger can be

operated safely, correctly and efficiently.

This Operation Manual complements and expands existing national reg-

ulations concerning work safety and accident prevention.

Target group

This Operation Manual is intended for engineers and qualified mechan-

ics who are responsible for operating the engine and the turbocharger

installed on it.

Availability of operation manual

An operation manual must be available at all times at the place where

the turbocharger is used.

Everyone who operates or works on the turbocharger must have first

read and understood the operation manual.

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1 Preliminary remarks / 1.2 Layout and function

1.2 Layout and function

1Suction branch / filter silencer

2Compressor casing

3Diffuser

8Gas outlet flange

9Nozzle ring

10Turbine casing

4Bearing casing

11Turbine-end bearing flange

5Axial thrust bearing

12Compressor-end bearing

flange

6Radial plain bearing (visible only

at turbine end)

13Compressor wheel

7Turbine

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Mode of operation

The turbocharger is a turbomachine consisting of the following main

components:

Turbine

Compressor

These are mounted on a common shaft.

Exhaust gases from the diesel or gas engine flow through the turbine

casing (10) and the nozzle ring (9) to impinge on the turbine (7).

The turbine (7) uses the energy contained in the exhaust gas to drive the

compressor wheel (13). The compressor draws in fresh air, compresses it

and then forces it into the engine's cylinders.

The exhaust gases escape into the ambient air through the exhaust gas

pipe, which is connected to the gas outlet flange (8).

The air, which is necessary for operation of the diesel or gas engine and

is compressed in the turbocharger, is drawn into the compressor wheel

(13) through the suction branch or filter silencer (1). It then passes

through the diffuser (3) and leaves the turbocharger through the outlet

on the compressor casing (2).

The rotor runs in two radial plain bearings (6), which are located in the

bearing flanges (11/12) between the compressor and the turbine. The

axial thrust bearing (5) is located between the two radial plain bearings.

The bearings are connected to a central lubricating oil duct which is sup-

plied by the engine's lubricating oil circuit. The oil outlet is always at the

lowest point of the bearing casing (4).

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1 Preliminary remarks / 1.3 Intended use of the turbocharger

1.3 Intended use of the turbocharger

NOTICE

This turbocharger supplied by ABB Turbocharging has been developed

for use on diesel engines to generate the volume of air and the char-

ging pressure required to operate the engine.

The enginebuilder has provided ABB Turbocharging with information

regarding the intended use of the engine, from which the operating

limits specific to the turbocharger shown on the rating plate, such as

operating speeds, temperatures, exchange intervals / replacement in-

tervals, have been derived.

Use in connection with a gas engine requires that the engine is not in-

stalled in a potentially explosive environment and that precautions are

taken to ensure that the engine room as a whole is classified as non-ex-

plosive.

Any other use is considered to be a special application, which must first

be clarified with ABB Turbocharging. The manufacturer accepts no liab-

ility for any other type of use. If the equipment is used for any other

purpose, ABB Turbocharging reserves the right to reject all warranty

claims.

State of the art

This turbocharger was built according to state-of-the-art technology

and is operationally safe according to recognised safety regulations.

WARNING

Improper operation and maintenance of the turbocharger can result in

danger to life and limb of the user or third parties. In addition, im-

proper use may cause damage to the machine.

u The machine may be operated only by trained personnel.

Use of the turbocharger as intended also includes observance of the in-

stallation / fitting, disassembly / removal, operating, maintenance / ser-

vicing and repair conditions specified by the manufacturer. Disposal reg-

ulations set down by local authorities must be observed.

Perfect condition

The turbocharger may be installed only when in technically perfect condi-

tion while observing the instructions given in the engine builder's

manual. It may be used only for the intended purpose and operated in

compliance with the operation manual.

u Malfunctions which could affect safety must be eliminated immedi-

ately.

The manufacturer accepts no liability for any damage resulting from un-

authorised alterations to the turbocharger.

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1 Preliminary remarks / 1.4 Storage of new turbochargers and spare

parts

1.4 Storage of new turbochargers and spare parts

Storage of new turbochargers and spare parts up to 6 months

New turbochargers and spare parts from ABB Turbocharging can be

stored in sealed packaging without additional mothballing measures for

up to 6 months from the date of delivery (marked by the VCI label on the

package).

Volatile Corrosion Inhibitor (VCI)

Only dry rooms in which the relative humidity is between 40…70 % and

no condensation can form are suitable for storage.

Storage of new turbochargers and spare parts for more than 6

months (VCI)

WARNING

Protection of health when handling VCIs

VCI products are not hazardous in the sense of the Hazardous Sub-

stances Ordinance. Nevertheless, the following points are to be ob-

served when handling VCIs:

u Ensure good room ventilation.

u Do not eat, drink or keep food at the workplace while working with

VCIs.

u Wear safety gloves.

u Clean hands and face after working with VCIs.

u For further information refer to www.branopac.com.

Wear safety gloves to protect against chemical hazards.

The following mothballing measures are required every 6 months:

u Open the package.

u Remove the VCI corrosion protection emitter from the package and

replace it with a new, identical VCI corrosion protection emitter. New

VCI corrosion protection emitters can be obtained at www.brano-

pac.com.

u Dispose of the old VCI corrosion protection emitter in an environ-

mentally compatible manner, professionally and in accordance with

local regulations.

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1 Preliminary remarks / 1.4 Storage of new turbochargers and spare

parts

u Seal the package. The better the external seal is designed, the more

permanent the protection.

Long-term storage of turbochargers

The turbochargers will be prepared for prolonged storage by ABB Tur-

bocharging on request. The package is equipped with a hygrometer (see

illustration).

The following measures are required every 6 months:

u Check the hygrometer (02) in the sight-glass. There is an opening (01)

in the wooden crate which allows this check to be carried out. When

the display field has changed colour at the 70% level, the maximum

permissible humidity has been exceeded. In this case, the turbochar-

ger must be inspected by an ABB Turbocharging Service Station and

repacked.

u Inspect the package for damage. If the package is damaged, the tur-

bocharger must be inspected by an ABB Turbocharging Service Sta-

tion and repacked.

After every 3 years the following work steps must be performed by an

ABB Turbocharging Service Station:

Inspect the component

Replace the desiccant agent

Repackage the component.

NOTICE

Turbocharger ready for operation

If the 70% field of the hygrometer (02) has not changed colour and the

package is undamaged, the turbocharger can be put into operation

without any prior inspection by an ABB Turbocharging Service Station.

Unpacking the turbochargers

The corrosion protection effect ends after the material is unpacked from

the VCI package.

To avoid the formation of condensation, the surroundings and the con-

tent of the package must have the same temperature during unpacking.

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1 Preliminary remarks / 1.5 Essential information

1.5 Essential information

Organisational measures

In addition to the Operation Manual, the general statutory regulations

for the prevention of accidents and protection of the environment are

also to be observed.

This also applies for the provision and wearing of personal protective

equipment.

NOTICE

The manner in which personnel work on and with the turbocharger with

regard to safety and risks is to be checked on a regular basis in accord-

ance with the Operation Manual.

u If the turbocharger shows modifications affecting safety or any cor-

responding operating behaviour, it must be shut down immediately

by stopping the engine. The malfunction must be reported to the per-

son or department responsible.

NOTICE

Any modifications, additions or conversions made to the turbocharger

that could impair safety require the prior approval of ABB Turbochar-

ging.

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1 Preliminary remarks / 1.5 Essential information

Original parts and safety

Original parts and accessories are specially designed for the turbochar-

ger supplied by ABB.

WARNING

Use original parts

Operation of the turbocharger with non-original parts can impair the

safety of the turbocharger and can cause serious damage to property

and injury to personnel.

u Only use original parts from ABB.

ABB accepts no liability for any damage resulting from the use of non-

original parts and corresponding accessories.

Competence of personnel

The turbocharger must only be operated and serviced by trained and au-

thorised personnel. Basic mechanical training is a prerequisite.

Design variants

This document is valid for different design variants of turbochargers.

There may be sections and descriptions of components that are not rel-

evant for a specific turbocharger variant.

ABB Turbocharging Service Stations will be happy to provide information

on questions regarding a design variant (see Contact information at

www.abb.com/turbocharging).

Accuracy of illustrations

The illustrations in this document are general in nature and intended for

ease of understanding. Differences in detail are therefore possible.

Registered Trademarks

Registered trademarks of external companies are used in this document.

The trademarks are marked with ®.

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1 Preliminary remarks / 1.6 Symbols and definitions

1.6 Symbols and definitions

The following symbols are used in the documents:

w Prerequisite

u Work step

Enumeration, first level

- Enumeration, second level

→ Refers to a page number

Definition of notes

NOTICE

Note

A note provides suggestions which facilitate the work on the product.

Definition of mandatory signs

Mandatory signs show the protective equipment to be worn for a task.

The mandatory signs are described in chapter Safety and must be com-

plied with.

Definition of caution / warning

The caution and warning signs are described in the chapter Safety.

ABB Turbocharging

ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging

in this document.

Official service stations of ABB Turbocharging

Official service stations are regularly audited and certified by ABB Tur-

bocharging. See also chapter Contact information →13.

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1 Preliminary remarks / 1.7 Turbocharger rating plate

1.7 Turbocharger rating plate

Operating limits

01 Turbocharger operating limits at engine overload (110 %).

Only when operating in the test rig unless otherwise agreed with the

enginebuilder.

02 Turbocharger operating limits during operation

Recommended inspection

and replacement intervals

for turbocharger compon-

ents

03 Inspection interval for plain bearings in 1000 h

04 Replacement interval for compressor in 1000 h

05 Replacement interval for turbine in 1000 h

Further information

06 Part number for customer

07 Designation of special design

08 Turbocharger weight in kg

09 Turbocharger type

10 Serial number

11 Year of turbocharger construction

12 Manufacturing plant

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1 Preliminary remarks / 1.8 Contact information

1.7.1 Explanation of the rating plate

The recommended replacement intervals and the corresponding opera-

tional limits are jointly defined with the engine manufacturer. This in-

formation is specific to the system.

Operation above the indicated values n_Bmax, t_Bmaxcan considerably shorten

the recommended replacement intervals. In such cases, we recommend that

you contact the nearest official ABB Turbocharging service station.

n_Mmaxand t_Mmaxnormally apply only when running at overload (110%) during

trials on the engine test bed. Operation above n_Mmaxand t_Mmaxis not permit-

ted.

Non-observance of the recommended replacement intervals increases the

risk of unpredictable component failures.

1.7.2 Positions of the rating plates

One rating plate (01) each is attached on the left and the right side of the

turbocharger bearing casing.

1.8 Contact information

Contact information for the official service stations of ABB Turbochar-

ging is available online.

u Scan the QR code to access our website.

ABB Switzerland Ltd, Turbocharging

Bruggerstrasse 71a

CH-5401 Baden

Switzerland

www.abb.com/turbocharging

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2 Safety / 2.1 Introduction

2 Safety

2.1 Introduction

Turbochargers manufactured by ABB are state of the art and comply

with the pertinent safety and health-protection requirements that ap-

plied when the turbocharger was manufactured. Consequently, the tur-

bocharger is safe to operate. Nevertheless, during turbocharger opera-

tion and when working on the turbocharger, residual risks can exist

which:

originate from the turbocharger itself and its accessories

originate from the operating and auxiliary materials used

are the consequence of insufficient observance of the safety instruc-

tions

are the consequence of unsatisfactory and improper execution of

maintenance and inspection work.

The operating company is responsible for access to the turbocharger as

well as the organisational measures that regulate the safe handling of

the turbocharger by its personnel.

All instructions contained in this chapter must be observed for safe and

trouble-free operation of the turbocharger and during all work on the

turbocharger.

All further safety instructions contained and specifically identified in

every chapter of this manual (see section Definition of Safety Instruc-

tions) must also be observed.

2.2 CE conformity

Information

ABB turbochargers fulfil Directive 2006/42/EC on machinery and are

considered partly completed machinery in the sense of Article 2 g.

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2 Safety / 2.3 Definition of mandatory signs

2.3 Definition of mandatory signs

To be worn at all times

Protective clothing

Safety footwear to pro-

tect against mechanical

hazard and risk of fall-

ing

To be worn according to the specific work

Safety glasses

Safety goggles

Safety gloves against

- Mechanical hazard

- Chemical hazard

- Thermal hazard

Respiratory mask

against

- Dusts

- Gases

Safety helmet

Ear protection

2.4 Definition of Safety instructions

The following symbols and terms used in this manual concern safety or

refer to possible hazards:

WARNING

Definition of warning

Serious personal injuries and even accidents with fatal consequences

may occur if work and operating instructions marked with this symbol

and the word WARNING are either not followed or not followed pre-

cisely.

u Warning signs must be observed at all times.

CAUTION

Definition of caution

Serious machine or property damage may occur if work and operating

instructions marked with this symbol and the word CAUTION are either

not followed or not followed precisely.

u Caution signs must be observed at all times.

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2 Safety / 2.5 Warning plates on the turbocharger

2.5 Warning plates on the turbocharger

Warning plates are attached to the turbocharger at the following places:

If warning plates are not present at the intended places or are not

legible, then proceed as follows:

u Order new warning plates from ABB Turbocharging Service Stations.

u Remove unreadable warning plates.

u Clean and degrease surfaces provided for warning plates.

u Attach new warning plates.

Uninsulated turbochargers

When uninsulated turbochargers are delivered to the engine builder, the

warning plates must be subsequently attached to the insulation. This is

the responsibility of the engine builder.

2.6 Safe operation and maintenance

The instructions specified in this section are for the safety of personnel.

Together with the instructions in the Hazards during operation and

maintenance section, they allow the user to safely use the turbocharger.

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2 Safety / 2.6 Safe operation and maintenance

Work safety and work area safety

WARNING

Risk of falling

There is the risk that someone can fall when working on the turbochar-

ger.

u Do not climb on the turbocharger or on parts attached to it or use

these as climbing aids.

u When working at levels above the head, use climbing aids and work

platforms suitable for this purpose.

u Observe all general regulations for the prevention of accidents.

u Do not work on the turbocharger if you are under physical or mental

stress.

u Work only with suitable tools as well as equipment and working ma-

terials that are in perfect condition.

u Electric tools must be solidly earthed, and connecting cables may not

be damaged.

u Keep the workplace clean, clear away loose objects and remove

obstacles on the floor.

u Keep the floor, equipment and the turbocharger clean.

u Have oil binding materials ready at hand and keep oil catch pans

ready or in position

u Eliminate leaks.

u Keep fire-protection materials and fire-extinguishing equipment

ready.

Welding work close to the turbocharger

u If welding work is being carried out in the vicinity of the turbocharger,

cover the filter silencer so that the filter mat is not damaged.

u Remove combustible objects and substances out of the range of fly-

ing sparks.

u Cover all connections on the turbocharger so that no foreign objects

can get into the turbocharger.

u Wear personal protective equipment (PPE) for welding operations.

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2 Safety / 2.6 Safe operation and maintenance

Safety during start-up / commissioning and operation

WARNING

The turbine casing insulation of the TPS44-F supplied by ABB is also

burst protection

Serious personal injuries or fatal accidents can occur, if the turbine cas-

ing insulation of the TPS44-F supplied by ABB is removed. The burst

protection is integrated into the turbine casing insulation of the TPS44-

F supplied by ABB.

Separate burst protection is fitted to TPS44-F turbochargers that have

been ordered from ABB without insulation.

u Never operate TPS44-F turbochargers that have been supplied by

ABB with insulation if this insulation from ABB is not in place.

u Never operate turbochargers without burst protection. If the insula-

tion from ABB is not in place, the separate burst protection (57200)

must be fitted before operation (see View of turbocharger showing

part numbers →110).

u Before starting work, carry out visual inspection of working area.

u Remove any obstacles and objects lying around.

u Before start-up / commissioning, check all pipes from and to tur-

bocharger for damage and leaks.

u Don't work in any way that could impair safety when working on tur-

bocharger.

u After about every 12 hours of operation or at least once a day, inspect

turbocharger for visible damage and defects.

u Immediately report any damage or changes in operational perform-

ance to person responsible.

u If damage is discovered, immediately shut down turbocharger and se-

cure it against inadvertent or unauthorized use.

u When switching on auxiliary power sources (hydraulics, pneumatics,

electricity, water), keep an eye open for any hazards resulting from

supplying these power sources.

Safety during cleaning

If cleaning agents or solvents are used for cleaning, the corresponding

material safety data sheet and the safety instructions in section "Haz-

ards due to operating and auxiliary materials" must 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.

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2 Safety / 2.6 Safe operation and maintenance

u Inspect the electric cables for abrasion and damage before and after

your cleaning work.

Safety during disassembly, assembly, maintenance and

troubleshooting

u Always perform the specified adjustments, servicing as well as in-

spection work and observe inspection intervals.

u Inform operating personnel about all service and repair work before

beginning.

u Before opening a cover or removing a protective device on a tur-

bocharger, the engine must be switched off and the turbocharger

must have come to a standstill.

u Ensure that the supply of oil is interrupted, especially with an external

oil supply.

u Put the engine into operation only after all parts have been refitted

properly.

CAUTION

Mechanical work on the turbocharger

Possible damage to or destruction of components on the turbocharger.

u Perform only those tasks that are described in this manual.

u Perform work only for which training has been carried out.

Safety when taking out of operation or preparing for mothballing

u Secure the rotor so it cannot turn. The rotor can turn on its own from

the force of the stack draught.

u Clean the turbocharger before mothballing it.

u Observe the material safety data sheet for the cleaning and moth-

balling agents.

u Wear personal protective equipment (PPE) according to the material

safety data sheet.

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2 Safety / 2.7 Hazards during operation and maintenance

2.7 Hazards during operation and maintenance

Mechanical hazards during operation

During normal operation, no mechanical hazards emanate from the tur-

bocharger if it has been installed properly.

WARNING

Risk of injury

Contact with rotating parts can lead to serious injuries. The turbochar-

ger must never be operated without a filter silencer or an air suction

branch. When the engine is at a standstill, the rotor can turn on its own

because of stack draught.

u Operate the turbocharger in accordance with instructions.

u During maintenance work, secure the rotor against unintentional ro-

tation.

Mechanical hazards when working on the turbocharger

During maintenance work, various risks can occur through the improper

handling of components, through the non-observance of work instruc-

tions, due to inadequate care or as a consequence of insufficient train-

ing.

WARNING

Mechanical hazard

Severe injuries to personnel or fatal accidents can be caused by mech-

anical influences as a consequence of hazardous and inadequate opera-

tional procedures.

u Observe the general rules for occupational safety and prevention of

accidents.

u Ensure workplace safety.

u Only perform operations that are described in this chapter.

u Only perform operations for which you have previously received in-

struction or training.

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2 Safety / 2.7 Hazards during operation and maintenance

Hazards due to noise

The development of noise during operation is influenced by the installa-

tion and operating conditions. Noise with a sound pressure level exceed-

ing 85 dB(A) is harmful.

WARNING

Hazards due to noise

Noise can cause impaired hearing, damage to health, mental disturb-

ances, diminished attention and irritation.

u Always wear ear protection when the engine is running.

u When the sound pressure level is above 85 dB(A), always wear ear

protection.

Wear ear protection.

Hazards due to hot surfaces and substances

During operation, turbocharger surfaces and attached parts as well as

operating materials (lubricating oil) become hot. The surface temperat-

ure is dependent on the effectiveness of the insulation being used. The

temperature can become high enough so that it falls into ranges where

burns are possible.

WARNING

Risk of burning

Touching hot surfaces or contact with hot operating materials can lead

to serious burns.

u Do not touch hot surfaces and heed the warning plate on the tur-

bocharger.

u Wear heat-resistant safety gloves and protective clothing.

u Allow the turbocharger to cool down before carrying out any work.

Wear safety gloves to protect against thermal hazards.

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2 Safety / 2.7 Hazards during operation and maintenance

WARNING

Hot surfaces on uninsulated turbochargers

Uninsulated turbochargers can cause serious personal injuries (burns).

The turbocharger is supplied with or without insulation in accordance

with the purchase order received from the enginebuilder. If supply is

without insulation, the enginebuilder is responsible for providing the

turbocharger with proper insulation and for providing protection

against contact with hot surfaces.

u Compliance with the instructions and specifications given by the en-

ginebuilder to protect against hot turbocharger surfaces is compuls-

ory.

Wear safety gloves to protect against thermal hazards.

Hazards due to operating and auxiliary materials

Operating and auxiliary materials are substances used for operation or

the execution of maintenance work. Oils, greases, coolants, cleaning

agents and solvents, acids, etc. can be regarded as hazardous materials.

Operating and auxiliary materials can be combustible and easily ignited.

WARNING

Handling operating and auxiliary materials

Ingestion or inhalation of vapours of operating and auxiliary materials

or contact with such can cause damage to health.

u Avoid inhalation and contact with the skin.

u Ensure good ventilation.

u Observe details in the safety data sheets of the operating and auxili-

ary materials.

u Observe local laws.

Wear safety goggles.

Wear safety gloves to protect against chemical hazards.

Wear a respiratory mask to protect against gases.

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2 Safety / 2.7 Hazards during operation and maintenance

WARNING

Risk of fire, explosion

Flammable and combustible operating materials and supplies can

catch fire or resulting vapours can lead to an explosion.

u Observe the details in the material safety data sheets of the operat-

ing and auxiliary materials.

u Comply with local legislation.

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

work.

u Carry out cleaning in the open or provide sufficient aeration and

ventilation.

CAUTION

Risk of environmental damage

The escape of operating and auxiliary materials into the atmosphere or

contamination of the ground and water due to improper disposal can

lead to environmental damage.

u Handle operating and auxiliary materials carefully.

u Heed the instructions for use, safety data sheets and hazard notices

on the containers of the operating and auxiliary materials.

u Wear appropriate protective clothing.

u Avoid inhalation and contact with the skin.

u Ensure that the work space is adequately ventilated.

u Seal containers tightly immediately after use and put them away.

u Collect used working and auxiliary materials safely, store them separ-

ately in suitable containers and dispose of them properly and in an

environmentally compatible manner in accordance with statutory reg-

ulations.

u In the event of leaks or after spilling, immediately spread a suitable

binding agent and dispose of it properly and in an environmentally

compatible manner in accordance with statutory regulations.

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2 Safety / 2.7 Hazards during operation and maintenance

Hazards when handling insulating materials

WARNING

Hazards due to insulating materials

Dust and fibres from insulating materials can cause damage to health

or irritations. Unsuitable, combustible insulating materials signify a fire

hazard.

u Use only suitable, non-combustible insulating materials.

u Ensure that the work area is well ventilated.

u Avoid stirring up dust.

u Use tools and processes which keep dust to a minimum.

u Remove packing materials only in the work area.

u Take particular care when removing old insulating materials.

u Dispose of insulating materials properly and in an environmentally

compatible way in accordance with applicable local regulations.

Wear safety goggles.

Wear a respiratory mask to protect against dusts.

Wear safety gloves to protect against chemical hazards.

u Use only suitable, non-combustible insulating materials.

u Ensure that the work area is well ventilated.

u Wear suitable work clothing (safety glasses, respiratory mask).

u Avoid stirring up dust.

u Use tools and processes which keep dust to a minimum.

u Remove packing materials only in the work area.

u Take particular care when removing old insulating materials.

u Dispose of insulating materials properly and in an environmentally

compatible way in accordance with applicable local regulations.

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2 Safety / 2.8 Deflagration on gas engines

Hazards due to electrical components

WARNING

Hazards due to electrical components

Electrical components operate with voltages which can present hazards

to humans.

u All work on or with electrical components may only be performed by

trained specialists.

u Heed any country-specific regulations.

2.8 Deflagration on gas engines

ABB turbochargers can withstand a deflagration with a transient pres-

sure increase of 12 bar.

ABB Turbocharging recommends that, following a deflagration event,

the turbocharger undergoes an inspection of the following points:

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 deflagration event has taken place, it is also recommended to

check the bearings of the turbochargers before the next start. This in-

spection and evaluation must be carried out by an ABB Turbocharging

Service Station.

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2 Safety / 2.9 Periodic checking of the pressure vessel

2.9 Periodic checking of the pressure vessel

The pressure vessels used by ABB, such as those for wet or dry cleaning,

are so-called "simple pressure vessels".

The locally applicable legal regulations regarding periodic checks of

the pressure vessels must be observed.

The operating company is responsible for the safe operation of the

pressure vessel.

WARNING

Danger due to pressure vessels

The operating company must make sure the pressure vessels are in

proper working condition and monitor them. Necessary repair or main-

tenance work must be carried out without delay and the required safety

precautions must be taken.

u Pressure equipment must not be operated if it has defects.

2.10 Lifting loads

WARNING

Suspended loads

Loads not suspended in compliance with regulations may lead to per-

sonal injury or accidents with fatal consequences.

u Loads must always be fastened to technically perfect lifting gear

with sufficient loading capacity.

u Make sure the load is suspended properly on the crane hook.

u Do not let anyone stand beneath a suspended load.

Wear safety gloves to protect against mechanical hazards.

Wear safety helmet.

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2 Safety / 2.10 Lifting loads

In the case of two or more suspension points, the slinging angle must

not exceed 45°. This avoids excessive loading due to inclined tensile

u Fasten turbocharger assemblies / components as described in re-

spective handling steps.

u Before attaching slings, allow turbocharger components to cool down

(maximum 80°C).

u Use suitable protection at sharp edges.

u Completely screw in assembly / fitting devices without fail so that

they cannot work loose during use.

u Use assembly / fitting devices only for applications described.

u Make sure removed turbocharger components stand safely and se-

curely.

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3 Start-up / 3.1 Oil supply

3 Start-up

3.1 Oil supply

A carefully designed and installed oil supply, which functions in all pos-

sible operational conditions, is an important prerequisite for trouble-

free turbocharger operation.

The turbocharger is normally lubricated with oil from the engine oil cir-

cuit. If a separate lubricating system is used, then emergency lubrication

is also to be provided.

u Heed the instructions of the engine builder when selecting the lubric-

ating oil and oil-change intervals.

Oil filtration

CAUTION

Depending on the turbine specifications and bearings used, varying

amounts of contaminants have to be filtered out of the lubricating oil

to avoid dangerous wear of the bearing parts.

The standard oil filter specification for the turbocharger is 34 µm. This

means that contaminants larger than 0.034 mm must be filtered out of

the oil with a separation efficiency > 99%.

u Fit an accessory filter if engine oil filter is not efficient enough.

u If the engine is started cold and the flow resistance rises to above 0.5

bar due to deposits of dirt in the accessory filter, a bypass must open

which ensures that oil flows to the turbocharger by circumventing the

filter.

u Check that oil filters are clean before commissioning.

NOTICE

Also follow the enginebuilder's instructions regarding filter mesh and

separation efficiency.

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3 Start-up / 3.1 Oil supply

Lubricant

NOTICE

All lubricating oils used for engines are admissible.

Oil inlet viscosity and temperature

The oil-inlet temperature must not exceed 105°C. Permissible oil-inlet

viscosities and oil-inlet temperatures are shown in the following chart.

Kinematic viscosity (mm²/s = cSt)

Oil-inlet temperature (°C)

Permissible range

CAUTION

Falling below the minimum oil inlet temperature

Serious machine or property damage can be caused by excessively high

oil viscosity and the resulting lack of oil in the bearings.

u Do not allow the oil inlet temperature to fall below the minimum 30

ºC when starting the engine.

u The oil inlet temperature must never be less than 10 °C.

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3 Start-up / 3.1 Oil supply

Oil pressure

The oil pressure in front of the turbocharger must be maintained pre-

cisely to ensure trouble-free operation.

Status for operation

Oil pressure in front

of turbocharger

[bar]

2.0 … 4.5

≤ 8.0

Normal operation

Engine start: cold oil, permissible for maximum 15

minutes

Engine idling

≥ 0.2

Pre- and post-lubrication (engine stopped)

≤ 1.0

CAUTION

Prelubrication

Serious machine or property damage might result if the turbocharger is

not supplied with oil when the engine is starting.

u Activate prelubrication device before starting engine.

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3 Start-up / 3.1 Oil supply

Lubricating oil temperature at the inlet

CAUTION

Machine damage

Machine damage may result if the oil temperature at the oil inlet ex-

ceeds the permissible range.

u Keep the oil temperature at the oil inlet as specified in the following

table.

Status for operation

Oil temperature at the in-

let

T_oil,inlet

30 … 105 °C

> 105 °C

> 110 °C

Admissible

Temporarily admissible (< 1 h) → alarm

Not admissible → stop engine

Not admissible → do not start engine (before

< 30 °C

starting: preheat oil)

Lubricating oil temperature at the outlet

The oil temperature at the outlet depends mainly on:

lubricating oil temperature and pressure at the oil inlet

engine load and turbocharger speed

exhaust gas temperature

The maximum permissible oil temperature at the outlet is listed in the

following table. The specified oil outlet temperature must be regarded

as an alarm value for turbocharger operation and be monitored in ac-

cordance with standard regulations.

Status for operation

Oil temperature at outlet

T_oil,outlet

Admissible

≤ 160 °C

Temporarily admissible → alarm

Not admissible → stop engine

Admissible

> 160 °C

> 180 °C

≤ T_oil,inlet+ 55 K

> T_oil,inlet+ 55 K

Temporarily admissible → alarm

If the turbocharger has been operated outside the permissible range for

a prolonged period of time, ABB Turbocharging recommends having the

turbocharger inspected by an ABB Turbocharging Service Station.

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3 Start-up / 3.2 Inspection work

3.2 Inspection work

Inspection work includes preventive visual controls plus monitoring and

measuring work before and during commissioning. Inspections help de-

tect changes to the turbocharger. Machine damage can be avoided.

3.2.1 Inspection before commissioning

Monitoring devices

u Check for correct functioning.

Filter mat

u Inspect for damage.

Lubricating system

u Check oil filter for cleanliness before commissioning.

CAUTION

Contaminated oil

Particles of dirt and solid matter in the oil can cause serious damage to

the machine or property.

u During initial commissioning and after all service work, the complete

lubricating system must be flushed thoroughly with warm oil.

u When running in the engine and after all service work on the lubricat-

ing system, special running-in filters must be used.

u Check oil pressure in oil supply lines.

CAUTION

Prelubrication

Serious machine or property damage might result if the turbocharger is

not supplied with oil when the engine is starting.

u Activate prelubrication device before starting engine.

Warning plates on tur-

bocharger

u Check whether the warning plates are present and legible.

u Check whether the protective sheets have been removed.

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3 Start-up / 3.2 Inspection work

3.2.2 Check after start-up (engine at idling speed)

Lubricating system

u Check oil pressure in oil supply lines.

u Check oil inlet temperature.

The permissible values are listed in the section Oil supply.

Gas, air and oil lines

u Check all gas, air and oil lines for leaks after starting the engine.

3.2.3 Check when running up engine

u Measure speed, oil pressure and charging pressure at various engine

performance levels.

u Measure exhaust gas temperature in front of and behind turbine.

u Measure air temperature in front of and behind compressor.

The measured values must be compared with the values in the accept-

ance test report, while taking different operating conditions into ac-

count.

NOTICE

Lubricants and pastes used during assembly of the turbocharger li-

quefy or vaporise and might escape as an oily liquid in the first few

hours after commissioning. If oily liquid continues to escape after this

period, an oil leak must be suspected. The first step is to check for leak-

age of the oil supply to the turbocharger. If this is leaky, contact an offi-

cial ABB Turbocharging service station.

3.2.4 Inspection after 100 service hours

Clean or replace lubricating oil filters after the first 100 service hours.

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3 Start-up / 3.3 Commissioning after taking out of operation

3.3 Commissioning after taking out of operation

If provided

u Remove cover plates (blind flanges) between compressor casing out-

let and charge air duct, before gas inlet and after gas outlet.

u Inspect exhaust gas duct / line in front of and after turbine for any

combustion deposits, foreign matter or residual water. Clean and re-

move.

u Inspect air supply line or filter silencer for any foreign matter. Clean

and remove.

u Start up turbocharger oil circulation system at engine end.

u Prepare turbocharger for operation as instructed in section "Inspec-

tion work before start-up / commissioning" of chapter headed "Start-

up / commissioning".

u Start up turbocharger.

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4 Operation / 4.1 Noise emissions

4 Operation

4.1 Noise emissions

WARNING

Hazards due to noise

Noise can cause impaired hearing, damage to health, mental disturb-

ances, diminished attention and irritation.

u Always wear ear protection when the engine is running.

u When the sound pressure level is above 85 dB(A), always wear ear

protection.

Wear ear protection.

The sound pressure level (A-weighted) of emissions is measured at a dis-

tance of 1 metre from the turbocharger.

The highest sound pressure level of emissions¹⁾reaches a maximum of

105 dB(A) near the filter silencer and over the entire speed range.

The following prerequisites must be fulfilled on the turbocharger in or-

der to observe this limit value:

Fitted air-inlet system

All standard, noise-reducing measures have been taken²⁾.

The bellows at the air outlet have been perfectly insulated acoustic-

ally by the engine builder. He is also responsible for insulating the

charge air / scavenging air line and the charge air cooler.

Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 :

A-weighted emission sound pressure level

In the event of divergent insulation designs, the engine builder must

ensure that equivalent acoustic insulating measures are taken.

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4 Operation / 4.2 Servicing work

Suggestion for noise insulation of the bellows

01 Compressor casing

02 Bellows

04 Insulation pads

05 Insulation mat (at least 15 mm)

03 Charge air duct / scavenging 06 Sheet metal cover

air line

4.2 Servicing work

Service work to be carried out during operation involves visual checks,

monitoring, measuring, inspection work and functional checks. It is then

possible for changes to the turbocharger to be identified and rectified.

In this way, it can be ensured that the turbocharger remains in full work-

ing order.

CAUTION

Service intervals

Service work on the turbocharger that is neglected or carried out too

late can lead to excessive contamination and wear as well as operating

failures.

u Carry out service work at specified time intervals.

CAUTION

Shortened service intervals

Despite observance of the service intervals, unusual loads, such as sev-

eral start-stops a day, harsh environmental factors, poor fuel quality or

heavy installation vibration can lead to premature machine damage.

u A shortened service interval must be arranged with ABB Turbochar-

ging.

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4 Operation / 4.2 Servicing work

NOTICE

Service inspection after 5 years

To prevent age- and stoppage-related machine damage, an inspection

by an ABB Turbocharging Service Station is recommended at the latest

5 years after the last service.

4.2.1 Service work every 25 … 50 hours

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

u Record operating data and enter it in the engine logbook.

u Clarify the cause of any variances.

CAUTION

Unknown changes during operation

The consequences can range from an impairment to a breakdown.

u Have unknown causes clarified by an ABB Turbocharging service sta-

tion.

4.2.2 Servicing work according to the engine

manufacturer's instructions

Oil filter

u Clean or replace oil filter in supply line to turbocharger when engine is

not running.

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4 Operation / 4.2 Servicing work

4.2.3 Service work in accordance with instructions on

rating plate

(In general, after 8000 … 16000 hours of operation)

Rotor and bearing parts must be inspected and assessed by an ABB Tur-

bocharging Service Station. The following work can be carried in prepar-

ation.

u Remove cartridge group as described in chapter Disassembly and as-

sembly.

u Measure clearances.

u Clean turbine and compressor casings and check them for cracks and

erosion / corrosion.

u Clean bearing casing and blow air through oil ports / holes.

u Clean nozzle ring and check for cracks and erosion.

4.2.4 Entries in engine logbook

By monitoring the engine, conclusions can be drawn about the tur-

bocharger performance.

The following operating data and measured values must be entered reg-

ularly in the engine manufacturer's engine logbook:

Engine performance and speed

Air intake temperature

Exhaust gas temperature in front of and behind the turbine

Pressure of charge air

Pressure drop in charge air cooler

Lubricating oil pressure and lubricating oil temperature

Air temperature behind compressor and charge air cooler

Turbocharger speed

If provided

Pressure loss in air filter

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4 Operation / 4.3 Expected exchange intervals

4.3 Expected exchange intervals

Rotating components

The recommended replacement intervals for compressor wheels and tur-

bine wheels are defined depending on the operating conditions and

based on the safety concept (SiKo) for rotating parts. These intervals

can be found on the turbocharger rating plate.

Non-rotating components

Depending on the system-specific operating conditions, a distinction is

made between:

the replacement interval for the bearing parts and

the replacement interval for those non-rotating components that are

exposed to hot gases.

Decisive in this respect are various influencing parameters, which can

drastically shorten the replacement intervals of these parts in extreme

cases.

During the specified periodic service work, the individual components

are inspected for wear and, if necessary, replaced.

Expected replacement intervals [h]

GAS / MDO

25000 … 50000

50000

HFO

Turbine casing

Nozzle ring

Gas outlet flange

Partition wall

25000 … 50000

10000 … 25000

35000 … 50000

50000

Rotor components

Bearing parts

Other casings

See rating plate information

12000 … 32000

50000

12000 … 24000

50000

GAS = Natural gas

MDO = Marine diesel oil

HFO = Heavy fuel oil

The specified values are a guide only and not guaranteed (see following

section Influencing parameters).

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4 Operation / 4.3 Expected exchange intervals

Influencing parameters

The specified values are only guide values and not guaranteed. The ac-

tual values can deviate considerably from the guide values due, for ex-

ample, to the following influences:

Fuel quality and preparation

Load profile (thermal load cycles, also starts / stops, emergency

shut-downs)

Gas inlet temperature

Frequency and execution of turbine and compressor cleaning

Turbocharger specification

System-specific operating conditions (operating point, combustion

quality, composition of exhaust gas)

For bearing parts

Lubricating oil quality (oil filtration, condition of lubricating oil, oil

monitoring)

Load profile (rpm / speed, pressure conditions, temperature)

State of rotor unbalance (degree of contamination)

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4 Operation / 4.4 Speed measurement

4.4 Speed measurement

A speed measuring system permits continuous monitoring of the tur-

bocharger speed.

CAUTION

Do not use cables as a climbing aid

If you pull the speed measurement cables too hard, contacts can be

pulled out.

u Do not tension the speed measurement cables.

86505(A)Speed sensor (cable not integ-

rated)

86526F/I converter

86505(B)Speed sensor (cable integrated)

86515(A)Cable connector to 86505(A)

86515(B)Cable connector to 86505(B)

86528Tachometer

01Screw plug

02Gasket

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4 Operation / 4.4 Speed measurement

4.4.1 Speed differences with multiple turbochargers per

engine

The speeds of all turbochargers on one engine differ only slightly from

each other in normal operation.

The difference between the highest and the lowest turbocharger speed

must not be more than 3 % relative to the speed limit n_Bmax

If this permissible range of difference is exceeded, the following steps

must be carried out:

u Reduce engine performance immediately until the highest turbochar-

ger speed no longer exceeds 70% of n_Bmax

u If the engine cannot be stopped, continue to run at this reduced en-

gine performance or turbocharger speed.

u If the turbocharger surges continuously, engine performance must be

reduced further.

u Measure the temperatures in the air and gas lines to and from the tur-

bochargers and compare them with standard values.

If the engine can be stopped for a short time:

u Inspect the air and gas lines as well as the turbocharger and eliminate

any problems.

u In any event, it is recommended that you contact the nearest ABB Tur-

bocharging Service Station.

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4 Operation / 4.4 Speed measurement

4.4.2 Replacing the speed sensor

WARNING

Hot cable connector and hot speed sensor

Risk of burning. During operation, the cable connector and the speed

sensor can reach temperatures exceeding 100 °C.

u Wear safety gloves when removing the cable connector and speed

sensor.

Wear safety gloves to protect against thermal hazards.

u Reduce engine performance to the idling speed, then stop the engine.

u Switch off the lubricating oil supply to the turbocharger.

u Disconnect the cable connector from the speed sensor.

u Screw out defective speed sensor.

u Screw in a new speed sensor up to the limit block.

u Adhere to tightening torque.

Part num-

ber

TPS44

TPS48

TPS52

TPS57

TPS61

86505

15 Nm

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4 Operation / 4.5 Stopping the engine

NOTICE

Sealing of the speed sensor

The speed sensor is designed with a sealing lip and does not require

any additional gasket for assembly.

u Connect cable connector to speed sensor.

u Switch on lubricating oil supply to turbocharger.

4.4.3 Failure of speed measuring system

Possible reasons for failure of the speed measuring system are de-

scribed in the chapter Troubleshooting.

4.5 Stopping the engine

CAUTION

Stopping the engine of oil-cooled turbocharger version

Heat in the turbocharger must be dissipated by the further circulating

lubricating oil.

u Post-lubricate for 15 … 20 minutes.

u Maintain oil pressure of 0.5 … 1.0 bar for post-lubrication.

CAUTION

Stopping the engine of water-cooled turbocharger version

Heat in the turbocharger must be dissipated.

u Allow turbocharger cooling water to run for 15 … 20 minutes after

stopping engine.

u Allow oil lubrication to continue running until rotor comes to a stop.

Further post-lubrication is not required and not recommended.

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5 Maintenance / 5.1 Foreword to Maintenance

5 Maintenance

5.1 Foreword to Maintenance

General maintenance work involves regular visual checks and cleaning

tasks which are intended to ensure the trouble-free functioning of the

turbocharger.

The maintenance points described here are differentiated as follows:

Cleaning during operation:

– Compressor

– Turbine and nozzle ring.

Mechanical cleaning of individual components:

– Filter silencer

– Casings, diffuser, nozzle ring

– Cartridge group: Compressor, turbine

CAUTION

Risk of damage during mechanical cleaning

If mechanical cleaning is carried out too often, this can lead to damage

and corrosion on the components.

u If cleaning during operation is not sufficient to achieve acceptable

values regarding thermal load and engine performance, mechanical

cleaning of certain spots can be carried out.

u Perform mechanical cleaning, especially of the cartridge group, only

once within the service interval.

To allow you to observe the standard service intervals and to maintain a

high turbocharger efficiency, ABB Turbocharging recommends that the

cleaning procedure be carried out during operation. This allows the

thermal load of the engine to be kept low while ensuring maximum fuel

efficiency.

u Dispose of dirty water and cleaning agents in an environmentally

compatible manner, professionally and in accordance with valid local

regulations.

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5 Maintenance / 5.2 Cleaning the compressor during operation

5.2 Cleaning the compressor during operation

General

The contamination of the compressor stage (compressor wheel, wall in-

sert and diffuser) depends on the degree of purity of the air that is

drawn in.

Deposits can form in the flow channels if salt, oil mist, exhaust gas or

dust are sucked in with the air.

Consequences of contamination:

Impaired compressor efficiency

Higher exhaust gas temperatures

Increased fuel consumption

Increased rotor unbalance

Periodic cleaning of the compressor during operation prevents or delays

any major increase in contamination. It does not, however, replace the

regular service work, during which the turbocharger is completely dis-

mantled and the compressor is cleaned mechanically.

NOTICE

If the coating of dirt is very thick and hard, the compressor can only be

cleaned manually when disassembled. This cleaning must be carried out

by an ABB Turbocharging Service Station.

Cleaning interval

The interval between periodic cleaning is very dependent on the operat-

ing conditions. In general, cleaning should be carried out every 25 ... 100

operating hours.

Should the specified cleaning intervals prove incompatible with engine

operation, please contact ABB Turbocharging.

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5 Maintenance / 5.2 Cleaning the compressor during operation

Cleaning method

Cleaning the compressor while in operation is carried out as wet clean-

ing. This cleaning method is tested and approved by ABB Turbocharging.

Principle of wet cleaning

To clean the compressor stage during operation, water is injected in

front of the compressor wheel through an injection pipe fitted in the fil-

ter silencer or the suction branch.

The water does not act as a solvent, but the contamination deposit is re-

moved by the mechanical impact of the droplets. This is a very suitable

process, provided that the degree of contamination is not too high.

CAUTION

Corrosion and deposits when cleaning

Damage and impairment of turbocharger parts due to salt water and

cooling water additives

u Don't use salt water for cleaning, but only clean fresh water.

CAUTION

The injection pipe must on no account be connected directly via a cock

to a water pipe or a dosing vessel larger than the one supplied. This

prevents uncontrolled volumes of water entering the turbocharger and

engine, which can lead to serious damage.

V-engines

In the case of V-engines with several turbochargers on each engine, we

recommend parallel cleaning of the compressors. This cleaning process

is faster and the risk of turbocharger surging is reduced.

Sequential charging

In the case of sequential charging, care must be taken to ensure that tur-

bocharger compressors are cleaned regularly, especially after periods of

operation in the lower performance range.

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5 Maintenance / 5.2 Cleaning the compressor during operation

5.2.1 Wet cleaning compressor using external water

pressure vessel (XC1)

Approval by enginebuilder

These instructions for wet cleaning only apply when cleaning is carried

out with clean water and under the precondition that the enginebuilder

approves the process.

NOTICE

Supplying water from the externally mounted water vessel is suitable

only for those applications where a negative pressure exists in front of

the compressor wheel (not used for: blowers connected in front of the

compressor or high-pressure compressor stages with two-stage char-

ging).

Operating state prerequisites for cleaning compressor with XC1

NOTICE

To be able to carry out a satisfactory cleaning process which has been

tested and is recommended by ABB Turbocharging, the following pre-

requisites must be fulfilled:

u Run engine at load from 50 … 85 %.

u Start cleaning cycle according to following description Wet cleaning

operation with XC1.

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5 Maintenance / 5.2 Cleaning the compressor during operation

Procedure for wet cleaning the compressor with XC1

XSealing plug

YValve activator

ZVessel

DCompressed air

WWater

Operating the water pres-

sure vessel

u Remove sealing plug (X).

u Fill the vessel (Z) with clean water.

u Screw in the sealing plug.

u Push the valve activator (Y) against the spring and hold for 10 to 15

seconds until the entire volume of water has been injected.

u Do not repeat the cleaning cycle until a stabilisation period of at least

10 minutes has elapsed.

NOTICE

Whether or not cleaning has been successful can be seen from the char-

ging or flushing pressure and also from the exhaust gas temperatures.

If the cleaning process is unsatisfactory, it can be repeated up to 2

times.

If the cleaning result is still not satisfactory after three attempts and

the engine values are also unsatisfactory, we recommend that you have

the turbocharger inspected and cleaned by an official ABB Turbochar-

ging Service Station.

Cleaning parameters per

turbocharger compressor

Product

Engine load

Contents

of cleaning me-

dium vessel

Water

injection time

t₁[s]

[dm³]

TPS

50 … 85 %

0.4

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5 Maintenance / 5.3 Turbine cleaning during operation

5.3 Turbine cleaning during operation

The combustion of fuels such as heavy fuel oil (HFO) in diesel engines

produces contamination of the turbocharger's turbine components. In

combination with a high exhaust gas temperature, poor quality fuel can

lead to particularly hard deposits on the nozzle ring and especially on the

gas outlet flange.

ABB Turbocharging recommends the use of fuels with low ash, sulphur,

sodium and vanadium contents.

Consequences of contamination:

Poor turbine efficiency

elevated exhaust gas temperatures

higher charging and ignition pressures as turbocharger speed rises

lower engine performance.

After stopping the engine, the rotor can become stuck in contamina-

tion deposits.

Experience with turbocharger operation shows that the intervals

between overhauls can be extended if cleaning while in operation is car-

ried out periodically. Wet cleaning the turbine, as described below,

should be used for 4-stroke applications when there are heavy deposits

from, for example, HFO.

Under no circumstances is periodic cleaning of the turbine during opera-

tion a substitute for the service work carried out when the turbocharger

is completely dismantled and cleaned mechanically.

Turbines which are very heavily contaminated cannot be cleaned this

way any longer. In this case, the contaminated components must be

mechanically cleaned by an ABB Turbocharging Service Station.

NOTICE

Regular cleaning

Regular turbine cleaning during operation prevents or delays excessive

build-up of contamination.

Cleaning intervals

The interval between periodic cleaning is very dependent on the operat-

ing conditions. In general, cleaning should be carried out every 50 to 200

operating hours.

NOTICE

Cleaning intervals

Should the specified cleaning intervals prove incompatible with engine

operation, please contact ABB Turbocharging.

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5 Maintenance / 5.3 Turbine cleaning during operation

Cleaning method

Turbine components are cleaned during operation by using the wet

cleaning method described below. This cleaning method is tested and

approved by ABB Turbocharging.

The turbine casing design and the type of turbine casing seal are decis-

ive for the choice of cleaning method.

NOTICE

Approval by engine manufacturer

The prerequisite for wet cleaning is that the engine manufacturer ap-

proves the method and his instructions are followed.

5.3.1 Wet cleaning methods

Process with short water injection time (3 x 30 seconds cleaning)

The cleaning process with short water injection time is used for tur-

bocharger designs without additional sealing by means of C-rings.

The process is based on the principle of thermal shock in combination

with a subsequent flushing phase.

Process with long water injection time (10 minutes cleaning)

The cleaning process with a long water injection time is used for tur-

bocharger designs with additional sealing by means of C-rings.

Based on a 10-minute injection phase, this cleaning process utilises the

water solubility of the dirty deposits.

NOTICE

Choice of cleaning method

If you need information about the choice of cleaning method (short /

long), you can contact the engine builder or an official ABB Turbochar-

ger service station.

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5 Maintenance / 5.3 Turbine cleaning during operation

5.3.2 Prerequisites

CAUTION

Risk of corrosion and deposits

Impairment and damage of turbocharger by salt water and cooling wa-

ter additives in flow ducts

u Don't use salt water for cleaning, but only clean fresh water.

u Avoid corrosion on casing inner surfaces.

u Let engine run for 10 minutes after wet cleaning.

CAUTION

Maximum temperature in front of turbine during cleaning

When cleaning, the temperature in front of the turbine will rise and can

heavily stress the material of turbine components. The temperature at

the turbine inlet can be up to 100 °C higher than the exhaust gas tem-

perature after the cylinder. This should be taken into consideration

when setting the operating point before cleaning.

u Don't exceed maximum temperature in front of turbine when clean-

ing.

CAUTION

Impermissible thermal stressing and flooding of the turbine

Smaller volumes of water can result in poor cleaning. Larger volumes of

water lead to impermissible thermal stressing of the turbine compon-

ents and can cause flooding of the turbine.

u Be absolutely sure to observe turbine cleaning parameters.

NOTICE

V-engines

In the case of V-engines with several turbochargers on each engine, we

recommend parallel cleaning of both turbochargers. This cleaning pro-

cess is faster and the risk of turbocharger surging is reduced.

Recommended operating state for turbine wet cleaning

The following operating state is tested and approved by ABB Turbochar-

ging:

Characteristic / com-

ponent

Conditions

short

long

Water injection time Water injection time

Engine load (guide value)

20 … 40 %

Turbine inlet temperature

350 … 400 °C

350 … 430 °C

T_TEbefore water injection

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5 Maintenance / 5.3 Turbine cleaning during operation

Characteristic / com-

ponent

Conditions

short

long

Water injection time Water injection time

Water supply

ensured

Water pressure (overpres-

2.0 bar

1.5 bar

sure over atmosphere) p_WT

If necessary, engine performance must be reduced to maintain these

conditions.

The cleaning cycle can now be started based on the following descrip-

tion.

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5 Maintenance / 5.3 Turbine cleaning during operation

5.3.3 Procedure for method with short water injection

time

w Prerequisites have been fulfilled.

u Wait 10 minutes during a stabilising phase after reducing the engine

load.

u Open the shut-off valve.

u Set the required water flow rate as specified in the table of cleaning

parameters using the flowmeter and inject for 30 seconds.

u Observe a pause of 3 or 5 minutes as specified in the table.

u Repeat the 30-second water injection two times.

u Close the shut-off valve.

u Wait 10 minutes during a stabilising phase before increasing engine

load again.

This completes the turbine cleaning process.

Cleaning parameters during the process

Temperature in

front of the tur-

bine during clean-

ing

Water

Injection time

[min]

Pause

between injec-

tions

volume flow ¹⁾

[dm³/min]

TPS

[min]

[°C]

≤ 450

4.5

0.5

(3 x)

¹⁾corresponds to a water pressure p_WTof 2.0 bar (overpressure over at-

mosphere)

CAUTION

Maximum temperature in front of turbine during cleaning

When cleaning, the temperature in front of the turbine will rise and can

heavily stress the material of turbine components. The temperature at

the turbine inlet can be up to 100 °C higher than the exhaust gas tem-

perature after the cylinder. This should be taken into consideration

when setting the operating point before cleaning.

u Don't exceed maximum temperature in front of turbine when clean-

ing.

5.3.4 Procedure for method with long water injection time

w Prerequisites have been fulfilled.

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5 Maintenance / 5.3 Turbine cleaning during operation

u Wait 10 minutes as a stabilising phase after reducing the engine load.

u Open the shut-off valve.

u Set the required water flow rate as specified in the table of cleaning

parameters using a flowmeter and inject for 10 minutes.

u Close the shut-off valve.

u Wait 10 minutes as a stabilising phase before increasing the engine

load again.

This completes the turbine cleaning process.

Cleaning parameters during the process

Temperature in

front of the tur-

bine during

Water

Injection Stabilising phase

volume flow ¹⁾

[dm³/min]

time

before / after wa-

ter injection

[min]

TPS

cleaning

[min]

[°C]

≤ 530

2.5

5.5

8.5

¹⁾corresponds to a water pressure p_WTof 1.5 bar (overpressure over at-

mosphere)

CAUTION

Maximum temperature in front of turbine during cleaning

When cleaning, the temperature in front of the turbine will rise and can

heavily stress the material of turbine components. The temperature at

the turbine inlet can be up to 100 °C higher than the exhaust gas tem-

perature after the cylinder. This should be taken into consideration

when setting the operating point before cleaning.

u Don't exceed maximum temperature in front of turbine when clean-

ing.

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5 Maintenance / 5.4 Cleaning components mechanically

5.4 Cleaning components mechanically

5.4.1 Introduction

CAUTION

Choosing cleaning tools

Turbocharger components are sensitive to mechanical damage. The

use of needle guns or other impact tools, for example, damages the

components. Depending on the specification, nozzle rings and turbine

casings have protective coatings, which can also be damaged.

u Only use soft tools such as cloths, brushes or wire brushes.

u In the event of heavy contamination, the cleaning methods that have

been described such as soaking can be repeated until a satisfactory

result has been achieved.

u Dispose of dirty water and cleaning agents in an environmentally

compatible manner, professionally and in accordance with valid local

regulations.

NOTICE

Disassembly and assembly

The disassembly and assembly of the components is described in

chapter Disassembly and assembly.

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5 Maintenance / 5.4 Cleaning components mechanically

5.4.2 Cleaning the filter silencer

81135Filter silencer body

81136Absorption segment

81137Sheet-metal covering

81265Filter ring

81266Cover grid

81270Tension band

81271Lock

NOTICE

Disassembly and assembly

The procedure for disassembly and assembly of the filter silencer is de-

scribed in the chapter entitled Disassembly and Assembly.

Cleaning the filter ring (if provided)

u Remove filter ring (81265).

u Clean filter ring (81265) as required or every 500 operating hours, and

replace after the fifth cleaning operation at the latest.

The degree of contamination of the filter ring depends on the cleanli-

ness of the air that is drawn in.

u Wash filter ring (81265) using water containing light-duty detergent

or, if very heavily contaminated, soak it while squeezing carefully.

Rinse in cold water. Avoid rough handling (do not use a water jet).

u Allow the filter ring to dry out completely before assembly.

u Dispose of dirty water and gentle detergents in accordance with valid

local regulations.

Cleaning the absorption segments

u Loosen the tension bands (81270).

u Remove the cover grid (81266).

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5 Maintenance / 5.4 Cleaning components mechanically

u Pull out the sheet-metal coverings (81137), bend them up and remove

the absorption segments (81136).

u Clean the absorption segments (81136).

During cleaning, ensure that the absorption segments (81136) are

only cleaned with a mild jet of compressed air, soft brush or a damp

cloth.

u Have absorption segments which are heavily contaminated replaced

by an official ABB Turbocharging Service Station.

Fitting the filter silencer

u Insert the absorption segments (81136) into the sheet-metal cover-

ings (81137).

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

and insert them into the slot guides in the silencer body (81135).

u Fit the cover grid (81266).

u Fit the tension bands (81270) and apply tension at the locks (81271).

u Damaged tension bands must be replaced with new ones.

u If provided, fit the filter ring (81265).

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5 Maintenance / 5.4 Cleaning components mechanically

5.4.3 Compressor-end, non-rotating parts

WARNING

Handling operating materials and supplies

Swallowing or inhaling vapours of operating materials and supplies or

contact 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 op-

erating materials and supplies.

u Wear personal protective equipment (PPE) according to the material

safety data sheet.

u Comply with local legislation.

Wear safety goggles.

Wear safety gloves to protect against chemical hazards.

Wear a respiratory mask to protect against gases.

The following performance-relevant parts can be cleaned according to

the following description.

72000 Compressor casing

77000 Wall insert

79000 Diffuser

u Clean the components specified above with steam or allow to soak in

diesel oil or water with household detergent. After soaking, remove

the dirt with a brush.

u Dry components completely.

u Spray cleaned surfaces with penetrating oil. Do not spray the outer

surfaces of the turbocharger.

u Dispose of dirty water and cleaning agent in accordance with the spe-

cifications in the safety data sheet.

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5 Maintenance / 5.4 Cleaning components mechanically

5.4.4 Turbine-end, non-rotating parts

WARNING

Handling operating materials and supplies

Swallowing or inhaling vapours of operating materials and supplies or

contact 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 op-

erating materials and supplies.

u Wear personal protective equipment (PPE) according to the material

safety data sheet.

u Comply with local legislation.

Wear safety goggles.

Wear safety gloves to protect against chemical hazards.

Wear a respiratory mask to protect against gases.

Baked-on layers of contamination, for example from heavy fuel oil or

coked oil, occur at the turbine end. The following performance-relevant

parts can be cleaned according to the following description.

51000

52400

Turbine casing

Gas outlet flange

56001

Nozzle ring

u Place contaminated parts in hot water or in a liquid such as brake

cleaner, so that the contamination softens.

u Brush off the contamination or remove it with a steam cleaner.

u Repeat the soaking and brushing if necessary.

u Completely remove any solvents from the parts in clean water.

u Dry components completely.

u Spray cleaned surfaces with penetrating oil. Do not spray the outer

surfaces of the turbocharger.

u Dispose of contaminated water and cleaning agent in accordance

with the specifications in the safety data sheet.

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5 Maintenance / 5.4 Cleaning components mechanically

5.4.5 Cartridge group

Introduction

CAUTION

Corrosion

If the cartridge group is not put into operation again immediately after

cleaning, parts may corrode.

u Re-install and use the cartridge group immediately after cleaning.

Compressor wheels or turbines may be heavily contaminated due to ex-

haust gas deposits or coked oil. Such contamination may possibly no

longer be removed through cleaning during operation and must be

cleaned mechanically during the standard service intervals (see chapter

entitled Service work).

u Remove turbocharger from the engine (see chapter Removal and in-

stallation →74).

u Remove cartridge group (see chapter Disassembly and assembly

→78).

First clean the compressor end and then the turbine end in accordance

with the following description.

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5 Maintenance / 5.4 Cleaning components mechanically

Cleaning the compressor end

CAUTION

Selection of the cleaning agent

Cleaning agents that contain chlorine corrode metals.

u Only use pH-neutral cleaning agents that do not corrode metals.

u Observe the material safety data sheet.

u Observe country-specific regulations regarding banned and restric-

ted substances.

CAUTION

Water and contamination in the cartridge group

If water or contamination penetrates the cartridge group, this can im-

pair the function of the turbocharger and damage parts inside the cart-

ridge group.

u Make sure that no water or contamination can enter into the cart-

ridge group.

u Clean compressor wheel with a cloth or soft brush soaked in water

with household detergent. Do not use any wire brushes!

u Dry the compressor wheel and the gap between the compressor and

the bearing casing with a weak jet of compressed air.

u Lightly spray the compressor wheel and the gap between the com-

pressor and the bearing casing with penetrating oil.

u Dispose of dirty water and cleaning agent in accordance with the

safety data sheet.

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5 Maintenance / 5.4 Cleaning components mechanically

Cleaning the turbine end

Soaking the dirt

Baked-on layers of dirt from heavy fuel oil or coked oil, occur at the tur-

bine end. The contamination can be removed by soaking and brushing.

The soaking of the layers of dirt as well as the cleaning of the turbine are

described below.

Product

TPS44

TPS48

TPS52

TPS57

TPS61

A [mm]

108

128

B [mm]

C [mm]

173

205

245

300

157

187

357

To soak the layers of dirt on the turbine, the cartridge group can be sub-

merged vertically in a tank (02) with liquid.

u Place the tank (02) in a larger container (03), so that the excess liquid

can be collected.

CAUTION

Selection of the cleaning agent

Cleaning agents which contain chlorine attack metals.

u Use only pH-neutral cleaning agents which do not attack metals.

u Observe safety data sheet.

u Fill the tank (02) with soaking liquid.

NOTICE

Heat the liquid

To shorten the soaking time the liquid can be heated to maximum

60 ºC.

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WARNING

Heating up of cleaning agents and operating fluids

When cleaning agents or operating fluids are heated up, explosive va-

pours can be produced which are hazardous to health.

u Observe the information in the material safety data sheet.

Wear a respiratory mask according to material safety data sheet.

CAUTION

Water and dirt in the cartridge group

If water or dirt gets into the cartridge group, the turbocharger function

may be impaired and parts in the cartridge group may be damaged.

u Place the cartridge group on suitable wooden or metal supports (01).

u Maintain dimension (B) for the supports (01), so that the cartridge

group does not submerge too deep.

u Allow the layers of dirt on the turbine to soak for four hours.

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5 Maintenance / 5.4 Cleaning components mechanically

Removing the dirt

WARNING

Health hazard due to soot particles

If soot particles enter the eyes or respiratory tract, this can be harmful

to health.

u Avoid the formation of dust.

u Vacuum up dust with a suitable vacuum cleaner.

u Wear a respiratory mask to protect against particles (P1 or P2 mask).

u Wear safety goggles.

Wear safety goggles.

Wear a respiratory mask to protect against dusts.

Wear safety gloves to protect against mechanical hazards.

u Raise the cartridge group and align horizontally.

u Remove dirt manually with a soft brush or wire brush.

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CAUTION

Water and dirt in the cartridge group

If water or dirt gets into the cartridge group, the turbocharger function

may be impaired and parts in the cartridge group may be damaged.

u Make sure that water or dirt does not get into the gap between the

partition wall and turbine.

CAUTION

Non-permissible rotor unbalance after cleaning

Unevenly distributed residual contamination deposits lead to rotor un-

balance. This can result in bearing or turbocharger damage.

u Remove all traces of contamination from the turbine.

u After brushing off the contamination, fill the tank (02) with clean wa-

ter, not salt water.

u Submerge the turbine of the cartridge group in clean water, so that

loose particles of dirt detach completely.

u Raise the cartridge group and align horizontally.

u Clamp the partition wall with the bearing casing.

u Dry the turbine and the gap between the turbine and partition wall

with a weak jet of compressed air.

u Lightly spray the turbine and the gap between the turbine and parti-

tion wall with penetrating oil.

u Dispose of dirty water and cleaning agent in accordance with the spe-

cifications in the safety data sheet.

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6 Troubleshooting / 6.1 Malfunctions when starting

6 Troubleshooting

6.1 Malfunctions when starting

Sluggish start-up

Possible causes

Elimination

Turbochar- Turbocharger contaminated

Clean it

ger

Damaged bearing

Rubbing rotor

Contact an ABB Turbocharging

Service Station

Foreign object in turbocharger

Vibrations

Possible causes

Elimination

Turbochar- Rotor unbalance

Contact an ABB Turbocharging

Service Station

ger

Damaged turbine or com-

pressor

Damaged bearing

Rubbing of rotating parts

Normal behaviour, no malfunction

Turbochar- Minor uniform wear around the periphery of rotor components,

ger

caused by slight local rubbing of adjacent components, is per-

missible. The compressor blades and turbine blades are then

shortened somewhat. Certain tolerances must be observed to

avoid a significant loss of efficiency.

If there is any doubt about the extent of rubbing, then an

ABB Turbocharging Service Station must be contacted.

Have a dimension check carried out by an ABB Turbochar-

ging Service Station.

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6 Troubleshooting / 6.2 Surging of the turbocharger

6.2 Surging of the turbocharger

Turbocharger surging

Possible causes

Elimination

Engine

Guard in front of the tur-

Clean / replace it

bocharger is contaminated

or damaged

Turbocharger Filter silencer or diffuser

Clean it

contaminated

Heavy deposits of dirt in the

turbine or nozzle ring

Charge air

cooler

Cooler contaminated

Charge air duct blocked

CAUTION

Prolonged or periodic surging

Possible damage to components, such as the compressor wheel, tur-

bine blades, bearings and filter silencer

u Have the cause clarified immediately by an ABB Turbocharging ser-

vice station and rectified.

u Have components inspected for damage and, if necessary, replaced

by an ABB Turbocharging service station.

Sporadic surge blows

Surging of the turbocharger can occur during certain operating condi-

tions such as when reducing the engine performance quickly when man-

oeuvring. At the same time, the flow direction in the compressor is mo-

mentarily reversed. Such sporadic surge blows do not impair the safe

operation of the turbocharger.

A surge blow is accompanied by a loud bang and escape of hot air

from the filter silencer.

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6 Troubleshooting / 6.3 Malfunctions during operation

6.3 Malfunctions during operation

Lubricating oil pressure too low

Possible causes

Elimination

Engine

Oil filter heavily contaminated Clean it

Defective oil pump in lubricat- Check / replace it

ing system

Manometer display wrong

Replace the manometer

Turbochar- Rotor axial clearance too large Contact an ABB Turbocharging

ger

Service Station

Reduction in speed

Possible causes

Elimination

Engine

Defects of connected cylinders Contact the enginebuilder

when pulse charging

Turbochar- Heavy contamination of the

Clean it

ger

turbine

Damaged rotor components or Contact an ABB Turbocharging

bearing Service Station

Pipes

Defects such as leaks in the ex- Make repairs

haust gas pipes or charge air

ducts

Increase in speed

Possible causes

Elimination

Turbochar- Heavily contaminated nozzle Contact an ABB Turbocharging

ger

ring (with 4-stroke application) Service Station

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6 Troubleshooting / 6.3 Malfunctions during operation

Exhaust gas temperature too high

Engine performance and engine speed unchanged

Possible causes

Engine Malfunctioning injection

system

Elimination

Repair it or contact the manu-

facturer

Turbocharger Air starvation, for example Clean it

filter silencer clogged with

dirt

Compressor / turbine con-

taminated

Exhaust counterpressure

too high

Clean or repair the boiler or ex-

haust silencer

Enlarged flow cross-section Contact an ABB Turbocharging

of the nozzle ring due to de- Service Station

formed blade trailing edges

Damaged or eroded turbine

Charge air

cooler

Cooler contaminated

Clean it

Cooling water volume too Top up the water

low

Entry temperature of cool- Inspect / clean the cooling sys-

ing water too high

tem

Inadequate ventilation

Improve the ventilation

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6 Troubleshooting / 6.3 Malfunctions during operation

Charge air pressure too low

Engine performance and engine speed unchanged, air intake condition

normal

Possible causes

Elimination

Engine

Air receiver leaking

Make repairs

Gas piping between the engine

and the turbine leaking

Poorly adjusted injection sys- Correct it

tem

Poorly adjusted valve control

Turbochar- Manometer display wrong

Replace the manometer

Repair the leak

Clean it

ger

Line to manometer leaking

Contaminated filter silencer

causing excessive loss of pres-

sure

Compressor / turbine contam-

inated

Damaged compressor / tur-

bine

Contact an ABB Turbocharging

Service Station

Exhaust counterpressure too Clean or repair the boiler or ex-

high

haust silencer

Charge air pressure too high

Engine performance and engine speed unchanged, air intake condition

normal

Possible causes

Engine Malfunctioning injection sys- Repair it or contact the manu-

tem facturer

Elimination

Poorly adjusted injection sys- Correct it

tem

Engine performance higher

than expected

Turbochar- Manometer display wrong

Check engine performance

Replace the manometer

ger

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6 Troubleshooting / 6.4 Malfunctions when stopping

Contamination of the compressor due to the feeding in of

ventilation gases

Reduced compressor performance / efficiency and therefore engine per-

formance losses

Possible causes

Elimination

Turbochar-Heavily contaminated com-

Clean the compressor

Optimise oil separation

ger

pressor components

Increased vibration, compressorCorrect the feed of ventilation

blade damage

gases according to instructions

of enginebuilder.

Reduced fatigue strength of the compressor wheel, compressor blade

breakage.

Possible causes

Elimination

Turbochar-Corroded compressor wheel

Check fuel and its corrosive con-

stituents and, if necessary,

change fuel.

ger

material

6.4 Malfunctions when stopping

Noises during run-down

Possible causes

Elimination

Turbochar- Turbocharger contaminated

Clean it

ger

Damaged bearing

Rubbing rotor

Contact an ABB Turbocharging

Service Station

Foreign object in turbocharger

Run-down time too short

Possible causes

Elimination

Turbochar- Turbocharger contaminated

Clean it

ger

Damaged bearing

Rubbing rotor

Contact an ABB Turbocharging

Service Station

Foreign object in turbocharger

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6 Troubleshooting / 6.5 Speed measurement system

6.5 Speed measurement system

Possible causes

Elimination

No signal or

amplitude is

poor

Fitting error

The screw plug for the sensor is fitted with

an additional gasket (copper ring).

When fitting the speed sensor, this gasket

must be removed. If the gasket is fitted by

mistake, the distance from the sensor tip

to the signal-generating sealing disc in-

creases. As a result, the voltage amplitude

of the speed signal decreases, which can

cause problems for the evaluation elec-

tronics.

This problem is eliminated by removing

the gasket.

Defective sensor Contact an ABB Turbocharging Service Sta-

tion

Measured

speeds too

high

Contaminated The sensor tip is magnetic and can thus at-

sensor tip

tract metal particles. As a result, the dis-

tance to the signal-generating sealing disc

is reduced, which can lead to amplification

of the noise component and consequently

to faulty triggering.

Dismantle the sensor, clean its tip and refit

the sensor using the specified tightening

torque.

Measured

- -

Contact an ABB Turbocharging Service Sta-

speed too low

tion

Other sources - -

If none of the above measures eliminates

the malfunction, we recommend that you

have the speed measuring system inspec-

ted by an ABB Turbocharging Service Sta-

tion.

of errors

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7 Removal and installation / 7.1 Transport

7 Removal and installation

7.1 Transport

Suspension of uninsulated turbocharger

Turbocharger with oil-cooled bearing Complete turbocharger with gas out-

casing

let casing

Suspension of insulated turbocharger

Turbocharger with oil-cooled bearing Complete turbocharger with gas out-

casing

let casing

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7 Removal and installation / 7.2 Turbocharger weights

7.2 Turbocharger weights

Lifting gear with a sufficient load limit must be used for removing and

installing the turbocharger. The following weight specification is the

heaviest variant possible. This standard value may deviate from the data

on the rating plate depending on the specification.

TPS44

[kg]

TPS48

[kg]

TPS52

[kg]

TPS57

[kg]

TPS61

[kg]

120

180

250

410

650

7.3 Removing the turbocharger

u Disconnect all exhaust gas and air lines according to the instructions

of the enginebuilder.

Version with water-cooled bearing casing:

u Disconnect the water pipes according to the instructions of the en-

ginebuilder.

If present, remove hard insulation as follows:

u Remove screws and sheet metal (B) from the bearing casing insula-

tion.

u Remove the remaining screws from the bearing casing insulation (A).

u Pull the bearing casing insulation up and off. The bearing casing insu-

lation can be compressed to facilitate the removal process.

u Unplug the cable connector from the speed sensor.

u Attach lifting gear to bearing casing.

u If a gas outlet bend is present, sling lifting gear around it or secure it

to the lifting gear with a swivel lifting eye (C).

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7 Removal and installation / 7.4 Installing the turbocharger

u Loosen the fixing screws (D) on the bearing casing.

u Lift the turbocharger from the engine and put it down.

u Cover oil connections.

7.4 Installing the turbocharger

u Remove covers from oil connections.

u Visually inspect O-ring gaskets of oil supply and drain pipe (O-ring

gaskets for engine are not included in the scope of delivery of ABB).

**) When the turbocharger is mounted on the engine support, the bolt

threads and screw heads must be lightly oiled (assumed friction coeffi-

cient µ = 0.12 for tightening torque)

Strength class in accordance with DIN/ISO 898: 10.9/12.9

Product

Through hole in

bearing casing

Thread size

Tightening torque

TPS44

TPS48

TPS52

TPS57

TPS61

17 mm

21 mm

25 mm

M16

M20

M24

230 Nm

455 Nm

780 Nm

u Attach lifting gear to bearing casing.

u If a gas outlet manifold is provided, sling lifting gear around it addi-

tionally or fasten it to lifting gear using a swivel lifting eye (C) (see

also section Transport / Weights).

u Lift turbocharger, place on bracket and align.

u Tighten fixing screws (D) to the bearing casing in accordance with the

table above.

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7 Removal and installation / 7.4 Installing the turbocharger

u Fasten all gas, water and air lines in accordance with the engineb-

uilder's instructions.

If present:

u Fit speed sensor and plug in cable connector.

u Adapt and fit bearing casing insulation (A).

u Adapt and fit sheet metal (B) of bearing casing insulation.

Version with water-cooled bearing casing:

u Remove the screw plugs from the water connections and fit the water

pipes in accordance with the enginebuilder's instructions.

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8 Disassembly and assembly / 8.1 Introduction

8 Disassembly and assembly

8.1 Introduction

Precondition for the work described below is a turbocharger removed

from the engine (refer to the chapter entitled Removal and Installation).

CAUTION

Further work

Only the work described in this Operation Manual may be carried out.

Incorrectly performed disassembly and assembly of the cartridge

group can lead to serious machine damage.

u ABB Turbocharging recommends having further work carried out

only by trained personnel from an ABB Turbocharging Service Sta-

tion.

u Mark the casing position for assembly.

Identifying assembly devices

Not all assembly devices are marked with a part number. They can be

identified using the tool list. This list is enclosed in the toolbox.

WARNING

Maintaining assembly devices

Assembly devices must be checked for damage before and after use.

u Check visually for corrosion, cracks, deformation and wear.

u Don't use damaged assembly devices, but replace them.

Customer spare part set

Before beginning work, ensure that the required customer spare part

sets are available.

u See chapter Spare parts.

Oil orifice

u When disassembling the turbocharger, a fitted oil orifice must not be

removed.

Tightening torques for turbocharger components

The specified tightening torques of screw connections for turbocharger

components must be observed (see section Table of tightening

torques).

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Tightening torques for assembly devices from ABB

Unless otherwise described, the screws and nuts of the assembly

devices must be secured so they are tight-fitting.

WARNING

Suspended loads

Loads not suspended in compliance with regulations may lead to per-

sonal injury or accidents with fatal consequences.

u Attach turbochargers, assemblies or individual components only to

lifting gear which is in technically perfect condition and has a suffi-

cient load limit.

u Make sure the load is suspended properly on the crane hook.

u Do not let anyone stand beneath a suspended load.

Wear safety gloves to protect against mechanical hazards.

Wear safety helmet.

Definition of terms

Suspension point

Defined load attachment point on a component or an assembly (blind

hole thread, eye, lug).

Assembly device

Devices that are fitted on the turbocharger in order to obtain a sus-

pension point. Assembly devices are specially constructed and de-

signed for the defined use; they are not commercially available

products. Use assembly devices only for the described applications.

Lifting gear

Equipment for lifting and transporting loads (lifting slings, chain

block, crane). Lifting gear is not supplied by ABB.

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Swivel lifting eye to be used

A swivel lifting eye is required to lift loads safely (not supplied by ABB).

Swivel lifting eye

Product Thread Length Minimum

load limit

(loading ca-

pacity)

TPS44

TPS48

TPS52

TPS57

TPS61

M10

M12

13 mm

17 mm

21 mm

150 kg

250 kg

350 kg

500 kg

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8 Disassembly and assembly / 8.2 Module weights

8.2 Module weights

The specified weights of individual parts or assemblies are guides roun-

ded off to the next highest value.

TPS44 TPS48 TPS52 TPS57 TPS61

Description

[kg]

1Filter silencer

2Radial air suction branch

3Axial air suction branch

4Compressor casing

5Wall insert

6Diffuser

7Cartridge group

8Nozzle ring

140

9Burst ring

10Turbine casing 1 inlet

130

150

170

with external

2 inlets

burst protec-

3 inlets

tion

4 inlets

11Gas outlet flange

12Exhaust manifold

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8 Disassembly and assembly / 8.3 Disassembling and assembling tur-

bocharger

8.3 Disassembling and assembling turbocharger

Removing the compressor casing

WARNING

Risk of burning

Touching hot surfaces or contact with hot operating materials can lead

to serious burns.

u Do not touch hot surfaces and heed the warning plate on the tur-

bocharger.

u Wear heat-resistant safety gloves and protective clothing.

u Allow the turbocharger to cool down before carrying out any work.

Wear safety gloves to protect against thermal hazards.

u Disconnect all air lines in accordance with the enginebuilder’s instruc-

tions.

If provided

u Remove the screws for the compressor casing insulation and dis-

mantle the insulation.

u Undo the V-clamp (72020) and remove the filter silencer (81000) or air

suction branch (82000).

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bocharger

Removing the insulation

If provided

u Loosen and remove the screws for the insulation plates (1, 2).

u If provided: Remove the insulation plates (1, 2).

u Remove the remaining screws for the insulation (3).

u Remove the insulation (3).

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bocharger

u Slightly loosen the screws (72011) and turn the compressor casing

(72000) until the swivel lifting eye can be fastened to the lifting gear.

(77006* only provided with the wall insert with acceleration aid.)

NOTICE

If the compressor casing cannot be removed easily, it can be pressed

off using the press-off tool (90042) against the turbine casing. To do

this, the two cover plates (1, 2) must be removed from the hard insula-

tion on the turbine casing.

CAUTION

Axial force

The press-off tool can generate a high axial force and, if it is not used

properly (too much pressure on one side), it can damage the rotor.

u It should thus be used alternately on both sides while avoiding ex-

cessive pressure on either side.

u Loosen the screws (72011) and remove them together with the fasten-

ing strips (72012).

u Move the compressor casing (72000) with the wall insert (77000)

carefully away, doing so horizontally.

u Tap the wall insert (77000) out of the compressor casing using a

nylon hammer and remove the O-ring seal (77005).

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bocharger

TPS61 wall insert removal

u Fasten lifting beam (90258) to wall insert.

u Fasten swivel lifting eye (a) to lifting beam.

u Remove wall insert (77000) using lifting gear.

Disassembly of diffuser

TPS..-F31/32 / FV31/32

u Loosen screws (72041) and remove them together with lockwashers

(72040) and diffuser (79000) from compressor casing (72000).

Installing compressor casing

u Refit wall insert (77000) and O-ring (77005) in the reverse order.

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NOTICE

O-rings

Used O-rings must always be replaced with new ones. O-rings are only

available as a set (see chapter Spare parts).

Fitting the diffuser

TPS..-F31/32 / FV31/32

u Refit diffuser in reverse order.

u Fit compressor housing in reverse order.

u Thoroughly clean fastening strips (72012) before fitting them.

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bocharger

Removing the cartridge group

u Check the lifting gear and fasten it to bearing casing (42001).

If provided

u Disconnect all lines in accordance with the engine builder's instruc-

tions, remove the insulation, remove the turbocharger and com-

pressor casing together with the filter silencer (also see the previous

chapter).

WARNING

Risk of burning

Touching hot surfaces or contact with hot operating materials can lead

to serious burns.

u Do not touch hot surfaces and heed the warning plate on the tur-

bocharger.

u Wear heat-resistant safety gloves and protective clothing.

u Allow the turbocharger to cool down before carrying out any work.

Wear safety gloves to protect against thermal hazards.

w The bearing casing is difficult to loosen.

u Use the press-off tool (90042) against the turbine casing to press off

the bearing casing (see the following illustration).

CAUTION

Axial force

The press-off tool can generate a high axial force and, if it is not used

properly (too much pressure on one side), it can damage the rotor.

u It should thus be used alternately on both sides while avoiding ex-

cessive pressure on either side.

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bocharger

u Withdraw nozzle ring (56001) using two extraction devices (90070)

and withdraw bottom part of service support (90012).

If provided

u Remove C-ring (51105).

Disassembly of diffuser

TPS..-F33

u Mount the cartridge group on the service support (90012) and bolt it

down firmly.

u Loosen screw (42008) and remove diffuser (79000) complete with O-

ring (42012).

u Measure the axial and radial clearances (see the section Axial and ra-

dial clearances).

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bocharger

Installing the cartridge group

NOTICE

O-rings

Used O-rings must always be replaced with new ones. O-rings are only

available as a set (see chapter Spare parts).

NOTICE

Protruding insulation

The insulation on the turbine casing may protrude at the gas outlet

side. This can be pushed back in with a screw driver.

u Fit the lamellar sealing ring (56005, if present) in the correct slot (see

detail A). When doing this, pay attention to correct winding of the

lamellar sealing ring (see detail B).

u Secure the lamellar sealing ring with adhesive tape.

u Insert the nozzle ring (56001) (with the cam facing forwards) into the

turbine casing as far as it will go. Align the cam on the nozzle ring with

the recesses of the turbine casing and insert it into the turbine casing

(51000) as far as it will go. Do not remove the adhesive tape (01).

If present

u Insert the C-ring (51105) into the turbine casing and secure with high-

vacuum grease.

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bocharger

NOTICE

To ensure the nozzle ring is held in place during operation, it must be

clamped between the partition wall and the turbine casing.

Nozzle ring press fit for

single inlet turbine casing

u Calculate the press fit (PD) as shown.

NOTICE

If the calculated value (PD) is less than 0.1 mm, an official ABB Tur-

bocharging Service Station must be contacted.

u Measure the axial and radial clearances (see the section Axial and ra-

dial clearances).

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bocharger

Nozzle ring press fit for

multiple inlet turbine cas-

ing

u Calculate the press fit (PD) as shown.

NOTICE

If the calculated value (PD) is outside ±0.2 mm, an official ABB Tur-

bocharging Service Station must be contacted.

u Measure the axial and radial clearances (see the section Axial and ra-

dial clearances).

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bocharger

Assembly of diffuser

TPS..-F33

u Fasten diffuser (79000) and O-ring (42012) using screw (42008).

u Check lifting gear and fasten to bearing casing (42001).

u Unscrew the cartridge group and lift it out of the service support

(90012).

u Apply high-temperature grease to the centering points and screw

threads.

u Remove temporary covers from oil connections.

CAUTION

Don't damage or shift gasket rings (A) in the mounting support when

fitting the cartridge group. The gasket rings (A) are supplied by the en-

gine builder.

NOTICE

If two turbochargers are mounted on an engine, one with a left-hand

and one with a right-hand oil inlet, a pin can be fitted in the bracket as a

precaution against incorrect positioning. This pin (B) locates in a cor-

respponing groove in the foot of the bearing casing.

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bocharger

u Fasten the cartridge group using fastening strips (51002), Verbus

Ripp® washers (51003) and nuts (51007) (also see the chapter entitled

Table of tightening torques).

u Fasten the bearing casing (42001) using the fixing screws (C).

u Tighten the fixing screws (C) to the torques listed in the following

table.

**) For the assembly of the turbocharger on the engine support, the

threads of the screws and screw heads must be lightly oiled (assumed

coefficient of friction µ = 0.12 for the tightening torque).

Product Hole in the bearing Fixing screws C [mm]

casing

Tightening

torques [Nm] **)

[mm]

TPS44

TPS48

TPS52

TPS57

TPS61

Ø 17

Ø 21

Ø 25

M16

M20

M24

230

455

780

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bocharger

If provided

u Plug in the cable connector (86515) for the speed sensor (86505) and

(if provided) fit the insulation plates (1, 2).

Removing gas outlet manifold and gas outlet flange

If provided

u Disconnect all lines in accordance with enginebuilder's instructions

and remove insulation (see also preceding chapter).

u Loop lifting gear around gas outlet manifold (51100).

u Remove gas outlet manifold (51100) and gasket (52406). Only gas

outlet manifolds from ABB have the gasket (52406).

u Remove gas outlet flange (52400) and, if fitted, C-ring (52408).

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bocharger

Fitting the gas outlet flange and gas outlet manifold

u If provided, fit the C-ring (52408).

u Fit the gas outlet flange (52400).

u For gas outlet manifolds (51100) from ABB:

always replace the gasket (52406) (see the chapter entitled Spare

parts).

u Apply high-temperature grease to contacting surfaces and threads.

u Fit the turbine casing using the nuts (52433) while observing tighten-

ing torques specified in the table of tightening torques.

If provided

u Fasten the insulation.

u Attach pipes in accordance with the enginebuilder's instructions.

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8 Disassembly and assembly / 8.4 Axial clearance A and radial clear-

ance B

8.4 Axial clearance A and radial clearance B

u Following removal and before installation of the cartridge group, the

axial clearance A and radial clearance B must be measured and noted.

NOTICE

In order to correctly measure the axial clearance A, the turbine must be

raised slightly.

WARNING

Risk of injury due to sharp edges on the compressor wheel

The compressor wheel has sharp edges which can cause injuries.

u Wear safety gloves.

Wear safety gloves to protect against mechanical hazards.

Axial clearance A and ra-

dial clearance B [mm]

TPS44

0.08

0.16

TPS48

0.08

0.16

TPS52

0.10

0.18

TPS57

0.12

0.21

TPS61

0.15

0.25

A minimum

A maximum

B minimum

0.51

0.50

0.61

0.72

0.81

B maximum

1.00

1.15

1.31

1.55

* Permissible B clearances for standard radial bearings. If the clearances

measured on TPS57 or TPS61 are outside the permissible range, this can

indicate radial bearings with a special bearing geometry. Different per-

missible values are valid for radial bearings with a special bearing geo-

metry (see the table below).

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8 Disassembly and assembly / 8.4 Axial clearance A and radial clear-

ance B

Identifying radial bearings

with a special bearing

geometry

The type of bearing can be determined by measuring the rotor run-out

time. To do so, the rotor must be pushed by hand, once to the left (L)

and once to the right (R), with a force as close to the same in both direc-

tions. The resulting run-out times until the rotor comes to a stop are

measured for the anticlockwise and clockwise rotations and then com-

pared. With standard radial bearings, the run-out time for anticlockwise

and clockwise rotating rotors is the same.

If one run-out time is at least 1.5 times longer than the other, then radial

bearings with a special bearing geometry are installed. The following B

clearances are valid for these special bearings.

TPS57

0.46

0.73

TPS61

0.52

0.82

B minimum

B maximum

CAUTION

Clearances out of tolerance

Clearances out of tolerance and excessively worn components can be

the cause of serious damage to machinery and property.

u Have components assessed and, if necessary, replaced by an ABB

Turbocharging Service Station.

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8 Disassembly and assembly / 8.5 Radial clearances N and R

8.5 Radial clearances N and R

N and R

These are the theoretical values of the radial clearance between the com-

pressor wheel and the wall insert and / or turbine wheel and the gas out-

let flange.

The minimum and maximum values result from the manufacturing toler-

ances of the compressor wheel and turbine wheel or the wall insert and

gas outlet flange.

Feeler gauge

N1 and N2 as well as R1 and R2 are each

measured at the same time using two

feeler gauges.

To measure N1 and N2, the feeler

gauges must be pushed between the

wall insert and the compressor wheel

free of play, in each case above and be-

low.

To measure R1 and R2, the feeler gauges

must be pushed between the gas outlet

flange and the turbine free of play, in

each case above and below.

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8 Disassembly and assembly / 8.5 Radial clearances N and R

Measuring N and R

The mean values measured must be within the permissible values of the

radial clearance N and R.

Radial clearances N and R

Product

TPS44

TPS48

TPS52

TPS57

TPS61

N [mm]

R [mm]

0.15 … 0.49

0.22 … 0.58

0.30 … 0.67

0.40 … 0.86

0.50 … 0.94

0.36 … 0.67

0.47 … 0.77

0.59 … 0.92

0.75 … 1.11

0.90 … 1.32

CAUTION

Clearances out of tolerance

Clearances out of tolerance and excessively worn components can be

the cause of serious damage to machinery and property.

u Have components assessed and, if necessary, replaced by an ABB

Turbocharging Service Station.

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8 Disassembly and assembly / 8.6 Table of tightening torques

8.6 Table of tightening torques

The following tightening torques must be observed for the specified

bolted connections:

Tightening torques [Nm]

Position Part num- TPS44

ber

TPS48

TPS52

TPS57

TPS61

72020

42008

52433

51007

72011

86505

60 Nm

6 Nm

20 Nm

25 Nm

35 Nm

15 Nm

60 Nm

10 Nm

20 Nm

25 Nm

35 Nm

15 Nm

60 Nm

10 Nm

40 Nm

45 Nm

70 Nm

15 Nm

60 Nm

20 Nm

65 Nm

75 Nm

105 Nm

15 Nm

60 Nm

40 Nm

65 Nm

75 Nm

170 Nm

15 Nm

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9 Taking out of operation / 9.1 Shutting down the turbocharger

9 Taking out of operation

9.1 Shutting down the turbocharger

If the turbocharger is damaged and the engine can be shut down for only

a short time for emergency repairs, proceed as follows:

u Fit the cover plate.

CAUTION

Always heed precisely the engine builder's instructions in case of en-

gine operation with a blocked / throttled turbocharger!

Dismantling the turbocharger

u Dismantle the turbocharger (see the section Dismantling and fitting

the turbocharger).

u Do not dismantle the nozzle ring.

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9 Taking out of operation / 9.1 Shutting down the turbocharger

Fitting the cover plate

u Close the opening in the turbine casing using the cover plate (A).

u Fasten the cover plate on the turbine casing (51000) using the fasten-

ing strips (51002), Verbus Ripp® Verbusripp washers (51003) and nuts

(51007) and screw it down securely on the support.

NOTICE

Thoroughly clean the fastening strips (51002) before fitting them. Apply

high-temperature grease to the stud threads (51006).

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9 Taking out of operation / 9.1 Shutting down the turbocharger

Cover plate drawing

The cover is not included in the scope of delivery of ABB and must be

manufactured by the operator according to the following drawing.

Material: Common structural steel, in compliance with DIN EN 10025-2

Product

±0.5

±0.2

TPS44

TPS48

TPS52

TPS57

TPS61

62.6

65.7

79.6

98.2

116.8

100

120

110

130

155

190

226

11.0

11.7

14.2

17.2

20.5

144

150

180

220

260

1.5

2.4

Product

ØD1

±0.2

ØD1*

±0.2

ØD2

TPS44

TPS48

TPS52

TPS57

TPS61

191.3

222.7

265.7

325.7

387.7

191.3

227.7

271.7

332.5

395.9

≤88

≤105

≤125

≤153

≤182

M10

35.7

39.6

48.2

56.8

Dimensions in [mm]

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Operation Manual / TPS44-F.. - TPS61-F..

9 Taking out of operation / 9.1 Shutting down the turbocharger

*) Diameter for turbine casing designs for optional C-ring sealing

NOTICE

Information about the turbine casing design (with / without C-ring

sealing) can be requested from an ABB Turbocharging Service Station.

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Operation Manual / TPS44-F.. - TPS61-F..

10 Mothballing the turbocharger / 10.1 Taking the engine out of opera-

tion for up to 12 months

10 Mothballing the turbocharger

10.1 Taking the engine out of operation for up to

12 months

Condition of engine lubricating oil

The turbocharger normally remains mounted on the engine. Mothballing

a turbocharger depends on the condition of the lubricating oil:

If the total acid number (TAN) is lower than 2 mg KOH/g, no meas-

ures have to be taken.

If the engine lubricating oil is replaced by preserving oil before taking

the engine out of operation and this is circulated by the pre-lubrica-

tion pump, no measures have to be taken. Any remaining old engine

oil will therefore be flushed away and the bearing sections largely

protected against corrosion.

Mothballing measures

WARNING

Handling operating materials and supplies

Swallowing or inhaling vapours of operating materials and supplies or

contact 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 op-

erating materials and supplies.

u Wear personal protective equipment (PPE) according to the material

safety data sheet.

u Comply with local legislation.

Wear safety goggles.

Wear safety gloves to protect against chemical hazards.

Wear a respiratory mask to protect against gases.

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Operation Manual / TPS44-F.. - TPS61-F..

10 Mothballing the turbocharger / 10.2 Taking the engine out of oper-

ation for more than 12 months

If the total acid number (TAN) is greater than 2 mg KOH/g, the following

mothballing measures are necessary after taking an engine out of opera-

tion:

u Dismantle the turbocharger.

u The rotor and the bearing parts must be removed by an official ABB

Turbocharging service station and refitted afterwards.

u Clean all parts.

u Machined, bright surfaces of steel and cast parts must be oiled with

anticorrosive oil.

u Reassemble complete turbocharger.

Rotor turning in stack draught

If the rotor turns as a result of the stack draught:

u Install blind flange between compressor casing outlet flange and

charge air duct.

10.2 Taking the engine out of operation for more

than 12 months

If the engine is taken out of operation, the following variants are pos-

sible with regard to the turbocharger:

The turbocharger remains mounted on the engine.

The turbocharger casing remains mounted on the engine, but the ro-

tor and the bearing parts are removed and stored separately by an

ABB Turbocharging Service Station.

The turbocharger is removed completely, either as a whole or in indi-

vidual parts.

See the section Taking out of operation for up to 12 months, under

Mothballing measures, for the measures always necessary when moth-

balling turbocharger parts.

If the turbocharger remains mounted on the engine, refer to the section

Taking out of operation for up to 12 months, under Rotor turning in

stack draught.

If the entire turbocharger is removed, or if the turbocharger is re-as-

sembled from the individual components thereof:

u Close all turbocharger openings using wooden covers and paraffin

paper.

Only dry rooms with 40 ... 70 % atmospheric humidity, in which no water

condensation can form, are suitable as storage locations.

HZTL2412_EN

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Operation Manual / TPS44-F.. - TPS61-F..

10 Mothballing the turbocharger / 10.2 Taking the engine out of oper-

ation for more than 12 months

Condition of the mothballed turbocharger

u Check the mothballed turbocharger parts for corrosion once per an-

num.

u If there are signs of rust: Clean parts thoroughly and renew protection

against corrosion.

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Operation Manual / TPS44-F.. - TPS61-F..

11 Disposing of turbocharger components /

11 Disposing of turbocharger

components

WARNING

Handling damaged thermal insulation

Damaged thermal insulation can lead to dust exposure. The glass fibres

can cause mechanical irritation of the eyes, skin, and respiratory tracts.

u Avoid the formation of dust.

u Vacuum up dust with a suitable vacuum cleaner.

u Wear a respiratory mask to protect against dusts (P1 or P2 mask).

u Wear safety gloves.

Wear safety goggles.

Wear a respiratory mask to protect against dusts.

Wear safety gloves to protect against mechanical hazards.

Disposal must be environmentally compatible, professional, and in com-

pliance with locally applicable regulations.

The turbocharger consists largely of metal (cast iron materials, steel,

nickel-steel alloys, aluminium and bearing brass).

Further components are: Non-metallic materials (filter components of

felt and polyethylene), lubricants (engine oil), electronic parts (speed

sensor and associated components), and thermal insulation.

u Dispose of metals as scrap metal for recycling.

u Dispose of non-metallic materials as waste.

u Dispose of residues of lubricants as waste oil.

u Dispose of electronic components as electronic waste.

u Dispose of thermal insulation as hazardous waste.

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Operation Manual / TPS44-F.. - TPS61-F..

12 Spare parts / 12.1 Ordering spare parts

12 Spare parts

12.1 Ordering spare parts

When making inquiries or ordering spare parts, the following data must

be specified:

Turbocharger type

Serial number (HT……)

Designation and part number.

Spare parts can be ordered from an official ABB Turbocharging service

station.

u If different design versions have not been taken into consideration in

this document, please contact an ABB Turbocharging service station.

CAUTION

Storage of spare parts

All spare parts ordered with the turbocharger must be kept complete

and ready for use.

u Parts showing signs of rust should be carefully cleaned and greased.

u Dispose of replaced and unusable parts in a professional and environ-

mentally compatible way.

Customer spare part set (97070)

The customer spare part set (97070) is required for the work described

in this Operation Manual.

Quantity

Description

Socket screw

O-ring

Gasket

O-ring

Part number

42008

42012

52406 *

77005

72041

Counter-sunk screw

O-ring

81010/ 82010

* This gasket can only be installed when a gas outlet casing from ABB is

used.

HZTL2412_EN

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Operation Manual / TPS44-F.. - TPS61-F..

12 Spare parts / 12.2 View of turbocharger showing part numbers

12.2 View of turbocharger showing part numbers

(……) only available in customer spare part set (97070).

HZTL2412_EN

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Operation Manual / TPS44-F.. - TPS61-F..

12 Spare parts / 12.2 View of turbocharger showing part numbers

Part number

Description

10900

Cartridge group

Socket screw

O-ring

42008 (in customer spare part set)

42012 (in customer spare part set)

51000

51002

51100

51105*

Turbine casing

Fastening strips

Exhaust bend

Metal C-ring

Gas outlet flange

Gasket

52400

52406 (in customer spare part set)

52408*

56001

Metal C-ring

Nozzle ring

57200

57210

Burst protection

Burst ring

72000

72011

72012

72020

Compressor casing

Socket screw

Fastening strips

V-clamp

72041 (in customer spare part set)

Counter-sunk screw with cross slot-

ted head

77000

Wall insert

77005 (in customer spare part set)

O-ring

79000

Diffuser

81000

Filter silencer

81010 (in customer spare part set)

O-ring

82000

Axial air suction branch

O-ring

82010 (in customer spare part set)

86505(A)*

86505(B)*

86515(A)*

86515(B)*

86526*

Speed sensor (cable not integrated)

Speed sensor (cable integrated)

Cable connector for 86505(A)

Cable connector for 86505(B)

F/I converter

86528*

Tachometer

* depends on the turbocharger specification.

HZTL2412_EN

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Operation Manual / TPS44-F.. - TPS61-F..

12 Spare parts / 12.3 View of cartridge group showing part numbers

12.3 View of cartridge group showing part numbers

HZTL2412_EN

Rev.G

March 2020

Operation Manual / TPS44-F.. - TPS61-F..

12 Spare parts / 12.3 View of cartridge group showing part numbers

Part number

Description

21000

Shaft

21002

Piston ring

25000

32101

32103

32105

Compressor wheel

Plain bearing bush

Locking ring

Thrust ring

32106

32108

Thrust bearing

Piston ring

32109

32110

32111

32112

32113

32114

32221

32222

Sealing disc

Bearing flange

Auxiliary bearing

Bearing flange

Socket screw

Bearing cover

O-ring

42001

42002

Bearing casing

Socket screw

Partition wall

Metal C-ring

42008 (in customer spare part set)

43001

43012*

* depends on the turbocharger specification.

HZTL2412_EN

Rev.G

March 2020

ABB

ABB Turbo Systems AG

Bruggerstrasse 71a

CH-5400 Baden

Switzerland

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