Page 1 Operation Manual TPS48-H33 HT569793 English Original Operation Manual Chapter Document-ID Introduction HZTL4005_EN_F Safety HZTL4026_EN_D Safety data sheet HT569793 Product description HZTL4037_EN_E ABB Turbocharging...
Page 2 Operating limits and replacement intervals The recommended replacement intervals 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: Table Of Contents
Operation Manual / 1 Introduction Table of contents Introduction Introduction......................2 Purpose of the manual....................2 Symbols, definitions...................... 3 Storage of new turbochargers and spare parts ............5 Contact information...................... 7 © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017...
Page 4: Introduction
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. © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017...
Page 5: Symbols, Definitions
ABB Turbo Systems Ltd is identified as ABB Turbo Systems in this document. Official service stations of ABB Turbo Systems Official service stations are identified in this document as ABB Turbocharging Service Sta- tions. They are regularly audited and certified by ABB Turbo Systems. Also see chapter Con- tact information →7.
Page 6 Dispose of in an environmentally ance with specifications compatible, professional way and in compliance with locally applic- Oil free, grease free and dry able regulations Table 1: Definition of pictograms © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017...
Page 7: Storage Of New Turbochargers And Spare Parts
Old VCI corrosion protection emitters must be disposed of in an environmentally compat- ible, professional way and in compliance with locally applicable regulations. Close package. The more tightly the package is sealed, the longer the protection dura- tion. © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017...
Page 8 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: ¡...
Page 9: Contact Information
Operation Manual / 1 Introduction 1 Introduction / 1.4 Contact information Contact information Contact information for the ABB Turbocharging Service Stations is available online. Scan the QR code to access our website. ABB Turbo Systems Ltd Bruggerstrasse 71a CH-5401 Baden Switzerland www.abb.com/turbocharging...
Page 11 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 © Copyright 2017 ABB. All rights reserved. HZTL4026_EN Revision D May 2017...
Page 12: Safety
Safety Introduction Turbochargers manufactured by ABB reflect the state of the art. The respective safety and health protection requirements are met. This ensures safe operation of the turbocharger. Nevertheless, there may be some residual risks during operation of and work on the tur- bocharger which: ¡...
Page 13: Definition Of Mandatory Signs
CAUTION can lead to seri- ous damage to engine or property with grave consequences. Caution signs must always be observed. © Copyright 2017 ABB. All rights reserved. HZTL4026_EN Revision D May 2017...
Page 14: Intended Use
These data are given on the rating plate. ABB accepts no liability and rejects all warranty claims for any non-intended uses. [1] Euromot = The European Association of Internal Combustion Engine Manufacturers...
Page 15: Deflagration On Gas Engines
If during external inspection anomalies are found or if a particularly strong deflagration event has taken place, it is also recommended to check the bearings of the turbochargers before the next start. An ABB Turbocharging Service Station should be instructed to carry out this inspection.
Page 16: Warning Plates On The Turbocharger
Manual, Chapter 4 Product description. Turbochargers supplied to the enginebuilder without insulation must be equipped later with warning plates on the insulation. This is the responsibility of the enginebuilder. © Copyright 2017 ABB. All rights reserved. HZTL4026_EN Revision D May 2017...
Page 17: Turbocharger Rating Plate
06 Customer part number 07 Designation for special design 08 Weight of turbocharger in kg 09 Turbocharger type 10 Serial number Year of construction of turbocharger 12 Manufacturing plant © Copyright 2017 ABB. All rights reserved. HZTL4026_EN Revision D May 2017...
Page 18: Periodic Check Of The Pressure Vessels
The locations of the rating plates are defined in the Operation Manual, Chapter 4 Product description. Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, are so-called "simple pressure vessels". ¡...
Page 19: Lifting Of Loads
The assembly devices must be completely screwed in and must not unscrew during use. Use assembly devices only for the described applications. Put down dismantled components of the turbocharger in such a way that they cannot tip over. © Copyright 2017 ABB. All rights reserved. HZTL4026_EN Revision D May 2017...
Page 20: Prerequisites For Operation And Maintenance
Original parts and accessories are specially designed by ABB Turbo Systems for the ABB tur- bochargers. ABB accepts no liability for any damage resulting from the use of non-original parts and cor- responding accessories. © Copyright 2017 ABB. All rights reserved.
Page 21: Hazards During Operation And Maintenance
Wear heat-resistant safety gloves and protective clothing. Wait for the turbocharger to cool down before carrying out any work. Wear safety gloves to protect against thermal hazards. © Copyright 2017 ABB. All rights reserved. HZTL4026_EN Revision D May 2017...
Page 22 At the same time, electrical or electronic components and parts can also be damaged or destroyed. Only specially trained personnel should perform work on, or with, elec- trical components. Observe national regulations. © Copyright 2017 ABB. All rights reserved. HZTL4026_EN Revision D May 2017...
Page 23: Safe Operation
When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay at- tention to the risks that may occur as a consequence of this energy input. © Copyright 2017 ABB. All rights reserved. HZTL4026_EN Revision D May 2017...
Page 24: Safe Maintenance
Keep the floor, equipment, and turbocharger clean. Have oil binding agents ready and provide or keep oil pans at hand. Clean up any spills. Have fire protection means and extinguishing agents available. © Copyright 2017 ABB. All rights reserved. HZTL4026_EN Revision D May 2017...
Page 25 Secure rotor against turning. The rotor can rotate due to the stack draught alone. Observe the material safety data sheet for the cleaning and mothballing agents. Wear personal protective equipment (PPE) according to the material safety data sheet. © Copyright 2017 ABB. All rights reserved. HZTL4026_EN Revision D...
Page 26 Wear personal protective equipment (PPE) according to the material safety data sheet. Comply with local legislation. Wear safety goggles. Wear safety gloves to protect against chemical hazards. Wear a respiratory mask to protect against gases. © Copyright 2017 ABB. All rights reserved. HZTL4026_EN Revision D May 2017...
Page 27 Dispose of insulation materials properly and in an environmentally com- patible manner in compliance with the legal regulations. Wear safety goggles. Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against chemical hazards. © Copyright 2017 ABB. All rights reserved. HZTL4026_EN Revision D May 2017...
Page 29 Operation Manual / TPS48-H33 / Safety data sheet Page 1 / 1 Safety data sheet TPS48-H33 HT569793 TPS48-H33 HT569793 1018 12501589 2017 © Copyright 2017 ABB. All rights reserved. HT569793 September 2017...
Page 31 Eliminating malfunctions..................39 Malfunctions when starting..................39 Malfunctions during operation ................40 Turbocharger is surging .................... 43 Malfunctions when stopping..................44 Speed measurement system ..................45 Dismantling and fitting..................46 © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 32 Taking the engine out of operation for more than 12 months ......73 Disposing of turbocharger components ............74 Spare parts ......................75 13.1 Spare part overview..................... 75 13.2 Ordering spare parts....................75 Figures........................76 Tables ........................77 © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 33: Introduction
This 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).
Page 34: Layout And Function Of The Turbocharger
Fig. 1: Layout and function of the turbocharger Air suction branch / filter silencer Plain bearing bush Compressor casing Turbine Diffuser Nozzle ring Bearing casing Turbine casing Axial thrust bearing Compressor wheel © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 35: Position Of The Rating Plate
The rating plate (01) is attached at the top on the bearing casing of the turbocharger. Ex- planations regarding the rating plate can be found in the chapter dealing with safety. Fig. 2: Position of the rating plate © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E...
Page 36: Warning Plates On The Turbocharger
This is the responsibility of the enginebuilder. If warning plates are not present in the designated locations or not readable, proceed as fol- lows: Order new warning plates (72080) from ABB Turbocharging Service Stations (see chapter Ordering spare parts →75).
Page 37: Removing And Installing
TPS48 TPS52 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) to be used Product Thread...
Page 38: Removing The Turbocharger
Disconnect all pipes according to the instructions of the enginebuilder. Loosen and remove water connections. Close the openings of the water connections with screw plugs. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 39: Fig. 5: Removing The Turbocharger
If cooling water freezes in the bearing casing, this can lead to severe dam- age. For transport and storage of the turbocharger, drain the cooling water from the bearing casing via one of the two bottom openings of the water connections. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 40: Installing The Turbocharger
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.
Page 41: Fig. 7: Inserting Threaded Rods Into The Bracket
Fastening material scope of delivery The threaded rods and nuts for fastening the turbocharger on the bracket are not included in the ABB Turbo Systems scope of delivery. These parts depend on the version of the en- gine-side bracket. © Copyright 2017 ABB. All rights reserved.
Page 42: Fig. 9: Placing The Turbocharger On The Bracket
8. Connect cable to speed sensor (86505). Remove the lifting gear. Connect all the gas pipes and air lines according to the enginebuilder's instructions. If the gas outlet casing from ABB has not been dismantled with the turbocharger, refer to chapter Installing the gas outlet casing →68.
Page 43: Commissioning
Filtering the lubricating oil with a filter mesh width of ≤ 0.034 mm is sufficient for this tur- bocharger. 3.1.4 Oil pressure Comply precisely with the oil pressure before the turbocharger for trouble-free operation. The admissible values are specified in chapter Monitoring operation →17. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 44: Inspection Procedures
Adhere to lubricating oil temperature at the inlet. For permissible values, see chapter Monitoring operation →17. Warning plates Check whether warning plates are present and legible. Check whether the protective sheets have been removed. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 45 Lubricants and pastes used during assembly can liquefy or vaporise and escape as oily fluids during the initial hours of operation. Continual escape of an oily fluid indicates an oil leak. If there is a leak, contact an ABB Turbocharging Service Station. © Copyright 2017 ABB. All rights reserved.
Page 46: Commissioning After Taking Out Of Operation
Put engine-side oil circulation to the turbocharger into operation. Prepare the turbocharger for operation according to section "Checks before commission- ing". The turbocharger is now ready for operation. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 47: Monitoring Operation
Oil pressure measuring point Oil temperature measuring point For monitoring the lubricating oil pressure, ABB Turbo Systems recommends installing an "M" manometer immediately before the turbocharger. If the pressure is controlled electron- ically, the appropriate signals are to be triggered at the warning and alarm values.
Page 48: Table 7: Lubricating Oil Temperature At The Inlet
Table 8: Lubricating oil temperature at the outlet If the turbocharger was operated for a longer period of time outside of the admissible range, ABB Turbo Systems recommends to have the turbocharger inspected by an ABB Tur- bocharging Service Station. © Copyright 2017 ABB. All rights reserved.
Page 49: Exhaust Gas Temperature Before Turbine
Operating limits: refer to chapter 3 of Operation Manual / Safety data sheet or examine rating plate. If no speed measurement system is present, the system below can be ordered from an ABB Turbocharging Service Station (see chapter Ordering spare parts →75).
Page 50: Fig. 10: Layout And Overview Of The Speed Measurement System
Speed sensor 42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F/I converter Plug with integrated voltage limiter 86528 Tachometer Alternative mounting position for speed sensor 32109 Sealing disc © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 51 Check the pressure loss of the alternative air inlet and compare it with normal values. If the engine can be stopped temporarily: Inspect air lines, gas piping and the turbochargers and remedy any malfunctions. In any case, contacting the nearest ABB Turbocharging Service Station is recommended. 4.3.4 Malfunctions on the speed measurement system...
Page 52: Fig. 11: Fitting The Speed Sensor
Wear safety gloves when disassembling the speed sensor. Wear safety gloves to protect against thermal hazards. The speed sensor supplied by ABB is equipped with a sealing lip and an O-ring. No additional gasket is required during assembly. Fig. 11: Fitting the speed sensor...
Page 53: Operation And Service
Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7: A-weighted emission sound pressure level The enginebuilder must provide acoustically equivalent measures in case of deviating in- sulation versions © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 54: Fig. 12: Noise Insulation, Bellows
Suggestion for noise insulation, bellows Fig. 12: Noise insulation, bellows Compressor casing Bellows Charge air duct / scavenging air duct Insulation cushion Insulation mat (at least 15 mm) Sheet metal cover © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 55: Service Work
5-year service inspection To prevent machine damage caused by ageing and downtime, we recom- mend having an inspection carried out by an ABB Turbocharging Service Sta- tion no later than 5 years after the last service. © Copyright 2017 ABB. All rights reserved.
Page 56 Impairment to the degree of a possible operating failure can be the con- sequence. Have any unknown causes clarified by an ABB Turbocharging Service Sta- tion. Monitoring the engine's operating data makes it possible to draw conclusions about the op- erating behaviour of the turbocharger.
Page 57 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.
Page 58: Expected Replacement Intervals
Lubricating oil quality (oil filtering, oil condition, oil monitoring) ¡ Load profile (speed, pressure conditions, temperature) ¡ Number of starts/stops ¡ Unbalance of the rotor (degree of contamination). © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 59: Stopping The Engine
≤1.0. 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.
Page 60: Periodic Maintenance Work
Cleaning components mechanically →30 Engine stopped ally every 8000 … 12000 h) Table 11: Maintenance table [h] = Hours of operation ABB Turbo Systems recommends having mechanical cleaning carried out by an ABB Tur- bocharging Service Station during the service work. Cleaning components mechanically 7.2.1 Preparation...
Page 61: Fig. 13: Cleaning The Filter Silencer
Rinse in cold water. Avoid high mechanical loads (water jet). Let the filter ring dry completely before assembling. Dirty water and mild detergent must be disposed of in compliance with locally applicable regulations. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 62 When cleaning, note that the absorption segments (81136) must only be cleaned lightly with compressed air, a soft brush or a moist cleaning cloth. 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)
Page 63: Fig. 14: Cleaning The Compressor Casing, Diffuser Mechanically
Spray cleaned surfaces with penetrating oil. Do not spray exterior surfaces of the tur- bocharger. Dispose of contaminated water and cleaning agents in accordance with the information in the material safety data sheet. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 64: Fig. 15: Cleaning The Nozzle Ring, Turbine Casing Mechanically
Use clean water to completely clean parts of any solvents. Dry components completely. Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the tur- bocharger. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 65 Dry the compressor wheel and the gap between the compressor and the bearing casing with low-pressure pressurized air. Lightly spray the compressor wheel and the gap between the compressor and the bearing casing with penetrating oil. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 66: Fig. 16: Soaking Contamination Of The Turbine
Observe safety data sheet. Fill the container (02) with soaking fluid. To shorten the soaking time, the fluid can be heated up to a maximum of 60 ºC. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 67 Wear safety gloves to protect against mechanical hazards. Lift up the cartridge group and align it horizontally. Remove dirt manually using a soft brush or a wire brush. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 68 Lightly spray the turbine and the gap between the turbine and the heat sheet metal with penetrating oil. Dispose of contaminated water and cleaning agents in accordance with the information in the material safety data sheet. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 69: Eliminating Malfunctions
This causes the compressor or turbine blades to be somewhat shortened. To prevent significant loss of efficiency, specific tolerances must be fulfilled. ¡ If there is any doubt about the extent of the rubbing, contact an ABB Tur- bocharging Service Station. ¡...
Page 70: Malfunctions During Operation
Remedy Turbocharger Turbine and/or nozzle ring severely con- Clean (see chapter Periodic maintenance taminated work →30) Rotor components or bearing damaged Contact ABB Turbocharging Service Sta- tion Engine Defects on the connected cylinders in Contact enginebuilder pulse charging Pipes Defects, such as leaks, in the exhaust gas...
Page 71: Table 19: Malfunctions During Operation - Exhaust Gas Temperature Too High
Injection mistimed Set correctly Valve control misadjusted Pipes Pipes downstream to the compressor Repair. outlet not sealed. Table 20: Malfunctions during operation – Charge air pressure too low © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 72: Table 21: Malfunctions During Operation - Charge Air Pressure Too High
Clean (see chapter Periodic maintenance work →30) Table 22: Malfunctions during operation – Engine performance losses © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 73: Turbocharger Is Surging
Gradually reduce the engine load. Have the cause clarified and remedied immediately by an ABB Turbochar- ging Service Station. Have parts assessed for damage and, if necessary, replaced by an ABB Turbocharging Service Station. Possible causes Remedy...
Page 74: Malfunctions When Stopping
Bearing damaged Check clearances (see chapter Axial clearance A and radial clearance B →59). If clearances are outside the tolerance or if in doubt, contact an ABB Tur- bocharging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R →67).
Page 75: Speed Measurement System
Table 29: Malfunction of the speed measurement system – Measured speed too low If none of the measures described above remedy the malfunction, have the speed measure- ment system checked by an ABB Turbocharging Service Station. © Copyright 2017 ABB. All rights reserved.
Page 76: Dismantling And Fitting
Further operations that are executed in an incorrect way can lead to serious damage to the machine. ABB Turbo Systems recommends having further operations carried out only by trained personnel from an ABB Turbocharging Service Station. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN...
Page 77 Damaged assembly devices must no longer be used and must be re- placed. Tightening torques for assembly devices Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB must be tightened so they rest firmly against the surface. © Copyright 2017 ABB. All rights reserved.
Page 78 Use assembly devices only for the described applica- tions. ¡ Lifting gear Equipment for the lifting and transporting of loads (ropes, chain block, crane). Lifting gear is not supplied by ABB. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 79: Table 31: Ring Nuts To Be Used
Operation Manual / 4 Product description / TPS44-H.. - TPS52-H.. 9 Dismantling and fitting / 9.1 Introduction 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) to be used Product...
Page 80: Weights Of Individual Parts
Radial air suction branch Axial air suction branch Filter silencer Compressor casing Diffuser Cartridge group Nozzle ring Turbine casing 1 inlet Gas outlet casing Table 32: Weights of the assemblies [kg] © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 81: Removing The Gas Outlet Casing
Removing the gas outlet casing 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).
Page 82: Removing Air Inlets
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). © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 83: 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). © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 84: Fig. 21: Removing The Compressor Casing (2/2)
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 casing. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 85: Removing The Cartridge Group
This can result in an oil leak. Do not loosen screw plugs. If any screw plugs have been loosened accidentally, have these properly fitted by an ABB Turbocharging Service Station. Fig. 22: Do not loosen screw plugs © Copyright 2017 ABB. All rights reserved.
Page 86: Fig. 23: Removing The Cartridge Group (1)
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. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 87: Fig. 24: Removing Cartridge Group 2
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. Measure: Axial clearance A and radial clearance B →59. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 88: Removing Nozzle Ring
9 Dismantling and fitting / 9.7 Removing nozzle ring Removing nozzle ring Fig. 26: Removing the nozzle ring 1. Remove the nozzle ring (56001) vertically. 2. Remove the lamellar sealing ring (56005). © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 89: Axial Clearance A And Radial Clearance B
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2017 ABB. All rights reserved.
Page 90: Nozzle Ring Compression Pd
-0.23 ... 0.23 TPS52 -0.24 ... 0.24 Table 34: Permitted nozzle ring compression PD If the calculated value (PD) lies outside the specified range, contact an ABB Turbochar- ging Service Station. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E...
Page 91: Fitting The Diffuser
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). © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 92: Installing The Cartridge Group
6. Lift cartridge group at the side of the ring nuts (VRM) and turn it into a vertical position (compressor wheel facing downwards). Use edge guard between turbines and lifting gear. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E...
Page 93: Fig. 31: Fitting The Cartridge Group
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). © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 94: Installing Nozzle 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. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E...
Page 95: Fitting The Turbine Casing
4. Place the turbine casing onto the cartridge group. 5. Align turbine casing to the marking. 6. Install the fastening strips (51002) with Verbus Ripp® washers (51003) and hexagon nuts (51007). Observe the tightening torque. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 96: Rotating The Turbocharger
3. Fit ring nuts (VRM). 4. Attach lifting gear. 5. Elevate and rotate the turbocharger. 6. Place the turbocharger on a soft underlay. Measure: Radial clearances N and R →67. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 97: Radial Clearances N And R
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. © Copyright 2017 ABB. All rights reserved.
Page 98: Installing The Gas Outlet Casing
4. Position the gasket (52400) on the threads of the hexagon-head screws (51008). 5. Install the gas outlet casing (61001) on the turbine casing with the two screws. 6. Fit the remaining screws (51008), then tighten all the screws. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E...
Page 99: Installing Air Inlets
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 the marking. 5. Tighten the V-clamp (72020). © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 100: Table Of Tightening Torques
Table 41: Overview of tightening torques *) These screw plugs must not be removed for maintenance work. If the screw plug is loosened, the tightness is no longer guaranteed. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 101: Taking Out Of Operation At Short Notice
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 or ap- propriate spare parts available in storage (see chapter Storage of new turbochargers and spare parts).
Page 102: Mothballing The Turbocharger
Removing and Installing →7). Dismantle turbocharger (see chapter Dismantling and fitting →46). The rotor and bearing parts must be dismantled and refitted by an ABB Turbocharging Service Station. © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 103: Taking The Engine Out Of Operation For More Than 12 Months
¡ The casings of the turbocharger remain attached to the engine, 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...
Page 104: 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 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 105: Spare Parts
Designation and part number Spare parts can be ordered from any ABB Turbocharging Service Station. If different model variants are not taken into account in this document, contact an ABB Turbocharging Service Station. Dispose of placed and unusable parts in an environmentally-friendly and professional manner in accordance with the local regulations.
Page 106: Figures
Fig. 27: Measuring clearance A and B ....... 59 Fig. 28: Measuring nozzle ring compression ..60 Fig. 29: Fitting the diffuser.......... 61 Fig. 30: Lifting the cartridge group and rotating it by 90° ................62 © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...
Page 107 Table 23: Malfunction – Turbocharger pumping..43 Table 24: Malfunction – Sporadic surge blows..43 Table 25: Malfunctions when stopping – Runout noises................44 Table 26: Malfunctions when stopping – Runout time too short ............... 44 © Copyright 2017 ABB. All rights reserved. HZTL4037_EN Revision E July 2017...

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ABB HT569793 Operation Manual

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