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Operation Manual / 4 Product description / TPS44-H.. - TPS52-H..

5 Operation and service / 5.2 Service work

© Copyright 2017 ABB. All rights reserved.

HZTL4037_EN

Revision E

July 2017

5.2.4

Service work according to data on the rating plate

WARNING

Incorrect handling of a cartridge group

Incorrect handling of a cartridge group can damage the turbocharger and
cause injuries to persons.

u

Have disassembly and assembly of the cartridge group carried out by an
ABB Turbocharging Service Station only.

NOTICE

Specialist knowledge of an ABB Turbocharging Service Station

Assembly and disassembly of the cartridge group and assessment of the ro-
tor and bearing parts requires the specialist knowledge of an ABB Tur-
bocharging Service Station. The rotor parts turn very 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

u

Dismantle the turbocharger and measure the clearances (see chapter

Dismantling and fit-

u

Mechanically clean the nozzle ring, the turbine casing and compressor casing (see chapter

Periodic maintenance work

).

u

Check the nozzle ring, turbine casing and compressor casing for cracks and erosion/cor-
rosion.

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Summary of Contents for HT588230

Page 1: ...arging Operation Manual TPS44 H32 HT588230 English Original Operation Manual Chapter Document ID 1 Introduction HZTL4005_EN_F 2 Safety HZTL4026_EN_D 3 Safety data sheet HT588230 4 Product description HZTL4037_EN_E ...

Page 2: ...als and the corresponding operating limits in chapter 3 are jointly defined with the enginebuilder This information is specific to the product Non observance of the recommended replacement intervals and the operating limits increases the risk of unpre dictable component failures ...

Page 3: ... contents Copyright 2017 ABB All rights reserved HZTL4005_EN Revision F May 2017 Introduction 1 Introduction 2 1 1 Purpose of the manual 2 1 2 Symbols definitions 3 1 3 Storage of new turbochargers and spare parts 5 1 4 Contact information 7 ...

Page 4: ...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 i...

Page 5: ...n 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 complied with Definition of Caution Warning Caution and warning signs are described in chapter Safety ABB Turbo Systems ABB Turbo Systems Ltd is identified as ABB Turbo Systems in this document Official service stations of ABB Turbo Systems Offici...

Page 6: ...Meaning Pictogram Meaning Tighten with specified torque Affix Tighten over specified tighten ing angle Measure Hand tight tighten without tools Note Oil Visually inspect Apply screw locking paste e g Loctite Please note text for numbered work step Apply high temperature grease See document Apply other paste in accord ance with specifications Dispose of in an environmentally compatible professional...

Page 7: ...ous in terms of the Ordinance on Hazardous Substances Nevertheless the following points must be observed when handling VCI u Observe information in material safety data sheet u Ensure proper space ventilation u Do not eat drink or store food at the workplace while working with VCI u Clean hands and face after working with VCI u For more information see www branopac com Wear safety gloves to protec...

Page 8: ... repackaged by an ABB Turbocharging Service Station u Check the package for damage If the package is damaged the turbocharger or cartridge group must be checked and repackaged by an ABB Turbocharging Service Station After every 3 years the following steps must be carried out by an ABB Turbocharging Service Station Checking the component Replacing the desiccant Repackaging the component NOTICE Repl...

Page 9: ...ights reserved HZTL4005_EN Revision F May 2017 1 4 Contact information Contact information for the ABB Turbocharging Service Stations is available online u Scan the QR code to access our website ABB Turbo Systems Ltd Bruggerstrasse 71a CH 5401 Baden Switzerland www abb com turbocharging Page 7 7 ...

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Page 11: ...ndatory signs 3 1 4 Definition of safety instructions 3 1 5 Intended use 4 1 6 Deflagration on gas engines 5 1 7 Warning plates on the turbocharger 6 1 8 Turbocharger rating plate 7 1 9 Periodic check of the pressure vessels 8 1 10 Lifting of loads 9 1 11 Prerequisites for operation and maintenance 10 1 12 Hazards during operation and maintenance 11 1 13 Safe operation 13 1 14 Safe maintenance 14 ...

Page 12: ...of insufficient compliance with safety instructions Are a consequence of insufficient or inappropriate performance of maintenance and in spection work The operating company is responsible for defining measures that regulate safe access to and safe handling of the turbocharger All instructions contained in this chapter must be observed for safe and trouble free opera tion of the turbocharger and du...

Page 13: ...ask to protect against Dusts Gases Safety helmet Ear protection Table 2 Personal protective equipment to be worn specific to the respective task 1 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 fatal ...

Page 14: ...e required for operation The turbocharger is solely intended to be operated with a clockwise direction of rotation as viewed from the turbine end The specific operating limits of the turbocharger were determined on the basis of informa tion from the enginebuilder about the intended use These data are given on the rating plate ABB accepts no liability and rejects all warranty claims for any non int...

Page 15: ... bocharger or improper operation 1 6 Deflagration on gas engines ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar After a deflagration event ABB Turbo Systems recommends verifying the following points on the turbocharger Position of the turbine and compressor casings to the bearing casing Shifting of the bearing casing in relation to the bracket Cracks in ...

Page 16: ...t always be present in the intended locations and must be legible Fig 1 Warning plate If warning plates are not present in the intended locations or are not legible they must be replaced with new warning plates The necessary information can be found in the Operation Manual Chapter 4 Product description Turbochargers supplied to the enginebuilder without insulation must be equipped later with warni...

Page 17: ...reed with the en ginebuilder 02 Turbocharger operating limits during operation Recommended inspection and replacement intervals of turbocharger components 03 Inspection interval of plain bearings in 1000 h 04 Replacement interval of compressor in 1000 h 05 Replacement interval of turbine in 1000 h Further data 06 Customer part number 07 Designation for special design 08 Weight of turbocharger in k...

Page 18: ...ove nMmax and tMmax is not permitted Non observance of the recommended inspection and replacement intervals increases the risk of unpredictable component failures Locations of the rating plates The locations of the rating plates are defined in the Operation Manual Chapter 4 Product description 1 9 Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging such as those f...

Page 19: ...inst mechanical hazards Wear safety helmet Fig 3 Attachment of loads on the crane hook Fig 4 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 ...

Page 20: ...cked 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 Modifications to the turbocha...

Page 21: ...unning always wear ear protection u Always wear ear protection if the sound pressure level exceeds 85 dB A Wear ear protection Hazards due to hot surfaces Surfaces of the turbocharger attached parts and operating fluids lubricating oil get 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 WARNIN...

Page 22: ...es to protect against thermal hazards Hazards due to rotating parts WARNING Physical hazards Contact with rotating parts can cause severe injury The turbocharger must never be used without the filter silencer or the air suction branch With the engine stopped the rotor can rotate due to the stack draught alone u Operate the turbocharger in compliance with the specifications u Secure the rotor again...

Page 23: ... installations u Do not carry out any tests with regard to insulation resistance or voltage on the electrical components 1 13 Safe operation Mechanical hazards during operation During standard operation no mechanical hazards are caused by the turbocharger itself if it has been properly installed Safety during commissioning and operation u Visually inspect your working environment before starting w...

Page 24: ...ve 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 for work above body height ...

Page 25: ...during disassembly assembly maintenance and repair u Observe the procedures for set up service and inspection work and the inspection inter vals u Inform the operating staff before starting any service or repair work Make sure the en gine is not started while work is being conducted on the turbocharger u Before taking off any cover or removing any guard from the turbocharger switch off the engine ...

Page 26: ... 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 materials and supplies ...

Page 27: ...n 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 combu...

Page 28: ......

Page 29: ...tion Manual TPS44 H32 Safety data sheet Page 1 1 Safety data sheet Copyright 2019 ABB All rights reserved HT588230 May 2019 TPS44 H32 HT588230 TPS44 H32 HT588230 1232 680 1207 650 12501588 120 16 60 60 2019 ...

Page 30: ......

Page 31: ...ger 10 3 Commissioning 13 3 1 Oil supply 13 3 2 Inspection procedures 14 3 3 Commissioning after taking out of operation 16 4 Monitoring operation 17 4 1 Oil pressure oil temperature 17 4 2 Exhaust gas temperature before turbine 19 4 3 Turbocharger speed 19 5 Operation and service 23 5 1 Noise emission 23 5 2 Service work 25 5 3 Expected replacement intervals 28 6 Stopping the engine 29 7 Periodic...

Page 32: ...user 61 9 11 Installing the cartridge group 62 9 12 Installing nozzle ring 64 9 13 Fitting the turbine casing 65 9 14 Rotating the turbocharger 66 9 15 Radial clearances N and R 67 9 16 Installing the gas outlet casing 68 9 17 Installing air inlets 69 9 18 Table of tightening torques 70 10 Taking out of operation at short notice 71 10 1 Possible emergency repairs 71 11 Mothballing the turbocharger...

Page 33: ...ny questions regarding a design variant see Contact information at www abb com turbocharging Accuracy of illustrations The illustrations in this document are general in nature and intended for ease of understand ing Differences in detail are therefore possible 1 2 Registered trademarks The trademarks of outside companies are used in this document These are marked with the symbol 1 3 Related docume...

Page 34: ...ts reserved HZTL4037_EN Revision E July 2017 1 4 Layout and function of the turbocharger Fig 1 Layout and function of the turbocharger 01 Air suction branch filter silencer 06 Plain bearing bush 02 Compressor casing 07 Turbine 03 Diffuser 08 Nozzle ring 04 Bearing casing 09 Turbine casing 05 Axial thrust bearing 10 Compressor wheel Page 4 77 ...

Page 35: ... in air or a mixture of gas and air through the air suction branch 01 or the filter silencer In the compressor wheel 10 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 06 that is located...

Page 36: ...to the enginebuilder without insulation must be equipped later with warning plates on the insulation This is the responsibility of the enginebuilder If warning plates are not present in the designated locations or not readable proceed as fol lows u Order new warning plates 72080 from ABB Turbocharging Service Stations see chapter Ordering spare parts 75 u Remove any warning plates that have become...

Page 37: ...s to the heaviest variant possible De pending on the specification the weight specified on the rating plate may be lower than the standard value specified here Product Weights kg TPS44 120 TPS48 180 TPS52 250 Table 2 Weight of the turbocharger One swivel lifting eye S is required to safely lift this turbocharger This is not included in the ABB Turbo Systems scope of delivery Swivel lifting eye S t...

Page 38: ... cool down before carrying out any work Wear safety gloves to protect against thermal hazards CAUTION Do not strain cables 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 casing is acc...

Page 39: ...turbocharger This protects the plug from being crushed 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 connections Version with water cooling CAUTION Freezing of the cooling water in the bearing casing If cooling water freezes i...

Page 40: ...gaskets Gaskets that are forgotten damaged or improperly inserted will lead to oil leaks u Always use new gaskets and insert them carefully into the slot The oil is supplied 02 and drained 03 through the bracket 01 The necessary sealing is provided by O rings The O rings are not included in the ABB Turbo Systems scope of delivery Fig 6 Inserting O rings into bracket 01 Bracket 02 Oil supply 03 Oil...

Page 41: ...nuts 01 3 Remove nuts 01 again Requirements for the threaded rods 02 Fig 8 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 4 Requirements for threaded rods Fastening material scope of delivery The threaded...

Page 42: ...and water connections are removed 2 Make sure that 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 6 Lightly oil the hexagon nuts 7 Fit the hexagon nuts Observe the tightening torque 8 Connect cable to spee...

Page 43: ...selection of lubricating oil and the oil change intervals 3 1 2 Pre lubrication Pre lubrication must be carried out as follows u Switch on the oil pump u Build up oil pressure see Table 6 Lubricating oil pressure at oil inlet before turbocharger 17 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 ...

Page 44: ... Lubricating 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 fil...

Page 45: ...issible values Leaktightness of pipes WARNING Risk of burning from hot gas Escaping gases are hot and will lead to serious burns in the event of contact u Check all pipes for leaks in accordance with the enginebuilder s instruc tions 3 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 temper...

Page 46: ...the locking 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 o...

Page 47: ... tur bocharger bar Normal operation 2 0 poil 4 5 Engine start Cold oil admissible for maximal 15 minutes 8 0 Engine idling admissible for maximal 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 immediately 0 5 Table 6 Lubricating oil pressure at oil inlet before turbocharger 01 Turboc...

Page 48: ...e at the outlet The oil temperature at the outlet is mainly dependant on Lubricating oil temperature and pressure at the oil inlet Engine load and turbocharger speed Exhaust gas temperature The maximum admissible oil temperature at the outlet is listed in the following table The specified oil outlet temperature is to be considered as alarm value for the turbocharger op eration and must be monitore...

Page 49: ...g plate 4 3 Turbocharger speed 4 3 1 Introduction A speed measuring system enables the constant monitoring of the turbocharger speed CAUTION Do not strain cables 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 shorten the r...

Page 50: ...HZTL4037_EN Revision E July 2017 4 3 2 Layout and overview Fig 10 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 20 77 ...

Page 51: ...ot be stopped it can continue to be driven at this reduced engine load or turbocharger speed u If a turbocharger surges continuously the engine performance must be reduced further 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...

Page 52: ... lip and an O ring No additional gasket is required during assembly Fig 11 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 9 Tightening torque 86505 u Reduce the engine performance to idling and then stop the engine Pay attention to post lubrication Stopping the engine 29 u Switch off the lubricating oil supply to the turbocharger ...

Page 53: ...at a distance of 1 meter from the turbocharger The highest value of the emission sound pressure level1 reaches a maximum of 105 dB A near the filter silencer The following prerequisites must be fulfilled with regard to the tur bocharger 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...

Page 54: ...opyright 2017 ABB All rights reserved HZTL4037_EN Revision E July 2017 Suggestion for noise insulation bellows Fig 12 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 24 77 ...

Page 55: ...performed too late can cause excessive contamination wear and operating failures u Carry out the service work at the specified time intervals CAUTION Shortened service intervals Exceptional stresses such as several starts stops per day harsh environ mental conditions poor fuel quality or high system vibrations can lead to untimely machine damage even if the prescribed service intervals are ob serv...

Page 56: ...easured values must be entered every 24 48 hours in the engine logbook 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 befor...

Page 57: ...isassembly of the cartridge group and assessment of the ro tor and bearing parts requires the specialist knowledge of an ABB Tur bocharging Service Station The rotor parts turn very 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...

Page 58: ...ied 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 considerably from the guideline values for example due to the following influences Fuel quality and fuel treatment Load profile thermal cycling also number of starts stops emer...

Page 59: ...ure while performing 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 Turbo Systems 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 ...

Page 60: ...and corrosion If 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 co...

Page 61: ...filter ring if present u Remove filter ring 81265 u Clean filter ring 81265 as required or every 500 hours of operation and replace 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 Rins...

Page 62: ...rption segments 81136 must only be cleaned lightly with compressed air a soft brush or a moist cleaning cloth u Have any heavily contaminated absorption segments replaced by an ABB Turbocharging Service Station Fitting the filter silencer see Fig 13 Cleaning the filter silencer 31 u Insert the absorption segments 81136 into the sheet metal coverings 81137 u Bend the sheet metal coverings 81137 bac...

Page 63: ...PE 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 parts which are relevant in terms of performance can be cleaned in accord ance with the description below Fig 14 Cleaning the compressor casing diffuser mechanically 72000 Compressor ...

Page 64: ...Comply with local 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 15 Cleaning the nozzle...

Page 65: ...Remove cartridge group see chapter Dismantling and fitting 46 First clean the compressor end and then the turbine end according to the following descrip tion 7 2 6 Cleaning the cartridge group on compressor end 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 CAU...

Page 66: ...ll as for cleaning the turbine are described in the following Fig 16 Soaking contamination of the turbine Product A mm B mm C mm TPS44 115 20 155 TPS48 115 29 180 TPS52 135 35 215 Table 12 Dimensions of the cleaning container To soak the layers of contamination on the turbine the cartridge group can be immersed vertically in a container 02 with fluid u Place the container 02 inside a larger contai...

Page 67: ...arger and damage parts inside the cartridge group u Place the cartridge group on suitable supports 01 made of wood or metal u Observe dimension B for the supports 01 so that the cartridge group is not immersed too deeply u Let the layers of contamination on the turbine soak for four hours Removing dirt WARNING Health hazard due to soot particles If soot particles enter the eyes or respiratory trac...

Page 68: ...tamination deposits lead to rotor unbal ance This can result in bearing or turbocharger damage u Remove all traces of contamination from the turbine u After brushing off the dirt fill the container 02 with clean water not salt water u Immerse the turbine of the cartridge group in clean water so that any loose dirt comes off u Lift up the cartridge group and align it horizontally u Clamp the heat s...

Page 69: ... Turbocharging Service Sta tion Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Contact enginebuilder Table 14 Malfunctions when starting Vibrations Rotating parts rubbing Normal behaviour not a malfunction Turbocharger A minimal and uniform wear on the circumference of the rotor components is per mitted This wear can be caused by slight local rubbing against adjacent c...

Page 70: ...ting oil pressure too low Speed reduces Possible causes Remedy Turbocharger Turbine and or nozzle ring severely con taminated Clean see chapter Periodic maintenance work 30 Rotor components or bearing damaged Contact ABB Turbocharging Service Sta tion Engine Defects on the connected cylinders in pulse charging Contact enginebuilder Pipes Defects such as leaks in the exhaust gas pipes or charge air...

Page 71: ...ling water too high Check clean cooling system Insufficient ventilation Improve ventilation Table 19 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 Turbocharger Manometer display not correct Replace manometer Supply pipe to manometer not sealed Repair leak Filte...

Page 72: ...e A severely contaminated 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 Turbocharger Compressor components severely con taminated by the ventilation gases that have been fed in Clean see chapter Periodic maintenance work 30 Optim...

Page 73: ... cause clarified and 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 maintenance work 30 Heavy contamination deposits in the turbine or in the nozzle ring Engine Protective grating i...

Page 74: ...able 25 Malfunctions 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 Turbocharger ...

Page 75: ...er to chapter Ordering spare parts 75 Replacing the speed sensor 22 Table 27 Malfunction of the speed measurement system No signal or poor signal amplitude Measured speed too high Possible causes Remedy Turbocharger 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 amplifica tion of the no...

Page 76: ... 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 against...

Page 77: ...sult Docu mentKind Catalogue QueryText spare parts set SortBy Score CountryCode CH Addition alLanguage Identification of the assembly devices Not all assembly devices are marked with a part number Identification is guaranteed by the tool list This list is enclosed with the toolbox WARNING Servicing the assembly devices Assembly devices must be checked for damage before and after use u Visually ins...

Page 78: ...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 point As sembly devices are specially constructe...

Page 79: ...ems scope of delivery Swivel lifting eye S to be used Product Thread Length H mm Diameter D mm Minimum load limit kg TPS44 M8 12 25 300 TPS48 M8 12 25 300 TPS52 M10 15 25 400 Table 30 Swivel lifting eye S to be used Two ring nuts are required for safer lifting of the cartridge group which are not included in the ABB Turbo Systems scope of delivery Ring nuts to be used VRM Product Thread Starpoint ...

Page 80: ...ghts of the individual parts or assemblies are rounded up standard values Fig 17 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 32 Weig...

Page 81: ...vision E July 2017 9 3 Removing the gas outlet casing u Mark the casing position for assembly Note Gas outlet casings which are not from ABB may also be secured with studs and nuts Fig 18 Removing the gas outlet casing 1 Manually secure the gas outlet casing 61001 2 Loosen and remove screws 51008 3 Remove the gas outlet casing 61001 4 Remove the gasket 52400 Page 51 77 ...

Page 82: ... 2017 9 4 Removing air inlets u Mark the casing position for assembly Fig 19 Removing the 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 74 Page 52 77 ...

Page 83: ...ing Copyright 2017 ABB All rights reserved HZTL4037_EN Revision E July 2017 9 5 Removing the compressor casing Fig 20 Removing the compressor casing 1 2 1 Place the turbocharger in a vertical position on a soft underlay 2 Loosen the hexagon head screws 72011 and remove them with fastening strips 72012 Page 53 77 ...

Page 84: ...n for assembly Fig 21 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 refer to chapter Disposing of turbocharger com ponents 74 5 Remove screw 72041 6 Remove the diffuser 79000 vertically from the compressor ca...

Page 85: ...the admissible values an oil orifice is mandatory 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 ...

Page 86: ...ights reserved HZTL4037_EN Revision E July 2017 Removing the turbine end fastening strips u Mark the casing position for assembly Fig 23 Removing the cartridge group 1 1 Loosen the hexagon nuts 51007 2 Remove hexagon nuts 51007 Verbus Ripp discs 51003 and fastening strips 51002 3 Screw in the swivel lifting eye S up to the stop Page 56 77 ...

Page 87: ...th washers 3 Secure the lifting gear to the ring nuts and swivel lifting eye as shown 4 Remove the cartridge group vertically from the turbine casing Fig 25 Rotating the 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 t...

Page 88: ...tling and fitting 9 7 Removing nozzle ring Copyright 2017 ABB All rights reserved HZTL4037_EN Revision E July 2017 9 7 Removing nozzle ring Fig 26 Removing the nozzle ring 1 Remove the nozzle ring 56001 vertically 2 Remove the lamellar sealing ring 56005 Page 58 77 ...

Page 89: ...0 86 1 52 TPS52 0 13 0 22 0 98 1 68 Table 33 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 ...

Page 90: ...01 and the turbine casing 51000 Fig 28 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 Product Compression PD mm TPS44 0 23 0 23 TPS48 0 23 0 23 TPS52 0 24 0 24 Table 34 Permitted nozzle ring compression P...

Page 91: ... Revision E July 2017 9 10 Fitting the diffuser Fig 29 Fitting the diffuser Part number TPS44 TPS48 TPS52 72041 M5 5 Nm M5 5 Nm M6 10 Nm Table 35 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 61 77 ...

Page 92: ...ting it by 90 1 Fit a new high temperature resisting O ring 42012 red or green see Customer spare part set 97070 47 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...

Page 93: ...tridge group Fig 31 Fitting the cartridge group Part number TPS44 TPS48 TPS52 72011 M8 40 Nm M8 40 Nm M10 80 Nm Table 36 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 hexalobular head screws 72011 Page...

Page 94: ...y 2017 9 12 Installing nozzle ring Fig 32 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 64 77 ...

Page 95: ...TPS52 51007 M8 30 Nm M8 30 Nm M10 60 Nm Table 37 Tightening torque 51007 1 Coat the threads of the studs 51006 with high temperature grease 2 Turn the turbine casing 51000 by 180 3 Fit two swivel lifting eyes 01 on the turbine casing Secure lifting gear to the swivel lift ing eyes 4 Place the turbine casing onto the cartridge group 5 Align turbine casing to the marking 6 Install the fastening stri...

Page 96: ...37_EN Revision E July 2017 9 14 Rotating the turbocharger Rotating the turbocharger Fig 34 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 67 Page 66 77 ...

Page 97: ...nce The upper direc tion N1 and lower direction N2 must be covered simultaneously 2 Calculate clearance N and compare it with the permissible values in the table 3 Push the feeler gauges 01 into the gap such that there is no clearance The upper direc tion R2 and lower direction R1 must be covered simultaneously 4 Calculate clearance R and compare it with the permissible values in the table CAUTION...

Page 98: ... Nm M10 50 Nm Table 39 Tightening torque 51101 1 Coat the threads of the hexagon head screws or studs 51008 with high temperature grease 2 Align the casing position of the gas outlet casing 61001 to the marking 3 Fit two hexagon head screws 51008 in the upper area of the gas outlet casing 4 Position the gasket 52400 on the threads of the hexagon head screws 51008 5 Install the gas outlet casing 61...

Page 99: ...S44 TPS48 TPS52 72020 M10 30 Nm M10 30 Nm M10 30 Nm Table 40 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 8200...

Page 100: ...5 50 Nm 03 72020 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...

Page 101: ...l 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 Turbo Systems recommends having a replacement turbocharger...

Page 102: ...tected against 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 materi...

Page 103: ...e the rotor 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 turboch...

Page 104: ...les Wear a respiratory mask to protect against dusts Wear safety gloves to protect against mechanical hazards Disposal must be environmentally compatible professional and in compliance with locally 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 componen...

Page 105: ...charger must be kept intact and ready for use u Carefully clean any rusted parts and grease them Please quote the following data when making queries and ordering spare parts Turbocharger type Serial number of the turbocharger Designation and part number Spare parts can be ordered from any ABB Turbocharging Service Station u If different model variants are not taken into account in this document co...

Page 106: ...ne casing mechanically 34 Fig 16 Soaking contamination of the turbine 36 Fig 17 Overview of assemblies 50 Fig 18 Removing the gas outlet casing 51 Fig 19 Removing the air inlets 52 Fig 20 Removing the compressor casing 1 2 53 Fig 21 Removing the compressor casing 2 2 54 Fig 22 Do not loosen screw plugs 55 Fig 23 Removing the cartridge group 1 56 Fig 24 Removing cartridge group 2 57 Fig 25 Rotating...

Page 107: ...s 40 Table 19 Malfunctions during operation Exhaust gas temperature too high 41 Table 20 Malfunctions during operation Charge air pressure too low 41 Table 21 Malfunctions during operation Charge air pressure too high 42 Table 22 Malfunctions during operation Engine performance losses 42 Table 23 Malfunction Turbocharger pumping 43 Table 24 Malfunction Sporadic surge blows 43 Table 25 Malfunctions...

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