Page 1 Operation Manual TPS48-F32 ABB Turbo Systems Ltd CH 5401 Baden Type TPS48-F32 HT566525 1029 Mmax Mmax °C Bmax Bmax SOLD08 00180 Application according to Year 2016 the Operation Manual made in Switzerland ABB Turbocharging...
Page 2 In case the operation conditions differs signiﬁ cantly from what is considered to be normal for the cur- rent application, it is recommended to contact ABB for a re-calculation of replacement intervals. Frequent load alterations, high temperatures and high speed lower the life of components.
Page 3: Table Of Contents
Periodic checking of the pressure vessel 2.10 Lifting loads Start-up Oil supply Inspection work Commissioning after taking out of operation Operation Noise emissions Servicing work Expected exchange intervals Speed measurement Stopping the engine © Copyright 2016 ABB. All rights reserved.
Page 4 Taking the engine out of operation for more than 12 months Disposing of turbocharger components Spare parts 12.1 Ordering spare parts 12.2 View of turbocharger showing part numbers 12.3 View of cartridge group showing part numbers © Copyright 2016 ABB. All rights reserved.
Page 5: Preliminary Remarks
Operation Manual This Operation Manual enables you to familiarize yourself with the turbo- charger supplied by ABB Turbo Systems and to use it as intended. It provides important information in order that the turbocharger can be op- erated safely, correctly and efficiently.
Page 6: Layout And Function
3 Diffuser 10 Turbine casing 4 Bearing casing 11 Turbine-end bearing flange 5 Axial thrust bearing 12 Compressor-end bearing flange 6 Radial plain bearing (visible only 13 Compressor wheel at turbine end) 7 Turbine © Copyright 2016 ABB. All rights reserved.
Page 7 The bearings are connected to a central lubricating oil duct which is sup- plied by the engine's lubricating oil circuit. The oil outlet is always at the lowest point of the bearing casing (4). © Copyright 2016 ABB. All rights reserved.
Page 8: Intended Use Of The Turbocharger
Any other use will be regarded as a special application which must first be discussed with ABB Turbo Systems. The manufacturer accepts no liability for other applications. If it is used otherwise, ABB Turbo Sys- tems reserves the right to reject all warranty claims.
Page 9: Storage Of New Turbochargers And Spare Parts
Storage of new turbochargers and spare parts up to 6 months New turbochargers and spare parts from ABB Turbo Systems can be stored in sealed packaging without additional mothballing measures for up to 6 months from the date of delivery (marked by the VCI label on the package).
Page 10 Page 8 spare parts Long-term storage of replacement turbochargers or spare parts Per order, turbochargers or cartridge groups will be prepared by ABB Tur- bo Systems for prolonged storage. The package is equipped with a hyg- rometer (see illustration). The following measures are required every 6 months: Check the hygrometer (02) in the sight-glass.
Page 11: Essential Information
The fault must be reported to the person or depart- ment responsible. Additions and alterations to, and conversions of the turbocharger that could compromise safety require the prior approval of ABB Turbo Sys- tems. NOTICE © Copyright 2016 ABB. All rights reserved.
Page 12 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 corresponding accessories. Competence of personnel The turbocharger must only be operated and serviced by trained and au- thorised personnel.
Page 13 This document is valid for different design variants of turbochargers. There may be sections and descriptions of components that are not rele- vant for a specific turbocharger variant. ABB Turbocharging Service Stations will be happy to provide information on questions regarding a design variant (see Contact information at www.abb.com/turbocharging).
Page 14: Symbols And Definitions
Definition of caution / warning The caution and warning signs are described in the chapter Safety. ABB Turbo Systems In this document, ABB Turbo Systems Ltd is abbreviated to ABB Turbo Systems. Official ABB Turbo Systems Service Stations In this document, official service stations are referred to as ABB Turbo- charging Service Stations.
Page 15: Turbocharger Rating Plate
Replacement interval of turbine in 1000 h Further data Customer part number Designation of the special design Weight of turbocharger in kg Turbocharger type Serial number Year of construction of turbocharger © Copyright 2016 ABB. All rights reserved.
Page 16 Operation above the indicated values n can considerably shorten the Bmax Bmax recommended replacement intervals. In such cases, we recommend that you contact the nearest official ABB Turbocharging service station. and t normally apply only when running at overload (110%) during tri- Mmax Mmax als on the engine test bed.
Page 17: Contact Information
Operation Manual / TPS44-F.. - TPS61-F.. Preliminary remarks Contact information Page 15 Contact information Contact information Contact information for the official service stations of ABB Turbo Systems is available online. Scan the QR code to access our website.  ABB Turbo Systems Ltd Bruggerstrasse 71a...
Page 19: Safety
Page 17 Safety Introduction Turbochargers manufactured by ABB Turbo Systems are state of the art and comply with the pertinent safety and health-protection requirements that applied when the turbocharger was manufactured. Consequently, the turbocharger is safe to operate. Nevertheless, during turbocharger opera- tion and when working on the turbocharger, residual risks can exist which: ...
Page 20: Ce Conformity
Operation Manual / TPS44-F.. - TPS61-F.. Safety CE conformity Page 18 CE conformity Information ABB turbochargers fulfil Directive 2006/42/EC on machinery and are con- sidered partly completed machinery in the sense of Article 2 g. © Copyright 2016 ABB. All rights reserved.
Page 21: Definition Of Mandatory Signs
To be worn according to the specific work Safety glasses Safety goggles Safety gloves to protect Respiratory mask to protect against against - Mechanical hazard - Dusts - Chemical hazard - Gases - Thermal hazard Safety helmet Ear protection © Copyright 2016 ABB. All rights reserved.
Page 22: Definition Of Safety Instructions
Serious machine or property damage may occur if work and operating instructions marked with this symbol and the word CAUTION are either CAUTION not followed or not followed precisely. Caution signs must be observed at all times.  © Copyright 2016 ABB. All rights reserved.
Page 23: Warning Plates On The Turbocharger
Warning plates are attached to the turbocharger at the following places: If warning plates are not present at the intended places or are not legible, then proceed as follows: Order new warning plates from ABB Turbocharging Service Stations.  Remove unreadable warning plates.
Page 24: Safe Operation And Maintenance
Keep flammable objects and substances out of the range of flying  sparks. Cover all connections on the turbocharger so that no foreign objects  can enter the turbocharger. Wear personal protective equipment (PPE) for welding operations.  © Copyright 2016 ABB. All rights reserved.
Page 25 Never operate turbochargers without burst protection. If the insula-  tion from ABB Turbo Systems is not in place, the separate burst pro- tection (57200) must be fitted before operation. (See View of tur- bocharger showing part numbers [➙ 126].) Before starting work, carry out visual inspection of working area.
Page 26 Clean the turbocharger before mothballing it.  Observe the material safety data sheet for the cleaning and mothball-  ing agents. Wear personal protective equipment (PPE) according to the material  safety data sheet. © Copyright 2016 ABB. All rights reserved.
Page 27: Hazards During Operation And Maintenance
Observe the general rules for occupational safety and prevention of  accidents. Ensure workplace safety.  Only perform operations that are described in this document.  Only perform operations for which you have previously received in-  struction or training. © Copyright 2016 ABB. All rights reserved.
Page 28 Do not touch hot surfaces and heed the warning plate on the turbo-  charger. Wear heat-resistant safety gloves and protective clothing.  Allow the turbocharger to cool down before carrying out any work.  Wear safety gloves to protect against thermal hazards. © Copyright 2016 ABB. All rights reserved.
Page 29 Non-insulated turbochargers can cause serious injuries to personnel (burns). WARNING The turbocharger is supplied by ABB Turbo Systems without insulation depending on the order from the enginebuilder. If supply is without insu- lation, the enginebuilder is responsible for providing the turbocharger with proper insulation and for providing protection against contact with hot surfaces.
Page 30 In the event of leaks or after spilling, immediately spread a suitable  binding agent and dispose of it properly and in an environmentally compatible manner in accordance with statutory regulations. © Copyright 2016 ABB. All rights reserved.
Page 31 Remove packing materials only in the work area.  Take particular care when removing old insulating materials.  Dispose of insulating materials properly and in an environmentally  compatible way in accordance with applicable local regulations. © Copyright 2016 ABB. All rights reserved.
Page 32 Hazards due to electrical components Electrical components operate with voltages which can present hazards to humans. WARNING All work on or with electrical components may only be performed by  trained specialists. Heed any country-specific regulations.  © Copyright 2016 ABB. All rights reserved.
Page 34: Periodic Checking Of The Pressure Vessel
Page 32 vessel Periodic checking of the pressure vessel The pressure vessels used by ABB Turbo Systems, such as those for wet or dry cleaning, are so-called "simple pressure vessels".  The local, statutory regulations covering periodic checks of pressure vessels must be observed.
Page 35: Lifting Loads
Completely screw in assembly / fitting devices without fail so that they  cannot work loose during use. Use assembly / fitting devices only for applications described.  Make sure removed turbocharger components stand safely and se-  curely. © Copyright 2016 ABB. All rights reserved.
Page 37: Start-Up
Check that oil filters are clean before commissioning.  Also follow the enginebuilder's instructions regarding filter mesh and separation efficiency. NOTICE © Copyright 2016 ABB. All rights reserved.
Page 38 CAUTION Do not allow the oil inlet temperature to fall below the minimum 30 ºC  when starting the engine. The oil inlet temperature must never be less than 10 °C.  © Copyright 2016 ABB. All rights reserved.
Page 39 Pre- and post-lubrication (engine stopped) ≤ 1.0 Prelubrication Serious machine or property damage might result if the turbocharger is not supplied with oil when the engine is starting. CAUTION Activate prelubrication device before starting engine.  © Copyright 2016 ABB. All rights reserved.
Page 40 + 55 K oil,inlet If the turbocharger has been operated outside the permissible range for a prolonged period of time, ABB Turbo Systems recommends having the turbocharger inspected by an ABB Turbocharging Service Station. © Copyright 2016 ABB. All rights reserved.
Page 41: Inspection Work
CAUTION Activate prelubrication device before starting engine.  Check whether the warning plates are present and legible. Warning plates on tur-  bocharger Check whether the protective sheets have been removed.  © Copyright 2016 ABB. All rights reserved.
Page 42 If oily liquid continues to escape after this period, an oil leak must be suspected. The first step is to check for leakage of the oil NOTICE supply to the turbocharger. If this is leaky, contact an official ABB Tur- bocharging service station. 3.2.4 Inspection after 100 service hours Clean or replace lubricating oil filters after the first 100 service hours.
Page 43: Commissioning After Taking Out Of Operation
Start up turbocharger oil circulation system at engine end.  Prepare turbocharger for operation as instructed in section "Inspection  work before start-up / commissioning" of chapter headed "Start-up / commissioning". Start up turbocharger.  © Copyright 2016 ABB. All rights reserved.
Page 45: Operation
Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 : A-weighted emission sound pressure level In the event of divergent insulation designs, the engine builder must en- sure that equivalent acoustic insulating measures are taken. © Copyright 2016 ABB. All rights reserved.
Page 46 Operation Noise emissions Page 44 Suggestion for noise insulation of the bellows Compressor casing Insulation pads Bellows Insulation mat (at least 15 mm) Charge air duct / scavenging Sheet metal cover air line © Copyright 2016 ABB. All rights reserved.
Page 47: Servicing Work
Despite observance of the service intervals, unusual loads, such as several start-stops a day, harsh environmental factors, poor fuel quality CAUTION or heavy installation vibration can lead to premature machine damage. A shortened service interval must be arranged with ABB Turbo Sys-  tems. Service inspection after 5 years...
Page 48 Service work in accordance with instructions on rating plate (In general, after 8000 - 12000 hours of operation) Rotor and bearing parts must be inspected and assessed by an ABB Turbo- charging Service Station. The following work can be carried in preparation.
Page 49  Pressure drop in charge air cooler  Lubricating oil pressure and lubricating oil temperature  Air temperature behind compressor and charge air cooler If provided  Turbocharger speed  Pressure loss in air filter © Copyright 2016 ABB. All rights reserved.
Page 50: Expected Exchange Intervals
Other casings 50000 50000 GAS = Natural gas MDO = Marine diesel oil HFO = Heavy fuel oil The specified values are a guide only and not guaranteed (see following section Influencing parameters). © Copyright 2016 ABB. All rights reserved.
Page 51 For bearing parts  Lubricating oil quality (oil filtration, condition of lubricating oil, oil moni- toring)  Load profile (rpm / speed, pressure conditions, temperature)  State of rotor unbalance (degree of contamination) © Copyright 2016 ABB. All rights reserved.
Page 52: Speed Measurement
Do not tension the speed measurement cables.  86505(A) Speed sensor (cable not integrated) 86526 F/I converter 86505(B) Speed sensor (cable integrated) 86528 Tachometer 86515(A) Cable connector to 86505(A) 01 Screw plug 86515(B) Cable connector to 86505(B) 02 Gasket © Copyright 2016 ABB. All rights reserved.
Page 53 If the engine can be stopped for a short time: Inspect the air and gas lines as well as the turbocharger and eliminate  any problems. In any event, it is recommended that you contact the nearest ABB  Turbocharging Service Station. © Copyright 2016 ABB. All rights reserved.
Page 54 Screw in a new speed sensor up to the limit block.  Adhere to tightening torque.  Part number TPS44 TPS48 TPS52 TPS57 TPS61 86505 15 Nm 15 Nm 15 Nm 15 Nm 15 Nm © Copyright 2016 ABB. All rights reserved.
Page 55 Connect cable connector to speed sensor.  Switch on lubricating oil supply to turbocharger.  4.4.3 Failure of speed measuring system Possible reasons for failure of the speed measuring system are described in the chapter Troubleshooting. © Copyright 2016 ABB. All rights reserved.
Page 56: Stopping The Engine
Allow turbocharger cooling water to run for 15 … 20 minutes after  CAUTION stopping engine. Allow oil lubrication to continue running until rotor comes to a stop.  Further post-lubrication is not required and not recommended. © Copyright 2016 ABB. All rights reserved.
Page 57: Maintenance
Cleaning method To allow you to observe the standard service intervals and to maintain a high turbocharger efficiency, ABB Turbo Systems recommends that the NOTICE cleaning procedure be carried out during operation. This allows the thermal load of the engine to be kept low while ensuring maximum fuel efficiency.
Page 58: Cleaning The Compressor During Operation
If the coating of dirt is very thick and hard, the compressor can only be cleaned manually when disassembled. This cleaning must be carried out by an ABB Turbocharging Service Station. NOTICE The interval between periodic cleaning is very dependent on the operating Cleaning interval conditions.
Page 59 Cleaning method Cleaning the compressor while in operation is carried out as wet cleaning. This cleaning method has been tested and approved by ABB Turbo Sys- tems. To clean the compressor stage during operation, water is injected in front...
Page 60 Operating state prerequisites for cleaning compressor with XC1 To be able to carry out a satisfactory cleaning process that has been tested and is recommended by ABB Turbo Systems, the following pre- requisites must be fulfilled: Run engine at load from 50 … 85 %.
Page 61 NOTICE If the cleaning result is still not satisfactory after three attempts and the engine values are also unsatisfactory, we recommend that you have the turbocharger inspected and cleaned by an official ABB Turbocharging Service Station. Cleaning parameters per Product...
Page 62: Turbine Cleaning During Operation
ABB Turbo Systems recommends using fuels with a low ash, sulphur, so- dium and vanadium content. Consequences of contamination: ...
Page 63 The cleaning process with a long water injection time is used for turbo- charger designs with additional sealing by means of C-rings. Based on a 10-minute injection phase, this cleaning process utilises the water solubility of the dirty deposits. © Copyright 2016 ABB. All rights reserved.
Page 64 Turbine cleaning during operation Page 62 Choice of cleaning method If you need information about the choice of cleaning method (short / long), you can contact the engine builder or an official ABB Turbo- NOTICE charger service station. 5.3.2 Prerequisites...
Page 65 Operation Manual / TPS44-F.. - TPS61-F.. Maintenance Turbine cleaning during operation Page 63 Recommended operating state for turbine wet cleaning The following operating state has been tested and is approved by ABB Turbo Systems: Characteristic / component Conditions short long...
Page 66 100 °C higher than the exhaust gas tem- perature after the cylinder. This should be taken into consideration when setting the operating point before cleaning. Don't exceed maximum temperature in front of turbine when cleaning.  © Copyright 2016 ABB. All rights reserved.
Page 67 100 °C higher than the exhaust gas tem- perature after the cylinder. This should be taken into consideration when setting the operating point before cleaning. Don't exceed maximum temperature in front of turbine when cleaning.  © Copyright 2016 ABB. All rights reserved.
Page 68: Cleaning Components Mechanically
Dispose of dirty water and cleaning agents in an environmentally com-  patible manner, professionally and in accordance with valid local regu- lations. Disassembly and assembly The disassembly and assembly of the components is described in chapter Disassembly and assembly. NOTICE © Copyright 2016 ABB. All rights reserved.
Page 69 Avoid rough handling (do not use a water jet). Allow the filter ring to dry out completely before assembly.  Dispose of dirty water and gentle detergents in accordance with valid  local regulations. © Copyright 2016 ABB. All rights reserved.
Page 70 Have absorption segments which are heavily contaminated replaced  by an official ABB Turbocharging Service Station. Fitting the filter silencer Insert the absorption segments (81136) into the sheet-metal coverings ...
Page 71 Spray cleaned surfaces with penetrating oil. Do not spray the outer  surfaces of the turbocharger. Dispose of dirty water and cleaning agent in accordance with the spec-  ifications in the safety data sheet. © Copyright 2016 ABB. All rights reserved.
Page 72 Brush away the contamination or remove with a steam cleaner.  Repeat the soaking and brushing if necessary.  Use clean water to completely clean parts of any solvents.  Dry components completely.  © Copyright 2016 ABB. All rights reserved.
Page 73 Remove turbocharger from the engine (see chapter Removal and in-  stallation [➙ 85]). Remove cartridge group (see chapter Disassembly and assembly  [➙ 91]). First clean the compressor end and then the turbine end in accordance with the following description. © Copyright 2016 ABB. All rights reserved.
Page 74 Lightly spray the compressor wheel and the gap between the com-  pressor and the bearing casing with penetrating oil. Dispose of dirty water and cleaning agent in accordance with the safe-  ty data sheet. © Copyright 2016 ABB. All rights reserved.
Page 75 Selection of the cleaning agent Cleaning agents which contain chlorine attack metals. Use only pH-neutral cleaning agents which do not attack metals.  CAUTION Observe safety data sheet.  Fill the tank (02) with soaking liquid.  © Copyright 2016 ABB. All rights reserved.
Page 76  Maintain dimension (B) for the supports (01), so that the cartridge  group does not submerge too deep. Allow the layers of dirt on the turbine to soak for four hours.  © Copyright 2016 ABB. All rights reserved.
Page 77 Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against mechanical hazards. Raise the cartridge group and align horizontally.  Remove dirt manually with a soft brush or wire brush.  © Copyright 2016 ABB. All rights reserved.
Page 78 Lightly spray the turbine and the gap between the turbine and partition  wall with penetrating oil. Dispose of dirty water and cleaning agent in accordance with the spec-  ifications in the safety data sheet. © Copyright 2016 ABB. All rights reserved.
Page 79: Troubleshooting
Certain tolerances must be observed to avoid a significant loss of efficiency.  If there is any doubt about the extent of rubbing, then an ABB Turbocharging Service Station must be contacted.  Have a dimension check carried out by an ABB Turbocharg- ing Service Station.
Page 80: Surging Of The Turbocharger
Possible damage to components, such as the compressor wheel, tur- bine blades, bearings and filter silencer CAUTION Have the cause clarified immediately by an ABB Turbocharging ser-  vice station and rectified. Have components inspected for damage and, if necessary, replaced ...
Page 81: Malfunctions During Operation
Defective oil pump in lubricat- Check / replace it ing system Manometer display wrong Replace the manometer Turbocharger Rotor axial clearance too large Contact an ABB Turbocharging Service Station Reduction in speed Possible causes Elimination Engine Defects of connected cylin-...
Page 82 Charge air Cooler contaminated Clean it cooler Cooling water volume too low Top up the water Entry temperature of cooling Inspect / clean the cooling water too high system Inadequate ventilation Improve the ventilation © Copyright 2016 ABB. All rights reserved.
Page 83 Elimination Engine Malfunctioning injection system Repair it or contact the man- ufacturer Poorly adjusted injection system Correct it Engine performance higher than Check engine performance expected Turbocharger Manometer display wrong Replace the manometer © Copyright 2016 ABB. All rights reserved.
Page 84 Reduced fatigue strength of the compressor wheel, compressor blade failure. Possible causes Remedy Turbocharger Material of compressor Check the fuel and its corrosive wheel corroded components, and change fuel if necessary. © Copyright 2016 ABB. All rights reserved.
Page 85: Malfunctions When Stopping
Rubbing rotor Foreign object in turbocharger Run-down time too short Possible causes Elimination Turbocharger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharg- ing Service Station Rubbing rotor Foreign object in turbocharger © Copyright 2016 ABB. All rights reserved.
Page 86: Speed Measurement System
As a result, the voltage amplitude of the speed signal decreases, which can cause problems for the evaluation electronics. This problem is eliminated by removing the gasket. Defective sensor Contact an ABB Turbocharging Service Sta- tion Measured Contaminated The sensor tip is magnetic and can thus at-...
Page 87: Removal And Installation
Removal and installation Transport Suspension of uninsulated turbocharger Turbocharger with oil-cooled bearing Complete turbocharger with gas outlet casing casing Suspension of insulated turbocharger Turbocharger with oil-cooled bearing Complete turbocharger with gas outlet casing casing © Copyright 2016 ABB. All rights reserved.
Page 88: Turbocharger Weights
The following weight specification is the heaviest possibility. This guide value can differ from data on the rating plate, de- pending on the specification. TPS44 TPS48 TPS52 TPS57 TPS61 [kg] [kg] [kg] [kg] [kg] Turbocharger weights © Copyright 2016 ABB. All rights reserved.
Page 89: Remove The Turbocharger
(C). Loosen the fixing screws (D) on the bearing casing.  Lift the turbocharger from the engine and put it down.  Cover oil connections.  © Copyright 2016 ABB. All rights reserved.
Page 90: Installing The Turbocharger
Visually inspect O-ring gaskets of oil supply and drain pipe (O-ring  gaskets for engine are not delivered by ABB Turbo Systems). **) When the turbocharger is mounted on the engine support, the bolt threads and screw heads must be lightly oiled (assumed friction coeffi- cient µ...
Page 91 Adapt and fit sheet metal (B) of bearing casing insulation.  Version with water-cooled bearing casing: Remove the screw plugs from the water connections and fit the water  pipes in accordance with the enginebuilder's instructions. © Copyright 2016 ABB. All rights reserved.
Page 93: Disassembly And Assembly
Incorrectly performed disassembly and assembly of the cartridge group CAUTION can lead to serious machine damage. ABB Turbo Systems recommends having further work carried out on-  ly by trained personnel from an ABB Turbocharging Service Station. Marking casing positions for assembly ABB Turbo Systems recommends that the casing positions are marked before disassembling the turbocharger.
Page 94 The specified tightening torques of screw connections for turbocharger components must be observed. (See section Table of tightening torques.) Tightening torques for assembly devices of ABB Turbo Systems If nothing else is described, the screws and nuts of the assembly devices must be tightened down firmly.
Page 95 Equipment for lifting and transporting loads (ropes, chain hoists, cranes). Lifting gear is not supplied by ABB Turbo Systems. Swivel lifting eye to be used A swivel lifting eye is required to lift loads safely (not supplied by ABB). Swivel lifting eye Product...
Page 96: Module Weights
6 Diffuser 7 Cartridge group 8 Nozzle ring 9 Burst ring 10 Turbine casing 1 inlet with external 2 inlets burst protection 3 inlets 4 inlets 11 Gas outlet flange 12 Exhaust manifold © Copyright 2016 ABB. All rights reserved.
Page 97: Disassembling And Assembling Turbocharger
Remove the screws for the compressor casing insulation and disman- If provided  tle the insulation. Undo the V-clamp (72020) and remove the filter silencer (81000) or air  suction branch (82000). © Copyright 2016 ABB. All rights reserved.
Page 98 Loosen and remove the screws for the insulation plates (1, 2). If provided  If provided: Remove the insulation plates (1, 2).  Remove the remaining screws for the insulation (3).  Remove the insulation (3).  © Copyright 2016 ABB. All rights reserved.
Page 99 Move the compressor casing (72000) with the wall insert (77000) care-  fully away, doing so horizontally. Tap the wall insert (77000) out of the compressor casing using a nylon  hammer and remove the O-ring seal (77005). © Copyright 2016 ABB. All rights reserved.
Page 100  Remove wall insert (77000) using lifting gear.  Disassembly of diffuser TPS..-F31/32 / FV31/32 Loosen screws (72041) and remove them together with lockwashers  (72040) and diffuser (79000) from compressor casing (72000). © Copyright 2016 ABB. All rights reserved.
Page 101 (see chapter Spare parts). NOTICE Refit diffuser in reverse order. Fitting the diffuser  TPS..-F31/32 / FV31/32 Fit compressor housing in reverse order.  Thoroughly clean fastening strips (72012) before fitting them.  © Copyright 2016 ABB. All rights reserved.
Page 102 The press-off tool can generate a high axial force and, if it is not used properly (too much pressure on one side), it can damage the rotor. CAUTION It should thus be used alternately on both sides while avoiding ex-  cessive pressure on either side. © Copyright 2016 ABB. All rights reserved.
Page 103 Mount the cartridge group on the service support (90012) and bolt  it down firmly. Loosen screw (42008) and remove diffuser (79000) complete with  O-ring (42012). Measure the axial and radial clearances (see the section Axial and  radial clearances). © Copyright 2016 ABB. All rights reserved.
Page 104 (51000) as far as it will go. Do not remove the adhesive tape (01). Insert the C-ring (51105) into the turbine casing and secure with high- If present  vacuum grease. © Copyright 2016 ABB. All rights reserved.
Page 105 Nozzle ring press fit for  single inlet turbine casing If the calculated value (PD) is less than 0.1 mm, an official ABB Turbo- charging Service Station must be contacted. NOTICE Measure the axial and radial clearances (see the section Axial and ra- ...
Page 106 Nozzle ring press fit for  multiple inlet turbine cas- If the calculated value (PD) is outside ±0.2 mm, an official ABB Turbo- charging Service Station must be contacted. NOTICE Measure the axial and radial clearances (see the section Axial and ra- ...
Page 107 Remove temporary covers from oil connections.  Don't damage or shift gasket rings (A) in the mounting support when fitting the cartridge group. The gasket rings (A) are supplied by the en- gine builder. CAUTION © Copyright 2016 ABB. All rights reserved.
Page 108 µ = 0.12 for the tightening torque). Product Hole in the bearing casing Fixing screws Tightening torques C [mm] [Nm] **) [mm] TPS44 Ø 17 TPS48 Ø 17 TPS52 Ø 21 TPS57 Ø 21 TPS61 Ø 25 © Copyright 2016 ABB. All rights reserved.
Page 109  Remove gas outlet bend (51100) and gasket (52406). Only gas outlet  bends from ABB Turbo Systems have the gasket (52406). Remove gas outlet flange (52400) and, if fitted, C-ring (52408).  © Copyright 2016 ABB. All rights reserved.
Page 110 If provided, fit the C-ring (52408).  Fit the gas outlet flange (52400).  In the case of gas outlet bends (51100) from ABB Turbo Systems:  always replace the gasket (52406) (see the chapter entitled Spare parts). Apply high-temperature grease to contacting surfaces and threads.
Page 111: Axial Clearance A And Radial Clearance B
TPS57 or TPS61 are outside the permissible range, this can indicate radial bearings with a special bearing geometry. Different permis- sible values are valid for radial bearings with a special bearing geometry (see the table below). © Copyright 2016 ABB. All rights reserved.
Page 112 Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property. CAUTION Have components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. © Copyright 2016 ABB. All rights reserved.
Page 113: Radial Clearances N And R
To measure R1 and R2, the feeler gaug- es must be pushed between the gas out- let flange and the turbine free of play, in each case above and below. © Copyright 2016 ABB. All rights reserved.
Page 114 Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property. CAUTION Have components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. © Copyright 2016 ABB. All rights reserved.
Page 115: Table Of Tightening Torques
Table of tightening torques The following tightening torques must be observed for the specified screw connections: Tightening torques [Nm] Position Part number TPS44 TPS48 TPS52 TPS57 TPS61 72020 42008 52433 51007 72011 86505 © Copyright 2016 ABB. All rights reserved.
Page 117: Taking Out Of Operation
Always heed precisely the engine builder's instructions in case of en- gine operation with a blocked / throttled turbocharger! CAUTION Dismantling the turbocharger Dismantle the turbocharger (see the section Dismantling and fitting the  turbocharger). Do not dismantle the nozzle ring.  © Copyright 2016 ABB. All rights reserved.
Page 118 (51002), Verbus Ripp® Verbusripp washers (51003) and nuts (51007) and screw it down securely on the support. Thoroughly clean the fastening strips (51002) before fitting them. Apply high-temperature grease to the stud threads (51006). NOTICE © Copyright 2016 ABB. All rights reserved.
Page 119 Shutting down the turbocharger Page 117 Cover plate drawing The cover is not supplied by ABB Turbo Systems and must be manufac- tured by the operator according to the following drawing. Material: Common structural steel, according to DIN EN 10025-2 Product ±0.5...
Page 120 Page 118 *) Diameter for turbine casing designs for optional C-ring sealing Information about the turbine casing design (with / without C-ring seal- ing) can be requested from an ABB Turbocharging Service Station. NOTICE © Copyright 2016 ABB. All rights reserved.
Page 121: Mothballing The Turbocharger
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 2016 ABB. All rights reserved.
Page 122: Taking The Engine Out Of Operation For Up To 12 Months
If the total acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking an engine out of operation: Dismantle the turbocharger.  The rotor and the bearing parts must be removed by an official ABB  Turbocharging service station and refitted afterwards. Clean all parts.
Page 123: Taking The Engine Out Of Operation For More Than 12 Months
 The turbocharger remains mounted on the engine.  The turbocharger casing remains mounted on the engine, but the rotor and the bearing parts are removed and stored separately by an ABB Turbocharging Service Station.  The turbocharger is removed completely, either as a whole or in indi- vidual parts.
Page 125: 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.
Page 127: Spare Parts
Socket screw 42008 O-ring 42012 Gasket 52406 * O-ring 77005 Counter-sunk screw 72041 O-ring 81010 / 82010 * This gasket can be used only when using a gas outlet casing from ABB Turbo Systems. © Copyright 2016 ABB. All rights reserved.
Page 128: View Of Turbocharger Showing Part Numbers
Operation Manual / TPS44-F.. - TPS61-F.. Spare parts View of turbocharger showing part 12.2 Page 126 numbers 12.2 View of turbocharger showing part numbers 12.2 © Copyright 2016 ABB. All rights reserved.
Page 129 O-ring 86505(A)* Speed sensor (cable not integrated) 86505(B)* Speed sensor (cable integrated) 86515(A)* Cable connector for 86505(A) 86515(B)* Cable connector for 86505(B) 86526* F/I converter 86528* Tachometer * depends on the turbocharger specification. © Copyright 2016 ABB. All rights reserved.
Page 130: View Of Cartridge Group Showing Part Numbers
Operation Manual / TPS44-F.. - TPS61-F.. Spare parts View of cartridge group showing part 12.3 Page 128 numbers 12.3 View of cartridge group showing part num- bers 12.3 © Copyright 2016 ABB. All rights reserved.
Page 131 Bearing flange 32113 Socket screw 32114 Socket screw 32221 Bearing cover 32222 O-ring 42001 Bearing casing 42002 Socket screw 42008 (in customer spare part set) Socket screw 43001 Partition wall 43012* Metal C-ring © Copyright 2016 ABB. All rights reserved.
Page 132 ABB Turbo Systems AG Bruggerstrasse 71a CH-5400 Baden Switzerland...

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