Page 1 Turbocharging Operation Manual TPS48-F33 ABB Turbo Systems Ltd CH 5401 Baden Type TPS48-F33 HT563047 1027 Mmax Mmax °C 1007 Bmax Bmax SGAK02 00180 Application according to Year 2016 the Operation Manual made in Switzerland ABB Turbo Systems Ltd...
Page 2 „European Machinery Directives“. We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without express authority by ABB Turbo Systems Ltd is strictly forbidden. © Copyright by ABB TURBO SYSTEMS Ltd 2004 Design and speciﬁ...
Page 3: Table Of Contents
Definition of mandatory signs Definition of Safety instructions Warning plates on the turbocharger Safe operation and maintenance Hazards during operation and maintenance Use of ABB turbochargers on gas engines Periodic checking of the pressure vessel 2.10 Lifting loads Start-up Oil supply...
Page 4 Taking the engine out of operation for more than 12 months Disposing of turbocharger components Spare parts 12.1 Ordering spare parts 12.2 View of turbocharger showing part numbers 12.3 View of cartridge group showing part numbers © Copyright 2015 ABB. All rights reserved.
Page 5: Preliminary Remarks
Operation Manual This Operation Manual enables you to familiarize yourself with the turbocharger supplied by ABB Turbo Systems and to use it as intended. It provides important information in order that the turbocharger can be operated safely, correctly and efficiently.
Page 6: Layout And Function
3 Diffuser 10 Turbine casing 4 Bearing casing 11 Turbine-end bearing flange 5 Axial thrust bearing 12 Compressor-end bearing flange 6 Radial plain bearing (visible only 13 Compressor wheel at turbine end) 7 Turbine © Copyright 2015 ABB. All rights reserved.
Page 7 The bearings are connected to a central lubricating oil duct which is supplied by the engine's lubricating oil circuit. The oil outlet is always at the lowest point of the bearing casing (4). © Copyright 2015 ABB. All rights reserved.
Page 8: Intended Use Of The Turbocharger
Any other use will be regarded as a special application which must first be discussed with ABB Turbo Systems. The manufacturer accepts no liability for other applications. If it is used otherwise, ABB Turbo Systems reserves the right to reject all warranty claims.
Page 9: Storage Of New Turbochargers And Spare Parts
Storage of new turbochargers and spare parts Storage of new turbochargers and spare parts up to 6 months New turbochargers and spare parts from ABB Turbo Systems 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).
Page 10 Page 8 spare parts Long-term storage of replacement turbochargers or spare parts Per order, turbochargers or cartridge groups will be prepared by ABB Turbo Systems for prolonged storage. The package is equipped with a hygrometer (see illustration). The following measures are required every 6 months: Check the hygrometer (2) in the sight-glass.
Page 11 NOTICE replacement cartridge group can be placed into operation without any prior testing by an ABB Turbocharging Service Station. Unpacking replacement turbochargers or spare parts The corrosion protection effect ends after the material is unpacked from the VCI package.
Page 12: Essential Information
The fault must be reported to the person or department responsible. Additions and alterations to, and conversions of the turbocharger that could compromise safety require the prior approval of ABB Turbo Systems. NOTICE © Copyright 2015 ABB. All rights reserved.
Page 13 Original parts and accessories are designed especially for the turbocharger supplied by ABB Turbo Systems. It is herewith explicitly stated that original parts and accessories that were not supplied by ABB Turbo Systems have also not been tested and approved by ABB Turbo Systems. NOTICE...
Page 14 It should be noted that the Operation Manual contains sections and descriptions that are not relevant for the turbocharger supplied. The ABB Turbocharging Service Stations are at your disposal for questions concerning the design version of the supplied turbocharger (see chapter Contact address and after-sales service [➙...
Page 15: Symbols And Definitions
Definition of caution / warning The caution and warning signs are described in the chapter Safety. ABB Turbo Systems In this document, ABB Turbo Systems Ltd is abbreviated to ABB Turbo Systems. Official ABB Turbo Systems Service Stations In this document, official service stations are referred to as ABB Turbocharging Service Stations.
Page 16: Turbocharger Rating Plate
Replacement interval for compressor in 1000 h for turbocharger components Replacement interval for turbine in 1000 h Further information Part number for customer Designation of special design Turbocharger weight in kg Turbocharger type Serial number Year of turbocharger construction © Copyright 2015 ABB. All rights reserved.
Page 17 Operation above the indicated values n can considerably shorten the Bmax Bmax recommended replacement intervals. In such cases, we recommend that you contact the nearest official ABB Turbocharging service station. and t normally apply only when running at overload (110%) during Mmax Mmax trials on the engine test bed.
Page 18: Contact Address And After-Sales Service
Page 16 Contact address and after-sales service Contact address ABB Turbo Systems AG Bruggerstrasse 71a CH-5401 Baden Switzerland www.abb.com/turbocharging After-sales service A list of the official ABB Turbo Systems service stations is available online. © Copyright 2015 ABB. All rights reserved.
Page 19: Safety
Page 17 Safety Introduction Turbochargers manufactured by ABB Turbo Systems are state of the art and comply with the pertinent safety and health-protection requirements that applied when the turbocharger was manufactured. Consequently, the turbocharger is safe to operate. Nevertheless, during turbocharger...
Page 20: Ce Conformity
Operation Manual / TPS44-F.. - TPS61-F.. Safety CE conformity Page 18 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. © Copyright 2015 ABB. All rights reserved.
Page 21: Definition Of Mandatory Signs
To be worn according to the specific work Safety glasses Safety goggles Safety gloves against Respiratory mask against - mechanical hazards - dust - chemical hazards - gases - heat hazards Safety helmet Ear protection © Copyright 2015 ABB. All rights reserved.
Page 22: Definition Of Safety Instructions
Serious machine or property damage may occur if work and operating instructions marked with this symbol and the word CAUTION are either CAUTION not followed or not followed precisely. Caution signs must be observed at all times.  © Copyright 2015 ABB. All rights reserved.
Page 23: 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: Order new warning plates from ABB Turbocharging Service Stations.  Remove unreadable warning plates.
Page 24: Safe Operation And Maintenance
Remove combustible objects and substances out of the range of flying  sparks. Cover all connections on the turbocharger so that no foreign objects  can get into the turbocharger. © Copyright 2015 ABB. All rights reserved.
Page 25 Safe operation and maintenance Page 23 Safety during start-up / commissioning and operation The turbine casing insulation of the TPS44-F supplied by ABB Turbo Systems is also burst protection. Serious personal injuries or fatal accidents can occur, if the turbine...
Page 26 Secure the rotor so it cannot turn. The rotor can turn on its own from  the force of the stack draught. Clean the turbocharger before mothballing it.  Wear appropriate protective clothing.  © Copyright 2015 ABB. All rights reserved.
Page 27: Hazards During Operation And Maintenance
Heed the general rules for work safety and accident prevention.  Ensure the safety of the work area.  Perform only those tasks that are described in this manual.  Perform work only for which training has been carried out.  © Copyright 2015 ABB. All rights reserved.
Page 28 Do not touch hot surfaces and heed the warning plate on the  turbocharger. Wear heat-resistant safety gloves and protective clothing.  Allow the turbocharger to cool down before carrying out any work.  Wear safety gloves against thermal risks. © Copyright 2015 ABB. All rights reserved.
Page 29 Hot surfaces on uninsulated turbochargers Uninsulated turbochargers can cause serious personal injuries (burns). The turbocharger is supplied by ABB Turbo Systems without insulation WARNING depending on the order from the engine builder. In this case, the engine builder is responsible for insulating the turbocharger properly or for providing protection against hot surfaces being touched.
Page 30 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. © Copyright 2015 ABB. All rights reserved.
Page 31 Remove packing materials only in the work area.  Take particular care when removing old insulating materials.  Dispose of insulating materials properly and in an environmentally  compatible way in accordance with applicable local regulations. © Copyright 2015 ABB. All rights reserved.
Page 32 Hazards due to electrical components Electrical components operate with voltages which can present hazards to humans. WARNING All work on or with electrical components may only be performed by  trained specialists. Heed any country-specific regulations.  © Copyright 2015 ABB. All rights reserved.
Page 33: Use Of Abb Turbochargers On Gas Engines
Use of ABB turbochargers on gas engines ABB turbochargers can withstand a deflagration with a transient pressure increase of 12 bar. A maximum of 11 bar has been measured during deflagration trials on engines with flame traps. The practical operating experience of well-known manufacturers of gas engines reinforces this value.
Page 34: Periodic Checking Of The Pressure Vessel
Page 32 vessel Periodic checking of the pressure vessel The pressure vessels used by ABB Turbo Systems, such as those for wet or dry cleaning, are so-called "simple pressure vessels".  The local, statutory regulations covering periodic checks of pressure vessels must be observed.
Page 35: Lifting Loads
Completely screw in assembly / fitting devices without fail so that they  cannot work loose during use. Use assembly / fitting devices only for applications described.  Make sure removed turbocharger components stand safely and  securely. © Copyright 2015 ABB. All rights reserved.
Page 37: Start-Up
Check that oil filters are clean before commissioning.  Also follow the enginebuilder's instructions regarding filter mesh and separation efficiency. NOTICE © Copyright 2015 ABB. All rights reserved.
Page 38 CAUTION Do not allow the oil inlet temperature to fall below the minimum 30 ºC  when starting the engine. The oil inlet temperature must never be less than 10 °C.  © Copyright 2015 ABB. All rights reserved.
Page 39 Pre- and post-lubrication (engine stopped) ≤ 1.0 Prelubrication Serious machine or property damage might result if the turbocharger is not supplied with oil when the engine is starting. CAUTION Activate prelubrication device before starting engine.  © Copyright 2015 ABB. All rights reserved.
Page 40 + 55 K oil,inlet If the turbocharger has been operated outside the permissible range for a prolonged period of time, ABB Turbo Systems recommends having the turbocharger inspected by an ABB Turbocharging Service Station. © Copyright 2015 ABB. All rights reserved.
Page 41: Inspection Work
Check the oil pressure in the oil supply lines.  Prelubrication Serious machine or property damage might result if the turbocharger is not supplied with oil when the engine is starting. CAUTION Activate prelubrication device before starting engine.  © Copyright 2015 ABB. All rights reserved.
Page 42 If oily liquid continues to escape after this period, an oil leak must be suspected. The first step is to check for leakage of the oil NOTICE supply to the turbocharger. If this is leaky, contact an official ABB Turbocharging service station. 3.2.4 Inspection after 100 service hours Clean or replace lubricating oil filters after the first 100 service hours.
Page 43: Commissioning After Taking Out Of Operation
Start up turbocharger oil circulation system at engine end.  Prepare turbocharger for operation as instructed in section "Inspection  work before start-up / commissioning" of chapter headed "Start-up / commissioning". Start up turbocharger.  © Copyright 2015 ABB. All rights reserved.
Page 45: Operation
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. © Copyright 2015 ABB. All rights reserved.
Page 46 Operation Noise emissions Page 44 Suggestion for noise insulation of the bellows Compressor casing Bellows Charge air duct / scavenging air line Insulation pads Insulation mat (at least 15 mm) Sheet metal cover © Copyright 2015 ABB. All rights reserved.
Page 47: Servicing Work
 Systems. 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 NOTICE 5 years after the last service. 4.2.1 Service work every 25 … 50 hours Visual inspection for air, exhaust gas, water and oil leaks.
Page 48 Service work in accordance with instructions on rating plate (In general, after 8000 … 12000 hours of operation) Rotor and bearing parts must be inspected and assessed by an ABB Turbocharging Service Station. The following work can be carried in preparation.
Page 49  Pressure drop in charge air cooler  Lubricating oil pressure and lubricating oil temperature  Air temperature behind compressor and charge air cooler If provided  Turbocharger speed  Pressure loss in air filter © Copyright 2015 ABB. All rights reserved.
Page 50: Expected Exchange Intervals
Other casings 50000 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). © Copyright 2015 ABB. All rights reserved.
Page 51 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) © Copyright 2015 ABB. All rights reserved.
Page 52: Speed Measurement
Do not tension the speed measurement cables.  86505(A) Speed sensor (cable not 86526 F/I converter integrated) 86505(B) Speed sensor (cable integrated) 86528 Tachometer 86515(A) Cable connector for 86505(A) 1 Screw plug 86515(B) Cable connector for 86505(B) 2 Gasket © Copyright 2015 ABB. All rights reserved.
Page 53 If the engine can be stopped for a short time: Inspect the air and gas lines as well as the turbocharger and eliminate  any problems. In any event, it is recommended that you contact the nearest ABB  Turbocharging Service Station. © Copyright 2015 ABB. All rights reserved.
Page 54 Screw in a new speed sensor up to the limit block.  Adhere to tightening torque.  Part number TPS44 TPS48 TPS52 TPS57 TPS61 86505 15 Nm 15 Nm 15 Nm 15 Nm 15 Nm © Copyright 2015 ABB. All rights reserved.
Page 55 Connect cable connector to speed sensor.  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 described in the chapter Troubleshooting. © Copyright 2015 ABB. All rights reserved.
Page 56: Stopping The Engine
Allow turbocharger cooling water to run for 15 … 20 minutes after  CAUTION stopping engine. Allow oil lubrication to continue running until rotor comes to a stop.  Further post-lubrication is not required and not recommended. © Copyright 2015 ABB. All rights reserved.
Page 57: Maintenance
Cleaning method To allow you to observe the standard service intervals and to maintain a high turbocharger efficiency, ABB Turbo Systems recommends that the NOTICE cleaning procedure be carried out during operation. This allows the thermal load of the engine to be kept low while ensuring maximum fuel efficiency.
Page 58: Cleaning The Compressor During Operation
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. NOTICE The interval between periodic cleaning is very dependent on the operating Cleaning interval conditions.
Page 59 Cleaning method Cleaning the compressor while in operation is carried out as wet cleaning. This cleaning method has been tested and approved by ABB Turbo Systems. To clean the compressor stage during operation, water is injected in front Principle of wet cleaning of the compressor wheel through an injection pipe fitted in the filter silencer or the suction branch.
Page 60 Operating state prerequisites for cleaning compressor with XC1 To be able to carry out a satisfactory cleaning process that has been tested and is recommended by ABB Turbo Systems, the following prerequisites must be fulfilled: Run engine at load from 50 … 85 %.
Page 61 NOTICE 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 Turbocharging Service Station. Cleaning parameters per Product...
Page 62: Turbine Cleaning During Operation
ABB Turbo Systems recommends using fuels with a low ash, sulphur, sodium and vanadium content. Consequences of contamination: ...
Page 63 The cleaning process with a long water injection time is used for turbocharger 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. © Copyright 2015 ABB. All rights reserved.
Page 64 Maintenance Turbine cleaning during operation Page 62 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 NOTICE Turbocharger service station. 5.3.2 Prerequisites...
Page 65 Operation Manual / TPS44-F.. - TPS61-F.. Maintenance Turbine cleaning during operation Page 63 Recommended operating state for turbine wet cleaning The following operating state has been tested and is approved by ABB Turbo Systems: Characteristic / component Conditions short long...
Page 66 100 °C higher than the exhaust gas temperature after the cylinder. This should be taken into consideration when setting the operating point before cleaning. Don't exceed maximum temperature in front of turbine when  cleaning. © Copyright 2015 ABB. All rights reserved.
Page 67 100 °C higher than the exhaust gas temperature after the cylinder. This should be taken into consideration when setting the operating point before cleaning. Don't exceed maximum temperature in front of turbine when  cleaning. © Copyright 2015 ABB. All rights reserved.
Page 68: Cleaning Components Mechanically
Dispose of dirty water and cleaning agents in an environmentally  compatible manner, professionally and in accordance with valid local regulations. Disassembly and assembly The disassembly and assembly of the components is described in chapter Disassembly and assembly. NOTICE © Copyright 2015 ABB. All rights reserved.
Page 69 Avoid rough handling (do not use a water jet). Allow the filter ring to dry out completely before assembly.  Dispose of dirty water and gentle detergents in accordance with valid  local regulations. © Copyright 2015 ABB. All rights reserved.
Page 70 Have absorption segments which are heavily contaminated replaced  by an official ABB Turbocharging Service Station. Fitting the filter silencer Insert the absorption segments (81136) into the sheet-metal coverings ...
Page 71 Spray cleaned surfaces with penetrating oil. Do not spray the outer  surfaces of the turbocharger. Dispose of dirty water and cleaning agent in accordance with the  specifications in the safety data sheet. © Copyright 2015 ABB. All rights reserved.
Page 72 Place contaminated parts in hot water or in a liquid such as carbon  remover, so that the dirt softens. Brush off the contamination or remove it with a steam cleaner.  Repeat the soaking and brushing if necessary.  © Copyright 2015 ABB. All rights reserved.
Page 73 Remove turbocharger from the engine (see chapter Removal and  installation [➙ 85]). Remove cartridge group (see chapter Disassembly and assembly  [➙ 89]). First clean the compressor end and then the turbine end in accordance with the following description. © Copyright 2015 ABB. All rights reserved.
Page 74 Lightly spray the compressor wheel and the gap between the  compressor and the bearing casing with penetrating oil. Dispose of dirty water and cleaning agent in accordance with the  safety data sheet. © Copyright 2015 ABB. All rights reserved.
Page 75 Selection of the cleaning agent Cleaning agents which contain chlorine attack metals. Use only pH-neutral cleaning agents which do not attack metals.  CAUTION Observe safety data sheet.  Fill the tank (02) with soaking liquid.  © Copyright 2015 ABB. All rights reserved.
Page 76  Maintain dimension (B) for the supports (01), so that the cartridge  group does not submerge too deep. Allow the layers of dirt on the turbine to soak for four hours.  © Copyright 2015 ABB. All rights reserved.
Page 77 Wear a respiratory mask to protect against particles. Wear safety gloves against mechanical risks. Raise the cartridge group and align horizontally.  Remove dirt manually with a soft brush or wire brush.  © Copyright 2015 ABB. All rights reserved.
Page 78 Lightly spray the turbine and the gap between the turbine and partition  wall with penetrating oil. Dispose of dirty water and cleaning agent in accordance with the  specifications in the safety data sheet. © Copyright 2015 ABB. All rights reserved.
Page 79: Troubleshooting
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 Turbocharging Service Station.
Page 80: Surging Of The Turbocharger
Prolonged or periodic surging Possible damage to components, such as the compressor wheel, turbine blades, bearings and filter silencer CAUTION Have the cause clarified immediately by an ABB Turbocharging  service station and rectified. Have components inspected for damage and, if necessary, replaced ...
Page 81: Malfunctions During Operation
Defects such as leaks in the Make repairs exhaust gas pipes or charge air ducts Increase in speed Possible causes Elimination Turbo- Heavily contaminated nozzle ring Contact an ABB Turbocharging charger (with 4-stroke application) Service Station © Copyright 2015 ABB. All rights reserved.
Page 82 Charge air Dirty cooler Clean it. cooler Cooling water volume too Top up water. small Entry temperature of cooling Inspect / clean cooling system. water too high Inadequate ventilation Improve ventilation. © Copyright 2015 ABB. All rights reserved.
Page 83 Possible causes Remedy Engine Malfunction in the injection Repair or contact manufacturer system Injection misaligned Set correctly Engine performance higher than Check engine performance expected Turbo- Manometer display defective Replace manometer charger © Copyright 2015 ABB. All rights reserved.
Page 84 Reduced fatigue strength of the compressor wheel, compressor blade failure. Possible causes Remedy Turbo- Material of compressor wheel Check the fuel and its corrosive charger corroded components, and change fuel if necessary. © Copyright 2015 ABB. All rights reserved.
Page 85: Malfunctions When Stopping
Rubbing rotor Foreign object in turbocharger Run-down time too short Possible causes Elimination Turbo- Turbocharger contaminated Clean it charger Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger © Copyright 2015 ABB. All rights reserved.
Page 86: Speed Measurement System
As a result, the voltage amplitude of the speed signal decreases, which can cause problems for the evaluation electronics. This problem is eliminated by removing the gasket. Defective sensor Contact an ABB Turbocharging Service Station Measured Contaminated The sensor tip is magnetic and can thus...
Page 87: Removal And Installation
Removal and installation Transport Suspension of uninsulated turbocharger Turbocharger with oil-cooled bearing Complete turbocharger with gas outlet casing casing Suspension of insulated turbocharger Turbocharger with oil-cooled bearing Complete turbocharger with gas outlet casing casing © Copyright 2015 ABB. All rights reserved.
Page 88: Turbocharger Weights
The following weight specification is the heaviest possibility. This guide value can differ from data on the rating plate, depending on the specification. TPS44 TPS48 TPS52 TPS57 TPS61 [kg] [kg] [kg] [kg] [kg] © Copyright 2015 ABB. All rights reserved.
Page 89: Remove The Turbocharger
(C). Unscrew fixing screws (D) on bearing casing.  Lift turbocharger off engine and set it down to one side.  Cover oil connections.  © Copyright 2015 ABB. All rights reserved.
Page 90: Installing The Turbocharger
 Visually inspect O-ring seals of oil supply and drain pipe (O-ring seals  for engine are not delivered by ABB Turbo Systems). Fasten lifting gear to bearing casing.  If a gas outlet manifold is provided, sling lifting gear around it ...
Page 91: Disassembly And Assembly
 only by trained personnel from an ABB Turbocharging Service Station. Marking casing positions for assembly ABB Turbo Systems recommends that the casing positions are marked before disassembling the turbocharger. NOTICE Identifying assembly devices Not all assembly devices are marked with a part number. They can be identified using the tool list.
Page 92 The specified tightening torques of screw connections for turbocharger components must be observed. (See section Table of tightening torques.) Tightening torques for assembly devices of ABB Turbo Systems If nothing else is described, the screws and nuts of the assembly devices must be tightened down firmly.
Page 93 Equipment for lifting and transporting loads (ropes, chain hoists, cranes). Lifting gear is not supplied by ABB Turbo Systems. 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...
Page 94: Module Weights
6 Diffuser 7 Cartridge group 8 Nozzle ring 9 Burst ring 10 Turbine casing 1 inlet with external 2 inlets burst protection 3 inlets 4 inlets 11 Gas outlet flange 12 Exhaust manifold © Copyright 2015 ABB. All rights reserved.
Page 95: Disassembling And Assembling Turbocharger
 instructions. Remove the screws for the compressor casing insulation and If provided  dismantle the insulation. Undo the V-clamp (72020) and remove the filter silencer (81000) or air  suction branch (82000). © Copyright 2015 ABB. All rights reserved.
Page 96 Loosen and remove the screws for the insulation plates (1, 2). If provided  If provided: Remove the insulation plates (1, 2).  Remove the remaining screws for the insulation (3).  Remove the insulation (3).  © Copyright 2015 ABB. All rights reserved.
Page 97 Move the compressor casing (72000) with the wall insert (77000)  carefully away, doing so horizontally. Tap the wall insert (77000) out of the compressor casing using a nylon  hammer and remove the O-ring seal (77005). © Copyright 2015 ABB. All rights reserved.
Page 98  Remove wall insert (77000) using lifting gear.  Disassembly of diffuser TPS..-F31/32 / FV31/32 Loosen screws (72041) and remove them together with lockwashers  (72040) and diffuser (79000) from compressor casing (72000). © Copyright 2015 ABB. All rights reserved.
Page 99 (see chapter Spare parts). NOTICE Refit diffuser in reverse order. Fitting the diffuser  TPS..-F31/32 / FV31/32 Fit compressor housing in reverse order.  Thoroughly clean fastening strips (72012) before fitting them.  © Copyright 2015 ABB. All rights reserved.
Page 100 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. CAUTION It should thus be used alternately on both sides while avoiding  excessive pressure on either side. © Copyright 2015 ABB. All rights reserved.
Page 101 Mount the cartridge group on the service support (90012) and bolt it  down firmly. Loosen screw (42008) and remove diffuser (79000) complete with O-  ring (42012). Measure the axial and radial clearances (see the section Axial and  radial clearances). © Copyright 2015 ABB. All rights reserved.
Page 102 Push the nozzle ring (56001) into the turbine casing (51000) as far as  it will go. Insert the C-ring (51105) into the turbine casing and hold it in place If provided  using high-vacuum grease. © Copyright 2015 ABB. All rights reserved.
Page 103 Nozzle ring press fit for  single inlet turbine casing If the calculated value (PD) is less than 0.1 mm, an official ABB Turbocharging Service Station must be contacted. NOTICE Measure the axial and radial clearances (see the section Axial and ...
Page 104 Nozzle ring press fit for  multiple inlet turbine casing If the calculated value (PD) is outside ±0.2 mm, an official ABB Turbocharging Service Station must be contacted. NOTICE Measure the axial and radial clearances (see the section Axial and ...
Page 105 Remove temporary covers from oil connections.  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 engine builder. CAUTION © Copyright 2015 ABB. All rights reserved.
Page 106 µ = 0.12 for the tightening torque). Product Hole in the bearing Fixing screws C [mm] Tightening casing torques [Nm] **) [mm] TPS44 Ø 17 TPS48 Ø 17 TPS52 Ø 21 TPS57 Ø 21 TPS61 Ø 25 If provided © Copyright 2015 ABB. All rights reserved.
Page 107  Remove gas outlet bend (51100) and gasket (52406). Only gas outlet  bends from ABB Turbo Systems have the gasket (52406). Remove gas outlet flange (52400) and, if fitted, C-ring (52408).  © Copyright 2015 ABB. All rights reserved.
Page 108 If provided, fit the C-ring (52408).  Fit the gas outlet flange (52400).  In the case of gas outlet bends (51100) from ABB Turbo Systems:  always replace the gasket (52406) (see the chapter entitled Spare parts). Apply high-temperature grease to contacting surfaces and threads.
Page 109: Axial Clearance A And Radial Clearance B
TPS57 or TPS61 are outside the permissible range, this can indicate radial bearings with a special bearing geometry. Different permissible values are valid for radial bearings with a special bearing geometry (see the table below). © Copyright 2015 ABB. All rights reserved.
Page 110 Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property. CAUTION Have components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. © Copyright 2015 ABB. All rights reserved.
Page 111: Radial Clearances N And R
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. © Copyright 2015 ABB. All rights reserved.
Page 112 Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property. CAUTION Have components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. © Copyright 2015 ABB. All rights reserved.
Page 113: Table Of Tightening Torques
Table of tightening torques The following tightening torques must be used for the specified screw connections: Tightening torques [Nm] Item Part TPS44 TPS48 TPS52 TPS57 TPS61 number 72020 42008 52433 51007 72011 86505 © Copyright 2015 ABB. All rights reserved.
Page 115: Taking Out Of Operation
Always heed precisely the engine builder's instructions in case of engine operation with a blocked / throttled turbocharger! CAUTION Dismantling the turbocharger Dismantle the turbocharger (see the section Dismantling and fitting the  turbocharger). Do not dismantle the nozzle ring.  © Copyright 2015 ABB. All rights reserved.
Page 116 (51002), Verbus Ripp® washers (51003) and nuts (51007) and screw it down securely on the support. Thoroughly clean the fastening strips (51002) before fitting them. Apply high-temperature grease to the stud threads (51006). NOTICE © Copyright 2015 ABB. All rights reserved.
Page 117 Shutting down the turbocharger Page 115 Cover plate drawing The cover is not supplied by ABB Turbo Systems and must be manufactured by the operator according to the following drawing. Material: Common structural steel, according to DIN EN 10025-2 Product ±0.5...
Page 118 Page 116 *) Diameter for turbine casing designs for optional C-ring sealing Information about the turbine casing design (with / without C-ring sealing) can be requested from an ABB Turbocharging Service Station. NOTICE © Copyright 2015 ABB. All rights reserved.
Page 119: Mothballing The Turbocharger
Observe the information in the material safety data sheet for the  operating materials and supplies. Comply with local legislation.  Wear safety goggles. Wear safety gloves against mechanical risks. Wear a respiratory mask to protect against gases. © Copyright 2015 ABB. All rights reserved.
Page 120: Taking The Engine Out Of Operation For Up To 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 operation: Dismantle the turbocharger.  The rotor and the bearing parts must be removed by an official ABB  Turbocharging service station and refitted afterwards. Clean all parts. ...
Page 121: Taking The Engine Out Of Operation For More Than 12 Months
 The turbocharger remains mounted on the engine.  The turbocharger casing remains mounted on the engine, but the rotor 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 individual parts.
Page 123: Disposing Of Turbocharger Components
 Dispose of non-metallic materials as waste.  Dispose of residues of lubricants as waste oil.  Dispose of electronic components as electronic waste.  Dispose of thermal insulation as hazardous waste.  © Copyright 2015 ABB. All rights reserved.
Page 125: Spare Parts
Socket screw 42008 O-ring 42012 Gasket 52406 * O-ring 77005 Counter-sunk screw 72041 O-ring 81010 / 82010 * This gasket can be used only when using a gas outlet casing from ABB Turbo Systems. © Copyright 2015 ABB. All rights reserved.
Page 126: View Of Turbocharger Showing Part Numbers
Operation Manual / TPS44-F.. - TPS61-F.. Spare parts View of turbocharger showing part 12.2 Page 124 numbers 12.2 View of turbocharger showing part numbers 12.2 © Copyright 2015 ABB. All rights reserved.
Page 127 O-ring 86505(A)* Speed sensor (cable not integrated) 86505(B)* Speed sensor (cable integrated) 86515(A)* Cable connector for 86505(A) 86515(B)* Cable connector for 86505(B) 86526* F/I converter 86528* Tachometer * depends on the turbocharger specification. © Copyright 2015 ABB. All rights reserved.
Page 128: View Of Cartridge Group Showing Part Numbers
Operation Manual / TPS44-F.. - TPS61-F.. Spare parts View of cartridge group showing part 12.3 Page 126 numbers 12.3 View of cartridge group showing part numbers 12.3 © Copyright 2015 ABB. All rights reserved.
Page 129 Socket screw 32221 Bearing cover 32222 O-ring 42001 Bearing casing 42002 Socket screw 42008 (in customer spare part set) Socket screw 43001 Partition wall 43012* Metal C-ring * depends on the turbocharger specification. © Copyright 2015 ABB. All rights reserved.
Page 130 ABB Turbo Systems AG Bruggerstrasse 71a CH-5400 Baden Switzerland...

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