Turbocharging

Operation Manual / TPS52-H33

HT602191

Document identification
Document number HZTL4037
Revision F
Language English
Original Operation Manual

Product identification
Serial number HT602191
Customer part number 12453771
Delivery date (yyyy-mm-dd) 2021-05-12
Weight 250 kg

Operating limits according to rating plate

Speed limit in test rig operation only nMmax 847 1/s
Speed limit during operation nBmax 805 1/s
Gas inlet temperature limit in test rig operation only tMmax 680 °C
Gas inlet temperature limit during operation tBmax 650 °C
Operation Manual / TPS44-H.. - TPS52-H..
Table of contents

Operation Manual / TPS44-H.. - TPS52-H..

1 Introduction............................................................................................................ 4
1.1 Purpose of the manual................................................................................................. 4
1.2 Contact information...................................................................................................... 5
1.3 Essential information.................................................................................................... 5
1.4 Registered trademarks ................................................................................................. 5
1.5 Layout and function of the turbocharger ................................................................ 6
1.6 Symbols, definitions...................................................................................................... 7
1.7 Storage of new turbochargers and spare parts .................................................... 10

2 Safety .................................................................................................................... 12
2.1 Introduction .................................................................................................................. 12
2.2 CE conformity ............................................................................................................... 12
2.3 Definition of mandatory signs .................................................................................. 13
2.4 Definition of safety instructions .............................................................................. 13
2.5 Intended use ................................................................................................................. 14
2.6 Deflagration on gas engines ..................................................................................... 15
2.7 Warning plates on the turbocharger........................................................................ 16
2.8 Turbocharger rating plate.......................................................................................... 17
2.9 Lifting of loads ............................................................................................................. 19
2.10 Prerequisites for operation and maintenance...................................................... 20
2.11 Hazards during operation and maintenance ......................................................... 21
2.12 Safe operation .............................................................................................................. 23
2.13 Safe maintenance ....................................................................................................... 24

3 Removing and Installing...................................................................................... 28

3.1 Turbocharger weight and transportation ............................................................. 28
3.2 Removing the turbocharger...................................................................................... 29
3.3 Installing the turbocharger ........................................................................................ 31

4 Commissioning .................................................................................................... 34
4.1 Oil supply ...................................................................................................................... 34
4.2 Inspection procedures ............................................................................................... 35
4.3 Commissioning after taking out of operation....................................................... 37

5 Monitoring operation .......................................................................................... 38

5.1 Oil pressure, oil temperature.................................................................................... 38
5.2 Exhaust gas temperature before turbine ............................................................... 41
5.3 Turbocharger speed .................................................................................................... 41

6 Operation and service ......................................................................................... 45

6.1 Noise emission ............................................................................................................ 45
6.2 Service work ................................................................................................................. 47

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
Table of contents

6.3 Expected replacement intervals .............................................................................. 50

7 Stopping the engine ............................................................................................ 52

8 Periodic maintenance work ................................................................................ 53

8.1 Foreword to maintenance......................................................................................... 53
8.2 Cleaning components mechanically ....................................................................... 53

9 Eliminating malfunctions.................................................................................... 63
9.1 Malfunctions when starting...................................................................................... 63
9.2 Malfunctions during operation ................................................................................ 64
9.3 Turbocharger is surging ............................................................................................ 67
9.4 Malfunctions when stopping.................................................................................... 68
9.5 Speed measurement system .................................................................................... 69

10 Dismantling and fitting....................................................................................... 70

10.1 Introduction ................................................................................................................. 70
10.2 Material required.......................................................................................................... 71
10.3 Weights of individual parts........................................................................................ 73
10.4 Removing the gas outlet casing .............................................................................. 74
10.5 Removing air inlets ...................................................................................................... 75
10.6 Removing the compressor casing ........................................................................... 76
10.7 Removing the cartridge group .................................................................................. 77
10.8 Removing nozzle ring ................................................................................................. 80
10.9 Measuring clearance A and B..................................................................................... 81
10.10 Nozzle ring compression PD..................................................................................... 82
10.11 Fitting the diffuser ..................................................................................................... 83
10.12 Installing the cartridge group .................................................................................. 84
10.13 Installing the nozzle ring ........................................................................................... 86
10.14 Fitting the turbine casing ......................................................................................... 87
10.15 Turning the turbocharger.......................................................................................... 88
10.16 Measuring radial clearances N and R ...................................................................... 89
10.17 Installing the gas outlet casing................................................................................ 90
10.18 Installing air inlets ....................................................................................................... 91
10.19 Table of tightening torques...................................................................................... 92

11 Taking out of operation at short notice ........................................................... 93

11.1 Possible emergency repairs...................................................................................... 93

12 Mothballing the turbocharger............................................................................ 94

12.1 Taking the engine out of operation for up to 12 months ................................... 94
12.2 Taking the engine out of operation for more than 12 months .......................... 95

13 Material and Disposal.......................................................................................... 96

13.1 REACH and RoHS Compliance Declaration For Products ................................... 96
13.2 Disposing of turbocharger components ............................................................... 97

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
Table of contents

14 Spare parts ........................................................................................................... 98

14.1 Ordering spare parts.................................................................................................. 98
14.2 Required customer spare part set (97070)............................................................ 98
14.3 Spare part - Illustrations............................................................................................ 99

15 Tools .................................................................................................................... 109

Figures................................................................................................................. 110

Tables ................................................................................................................... 111

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
1 Introduction / 1.1 Purpose of the manual

1 Introduction

1.1 Purpose of the manual

Fig. 1: Serial number (01) on the rating plate

This Operation Manual belongs to the turbocharger with the identical serial number (01), see
the Operation Manual title page and the rating plate on the turbocharger.
Page 4 / 111

Operation Manual
The Operation Manual explains the turbocharger and contains instructions for safe opera-
tion.
The Operation Manual is a complement to and expansion of existing national regulations for
occupational safety, accident prevention and environmental protection.

Target group
The Operation Manual is aimed at engineers and trained mechanics responsible for the
proper operation of the engine and for the turbocharger connected to it.

Availability of the Operation Manual

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 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
1 Introduction / 1.2 Contact information

1.2 Contact information

Contact information for the ABB Turbocharging Service Stations is available online.
u Scan the QR code to access our website.

ABB Switzerland Ltd, Turbocharging

Bruggerstrasse 71a
CH-5401 Baden
Switzerland

www.abb.com/turbocharging

1.3 Essential information

Design variants
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.

Page 5 / 111
Please contact an ABB Turbocharging Service Station if you have any questions regarding a
design variant (see Contact information at www.abb.com/turbocharging).

Accuracy of illustrations
The illustrations in this document are general in nature and intended for ease of understand-
ing. Differences in detail are therefore possible.

1.4 Registered trademarks

The trademarks of outside companies are used in this document. These are marked with the
® symbol.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
1 Introduction / 1.5 Layout and function of the turbocharger

1.5 Layout and function of the turbocharger

Page 6 / 111

Fig. 2: Layout and function of the turbocharger

01 Air suction branch / filter silencer 07 Plain bearing bush

02 Compressor casing 08 Turbine
03 Diffuser 09 Nozzle ring
04 Bearing casing 10 Turbine casing
05 Axial thrust bearing 11 Compressor wheel
06 Gas outlet casing

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
1 Introduction / 1.6 Symbols, definitions

Mode of operation
The turbocharger is a turbomachine and consists of the following main components:
¡ Turbine
¡ Compressor.
These components are installed on a common shaft and form the rotor (see Fig. 2: Layout
and function of the turbocharger →6).
The exhaust gases of the internal combustion engine flow through the turbine casing (10)
and the nozzle ring (09) onto the turbine (08). The turbine (08) uses the energy contained in
the exhaust gas to drive the rotor and thus the compressor wheel (11). The exhaust gases
then reach the atmosphere through the exhaust gas pipe connected to the gas outlet cas-
ing (06).
The compressor wheel (11) sucks in air or a mixture of air and gas through the air suction
branch (01) or the filter silencer. In the compressor wheel (11), the energy required for build-
ing up the pressure is transferred to the air. By flowing through the diffuser (03) and the
compressor casing (02), the air is compressed further and is then directed to the engine cyl-
inders.
The rotor runs in a radial plain bearing bush (07) which is located in the bearing casing (04)
between the compressor and the turbine. The axial thrust bearing (05) is located in front of
the radial plain bearing bush.

Page 7 / 111
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 deepest point of the bearing cas-
ing (04).

1.6 Symbols, definitions

Symbols
The following symbols are used in this document:
u Indicates an action step.

1. Indicates a numbered action step.

→ Refers to a page number

Definition of Note

NOTICE
Note
The note provides advice which facilitates the work.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
1 Introduction / 1.6 Symbols, definitions

Definition of mandatory signs

Mandatory signs show the protective equipment to be worn for a task. The mandatory signs
are described in chapter Safety and must be complied with.

Definition of Caution / Warning

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.
Page 8 / 111

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
1 Introduction / 1.6 Symbols, definitions

Definition of pictograms
The following pictograms can occur in this document. These point out actions that must be
taken in accordance with the meaning of the relevant pictogram.

Pictogram Meaning
Tighten with specified torque

Tighten over specified tightening angle

Hand-tight, tighten without tools

Oil

Apply screw locking paste (e.g. Loctite)

Apply high-temperature grease

Apply other paste in accordance with specifications

Oil free, grease free and dry

Affix

Page 9 / 111
Measure

Note

Visually inspect

Please note text for numbered work step.

See document

Dispose of in an environmentally compatible, professional way and in compliance

with locally applicable regulations.
Table 1: Definition of pictograms

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
1 Introduction / 1.7 Storage of new turbochargers and spare parts

1.7 Storage of new turbochargers and spare parts

Storage of new turbochargers and spare parts up to 6 months

New turbochargers and spare parts can be stored in their closed packages for 6 months
from the date of delivery without additional mothballing measures.
Only dry rooms in which the relative humidity is between 40…70 % and no condensation can
form are suitable for storage.

Storage of new turbochargers and spare parts for more than 6 months
As the contents of the package are adapted as required, turbochargers may also be de-
livered without a VCI label.
For parts with a VCI label on the package, the following instructions must be observed.

Fig. 3: Volatile Corrosion Inhibitor (VCI)

Page 10 / 111

WARNING
Health protection when handling VCI
VCI products are not hazardous in terms of the Ordinance on Hazardous
Substances. Nevertheless, the following points must be observed when
handling VCI:
u Observe information in material safety data sheet
u Ensure proper space ventilation.
u Do not eat, drink or store food at the workplace while working with VCI.
u Clean hands and face after working with VCI.
u For more information, see www.branopac.com.

Wear safety gloves to protect against mechanical hazards.

Every 6 months, the following mothballing measures are required:

u Open package.

u Remove VCI corrosion protection emitter from package and replace with a new VCI corro-
sion protection emitter of the same kind. New VCI corrosion protection emitters can be
obtained from www.branopac.com.
u Old VCI corrosion protection emitters must be disposed of in an environmentally compat-
ible, professional way and in compliance with locally applicable regulations.
u Close package. The more tightly the package is sealed, the longer the protection dura-
tion.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
1 Introduction / 1.7 Storage of new turbochargers and spare parts

Long-term storage of turbochargers

The turbochargers will be prepared for long-term storage if requested in the purchase order.
The package is equipped with a hygrometer (see illustration).

Fig. 4: Package with hygrometer

Every 6 months, the following measures are required:

u Check the hygrometer (02) in the sight-glass. There is an opening (01) in the wooden
crate which allows this check to be carried out. When the display field has changed colour
at the 70% level, the maximum permissible humidity has been exceeded. In this case, the
turbocharger must be inspected by an ABB Turbocharging Service Station and repacked.
u Inspect the package for damage. If the package is damaged, the turbocharger must be in-
spected by an ABB Turbocharging Service Station and repacked.

Page 11 / 111
After every 3 years the following work steps must be performed by an ABB Turbocharging
Service Station:
¡ Inspect the component
¡ Replace the desiccant agent
¡ Repackage the component.

NOTICE
70% field of the hygrometer has not changed colour
If the 70% field of the hygrometer (02) has not changed colour and the pack-
age is undamaged, the turbocharger can be put into operation without any
prior inspection by an ABB Turbocharging Service Station.

Unpacking the turbochargers

The corrosion protection effect ends after the material is unpacked from the VCI package.
To avoid the formation of condensation, the surroundings and the content of the package
must have the same temperature during unpacking.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
2 Safety / 2.1 Introduction

2 Safety

2.1 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:
¡ are caused by the turbocharger itself or its accessories.
¡ are caused by the operating equipment used or supplies and materials.
¡ are a consequence of insufficient compliance with safety instructions.
¡ are a consequence of insufficient or inappropriate performance of maintenance and in-
spection work.
The operating company is responsible for defining measures that regulate safe access to
and safe handling of the turbocharger.
All instructions contained in this chapter must be observed for safe and trouble-free opera-
tion of the turbocharger and during all work on the turbocharger.
Page 12 / 111

All further specifically identified safety instructions (Definition of safety instructions →13)
must also be observed.

2.2 CE conformity

Information
ABB turbochargers comply with the Machinery Directive 2006/42/EC and are partly com-
pleted machinery as defined by Article 2 g in this directive.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
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 protect
against mechanical hazard and
risk of falling

Table 2: Personal protective equipment to be worn at all times

To be worn specific to the respective task

Safety glasses Safety goggles

Safety gloves to protect Respiratory mask to protect

against against
- Mechanical hazard - Dusts
- Chemical hazard - Gases
- Thermal hazard
- Electrical hazard
Safety helmet Ear protection

Page 13 / 111
Table 3: Personal protective equipment to be worn specific to the respective task

2.4 Definition of safety instructions

WARNING
Definition of Warning
Non-compliance or inaccurate compliance with working or operating in-
structions indicated by this symbol and the word WARNING can lead to seri-
ous injuries to personnel and even to fatal accidents.
u Warning signs must always be observed.

CAUTION
Definition of Caution
Non-compliance or inaccurate compliance with working or operating in-
structions indicated by this symbol and the word CAUTION can lead to seri-
ous damage to engine or property with grave consequences.
u Caution signs must always be observed.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
2 Safety / 2.5 Intended use

2.5 Intended use

Use on internal combustion engines in general

ABB turbochargers are intended for charging internal combustion engines.
To ensure compliance with the machinery directive 2006/42/EC when using on gas engines,
the turbocharger must be operated in an engine room classified as "not at risk of explosion".
This is in accordance with the position paper [2] relating to ATEX issued by EUROMOT [1].
For use on pre-mix gas engines with ignitable propellents in the gas control system, the en-
ginebuilder must implement appropriate safety measures for explosion protection [3] (such
as flame barriers in the inlet system, for example) to assure that there is no transient pres-
sure increase exceeding a maximum of 12 bar before the turbocharger in case of a deflagra-
tion.
The turbocharger supplies the engine with the air volume or air/gas mixture and the associ-
ated charging pressure required for operation.
The turbocharger is solely intended to be operated with a clockwise direction of rotation as
viewed from the turbine end.
The specific operating limits of the turbocharger were determined on the basis of informa-
tion from the enginebuilder about the intended use. These data are given on the rating
Page 14 / 111

plate.
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
[2]Directive 94/9/EC concerning equipment and protective systems intended for use in po-
tentially explosive atmospheres (ATEX) The Euromot Position as of November 2003, ATEX
Euromot Position 191103
[3]Guidelines for proper safety design of inlet systems on gas engines, RWTÜV Essen, 1991

WARNING
Unapproved operation
Any operation of the turbocharger outside of its operating limits can be haz-
ardous to personnel.
u Only operate the turbocharger within the operating limits.
u Only trained personnel must operate the turbocharger.

The intended use of the turbocharger includes compliance with all regulations and condi-
tions. In particular, the following must be observed:
¡ Operation Manual
¡ Instructions of the enginebuilder

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
2 Safety / 2.6 Deflagration on gas engines

State of the art

The turbocharger is designed and manufactured according to the state of the art and is safe
to operate.

Perfect condition
The turbocharger must only be used when it is in a technically flawless condition and oper-
ated in compliance with its intended use.
ABB excludes any liability for damage resulting from unauthorized modifications to the tur-
bocharger or improper operation.

2.6 Deflagration on gas engines

ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar.
After a deflagration event ABB recommends verifying the following points on the turbochar-
ger:
¡ Position of the turbine and compressor casings to the bearing casing
¡ Shifting of the bearing casing in relation to the bracket

Page 15 / 111
¡ Cracks in casings
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.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
2 Safety / 2.7 Warning plates on the turbocharger

2.7 Warning plates on the turbocharger

Warning plates are affixed at the following locations:
Page 16 / 111

Fig. 5: Warning plate locations

If warning plates are not present in the designated locations or not readable, proceed as fol-
lows:
u Order new warning plates from ABB Turbocharging Service Stations.

u Remove any warning plates that have become unreadable.

u Clean and degrease the areas designated for the warning plates.

u Fit new warning plates and remove protective sheets.

Turbochargers supplied to the enginebuilder without insulation must be equipped later with
warning plates on the insulation. This is the responsibility of the enginebuilder.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
2 Safety / 2.8 Turbocharger rating plate

2.8 Turbocharger rating plate

Fig. 6: Rating plate

Operating limits
01 Turbocharger operating limits at engine overload (110 %).
In test rig operation only, unless otherwise agreed with the en-
ginebuilder.

Page 17 / 111
02 Turbocharger operating limits during operation

Recommended inspection and replacement intervals of turbocharger components

03 Inspection interval of plain bearings in 1000 h
04 Replacement interval of compressor in 1000 h
05 Replacement interval of turbine in 1000 h

If the turbocharger is used for the ‘Peak shaving’ mode with frequent engine start/stop
cycles, the number of successful engine start/stop cycles must be taken into account in ad-
dition to the replacement intervals (in operating hours) for the compressor and the turbine
wheels as well as the bearing check interval, specified on the rating plate.
Further information and specifications regarding inspection and replacement intervals for
the ‘Peak shaving’ mode use can be found in the chapter Operation and service of the Opera-
tion Manual.

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
12 Manufacturing plant

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
2 Safety / 2.8 Turbocharger rating plate

Explanations regarding the rating plate

The recommended inspection and replacement intervals and the corresponding operating
limits are jointly defined with the enginebuilder. This information is specific to the system.
Operation above the indicated values nBmax, tBmax can considerably shorten the recommended
replacement intervals. In such cases, we recommend contacting the nearest ABB Turbochar-
ging Service Station.
nMmax, tMmax normally apply only when running at overload (110 %) during trials on the engine
test bed. These limit values can also be permitted during operation for special applications.
Operation above nMmax and tMmax is not permitted.
Non-observance of the recommended inspection and replacement intervals increases the
risk of unpredictable component failures.
For operating limits, refer to the Operation Manual title page or the rating plate on the tur-
bocharger.

Position of the rating plate

The rating plate (01) is attached at the top on the bearing casing of the turbocharger.
Page 18 / 111

Fig. 7: Position of the rating plate

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
2 Safety / 2.9 Lifting of loads

2.9 Lifting of loads

WARNING
Suspended loads
Loads that are not attached according to regulations can cause injury to
personnel or fatal accidents.
u Loads must always be fastened to properly functional lifting gear with a
sufficient load limit.
u Pay attention to the correct attachment of loads on the crane hook.
u People must not stand beneath suspended loads.

Wear safety gloves to protect against mechanical hazards.

Wear safety helmet.

Page 19 / 111
Fig. 8: Attachment of loads on the crane hook

Fig. 9: Attachment angle

If there are two or more suspension points, the attachment angle of 45° must not be ex-
ceeded. This prevents excessive loading due to diagonal pull.
u Before looping around the components of the turbocharger, let them cool down (max-
imum 80 °C).
u Attach components of the turbocharger as described in the respective action steps.

u Use a suitable edge guard if there are sharp edges.

u The assembly devices must be completely screwed in and must not loosen during use.

u Use assembly devices only for the described applications.

u Put down dismantled components of the turbocharger in such a way that they cannot tip
over.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
2 Safety / 2.10 Prerequisites for operation and maintenance

2.10 Prerequisites for operation and maintenance

Responsibility of the operating company

In awareness of its responsibility, the operating company must ensure that only authorised
personnel work on the turbocharger, who:
¡ Are versed in the general and locally applicable regulations for occupational safety and
accident prevention
¡ Are equipped with the prescribed personal protective equipment
¡ Have read and understood the Operation Manual
¡ Have been instructed in the use of the turbocharger.
The safety-conscious work of the personnel and adherence to the Operation Manual must be
checked periodically.
Suitable working materials and personal protective equipment must be kept in a perfect
condition.
Only authorised personnel may remain in the vicinity of the turbocharger when the engine is
running.
Page 20 / 111

Competence of personnel
The turbocharger must only be operated and serviced by trained and authorised personnel.
Basic mechanical training is a prerequisite.

Modifications to the turbocharger

Modifications to the turbocharger must be approved by ABB.

WARNING
Use original parts
Operation of the turbocharger with non-original parts can impair the safety
of the turbocharger and can cause serious damage to property and injury to
personnel.
u Only use original parts from ABB.

Original parts and accessories are specially designed for ABB turbochargers.
ABB accepts no liability for any damage resulting from the use of non-original parts and cor-
responding accessories.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
2 Safety / 2.11 Hazards during operation and maintenance

2.11 Hazards during operation and maintenance

Noise hazards
The turbocharger's noise emission is influenced by its installation and operating conditions.
A noise level exceeding 85 dB(A) is harmful.

WARNING
Noise hazards
Exposure to noise can harm the hearing system, impair health and the psy-
chological state and may lead to lack of attention and irritation.
u When the engine is running, always wear ear protection.
u Always wear ear protection if the sound pressure level exceeds 85 dB(A).

Wear ear protection.

Hazards due to hot surfaces

Surfaces of the turbocharger, attached parts and operating fluids (lubricating oil) get hot

Page 21 / 111
during operation. The surface temperature depends on the efficacy of the existing insula-
tion. The temperature may rise to a level that can cause burns.

WARNING
Danger of burns
Touching hot surfaces or contact with hot operating fluids can cause burns.
u Do not touch hot surfaces. Observe the warning plate on the turbochar-
ger.
u Wear heat-resistant safety gloves and protective clothing.
u Wait for the turbocharger to cool down before carrying out any work.

Wear safety gloves to protect against thermal hazards.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
2 Safety / 2.11 Hazards during operation and maintenance

WARNING
Hot surfaces on a non-insulated turbocharger
Non-insulated turbochargers can cause serious injuries to personnel (burns).
The turbocharger is supplied with or without insulation in accordance with
the purchase order received from the enginebuilder. If supply is without in-
sulation, the enginebuilder is responsible for providing the turbocharger
with proper insulation and for providing protection against contact with hot
surfaces.
u Compliance with the instructions and specifications given by the en-
ginebuilder to protect against hot turbocharger surfaces is compulsory.

Wear safety gloves to protect against thermal hazards.

Hazards due to rotating parts

WARNING
Hazards due to rotating parts
Contact with rotating parts can cause severe injury. The turbocharger is
Page 22 / 111

never allowed to be operated without filter silencer or air-inlet casing. With

the engine stopped, the rotor can rotate due to the stack draught alone.
u Operate the turbocharger in compliance with the specifications.
u Secure the rotor against unintentional rotation during maintenance.

Wear safety gloves to protect against mechanical hazards.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
2 Safety / 2.12 Safe operation

2.12 Safe operation

Mechanical hazards during operation

During standard operation, no mechanical hazards are caused by the turbocharger itself if it
has been properly installed.

Safety during commissioning and operation

u Visually inspect your working environment before starting work.

u Remove any obstacles and objects littering the workplace.

u Check all pipes to and from the turbocharger for damage and leaks before commission-
ing.
u Check turbocharger for recognisable damage or defects every 12 hours of operation or at
least once a day.
u Report any damage and any alterations of operational characteristics to the responsible
department immediately.
u In case of damage, take the turbocharger out of operation immediately and safeguard
against accidental/unauthorised use.

Page 23 / 111
u When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay at-
tention to the risks that may occur as a consequence of this energy input.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
2 Safety / 2.13 Safe maintenance

2.13 Safe maintenance

Occupational safety

WARNING
Injuries to persons
Severe injuries to personnel or fatal accidents can be caused by mechanical
influences as a consequence of hazardous and inadequate operational pro-
cedures or non-compliance with safety and health standards.
u When working on the turbocharger always wear safety footwear and pro-
tective clothing to protect against mechanical hazards.
u Keep personal protective equipment in perfect condition.
u Obey mandatory signs.
u Observe the general rules for occupational safety and prevention of acci-
dents.
u Only perform operations that are described in this chapter.
u Only perform operations for which you have received instruction or train-
ing.
Page 24 / 111

Wear safety footwear to protect against mechanical hazard and risk of fall-
ing.

Wear protective clothing.

WARNING
Risk of falling
When working on the turbocharger, there is a risk of falling.
u Do not climb onto the turbocharger or onto attached parts and do not
use them as climbing aids.
u Use suitable climbing aids and working platforms for work above body
height.

u Only perform work on the turbocharger when you are in a physically and psychologically
stable condition.
u Only work with suitable tools, equipment and appliances that function properly.

u Power tools must be grounded and cables must be undamaged.

u Keep the workplace clean; clear away any loose objects and obstacles on the floor.

u Keep the floor, equipment, and turbocharger clean.

u Have oil binding agents ready and provide or keep oil pans at hand.

u Clean up any spills.

u Have fire protection means and extinguishing agents available.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
2 Safety / 2.13 Safe maintenance

Use of assembly devices

Assembly devices are specially constructed and designed for the defined use; they are not
commercially available products.
u Use assembly devices only for the described applications.

Welding work in the vicinity of the turbocharger

u When performing welding work in the vicinity of the turbocharger, always cover the filter
silencer to prevent the filter mat from being damaged.
u Keep flammable objects and substances out of the vicinity of flying sparks.

u Cover all connections on the turbocharger so that no foreign objects can enter the tur-
bocharger.
u Wear personal protective equipment (PPE) for welding operations.

Safety during cleaning

If cleaning agents or solvents are used for cleaning, the corresponding material safety data
sheet and the safety instructions in section Hazards due to operating materials and supplies
must be observed.

Page 25 / 111
u Observe the material safety data sheet for the cleaning agent or solvent.

u Wear personal protective equipment (PPE) according to the material safety data sheet.

u Inspect the electric cables for abrasion and damage before and after your cleaning work.

Safety during disassembly, assembly, maintenance and repair

u Observe the procedures for set-up, service and inspection work and the inspection inter-
vals.
u Inform the operating staff before starting any service or repair work. Make sure the en-
gine is not started while work is being conducted on the turbocharger.
u Before taking off any cover or removing any guard from the turbocharger, switch off the
engine and wait until the turbocharger has come to a standstill.
u Make sure that the oil supply is interrupted, especially with an external oil supply.

u Only restart the engine after all parts have been properly fitted again and oil supply is en-
sured.

CAUTION
Mechanical operations on the turbocharger
Components of the turbocharger can be damaged or destroyed as a result
of improper procedures.
u Only perform operations that are described in this chapter.
u Only perform operations for which you have received instruction or train-
ing.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
2 Safety / 2.13 Safe maintenance

Safety when taking out of operation or preparing for mothballing

u Observe the material safety data sheet for the cleaning and mothballing agents.

u Wear personal protective equipment (PPE) according to the material safety data sheet.

Mechanical hazards when working on the turbocharger

WARNING
Mechanical hazard
Severe injuries to personnel or fatal accidents can be caused by mechanical
influences as a consequence of hazardous and inadequate operational pro-
cedures.
u Observe the general rules for occupational safety and prevention of acci-
dents.
u Ensure workplace safety.
u Only perform operations that are described in this chapter.
u Only perform operations for which you have previously received instruc-
tion or training.
Page 26 / 111

Hazards due to operating materials and supplies

Operating materials and supplies are substances required for the operation of the tur-
bocharger or for the performance of maintenance work. Oils, greases, coolants, detergents
and solvents, acids and similar substances can be classified as hazardous substances.

WARNING
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or con-
tact with them may be harmful to health.
u Do not breathe in these substances and avoid contact with the skin.
u Ensure proper ventilation.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Wear personal protective equipment (PPE) according to the material
safety data sheet.
u Comply with local legislation.

Wear safety goggles.

Wear safety gloves to protect against chemical hazards.

Wear a respiratory mask to protect against gases.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
2 Safety / 2.13 Safe maintenance

WARNING
Danger of fire or explosion
Flammable and combustible operating materials and supplies can catch fire
or resulting vapours can lead to an explosion.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Comply with local legislation.
u Do not allow any exposed flame or ignition source during cleaning work.
u Carry out cleaning in the open or provide sufficient ventilation.

CAUTION
Environmental hazard
Improper handling of operating materials and supplies can lead to environ-
mental damage.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Comply with local legislation.

Page 27 / 111
Hazards due to the handling of insulation materials

WARNING
Danger from insulation materials
Dust or fibres from insulation materials can have adverse effects on the
health or cause irritations. Unsuitable and combustible insulation materials
are a fire hazard.
u Only use suitable and non-combustible insulation materials.
u Ensure good ventilation at the workplace.
u Avoid whirling up dust.
u Use dust-free tools and working methods.
u Remove package at the workplace only.
u Proceed with particular care when removing old insulation materials.
u Dispose of insulation materials properly and in an environmentally com-
patible manner in compliance with the legal regulations.

Wear safety goggles.

Wear a respiratory mask to protect against dusts.

Wear safety gloves to protect against chemical hazards.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
3 Removing and Installing / 3.1 Turbocharger weight and transporta-
tion

3 Removing and Installing

3.1 Turbocharger weight and transportation

Lifting gear with a sufficient load limit must be used for removing, installing and transport-
ing the turbocharger. The weight specified below applies to the heaviest variant possible.
Depending on the specification, the weight specified on the rating plate may be lower than
the standard value specified here.

Produkt Gewicht Turbolader komplett [kg]

TPS44 120
TPS48 180
TPS52 250
Table 4: Gesamtgewicht

3.1.1 Swivel lifting eyes to be used

One swivel lifting eye (S) is required to safely lift this turbocharger. This is not included in
the ABB scope of delivery.
Page 28 / 111

Fig. 10: Swivel lifting eyes

Product Thread M Length H Diameter D Minimum load limit

[mm] [mm] [kg]
TPS44 M8 ≤ 12 ≤ 25 300
TPS48 M8 ≤ 12 ≤ 25 300
TPS52 M10 ≤ 15 ≤ 25 400
Table 5: Swivel lifting eyes to be used

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
3 Removing and Installing / 3.2 Removing the turbocharger

3.2 Removing the turbocharger

WARNING
Danger of burns
Touching hot surfaces or contact with hot operating fluids can cause burns.
u Do not touch hot surfaces. Observe the warning plate on the turbochar-
ger.
u Wear heat-resistant safety gloves and protective clothing.
u Wait for the turbocharger to cool down before carrying out any work.

Wear safety gloves to protect against thermal hazards.

CAUTION
Do not put the speed measurement cables under strain by pulling them
If you pull the speed measurement cables too hard, contacts can be pulled
out.
u Do not strain the speed measurement cables by pulling.

Page 29 / 111
NOTICE
Gas outlet casing (61001)
The gas outlet casing (61001) can remain fitted in the exhaust gas pipe if the
locking to the turbine casing is accessible. Otherwise the complete tur-
bocharger unit including gas outlet casing must be removed.

u Disconnect all pipes according to the instructions of the enginebuilder.

u Loosen and remove water connections.

u Close the openings of the water connections with screw plugs.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
3 Removing and Installing / 3.2 Removing the turbocharger

Fig. 11: Removing the turbocharger

1. Treat the threads of studs and nuts with penetrating oil and allow to work in.
2. Loosen and remove nuts.
3. If present: Disconnect the plug to the speed sensor (86505) and secure the rolled-up
Page 30 / 111

cable on the turbocharger. This protects the plug from being crushed.
4. Install the swivel lifting eye (S) and attach the lifting gear to it.
5. Lift the turbocharger away from the support vertically. The bracket-turbocharger con-
nection may be in the form of a pin with the TPS52-H.
6. Cover the oil supply and oil drain on the engine-side bracket and the connections on the
turbocharger.

Version with water cooling

CAUTION
Freezing of the cooling water in the bearing casing
If cooling water freezes in the bearing casing, this can lead to severe dam-
age.
u 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 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
3 Removing and Installing / 3.3 Installing the turbocharger

3.3 Installing the turbocharger

3.3.1 Inserting gaskets into the bracket

CAUTION
Inserting the gaskets
Gaskets that are forgotten, damaged or improperly inserted will lead to oil
leaks.
u 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.

Page 31 / 111
Fig. 12: Inserting gaskets into the bracket

01 Bracket 04 Slot for O-ring

02 Oil supply 05 O-rings
03 Oil drain 06 Pin (optional)

Pin (06) as installation safety device

Turbochargers can have an oil inlet either on their right or left side; the oil inlet position can
be different for the turbocharger fitted on the left and on the right engine bank.
A pin can be installed in every support as an installation safety device to prevent inadvertent
incorrect fitting. This pin fits into the respective slot on the foot of the bearing casing. In-
structions of the enginebuilder must be observed.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
3 Removing and Installing / 3.3 Installing the turbocharger

3.3.2 Fitting threaded rods

Fig. 13: Inserting threaded rods into the bracket

1. Lightly oil the surfaces of the threaded rods (02) to be screwed in.
2. Screw the threaded rods into the bracket with the aid of locknuts (01).
3. Remove nuts (01) again.

Requirements for the threaded rods (02)

Page 32 / 111

Fig. 14: Requirements for threaded rods

Product Diameter Material Thread length Length of

Threaded rod DIN / ISO 898 L1 [mm] threaded rod
[mm] (Part 1) L2 [mm]

TPS44 Ø 16 / M16 10.9 / 12.9 ≥ 30 150

TPS48 Ø 16 / M16 10.9 / 12.9 ≥ 30 170
TPS52 Ø 20 / M20 10.9 / 12.9 ≥ 30 195
Table 6: Requirements for threaded rods

Fastening material, scope of delivery

The threaded rods and nuts required for attaching the turbocharger to the bracket are not
included in the ABB scope of delivery. These parts depend on the version of the engine-side
bracket.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
3 Removing and Installing / 3.3 Installing the turbocharger

3.3.3 Attaching the turbocharger to the bracket

Fig. 15: Placing the turbocharger on the bracket

Product Through hole in Fixing screws [mm] Tightening torque [Nm]

bearing casing [mm] (assumed friction coeffi-

Page 33 / 111
cient µ = 0.12)
TPS44 Ø 17 M16 280
TPS48 Ø 17 M16 280
TPS52 Ø 21 M20 560
Table 7: Tightening torque for standard nuts

1. Make sure that the covers of the oil and water connections are removed.
2. Make sure that the gaskets are not damaged and are positioned correctly in the slots.
3. Install the swivel lifting eye (S) and attach the lifting gear to it.
4. Align the turbocharger over the threaded rods of the bracket.
5. Place the turbocharger on the bracket. If present: Pay attention to the correct position of
the pin in the bracket.
6. Lightly oil the hexagon nuts.
7. Fit the hexagon nuts. Observe tightening torque.
8. Connect cable to speed sensor (86505).
u Remove the lifting gear.

u Connect all gas and air lines according to the instructions of the enginebuilder.

u If the gas outlet casing from ABB has not been dismantled with the turbocharger, refer to
chapter Removing the gas outlet casing →74.
u Fit the water pipes according to the instructions of the enginebuilder.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
4 Commissioning / 4.1 Oil supply

4 Commissioning

4.1 Oil supply

4.1.1 Introduction
In all operating states, a functioning and carefully executed oil supply is an important pre-
requisite for trouble-free operation of the turbocharger.
The lubrication of the turbocharger is usually carried out with oil from the engine oil circula-
tion.
u Comply with the enginebuilder's specifications regarding the selection of lubricating oil
and the oil change intervals.

4.1.2 Pre-lubrication
Pre-lubrication must be carried out as follows:
u Switch on the oil pump.
Page 34 / 111

u Build up oil pressure.

u Do not exceed a pre-lubrication time of 2 minutes.

u Start the engine.

u Let the oil pump run until the pump driven by the engine generates sufficient pressure.

4.1.3 Oil filtering

Filtering the lubricating oil with a filter mesh width of ≤ 0.034 mm is sufficient for this tur-
bocharger.

4.1.4 Oil pressure

Comply precisely with the oil pressure before the turbocharger for trouble-free operation.
The admissible values are specified in chapter Monitoring operation →38.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
4 Commissioning / 4.2 Inspection procedures

4.2 Inspection procedures

4.2.1 Introduction
Inspection procedures include preventative visual controls, monitoring and measuring work
before and during commissioning. Inspection procedures enable changes to the turbochar-
ger to be detected. Machine damage can be prevented.

4.2.2 Checks before commissioning

Filter mat (if available)

u Check for damage and contamination.

Lubricating system

CAUTION
Contaminated oil
Serious damage to engine or property can be caused by dirt and solid ma-

Page 35 / 111
terial particles in the oil.
u For the initial commissioning phase and after all service work, flush the
complete lubricating system with warm oil.
u Use special running-in filters when running in the engine and after all ser-
vice work on the lubricating system.

u Check that the oil filter is clean before commissioning.

u Adhere to lubricating oil pressure at the inlet.

u Adhere to lubricating oil temperature at the inlet.

u For permissible values, see chapter Monitoring operation →38.

Warning plates
u Check whether warning plates are present and legible.

u Check whether the protective sheets have been removed.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
4 Commissioning / 4.2 Inspection procedures

Water-cooled bearing casing

CAUTION
Failure of bearing casing cooling
Any prolonged failure of the water cooling will shorten the lifetime of the
turbocharger.
u Make sure that an uninterrupted supply of cooling water is provided dur-
ing operation.

u Check whether water pipes are fitted on the bearing casing.

4.2.3 Checks after commissioning (engine in idle mode)

Lubricating system
u Keep to the lubricating oil pressure at the inlet.

u Keep to the lubricating oil temperature at the inlet.

u Refer to chapter Monitoring operation →38 for admissible values.

Page 36 / 111

Leaktightness of pipes

WARNING
Risk of burning from hot gas
Escaping gases are hot and will lead to serious burns in the event of contact.
u Check all pipes for leaks in accordance with the enginebuilder’s instruc-
tions.

Wear safety gloves to protect against thermal hazards.

4.2.4 Checks when starting up the engine

If present:
u Measure speed, oil pressure and charging pressure at various engine performances.

u Measure the exhaust gas temperature before and after the turbine.

u Measure the air temperature before and after the compressor.

u Compare the measured values with the values of the acceptance report. Different operat-
ing conditions indicate a malfunction (see chapter Eliminating malfunctions →63).
Lubricants and pastes used during assembly can liquefy or vaporise and escape as oily fluids
during the initial hours of operation. Continual escape of an oily fluid indicates an oil leak. If
there is a leak, contact an ABB Turbocharging Service Station.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
4 Commissioning / 4.3 Commissioning after taking out of operation

4.3 Commissioning after taking out of operation

If present
u Remove cover plates (blind flanges) from the compressor casing, the gas inlet and the
gas outlet.
u Remove the locking screws on the water connections and fit the water pipe.

General
u Check the exhaust gas pipe before and after the turbine for combustion residues or wa-
ter residues and clean it. Remove any foreign objects that may be present.
u Check and clean filter silencer or air supply line, and remove any foreign objects that may
be present.
u Put engine-side oil circulation to the turbocharger into operation.

u Prepare the turbocharger for operation (see Checks before commissioning →35).

u The turbocharger is now ready for operation.

Page 37 / 111

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
5 Monitoring operation / 5.1 Oil pressure, oil temperature

5 Monitoring operation

5.1 Oil pressure, oil temperature

Lubricating oil pressure, oil inlet

To limit the oil flow rate through the turbocharger to the admissible values with the engine
at full load, an oil orifice is mandatory or already fitted at the turbocharger oil inlet if the oil
inlet pressure is > 3 bar.

CAUTION
Assuring lubricating oil pressure
Serious damage to the engine or property can result from a missing or insuf-
ficient lubricating oil supply.
u The lubricating oil pressure must be monitored during operation and the
necessary pressure assured at the oil inlet.

Status for operation Pressure at oil inlet upstream of

Page 38 / 111

the turbocharger
[bar] Overpressure
Normal operation 2.0 < poil ≤ 4.5
Engine start: Cold oil, admissible for a maximum of 15 < 8.0
minutes
Engine idling, admissible for a maximum of 1 hour 0.5 < poil ≤ 2.5
Pre-lubrication and post-lubrication (engine stopped) 0.5 < poil ≤ 1.0
Warning signal: (n ≥ 0.5 x nBmax) < 1.25
Alarm signal: Not admissible. Stop the engine immedi- < 0.5
ately.
Table 8: Lubricating oil pressure at oil inlet before turbocharger

Arrangement of temperature and pressure measuring points

01 Turbocharger contact surface
02 Oil inlet
03 Oil outlet
P Oil pressure measuring point
T 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.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
5 Monitoring operation / 5.1 Oil pressure, oil temperature

*) If the drain pipe is vented, the lubricating oil temperature measuring point can be installed
at the outlet in the vent tank. Otherwise the measurement should be taken in the drain pipe
as close to the turbocharger as possible.

Page 39 / 111

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
5 Monitoring operation / 5.1 Oil pressure, oil temperature

Lubricating oil temperature at the inlet

CAUTION
Machine damage
If the oil temperature at the oil inlet exceeds the admissible range, this may
lead to engine damage.
u Observe oil temperature at the oil inlet according to the following table.

Status for operation Oil temperature at the inlet

Toil,inlet
Admissible 10 … 105 °C
Temporarily admissible (< 1 h) → alarm > 105 °C
Not admissible → stop engine > 110 °C
Temporarily admissible when the engine is started → prior < 10 °C
to start: generally preheat oil
Table 9: Lubricating oil temperature at the inlet

Lubricating oil temperature at the outlet

The oil temperature at the outlet is mainly dependant on:
Page 40 / 111

¡ Lubricating oil temperature and pressure at the oil inlet

¡ Engine load and turbocharger speed
¡ Exhaust gas temperature
The maximum admissible oil temperature at the outlet is listed in the following table. The
specified oil outlet temperature is to be considered as alarm value for the turbocharger op-
eration and must be monitored according to the current regulations.

Status for operation Oil temperature at the outlet

Toil,outlet
Admissible ≤ 160 °C
Temporarily admissible (< 0.5 h) → alarm > 160 °C
Not admissible → stop engine > 180 °C
Admissible ≤ Toil,inlet + 55 K
Temporarily admissible → alarm > Toil,inlet + 55 K
Table 10: Lubricating oil temperature at the outlet

If the turbocharger has been operated for a longer period of time outside the admissible
range, ABB Turbocharging recommends having the turbocharger inspected by an ABB Tur-
bocharging Service Station.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
5 Monitoring operation / 5.2 Exhaust gas temperature before turbine

5.2 Exhaust gas temperature before turbine

CAUTION
Factors influencing replacement intervals
Operation above the operating limits defined on the rating plate can
shorten the recommended replacement intervals considerably.
u Measure exhaust gas temperature upstream of turbine.
u Comply with operating limits on rating plate.

u For a definition and explanations concerning the rating plate, refer to chapter Safety /
Turbocharger rating plate →17.
u For operating limits, refer to the Operation Manual title page or the rating plate on the
turbocharger.

5.3 Turbocharger speed

5.3.1 Introduction

Page 41 / 111
A speed measuring system enables the constant monitoring of the turbocharger speed.

CAUTION
Do not put the speed measurement cables under strain by pulling them
If you pull the speed measurement cables too hard, contacts can be pulled
out.
u Do not strain the speed measurement cables by pulling.

CAUTION
Machine damage
Operation above the operating limits defined on the rating plate can
shorten the recommended replacement intervals considerably and cause
machine damage.
u Measure turbocharger speed.
u Comply with operating limits on rating plate.

u For a definition and explanations concerning the rating plate, refer to chapter Safety /
Turbocharger rating plate →17.
u 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).

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
5 Monitoring operation / 5.3 Turbocharger speed

5.3.2 Layout and overview

Fig. 16: Layout and overview of the speed measurement system

86505 Speed sensor 42188 Screw plug

Page 42 / 111

86515 Cable connector 42189 Gasket

86526 F/I converter 01 Plug with integrated voltage limiter
86528 Tachometer *) Alternative mounting position for speed
sensor
32109 Sealing disc

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
5 Monitoring operation / 5.3 Turbocharger speed

5.3.3 Speed differences with several turbochargers per engine

The speeds of all turbochargers on an engine vary only slightly from each other in standard
operation.
The difference between the highest and the lowest turbocharger speed must not be more
than 3 %, relative to the speed limit nBmax.
If this permissible range of difference is exceeded, the following steps must be carried out:
u Reduce the engine performance immediately to the point at which the maximum tur-
bocharger speed does not exceed 70 % of nBmax.
u If the engine cannot be stopped, it can continue to be driven at this reduced engine load
or turbocharger speed.
u If a turbocharger surges continuously, the engine performance must be reduced further.

u Measure the temperatures in the air lines and gas piping from and to the turbochargers
and compare with normal values. If clear deviations of temperature are found, the nearest
ABB Turbocharging Service Station has to be contacted.
u Check the pressure loss of the alternative air inlet and compare it with normal values.

If the engine can be stopped temporarily:

u Inspect air lines, gas piping and the turbochargers and remedy any malfunctions.

Page 43 / 111
u In any case, contacting the nearest ABB Turbocharging Service Station is recommended.

5.3.4 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 →69.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
5 Monitoring operation / 5.3 Turbocharger speed

5.3.5 Replacing the speed sensor

WARNING
Hot speed sensor
Danger of burns. The speed sensor can reach temperatures of more than
100 °C during operation.
u 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.
Page 44 / 111

Fig. 17: Fitting the speed sensor

Part number TPS44 TPS48 TPS52

86505 M12 x 1.5 M12 x 1.5 M12 x 1.5
15 Nm 15 Nm 15 Nm
Table 11: Tightening torque (86505)

u Reduce the engine performance to idling and then stop the engine. Pay attention to post-
lubrication (Stopping the engine →52).
u Switch off the lubricating oil supply to the turbocharger.

u Disconnect cable connector (86515) from speed sensor (86505).

u Unscrew and remove defective speed sensor (86505).

u Screw in new speed sensor (86505) as far as it will go and tighten.

u Connect cable connector (86515) to speed sensor (86505).

u Switch on lubricating oil supply to the turbocharger.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
6 Operation and service / 6.1 Noise emission

6 Operation and service

6.1 Noise emission

WARNING
Noise hazards
Exposure to noise can harm the hearing system, impair health and the psy-
chological state and may lead to lack of attention and irritation.
u When the engine is running, always wear ear protection.
u Always wear ear protection if the sound pressure level exceeds 85 dB(A).

Wear ear protection.

The emission sound pressure level (A-weighted) is measured at a distance of 1 meter from
the turbocharger.
The highest value of the emission sound pressure level1) reaches a maximum of 105 dB(A)
near the air inlet. The following prerequisites must be fulfilled with regard to the turbochar-

Page 45 / 111
ger to observe this limit value:
¡ Air-inlet system has been fitted
¡ All standard, noise-reducing measures2) have been fitted
¡ Bellows at the air outlet has been acoustically insulated by the enginebuilder (see Fig. 18:
Noise insulation, bellows →46).
The enginebuilder is responsible for insulating the charge air/scavenging air line and the
charge air cooler.
1) Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 :
A-weighted emission sound pressure level
2) The enginebuilder must provide acoustically equivalent measures in case of deviating in-
sulation versions

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
6 Operation and service / 6.1 Noise emission

Suggestion for noise insulation, bellows

Fig. 18: Noise insulation, bellows

01 Compressor casing
02 Bellows
Page 46 / 111

03 Charge air duct / scavenging air duct

04 Insulation cushion
05 Insulation mat (at least 15 mm)
06 Sheet metal cover

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
6 Operation and service / 6.2 Service work

6.2 Service work

Service work includes visual controls, monitoring, measuring and inspection as well as func-
tional checks. Service work enables the detection and rectification of changes to the tur-
bocharger and ensures full operability of the turbocharger.

CAUTION
Service intervals
Any service work on the turbocharger that is omitted or performed too late
can cause excessive contamination, wear and operating failures.
u Carry out the service work at the specified time intervals.

CAUTION
Specific service interval
Exceptional stresses such as a high number of starts and stops, harsh envir-
onmental conditions, poor fuel quality or high system vibrations can lead to
untimely machine damage even if the prescribed service intervals are ob-
served.
u Agree on a specific service interval with ABB Turbocharging.

Page 47 / 111
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.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
6 Operation and service / 6.2 Service work

6.2.1 Service work every 24 … 48 hours

Pipes
u Check all the inlet and outlet pipes of the turbocharger for leaks.

Operating data

CAUTION
Unknown operational changes
Impairment to the degree of a possible operating failure can be the con-
sequence.
u Have any unknown causes clarified by an ABB Turbocharging Service Sta-
tion.

Monitoring the engine's operating data makes it possible to draw conclusions about the op-
erating behaviour of the turbocharger.
Page 48 / 111

u The following operating data and measured values must be entered every 24 … 48 hours
in the engine logbook of the enginebuilder.
¡ Performance and speed of the engine
¡ Air intake temperature
¡ Charging pressure
¡ Pressure loss in the charge air cooler
¡ Lubricating oil pressure and lubricating oil temperature
If present:
¡ Speed of the turbocharger
¡ Air temperature after the compressor and after the charge-air cooler
¡ Exhaust gas temperature before and after the turbine
¡ Pressure loss in the filter silencer.
u In case of different values, determine the cause.

6.2.2 Service work at 100 hours after commissioning

u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en-
gine is stopped, in accordance with the instructions of the enginebuilder.

6.2.3 Service work according to instructions of enginebuilder

u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en-
gine is stopped, in accordance with the instructions of the enginebuilder.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
6 Operation and service / 6.2 Service work

6.2.4 Service work according to data on the rating plate

WARNING
Incorrect handling of a cartridge group
The disassembly and assembly of the cartridge group, as well as the assess-
ment of the rotor and bearing parts, requires the expertise of an ABB Tur-
bocharging Service Station. The rotor parts rotate extremely quickly and are
sensitive to unbalance. Incorrect handling of a cartridge group can damage
the turbocharger and cause injuries to persons.
u Ensure that the disassembly and assembly of the cartridge group is only
carried out by an ABB Turbocharging Service Station.

NOTICE
Specialist knowledge of an ABB Turbocharging Service Station
Assembly and disassembly of the cartridge group and assessment of the ro-
tor and bearing parts requires the specialist knowledge of an ABB Tur-
bocharging Service Station. The rotor parts turn very fast and are very sens-
itive to unbalance.

Page 49 / 111
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.
u Remove turbocharger from engine (see chapter Removing and Installing →28).

u Dismantle the turbocharger and measure the clearances (see chapter Dismantling and fit-
ting →70).
u Mechanically clean the nozzle ring, the turbine casing and compressor casing (see chapter
Periodic maintenance work →53).
u Check the nozzle ring, turbine casing and compressor casing for cracks and erosion/cor-
rosion.

Application with frequent engine start/stop cycles (Peak shaving)

If the turbocharger is used for the ‘Peak shaving’ mode with frequent engine start/stop
cycles, the number of successful engine start/stop cycles must be taken into account in ad-
dition to the inspection interval for the bearing parts specified on the rating plate (in oper-
ating hours).
u ABB Turbocharging recommends having the rotor and bearing parts, as well as the casing
parts on the turbine end, including the nozzle ring, checked and maintained by an ABB
Turbocharging Service Station after 5000 successful engine start cycles.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
6 Operation and service / 6.3 Expected replacement intervals

6.3 Expected replacement intervals

Fuel
The expected replacement intervals apply to engine operation with pre-mix gas and diesel
oil.

Applications with frequent engine start/stop cycles (Peak shaving)

In addition to the replacement intervals specified on the rating plate for the compressor and
turbine wheel (in operating hours), the number of successful engine start/stop cycles must
also be taken into account.

Rotating components
The recommended replacement intervals of the compressor and turbine wheels are spe-
cified with the aid of the safety concept for rotating parts (SIKO) and dependent on the op-
erating conditions. These intervals are shown on the rating plate of the turbocharger.
When employing the ‘Peak shaving’ mode, ABB Turbocharging generally recommends repla-
cing the compressor and turbine wheel after 20000 successful engine start/stop cycles or
Page 50 / 111

after reaching the number of operating hours specified on the rating plate.

Non-rotating components
Depending on the system-specific operating conditions, a differentiation must be made
between the intervals to be expected for:
¡ replacing the bearing parts and
¡ replacing the non-rotating components exposed to hot gas.
A decisive role is played by various influencing parameters which, in extreme cases, can sig-
nificantly reduce the replacement interval of these parts.
When utilising the ‘Peak shaving’ mode with frequent engine start/stop cycles, the tur-
bocharger components on the exhaust gas side are subjected to high thermal loads. This
load can cause thermal fatigue when the operating time and number of engine start cycles
increase, thereby resulting in wear and cracking of the components. 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.
The individual components will generally be examined for wear and replaced, if necessary,
during the prescribed periodic service work.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
6 Operation and service / 6.3 Expected replacement intervals

Component Operating hours [h] Number of engine start cycles

(GAS / MDO) (Peak shaving mode)
Turbine casing 25000 … 50000 5000 … 10000
Nozzle ring 25000 … 50000 5000 … 10000
Heat sheet metal 25000 … 50000 5000 … 10000
Rotating components See rating plate information 1) 20000
Bearing parts 12000 … 24000 5000
Other casings 50000 --
Table 12: Expected replacement intervals

GAS = Gas
MDO = Marine Diesel Oil
1)
The recommended replacement intervals of the compressor and turbine wheels are spe-
cified with the aid of the safety concept for rotating parts (SIKO) and dependent on the
operating conditions.

Influencing parameters
The specified values are guideline values and are not guaranteed. The actual values can devi-
ate significantly from the guideline values, for example, due to the following influences:
¡ Fuel quality and fuel treatment

Page 51 / 111
¡ Load profile (thermal cycling, also number of starts/stops, emergency shutdowns, oper-
ating point)
¡ Gas inlet temperature
¡ Turbocharger specification
¡ System-specific operating conditions (combustion quality, exhaust gas composition)
For bearing parts
¡ 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 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
7 Stopping the engine / ​

7 Stopping the engine

Water-cooled turbocharger variant
u Post-lubricate as long as the rotor is turning.

u Observe the oil pressure while performing post-lubrication: 0.5 < poil ≤1.0.

u 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.
u Allow the water cooling of the turbocharger to continue operating for 15
to 20 minutes after stopping the engine.
Page 52 / 111

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
8 Periodic maintenance work / 8.1 Foreword to maintenance

8 Periodic maintenance work

8.1 Foreword to maintenance

Maintenance work includes regular visual controls and cleaning operations which are inten-
ded to ensure the trouble-free functioning of the turbocharger.

Maintenance interval Maintenance work Operating status

Similar to the service interval Cleaning components mechanically Engine stopped
(usually every 8000 … 12000 h) →53 1)
Table 13: Maintenance table

[h] = Hours of operation

1)
ABB Turbocharging recommends having mechanical cleaning carried out by an ABB Tur-
bocharging Service Station during the service work.

8.2 Cleaning components mechanically

Page 53 / 111
8.2.1 Preparation

CAUTION
Component damage and corrosion
If mechanical cleaning is carried out incorrectly, this can lead to damage and
corrosion on the components.
u Pay attention to the specifications in this chapter pertaining to mechan-
ical cleaning.

CAUTION
Selection of cleaning tools
Turbocharger components are sensitive and easily sustain mechanical dam-
age. The use of needle descalers (for example) or other striking tools dam-
ages the components. Depending on the specification, nozzle rings or tur-
bine casings may have protective coatings which can also be damaged.
u Use only soft tools such as rags, brushes or wire brushes.
u In case of heavy contamination, the cleaning methods described in this
chapter (such as soaking, for example) can be repeated until a satisfact-
ory result is achieved.

The disassembly and assembly of the components is described in chapter Dismantling and
fitting →70.
u Contaminated water and cleaning agents must be disposed of in an environmentally
compatible, professional way and in compliance with locally applicable regulations.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
8 Periodic maintenance work / 8.2 Cleaning components mechanically

8.2.2 Cleaning the filter silencer

Fig. 19: Cleaning the filter silencer

Page 54 / 111

81135 Filter silencer body 81266 Cover grid

81136 Absorption segment 81270 Tension band
81137 Sheet-metal covering 81271 Lock
81265 Filter ring

Cleaning the filter ring (if present)

u Remove filter ring (81265).

u Clean filter ring (81265) as required or every 500 hours of operation and replace after the
fifth cleaning process at the latest.
Contamination of the filter ring depends on the degree of purity of the sucked-in air.
u Rinse the filter ring (81265) with water and mild detergent or, in the case of heavy con-
tamination, soak and carefully push through. Rinse in cold water. Avoid high mechanical
loads (water jet).
u Let the filter ring dry completely before assembling.

u Dirty water and mild detergent must be disposed of in compliance with locally applicable
regulations.

Cleaning the absorption segments

(see Fig. 19: Cleaning the filter silencer →54)
u Loosen the tension bands (81270).

u Remove the cover grid (81266).

u Pull out and bend up the sheet-metal coverings (81137), and remove the absorption seg-
ments (81136).

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
8 Periodic maintenance work / 8.2 Cleaning components mechanically

u Clean the absorption segments (81136).

When cleaning, note that the absorption segments (81136) must only be cleaned lightly
with compressed air, a soft brush or a moist cleaning cloth.
u 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)
u Insert the absorption segments (81136) into the sheet-metal coverings (81137).

u Bend the sheet-metal coverings (81137) back to their original shape and insert into the
slotted guides in the filter silencer body (81135).
u Fit the cover grid (81266).

u Fit the tension bands (81270) and tighten them at the locks (81271).

u Any tension bands that have become damaged must be replaced.

u Fit the filter ring (81265), if present.

Page 55 / 111

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
8 Periodic maintenance work / 8.2 Cleaning components mechanically

8.2.3 Compressor-end, non-rotating parts

WARNING
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or con-
tact with them may be harmful to health.
u Do not breathe in these substances and avoid contact with the skin.
u Ensure proper ventilation.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Wear personal protective equipment (PPE) according to the material
safety data sheet.
u Comply with local legislation.

Wear safety goggles.

Wear safety gloves to protect against chemical hazards.

Wear a respiratory mask to protect against gases.

Page 56 / 111

The following parts, which are relevant in terms of performance, can be cleaned in accord-
ance with the description below.

Fig. 20: Cleaning the compressor casing, diffuser mechanically

72000 Compressor casing

79000 Diffuser
u Steam-clean the above-mentioned components or soak in diesel oil or water with house-
hold cleaning agents. After soaking, remove contamination with a brush.
u Dry components completely.

u Spray cleaned surfaces with penetrating oil. Do not spray exterior surfaces of the tur-
bocharger.
u Dispose of contaminated water and cleaning agents in accordance with the information
in the material safety data sheet.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
8 Periodic maintenance work / 8.2 Cleaning components mechanically

8.2.4 Turbine-end, non-rotating parts

WARNING
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or con-
tact with them may be harmful to health.
u Do not breathe in these substances and avoid contact with the skin.
u Ensure proper ventilation.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Wear personal protective equipment (PPE) according to the material
safety data sheet.
u Comply with local legislation.

Wear safety goggles.

Wear safety gloves to protect against chemical hazards.

Wear a respiratory mask to protect against gases.

Page 57 / 111
Baked layers of contamination, for example, from heavy fuel oil or coked oil occur at the tur-
bine end. The following parts, which are relevant in terms of performance, can be cleaned in
accordance with the description below.

Fig. 21: Cleaning the nozzle ring, turbine casing mechanically

56001 Nozzle ring

51000 Turbine casing
u Place contaminated parts in hot water or in a liquid such as brake cleaner to soften the
contamination.
u Brush away the contamination or remove with a steam cleaner.

u If necessary, repeat soaking and brushing.

u Use clean water to completely clean parts of any solvents.

u Dry components completely.

u Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the tur-
bocharger.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
8 Periodic maintenance work / 8.2 Cleaning components mechanically

u Dispose of contaminated water and cleaning agents in accordance with the information
in the material safety data sheet.

8.2.5 Cartridge group, general

CAUTION
Corrosion
If the cartridge group is not put back into operation immediately after clean-
ing, parts may corrode.
u Immediately after cleaning, install the cartridge group and put it back
into operation.

Compressor wheels can be heavily contaminated due to poorly filtered suction air; turbines
can be heavily contaminated due to coked oil. Contamination such as this must be removed
during the standard service intervals (see chapter Service work).
u Remove the turbocharger from the engine (see chapter Removing and Installing →28).

u Remove the cartridge group (see chapter Dismantling and fitting →70).

First clean the compressor end and then the turbine end according to the following descrip-
tion.
Page 58 / 111

8.2.6 Cleaning the cartridge group on compressor end

CAUTION
Selection of the cleaning agent
Cleaning agents that contain chlorine corrode metals.
u Only use pH-neutral cleaning agents that do not corrode metals.
u Observe the material safety data sheet.
u Observe country-specific regulations regarding banned and restricted
substances.

CAUTION
Water and contamination in the cartridge group
If water or contamination penetrates the cartridge group, this can impair
the function of the turbocharger and damage parts inside the cartridge
group.
u Make sure that no water or contamination can enter into the cartridge
group.

u Cleaning procedures should be selected that do not result in removal of the compressor
wheel material or cause damage to its surfaces. Clean the compressor wheel with a rag or
soft brush which has been soaked in water with a household cleaning agent. Do not use a
wire brush!

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
8 Periodic maintenance work / 8.2 Cleaning components mechanically

u Dry the compressor wheel and the gap between the compressor and the bearing casing
with low-pressure pressurized air.
u Lightly spray the compressor wheel and the gap between the compressor and the bearing
casing with penetrating oil.
u Dispose of dirty water and cleaning agents in accordance with the material safety data
sheet.

8.2.7 Cleaning the cartridge group on turbine end

Soaking the contamination
Baked layers of contamination from fuel residue or coked oil may occur at the turbine end.
The contamination can be removed by soaking and brushing. The procedure for soaking the
layers of contamination as well as for cleaning the turbine are described in the following.

Page 59 / 111
Fig. 22: Soaking contamination of the turbine

Product A [mm] B [mm] C [mm]

TPS44 115 20 155
TPS48 115 29 180
TPS52 135 35 215
Table 14: Dimensions of the cleaning container

To soak the layers of contamination on the turbine, the cartridge group can be immersed
vertically in a container (02) with fluid.
u Place the container (02) inside a larger container (03) so that the overflowing fluid can be
collected.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
8 Periodic maintenance work / 8.2 Cleaning components mechanically

CAUTION
Selection of the cleaning agent
Cleaning agents that contain chlorine corrode metals.
u Only use pH-neutral cleaning agents that do not corrode metals.
u Observe the material safety data sheet.
u Observe country-specific regulations regarding banned and restricted
substances.

u Fill the container (02) with soaking fluid. To shorten the soaking time, the fluid can be
heated up to a maximum of 60 ºC.

WARNING
Heating up of cleaning agents and operating fluids
When cleaning agents or operating fluids are heated up, explosive vapours
can be produced which are hazardous to health.
u Observe the information in the material safety data sheet.

Wear a respiratory mask according to material safety data sheet.

Page 60 / 111

CAUTION
Water and contamination in the cartridge group
If water or contamination penetrates the cartridge group, this can impair
the function of the turbocharger and damage parts inside the cartridge
group.
u Place the cartridge group on suitable supports (01) made of wood or
metal.
u Observe dimension (B) for the supports (01) so that the cartridge group
is not immersed too deeply.

u Let the layers of contamination on the turbine soak for four hours.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
8 Periodic maintenance work / 8.2 Cleaning components mechanically

Removing dirt

WARNING
Health hazard due to soot particles
If soot particles enter the eyes or respiratory tract, this can be harmful to
health.
u Avoid the formation of dust.
u Vacuum up dust with a suitable vacuum cleaner.
u Wear a respiratory mask to protect against particles (P1 or P2 mask).
u Wear safety goggles.

Wear safety goggles.

Wear a respiratory mask to protect against dusts.

Wear safety gloves to protect against mechanical hazards.

u Lift up the cartridge group and align it horizontally.

Page 61 / 111
u Remove dirt manually using a soft brush or a wire brush.

CAUTION
Water and contamination in the cartridge group
If water or contamination penetrates the cartridge group, this can impair
the function of the turbocharger and damage parts inside the cartridge
group.
u Make sure that no water or dirt enters the gap between the heat sheet
metal and the turbine.

CAUTION
Non-permissible rotor unbalance after cleaning
Unevenly distributed residual contamination deposits lead to rotor unbal-
ance. This can result in bearing or turbocharger damage.
u Remove all traces of contamination from the turbine.

u After brushing off the dirt, fill the container (02) with clean water, not salt water.

u Immerse the turbine of the cartridge group in clean water so that any loose dirt comes
off.
u Lift up the cartridge group and align it horizontally.

u Clamp the heat sheet metal to the bearing casing.

u Dry the turbine and the gap between the turbine and the heat sheet metal with low-pres-
sure pressurized air.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
8 Periodic maintenance work / 8.2 Cleaning components mechanically

u Lightly spray the turbine and the gap between the turbine and the heat sheet metal with
penetrating oil.
u Dispose of contaminated water and cleaning agents in accordance with the information
in the material safety data sheet.
Page 62 / 111

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
9 Eliminating malfunctions / 9.1 Malfunctions when starting

9 Eliminating malfunctions

9.1 Malfunctions when starting

Delayed start-up
Possible causes Remedy
Turbochar- Turbocharger contaminated Clean (see chapter Periodic mainten-
ger ance work →53)
Bearing damaged Contact ABB Turbocharging Service
Rotor rubbing Station
Foreign object in the turbocharger
Table 15: Malfunctions when starting – Delayed start-up

Vibrations
Possible causes Remedy
Turbochar- Rotor unbalance Contact ABB Turbocharging Service
ger Turbine or compressor damaged Station

Page 63 / 111
Bearing damaged
Engine Vibrations from engine Contact enginebuilder
Table 16: Malfunctions when starting – Vibrations

Rotating parts rubbing

Normal behaviour, not a malfunction
Turbochar- A minimal and uniform wear on the circumference of the rotor components is
ger permitted. This wear can be caused by slight local rubbing against adjacent com-
ponents. This causes the compressor or turbine blades to be somewhat
shortened. To prevent significant loss of efficiency, specific tolerances must be
fulfilled.
¡ If there is any doubt about the extent of the rubbing, contact an ABB Tur-
bocharging Service Station.
¡ Have a dimension check carried out by an ABB Turbocharging Service Sta-
tion.
Table 17: Malfunctions when starting - Rotating parts rubbing

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
9 Eliminating malfunctions / 9.2 Malfunctions during operation

9.2 Malfunctions during operation

Lubricating oil pressure too low

WARNING
Danger of fire and explosion due to lubricating oil leaks
Leaking oil may ignite on hot surfaces. This can result in serious injuries to
personnel or fatal accidents.
u Cordon off danger area.
u Raise the alarm and, depending on the situation, stop the engine.
u Seal the oil leak.
u Soak up oil and dispose of in an environmentally compatible manner.

Wear safety gloves to protect against thermal hazards.

Possible causes Remedy

Turbochar- Axial clearance of the rotor excessive Contact an ABB Turbocharging
ger Service Station
Page 64 / 111

Engine Oil filter heavily contaminated Clean

Oil pump in lubricating system defect- Check/replace
ive
Manometer displays incorrectly Replace manometer
Table 18: Malfunctions during operation – Lubricating oil pressure too low

Speed reduces
Possible causes Remedy
Turbochar- Turbine and/or nozzle ring severely con- Clean (see chapter Periodic mainten-
ger 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 Repair
gas pipes or charge air ducts
Table 19: Malfunctions during operation – Speed reduces

Speed increases
Possible causes Remedy
Turbochar- Light to medium contamination of the Clean (see chapter Periodic mainten-
ger turbine and/or nozzle ring (with 4- ance work →53) or contact an ABB Tur-
stroke application) bocharging Service Station
Table 20: Malfunctions during operation – Speed increases

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
9 Eliminating malfunctions / 9.2 Malfunctions during operation

Exhaust gas temperature too high

Engine performance and engine speed unchanged

Possible causes Remedy

Turbocharger Insufficient air, for example, when fil- Clean (see chapter Periodic mainten-
ter silencer is blocked by contamina- ance work →53)
tion
Compressor/turbine contaminated
Exhaust gas back pressure too high Clean or repair boiler or exhaust gas si-
lencer
Turbine damaged or eroded Contact ABB Turbocharging Service
Station
Engine Malfunction in the injection system Repair or contact manufacturer
Charge air Cooler contaminated Clean
cooler Cooling water volume too low Fill
Inlet temperature of cooling water Check/clean cooling system
too high
Insufficient ventilation Improve ventilation
Table 21: Malfunctions during operation – Exhaust gas temperature too high

Charge air pressure too low

Page 65 / 111
Engine performance and engine speed unchanged, suction condition normal

Possible causes Remedy

Turbochar- Manometer display not correct Replace manometer
ger Supply pipe to manometer not sealed Repair leak
Filter silencer contaminated, therefore Clean (see chapter Periodic mainten-
pressure drop too high ance work →53)
Compressor end and/or turbine end
contaminated
Compressor/turbine damaged Contact ABB Turbocharging Service
Station
Exhaust gas back pressure too high Clean or repair boiler or exhaust gas si-
lencer
Engine Air receiver not sealed Repair
Gas piping between engine and turbine
leaking
Injection mistimed Set correctly
Valve control misadjusted
Pipes Pipes downstream to the compressor Repair.
outlet not sealed.
Table 22: Malfunctions during operation – Charge air pressure too low

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
9 Eliminating malfunctions / 9.2 Malfunctions during operation

Charge air pressure too high

Engine performance and engine speed unchanged, suction condition normal

Possible causes Remedy

Turbochar- Manometer display not correct Replace manometer
ger Increased speed due to contamination Clean (see chapter Periodic mainten-
of nozzle ring ance work →53) or contact an ABB Tur-
bocharging Service Station
Engine Malfunction in the injection system Repair or contact manufacturer
Injection mistimed Set correctly
Engine performance higher than indic- Check engine performance
ated
Table 23: Malfunctions during operation – Charge air pressure too high

Reduced compressor performance/efficiency and therefore engine performance

losses

CAUTION
Compressor damage
A severely contaminated or corroded compressor wheel can reduce the com-
Page 66 / 111

pressor wheel’s fatigue endurance limit and result in the turbocharger being
damaged.
u Rectify malfunction in accordance with the following table.

Possible causes Remedy

Turbochar- Compressor components severely con- Clean (see chapter Periodic mainten-
ger taminated by the ventilation gases that ance work →53)
have been fed in Optimize oil separation
Increased blade vibration, compressor Correct the feed of ventilation gases ac-
blade damage due to the ventilation cording to instructions of engineb-
gases that have been fed in uilder.
Material of the compressor wheel cor- Correct the feed of ventilation gases ac-
roded due to the feeding in of ventila- cording to instructions of engineb-
tion gases containing corrosive com- uilder.
ponents
Material of the compressor wheel cor- Prevent exhaust gas leakages in the en-
roded due to intake air containing ex- gine space
haust gases or salt Clean (see chapter Periodic mainten-
ance work →53)
Table 24: Malfunctions during operation – Engine performance losses

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
9 Eliminating malfunctions / 9.3 Turbocharger is surging

9.3 Turbocharger is surging

WARNING
Hot air escapes from the air inlet
A surge blow is accompanied by a loud bang and escape of hot air from the
air inlet. This may result in injury to personnel.
u While the turbocharger is pumping, keep a distance from the air inlet.

Turbocharger surges continuously or periodically

CAUTION
Continuous or periodic surging
If the turbocharger surges continuously or periodically, parts of the tur-
bocharger may be damaged.
u Gradually reduce the engine load.
u Have the cause clarified and remedied immediately by an ABB Turbochar-

Page 67 / 111
ging Service Station.
u Have parts assessed for damage and, if necessary, replaced by an ABB
Turbocharging Service Station.

Possible causes Remedy

Turbocharger Filter silencer or diffuser contamin- Clean (see chapter Periodic mainten-
ated ance work →53)
Heavy contamination deposits in the
turbine or in the nozzle ring
Engine Protective grating in front of the tur- Clean/replace
bocharger contaminated or damaged
Charge air Cooler contaminated Clean
cooler Charge air duct blocked
Table 25: Malfunction – Turbocharger pumping

Sporadic surge blows

Possible causes Remedy
Engine Engine load reduced quickly when --
manoeuvring.
When this happens, the flow direc-
tion in the compressor is momentar-
ily reversed. Such sporadic surge
blows do not impair the safe opera-
tion of the turbocharger.
Table 26: Malfunction – Sporadic surge blows

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
9 Eliminating malfunctions / 9.4 Malfunctions when stopping

9.4 Malfunctions when stopping

Runout noises
Possible causes Remedy
Turbochar- Turbocharger contaminated Clean (see chapter Periodic maintenance work
ger →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.
Foreign object in the tur- Dismantle turbocharger (see chapter Dismantling
bocharger and fitting →70). In case of damage, replace the
corresponding parts or contact an ABB Turbochar-
ging Service Station.
Table 27: Malfunctions when stopping – Runout noises

Runout time too short

Page 68 / 111

The runout time must be noted down as a reference. Because the runout time depends on
the oil viscosity, the runout time must always be measured at the same oil temperature.
If the runout time is significantly shorter in comparison to a previous measurement, the fol-
lowing table must be observed.

Possible causes Remedy

Turbochar- Turbocharger contaminated Clean (see chapter Periodic maintenance work
ger →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.
Foreign object in the tur- Dismantle turbocharger (see chapter Dismantling
bocharger and fitting →70). In case of damage, replace the
corresponding parts or contact an ABB Turbochar-
ging Service Station.
Table 28: Malfunctions when stopping – Runout time too short

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
9 Eliminating malfunctions / 9.5 Speed measurement system

9.5 Speed measurement system

No signal or poor signal amplitude of the speed measurement

Possible causes Remedy
Turbochar- The speed sensor was acci- The screw plug for the sensor is fitted with an ad-
ger dentally fitted with an addi- ditional gasket (copper ring).
tional gasket. For information regarding the disassembly and as-
An enlarged distance sembly of the speed sensor, refer to chapter Re-
between the sensor tip and placing the speed sensor →44.
the signal-emitting sealing Install the speed sensor without the additional
disc reduces the voltage gasket (copper ring).
amplitude of the speed sig-
nal.
Sensor or cable defective Contact an ABB Turbocharging Service Station.
Order a new speed sensor (86505) from an ABB
Turbocharging Service Station.
Replacing the speed sensor →44.
Table 29: Malfunction of the speed measurement system – No signal or poor signal amplitude

Measured speed too high

Possible causes Remedy

Page 69 / 111
Turbochar- Sensor tip contaminated, For information regarding the disassembly and as-
ger since it is magnetic and can sembly of the speed sensor, refer to chapter Re-
attract metallic particles. placing the speed sensor →44.
This reduces the distance to Dismantle the sensor, clean the sensor tip, and fit
the signal-emitting sealing the sensor back on with the specified tightening
disc, which can lead to ampli- torque.
fication of the noise com-
ponent and therefore to false
triggering.
Table 30: Malfunction of the speed measurement system – Measured speed too high

Measured speed too low

Possible causes Remedy
Turbochar- -- Contact ABB Turbocharging Service Station
ger
Table 31: Malfunction of the speed measurement system – Measured speed too low

If none of the measures described above remedy the malfunction, have the speed measure-
ment system checked by an ABB Turbocharging Service Station.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
10 Dismantling and fitting / 10.1 Introduction

10 Dismantling and fitting

10.1 Introduction
The precondition for the work described in the following is a turbocharger removed from the
engine (see chapter Removing and Installing →28).

WARNING
Danger of burns
Touching hot surfaces or contact with hot operating fluids can cause burns.
u Do not touch hot surfaces. Observe the warning plate on the turbochar-
ger.
u Wear heat-resistant safety gloves and protective clothing.
u Wait for the turbocharger to cool down before carrying out any work.

Wear safety gloves to protect against thermal hazards.

Page 70 / 111

WARNING
Cutting injuries when working on the turbocharger
Some parts on the turbocharger may have sharp edges. There is a risk of a
cutting injury.
u Wear safety gloves against mechanical risks when conducting assembly
and disassembly work.

Wear safety gloves to protect against mechanical hazards.

CAUTION
Further work
This Operation Manual may be used to carry out only the work described in
it. Further work that is carried out in an incorrect way can lead to serious
damage to the machine.
u ABB Turbocharging recommends having further work carried out only by
trained personnel from an ABB Turbocharging Service Station.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
10 Dismantling and fitting / 10.2 Material required

10.2 Material required

Customer spare part set

Before starting operations, make sure the required customer spare part set is available (see
chapter Spare parts →98).

Customer tool
Before starting work, make sure the required tool is available (see chapter Tools →109).
Not all tools are marked with a part number. Identification is guaranteed by the tool list. This
list is enclosed with the tool set.

WARNING
Servicing the tools
The tools must be checked for damage before and after use.
u Visually inspect for corrosion, cracks, deformation and wear.
u Damaged tools must no longer be used and must be replaced.

Page 71 / 111
Swivel lifting eyes
One swivel lifting eye (S) is required to safely lift this turbocharger. This is not included in
the ABB scope of delivery.

Fig. 23: Swivel lifting eyes

Product Thread M Length H Diameter D Minimum load limit

[mm] [mm] [kg]
TPS44 M8 ≤ 12 ≤ 25 300
TPS48 M8 ≤ 12 ≤ 25 300
TPS52 M10 ≤ 15 ≤ 25 400
Table 32: Swivel lifting eyes to be used

Ring nuts
Two ring nuts are required for safer lifting of the cartridge group, which are not included in
the ABB scope of delivery.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
10 Dismantling and fitting / 10.2 Material required

Fig. 24: Ring nuts

Product Thread
TPS44 M16
TPS48 M16
TPS52 M16
Table 33: Ring nuts to be used (VRM)

Lifting gear

WARNING
Suspended loads
Loads that are not attached according to regulations can cause injury to
Page 72 / 111

personnel or fatal accidents.

u Only fasten the turbocharger, assemblies or individual parts on properly
functional lifting gear with sufficient load limit.
u Pay attention to the correct attachment of loads on the crane hook.
u People must not stand beneath suspended loads.

Wear safety gloves to protect against mechanical hazards.

Wear safety helmet.

Definition of terms
¡ Suspension point
Defined loading point on a component or an assembly (blind hole thread, eyelet, lug).
¡ Assembly device
Devices that are fitted on the turbocharger in order to obtain a suspension point. As-
sembly devices are specially constructed and designed for the defined use; they are not
commercially available products. Use assembly devices only for the described applica-
tions.
¡ Lifting gear
Equipment for the lifting and transporting of loads (ropes, chain block, crane). Lifting
gear is not supplied by ABB.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
10 Dismantling and fitting / 10.3 Weights of individual parts

10.3 Weights of individual parts

The specified weights of the individual parts or assemblies are rounded-up standard values.

Page 73 / 111
Fig. 25: Overview of assemblies

Designation TPS44 TPS48 TPS52

01 Radial air suction branch 5 6 8
02 Axial air suction branch 3 4 4
03 Filter silencer 15 -- --
04 Compressor casing 17 30 45
05 Diffuser 2 3 4
06 Cartridge group 24 40 65
07 Nozzle ring 1 2 3
08 Turbine casing 1 inlet 30 45 70
09 Gas outlet casing 16 18 25
Table 34: Weights of the assemblies [kg]

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
10 Dismantling and fitting / 10.4 Removing the gas outlet casing

10.4 Removing the gas outlet casing

u Mark the casing position for assembly.
Page 74 / 111

Fig. 26: Removing the gas outlet casing

1. Manually secure the gas outlet casing (61001).

2. Loosen and remove hexagon nuts (51009).
3. Remove the gas outlet casing (61001).

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
10 Dismantling and fitting / 10.5 Removing air inlets

10.5 Removing air inlets

u Mark the casing position for assembly.

Page 75 / 111
Fig. 27: Removing air inlets

1. Manually secure the filter silencer (81000) or air suction branch (82000).
2. Loosen and remove V-clamp (72020).
3. Remove the filter silencer (81000) or air suction branch (82000).
4. Remove and dispose of O-ring (81010 / 82010) (refer to Disposing of turbocharger com-
ponents →97).

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
10 Dismantling and fitting / 10.6 Removing the compressor casing

10.6 Removing the compressor casing

Fig. 28: 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).
Page 76 / 111

Fig. 29: Removing the compressor casing (2/2)

1. Secure lifting gear to compressor casing (72000).

2. Remove the compressor casing (72000) vertically.
3. Rotate the compressor casing (72000) through 180° and put it in place.
4. Remove and dispose of O-ring (42012) (see chapter Disposing of turbocharger compon-
ents →97).
5. Remove screw (72041).
6. Remove the diffuser (79000) vertically from the compressor casing.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
10 Dismantling and fitting / 10.7 Removing the cartridge group

10.7 Removing the cartridge group

Do not remove oil orifice (if present)

Fig. 30

42001 Bearing casing

42156 Oil orifice in the oil inlet

To limit the oil flow rate through the bearing casing during operation (engine under load) to
the admissible values, an oil orifice is mandatory at the oil inlet of the bearing casing if the
oil inlet pressure is > 3 bar (overpressure).
If an oil orifice is fitted in the oil inlet of the bearing casing, it must not be removed.

Page 77 / 111
Do not loosen screw plugs

CAUTION
Oil leaks
These screw plugs must not be removed for maintenance work. If a screw
plug is loosened, the gasket can be damaged. This can result in an oil leak.
u Do not loosen screw plugs.
u 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

u Mark the casing position for assembly.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
10 Dismantling and fitting / 10.7 Removing the cartridge group

Fig. 32: Removing the cartridge group (1)

1. Loosen the hexagon nuts (51007).

2. Remove hexagon nuts (51007), Verbus Ripp® washers (51003) and fastening
strips (51002).
3. Screw in the swivel lifting eye (S) up to the stop.
Page 78 / 111

Removing the cartridge group

Fig. 33: Removing cartridge group 2

1. Insert screws from service support into cartridge group.

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.
5. If present: Remove the metal C-ring (51105).

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
10 Dismantling and fitting / 10.7 Removing the cartridge group

Page 79 / 111
Fig. 34: Rotating the cartridge group and fitting the service support

1. Lift the cartridge group and rotate in the horizontal position.

2. Remove the lifting gear from the ring nuts.
3. Remove the ring nuts (VRM) and screws from the service support.
4. Place the cartridge group onto the fitted service support (90012).
5. Fit and hand-tighten nuts.
u Measure: Axial clearance A and radial clearance B.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
10 Dismantling and fitting / 10.8 Removing nozzle ring

10.8 Removing nozzle ring

Fig. 35: Removing the nozzle ring

1. Remove the nozzle ring (56001) vertically.

2. Remove the lamellar sealing ring (56005).
Page 80 / 111

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
10 Dismantling and fitting / 10.9 Measuring clearance A and B

10.9 Measuring clearance A and B

u Measure and record clearances A and B after the removal and before the installation of
the cartridge group.
u Attach the dial indicator and align it for the respective clearance as per the illustration.

Fig. 36: Measuring clearance A and B

Product A [mm] B [mm]

TPS44 0.10 ... 0.18 0.69 ... 1.27
TPS48 0.11 ... 0.19 0.86 ... 1.52
TPS52 0.13 ... 0.22 0.98 ... 1.68

Page 81 / 111
Table 35: Permissible clearances A and B

1. Move the rotor to and fro up to the stop. In order to obtain a correct measurement, elev-
ate the turbine a little.
2. Measure clearance A and compare it with the permissible values in the table.
3. Raise the compressor and push the turbine down at the same time.
4. Raise the turbine and push the compressor down at the same time.
5. Measure clearance B and compare it with the permissible values in the table.

CAUTION
Clearances outside the tolerance
Serious damage to engines or property can be caused by clearances outside
the tolerance and excessively worn parts.
u Have the components assessed and, if necessary, replaced by an ABB Tur-
bocharging Service Station.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
10 Dismantling and fitting / 10.10 Nozzle ring compression PD

10.10 Nozzle ring compression PD

For the nozzle ring (56001) to be fixed during operation, it must be clamped between the
bearing casing (42001) and the turbine casing (51000).
Page 82 / 111

Fig. 37: Measuring nozzle ring compression

42001 Bearing casing

51000 Turbine casing
56001 Nozzle ring
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.
u If the calculated value (PD) lies outside the specified range, contact an ABB Turbochar-
ging Service Station.
Product Compression PD [mm]
TPS44 -0.23 ... 0.23
TPS48 -0.23 ... 0.23
TPS52 -0.24 ... 0.24
Table 36: Nozzle ring compression PD

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
10 Dismantling and fitting / 10.11 Fitting the diffuser

10.11 Fitting the diffuser

Fig. 38: Fitting the diffuser

Product Size Tightening torque [Nm]

Page 83 / 111
TPS44 M5 5 Nm
TPS48 M5 5 Nm
TPS52 M6 10 Nm
Table 37: Tightening torque (72041)

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 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
10 Dismantling and fitting / 10.12 Installing the cartridge group

10.12 Installing the cartridge group

Lifting the cartridge group and rotating it by 90°

Page 84 / 111

Fig. 39: Lifting the cartridge group and rotating it by 90°

1. Fit a new, high temperature-resisting O-ring (42012, red or green) (see Customer spare
part set (97070) →98).
2. Loosen and remove nuts.
3. Lift the cartridge group out of the service support (90012).
4. Insert the screws of the service support from above and fit ring nuts (VRM) with washers.
5. Attach lifting gear to the ring nuts (VRM).
6. Lift cartridge group at the side of the ring nuts (VRM) and turn it into a vertical position
(compressor wheel facing downwards). Use edge guard between turbines and lifting
gear.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
10 Dismantling and fitting / 10.12 Installing the cartridge group

Fitting the cartridge group

Page 85 / 111
Fig. 40: Fitting the cartridge group

Product Size Tightening torque [Nm]

TPS44 M8 40 Nm
TPS48 M8 40 Nm
TPS52 M10 80 Nm
Table 38: Tightening torque (72011)

1. Lower cartridge group carefully into the compressor casing.

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 hexagon-head screws (72011).

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
10 Dismantling and fitting / 10.13 Installing the nozzle ring

10.13 Installing the nozzle ring

Page 86 / 111

Fig. 41: Installing the nozzle ring

1. Fit lamellar sealing ring (56005) in the slot of the nozzle ring. When doing this, pay atten-
tion to correct winding of the lamellar sealing 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 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
10 Dismantling and fitting / 10.14 Fitting the turbine casing

10.14 Fitting the turbine casing

Page 87 / 111
Fig. 42: Fitting the turbine casing

Product Size Tightening torque [Nm]

TPS44 M8 30 Nm
TPS48 M8 30 Nm
TPS52 M10 60 Nm
Table 39: Tightening torque (51007)

1. Coat thread of studs (51006) with high-temperature grease.

2. Fit two swivel lifting eyes (01) on the turbine casing (51000). Secure lifting gear to the
swivel lifting eyes.
3. Turn the turbine casing (51000) by 180°.
4. If present: Fit the metal C-ring (51105).
5. Align turbine casing with marking and position on cartridge group.
6. Fit fastening strips (51002) with Verbus Ripp® washers (51003) and hexagon
nuts (51007). Observe tightening torque.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
10 Dismantling and fitting / 10.15 Turning the turbocharger

10.15 Turning the turbocharger

Page 88 / 111

Fig. 43: Rotating the turbocharger

1. Fit swivel lifting eye (S).

2. Insert screws from the service support.
3. Fit ring nuts (VRM).
4. Attach lifting gear.
5. Elevate and rotate the turbocharger.
6. Place the turbocharger on a soft underlay.
u Measure: Radial clearances N and R.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
10 Dismantling and fitting / 10.16 Measuring radial clearances N and R

10.16 Measuring radial clearances N and R

Fig. 44: Measuring clearances N and R

Page 89 / 111
Product N [mm] R [mm]
TPS44 0.25 ... 0.50 0.40 ... 0.70
TPS48 0.30 ... 0.60 0.50 ... 0.80
TPS52 0.40 ... 0.70 0.60 ... 0.95
Table 40: Permissible clearances N and R

1. Push the feeler gauges (01) into the gap without clearance, and measure simultaneously
at the top (N1) and the bottom (N2).
2. Calculate clearance N and compare it with the permissible values in the table.
3. Push the feeler gauges (01) into the gap without clearance, and measure simultaneously
at the top (R2) and the bottom (R1).
4. Calculate clearance R and compare it with the permissible values in the table.

CAUTION
Clearances outside the tolerance
Serious damage to engines or property can be caused by clearances outside
the tolerance and excessively worn parts.
u Have the components assessed and, if necessary, replaced by an ABB Tur-
bocharging Service Station.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
10 Dismantling and fitting / 10.17 Installing the gas outlet casing

10.17 Installing the gas outlet casing

Page 90 / 111

Fig. 45: Fitting the gas outlet casing

Product Size Tightening torque [Nm]

TPS44 M8 25 Nm
TPS48 M8 25 Nm
TPS52 M10 50 Nm
Table 41: Tightening torque (51008)

1. Coat thread of studs (51008) with high-temperature grease.

2. Align the casing position of the gas outlet casing (61001) to the marking.
3. Position the gas outlet casing and fit with two hexagon nuts (51009) in the upper area.
4. Fit the remaining hexagon nuts (51009), then tighten all the screws. Observe tightening
torque.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
10 Dismantling and fitting / 10.18 Installing air inlets

10.18 Installing air inlets

Page 91 / 111
Fig. 46: Installing the air inlets

Product Size Tightening torque [Nm]

TPS44 M10 30 Nm
TPS48 M10 30 Nm
TPS52 M10 30 Nm
Table 42: Tightening torque (72020)

1. Fit the new O-ring (81010 / 82010) to the filter silencer (81000) or the air suction
branch (82000).
2. Manually position the filter silencer (81000) or the air suction branch (82000) on the com-
pressor casing (72000).
3. Fit the V-clamp (72020).
4. Align the casing position of the filter silencer (81000) or the air suction branch (82000) to
the marking.
5. Tighten the V-clamp (72020).

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
10 Dismantling and fitting / 10.19 Table of tightening torques

10.19 Table of tightening torques

Fig. 47: Overview of tightening torques

Position Part number TPS44 TPS48 TPS52

01 82007 M18 x 1.5 M18 x 1.5 M18 x 1.5
60 Nm 60 Nm 60 Nm
02 82005 / 81005 M16 x 1.5 M16 x 1.5 M16 x 1.5
50 Nm 50 Nm 50 Nm
Page 92 / 111

03 72020 M10 M10 M10

30 Nm 30 Nm 30 Nm
04 72041 M5 M5 M6
5 Nm 5 Nm 10 Nm
05 72011 M8 M8 M10
40 Nm 40 Nm 80 Nm
06 42188 M12 x 1.5 M12 x 1.5 M12 x 1.5
35 Nm 35 Nm 35 Nm
07 51007 M8 M8 M10
30 Nm 30 Nm 60 Nm
08 51006 M8 M8 M10
25 Nm 25 Nm 45 Nm
09a / 51008 / M8 M8 M10
09b 51009 25 Nm 25 Nm 50 Nm
10 61005 M18 x 1.5 M18 x 1.5 M18 x 1.5
60 Nm 60 Nm 60 Nm
11 86505 M12 x 1.5 M12 x 1.5 M12 x 1.5
15 Nm 15 Nm 15 Nm
12 *) -- 90 Nm 90 Nm 90 Nm
Table 43: Overview of tightening torques

*) These screw plugs must not be removed for maintenance work. If the screw plug is
loosened, the tightness is no longer guaranteed.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
11 Taking out of operation at short notice / 11.1 Possible emergency
repairs

11 Taking out of operation at short notice

11.1 Possible emergency repairs

WARNING
Danger of fire and explosion due to lubricating oil leaks
Leaking oil may ignite on hot surfaces. This can result in serious injuries to
personnel or fatal accidents.
u Cordon off danger area.
u Raise the alarm and, depending on the situation, stop the engine.
u Seal the oil leak.
u Soak up oil and dispose of in an environmentally compatible manner.

Wear safety gloves to protect against thermal hazards.

CAUTION

Page 93 / 111
Directives for taking out of operation
Serious damage to engine or property can be caused by non-compliance
with the directives for blanking the turbocharger off the engine.
u Follow the directives of the enginebuilder.

To enable you to quickly put an engine back into operation after a turbocharger has sus-
tained damage, ABB Turbocharging recommends having a replacement turbocharger or ap-
propriate spare parts available in storage. The defective turbocharger can be removed and
the replacement turbocharger installed within a short period of time.
u Remove defective turbocharger (see chapter Removing and Installing →28).

u Install replacement turbocharger (see chapter Removing and Installing →28).

u Send the defective turbocharger to an ABB Turbocharging Service Station for inspection
and repair.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
12 Mothballing the turbocharger / 12.1 Taking the engine out of opera-
tion for up to 12 months

12 Mothballing the turbocharger

12.1 Taking the engine out of operation for up to

12 months

State of the engine lubricating oil

The turbocharger normally remains attached to the engine. The measures to be taken for
mothballing the turbocharger depend on the state of the lubricating oil. No measures are
necessary under the following conditions:
¡ Acid number (TAN) < 2 mg KOH/g
¡ Before taking out of operation, the engine lubricating oil is replaced with a preservative
oil and circulated with the pre-lubrication pump. Residues of old engine oil are flushed
away in this way and the bearing parts are largely protected against corrosion.

Preparations for mothballing

Page 94 / 111

WARNING
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or con-
tact with them may be harmful to health.
u Do not breathe in these substances and avoid contact with the skin.
u Ensure proper ventilation.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Wear personal protective equipment (PPE) according to the material
safety data sheet.
u Comply with local legislation.

Wear safety goggles.

Wear safety gloves to protect against chemical hazards.

Wear a respiratory mask to protect against gases.

If the acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures
are necessary after taking out of operation:
u Remove turbocharger (see chapter Removing and Installing →28).

u Dismantle turbocharger (see chapter Dismantling and fitting →70).

u The rotor and bearing parts must be dismantled and refitted by an ABB Turbocharging
Service Station.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
12 Mothballing the turbocharger / 12.2 Taking the engine out of opera-
tion for more than 12 months

u Clean all parts.

u Coat the plain surfaces of steel and cast parts with anti-corrosive oil.

u Fit turbocharger completely.

CAUTION
Rotation of the rotor in the stack draught
The rotor can rotate in the stack draught. If the bearings are not lubricated,
this can result in wear.
u Install blind flange between gas outlet casing and exhaust gas pipe.

12.2 Taking the engine out of operation for more than

12 months
If the engine is taken out of operation, the following variants are possible with regard to the
turbocharger:
¡ Turbocharger remains attached to the engine
¡ The casings of the turbocharger remain attached to the engine, the rotor and bearing

Page 95 / 111
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
for mothballing.
If the turbocharger remains attached to the engine, see section Taking the engine out of op-
eration for up to 12 months →94, subsection Rotor turning in stack draught.
If the complete turbocharger is removed or the turbocharger is assembled again from the
individual parts:
u Seal all openings of the turbocharger with paraffin paper and wooden lids.

Only dry rooms with 40 ... 70 % atmospheric humidity, in which no water condensation can
form, are suitable as storage locations.

State of the mothballed turbocharger

u Check the turbocharger parts annually for corrosion.

u If there are signs of rust: Thoroughly clean parts and renew corrosion protection.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
13 Material and Disposal / 13.1 REACH and RoHS Compliance Declara-
tion For Products

13 Material and Disposal

13.1 REACH and RoHS Compliance Declaration For

Products
We hereby confirm that all genuine products, parts and components supplied by ABB
Switzerland Ltd, Turbocharging are fully compliant with the requirements of European
Union Regulation (EC) 1907/2006 concerning the Registration, Evaluation, Authorization and
Restriction of Chemicals (REACH):

Article 33 (of requirements of European Union Regulation (EC) 1907/2006)

[in English only]
A supplier of a product composed of one or more constituent articles (products) of which
contain(s) a candidate list substance (SVHC, Substance of Very High Concern) in a concen-
tration above 0.1% wlw, shall inform the customer of the presence of such substance(s) with
sufficient information, available to the supplier.
Page 96 / 111

RoHS2 Directive 2011/65/EC

[in English only]
The EU Directive 2011/65/EC (recast) restricts the use of certain hazardous substances in
electrical and electronic equipment (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)).

Electrical or electronic equipment supplied by ABB Switzerland Ltd, Turbocharging fulfil re-
quirements of RoHS2 Directive 2011/65/EC and fall under the exception 6a and 6c of the
same Directive:
¡ 6a) Lead as an alloying element in steel for machining purposes and in galvanised steel
containing up to 0.35 % lead by weight
¡ 6c) Copper alloy containing up to 4 % lead by weight.

The maximum concentration of lead and lead compounds for our products is known to reach
max. 0.8 % (mass % in homogeneous material).

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
13 Material and Disposal / 13.2 Disposing of turbocharger components

13.2 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.
u Avoid the formation of dust.
u Vacuum up dust with a suitable vacuum cleaner.
u Wear a respiratory mask to protect against dusts (P1 or P2 mask).
u Wear safety gloves.

Wear safety goggles.

Wear a respiratory mask to protect against dusts.

Wear safety gloves to protect against mechanical hazards.

Disposal must be environmentally compatible, professional, and in compliance with locally

Page 97 / 111
applicable regulations.
The turbocharger consists largely of metal (cast iron materials, steel, nickel-steel alloys, alu-
minium and bearing brass).
Further components are: Non-metallic materials (filter components of felt and polyethylene),
lubricants (engine oil), electronic parts (speed sensor and associated components), and
thermal insulation.
u Dispose of metals as scrap metal for recycling.

u Dispose of non-metallic materials as waste.

u Dispose of residues of lubricants as waste oil.

u Dispose of electronic components as electronic waste.

u Dispose of thermal insulation as hazardous waste.

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
14 Spare parts / 14.1 Ordering spare parts

14 Spare parts

14.1 Ordering spare parts

CAUTION
Spare part storage
All spare parts that were ordered together with the turbocharger must be
kept intact and ready for use.
u Carefully clean any rusted parts and grease them.

Please quote the following data when making queries and ordering spare parts:
¡ Turbocharger type
¡ Serial number of the turbocharger
¡ Designation and part number.
Spare parts can be ordered from any ABB Turbocharging Service Station.
u If different model variants are not taken into account in this document, contact an ABB
Page 98 / 111

Turbocharging Service Station.

u Dispose of placed and unusable parts in an environmentally-friendly and professional
manner in accordance with the local regulations.
u Dispose of the packaging of new parts in an environmentally-friendly and professional
manner in accordance with the local regulations.

14.2 Required customer spare part set (97070)

For the work described in the Operation Manual, the customer spare part set (97070) is re-
quired. These parts are only available in the complete set.

Customer spare part set

97070 Designation Quantity
42012 O-ring (green) 1
52406 Gasket 1
72041 Counter-sunk screw 1
81010 / 82010 O-ring 1
Table 44: Customer spare part set (97070)

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
14 Spare parts / 14.3 Spare part - Illustrations

14.3 Spare part - Illustrations

The spare parts lists shown below are only available in English.

Cartridge
42184*(p)

42183*(p)
98105

98100

42189(p)

42188(p)

42183*(p)

42182*(p)

Page 99 / 111
10900

42196

(p) = pre-assembled
42012*
* = Available within the spare part set HZTL443461 Mod. A

Part no. Designation

10900 Cartridge
42012* O-ring
42182* (p) Screw plug
42183* (p) Gasket
42184* (p) Screw plug
42188(p) Hexagon-head screw
42189(p) Gasket
42196 Orifice oil inlet
98100 Rating plate
98105 Round head threaded rivet
Table 45: Spare parts - Cartridge

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
14 Spare parts / 14.3 Spare part - Illustrations

Bearing casing
42184*(p)
42402
42183*(p)

98105

98100

42189(p)
42188(p)

42302*

42182*(p)

42183*(p)

42001
Page 100 / 111

42196

42041*

42301

42008*

(p) = pre-assembled
* = Available within the spare part set HZTL443412 Mod. B

Part no. Designation

42001 Bearing casing
42008* Socket screw
42041* Gasket
42182* (p) Screw plug
42183* (p) Gasket
42184* (p) Screw plug
42188(p) Hexagon-head screw
42189(p) Gasket
42196 Orifice oil inlet
42301 Bearing cover
42302* Piston ring
42402 Heat sheet metal
98100 Rating plate
98105 Round head threaded rivet
Table 46: Spare parts - Bearing casing

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
14 Spare parts / 14.3 Spare part - Illustrations

Rotor & Bearing parts

21000

21002*

32167*

25000

32186*

32103*

Page 101 / 111

32104*

42002*

32109*

* = Available within the spare part set HZTL443462 Mod. A

Part no. Designation

21000 Turbine
21002* Piston ring
25000 Compressor wheel
32103* Thrust ring
32104* Thrust bearing
32109* Sealing disc
32167* Snap ring
32186* Plain bearing bush
42002* Socket screw
Table 47: Spare parts - Rotor and Bearing parts

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
14 Spare parts / 14.3 Spare part - Illustrations

Turbine casing

51009

51008

51027(p)

51000 51008**

51006 52406* **
Page 102 / 111

56005
55653**
51105**
56001
51002
51003
51007
(p) = pre-assembled
** = if provided
* = Available within the spare part set HZTL443413 Mod. B

Part no. Designation

51000 Turbine casing
51002 Fastening strip
51003 Verbusripp washer
51006 Stud
51007 Hexagon nut
51008 Stud
51008** Hexagon head screw
51009 Hexagon nut
51027(p) Screw plug
51105** Metal C-ring
52406* ** Gasket
55653** Gasketring
56001 Nozzle ring
56005 Lamellar sealing ring
Table 48: Spare parts - Turbine casing

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
14 Spare parts / 14.3 Spare part - Illustrations

Compressor casing

72011

72012

72041*

79000

72000

Page 103 / 111

72080
72020

72006(p)
72005(p)
(p) = pre-assembled
* = Available within the spare part set HZTL443414 Mod. B

Part no. Designation

72000 Compressor casing
72005(p) Screw plug
72006(p) Gasket
72011 Hexagon-head screw
72012 Fastening strip
72020 V-clamp
72041* Counter-sunk screw
72080 Warning plate
79000 Diffuser
Table 49: Spare parts - Compressor casing

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
14 Spare parts / 14.3 Spare part - Illustrations

Filter silencer

81137

81136
81000

81135

81266

81270

81271

81265**

81010*

81006(p)
Page 104 / 111

81005(p)

81171(p)

81170(p)

(p) = pre-assembled
** = if provided
* = Available within the spare part set HZTL443011 Mod. F

Part no. Designation

81000 Filter silencer complete
81005(p) Screw plugt
81006(p) Gasket
81010* O-ring
81135 Silencer body
81136 Absorption sgment
81137 Sheet-metal covering
81170(p) Screw plug
81171(p) Gasket
81265** Filter ring
81266 Cover grid
81270 Tension band
81271 Lock
Table 50: Spare parts - Filter silencer

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
14 Spare parts / 14.3 Spare part - Illustrations

Air suction branch radial

Page 105 / 111

82007(p) 82008(p) 82000 82005(p) 82006(p) 82010*

(p) = pre-assembled
* = Available within the spare part set HZTL443416 Mod. A

Part no. Designation

82000 Air sucton branch
82005(p) Screw plug
82006(p) Gasket
82007(p) Screw plug
82008(p) Gasket
82010* O-ring
Table 51: Spare parts - Air suction branch radial

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
14 Spare parts / 14.3 Spare part - Illustrations

Air suction branch axial

82005(p)

82008(p)
Page 106 / 111

82006(p) 82007(p) 82000 82010*

(p) = pre-assembled
* = Available within the spare part set HZTL443418 Mod. A

Part no. Designation

82000 Air suction branch
82005(p) Screw plug
82006(p) Gasket
82007(p) Screw plug
82008(p) Gasket
82010* O-ring
Table 52: Spare parts - Air suction brach axial

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
14 Spare parts / 14.3 Spare part - Illustrations

Gas outlet casing

61005(p)

61001

Page 107 / 111

(p) = pre-assembled HZTL443417 Mod. B

Part no. Designation

61001 Gas outlet casing
61005(p) Screw plug
Table 53: Spare parts - Gas outlet casing

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
14 Spare parts / 14.3 Spare part - Illustrations

Speed measurement system

86526

86528**
86505

86515
Page 108 / 111

** = if provided HZTL443419 Mod. -

Part no. Designation

86505 Speed sensor
86515 Cable connector
86526 F/I-converter
86528** Tachometer
Table 54: Spare parts - Speed measurement system

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
15 Tools / ​

15 Tools
The following tool is required for the work described in the Operation Manual.

Part number Designation Quantity

90012 Service support 1
Table 55: 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.

Page 109 / 111

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Rev.F May 2021
 Operation Manual / TPS44-H.. - TPS52-H..
Figures

Figures
Fig. 1: Serial number (01) on the rating plate ........... 4 Fig. 32: Removing the cartridge group (1) ................ 78

Fig. 2: Layout and function of the turbocharger...... 6 Fig. 33: Removing cartridge group 2.......................... 78

Fig. 3: Volatile Corrosion Inhibitor (VCI)................... 10 Fig. 34: Rotating the cartridge group and fitting the
service support .............................................................. 79
Fig. 4: Package with hygrometer ............................... 11
Fig. 35: Removing the nozzle ring............................... 80
Fig. 5: Warning plate locations ................................... 16
Fig. 36: Measuring clearance A and B ........................ 81
Fig. 6: Rating plate ........................................................ 17
Fig. 37: Measuring nozzle ring compression ............ 82
Fig. 7: Position of the rating plate ............................. 18
Fig. 38: Fitting the diffuser.......................................... 83
Fig. 8: Attachment of loads on the crane hook ....... 19
Fig. 39: Lifting the cartridge group and rotating it
Fig. 9: Attachment angle.............................................. 19 by 90° ............................................................................... 84
Fig. 10: Swivel lifting eyes........................................... 28 Fig. 40: Fitting the cartridge group ........................... 85
Fig. 11: Removing the turbocharger.......................... 30 Fig. 41: Installing the nozzle ring ................................ 86
Fig. 12: Inserting gaskets into the bracket............... 31 Fig. 42: Fitting the turbine casing .............................. 87
Fig. 13: Inserting threaded rods into the bracket ... 32 Fig. 43: Rotating the turbocharger ............................ 88
Page 110 / 111

Fig. 14: Requirements for threaded rods.................. 32 Fig. 44: Measuring clearances N and R...................... 89
Fig. 15: Placing the turbocharger on the bracket.... 33 Fig. 45: Fitting the gas outlet casing......................... 90
Fig. 16: Layout and overview of the speed measure- Fig. 46: Installing the air inlets.................................... 91
ment system.................................................................. 42
Fig. 47: Overview of tightening torques ................... 92
Fig. 17: Fitting the speed sensor ............................... 44

Fig. 18: Noise insulation, bellows .............................. 46

Fig. 19: Cleaning the filter silencer............................ 54

Fig. 20: Cleaning the compressor casing, diffuser

mechanically.................................................................. 56

Fig. 21: Cleaning the nozzle ring, turbine casing

mechanically................................................................... 57

Fig. 22: Soaking contamination of the turbine....... 59

Fig. 23: Swivel lifting eyes ............................................ 71

Fig. 24: Ring nuts ........................................................... 72

Fig. 25: Overview of assemblies ................................. 73

Fig. 26: Removing the gas outlet casing.................. 74

Fig. 27: Removing air inlets.......................................... 75

Fig. 28: Removing the compressor casing (1/2) .... 76

Fig. 29: Removing the compressor casing (2/2) .... 76

Fig. 30 .............................................................................. 77

Fig. 31: Do not loosen screw plugs............................. 77

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Revision F May 2021
Operation Manual / TPS44-H.. - TPS52-H..
Tables

Tables
Table 1: Definition of pictograms ............................... 9 Table 27: Malfunctions when stopping – Runout
noises ............................................................................... 68
Table 2: Personal protective equipment to be worn
at all times ...................................................................... 13 Table 28: Malfunctions when stopping – Runout
time too short ................................................................ 68
Table 3: Personal protective equipment to be worn
specific to the respective task ................................... 13 Table 29: Malfunction of the speed measurement
system – No signal or poor signal amplitude .......... 69
Table 4: Gesamtgewicht ............................................. 28
Table 30: Malfunction of the speed measurement
Table 5: Swivel lifting eyes to be used ..................... 28 system – Measured speed too high ........................... 69
Table 6: Requirements for threaded rods ................ 32 Table 31: Malfunction of the speed measurement
system – Measured speed too low............................. 69
Table 7: Tightening torque for standard nuts ......... 33
Table 32: Swivel lifting eyes to be used......................71
Table 8: Lubricating oil pressure at oil inlet before
turbocharger ................................................................. 38 Table 33: Ring nuts to be used (VRM) ........................ 72
Table 9: Lubricating oil temperature at the inlet... 40 Table 34: Weights of the assemblies [kg]................. 73
Table 10: Lubricating oil temperature at the outlet .... Table 35: Permissible clearances A and B ................. 81
40
Table 36: Nozzle ring compression PD ...................... 82
Table 11: Tightening torque (86505) ........................ 44

Page 111 / 111

Table 37: Tightening torque (72041) .......................... 83
Table 12: Expected replacement intervals................ 51
Table 38: Tightening torque (72011) .......................... 85
Table 13: Maintenance table....................................... 53
Table 39: Tightening torque (51007) ......................... 87
Table 14: Dimensions of the cleaning container .... 59
Table 40: Permissible clearances N and R ................ 89
Table 15: Malfunctions when starting – Delayed
start-up .......................................................................... 63 Table 41: Tightening torque (51008) ......................... 90

Table 16: Malfunctions when starting – Vibrations 63 Table 42: Tightening torque (72020) ......................... 91

Table 17: Malfunctions when starting - Rotating Table 43: Overview of tightening torques ................ 92
parts rubbing ................................................................ 63
Table 44: Customer spare part set (97070) ............. 98
Table 18: Malfunctions during operation – Lubricat-
ing oil pressure too low............................................... 64 Table 45: Spare parts - Cartridge ............................... 99

Table 19: Malfunctions during operation – Speed re- Table 46: Spare parts - Bearing casing.................... 100
duces............................................................................... 64
Table 47: Spare parts - Rotor and Bearing parts ... 101
Table 20: Malfunctions during operation – Speed in-
creases ........................................................................... 64 Table 48: Spare parts - Turbine casing.................... 102

Table 21: Malfunctions during operation – Exhaust Table 49: Spare parts - Compressor casing ........... 103
gas temperature too high .......................................... 65
Table 50: Spare parts - Filter silencer ...................... 104
Table 22: Malfunctions during operation – Charge air
Table 51: Spare parts - Air suction branch radial... 105
pressure too low........................................................... 65
Table 52: Spare parts - Air suction brach axial....... 106
Table 23: Malfunctions during operation – Charge air
pressure too high ......................................................... 66 Table 53: Spare parts - Gas outlet casing ............... 107
Table 24: Malfunctions during operation – Engine Table 54: Spare parts - Speed measurement system .
performance losses ..................................................... 66 108
Table 25: Malfunction – Turbocharger pumping.... 67 Table 55: TPS-H Tool ................................................... 109
Table 26: Malfunction – Sporadic surge blows....... 67

© Copyright 2021 ABB. All rights reserved. HZTL4037_EN Revision F May 2021