The recommended replacement intervals and the corresponding operating limits in chapter 3 are jointly defined
with the enginebuilder. This information is specific to the product.
Non-observance of the recommended replacement intervals and the operating limits increases the risk of unpredictable component failures.
This Operation Manual belongs to the turbocharger with the identical serial number (01), see
chapter 3 (Safety data sheet) and the rating plate on the turbocharger.
Operation Manual
The Operation Manual explains the turbocharger and contains instructions for safe opera-
Page 2 / 7
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.
The note provides advice which facilitates the work.
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 Turbo Systems
ABB Turbo Systems Ltd is identified as ABB Turbo Systems in this document.
Official service stations of ABB Turbo Systems
Official service stations are identified in this document as ABB Turbocharging Service Stations. They are regularly audited and certified by ABB Turbo Systems. Also see chapter Con-
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.
PictogramMeaningPictogramMeaning
Tighten with specified torqueAffix
Tighten over specified tightening angle
Hand-tight, tighten without
tools
OilVisually inspect
Apply screw locking paste (e.g.
Loctite)
Apply high-temperature greaseSee document
Apply other paste in accordance with specifications
Oil free, grease free and dry
Table1: Definition of pictograms
Measure
Note
Please note text for numbered
work step
Dispose of in an environmentally
compatible, professional way and
in compliance with locally applicable regulations
1 Introduction / 1.3 Storage of new turbochargers and spare parts
1.3Storage of new turbochargers and spare parts
Storage of new turbochargers and spare parts for 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, indicated by the VCI label on the package.
Fig.2: Volatile Corrosion Inhibitor (VCI)
Only dry rooms with 40...70 % atmospheric humidity, in which no water condensation can
form, are suitable as storage locations.
Storage of new turbochargers and spare parts for more than 6 months
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.
Page 5 / 7
u Close package. The more tightly the package is sealed, the longer the protection dura-
1 Introduction / 1.3 Storage of new turbochargers and spare parts
Long-term storage of replacement turbochargers or spare parts
The turbochargers or cartridge groups will be prepared for long-term storage if requested in
the purchase order. The package is equipped with a hygrometer (see illustration).
Fig.3: 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 to enable you to perform this check. If the 70% indicator field has changed colour,
the maximum admissible atmospheric humidity has been exceeded. In this case, the turbocharger or cartridge group must be checked and repackaged by an ABB Turbocharging
Service Station.
u Check the package for damage. If the package is damaged, the turbocharger or cartridge
group must be checked and repackaged by an ABB Turbocharging Service Station.
After every 3 years, the following steps must be carried out by an ABB Turbocharging Service
Station:
Page 6 / 7
¡Checking the component
¡Replacing the desiccant
¡Repackaging the component.
NOTICE
Replacement components which are ready for operation
If the 70% field of the hygrometer(02) has not changed colour and the package is not damaged, the replacement turbocharger or replacement cartridge
group can be put into operation without previously having been checked by
an ABB Turbocharging Service Station.
Unpackaging replacement turbochargers or spare parts
Once the material has been unpackaged from the VCI package, the corrosion protection is
no longer effective.
To prevent condensation, the temperature of the package contents must be the same as the
ambient temperature.
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 turbocharger 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.
Page 2 / 16
All instructions contained in this chapter must be observed for safe and trouble-free operation of the turbocharger and during all work on the turbocharger.
All further safety instructions contained and specifically identified in every chapter of this
manual (Definition of safety instructions →3) must also be observed.
1.2CE conformity
Information
ABB turbochargers comply with the Machinery Directive 2006/42/EC and are partly completed machinery as defined by Article 2 g in this directive.
Table1: Personal protective equipment to be worn at all times
To be worn specific to the respective task
Safety glassesSafety goggles
Safety gloves to protect
against
- Mechanical hazard
- Chemical hazard
- Thermal hazard
- Electrical hazard
Safety helmetEar protection
Table2: Personal protective equipment to be worn specific to the respective task
Respiratory mask to protect
against
- Dusts
- Gases
1.4Definition of safety instructions
WARNING
Definition of Warning
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.
u Warning signs must always be observed.
Page 3 / 16
CAUTION
Definition of Caution
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.
ABB turbochargers are intended for charging internal combustion engines.
The turbocharger supplies the engine with the air volume or air/gas mixture and the associated 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 information from the enginebuilder about the intended use. These data are given on the rating
plate.
ABB accepts no liability and rejects all warranty claims for any non-intended uses.
WARNING
Unapproved operation
Any operation of the turbocharger outside of its operating limits can be hazardous to personnel.
u Only operate the turbocharger within the operating limits.
u Only trained personnel must operate the turbocharger.
Page 4 / 16
The intended use of the turbocharger includes compliance with all regulations and conditions. In particular, the following must be observed:
¡Operation Manual
¡Instructions of the enginebuilder
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 operated in compliance with its intended use.
ABB excludes any liability for damage resulting from unauthorized modifications to the turbocharger or improper operation.
Warning plates are attached to the turbocharger, which must be observed. The warning
plates must always be present in the intended locations and must be legible.
Fig.1: Warning plate
If warning plates are not present in the intended locations or are not legible, they must be
replaced with new warning plates. The necessary information can be found in the Operation
Manual, Chapter 4 Product description.
Turbochargers supplied to the enginebuilder without insulation must be equipped later with
warning plates on the insulation. This is the responsibility of the enginebuilder.
01Turbocharger operating limits at engine overload (110%).
In test rig operation only, unless otherwise agreed with the enginebuilder.
02 Turbocharger operating limits during operation
Recommended inspection and replacement intervals of turbocharger components
03 Inspection interval of plain bearings in 1000h
04 Replacement interval of compressor in 1000h
05 Replacement interval of turbine in 1000h
Further data
06 Customer part number
07 Designation for special design
08 Weight of turbocharger in kg
09 Turbocharger type
10Serial number
11Year of construction of turbocharger
12Manufacturing plant
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 n
Bmax
, t
can considerably shorten the recommended
Bmax
replacement intervals. In such a case, we recommend that you contact the nearest official
service station of ABB Turbo Systems.
n
, t
Mmax
normally apply only when running at overload (110%) during trials on the engine
Mmax
test bed. These limit values can also be permitted during operation for special applications.
Operation above n
Mmax
and t
is not permitted.
Mmax
Non-observance of the recommended inspection and replacement intervals increases the
risk of unpredictable component failures.
Locations of the rating plates
The locations of the rating plates are defined in the Operation Manual, Chapter 4 Product
description.
1 Safety / 1.9 Prerequisites for operation and maintenance
1.9Prerequisites 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.
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 Turbo Systems.
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 corresponding accessories.
1 Safety / 1.10 Hazards during operation and maintenance
1.10Hazards 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
Danger due to noise
Exposure to noise can harm the hearing system, impair health and the psychological 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.
Page 10 / 16
Hazards due to hot surfaces
Surfaces of the turbocharger, attached parts and operating fluids (lubricating oil) get hot
during operation. The surface temperature depends on the efficacy of the existing insulation. 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.
1 Safety / 1.10 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 insulation, 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
Physical hazards
Contact with rotating parts can cause severe injury. The turbocharger must
never be used without the filter silencer or the air suction branch. 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.
Severe injuries to personnel or fatal accidents can be caused by mechanical
influences as a consequence of hazardous and inadequate operational procedures 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 manual.
u Only perform operations for which you have received instruction or train-
ing.
Wear safety footwear to protect against mechanical hazard and risk of falling.
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 Comply with the general accident prevention regulations.
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.
Page 13 / 16
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.
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
Page 14 / 16
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.
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-
Safety when taking out of operation or preparing for mothballing
u Secure rotor against turning. The rotor can rotate due to the stack draught alone.
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
Physical hazards due to rotating parts
The rotor can rotate due to the stack draught alone. Contact with rotating
parts can cause severe injury.
u Secure rotor against turning.
WARNING
Mechanical hazard
Severe injuries to personnel or fatal accidents can be caused by mechanical
influences as a consequence of hazardous and inadequate operational procedures.
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-
Operating materials and supplies are substances required for the operation of the turbocharger 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 contact 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.
Page 16 / 16
Wear safety goggles.
Wear safety gloves to protect against chemical hazards.
Wear a respiratory mask to protect against gases.
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 environmental damage.
u Observe the information in the material safety data sheet for the operat-
This document is valid for different design variants of turbochargers. There may be sections
and descriptions of components that are not relevant for a specific turbocharger variant.
Please contact an ABB Turbocharging Service Station if you have any questions regarding a
design variant (see Contact information at www.abb.com/turbocharging).
Accuracy of illustrations
The illustrations in this document are general in nature and intended for ease of understanding. Differences in detail are therefore possible.
1.2Registered trademarks
The trademarks of outside companies are used in this document. These are marked with the
® symbol.
1.3Related documents
ChapterDocument number
Operation Manual / 1 IntroductionHZTL4005
Operation Manual / 2 SafetyHZTL4027
Operation Manual / 3 Safety data sheet *)Serial number of the turbocharger
Table1: Related documents
*) This chapter is only present in serialised operation manuals.
1 Introduction / 1.5 Locations of the rating plates
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.1: Layout
and function of TPS61-R →4).
The exhaust gases of the internal combustion engine flow through the turbine casing(08)
and the nozzle ring(09) onto the turbine(07). The turbine(07) uses the energy contained in
the exhaust gas to drive the rotor and thus the compressor wheel(10). The exhaust gases
then reach the atmosphere through the exhaust gas pipe connected to the turbine casing.
The compressor wheel(10) sucks in air through the air suction branch(01). In the compressor wheel(10), the energy required for building 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 cylinders.
The rotor runs in two radial plain bearing bushes(06) which are located in the bearing casing(04) between the compressor and turbine. The axial thrust bearing(05) is located in
front of the two radial plain bearing bushes.
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 casing(04).
1.5Locations of the rating plates
Page 5 / 40
Fig.2: Locations of the rating plates
One rating plate (01) each is attached on the left and the right side of the turbocharger bearing casing.
Explanations regarding the rating plate can be found in the chapter dealing with safety.
1 Introduction / 1.6 Warning plates on the turbocharger
1.6Warning plates on the turbocharger
Warning plates are affixed at the following locations:
Page 6 / 40
Fig.3: Warning plates on the turbocharger
ABB does not supply insulation for this turbocharger. If the turbocharger is insulated at a
later date and warning plates are covered, the warning signs must be attached to the insulation. This is the responsibility of the enginebuilder.
If warning plates are not present in the designated locations or not readable, proceed as follows:
u Order new warning plates (72080) from ABB Turbocharging Service Stations (see chapter
Ordering spare parts →38).
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.
2 Removing and Installing / 2.1 Turbocharger weight and transportation
2Removing and Installing
2.1Turbocharger weight and transportation
Lifting gear with a sufficient load limit must be used for removing and installing the turbocharger. The following weight specification 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.
CAUTION
Damage to bellows
The turbochargers are supplied without fitted pipe sections and bellows.
The parts are delivered separately, because they can be damaged or destroyed during turbocharger transport if they are fitted.
u Never transport turbocharger with bellows fitted.
2 Removing and Installing / 2.3 Installing the turbocharger
The compressor casing(72000) can be lower than the turbocharger support depending on
the casing position.
Fig.6: Putting down the turbocharger
u Put the turbocharger down onto a solid surface so that the turbocharger cannot tip over.
Support the turbocharger if necessary.
2.3Installing the turbocharger
Requirements for the fixing screws(01)
The fixing screws(01) that are required for attaching the turbocharger bracket(02) to the
engine support(03) are not included in the ABB Turbo Systems scope of delivery. These
parts depend on the version of the engine-side bracket.
Inspection procedures include preventative visual controls, monitoring and measuring work
before and during commissioning. Inspection procedures enable changes to the turbocharger to be detected. Machine damage can be prevented.
3.2.2Checks before commissioning
Lubricating system
CAUTION
Contaminated oil
Serious damage to engine or property can be caused by dirt and solid material 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.
Page 12 / 40
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 →15.
Warning plates
u Check whether warning plates are present and legible.
u Check whether the protective sheets have been removed.
3.2.3Checks 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 →15 for admissible values.
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.
3.2.4Checks 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 →28).
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.
4 Monitoring operation / 4.1 Oil pressure, oil temperature
4Monitoring operation
4.1Oil 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 > 3bar.
CAUTION
Assuring lubricating oil pressure
Serious damage to the engine or property can result from a missing or insufficient lubricating oil supply.
u The lubricating oil pressure must be monitored during operation and the
necessary pressure assured at the oil inlet.
Status for operationPressure at oil inlet upstream of
the turbocharger
[bar] Overpressure
Normal operation2.0< p
Engine start: Cold oil, admissible for a maximum of 15
minutes
Engine idling, admissible for a maximum of 1 hour0.2< p
Pre-lubrication and post-lubrication (engine stopped)0.2< p
Warning signal: (n ≥ 0.5 x n
Alarm signal: Not admissible. Stop the engine immediately.<0.2
Table5: Lubricating oil pressure at oil inlet before turbocharger
Fig.9: Arrangement of oil temperature and oil pressure measuring points
POil pressure measuring point
TOil temperature measuring point
)<1.25
Bmax
oil
<8.0
oil
oil
≤4.5
≤2.5
≤1.0
Page 15 / 40
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.
4 Monitoring operation / 4.1 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.
The measuring points for temperature(T) and pressure (M) 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. The temperature and pressure are measured to monitor the lubrication.
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.
Page 16 / 40
Status for operationOil temperature at the inlet
T
oil,inlet
Admissible8…105°C
Temporarily admissible (<1h) → Alarm>105°C
Not admissible → stop engine>110°C
Not admissible → do not start engine (before start: preheat
<8°C
oil)
Table6: Lubricating oil temperature at the inlet
Lubricating oil temperature at the outlet
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 operationOil temperature at the outlet
T
oil,outlet
Admissible≤160°C
Temporarily admissible → alarm>160°C
Not admissible → stop engine>180°C
Admissible≤ T
Temporarily admissible → alarm> T
Table7: Lubricating oil temperature at the outlet
4 Monitoring operation / 4.1 Oil pressure, oil temperature
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.
4 Monitoring operation / 4.2 Exhaust gas temperature before turbine
4.2Exhaust 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 Definition and explanations concerning rating plate: refer to chapter 2 of Operation
Manual / Safety.
u Operating limits: refer to chapter 3 of Operation Manual / Safety data sheet or examine
rating plate.
4.3Turbocharger speed
Page 18 / 40
4.3.1Introduction
A speed measuring system enables the constant monitoring of the turbocharger speed.
CAUTION
Do not strain cables
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 Definition and explanations concerning rating plate: refer to chapter 2 of Operation
Manual / Safety.
u 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 below can be ordered from an ABB
Turbocharging Service Station (see chapter Ordering spare parts →38).
Exposure to noise can harm the hearing system, impair health and the psychological 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 filter silencer. The following prerequisites must be fulfilled with regard to the turbocharger 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.12:
Noise insulation, bellows →22).
The enginebuilder is responsible for insulating the charge air/scavenging air line and the
charge air cooler.
Service work includes visual controls, monitoring, measuring and inspection as well as functional checks. Service work enables the detection and rectification of changes to the turbocharger 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
Shortened service intervals
Exceptional stresses such as several starts/stops per day, harsh environmental conditions, poor fuel quality or high system vibrations can lead to
untimely machine damage even if the prescribed service intervals are observed.
u Agree on a shortened 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.
5.2.4Service 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 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.
u 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/corro-
sion.
¡Check and assess rotor and bearing parts.
The following work can be carried out as preparation.
u Remove the turbocharger from the engine (see chapter Removing and Installing →7).
5 Operation and service / 5.3 Expected replacement intervals
5.3Expected replacement intervals
ComponentOperating hours
Turbine casing25000…50000
Nozzle ring50000
Gas outlet flange50000
Partition wall50000
Rotating componentsSee rating plate information
Bearing parts12000…24000
Other casings50000
Table9: Expected replacement intervals [h]
1)
Page 26 / 40
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.
Influencing parameters
The specified values are guideline values and are not guaranteed. The actual values can deviate considerably from the guideline values, for example, due to the following influences:
¡Fuel quality and fuel treatment
¡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)
7 Eliminating malfunctions / 7.1 Malfunctions when starting
7Eliminating malfunctions
7.1Malfunctions when starting
Delayed start-up
Possible causesRemedy
Turbocharger
Table10: Malfunctions when starting – Delayed start-up
Vibrations
Turbocharger contaminatedHave cleaning carried out by an ABB
Turbocharging Service Station.
Bearing damagedContact ABB Turbocharging Service Sta-
Rotor rubbing
Foreign object in the turbocharger
tion
Page 28 / 40
Possible causesRemedy
Turbocharger
EngineVibrations from engineContact enginebuilder
Table11: Malfunctions when starting – Vibrations
Rotor unbalanceContact ABB Turbocharging Service
Turbine or compressor damaged
Bearing damaged
Station
Rotating parts rubbing
Normal behaviour, not a malfunction
Turbocharger
Table12: Malfunctions when starting - Rotating parts rubbing
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.
¡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-
7 Eliminating malfunctions / 7.2 Malfunctions during operation
Charge air pressure too high
Engine performance and engine speed unchanged, suction condition normal
Possible causesRemedy
EngineMalfunction in the injection systemRepair or contact manufacturer
Injection mistimedSet correctly
Engine performance higher than indicated
Table18: Malfunctions during operation – Charge air pressure too high
Check engine performance
Reduced compressor performance/efficiency and therefore engine performance
losses
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.
u Rectify malfunction in accordance with the following table.
Possible causesRemedy
Turbocharger
Table19: Malfunctions during operation – Engine performance losses
Compressor components severely contaminated by the ventilation gases that
have been fed in
Increased blade vibration, compressor
blade damage due to the ventilation
gases that have been fed in
Material of the compressor wheel corroded due to the feeding in of ventilation
gases containing corrosive components
Material of the compressor wheel corroded due to intake air containing exhaust gases or salt
Have cleaning carried out by an ABB
Turbocharging Service Station.
Optimize oil separation
Correct the feed of ventilation gases according to instructions of enginebuilder.
Correct the feed of ventilation gases according to instructions of enginebuilder.
Prevent exhaust gas leakages in the engine space
Have cleaning carried out by an ABB Turbocharging Service Station.
7 Eliminating malfunctions / 7.3 Turbocharger is surging
7.3Turbocharger is surging
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.
u Keep a distance from the air inlet while the turbocharger is surging.
Turbocharger surges continuously or periodically
CAUTION
Continuous or periodic surging
If the turbocharger surges continuously or periodically, parts of the turbocharger may be damaged.
u Gradually reduce the engine load.
u Have the cause clarified and remedied immediately by an ABB Turbochar-
ging Service Station.
u Have parts assessed for damage and, if necessary, replaced by an ABB
Turbocharging Service Station.
Page 32 / 40
Possible causesRemedy
TurbochargerDiffuser contaminatedHave cleaning carried out by an ABB
Heavy contamination deposits in the
turbine or in the nozzle ring
Air inlet system Air inlet filter contaminatedClean
EngineProtective grating in front of the tur-
bocharger contaminated or damaged
Charge air
cooler
Table20: Malfunction – Turbocharger pumping
Cooler contaminatedClean
Charge air duct blocked
Turbocharging Service Station.
Clean/replace
Sporadic surge blows
Possible causesRemedy
EngineEngine load changed quickly.
When this happens, the flow direction in the compressor is momentarily reversed. Such sporadic surge
blows do not impair the safe operation of the turbocharger.
7 Eliminating malfunctions / 7.4 Malfunctions when stopping
7.4Malfunctions when stopping
Runout noises
Possible causesRemedy
Turbocharger
Table22: Malfunctions when stopping – Runout noises
Runout time too short
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.
Turbocharger contaminatedHave cleaning carried out by an ABB Turbochar-
ging Service Station.
Bearing damagedContact an ABB Turbocharging Service Station.
Rotor rubbing
Foreign object in the turbocharger
If the runout time is significantly shorter in comparison to a previous measurement, the following table must be observed.
Possible causesRemedy
Turbocharger
Table23: Malfunctions when stopping – Runout time too short
Turbocharger contaminatedHave cleaning carried out by an ABB Turbochar-
ging Service Station.
Bearing damagedContact an ABB Turbocharging Service Station.
Rotor rubbing
Foreign object in the turbocharger
7.5Speed measurement system
No signal or poor signal amplitude of the speed measurement
Possible causesRemedy
Turbocharger
Table24: Malfunction of the speed measurement system – No signal or poor signal amplitude
The speed sensor was accidentally fitted with an additional gasket.
An enlarged distance
between the sensor tip and
the signal-emitting sealing
disc reduces the voltage
amplitude of the speed signal.
Sensor or cable defectiveContact an ABB Turbocharging Service Station.
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 Re-
placing the speed sensor →20.
Install the speed sensor without the additional
gasket (copper ring).
Order new speed sensor(86505) (refer to chapter
Ordering spare parts →38).
Replacing the speed sensor →20.
7 Eliminating malfunctions / 7.5 Speed measurement system
Measured speed too high
Possible causesRemedy
Turbocharger
Table25: Malfunction of the speed measurement system – Measured speed too high
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, hence, to false
triggering.
For information regarding the disassembly and assembly of the speed sensor, refer to chapter Re-
placing the speed sensor →20.
Dismantle the sensor, clean the sensor tip, and fit
the sensor back on with the specified tightening
torque.
Measured speed too low
Possible causesRemedy
Turbocharger
Table26: Malfunction of the speed measurement system – Measured speed too low
- -Contact ABB Turbocharging Service Station
Page 34 / 40
If none of the measures described above remedy the malfunction, have the speed measurement system checked by an ABB Turbocharging Service Station.
8 Mothballing the turbocharger / 8.1 Taking the engine out of operation for up to 12months
8Mothballing the turbocharger
8.1Taking the engine out of operation for up to
12months
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 required under the following conditions:
¡Acid number (TAN) <2mg KOH/g
¡The engine lubricating oil is replaced by a preservative oil and circulated with the pre-lub-
rication 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.
Preparations for mothballing
WARNING
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or contact 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 35 / 40
If the acid number (TAN) is greater than 2mg KOH/g, the following mothballing measures
are necessary after the engine is taken out of operation:
u Remove turbocharger (see chapter Removing and Installing →7).
u Have turbocharger dismantled, cleaned, oiled and fitted again by an ABB Turbocharging
8 Mothballing the turbocharger / 8.2 Taking the engine out of operation for more than 12months
8.2Taking the engine out of operation for more than
12months
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
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 12months, subsection Preparations
for mothballing.
If the turbocharger remains attached to the engine, see section Taking the engine out of op-
eration for up to 12months →35, subsection Rotor turning in stack draught.
Page 36 / 40
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.