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Turbocharging Operation Manual / TPS48-H32 HT846728 Document identification Document number HZTL4037 Revision Language English Original Operation Manual Product identification Serial number HT846728 Customer part number 1236464 Delivery date (yyyy-mm-dd) 2021-12-10 Weight Operating limits according to rating plate 1035 Speed limit in test rig operation only...
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).
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Caution and warning signs are described in chapter Safety. ABB Turbocharging ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging in this document. Official service stations of ABB Turbocharging Official service stations are regularly audited and certified by ABB Turbocharging. See also chapter Contact information →5.
Inspect the package for damage. If the package is damaged, the turbocharger must be in- spected by an ABB Turbocharging Service Station and repacked. After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station: ¡...
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: ¡...
The use of the turbocharger is limited to the specific application released at the time of de- livery. ABB accepts no liability and rejects all warranty claims for any non-intended uses. [1]Euromot = The European Association of Internal Combustion Engine Manufacturers...
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.
If warning plates are not present in the designated locations or not readable, proceed as fol- lows: Order new warning plates from ABB Turbocharging Service Stations. Remove any warning plates that have become unreadable. Clean and degrease the areas designated for the warning plates.
Operation above the indicated values n can considerably shorten the recommended Bmax Bmax replacement intervals. In such cases, we recommend contacting the nearest ABB Turbochar- ging Service Station. normally apply only when running at overload (110 %) during trials on the engine Mmax Mmax test bed.
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 scope of delivery. Fig. 12: Inserting gaskets into the bracket...
8. Connect cable to speed sensor (86505). Remove the lifting gear. Connect all gas and air lines according to the instructions of the enginebuilder. If the gas outlet casing from ABB has not been dismantled with the turbocharger, refer to chapter Removing the gas outlet casing →74.
Oil pressure measuring point Oil temperature measuring point For monitoring the lubricating oil pressure, ABB Turbocharging recommends installing a "P" manometer immediately upstream of the turbocharger oil inlet before the orifice. If the pressure is controlled electronically, the relevant signals should be triggered at the warning and alarm values.
For operating limits, refer to the Operation Manual title page or the rating plate on the turbocharger. If no speed measurement system is present, the system below can be ordered from an ABB Turbocharging Service Station (see chapter Ordering spare parts →98).
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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. 5.3.4 Malfunctions on the speed measurement system...
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. 17: Fitting the speed sensor...
Agree on a specific service interval with ABB Turbocharging. To prevent machine damage caused by ageing and downtime, we recommend having an in- spection carried out by an ABB Turbocharging Service Station no later than 5 years after the last service.
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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.
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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.
ABB Turbocharging therefore recommends having the components periodically inspected and replaced, if neces- sary, by an ABB Turbocharging Service Station based on the number of successful engine start cycles specified in the following table.
Observe the oil pressure while performing post-lubrication: 0.5 < p Switch off post-lubrication as soon as the rotor is stationary or after no more than two minutes. Deviating procedures must be coordinated with ABB Turbocharging. CAUTION Water cooling after stopping the engine If the heat in the turbocharger is not dissipated after the engine stops, dam- age may result.
Cleaning components mechanically Engine stopped (usually every 8000 … 12000 h) →53 Table 13: Maintenance table [h] = Hours of operation ABB Turbocharging recommends having mechanical cleaning carried out by an ABB Tur- bocharging Service Station during the service work. Cleaning components mechanically 8.2.1 Preparation CAUTION...
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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. 19: Cleaning the filter silencer →54)
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. ¡ Have a dimension check carried out by an ABB Turbocharging Service Sta- tion.
Turbochar- Turbine and/or nozzle ring severely con- Clean (see chapter Periodic mainten- taminated ance work →53) Rotor components or bearing damaged Contact ABB Turbocharging Service Station Engine Defects on the connected cylinders in Contact enginebuilder pulse charging Pipes Defects, such as leaks, in the exhaust...
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...
→53) Bearing damaged Check clearances (see chapter Measuring clear- ance A and B). If clearances are outside the toler- ance or if in doubt, contact an ABB Turbocharging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station.
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. 31: Do not loosen screw plugs Removing the turbine-end fastening strips Mark the casing position for assembly.
1. Measure dimensions A, B, and C on cleaned surfaces. 2. Calculate the compression (PD) and compare it with the permissible values in the follow- ing table. If the calculated value (PD) lies outside the specified range, contact an ABB Turbochar- ging Service Station. Product...
¡ 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...
(RoHS2). Products and related accessories manufac- tured by ABB Switzerland Ltd, Turbocharging do not fall within the Scope of RoHS2 due to their application in large scale fixed installations, means of transports for persons or goods, non-road mobile machinery (Directive 2011/65/EC Article 2, 4.(e), (f), (g)).
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.
Designation Quantity 90012 Service support Table 53: TPS-H Tool This tool can be ordered from any ABB Turbocharging Service Station. The following spe- cifications must be included in the order: ¡ Turbocharger type ¡ Part number and designation of the tool.