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Operation Manual / TPS44-H.. - TPS52-H..

1 Introduction / 1.1 Purpose of the manual

© Copyright 2021 ABB. All rights reserved.

HZTL4037_EN

Rev.G

June 2021

1

Introduction

1.1

Purpose of the manual

Fig. 1: Serial number (01) on the rating plate

This Operation Manual belongs to the turbocharger with the identical serial number (01), see
the Operation Manual title page and the rating plate on the turbocharger.

Operation Manual

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

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

Target group

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

Availability of the Operation Manual

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

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

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Summary of Contents for 1254058

Page 1: ...identification Serial number HT847135 Customer part number 1254058 Delivery date yyyy mm dd 2022 05 27 Weight 250 kg Operating limits according to rating plate Speed limit in test rig operation only nMmax 868 1 s Speed limit during operation nBmax 859 1 s Gas inlet temperature limit in test rig operation only tMmax 710 C Gas inlet temperature limit during operation tBmax 680 C ...

Page 2: ......

Page 3: ...e 14 2 6 Deflagration on gas engines 15 2 7 Warning plates on the turbocharger 16 2 8 Turbocharger rating plate 17 2 9 Lifting of loads 19 2 10 Prerequisites for operation and maintenance 20 2 11 Hazards during operation and maintenance 21 2 12 Safe operation 23 2 13 Safe maintenance 24 3 Removing and Installing 28 3 1 Turbocharger weight and transportation 28 3 2 Removing the turbocharger 29 3 3 ...

Page 4: ...ng the compressor casing 76 10 7 Removing the cartridge group 77 10 8 Removing nozzle ring 80 10 9 Measuring clearance A and B 81 10 10 Nozzle ring compression PD 82 10 11 Fitting the diffuser 83 10 12 Installing the cartridge group 84 10 13 Installing the nozzle ring 86 10 14 Fitting the turbine casing 87 10 15 Turning the turbocharger 88 10 16 Measuring radial clearances N and R 89 10 17 Install...

Page 5: ...of contents Copyright 2021 ABB All rights reserved HZTL4037_EN Rev G June 2021 14 Spare parts 98 14 1 Ordering spare parts 98 14 2 Required customer spare part set 97070 98 14 3 Spare part Illustrations 99 15 Tools 107 Figures 108 Tables 109 ...

Page 6: ...xplains the turbocharger and contains instructions for safe opera tion The Operation Manual is a complement to and expansion of existing national regulations for occupational safety accident prevention and environmental protection Target group The Operation Manual is aimed at engineers and trained mechanics responsible for the proper operation of the engine and for the turbocharger connected to it...

Page 7: ...his document is valid for different design variants of turbochargers There may be sections and descriptions of components that are not relevant for a specific turbocharger variant Please contact an ABB Turbocharging Service Station if you have any questions regarding a design variant see Contact information at www abb com turbocharging Accuracy of illustrations The illustrations in this document a...

Page 8: ..._EN Rev G June 2021 1 5 Layout and function of the turbocharger Fig 2 Layout and function of the turbocharger 01 Air suction branch filter silencer 07 Plain bearing bush 02 Compressor casing 08 Turbine 03 Diffuser 09 Nozzle ring 04 Bearing casing 10 Turbine casing 05 Axial thrust bearing 11 Compressor wheel 06 Gas outlet casing Page 6 109 ...

Page 9: ...f air and gas through the air suction branch 01 or the filter silencer In the compressor wheel 11 the energy required for build ing up the pressure is transferred to the air By flowing through the diffuser 03 and the compressor casing 02 the air is compressed further and is then directed to the engine cyl inders The rotor runs in a radial plain bearing bush 07 which is located in the bearing casin...

Page 10: ...andatory signs are described in chapter Safety and must be complied with Definition of Caution Warning Caution and warning signs are described in chapter Safety ABB Turbocharging ABB Switzerland Ltd Turbocharging is identified as ABB Turbocharging in this document Official service stations of ABB Turbocharging Official service stations are regularly audited and certified by ABB Turbocharging See a...

Page 11: ...ctogram Meaning Tighten with specified torque Tighten over specified tightening angle Hand tight tighten without tools Oil Apply screw locking paste e g Loctite Apply high temperature grease Apply other paste in accordance with specifications Oil free grease free and dry Affix Measure Note Visually inspect Please note text for numbered work step See document Dispose of in an environmentally compat...

Page 12: ...ARNING Health protection when handling VCI VCI products are not hazardous in terms of the Ordinance on Hazardous Substances Nevertheless the following points must be observed when handling VCI u Observe information in material safety data sheet u Ensure proper space ventilation u Do not eat drink or store food at the workplace while working with VCI u Clean hands and face after working with VCI u ...

Page 13: ...inspected by an ABB Turbocharging Service Station and repacked u Inspect the package for damage If the package is damaged the turbocharger must be in spected by an ABB Turbocharging Service Station and repacked After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station Inspect the component Replace the desiccant agent Repackage the component NOTICE 70 fi...

Page 14: ...s are a consequence of insufficient compliance with safety instructions are a consequence of insufficient or inappropriate performance of maintenance and in spection work The operating company is responsible for defining measures that regulate safe access to and safe handling of the turbocharger All instructions contained in this chapter must be observed for safe and trouble free opera tion of the...

Page 15: ...tory mask to protect against Dusts Gases Safety helmet Ear protection Table 3 Personal protective equipment to be worn specific to the respective task 2 4 Definition of safety instructions WARNING Definition of Warning Non compliance or inaccurate compliance with working or operating in structions indicated by this symbol and the word WARNING can lead to seri ous injuries to personnel and even to ...

Page 16: ...nded to be operated with a clockwise direction of rotation as viewed from the turbine end The specific operating limits of the turbocharger were determined on the basis of informa tion from the enginebuilder about the intended use These data are given on the rating plate The use of the turbocharger is limited to the specific application released at the time of de livery ABB accepts no liability an...

Page 17: ... tur bocharger or improper operation 2 6 Deflagration on gas engines ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar After a deflagration event ABB recommends verifying the following points on the turbochar ger Position of the turbine and compressor casings to the bearing casing Shifting of the bearing casing in relation to the bracket Cracks in casings I...

Page 18: ... present in the designated locations or not readable proceed as fol lows u Order new warning plates from ABB Turbocharging Service Stations u Remove any warning plates that have become unreadable u Clean and degrease the areas designated for the warning plates u Fit new warning plates and remove protective sheets Turbochargers supplied to the enginebuilder without insulation must be equipped later...

Page 19: ...interval of turbine in 1000 h If the turbocharger is used for the Peak shaving mode with frequent engine start stop cycles the number of successful engine start stop cycles must be taken into account in ad dition to the replacement intervals in operating hours for the compressor and the turbine wheels as well as the bearing check interval specified on the rating plate Further information and speci...

Page 20: ...recommend contacting the nearest ABB Turbochar ging Service Station nMmax tMmax normally apply only when running at overload 110 during trials on the engine test bed These limit values can also be permitted during operation for special applications Operation above nMmax and tMmax is not permitted Non observance of the recommended inspection and replacement intervals increases the risk of unpredict...

Page 21: ...t mechanical hazards Wear safety helmet Fig 8 Attachment of loads on the crane hook Fig 9 Attachment angle If there are two or more suspension points the attachment angle of 45 must not be ex ceeded This prevents excessive loading due to diagonal pull u Before looping around the components of the turbocharger let them cool down max imum 80 C u Attach components of the turbocharger as described in ...

Page 22: ...ration Manual must be checked periodically Suitable working materials and personal protective equipment must be kept in a perfect condition Only authorised personnel may remain in the vicinity of the turbocharger when the engine is running Competence of personnel The turbocharger must only be operated and serviced by trained and authorised personnel Basic mechanical training is a prerequisite Modi...

Page 23: ...wear ear protection u Always wear ear protection if the sound pressure level exceeds 85 dB A Wear ear protection Hazards due to hot surfaces Surfaces of the turbocharger attached parts and operating fluids lubricating oil get hot during operation The surface temperature depends on the efficacy of the existing insula tion The temperature may rise to a level that can cause burns WARNING Danger of bu...

Page 24: ...oviding protection against contact with hot surfaces u Compliance with the instructions and specifications given by the en ginebuilder to protect against hot turbocharger surfaces is compulsory Wear safety gloves to protect against thermal hazards Hazards due to rotating parts WARNING Hazards due to rotating parts Contact with rotating parts can cause severe injury The turbocharger is never allowe...

Page 25: ...nd objects littering the workplace u Check all pipes to and from the turbocharger for damage and leaks before commission ing u Check turbocharger for recognisable damage or defects every 12 hours of operation or at least once a day u Report any damage and any alterations of operational characteristics to the responsible department immediately u In case of damage take the turbocharger out of operat...

Page 26: ... operations for which you have received instruction or train ing Wear safety footwear to protect against mechanical hazard and risk of fall ing Wear protective clothing WARNING Risk of falling When working on the turbocharger there is a risk of falling u Do not climb onto the turbocharger or onto attached parts and do not use them as climbing aids u Use suitable climbing aids and working platforms...

Page 27: ...u Observe the material safety data sheet for the cleaning agent or solvent u Wear personal protective equipment PPE according to the material safety data sheet u Inspect the electric cables for abrasion and damage before and after your cleaning work Safety during disassembly assembly maintenance and repair u Observe the procedures for set up service and inspection work and the inspection inter val...

Page 28: ...ons for which you have previously received instruc tion or training Hazards due to operating materials and supplies Operating materials and supplies are substances required for the operation of the tur bocharger or for the performance of maintenance work Oils greases coolants detergents and solvents acids and similar substances can be classified as hazardous substances WARNING Handling operating m...

Page 29: ...the material safety data sheet for the operat ing materials and supplies u Comply with local legislation Hazards due to the handling of insulation materials WARNING Danger from insulation materials Dust or fibres from insulation materials can have adverse effects on the health or cause irritations Unsuitable and combustible insulation materials are a fire hazard u Only use suitable and non combust...

Page 30: ...eaviest variant possible Depending on the specification the weight specified on the rating plate may be lower than the standard value specified here Produkt Gewicht Turbolader komplett kg TPS44 120 TPS48 180 TPS52 250 Table 4 Gesamtgewicht 3 1 1 Swivel lifting eyes to be used One swivel lifting eye S is required to safely lift this turbocharger This is not included in the ABB scope of delivery Fig...

Page 31: ...k Wear safety gloves to protect against thermal hazards CAUTION Do not put the speed measurement cables under strain by pulling them If you pull the speed measurement cables too hard contacts can be pulled out u Do not strain the speed measurement cables by pulling NOTICE Gas outlet casing 61001 The gas outlet casing 61001 can remain fitted in the exhaust gas pipe if the locking to the turbine cas...

Page 32: ... 4 Install the swivel lifting eye S and attach the lifting gear to it 5 Lift the turbocharger away from the support vertically The bracket turbocharger con nection may be in the form of a pin with the TPS52 H 6 Cover the oil supply and oil drain on the engine side bracket and the connections on the turbocharger Version with water cooling CAUTION Freezing of the cooling water in the bearing casing ...

Page 33: ... sealing is provided by O rings The O rings are not included in the ABB scope of delivery Fig 12 Inserting gaskets into the bracket 01 Bracket 04 Slot for O ring 02 Oil supply 05 O rings 03 Oil drain 06 Pin optional Pin 06 as installation safety device Turbochargers can have an oil inlet either on their right or left side the oil inlet position can be different for the turbocharger fitted on the l...

Page 34: ...emove nuts 01 again Requirements for the threaded rods 02 Fig 14 Requirements for threaded rods Product Diameter Threaded rod mm Material DIN ISO 898 Part 1 Thread length L1 mm Length of threaded rod L2 mm TPS44 Ø 16 M16 10 9 12 9 30 150 TPS48 Ø 16 M16 10 9 12 9 30 170 TPS52 Ø 20 M20 10 9 12 9 30 195 Table 6 Requirements for threaded rods Fastening material scope of delivery The threaded rods and ...

Page 35: ... the gaskets are not damaged and are positioned correctly in the slots 3 Install the swivel lifting eye S and attach the lifting gear to it 4 Align the turbocharger over the threaded rods of the bracket 5 Place the turbocharger on the bracket If present Pay attention to the correct position of the pin in the bracket 6 Lightly oil the hexagon nuts 7 Fit the hexagon nuts Observe tightening torque 8 ...

Page 36: ...cations regarding the selection of lubricating oil and the oil change intervals 4 1 2 Pre lubrication Pre lubrication must be carried out as follows u Switch on the oil pump u Build up oil pressure u Do not exceed a pre lubrication time of 2 minutes u Start the engine u Let the oil pump run until the pump driven by the engine generates sufficient pressure 4 1 3 Oil filtering Filtering the lubricat...

Page 37: ...system CAUTION Contaminated oil Serious damage to engine or property can be caused by dirt and solid ma terial particles in the oil u For the initial commissioning phase and after all service work flush the complete lubricating system with warm oil u Use special running in filters when running in the engine and after all ser vice work on the lubricating system u Check that the oil filter is clean ...

Page 38: ...k of burning from hot gas Escaping gases are hot and will lead to serious burns in the event of contact u Check all pipes for leaks in accordance with the enginebuilder s instruc tions Wear safety gloves to protect against thermal hazards 4 2 4 Checks when starting up the engine If present u Measure speed oil pressure and charging pressure at various engine performances u Measure the exhaust gas t...

Page 39: ...cking screws on the water connections and fit the water pipe General u Check the exhaust gas pipe before and after the turbine for combustion residues or wa ter residues and clean it Remove any foreign objects that may be present u Check and clean filter silencer or air supply line and remove any foreign objects that may be present u Put engine side oil circulation to the turbocharger into operati...

Page 40: ...r operation Pressure at oil inlet upstream of the turbocharger bar Overpressure Normal operation 2 0 poil 4 5 Engine start Cold oil admissible for a maximum of 15 minutes 8 0 Engine idling admissible for a maximum of 1 hour 0 5 poil 2 5 Pre lubrication and post lubrication engine stopped 0 5 poil 1 0 Warning signal n 0 5 x nBmax 1 25 Alarm signal Not admissible Stop the engine immedi ately 0 5 Tab...

Page 41: ...ght 2021 ABB All rights reserved HZTL4037_EN Rev G June 2021 If the drain pipe is vented the lubricating oil temperature measuring point can be installed at the outlet in the vent tank Otherwise the measurement should be taken in the drain pipe as close to the turbocharger as possible Page 39 109 ...

Page 42: ... the outlet The oil temperature at the outlet is mainly dependant on Lubricating oil temperature and pressure at the oil inlet Engine load and turbocharger speed Exhaust gas temperature The maximum admissible oil temperature at the outlet is listed in the following table The specified oil outlet temperature is to be considered as alarm value for the turbocharger op eration and must be monitored ac...

Page 43: ...ntroduction A speed measuring system enables the constant monitoring of the turbocharger speed CAUTION Do not put the speed measurement cables under strain by pulling them If you pull the speed measurement cables too hard contacts can be pulled out u Do not strain the speed measurement cables by pulling CAUTION Machine damage Operation above the operating limits defined on the rating plate can sho...

Page 44: ...EN Rev G June 2021 5 3 2 Layout and overview Fig 16 Layout and overview of the speed measurement system 86505 Speed sensor 42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F I converter 01 Plug with integrated voltage limiter 86528 Tachometer Alternative mounting position for speed sensor 32109 Sealing disc Page 42 109 ...

Page 45: ...it can continue to be driven at this reduced engine load or turbocharger speed u If a turbocharger surges continuously the engine performance must be reduced further u Measure the temperatures in the air lines and gas piping from and to the turbochargers and compare with normal values If clear deviations of temperature are found the nearest ABB Turbocharging Service Station has to be contacted u C...

Page 46: ...ing No additional gasket is required during assembly Fig 17 Fitting the speed sensor Part number TPS44 TPS48 TPS52 86505 M12 x 1 5 15 Nm M12 x 1 5 15 Nm M12 x 1 5 15 Nm Table 11 Tightening torque 86505 u Reduce the engine performance to idling and then stop the engine Pay attention to post lubrication Stopping the engine 52 u Switch off the lubricating oil supply to the turbocharger u Disconnect c...

Page 47: ...of 1 meter from the turbocharger The highest value of the emission sound pressure level1 reaches a maximum of 105 dB A near the air inlet The following prerequisites must be fulfilled with regard to the turbochar ger to observe this limit value Air inlet system has been fitted All standard noise reducing measures2 have been fitted Bellows at the air outlet has been acoustically insulated by the en...

Page 48: ...2021 ABB All rights reserved HZTL4037_EN Rev G June 2021 Suggestion for noise insulation bellows Fig 18 Noise insulation bellows 01 Compressor casing 02 Bellows 03 Charge air duct scavenging air duct 04 Insulation cushion 05 Insulation mat at least 15 mm 06 Sheet metal cover Page 46 109 ...

Page 49: ...ed or performed too late can cause excessive contamination wear and operating failures u Carry out the service work at the specified time intervals CAUTION Specific service interval Exceptional stresses such as a high number of starts and stops harsh envir onmental conditions poor fuel quality or high system vibrations can lead to untimely machine damage even if the prescribed service intervals ar...

Page 50: ...of the enginebuilder Performance and speed of the engine Air intake temperature Charging pressure Pressure loss in the charge air cooler Lubricating oil pressure and lubricating oil temperature If present Speed of the turbocharger Air temperature after the compressor and after the charge air cooler Exhaust gas temperature before and after the turbine Pressure loss in the filter silencer u In case ...

Page 51: ...ry fast and are very sens itive to unbalance The rotor and bearing parts must be checked and assessed by an ABB Turbocharging Service Station The following work can be carried out as preparation u Remove turbocharger from engine see chapter Removing and Installing 28 u Dismantle the turbocharger and measure the clearances see chapter Dismantling and fit ting 70 u Mechanically clean the nozzle ring...

Page 52: ...ne start stop cycles or after reaching the number of operating hours specified on the rating plate Non rotating components Depending on the system specific operating conditions a differentiation must be made between the intervals to be expected for replacing the bearing parts and replacing the non rotating components exposed to hot gas A decisive role is played by various influencing parameters wh...

Page 53: ...ine wheels are spe cified with the aid of the safety concept for rotating parts SIKO and dependent on the operating conditions Influencing parameters The specified values are guideline values and are not guaranteed The actual values can devi ate significantly from the guideline values for example due to the following influences Fuel quality and fuel treatment Load profile thermal cycling also numb...

Page 54: ...orming post lubrication 0 5 poil 1 0 u Switch off post lubrication as soon as the rotor is stationary or after no more than two minutes Deviating procedures must be coordinated with ABB Turbocharging CAUTION Water cooling after stopping the engine If the heat in the turbocharger is not dissipated after the engine stops dam age may result u Allow the water cooling of the turbocharger to continue op...

Page 55: ...f mechanical cleaning is carried out incorrectly this can lead to damage and corrosion on the components u Pay attention to the specifications in this chapter pertaining to mechan ical cleaning CAUTION Selection of cleaning tools Turbocharger components are sensitive and easily sustain mechanical dam age The use of needle descalers for example or other striking tools dam ages the components Depend...

Page 56: ...after the fifth cleaning process at the latest Contamination of the filter ring depends on the degree of purity of the sucked in air u Rinse the filter ring 81265 with water and mild detergent or in the case of heavy con tamination soak and carefully push through Rinse in cold water Avoid high mechanical loads water jet u Let the filter ring dry completely before assembling u Dirty water and mild ...

Page 57: ...taminated absorption segments replaced by an ABB Turbocharging Service Station Fitting the filter silencer see Fig 19 Cleaning the filter silencer 54 u Insert the absorption segments 81136 into the sheet metal coverings 81137 u Bend the sheet metal coverings 81137 back to their original shape and insert into the slotted guides in the filter silencer body 81135 u Fit the cover grid 81266 u Fit the ...

Page 58: ...o 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 parts which are relevant in terms of performance can be cleaned in accord ance with the description below Fig 20 Cleaning the compressor casing diffuser mechanically 72000 Compressor casing 79000 D...

Page 59: ...cal legislation Wear safety goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mask to protect against gases Baked layers of contamination for example from heavy fuel oil or coked oil occur at the tur bine end The following parts which are relevant in terms of performance can be cleaned in accordance with the description below Fig 21 Cleaning the nozzle ring turbine ...

Page 60: ...e cartridge group see chapter Dismantling and fitting 70 First clean the compressor end and then the turbine end according to the following descrip tion 8 2 6 Cleaning the cartridge group on compressor end CAUTION Selection of the cleaning agent Cleaning agents that contain chlorine corrode metals u Only use pH neutral cleaning agents that do not corrode metals u Observe the material safety data s...

Page 61: ...dge group on turbine end Soaking the contamination Baked layers of contamination from fuel residue or coked oil may occur at the turbine end The contamination can be removed by soaking and brushing The procedure for soaking the layers of contamination as well as for cleaning the turbine are described in the following Fig 22 Soaking contamination of the turbine Product A mm B mm C mm TPS44 115 20 1...

Page 62: ...0 ºC WARNING Heating up of cleaning agents and operating fluids When cleaning agents or operating fluids are heated up explosive vapours can be produced which are hazardous to health u Observe the information in the material safety data sheet Wear a respiratory mask according to material safety data sheet CAUTION Water and contamination in the cartridge group If water or contamination penetrates t...

Page 63: ...r and contamination in the cartridge group If water or contamination penetrates the cartridge group this can impair the function of the turbocharger and damage parts inside the cartridge group u Make sure that no water or dirt enters the gap between the heat sheet metal and the turbine CAUTION Non permissible rotor unbalance after cleaning Unevenly distributed residual contamination deposits lead ...

Page 64: ...yright 2021 ABB All rights reserved HZTL4037_EN Rev G June 2021 u Lightly spray the turbine and the gap between the turbine and the heat sheet metal with penetrating oil u Dispose of contaminated water and cleaning agents in accordance with the information in the material safety data sheet Page 62 109 ...

Page 65: ...g Service Station Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Contact enginebuilder Table 16 Malfunctions when starting Vibrations Rotating parts rubbing Normal behaviour not a malfunction Turbochar ger A minimal and uniform wear on the circumference of the rotor components is permitted This wear can be caused by slight local rubbing against adjacent com ponents Thi...

Page 66: ...Oil filter heavily contaminated Clean Oil pump in lubricating system defect ive Check replace Manometer displays incorrectly Replace manometer Table 18 Malfunctions during operation Lubricating oil pressure too low Speed reduces Possible causes Remedy Turbochar ger Turbine and or nozzle ring severely con taminated Clean see chapter Periodic mainten ance work 53 Rotor components or bearing damaged ...

Page 67: ... high Check clean cooling system Insufficient ventilation Improve ventilation Table 21 Malfunctions during operation Exhaust gas temperature too high Charge air pressure too low Engine performance and engine speed unchanged suction condition normal Possible causes Remedy Turbochar ger Manometer display not correct Replace manometer Supply pipe to manometer not sealed Repair leak Filter silencer co...

Page 68: ...taminated or corroded compressor wheel can reduce the com pressor wheel s fatigue endurance limit and result in the turbocharger being damaged u Rectify malfunction in accordance with the following table Possible causes Remedy Turbochar ger Compressor components severely con taminated by the ventilation gases that have been fed in Clean see chapter Periodic mainten ance work 53 Optimize oil separa...

Page 69: ...nd remedied immediately by an ABB Turbochar ging Service Station u Have parts assessed for damage and if necessary replaced by an ABB Turbocharging Service Station Possible causes Remedy Turbocharger Filter silencer or diffuser contamin ated Clean see chapter Periodic mainten ance work 53 Heavy contamination deposits in the turbine or in the nozzle ring Engine Protective grating in front of the tu...

Page 70: ...ctions when stopping Runout noises Runout time too short The runout time must be noted down as a reference Because the runout time depends on the oil viscosity the runout time must always be measured at the same oil temperature If the runout time is significantly shorter in comparison to a previous measurement the fol lowing table must be observed Possible causes Remedy Turbochar ger Turbocharger ...

Page 71: ...rging Service Station Replacing the speed sensor 44 Table 29 Malfunction of the speed measurement system No signal or poor signal amplitude Measured speed too high Possible causes Remedy Turbochar ger Sensor tip contaminated since it is magnetic and can attract metallic particles This reduces the distance to the signal emitting sealing disc which can lead to ampli fication of the noise com ponent ...

Page 72: ...hing u Wait for the turbocharger to cool down before carrying out any work Wear safety gloves to protect against thermal hazards WARNING Cutting injuries when working on the turbocharger Some parts on the turbocharger may have sharp edges There is a risk of a cutting injury u Wear safety gloves against mechanical risks when conducting assembly and disassembly work Wear safety gloves to protect aga...

Page 73: ... is enclosed with the tool set WARNING Servicing the tools The tools must be checked for damage before and after use u Visually inspect for corrosion cracks deformation and wear u Damaged tools must no longer be used and must be replaced Swivel lifting eyes One swivel lifting eye S is required to safely lift this turbocharger This is not included in the ABB scope of delivery Fig 23 Swivel lifting ...

Page 74: ...ttention to the correct attachment of loads on the crane hook u People must not stand beneath suspended loads Wear safety gloves to protect against mechanical hazards Wear safety helmet Definition of terms Suspension point Defined loading point on a component or an assembly blind hole thread eyelet lug Assembly device Devices that are fitted on the turbocharger in order to obtain a suspension poin...

Page 75: ...individual parts or assemblies are rounded up standard values Fig 25 Overview of assemblies Designation TPS44 TPS48 TPS52 01 Radial air suction branch 5 6 8 02 Axial air suction branch 3 4 4 03 Filter silencer 15 04 Compressor casing 17 30 45 05 Diffuser 2 3 4 06 Cartridge group 24 40 65 07 Nozzle ring 1 2 3 08 Turbine casing 1 inlet 30 45 70 09 Gas outlet casing 16 18 25 Table 34 Weights of the a...

Page 76: ...t 2021 ABB All rights reserved HZTL4037_EN Rev G June 2021 10 4 Removing the gas outlet casing u Mark the casing position for assembly Fig 26 Removing the gas outlet casing 1 Manually secure the gas outlet casing 61001 2 Loosen and remove hexagon nuts 51009 3 Remove the gas outlet casing 61001 Page 74 109 ...

Page 77: ...emoving air inlets u Mark the casing position for assembly Fig 27 Removing air inlets 1 Manually secure the filter silencer 81000 or air suction branch 82000 2 Loosen and remove V clamp 72020 3 Remove the filter silencer 81000 or air suction branch 82000 4 Remove and dispose of O ring 81010 82010 refer to Disposing of turbocharger com ponents 97 Page 75 109 ...

Page 78: ... soft underlay 2 Loosen the hexagon head screws 72011 and remove them with fastening strips 72012 Fig 29 Removing the compressor casing 2 2 1 Secure lifting gear to compressor casing 72000 2 Remove the compressor casing 72000 vertically 3 Rotate the compressor casing 72000 through 180 and put it in place 4 Remove and dispose of O ring 42012 see chapter Disposing of turbocharger compon ents 97 5 Re...

Page 79: ...at the oil inlet of the bearing casing if the oil inlet pressure is 3 bar overpressure If an oil orifice is fitted in the oil inlet of the bearing casing it must not be removed Do not loosen screw plugs CAUTION Oil leaks These screw plugs must not be removed for maintenance work If a screw plug is loosened the gasket can be damaged This can result in an oil leak u Do not loosen screw plugs u If an...

Page 80: ...s Ripp washers 51003 and fastening strips 51002 3 Screw in the swivel lifting eye S up to the stop Removing the cartridge group Fig 33 Removing cartridge group 2 1 Insert screws from service support into cartridge group 2 Secure ring nuts VRM onto the screws with washers 3 Secure the lifting gear to the ring nuts and swivel lifting eye as shown 4 Remove the cartridge group vertically from the turb...

Page 81: ...he cartridge group and fitting the service support 1 Lift the cartridge group and rotate in the horizontal position 2 Remove the lifting gear from the ring nuts 3 Remove the ring nuts VRM and screws from the service support 4 Place the cartridge group onto the fitted service support 90012 5 Fit and hand tighten nuts u Measure Axial clearance A and radial clearance B Page 79 109 ...

Page 82: ...fitting 10 8 Removing nozzle ring Copyright 2021 ABB All rights reserved HZTL4037_EN Rev G June 2021 10 8 Removing nozzle ring Fig 35 Removing the nozzle ring 1 Remove the nozzle ring 56001 vertically 2 Remove the lamellar sealing ring 56005 Page 80 109 ...

Page 83: ... 0 98 1 68 Table 35 Permissible clearances A and B 1 Move the rotor to and fro up to the stop In order to obtain a correct measurement elev ate the turbine a little 2 Measure clearance A and compare it with the permissible values in the table 3 Raise the compressor and push the turbine down at the same time 4 Raise the turbine and push the compressor down at the same time 5 Measure clearance B and...

Page 84: ... the turbine casing 51000 Fig 37 Measuring nozzle ring compression 42001 Bearing casing 51000 Turbine casing 56001 Nozzle ring 1 Measure dimensions A B and C on cleaned surfaces 2 Calculate the compression PD and compare it with the permissible values in the follow ing table u If the calculated value PD lies outside the specified range contact an ABB Turbochar ging Service Station Product Compress...

Page 85: ... 10 11 Fitting the diffuser Fig 38 Fitting the diffuser Product Size Tightening torque Nm TPS44 M5 5 Nm TPS48 M5 5 Nm TPS52 M6 10 Nm Table 37 Tightening torque 72041 1 Position the diffuser 79000 in the compressor casing 72000 2 Rotate the diffuser until its bore is aligned with the bore in the compressor casing 3 Fit and tighten screw 72041 Page 83 109 ...

Page 86: ...0 1 Fit a new high temperature resisting O ring 42012 red or green see Customer spare part set 97070 98 2 Loosen and remove nuts 3 Lift the cartridge group out of the service support 90012 4 Insert the screws of the service support from above and fit ring nuts VRM with washers 5 Attach lifting gear to the ring nuts VRM 6 Lift cartridge group at the side of the ring nuts VRM and turn it into a vert...

Page 87: ... Fitting the cartridge group Product Size Tightening torque Nm TPS44 M8 40 Nm TPS48 M8 40 Nm TPS52 M10 80 Nm Table 38 Tightening torque 72011 1 Lower cartridge group carefully into the compressor casing 2 Align cartridge group to the marking 3 Place first fastening strip 72012 according to illustration 4 Place remaining fastening strips 72012 5 Fit and tighten hexagon head screws 72011 Page 85 109...

Page 88: ...Installing the nozzle ring Fig 41 Installing the nozzle ring 1 Fit lamellar sealing ring 56005 in the slot of the nozzle ring When doing this pay atten tion to correct winding of the lamellar sealing ring see detail A 2 Secure the lamellar sealing ring 56005 with adhesive tape 3 Installing the nozzle ring Ensure correct position according to illustration Page 86 109 ...

Page 89: ...0 Nm TPS52 M10 60 Nm Table 39 Tightening torque 51007 1 Coat thread of studs 51006 with high temperature grease 2 Fit two swivel lifting eyes 01 on the turbine casing 51000 Secure lifting gear to the swivel lifting eyes 3 Turn the turbine casing 51000 by 180 4 If present Fit the metal C ring 51105 5 Align turbine casing with marking and position on cartridge group 6 Fit fastening strips 51002 with...

Page 90: ...HZTL4037_EN Rev G June 2021 10 15 Turning the turbocharger Fig 43 Rotating the turbocharger 1 Fit swivel lifting eye S 2 Insert screws from the service support 3 Fit ring nuts VRM 4 Attach lifting gear 5 Elevate and rotate the turbocharger 6 Place the turbocharger on a soft underlay u Measure Radial clearances N and R Page 88 109 ...

Page 91: ...ap without clearance and measure simultaneously at the top N1 and the bottom N2 2 Calculate clearance N and compare it with the permissible values in the table 3 Push the feeler gauges 01 into the gap without clearance and measure simultaneously at the top R2 and the bottom R1 4 Calculate clearance R and compare it with the permissible values in the table CAUTION Clearances outside the tolerance S...

Page 92: ...ing Product Size Tightening torque Nm TPS44 M8 25 Nm TPS48 M8 25 Nm TPS52 M10 50 Nm Table 41 Tightening torque 51008 1 Coat thread of studs 51008 with high temperature grease 2 Align the casing position of the gas outlet casing 61001 to the marking 3 Position the gas outlet casing and fit with two hexagon nuts 51009 in the upper area 4 Fit the remaining hexagon nuts 51009 then tighten all the scre...

Page 93: ...TPS44 M10 30 Nm TPS48 M10 30 Nm TPS52 M10 30 Nm Table 42 Tightening torque 72020 1 Fit the new O ring 81010 82010 to the filter silencer 81000 or the air suction branch 82000 2 Manually position the filter silencer 81000 or the air suction branch 82000 on the com pressor casing 72000 3 Fit the V clamp 72020 4 Align the casing position of the filter silencer 81000 or the air suction branch 82000 to...

Page 94: ...2020 M10 30 Nm M10 30 Nm M10 30 Nm 04 72041 M5 5 Nm M5 5 Nm M6 10 Nm 05 72011 M8 40 Nm M8 40 Nm M10 80 Nm 06 42188 M12 x 1 5 35 Nm M12 x 1 5 35 Nm M12 x 1 5 35 Nm 07 51007 M8 30 Nm M8 30 Nm M10 60 Nm 08 51006 M8 25 Nm M8 25 Nm M10 45 Nm 09a 09b 51008 51009 M8 25 Nm M8 25 Nm M10 50 Nm 10 61005 M18 x 1 5 60 Nm M18 x 1 5 60 Nm M18 x 1 5 60 Nm 11 86505 M12 x 1 5 15 Nm M12 x 1 5 15 Nm M12 x 1 5 15 Nm 1...

Page 95: ...gainst thermal hazards CAUTION Directives for taking out of operation Serious damage to engine or property can be caused by non compliance with the directives for blanking the turbocharger off the engine u Follow the directives of the enginebuilder To enable you to quickly put an engine back into operation after a turbocharger has sus tained damage ABB Turbocharging recommends having a replacement...

Page 96: ... corrosion Preparations for mothballing WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or con tact with them may be harmful to health u Do not breathe in these substances and avoid contact with the skin u Ensure proper ventilation u Observe the information in the material safety data sheet for the operat ing materials and suppli...

Page 97: ...or and bearing parts are dismantled by an ABB Turbocharging Service Station and stored separately The turbocharger is completely removed either as a whole unit or in individual parts For the measures always necessary for preparing the turbocharger parts for mothballing see section Taking the engine out of operation for up to 12 months subsection Preparations for mothballing If the turbocharger rem...

Page 98: ...f the presence of such substance s with sufficient information available to the supplier RoHS2 Directive 2011 65 EC in English only The EU Directive 2011 65 EC recast restricts the use of certain hazardous substances in electrical and electronic equipment RoHS2 Products and related accessories manufac tured by ABB Switzerland Ltd Turbocharging do not fall within the Scope of RoHS2 due to their app...

Page 99: ...ar a respiratory mask to protect against dusts Wear safety gloves to protect against mechanical hazards Disposal must be environmentally compatible professional and in compliance with locally applicable regulations The turbocharger consists largely of metal cast iron materials steel nickel steel alloys alu minium and bearing brass Further components are Non metallic materials filter components of ...

Page 100: ...rvice Station u If different model variants are not taken into account in this document contact an ABB Turbocharging Service Station u Dispose of placed and unusable parts in an environmentally friendly and professional manner in accordance with the local regulations u Dispose of the packaging of new parts in an environmentally friendly and professional manner in accordance with the local regulati...

Page 101: ...in English Cartridge 42196 42188 p 42189 p 42183 p 98105 10900 42183 p 42182 p 98100 42184 p 42012 Available within the spare part set HZTL443461 Mod A p pre assembled Part no Designation 10900 Cartridge 42012 O ring 42182 p Screw plug 42183 p Gasket 42184 p Screw plug 42188 p Hexagon head screw 42189 p Gasket 42196 Orifice oil inlet 98100 Rating plate 98105 Round head threaded rivet Table 45 Spar...

Page 102: ...1002 51003 51007 Available within the spare part set HZTL443413 Mod B p pre assembled if provided Part no Designation 51000 Turbine casing 51002 Fastening strip 51003 Verbusripp washer 51006 Stud 51007 Hexagon nut 51008 Stud 51008 Hexagon head screw 51009 Hexagon nut 51027 p Screw plug 51105 Metal C ring 52406 Gasket 55653 Gasketring 56001 Nozzle ring 56005 Lamellar sealing ring Table 46 Spare par...

Page 103: ...72011 72041 79000 72005 p 72006 p 72000 72080 72020 Available within the spare part set HZTL443414 Mod B p pre assembled Part no Designation 72000 Compressor casing 72005 p Screw plug 72006 p Gasket 72011 Hexagon head screw 72012 Fastening strip 72020 V clamp 72041 Counter sunk screw 72080 Warning plate 79000 Diffuser Table 47 Spare parts Compressor casing Page 101 109 ...

Page 104: ...1170 p 81266 81271 81270 Available within the spare part set HZTL443011 Mod F p pre assembled if provided Part no Designation 81000 Filter silencer complete 81005 p Screw plugt 81006 p Gasket 81010 O ring 81135 Silencer body 81136 Absorption sgment 81137 Sheet metal covering 81170 p Screw plug 81171 p Gasket 81265 Filter ring 81266 Cover grid 81270 Tension band 81271 Lock Table 48 Spare parts Filt...

Page 105: ...G June 2021 Air suction branch radial 82010 82005 p 82006 p 82000 82008 p 82007 p Available within the spare part set HZTL443416 Mod A p pre assembled Part no Designation 82000 Air sucton branch 82005 p Screw plug 82006 p Gasket 82007 p Screw plug 82008 p Gasket 82010 O ring Table 49 Spare parts Air suction branch radial Page 103 109 ...

Page 106: ... G June 2021 Air suction branch axial 82005 p 82007 p 82008 p 82006 p 82010 82000 Available within the spare part set HZTL443418 Mod A p pre assembled Part no Designation 82000 Air suction branch 82005 p Screw plug 82006 p Gasket 82007 p Screw plug 82008 p Gasket 82010 O ring Table 50 Spare parts Air suction brach axial Page 104 109 ...

Page 107: ...rt Illustrations Copyright 2021 ABB All rights reserved HZTL4037_EN Rev G June 2021 Gas outlet casing 61005 p 61001 HZTL443417 Mod B p pre assembled Part no Designation 61001 Gas outlet casing 61005 p Screw plug Table 51 Spare parts Gas outlet casing Page 105 109 ...

Page 108: ...2021 ABB All rights reserved HZTL4037_EN Rev G June 2021 Speed measurement system 86526 86528 86505 86515 HZTL443419 Mod if provided Part no Designation 86505 Speed sensor 86515 Cable connector 86526 F I converter 86528 Tachometer Table 52 Spare parts Speed measurement system Page 106 109 ...

Page 109: ...l is required for the work described in the Operation Manual Part number Designation Quantity 90012 Service support 1 Table 53 TPS H Tool This tool can be ordered from any ABB Turbocharging Service Station The following spe cifications must be included in the order Turbocharger type Part number and designation of the tool Page 107 109 ...

Page 110: ...ing diffuser mechanically 56 Fig 21 Cleaning the nozzle ring turbine casing mechanically 57 Fig 22 Soaking contamination of the turbine 59 Fig 23 Swivel lifting eyes 71 Fig 24 Ring nuts 72 Fig 25 Overview of assemblies 73 Fig 26 Removing the gas outlet casing 74 Fig 27 Removing air inlets 75 Fig 28 Removing the compressor casing 1 2 76 Fig 29 Removing the compressor casing 2 2 76 Fig 30 77 Fig 31 ...

Page 111: ...le 23 Malfunctions during operation Charge air pressure too high 66 Table 24 Malfunctions during operation Engine performance losses 66 Table 25 Malfunction Turbocharger pumping 67 Table 26 Malfunction Sporadic surge blows 67 Table 27 Malfunctions when stopping Runout noises 68 Table 28 Malfunctions when stopping Runout time too short 68 Table 29 Malfunction of the speed measurement system No sign...

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