ABB TPS61-R35 (01) PDF MANUAL

The Safety Data Sheet includes the following details for the TPS61-R35 turbocharger, identified by HT594627:

• Type: TPS61-R35
• Manufacturer: ABB Turbo Systems Ltd, CH 5401 Baden
• Document ID: HT594627
• n Mmax (Maximum speed): 511 1/s
• t Mmax (Maximum temperature): 650 °C
• n Bmax (Operating speed limit): 511 1/s
• t Bmax (Operating temperature limit): 620 °C
• Specific Model: TPS61R35-162850A
• Weight: 720 kg
• Inspection/Replacement Intervals (Compressor/Turbine): 12 / 50 / 50 (in 1000 h, likely Inspection/Compressor/Turbine)
• Year of Construction: 2020
• Origin: made in Switzerland
• Application Note: Application according to the Operation Manual

The recommended replacement intervals and the corresponding operating limits found in chapter 3 (Safety data sheet) are jointly defined with the enginebuilder. This information is specific to the product. Non-observance of these recommended intervals and limits increases the risk of unpredictable component failures.

This Operation Manual belongs to the turbocharger with the identical serial number (01) found on the rating plate. It explains the turbocharger and contains instructions for safe operation. The manual complements and expands upon existing national regulations for occupational safety, accident prevention, and environmental protection.

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

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.

Symbols:

► Indicates an action step.

1. Indicates a numbered action step.

→ Refers to a page number (Note: Page numbers are specific to the original PDF and not included here).

Note (i): Provides advice which facilitates the work.

Pictograms:

Pictogram Symbol Text/Representation	Meaning
Nm	Tighten with specified torque
Angle symbol	Tighten over specified tightening angle
Hand symbol	Hand-tight, tighten without tools
Oil can	Oil
Glue bottle	Apply screw locking paste (e.g. Loctite)
Brush with grease	Apply high-temperature grease
Brush	Apply other paste in accordance with specifications
Crossed out oil drop/grease	Oil free, grease free and dry
Arrows pointing to surface	Affix
Gauge/Measure tool	Measure
Notepad/List	Note
Eye symbol	Visually inspect
Numbered eye symbol	Please note text for numbered work step.
Document symbol	See document
Recycling bin	Dispose of in an environmentally compatible, professional way and in compliance with locally applicable regulations.

New turbochargers and spare parts can be stored in sealed packaging without additional mothballing measures for up to 6 months from the date of delivery (marked by the VCI label on the package).

Storage Requirements:

Store in dry rooms only.

Relative humidity must be between 40…70 %.

No condensation should form.

For storage exceeding 6 months, the following mothballing measures are required every 6 months:

1. Open the package.

2. Remove the VCI corrosion protection emitter and replace it with a new, identical one (available at http://www.branopac.com).

3. Dispose of the old VCI emitter in an environmentally compatible, professional manner, following local regulations.

4. Seal the package securely. A better external seal provides more permanent protection.

Safety Precautions when handling VCIs:

WARNING: VCI products are not hazardous per the Hazardous Substances Ordinance, but observe the following:

► Observe specifications in the safety data sheet.

► Ensure good room ventilation.

► Do not eat, drink, or keep food at the workplace while working with VCIs.

► Clean hands and face after working with VCIs.

► Wear safety gloves to protect against mechanical hazards.

► For further information refer to http://www.branopac.com.

Turbochargers prepared for prolonged storage by ABB Turbo Systems will have the package equipped with a hygrometer.

Every 6 Months:

► Check the hygrometer (02) through the sight-glass opening (01) in the crate. If the 70% display field has changed colour, the maximum permissible humidity has been exceeded. The turbocharger must be inspected by an ABB Turbocharging Service Station and repacked.

► Inspect the package for damage. If damaged, the turbocharger must be inspected by an ABB Turbocharging Service Station and repacked.

Every 3 Years (Performed by an ABB Turbocharging Service Station):

► Inspect the components.

► Replace the desiccant agent.

► Repackage the components.

If the 70% display field has not changed colour and the package is undamaged, the turbocharger can be placed into operation without prior testing by an ABB Turbocharging Service Station.

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

Mandatory signs show the protective equipment to be worn for a task.

Table 1: Personal protective equipment to be worn at all times

Symbol Description	Meaning
Jacket symbol	Protective clothing
Boot symbol	Safety footwear to protect against mechanical hazard and risk of falling

Table 2: Personal protective equipment to be worn specific to the respective task

Symbol Description	Meaning
Safety glasses symbol	Safety glasses
Safety goggles symbol	Safety goggles
Gloves symbol	Safety gloves to protect against: Mechanical hazard, Chemical hazard, Thermal hazard, Electrical hazard
Respirator mask symbol	Respiratory mask to protect against: Dusts, Gases
Hard hat symbol	Safety helmet
Ear protection symbol	Ear protection

WARNING:

Definition: Non-compliance or inaccurate compliance with working or operating instructions indicated by this symbol and the word WARNING can lead to serious injuries to personnel and even to fatal accidents.

Requirement: Warning signs must always be observed.

CAUTION:

Definition: Non-compliance or inaccurate compliance with working or operating instructions indicated by this symbol and the word CAUTION can lead to serious damage to engine or property with grave consequences.

Requirement: Caution signs must always be observed.

ABB turbochargers are intended for charging internal combustion engines. They supply the engine with the required air volume or air/gas mixture and associated charging pressure. The turbocharger is solely intended for operation with a clockwise direction of rotation as viewed from the turbine end.

Operating limits are determined based on information from the enginebuilder about the intended use and are given on the rating plate.

WARNING: Unapproved operation outside of operating limits can be hazardous. Only operate within limits, and only trained personnel must operate the turbocharger.

The intended use includes compliance with:

• Operation Manual

• Instructions of the enginebuilder

The turbocharger must only be used when in a technically flawless condition and operated in compliance with its intended use. ABB excludes liability for damage from unauthorized modifications or improper operation.

Warning plates must always be present in the intended locations and be legible. If warning plates (part number 72080) are missing or illegible, follow these steps:

► Order new warning plates from ABB Turbocharging Service Stations (see chapter Ordering spare parts).

► Remove any warning plates that have become unreadable.

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

► Fit new warning plates and remove protective sheets.

Note: If the turbocharger is supplied without insulation and insulated later by the enginebuilder, warning signs must be attached to the insulation. This is the enginebuilder’s responsibility.

The rating plate contains several pieces of information:

Operating limits:

01: Turbocharger operating limits at engine overload (110 %). Typically for test rig operation only, unless otherwise agreed.

02: Turbocharger operating limits during normal operation (n Bmax, t Bmax).

Recommended inspection and replacement intervals:

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.

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.

12: Manufacturing plant.

Explanations:

• Intervals and limits are jointly defined with the enginebuilder and are system-specific.

• Operation above n Bmax, t Bmax can shorten replacement intervals. Contact ABB Turbo Systems service station in such cases.

• n Mmax, t Mmax (overload limits) normally apply only during trials on the engine test bed or for special applications. Operation above these limits is not permitted.

• Non-observance of intervals increases the risk of unpredictable component failures.

WARNING: Suspended loads not attached correctly can cause injury or fatal accidents.

► Loads must always be fastened to properly functional lifting gear with a sufficient load limit.

► Pay attention to the correct attachment of loads on the crane hook (see diagrams for correct/incorrect attachment).

► People must not stand beneath suspended loads.

► Wear safety gloves to protect against mechanical hazards.

► Wear safety helmet.

Attachment Angle:

► If using two or more suspension points, the attachment angle must not exceed 45° to prevent excessive loading from diagonal pull.

Procedure:

► Before looping around components, let them cool down (maximum 80 °C).

► Attach components as described in the respective action steps.

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

► Assembly devices must be completely screwed in and must not unscrew during use.

► Use assembly devices only for their described applications.

► Put down dismantled components securely so they cannot tip over.

Responsibility of the operating company:

Ensure only authorised personnel work on the turbocharger, who:

• Are versed in general and local safety/accident prevention regulations.

• Are equipped with the prescribed PPE.

• Have read and understood the Operation Manual.

• Have been instructed in the use of the turbocharger.

Personnel safety-conscious work and adherence to the manual must be checked periodically. Suitable working materials and PPE must be kept in perfect condition. Only authorised personnel may remain near the turbocharger when the engine is running.

Competence of personnel:

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

Modifications:

Modifications must be approved by ABB Turbo Systems.

WARNING: Use original parts. Operation with non-original parts can impair safety and cause serious damage or injury. Only use original parts from ABB. ABB accepts no liability for damage from non-original parts.

Noise Hazards:

Noise emission depends on installation and operating conditions. Levels exceeding 85 dB(A) are harmful.

WARNING: Danger due to noise. Exposure can harm hearing, impair health, and lead to lack of attention/irritation.

► When the engine is running, always wear ear protection.

► Always wear ear protection if the sound pressure level exceeds 85 dB(A).

► PPE: Wear ear protection.

Hazards due to Hot Surfaces:

Surfaces of the turbocharger, attached parts, and lubricating oil get hot. Temperature depends on insulation efficacy and can cause burns.

WARNING: Danger of burns from touching hot surfaces or contact with hot operating fluids.

► Do not touch hot surfaces. Observe the warning plate.

► Wear heat-resistant safety gloves and protective clothing.

► Wait for the turbocharger to cool down before any work.

► PPE: Wear safety gloves for thermal hazards.

WARNING: Hot surfaces on a non-insulated turbocharger can cause serious burns. If supplied without insulation, the enginebuilder is responsible for proper insulation and protection against contact.

► Compliance with enginebuilder’s instructions for protection is compulsory.

► PPE: Wear safety gloves for thermal hazards.

Hazards due to Rotating Parts:

WARNING: Physical hazards. Contact with rotating parts can cause severe injury. Never use without filter silencer or air suction branch. The rotor can rotate due to stack draught even with the engine stopped.

► Operate the turbocharger in compliance with specifications.

► Secure the rotor against unintentional rotation during maintenance.

► PPE: Wear safety gloves for mechanical hazards.

Hazards due to Operating Materials and Supplies:

Oils, greases, coolants, detergents, solvents, acids etc. can be hazardous substances.

WARNING: Handling operating materials. Swallowing/inhaling vapours or skin contact may be harmful.

► Do not breathe substances; avoid skin contact.

► Ensure proper ventilation.

► Observe material safety data sheet (MSDS).

► Wear appropriate PPE (goggles, chemical-resistant gloves, respiratory mask if needed).

► Comply with local legislation.

WARNING: Danger of fire or explosion. Flammable/combustible materials can catch fire; vapours can explode.

► Observe MSDS.

► Comply with local legislation.

► No exposed flames/ignition sources during cleaning.

► Clean in the open or with sufficient ventilation.

CAUTION: Environmental hazard. Improper handling can cause environmental damage.

► Observe MSDS.

► Comply with local legislation.

► Visually inspect your working environment before starting work.

► Remove any obstacles and objects littering the workplace.

► Check all pipes to and from the turbocharger for damage and leaks before commissioning.

► Check turbocharger for recognisable damage or defects every 12 hours of operation or at least once a day.

► Report any damage and alterations of operational characteristics immediately to the responsible department.

► In case of damage, take the turbocharger out of operation immediately and safeguard against accidental/unauthorised use.

► When switching on operating energy supplies (hydraulics, pneumatics, electricity), be aware of risks from this energy input.

Occupational Safety:

WARNING: Injuries to persons can result from hazardous procedures or non-compliance with safety standards.

► Always wear safety footwear and protective clothing against mechanical hazards.

► Keep PPE in perfect condition.

► Obey mandatory signs.

► Observe general rules for occupational safety and accident prevention.

► Only perform operations described in this manual or for which you have training/instruction.

► PPE: Wear safety footwear and protective clothing.

WARNING: Risk of falling when working on the turbocharger.

► Do not climb onto the turbocharger or attached parts; do not use them as climbing aids.

► Use suitable climbing aids and working platforms for work above body height.

General Practices:

► Comply with general accident prevention regulations.

► Only perform work when physically and psychologically stable.

► Use only suitable, functional tools, equipment, and appliances.

► Power tools must be grounded; cables must be undamaged.

► Keep workplace, floor, equipment, and turbocharger clean. Clear loose objects/obstacles.

► Have oil binding agents ready; keep oil pans at hand.

► Clean up any spills.

► Have fire protection means and extinguishing agents available.

► Always cover the filter silencer to prevent damage to the filter mat.

► Keep flammable objects and substances out of the vicinity of flying sparks.

► Cover all connections on the turbocharger to prevent foreign objects from entering.

► Wear personal protective equipment (PPE) for welding operations.

If using cleaning agents or solvents:

► Observe the corresponding material safety data sheet (MSDS).

► Observe safety instructions regarding hazards due to operating materials and supplies.

► Wear personal protective equipment (PPE) according to the MSDS.

► Inspect electric cables for abrasion and damage before and after cleaning work.

► Observe procedures for set-up, service, and inspection work and intervals.

► Inform operating staff before starting any service or repair work. Ensure the engine is not started during work.

► Before removing any cover or guard, switch off the engine and wait for the turbocharger to stop.

► Ensure oil supply is interrupted, especially with external oil supply.

► Only restart the engine after all parts are properly fitted and oil supply is ensured.

CAUTION: Improper mechanical operations can damage or destroy components.

► Only perform operations described in this chapter (or manual).

► Only perform operations for which you have received instruction or training.

► Secure rotor against turning. It can rotate due to stack draught alone.

► Observe the material safety data sheet (MSDS) for cleaning and mothballing agents.

► Wear personal protective equipment (PPE) according to the MSDS.

WARNING: Physical hazards due to rotating parts. The rotor can rotate due to stack draught. Contact can cause severe injury.

► Secure rotor against turning.

WARNING: Mechanical hazard. Severe injuries/fatal accidents can occur from hazardous/inadequate procedures.

► Observe general rules for occupational safety and accident prevention.

► Ensure workplace safety.

► Only perform operations described in this chapter (or manual).

► Only perform operations for which you have previously received instruction or training.

The weight of the complete turbocharger unit is approximately 720 kg. This applies to the heaviest variant; the specific weight on the rating plate may be lower.

Product	Weight of complete turbocharger unit [kg]
TPS61-R	720

CAUTION: Damage to bellows. Turbochargers are supplied without fitted pipe sections and bellows, which are delivered separately as they can be damaged or destroyed during transport if fitted. Never transport the turbocharger with bellows fitted.

Touching hot surfaces or contact with hot operating fluids can cause burns.

Do not touch hot surfaces. Observe the warning plate on the turbocharger.

Wear heat-resistant safety gloves and protective clothing.

Wait for the turbocharger to cool down before carrying out any work.

Wear safety gloves to protect against thermal hazards.

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.

Do not strain the speed measurement cables by pulling.

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

2. Unplug the cable connector at the speed sensor (86505).

3. Ensure that the oil connections have been dismantled.

4. Remove the bellows.

5. Attach lifting gear to the turbocharger.

6. Loosen and remove screws.

7. Lift turbocharger from engine support vertically upwards.

Put the turbocharger down onto a solid surface so that the turbocharger cannot tip over. Support the turbocharger if necessary. Note that the compressor casing (72000) can be lower than the turbocharger support depending on the casing position.

The fixing screws (01) are not included in the ABB Turbo Systems scope of delivery and depend on the version of the engine-side bracket. The requirements based on the provided table are:

Product	Diameter Hole in bracket [mm]	Screw size	Length L1 [mm]	Length L2 [mm]	Material DIN / ISO 898 (Part 1)	Tightening torque
TPS61-R	Ø18 / M16	M16	≥ 30	120	10.9	300 Nm

Table 3: Requirements for fixing screws

Damage to bellows can occur if the axes of the flanges of the turbine casing do not align with the piping. During installation of the bellows, ensure that the axes of the flanges of the turbine casing align with the piping. If necessary, correct alignment of the turbocharger on the engine support.

1. Attach lifting gear to turbocharger and place turbocharger onto bracket.

2. Fit hexagon head screws (01) but do not tighten them yet.

3. Coat thread of hexagon-head screws (02) with high-temperature grease such as Loctite® 8009. Fit bellows with hexagon-head screws (02), Verbus Ripp® washers and nuts. Observe the tightening torque (see table below).

4. Tighten hexagon-head screws (01). Observe the tightening torque (see table below).

5. Connect the oil supply. Ensure that the connection is tight.

6. Connect cable to speed sensor (86505).

7. Remove the lifting gear.

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

Product	Screw position	Tightening torque (assumed friction coefficient μ = 0.12)
TPS61-R	01	M16 300 Nm
TPS61-R	02	M16 325 Nm

Table 4: Tightening torque for turbocharger fixing screws

The lubrication of the turbocharger is usually carried out with oil from the engine oil circulation. Comply with the enginebuilder’s specifications regarding the selection of lubricating oil and the oil change intervals.

Pre-lubrication must be carried out as follows:

1. Switch on the oil pump.

2. Build up oil pressure.

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

4. Start the engine.

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

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

Check that the oil filter is clean before commissioning.

Adhere to lubricating oil pressure at the inlet.

Adhere to lubricating oil temperature at the inlet.

For permissible values, see chapter Monitoring operation.

Serious damage to engine or property can be caused by dirt and solid material particles in the oil.

For the initial commissioning phase and after all service work, flush the complete lubricating system with warm oil.

Use special running-in filters when running in the engine and after all service work on the lubricating system.

Check whether warning plates are present and legible.

Check whether the protective sheets have been removed.

Keep to the lubricating oil pressure at the inlet.

Keep to the lubricating oil temperature at the inlet.

Refer to chapter Monitoring operation for admissible values.

WARNING: Risk of burning from hot gas. Escaping gases are hot and will lead to serious burns in the event of contact.

Check all pipes for leaks in accordance with the enginebuilder’s instructions.

Wear safety gloves to protect against thermal hazards.

If present:

Measure speed, oil pressure and charging pressure at various engine performances.

Measure the exhaust gas temperature before and after the turbine.

Measure the air temperature before and after the compressor.

Compare the measured values with the values of the acceptance report. Different operating conditions indicate a malfunction (see chapter Eliminating malfunctions).

Note: 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.

If present: Remove cover plates (blind flanges) from the compressor casing, the gas inlet and the gas outlet.

General Steps:

1. Check the exhaust gas pipe before and after the turbine for combustion residues or water residues and clean it. Remove any foreign objects that may be present.

2. Check and clean the air supply system, and remove any foreign objects that may be present.

3. Put engine-side oil circulation to the turbocharger into operation.

4. Prepare the turbocharger for operation according to section “Checks before commissioning”.

5. The turbocharger is now ready for operation.

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 is critical. Serious damage to the engine or property can result from a missing or insufficient lubricating oil supply. 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 the turbocharger [bar] Overpressure
Normal operation	2.0 < poil ≤ 4.5
Engine start: Cold oil, admissible for a maximum of 15 minutes	< 8.0
Engine idling, admissible for a maximum of 1 hour	0.2 < poil ≤ 2.5
Pre-lubrication and post-lubrication (engine stopped)	0.2 < poil ≤ 1.0
Warning signal: (n ≥ 0.5 x nBmax)	< 1.25
Alarm signal: Not admissible. Stop the engine immediately.	< 0.2

Table 5: Lubricating oil pressure at oil inlet before turbocharger

For monitoring the lubricating oil pressure, ABB Turbo Systems 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 specified in the table.

The measuring points for temperature (T) and pressure (P) in the oil supply pipe should be attached as closely to the turbocharger as possible. No reducing installations such as orifices or valves may be attached at the engine side between the measuring point and the turbocharger oil inlet.

For the outlet 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.

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

Status for operation	Oil temperature at the inlet Toil,inlet
Admissible	8 … 105 °C
Temporarily admissible (< 1 h) → Alarm	> 105 °C
Not admissible → stop engine	> 110 °C
Not admissible → do not start engine (before start: preheat oil)	< 8 °C

Table 6: Lubricating oil temperature at the inlet

The oil temperature at the outlet is mainly dependant on:

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 operation and must be monitored according to the current regulations.

Status for operation	Oil temperature at the outlet Toil,outlet
Admissible	≤ 160 °C
Temporarily admissible → alarm	> 160 °C
Not admissible → stop engine	> 180 °C
Admissible	≤ Toil,inlet + 55 K
Temporarily admissible → alarm	> Toil,inlet + 55 K

Table 7: Lubricating oil temperature at the outlet

If the turbocharger was operated for a longer period of time outside of the admissible range, ABB Turbo Systems recommends to have the turbocharger inspected by an ABB Turbocharging Service Station.

CAUTION: Factors influencing replacement intervals. Operation above the operating limits defined on the rating plate can shorten the recommended replacement intervals considerably.

Measure exhaust gas temperature upstream of turbine.

Comply with operating limits on rating plate.

Definition and explanations concerning rating plate: refer to chapter 2 of Operation Manual / Safety.

Operating limits: refer to chapter 3 of Operation Manual / Safety data sheet or examine rating plate.

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. 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.

A speed measuring system enables the constant monitoring of the turbocharger speed.

Measure turbocharger speed.

Comply with operating limits on rating plate.

Definition and explanations concerning rating plate: refer to chapter 2 of Operation Manual / Safety.

Operating limits: refer to chapter 3 of Operation Manual / Safety data sheet or examine rating plate.

If no speed measurement system is present, the system can be ordered from an ABB Turbocharging Service Station.

Based on Figure 10:

86505: Speed sensor (cable not integrated)

86515: Cable connector to 86505

32109: Sealing disc

01: Screw plug

02: Gasket

In the case of malfunctions of the speed measurement system, refer to the chapter entitled Troubleshooting/Speed measurement system.

WARNING: Hot speed sensor. Danger of burns. The speed sensor can reach temperatures of more than 100 °C during operation. Wear safety gloves when disassembling the speed sensor. Wear safety gloves to protect against thermal hazards.

Note: The speed sensor supplied by ABB is equipped with a sealing lip and an O-ring. No additional gasket is required during assembly.

Procedure:

1. Reduce the engine performance to idling and then stop the engine. Pay attention to post-lubrication (Stopping the engine).

2. Switch off the lubricating oil supply to the turbocharger.

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

4. Unscrew and remove defective speed sensor (86505).

5. Screw in new speed sensor (86505) as far as it will go and tighten to the specified torque (15 Nm).

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

7. Switch on lubricating oil supply to the turbocharger.

Part number	Tightening torque
86505	15 Nm

Table 8: Tightening torque (86505)

WARNING: Noise hazards. Exposure to noise can harm the hearing system, impair health and the psychological state and may lead to lack of attention and irritation.

When the engine is running, always wear ear protection.

Always wear ear protection if the sound pressure level exceeds 85 dB(A).

Wear ear protection.

The highest value of the emission sound pressure level (A-weighted, measured at 1 meter) reaches a maximum of 105 dB(A) near the air inlet. The following prerequisites must be fulfilled:

Air-inlet system has been fitted.

All standard, noise-reducing measures have been fitted.

Bellows at the air outlet has been acoustically insulated by the enginebuilder (see Fig. 12: Noise insulation, bellows).

Note: The enginebuilder must provide acoustically equivalent measures in case of deviating insulation versions.

The enginebuilder is responsible for insulating the charge air/scavenging air line and the charge air cooler.

Based on Figure 12, the suggestion includes:

01: Compressor casing

02: Bellows

03: Charge air duct / scavenging air duct

04: Insulation cushion

05: Insulation mat (at least 15 mm)

06: Sheet metal cover

CAUTION: Service intervals. Any service work on the turbocharger that is omitted or performed too late can cause excessive contamination, wear and operating failures. 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 environmental conditions, poor fuel quality or high system vibrations can lead to untimely machine damage even if the prescribed service intervals are observed. Agree on a specific service interval with ABB Turbo Systems.

To prevent machine damage caused by ageing and downtime, we recommend having an inspection carried out by an ABB Turbocharging Service Station no later than 5 years after the last service.

Check all the inlet and outlet pipes of the turbocharger for leaks. Monitor the engine’s operating data.

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

Pressure in air inlet system

In case of different values, determine the cause.

CAUTION: Unknown operational changes. Impairment to the degree of a possible operating failure can be the consequence. Have any unknown causes clarified by an ABB Turbocharging Service Station.

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

Clean or replace the oil filter located in the supply pipe to the turbocharger while the engine is stopped, in accordance with the instructions of the enginebuilder. (This applies generally, not just at 100 hours).

WARNING: Incorrect handling of a cartridge group. The disassembly and assembly of the cartridge group, as well as the assessment of the rotor and bearing parts, requires the expertise of an ABB Turbocharging 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. Ensure that the disassembly and assembly of the cartridge group is only carried out by an ABB Turbocharging Service Station.

The following service work must be carried out by an ABB Turbocharging Service Station:

Dismantle turbocharger and measure clearances.

Clean nozzle ring, turbine casing and compressor casing mechanically.

Check nozzle ring, turbine casing and compressor casing for cracks and erosion/corrosion.

Check and assess rotor and bearing parts.

Remove the turbocharger from the engine (see chapter Removing and Installing).

Component	Operating hours
Turbine casing	25000 … 50000
Nozzle ring	50000
Gas outlet flange	50000
Partition wall	50000
Rotating components	See rating plate information ¹
Bearing parts	12000 … 24000
Other casings	50000

Table 9: Expected replacement intervals [h]

¹) The recommended replacement intervals of the compressor and turbine wheels are specified with the aid of the safety concept for rotating parts (SIKO) and dependent on the operating conditions.

Note: These are guideline values and are not guaranteed. Actual values can deviate significantly.

The specified values are guideline values and are not guaranteed. The actual values can deviate significantly from the guideline values, for example, due to the following influences:

General Influences:

Fuel quality and fuel treatment

Load profile (thermal cycling, also number of starts/stops, emergency shutdowns, operating 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).

CAUTION: Post-lubrication. If the heat in the turbocharger is not dissipated after the engine stops, damage may result. Perform post-lubrication 15 … 20 minutes after stopping the engine.

Possible causes	Remedy
Turbocharger contaminated	Clean the turbocharger
Bearing damaged	Replace the bearing
Rotor rubbing	Check clearances
Foreign object in the turbocharger	Remove foreign object

Table 10: Malfunctions when starting – Delayed start-up

Possible causes	Remedy
Rotor unbalance	Balance the rotor
Turbine or compressor damaged	Replace damaged parts
Bearing damaged	Replace the bearing
Vibrations from engine	Contact enginebuilder

Table 11: Malfunctions when starting – Vibrations

Normal behaviour, not a malfunction: A minimal and uniform wear on the circumference of the rotor components is permitted. This wear can be caused by slight local rubbing against adjacent components. This causes the compressor or turbine blades to be somewhat shortened. To prevent significant loss of efficiency, specific tolerances must be fulfilled.

Possible causes	Remedy
Axial clearance of the rotor excessive	Replace the axial bearing and thrust bearing
Oil filter heavily contaminated	Clean
Oil pump in lubricating system defective	Check/replace
Manometer displays incorrectly	Replace manometer

Table 13: Malfunctions during operation – Lubricating oil pressure too low

Possible causes	Remedy
Turbine and/or nozzle ring severely contaminated	Clean the turbine and/or nozzle ring
Rotor components or bearing damaged	Replace damaged parts
Defects on the connected cylinders in pulse charging	Contact enginebuilder
Defects, such as leaks, in the exhaust gas pipes or charge air ducts	Repair

Table 14: Malfunctions during operation – Speed reduces

Possible causes	Remedy
Light to medium contamination of the turbine and/or nozzle ring	Clean the turbine and/or nozzle ring

Table 15: Malfunctions during operation – Speed increases

Possible causes	Remedy
Compressor/turbine contaminated	Clean the compressor/turbine
Exhaust gas back pressure too high	Check the exhaust gas system.
Turbine damaged or eroded	Replace damaged parts
Insufficient air, for example, if the air filter is blocked	Clean or replace the air filter.
Malfunction in the injection system	Repair or contact manufacturer
Cooler contaminated	Clean
Cooling water volume too low	Fill
Inlet temperature of cooling water too high	Check/clean cooling system
Insufficient ventilation	Improve ventilation

Table 16: Malfunctions during operation – Exhaust gas temperature too high

Possible causes	Remedy
Compressor end and/or turbine end contaminated	Clean the compressor and/or turbine
Compressor/turbine damaged	Replace damaged parts
Insufficient air, for example, if the air filter is blocked	Clean or replace the air filter.
Air receiver not sealed	Repair
Gas piping between engine and turbine not sealed	Repair
Injection mistimed	Set correctly
Valve control misadjusted	Set correctly
Pipes downstream to the compressor outlet not sealed.	Repair.
Exhaust gas back pressure too high	Check the exhaust gas system.

Table 17: Malfunctions during operation – Charge air pressure too low

Possible causes	Remedy
Malfunction in the injection system	Repair or contact manufacturer
Injection mistimed	Set correctly
Engine performance higher than indicated	Check engine performance

Table 18: Malfunctions during operation – Charge air pressure too high

CAUTION: Compressor damage. A severely contaminated or corroded compressor wheel can reduce the compressor wheel’s fatigue endurance limit and result in the turbocharger being damaged.

Possible causes	Remedy
Compressor components severely contaminated by the ventilation gases that have been fed in	Clean the turbocharger / Optimize oil separation
Increased blade vibration, compressor blade damage due to the ventilation gases that have been fed in	Correct the feed of ventilation gases according to instructions of enginebuilder.
Material of the compressor wheel corroded due to the feeding in of ventilation gases containing corrosive components	Correct the feed of ventilation gases according to instructions of enginebuilder.
Material of the compressor wheel corroded due to intake air containing exhaust gases or salt	Prevent exhaust gas leakages in the engine space / Clean the turbocharger

Table 19: Malfunctions during operation – Engine performance losses

WARNING: Hot air escapes from the air inlet system. A surge blow is accompanied by a loud bang and escape of hot air from the air inlet system. This may result in injury to personnel. Keep a distance from the air inlet while the turbocharger is surging.

CAUTION: Continuous or periodic surging. If the turbocharger surges continuously or periodically, parts of the turbocharger may be damaged.

Gradually reduce the engine load.

Immediately clarify and remedy the cause.

Examine components for damage and replace if necessary.

Possible causes	Remedy
Diffuser contaminated	Clean the turbocharger
Heavy contamination deposits in the turbine or in the nozzle ring	Clean the turbocharger
Air inlet filter contaminated	Clean
Protective grating in front of the turbocharger contaminated or damaged	Clean/replace
Cooler contaminated	Clean
Charge air duct blocked	Clean

Table 20: Malfunction – Turbocharger surging

Sporadic surge blows occur when the engine load is changed quickly, causing the flow direction in the compressor to be momentarily reversed. Such sporadic surge blows do not impair the safe operation of the turbocharger. No remedy is needed.

Possible causes	Remedy
Turbocharger contaminated	Clean the turbocharger
Bearing damaged	Replace the bearing
Rotor rubbing	Check clearances
Foreign object in the turbocharger	Remove foreign object

Table 22: Malfunctions when stopping – Runout noises

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 following table must be observed:

Possible causes	Remedy
Turbocharger contaminated	Clean the turbocharger
Bearing damaged	Replace the bearing
Rotor rubbing	Check clearances
Foreign object in the turbocharger	Remove foreign object

Table 23: Malfunctions when starting – Delayed start-up (Note: This table also applies to “Runout time too short”)

Possible causes	Remedy
The speed sensor was accidentally fitted with an additional gasket (copper ring). An enlarged distance between the sensor tip and the signal-emitting sealing disc reduces the voltage amplitude of the speed signal.	The screw plug for the sensor is fitted with an additional gasket (copper ring). For information regarding the disassembly and assembly of the speed sensor, refer to chapter Replacing the speed sensor. Install the speed sensor without the additional gasket (copper ring).
Sensor or cable defective	Order new speed sensor (86505) (refer to chapter Ordering spare parts). Replacing the speed sensor.

Table 24: Malfunction of the speed measurement system – No signal or poor signal amplitude

Possible causes	Remedy
Sensor tip contaminated, since it is magnetic and can attract metallic particles. This reduces the distance to the signal-emitting sealing disc, which can lead to amplification of the noise component and therefore to false triggering.	For information regarding the disassembly and assembly of the speed sensor, refer to chapter Replacing the speed sensor. Dismantle the sensor, clean the sensor tip, and fit the sensor back on with the specified tightening torque.

Table 25: Malfunction of the speed measurement system – Measured speed too high

Possible causes	Remedy
Turbocharger contaminated	Clean the turbocharger
Bearing damaged	Replace the bearing
Rotor rubbing	Check clearances

Table 26: Malfunction of the speed measurement system – Measured speed too low

The turbocharger normally remains attached to the engine. No measures are required under the following conditions:

Acid number (TAN) < 2 mg KOH/g

OR

The engine lubricating oil is replaced by a preservative oil and circulated with the pre-lubrication pump before the engine is taken out of operation. Residues of old engine oil are flushed away in this way and the bearing parts are largely protected against corrosion.

WARNING: Handling operating materials and supplies. Swallowing or inhaling vapours of operating materials and supplies or contact with them may be harmful to health.

Do not breathe in these substances and avoid contact with the skin.

Ensure proper ventilation.

Observe the information in the material safety data sheet for the operating materials and supplies.

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

Comply with local legislation.

Wear safety goggles.

Wear safety gloves to protect against chemical hazards.

Wear a respiratory mask to protect against gases.

If the acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after the engine is taken out of operation:

Remove turbocharger (see chapter Removing and Installing).

Have turbocharger dismantled, cleaned, oiled and fitted again by an ABB Turbocharging Service Station.

If the engine is taken out of operation for more than 12 months, 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 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, follow the procedures in section 8.1.

If the complete turbocharger is removed or the turbocharger is assembled again from the individual parts:

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.

Check the turbocharger parts annually for corrosion.

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

Disposal must be environmentally compatible, competent and in compliance with locally applicable regulations.

The turbocharger consists largely of metal (cast iron materials, steel, nickel-steel alloys, aluminium and bearing brass). Further components are: Non-metallic materials (gaskets), lubricants (engine oil) and electronic parts (speed sensor and associated components).

Dispose of metals as scrap metal for recycling.

Dispose of non-metallic materials as waste.

Dispose of residues of lubricants as waste oil.

Dispose of electronic components as electronic waste.

CAUTION: Spare part storage. All spare parts that were ordered together with the turbocharger must be kept intact and ready for use. 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. If different model variants are not taken into account in this document, contact an ABB Turbocharging Service Station.

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

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

Part number	Designation
86505	Speed sensor
86515	Cable connector

Table 27: Spare parts of the speed measurement system

Important technical data and characteristics	Value
Weight, complete [kg]	720
Pressure at oil inlet before turbocharger [bar]	2.0 < poil ≤ 4.5
Lubricating oil temperature at the inlet [°C]	8….105
Lubricating oil temperature at the outlet [°C]	≤ 160
Maximum speed [rps]	511
Maximum sound pressure level [dB]	105
Volume flow [m3/s]	up to 6.0
Pressure ratio	up to 4.6
Turbocharger efficiency [%]	up to 67
Residual rotor unbalance on compressor end [gr/mm]	<68.0
Residual rotor unbalance on turbine end [gr/mm]	<47.0
Clearance between compressor wheel blades and wall insert [mm]	0.64 … 0.80
Axial clearance of the rotor [mm]	0.15 … 0.19

Table 28: Important technical data and characteristics

Operating limits: refer to chapter 3 of Operation Manual / Safety data sheet or examine rating plate.