Page 1 Operation Manual TPS48-H33 HT566298 English Original Operation Manual Chapter Document-ID Introduction HZTL4005_EN_E Safety HZTL4026_EN_B Safety data sheet HT566298 Product description HZTL4037_EN_A 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
Table of contents Page 1 / 8 Introduction Introduction .................... Purpose of the manual ................Symbols, definitions ................... Storage of new turbochargers and spare parts .......... Contact information ..................© Copyright 2016 ABB. All rights reserved. HZTL4005_EN Revision E July 2016...
Page 5: 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 2016 ABB. All rights reserved. HZTL4005_EN Revision E July 2016...
Page 6: Symbols, Definitions
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 [➙ 8]. © Copyright 2016 ABB. All rights reserved.
Page 7 Dispose of in an environmentally with specifications compatible, professional way and in compliance with locally applica- Oil free, grease free and dry ble regulations. Table 1: Definition of pictograms © Copyright 2016 ABB. All rights reserved. HZTL4005_EN Revision E July 2016...
Page 8: Storage Of New Turbochargers And Spare Parts
Old VCI corrosion protection emitters must be disposed of in an environmentally compati-  ble, professional way and in compliance with locally applicable regulations. Close package. The more tightly the package is sealed, the longer the protection duration.  © Copyright 2016 ABB. All rights reserved. HZTL4005_EN Revision E July 2016...
Page 9 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 ...
Page 10: Contact Information
Operation Manual / 1 Introduction Introduction Page 8 / 8 Contact information Contact information of 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 Periodic check of the pressure vessels ............1.10 Lifting of loads .................... 1.11 Prerequisites for operation and maintenance ..........1.12 Hazards during operation and maintenance ..........1.13 Safe operation ................... 1.14 Safe maintenance ..................© Copyright 2016 ABB. All rights reserved. HZTL4026_EN Revision B May 2016...
Page 13: Safety
Safety Introduction Turbochargers manufactured by ABB Turbo Systems are state of the art and comply with the respective health and safety standards in effect at the time the turbocharger was built. This ensures safe operation of the turbocharger. Nevertheless, there may be some residual risks during operation of and work on the turbocharger which: ...
Page 14: Definition Of Mandatory Signs
CAUTION can lead to serious CAUTION damage to engine or property with grave consequences. Caution signs must always be observed.  © Copyright 2016 ABB. All rights reserved. HZTL4026_EN Revision B May 2016...
Page 15: Intended Use
The specific operating limits of the turbocharger were determined on the basis of information from the enginebuilder about the intended use. These data are given on the rating plate. ABB Turbo Systems accepts no liability and rejects all warranty claims for any non-intended uses.
Page 16: Deflagration On Gas Engines
Deflagration on gas engines ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar. ABB Turbo Systems recommends subjecting the turbocharger to a visual inspection after a deflagration event. As part of the inspection, the position of the turbine casing and the position of the compressor casing to the bearing casing must be checked, and the bearing casing must be examined to see if it has shifted in relation to the bracket.
Page 17: Turbocharger Rating Plate
Further data 06 Customer part number 07 Designation for special design 08 Weight of turbocharger in kg 09 Turbocharger type 10 Serial number 11 Year of construction of turbocharger © Copyright 2016 ABB. All rights reserved. HZTL4026_EN Revision B May 2016...
Page 18: Periodic Check Of The Pressure Vessels
The locations of the rating plates are defined in the Operation Manual / Product description. Periodic check of the pressure vessels The pressure vessels used by ABB Turbo Systems, for example, in the wet or dry cleaning process, 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 2016 ABB. All rights reserved. HZTL4026_EN Revision B May 2016...
Page 20: Prerequisites For Operation And Maintenance
WARNING personnel. Only use original parts from ABB Turbo Systems.  ABB Turbo Systems accepts no liability for any damage resulting from the use of non-original parts and associated accessories. © Copyright 2016 ABB. All rights reserved. HZTL4026_EN Revision B...
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 2016 ABB. All rights reserved. HZTL4026_EN Revision B May 2016...
Page 22 Page 12 / 17 Hot surfaces on the non-insulated turbocharger Non-insulated turbochargers can cause serious injuries to personnel (burns). ABB Turbo Systems supplies the turbocharger with or without insulation in WARNING accordance with the purchase order received from the enginebuilder. If sup-...
Page 23: Safe Operation
When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay  attention to the risks that may occur as a consequence of this energy input. © Copyright 2016 ABB. All rights reserved. HZTL4026_EN Revision B May 2016...
Page 24: Safe Maintenance
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 2016 ABB. All rights reserved. HZTL4026_EN Revision B May 2016...
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 2016 ABB. All rights reserved. HZTL4026_EN Revision B May 2016...
Page 26  ty 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 2016 ABB. All rights reserved. HZTL4026_EN Revision B May 2016...
Page 27  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 2016 ABB. All rights reserved. HZTL4026_EN Revision B May 2016...
Page 29 Operation Manual / TPS48-H33 / Safety data sheet Page 1 / 1 Safety data sheet TPS48-H33 HT566298 TPS48-H33 HT566298 1018 11379956 2017 © Copyright 2017 ABB. All rights reserved. HT566298 January 2017...
Page 31: Table 13 Malfunctions When Starting
Stopping the engine ................Periodic maintenance work ..............Foreword to maintenance ................Cleaning components mechanically ............Eliminating malfunctions ................. Malfunctions when starting ................. Malfunctions during operation ..............Turbocharger is surging ................© Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 32: Table 25 Malfunctions When Stopping
Taking the engine out of operation for more than 12 months ...... Disposing of turbocharger components ............ Spare parts ..................... 13.1 Ordering spare parts .................. 13.2 Required customer spare part set (97070) ..........© Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 33 Operation Manual / 4 Product description / TPS44-H.. - TPS52-H.. Table of contents Page 3 / 99 13.3 View of turbocharger with part numbers ............. Figures ....................Tables ....................© Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 35: Introduction
This document is valid for different turbocharger design variants. As a result, it might contain sections and descriptions of components that do not apply to a certain turbocharger. If you have any queries about a design variant, ABB Turbocharging Service Stations will be pleased to provide information (see Contact information at www.abb.com/turbocharging).
Page 36: Layout And Function Of The Turbocharger
Figure 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 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 37 The bearings are connected to a central lubricating oil duct which is normally supplied by the lubricating oil circuit of the engine. The oil outlet lies at the lowest point of the bearing casing (04). © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A...
Page 38: 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 [➙ 93]).
Page 39: Position Of The Rating Plate
The rating plate (01) is attached at the top on the bearing casing of the turbocharger. Explana- tions regarding the rating plate can be found in the chapter dealing with safety. Figure 3: Position of the rating plate © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A...
Page 41: Removing And Installing
Swivel lifting eye (S) to be used Product Thread Length Minimum load limit [kg] L [mm] TPS44 TPS48 TPS52 Table 3: Swivel lifting eye (S) to be used Figure 4: Turbocharger transport © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 42: Removing The Turbocharger
Disconnect all pipes according to the instructions of the enginebuilder.  Version with water-cooled bearing casing: Loosen and remove water connections.  Close the openings of the water connections with screw plugs.  © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 43 CAUTION 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 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 44: 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. Figure 6: Inserting O-rings into bracket...
Page 45: Table 4 Requirements For Threaded Rods
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 engine- side bracket. © Copyright 2016 ABB. All rights reserved.
Page 46: Table 5: Tightening Torque For Turbocharger Fixing Screws
(assumed friction coefficient µ = 0.12) TPS44 Ø 17 TPS48 Ø 17 TPS52 Ø 20 Table 5: Tightening torque for turbocharger fixing screws Remove the lifting gear.  © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 47 Connecting the turbocharger 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 [➙ 81].
Page 49: Commissioning
Lubricating oil filtering with a filter mesh width of ≤ 0.034 mm is sufficient for this turbocharger. 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 [➙ 23]. © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 50: Inspection Procedures
For permissible values, see chapter Monitoring operation [➙ 23].  Warning plates Check whether warning plates are present and legible.  Check whether the protective sheets have been removed.  © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 52: 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 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 53: 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 electronically, the appropriate signals are to be triggered at the warning and alarm values.
Page 54: Table 7 Lubricating Oil Temperature At
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 Turbocharg- ing Service Station.
Page 55: 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 [➙ 93]). © Copyright 2016 ABB. All rights reserved.
Page 56 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 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 57  If the engine can be stopped temporarily: Inspect air lines, exhaust gas pipes and the turbochargers and remedy any malfunctions.  ABB Turbo Systems recommends contacting the nearest ABB Turbocharging Service Sta-  tion. 4.3.4 Malfunctions on the speed measurement system In the case of malfunctions of the speed measurement system, refer to the chapter entitled Troubleshooting/Speed measurement system [➙...
Page 58 Screw in new speed sensor (86505) as far as it will go and tighten.  Connect cable connector (86515) to speed sensor (86505).  Switch on lubricating oil supply to the turbocharger.  © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 59: 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 insula- tion versions © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 60 Suggestion for noise insulation, bellows Figure 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 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 61: 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 Turbocharger Service Sta- NOTICE tion no later than 5 years after the last service. © Copyright 2016 ABB. All rights reserved.
Page 62 Impairment to the degree of a possible operating failure can be the conse- quence. CAUTION Get an ABB Turbocharging Service Station to clarify unknown causes.  Monitoring the engine's operating data makes it possible to draw conclusions about the oper- ating behaviour of the turbocharger.
Page 63 Service Station. The rotor parts turn very fast and are very sensitive 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 64: Expected Replacement Intervals
Other casings 50000 Table 10: Expected replacement intervals [h] = Gas = Marine Diesel Oil The specified values are guideline values and not guaranteed values, see Influencing parameters. © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 65  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 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 67: Stopping The Engine
Switch off post-lubrication as soon as the rotor has come to a standstill.  Deviating procedures must be coordinated with ABB Turbo Systems. Water cooling after stopping the engine If the heat in the turbocharger is not dissipated after the engine stops, dam- age may result.
Page 69: Periodic Maintenance Work
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. © Copyright 2016 ABB. All rights reserved.
Page 70: Cleaning Components Mechanically
Dismantling and fitting [➙ 59]. NOTICE Contaminated water and cleaning agents must be disposed of in an environmentally com-  patible, professional way and in compliance with locally applicable regulations. © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 71 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 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 72  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 Figure 13) Insert the absorption segments (81136) into the sheet-metal coverings (81137).
Page 73 Spray cleaned surfaces with penetrating oil. Do not spray exterior surfaces of the turbo-  charger. Dispose of contaminated water and cleaning agents in accordance with the information in  the material safety data sheet. © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 74 Spray cleaned surfaces with penetrating oil. Do not spray exterior surfaces of the turbo-  charger. Dispose of contaminated water and cleaning agents in accordance with the information in  the material safety data sheet. © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 75 Remove turbocharger from engine (see chapter Removing and Installing [➙ 11]).  Remove cartridge group (see chapter Dismantling and fitting [➙ 59]).  First clean the compressor end and then the turbine end according to the following description. © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 76 Lightly spray the compressor wheel and the gap between the compressor and the bearing  casing with penetrating oil. Dispose of dirty water and cleaning agents in accordance with the material safety data  sheet. © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 77: Table 12 Dimensions Of The Cleaning
Cleaning agents which contain chlorine attack metals. Use only pH-neutral cleaning agents which do not attack metals.  CAUTION Observe safety data sheet.  Fill the container (02) with soaking fluid.  © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 78 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 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 79 Lightly spray the turbine and the gap between the turbine and the partition wall with pene-  trating oil. Dispose of dirty water and cleaning agents in accordance with the information in the mate-  rial safety data sheet. © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 81: 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 Turbocharging Service Station.
Page 82: Malfunctions During Operation
Remedy Turbocharger Light to medium contamination of the Clean (see chapter Periodic maintenance turbine and/or nozzle ring (with 4-stroke work [➙ 39]) or contact an ABB Turbocharg- application) ing Service Station Table 18: Malfunctions during operation – Speed increases © Copyright 2016 ABB. All rights reserved.
Page 83: Table 20 Malfunctions During Operation - Charge Air Pressure Too Low
Clean or repair boiler or exhaust gas si- lencer Pipes Pipes downstream to the compressor out- Repair. let not sealed. Table 20: Malfunctions during operation – Charge air pressure too low © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 84: Table 21 Malfunctions During Operation - Charge Air Pressure Too High
Increased speed due to contamination of Clean (see chapter Periodic maintenance nozzle ring work [➙ 39]) or contact an ABB Turbo- charging Service Station Table 21: Malfunctions during operation – Charge air pressure too high Reduced compressor performance/efficiency, hence engine performance losses...
Page 85: Turbocharger Is Surging
Gradually reduce the engine load.  Have the cause clarified and remedied immediately by an ABB Turbo-  charging Service Station. Have parts assessed for damage and, if necessary, replaced by an ABB  Turbocharging Service Station. Possible causes Remedy...
Page 86: Malfunctions When Stopping
Bearing damaged Check clearances (see chapter Axial clearance A and radial clearance B [➙ 72]). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R [➙...
Page 87: Speed Measurement System
Table 29: Malfunction of the speed measurement system – Measured speed too low Other causes of malfunction If none of the measures described above remedy the malfunction, have the speed measurement system checked by an ABB Turbocharging Service Sta- NOTICE tion.
Page 89: Dismantling And Fitting
ABB Turbo Systems recommends having further operations carried out  only by trained personnel from an ABB Turbocharging Service Station. Customer spare part set Before starting operations, make sure the required customer spare part sets are available.
Page 90  placed. Tightening torques for assembly devices Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB Turbo Systems must be tightened so they rest firmly against the surface. Suspended loads Loads that are not attached according to regulations can cause injury to per- sonnel or fatal accidents.
Page 91: Table 31 Ring Nuts To Be Used
ABB Turbo Systems scope of delivery. Ring nuts to be used (VRM) Product Thread TPS44 TPS48 TPS52 Starpoint ring nut VRM Table 31: Ring nuts to be used © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 92: 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 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 93: Removing The Gas Outlet Casing
Dismantling and fitting Page 63 / 99 Removing the gas outlet casing Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to dis- assembly. NOTICE Figure 18: Removing the gas outlet casing 1. Manually secure the gas outlet casing (61001).
Page 94: Removing Air Inlets
Dismantling and fitting Page 64 / 99 Removing air inlets Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to dis- assembly. NOTICE Figure 19: Removing the air inlets 1. Manually secure the filter silencer (81000) or air suction branch (82000).
Page 95: Removing The Compressor Casing
Figure 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 2016 ABB. All rights reserved. HZTL4037_EN Revision A...
Page 96 Operation Manual / 4 Product description / TPS44-H.. - TPS52-H.. Dismantling and fitting Page 66 / 99 Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to dis- assembly. NOTICE Loosening the compressor casing with press-off tool If the compressor casing cannot be loosened, it can be pressed off against the turbine casing with the press-off tool (90042).
Page 97: Pressing Off The Casing
Use the tool on both sides in alternation and make sure not to press off  too hard on either side. Figure 22: Press off the casing © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 98: Removing The Cartridge Group
Do not loosen screw plugs.  If any screw plugs have been loosened accidentally, have these properly  fitted by an ABB Turbocharging Service Station. Figure 23: Do not loosen screw plugs © Copyright 2016 ABB. All rights reserved. HZTL4037_EN...
Page 99 Dismantling and fitting Page 69 / 99 Removing the turbine-end fastening strips Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to dis- assembly. NOTICE Figure 24: Removing the cartridge group (1) 1. Loosen the hexagon nuts (51007).
Page 100 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 turbine casing. © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A...
Page 101: Removing Nozzle Ring
Measure: Axial clearance A and radial clearance B [➙ 72].  Removing nozzle ring Figure 27: Removing the nozzle ring 1. Remove the nozzle ring (56001) vertically. 2. Remove the lamellar sealing ring (56005). © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 102: Axial Clearance A And Radial Clearance B
Serious damage to engines or property can be caused by clearances out- side the tolerance and excessively worn parts. CAUTION Have the components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. Measure and record clearances A and B after the removal and before the installation of the ...
Page 103: Nozzle Ring Compression Pd
TPS48 -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 Turbocharging  Service Station. © Copyright 2016 ABB. All rights reserved. HZTL4037_EN...
Page 104: 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 2016 ABB. All rights reserved. HZTL4037_EN Revision A...
Page 105: Installing The Cartridge Group
4. Attach lifting gear to the ring nuts (VRM). 5. Lift cartridge group at the side of the ring nuts (VRM) and turn it into a vertical position. Use edge guard between turbines and lifting gear. © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A...
Page 106: Table 36 Tightening Torque (72011)
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 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 107: 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 2016 ABB. All rights reserved. HZTL4037_EN Revision A...
Page 108: Fitting The Turbine Casing
4. Place the turbine casing onto the cartridge group. 5. Align turbine casing to the marking. 6. Fit and tighten the fastening strips (51002) with Verbus Ripp® discs (51003) and hexagon nuts (51007). © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 109: 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 [➙ 80].  © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 110: Radial Clearances N And R
Serious damage to engines or property can be caused by clearances out- side the tolerance and excessively worn parts. CAUTION Have the components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. Figure 36: Measuring clearances N and R...
Page 111: 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 2016 ABB. All rights reserved. HZTL4037_EN Revision A...
Page 112: Installing Air Inlets
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 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 113: Table Of Tightening Torques
35 Nm 35 Nm 51007 30 Nm 30 Nm 60 Nm 51006 25 Nm 25 Nm 45 Nm 09a / 51008 / 51009 25 Nm 25 Nm 50 Nm © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 114 Table 41: Overview of tightening torques *) These screw plugs must not be removed for maintenance work. If the screw plug is loos- ened, the tightness is no longer guaranteed. © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A...
Page 115: Taking Out Of Operation At Short Notice
 If a replacement turbocharger or cartridge group is not available: Fit cover plate [➙ 87] and contact an ABB Turbocharging Service Station. Observe the following sections in connection with the emergency repairs mentioned.  © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 116: Installing A Replacement Turbocharger
The repair of a cartridge group requires special tools and the expertise of an ABB Turbocharg- ing Service Station. The rotating parts turn very fast and are very sensitive to unbalance.
Page 117: Fitting The Cover Plate
3. Coat the threads of the studs (51006) with high-temperature grease. 4. Fasten the cover plate on the turbine casing (51000) with fastening strips (51002), Verbus Ripp® washers (51003) and nuts (51007), and screw it onto the bracket. © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A...
Page 118: Table 43 Cover Plate Dimensions [Mm]
Taking out of operation at short notice Page 88 / 99 The cover plate is not included in the ABB Turbo Systems scope of delivery and must be manufactured by the operating company according to the following drawing. Material: General structural steel, in compliance with DIN EN 10025-2.
Page 119: Mothballing The Turbocharger
Remove turbocharger (see chapter Removing and Installing [➙ 11]).  Dismantle turbocharger (see chapter Dismantling and fitting [➙ 59]).  The rotor and bearing parts must be dismantled and refitted by an ABB Turbocharging  Service Station. Clean all parts.
Page 120: 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 has been completely removed, either as a whole unit or in individual...
Page 121: 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 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 123: Spare Parts
 Serial number (HT……)  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 ...
Page 124 Spare parts Page 94 / 99 13.3 View of turbocharger with part numbers Figure 42: View of turbocharger with part numbers * Depending on the specification of the turbocharger © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 125: Table 45 Turbocharger Part Numbers
Screw plug 82008 Gasket 82010 (in the customer spare part set) O-ring 86505* Speed sensor 86515* Cable connector 86526* F/I converter 86528* Tachometer Table 45: Turbocharger part numbers © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 126 Operation Manual / 4 Product description / TPS44-H.. - TPS52-H.. Spare parts Page 96 / 99 * Depending on the specification of the turbocharger © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 127 Fig. 25 Removing cartridge group 2 ..Fig. 26 Rotating the cartridge group and fitting the service support ... Fig. 27 Removing the nozzle ring ..Fig. 28 Measuring clearance A and B ... © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...
Page 129 Table 45 Turbocharger part numbers ..95 Table 21 Malfunctions during operation – Charge air pressure too high Table 22 Malfunctions during operation – Engine performance losses .. © Copyright 2016 ABB. All rights reserved. HZTL4037_EN Revision A August 2016...

ABB TPS48-H33 Operation Manual

Introduction

Safety

Product Description

1 Introduction

2 Removing and Installing

3 Commissioning

4 Monitoring Operation

5 Operation and Service

6 Stopping the Engine

7 Periodic Maintenance Work

8 Eliminating Malfunctions

9 Dismantling and Fitting

10 Taking out of Operation at Short Notice

11 Mothballing the Turbocharger

12 Disposing of Turbocharger Components

13 Spare Parts

Quick Links

Chapters

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Questions and answers

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Summary of Contents for ABB TPS48-H33

Table of Contents