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All manuals and user guides at all-guides.com Operation Manual TPS 61D01 Type TPS 61D01 HT846638 Mmax Mmax °C Bmax Bmax 00650 Application according to Year 2021 the Operation Manual ABB Turbocharging...
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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.
All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. Table of contents Operation Manual Preliminary remarks....................3 Purpose of this manual ....................3 Layout and function......................4 Intended use of the turbocharger ................6 Storage of new turbochargers and spare parts ............7 Essential information.....................
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. Table of contents Troubleshooting....................68 Malfunctions when starting..................68 Surging of the turbocharger..................69 Malfunctions during operation .................. 70 Malfunctions when stopping ..................72 Speed measurement system ..................73 Removal and installation..................
Operation Manual This Operation Manual helps familiarise the user with the turbocharger from ABB Turbocharging and how to use it as intended. It provides important information in order that the turbocharger can be operated safely, correctly and efficiently.
All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 1 Preliminary remarks / 1.2 Layout and function 1.2 Layout and function 1Suction branch / filter silencer 8Gas outlet flange 2Compressor casing 9Nozzle ring 3Diffuser 10Turbine casing 4Bearing casing 11Turbine-end bearing flange 5Axial thrust bearing...
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 1 Preliminary remarks / 1.2 Layout and function Mode of operation The turbocharger is a turbomachine consisting of the following main components: ¡ Turbine ¡ Compressor These are mounted on a common shaft. Exhaust gases from the diesel or gas engine flow through the turbine casing (10) and the nozzle ring (9) to impinge on the turbine (7).
Any other use is considered to be a special application, which must first be clarified with ABB Turbocharging. The manufacturer accepts no liab- ility for any other type of use. If the equipment is used for any other purpose, ABB Turbocharging reserves the right to reject all warranty claims.
1.4 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 Turbocharging 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).
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Seal the package. The better the external seal is designed, the more permanent the protection. Long-term storage of turbochargers The turbochargers will be prepared for prolonged storage by ABB Tur- bocharging on request. The package is equipped with a hygrometer (see illustration).
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Only use original parts from ABB. ABB 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.
All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 1 Preliminary remarks / 1.7 Turbocharger rating plate 1.7 Turbocharger rating plate Operating limits 01 Turbocharger operating limits at engine overload (110 %). Only when operating in the test rig unless otherwise agreed with the enginebuilder.
One rating plate (01) each is attached on the left and the right side of the turbocharger bearing casing. 1.8 Contact information Contact information for the official service stations of ABB Turbochar- ging is available online. Scan the QR code to access our website.
2 Safety / 2.1 Introduction 2 Safety 2.1 Introduction Turbochargers manufactured by ABB are state of the art and comply with the pertinent safety and health-protection requirements that ap- plied when the turbocharger was manufactured. Consequently, the tur- bocharger is safe to operate. Nevertheless, during turbocharger opera-...
All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 2 Safety / 2.3 Definition of mandatory signs 2.3 Definition of mandatory signs To be worn at all times Protective clothing Safety footwear to pro- tect against mechanical hazard and risk of falling To be worn according to the specific work Safety glasses...
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. Clean and degrease surfaces provided for warning plates.
All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 2 Safety / 2.6 Safe operation and maintenance 2.6 Safe operation and maintenance The instructions specified in this section are for the safety of personnel. Together with the instructions in the Hazards during operation and maintenance section, they allow the user to safely use the turbocharger.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 2 Safety / 2.6 Safe operation and maintenance Safety during start-up / commissioning and operation Before starting work, carry out visual inspection of working area. Remove any obstacles and objects lying around. Before start-up / commissioning, check all pipes from and to tur- bocharger for damage and leaks.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 2 Safety / 2.6 Safe operation and maintenance Safety during disassembly, assembly, maintenance and troubleshooting Always perform the specified adjustments, servicing as well as in- spection work and observe inspection intervals. Inform operating personnel about all service and repair work before beginning.
All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 2 Safety / 2.7 Hazards during operation and maintenance 2.7 Hazards during operation and maintenance Mechanical hazards during operation During normal operation, no mechanical hazards emanate from the tur- bocharger if it has been installed properly.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 2 Safety / 2.7 Hazards during operation and maintenance Hazards due to noise The development of noise during operation is influenced by the installa- tion and operating conditions. Noise with a sound pressure level exceed- ing 85 dB(A) is harmful.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 2 Safety / 2.7 Hazards during operation and maintenance WARNING Hot surfaces on uninsulated turbochargers Uninsulated turbochargers can cause serious personal injuries (burns). The turbocharger is supplied with or without insulation in accordance with the purchase order received from the enginebuilder.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 2 Safety / 2.7 Hazards during operation and maintenance WARNING Risk of fire, explosion Flammable and combustible operating materials and supplies can catch fire or resulting vapours can lead to an explosion. Observe the details in the material safety data sheets of the operat- ing and auxiliary materials.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 2 Safety / 2.7 Hazards during operation and maintenance Hazards when handling insulating materials WARNING Hazards due to insulating materials Dust and fibres from insulating materials can cause damage to health or irritations.
Operation Manual / TPS48-D/E.. - TPS61-D/E.. 2 Safety / 2.9 Periodic checking of the pressure vessel 2.9 Periodic checking of the pressure vessel The pressure vessels used by ABB, such as those for wet or dry cleaning, are so-called "simple pressure vessels". ¡...
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 2 Safety / 2.10 Lifting loads In the case of two or more suspension points, the slinging angle must not exceed 45°. This avoids excessive loading due to inclined tensile loading.
All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 3 Commissioning / 3.1 Oil supply 3 Commissioning 3.1 Oil supply A carefully designed and installed oil supply, which functions in all pos- sible operational conditions, is an important prerequisite for trouble- free turbocharger operation.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 3 Commissioning / 3.1 Oil supply Lubricant NOTICE All lubricating oils used for engines are admissible. Oil inlet viscosity and temperature The oil-inlet temperature must not exceed 105°C. Permissible oil-inlet viscosities and oil-inlet temperatures are shown in the following chart.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 3 Commissioning / 3.1 Oil supply Oil pressure The oil pressure in front of the turbocharger must be maintained pre- cisely to ensure trouble-free operation. Status for operation Oil pressure in front of turbocharger [bar]...
All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 3 Commissioning / 3.2 Inspection work 3.2 Inspection work Inspection work includes preventive visual controls plus monitoring and measuring work before and during commissioning. Inspections help de- tect changes to the turbocharger.
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The first step is to check for leak- age of the oil supply to the turbocharger. If this is leaky, contact an offi- cial ABB Turbocharging service station. 3.2.4 Inspection after 100 service hours Clean or replace lubricating oil filters after the first 100 service hours.
All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 3 Commissioning / 3.3 Commissioning after taking out of operation 3.3 Commissioning after taking out of operation If provided Remove cover plates (blind flanges) between compressor casing out- let and charge air duct, before gas inlet and after gas outlet.
All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 4 Operation / 4.1 Noise emissions 4 Operation 4.1 Noise emissions WARNING Hazards due to noise Noise can cause impaired hearing, damage to health, mental disturb- ances, diminished attention and irritation. Always wear ear protection when the engine is running.
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4.2.3 Service work in accordance with instructions on rating plate (In general, after 8000 … 16000 hours of operation) Rotor and bearing parts must be inspected and assessed by an ABB Tur- bocharging Service Station. The following work can be carried in prepar- ation.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 4 Operation / 4.2 Servicing work 4.2.4 Entries in engine logbook By monitoring the engine, conclusions can be drawn about the tur- bocharger performance. The following operating data and measured values must be entered reg- ularly in the engine manufacturer's engine logbook: ¡...
All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 4 Operation / 4.3 Expected exchange intervals 4.3 Expected exchange intervals Rotating components The recommended replacement intervals for compressor wheels and tur- bine wheels are defined depending on the operating conditions and based on the safety concept (SiKo) for rotating parts.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 4 Operation / 4.3 Expected exchange intervals Influencing parameters The specified values are only guide values and not guaranteed. The ac- tual values can deviate considerably from the guide values due, for ex- ample, to the following influences: ¡...
All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 4 Operation / 4.4 Speed measurement 4.4 Speed measurement A speed measuring system permits continuous monitoring of the tur- bocharger speed. CAUTION Do not use cables as a climbing aid If you pull the speed measurement cables too hard, contacts can be pulled out.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 4 Operation / 4.4 Speed measurement 4.4.2 Replacing the speed sensor WARNING Hot cable connector and hot speed sensor Risk of burning. During operation, the cable connector and the speed sensor can reach temperatures exceeding 100 °C.
All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 4 Operation / 4.5 Stopping the engine NOTICE Sealing of the speed sensor The speed sensor is designed with a sealing lip and does not require any additional gasket for assembly. Connect cable connector to speed sensor.
To allow you to observe the standard service intervals and to maintain a high turbocharger efficiency, ABB Turbocharging recommends that the cleaning procedure be carried out during operation. This allows the thermal load of the engine to be kept low while ensuring maximum fuel efficiency.
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. Cleaning interval The interval between periodic cleaning is very dependent on the operat- ing conditions.
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Cleaning method Cleaning the compressor while in operation is carried out as wet clean- ing. This cleaning method is tested and approved by ABB Turbocharging. Principle of wet cleaning To clean the compressor stage during operation, water is injected in front of the compressor wheel through an injection pipe fitted in the fil- ter silencer or the suction branch.
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Operating state prerequisites for cleaning compressor with XC1 NOTICE To be able to carry out a satisfactory cleaning process which has been tested and is recommended by ABB Turbocharging, the following pre- requisites must be fulfilled: Run engine at load from 50 … 85 %.
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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 Turbochar- ging Service Station. Cleaning parameters per...
ABB Turbocharging recommends the use of fuels with low ash, sulphur, sodium and vanadium contents. Consequences of contamination: ¡...
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NOTICE Cleaning intervals Should the specified cleaning intervals prove incompatible with engine operation, please contact ABB Turbocharging. Cleaning method Turbine components are cleaned during operation by using the wet cleaning method described below. This cleaning method is tested and approved by ABB Turbocharging.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 5 Maintenance / 5.3 Turbine cleaning during operation 5.3.2 Prerequisites CAUTION Risk of corrosion and deposits Impairment and damage of turbocharger by salt water and cooling wa- ter additives in flow ducts Don't use salt water for cleaning, but only clean fresh water.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 5 Maintenance / 5.3 Turbine cleaning during operation Recommended operating state for turbine wet cleaning The following operating state is tested and approved by ABB Turbochar- ging: Characteristic / com- Conditions...
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 5 Maintenance / 5.3 Turbine cleaning during operation 5.3.3 Procedure for method with short water injection time Prerequisites have been fulfilled. Wait 10 minutes during a stabilising phase after reducing the engine load.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 5 Maintenance / 5.3 Turbine cleaning during operation 5.3.4 Procedure for method with long water injection time Prerequisites have been fulfilled. Wait 10 minutes as a stabilising phase after reducing the engine load. Open the shut-off valve.
All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 5 Maintenance / 5.4 Cleaning components mechanically 5.4 Cleaning components mechanically 5.4.1 Introduction CAUTION Choosing cleaning tools Turbocharger components are sensitive to mechanical damage. The use of needle guns or other impact tools, for example, damages the components.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 5 Maintenance / 5.4 Cleaning components mechanically 5.4.2 Cleaning the filter silencer 81135Filter silencer body 81266Cover grid 81136Absorption segment 81270Tension band 81137Sheet-metal covering 81271Lock 81265Filter ring NOTICE Disassembly and assembly The procedure for disassembly and assembly of the filter silencer is de- scribed in the chapter entitled Disassembly and Assembly.
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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 cover- ings (81137).
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 5 Maintenance / 5.4 Cleaning components mechanically 5.4.3 Compressor-end, non-rotating parts WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or contact with them may be harmful to health.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 5 Maintenance / 5.4 Cleaning components mechanically 5.4.4 Turbine-end, non-rotating parts WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or contact with them may be harmful to health.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 5 Maintenance / 5.4 Cleaning components mechanically Dispose of contaminated water and cleaning agents in accordance with the information in the material safety data sheet. 5.4.5 Cartridge group Introduction CAUTION Corrosion...
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 5 Maintenance / 5.4 Cleaning components mechanically Cleaning the compressor end CAUTION Selection of the cleaning agent Cleaning agents which contain chlorine attack metals. Use only pH-neutral cleaning agents which do not attack metals. Observe safety data sheet.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 5 Maintenance / 5.4 Cleaning components mechanically Cleaning the turbine end Soaking the dirt Baked-on layers of dirt from heavy fuel oil or coked oil, occur at the tur- bine end.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 5 Maintenance / 5.4 Cleaning components mechanically WARNING Heating up of cleaning agents and operating fluids When cleaning agents or operating fluids are heated up, explosive va- pours can be produced which are hazardous to health.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 5 Maintenance / 5.4 Cleaning components mechanically CAUTION Water and dirt in the cartridge group If water or dirt gets into the cartridge group, the turbocharger function may be impaired and parts in the cartridge group may be damaged.
Prolonged or periodic surging Possible damage to components, such as the compressor wheel, tur- bine blades, bearings and filter silencer Have the cause clarified immediately by an ABB Turbocharging ser- vice station and rectified. Have components inspected for damage and, if necessary, replaced by an ABB Turbocharging service station.
Defective oil pump in lubricat- Check / replace it ing system Manometer display wrong Replace the manometer Turbochar- Rotor axial clearance too large Contact an ABB Turbocharging Service Station Reduction in speed Possible causes Elimination Engine Defects of connected cylinders...
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Exhaust counterpressure Clean or repair the boiler or ex- too high haust silencer Enlarged flow cross-section Contact an ABB Turbocharging of the nozzle ring due to de- Service Station formed blade trailing edges Damaged or eroded turbine Charge air...
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-...
All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 7 Removal and installation / 7.1 Transport 7 Removal and installation 7.1 Transport Suspension of uninsulated turbocharger Turbocharger with oil-cooled bearing Complete turbocharger with gas out- casing let casing Suspension of insulated turbocharger Turbocharger with oil-cooled bearing...
All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 7 Removal and installation / 7.2 Turbocharger weights 7.2 Turbocharger weights Lifting gear with a sufficient load limit must be used for removing and installing the turbocharger. The following weight specification is the heaviest variant possible.
Remove covers from oil connections. Visually inspect O-ring gaskets of oil supply and drain pipe (O-ring gaskets for engine are not included in the scope of delivery of ABB). **) When the turbocharger is mounted on the engine support, the bolt threads and screw heads must be lightly oiled (assumed friction coeffi- cient µ...
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 7 Removal and installation / 7.4 Installing the turbocharger If present: Fit speed sensor and plug in cable connector. Adapt and fit bearing casing insulation (A). 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.
Incorrectly performed disassembly and assembly of the cartridge group can lead to serious machine damage. ABB Turbocharging recommends having further work carried out only by trained personnel from an ABB Turbocharging Service Sta- tion. Mark the casing position for assembly.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 8 Disassembly and assembly / 8.1 Introduction Swivel lifting eye to be used A swivel lifting eye is required to lift loads safely (not supplied by ABB). Swivel lifting eye Product Thread Length...
All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 8 Disassembly and assembly / 8.2 Module weights 8.2 Module weights The specified weights of individual parts or assemblies are guides roun- ded off to the next highest value. Description TPS48 TPS52...
All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bocharger 8.3 Disassembling and assembling turbocharger Removing the compressor casing WARNING Risk of burning Touching hot surfaces or contact with hot operating materials can lead to serious burns.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bocharger Remove the insulation plates (1, 2). Slightly loosen the screws (72011) and turn the compressor casing (72000) until the swivel lifting eye can be fastened to the lifting gear.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bocharger NOTICE If the compressor casing cannot be removed easily, it can be pressed off using the press-off tool (90042) against the turbine casing. To do this, the two cover plates (1, 2) must be removed from the hard insula- tion on the turbine casing.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bocharger NOTICE O-rings Used O-rings must always be replaced with new ones. O-rings are only available as a set (see chapter Spare parts). Install compressor casing in reverse order.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bocharger Withdraw nozzle ring (56001) using two extraction devices (90070) and withdraw bottom part of service support (90012). If provided Remove C-ring (51105).
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bocharger Removing the diffuser Put cartridge group (42001) on service support (90012) and secure us- ing bolts. Remove screw (42008) and remove diffuser (79000) complete with O- ring (42012).
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bocharger Installing the cartridge group NOTICE O-rings Used O-rings must always be replaced with new ones. O-rings are only available as a set (see chapter Spare parts).
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Calculate the press fit (PD) as shown. single inlet turbine casing NOTICE If the calculated value (PD) is less than 0.1 mm, an official ABB Tur- bocharging Service Station must be contacted. Measure the axial and radial clearances (see the section Axial and ra- dial clearances).
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Calculate the press fit (PD) as shown. multiple inlet turbine cas- NOTICE If the calculated value (PD) is outside ±0.2 mm, an official ABB Tur- bocharging Service Station must be contacted. Measure the axial and radial clearances (see the section Axial and ra- dial clearances).
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bocharger Fitting diffuser Fasten diffuser (79000) and O-ring (42012) using screw (42008). Check lifting gear and fasten to bearing casing (42001). Unscrew the cartridge group and lift it out of the service support (90012).
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 8 Disassembly and assembly / 8.3 Disassembling and assembling tur- bocharger Fasten the cartridge group using fastening strips (51002), Verbus Ripp® washers (51003) and nuts (51007) (also see the chapter entitled Table of tightening torques).
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Fitting the gas outlet flange and gas outlet manifold If provided, fit the C-ring (52408). Fit the gas outlet flange (52400). For gas outlet manifolds (51100) from ABB: always replace the gasket (52406) (see the chapter entitled Spare parts). Apply high-temperature grease to contacting surfaces and threads.
All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 8 Disassembly and assembly / 8.5 Radial clearances N and R 8.5 Radial clearances N and R N and R These are the theoretical values of the radial clearance between the com- pressor wheel and the wall insert and / or turbine wheel and the gas out- let flange.
All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 8 Disassembly and assembly / 8.6 Table of tightening torques 8.6 Table of tightening torques The following tightening torques must be observed for the designated screw fittings: Tightening torques [Nm] Position Part number...
All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 9 Taking out of operation / 9.1 Shutting down the turbocharger 9 Taking out of operation 9.1 Shutting down the turbocharger If the turbocharger is damaged and the engine can be shut down for only a short time for emergency repairs, proceed as follows: Fit the cover plate.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 9 Taking out of operation / 9.1 Shutting down the turbocharger Fitting the cover plate Close the opening in the turbine casing using the cover plate (A). Fasten the cover plate on the turbine casing (51000) using the fasten- ing strips (51002), Verbus Ripp®...
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9 Taking out of operation / 9.1 Shutting down the turbocharger Cover plate drawing The cover is not included in the scope of delivery of ABB and must be manufactured by the operator according to the following drawing. Material: Common structural steel, in compliance with DIN EN 10025-2 Product ±0.5...
All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 10 Mothballing the turbocharger / 10.1 Taking the engine out of opera- tion for up to 12 months 10 Mothballing the turbocharger 10.1 Taking the engine out of operation for up to 12 months Condition of engine lubricating oil The turbocharger normally remains mounted on the engine.
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. Machined, bright surfaces of steel and cast parts must be oiled with anticorrosive oil.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 10 Mothballing the turbocharger / 10.2 Taking the engine out of oper- ation for more than 12 months Suitable storage locations are only dry rooms where the relative humid- ity is between 40 … 70 % and no condensation can form.
All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 11 Disposing of turbocharger components / 11 Disposing of turbocharger components WARNING Handling damaged thermal insulation Damaged thermal insulation can lead to dust exposure. The glass fibres can cause mechanical irritation of the eyes, skin, and respiratory tracts.
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 12 Spare parts / 12.2 View of turbocharger showing part numbers Part number Description 42008 (in customer spare part Socket screw set) 42012 (in customer spare part O-ring set) 51000...
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All manuals and user guides at all-guides.com Operation Manual / TPS48-D/E.. - TPS61-D/E.. 12 Spare parts / 12.3 View of cartridge group showing part numbers Part number Description 21000 Shaft 21002 Piston ring 25000 Compressor wheel 32101 Plain bearing bush 32103 Locking ring 32105...
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All manuals and user guides at all-guides.com ABB Switzerland Ltd Turbocharging Bruggerstrasse 71a CH-5401 Baden Switzerland...