ABB TPS61 R User Manual

Operation Manual  
TPS61-R  
HT591545 English  
Original Operation Manual  
Chapter  
Document-ID  
HZTL4005_EN_F  
HZTL4027_EN_A  
HT591545  
1
2
3
4
Introduction  
Safety  
Safety data sheet  
Product description  
HZTL4042_EN_B  
ABB Turbocharging  
Operation Manual / 1 Introduction  
1 Introduction / 1.1 Purpose of the manual  
1
Introduction  
1.1  
Purpose of the manual  
Fig. 1: Serial number (01) on the rating plate  
This Operation Manual belongs to the turbocharger with the identical serial number (01), see  
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-  
tion.  
The Operation Manual is a complement to and expansion of existing national regulations for  
occupational safety, accident prevention and environmental protection.  
Target group  
The Operation Manual is aimed at engineers and trained mechanics responsible for the  
proper operation of the engine and for the turbocharger connected to it.  
Availability of the Operation Manual  
The Operation Manual must be available where the turbocharger is used.  
All persons operating or working on the turbocharger must have read and fully understood  
the Operation Manual.  
© Copyright 2017 ABB. All rights reserved.  
HZTL4005_EN  
Revision F  
May 2017  
   
Operation Manual / 1 Introduction  
1 Introduction / 1.2 Symbols, definitions  
1.2  
Symbols, definitions  
Symbols  
The following symbols are used in this document:  
u Indicates an action step.  
1. Indicates a numbered action step.  
Refers to a page number.  
Definition of Note  
NOTICE  
Note  
The note provides advice which facilitates the work.  
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 Sta-  
tions. They are regularly audited and certified by ABB Turbo Systems. Also see chapter Con-  
© Copyright 2017 ABB. All rights reserved.  
HZTL4005_EN  
Revision F  
May 2017  
 
Operation Manual / 1 Introduction  
1 Introduction / 1.2 Symbols, definitions  
Definition of pictograms  
The following pictograms can occur in this document. These point out actions that must be  
taken in accordance with the meaning of the relevant pictogram.  
Pictogram  
Meaning  
Pictogram  
Meaning  
Tighten with specified torque  
Affix  
Tighten over specified tighten-  
ing angle  
Measure  
Hand-tight, tighten without  
tools  
Note  
Oil  
Visually inspect  
Apply screw locking paste (e.g.  
Loctite)  
Please note text for numbered  
work step  
Apply high-temperature grease  
See document  
Apply other paste in accord-  
ance with specifications  
Dispose of in an environmentally  
compatible, professional way and  
in compliance with locally applic-  
able regulations  
Oil free, grease free and dry  
Table 1: Definition of pictograms  
© Copyright 2017 ABB. All rights reserved.  
HZTL4005_EN  
Revision F  
May 2017  
Operation Manual / 1 Introduction  
1 Introduction / 1.3 Storage of new turbochargers and spare parts  
1.3  
Storage 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 la-  
bel 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.  
u Close package. The more tightly the package is sealed, the longer the protection dura-  
tion.  
© Copyright 2017 ABB. All rights reserved.  
HZTL4005_EN  
Revision F  
May 2017  
 
Operation Manual / 1 Introduction  
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 tur-  
bocharger 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:  
¡
¡
¡
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 pack-  
age 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.  
© Copyright 2017 ABB. All rights reserved.  
HZTL4005_EN  
Revision F  
May 2017  
Operation Manual / 1 Introduction  
1 Introduction / 1.4 Contact information  
1.4  
Contact information  
Contact information for the ABB Turbocharging Service Stations is available online.  
u Scan the QR code to access our website.  
ABB Turbo Systems Ltd  
Bruggerstrasse 71a  
CH-5401 Baden  
Switzerland  
© Copyright 2017 ABB. All rights reserved.  
HZTL4005_EN  
Revision F  
May 2017  
 
Operation Manual / 2 Safety / TPS-R  
Table of contents  
Safety  
© Copyright 2018 ABB. All rights reserved.  
HZTL4027_EN  
Revision A  
April 2018  
Operation Manual / 2 Safety / TPS-R  
1 Safety / 1.1 Introduction  
1
Safety  
1.1  
Introduction  
Turbochargers manufactured by ABB reflect the state of the art. The respective safety and  
health protection requirements are met. This ensures safe operation of the turbocharger.  
Nevertheless, there may be some residual risks during operation of and work on the tur-  
bocharger which:  
¡
¡
¡
¡
Are caused by the turbocharger itself or its accessories.  
Are caused by the operating equipment used or supplies and materials.  
Are a consequence of insufficient compliance with safety instructions.  
Are a consequence of insufficient or inappropriate performance of maintenance and in-  
spection work.  
The operating company is responsible for defining measures that regulate safe access to  
and safe handling of the turbocharger.  
All instructions contained in this chapter must be observed for safe and trouble-free opera-  
tion of the turbocharger and during all work on the turbocharger.  
All further safety instructions contained and specifically identified in every chapter of this  
manual (Definition of safety instructions 3) must also be observed.  
1.2  
CE conformity  
Information  
ABB turbochargers comply with the Machinery Directive 2006/42/EC and are partly com-  
pleted machinery as defined by Article 2 g in this directive.  
© Copyright 2018 ABB. All rights reserved.  
HZTL4027_EN  
Revision A  
April 2018  
     
Operation Manual / 2 Safety / TPS-R  
1 Safety / 1.3 Definition of mandatory signs  
1.3  
Definition of mandatory signs  
To be worn at all times  
Protective clothing  
Safety footwear to protect  
against mechanical hazard and  
risk of falling  
Table 1: Personal protective equipment to be worn at all times  
To be worn specific to the respective task  
Safety glasses  
Safety goggles  
Safety gloves to protect  
against  
Respiratory mask to protect  
against  
- Dusts  
- Gases  
- Mechanical hazard  
- Chemical hazard  
- Thermal hazard  
- Electrical hazard  
Safety helmet  
Ear protection  
Table 2: Personal protective equipment to be worn specific to the respective task  
1.4  
Definition of safety instructions  
WARNING  
Definition of Warning  
Non-compliance or inaccurate compliance with working or operating in-  
structions indicated by this symbol and the word WARNING can lead to seri-  
ous injuries to personnel and even to fatal accidents.  
u Warning signs must always be observed.  
CAUTION  
Definition of Caution  
Non-compliance or inaccurate compliance with working or operating in-  
structions indicated by this symbol and the word CAUTION can lead to seri-  
ous damage to engine or property with grave consequences.  
u Caution signs must always be observed.  
© Copyright 2018 ABB. All rights reserved.  
HZTL4027_EN  
Revision A  
April 2018  
   
Operation Manual / 2 Safety / TPS-R  
1 Safety / 1.5 Intended use  
1.5  
Intended use  
Use on internal combustion engines in general  
ABB turbochargers are intended for charging internal combustion engines.  
The turbocharger supplies the engine with the air volume or air/gas mixture and the associ-  
ated charging pressure required for operation.  
The turbocharger is solely intended to be operated with a clockwise direction of rotation as  
viewed from the turbine end.  
The specific operating limits of the turbocharger were determined on the basis of informa-  
tion from the enginebuilder about the intended use. These data are given on the rating  
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 haz-  
ardous to personnel.  
u Only operate the turbocharger within the operating limits.  
u Only trained personnel must operate the turbocharger.  
The intended use of the turbocharger includes compliance with all regulations and condi-  
tions. In particular, the following must be observed:  
¡
¡
Operation Manual  
Instructions of the enginebuilder  
State of the art  
The turbocharger is designed and manufactured according to the state of the art and is safe  
to operate.  
Perfect condition  
The turbocharger must only be used when it is in a technically flawless condition and oper-  
ated in compliance with its intended use.  
ABB excludes any liability for damage resulting from unauthorized modifications to the tur-  
bocharger or improper operation.  
© Copyright 2018 ABB. All rights reserved.  
HZTL4027_EN  
Revision A  
April 2018  
 
Operation Manual / 2 Safety / TPS-R  
1 Safety / 1.6 Warning plates on the turbocharger  
1.6  
Warning plates on the turbocharger  
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.  
© Copyright 2018 ABB. All rights reserved.  
HZTL4027_EN  
Revision A  
April 2018  
 
Operation Manual / 2 Safety / TPS-R  
1 Safety / 1.7 Turbocharger rating plate  
1.7  
Turbocharger rating plate  
Fig. 2: Rating plate  
Operating limits  
01 Turbocharger operating limits at engine overload (110 %).  
In test rig operation only, unless otherwise agreed with the en-  
ginebuilder.  
02 Turbocharger operating limits during operation  
Recommended inspection and replacement intervals of turbocharger components  
03 Inspection interval of plain bearings in 1000 h  
04 Replacement interval of compressor in 1000 h  
05 Replacement interval of turbine in 1000 h  
Further data  
06 Customer part number  
07 Designation for special design  
08 Weight of turbocharger in kg  
09 Turbocharger type  
10 Serial number  
11 Year of construction of turbocharger  
12 Manufacturing plant  
© Copyright 2018 ABB. All rights reserved.  
HZTL4027_EN  
Revision A  
April 2018  
 
Operation Manual / 2 Safety / TPS-R  
1 Safety / 1.7 Turbocharger rating plate  
Explanations regarding the rating plate  
The recommended inspection and replacement intervals and the corresponding operating  
limits are jointly defined with the enginebuilder. This information is specific to the system.  
Operation above the indicated values nBmax, tBmax can considerably shorten the recommended  
replacement intervals. In such a case, we recommend that you contact the nearest official  
service station of ABB Turbo Systems.  
nMmax, tMmax normally apply only when running at overload (110 %) during trials on the engine  
test bed. These limit values can also be permitted during operation for special applications.  
Operation above nMmax and tMmax is not permitted.  
Non-observance of the recommended inspection and replacement intervals increases the  
risk of unpredictable component failures.  
Locations of the rating plates  
The locations of the rating plates are defined in the Operation Manual, Chapter 4 Product  
description.  
© Copyright 2018 ABB. All rights reserved.  
HZTL4027_EN  
Revision A  
April 2018  
Operation Manual / 2 Safety / TPS-R  
1 Safety / 1.8 Lifting of loads  
1.8  
Lifting of loads  
WARNING  
Suspended loads  
Loads that are not attached according to regulations can cause injury to  
personnel or fatal accidents.  
u Loads must always be fastened to properly functional lifting gear with a  
sufficient load limit.  
u Pay attention to the correct attachment of loads on the crane hook.  
u People must not stand beneath suspended loads.  
Wear safety gloves to protect against mechanical hazards.  
Wear safety helmet.  
Fig. 3: Attachment of loads on the crane hook  
Fig. 4: Attachment angle  
If there are two or more suspension points, the attachment angle of 45° must not be ex-  
ceeded. This prevents excessive loading due to diagonal pull.  
u Before looping around the components of the turbocharger, let them cool down (max-  
imum 80 °C).  
u Attach components of the turbocharger as described in the respective action steps.  
u Use a suitable edge guard if there are sharp edges.  
u The assembly devices must be completely screwed in and must not unscrew during use.  
u Use assembly devices only for the described applications.  
u Put down dismantled components of the turbocharger in such a way that they cannot tip  
over.  
© Copyright 2018 ABB. All rights reserved.  
HZTL4027_EN  
Revision A  
April 2018  
 
Operation Manual / 2 Safety / TPS-R  
1 Safety / 1.9 Prerequisites for operation and maintenance  
1.9  
Prerequisites for operation and maintenance  
Responsibility of the operating company  
In awareness of its responsibility, the operating company must ensure that only authorised  
personnel work on the turbocharger, who:  
¡
Are versed in the general and locally applicable regulations for occupational safety and  
accident prevention  
¡
¡
¡
Are equipped with the prescribed personal protective equipment  
Have read and understood the Operation Manual  
Have been instructed in the use of the turbocharger.  
The safety-conscious work of the personnel and adherence to the Operation Manual must be  
checked periodically.  
Suitable working materials and personal protective equipment must be kept in a perfect  
condition.  
Only authorised personnel may remain in the vicinity of the turbocharger when the engine is  
running.  
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 cor-  
responding accessories.  
© Copyright 2018 ABB. All rights reserved.  
HZTL4027_EN  
Revision A  
April 2018  
 
Operation Manual / 2 Safety / TPS-R  
1 Safety / 1.10 Hazards during operation and maintenance  
1.10  
Hazards during operation and maintenance  
Noise hazards  
The turbocharger's noise emission is influenced by its installation and operating conditions.  
A noise level exceeding 85 dB(A) is harmful.  
WARNING  
Danger due to noise  
Exposure to noise can harm the hearing system, impair health and the psy-  
chological state and may lead to lack of attention and irritation.  
u When the engine is running, always wear ear protection.  
u Always wear ear protection if the sound pressure level exceeds 85 dB(A).  
Wear ear protection.  
Hazards due to hot surfaces  
Surfaces of the turbocharger, attached parts and operating fluids (lubricating oil) get hot  
during operation. The surface temperature depends on the efficacy of the existing insula-  
tion. The temperature may rise to a level that can cause burns.  
WARNING  
Danger of burns  
Touching hot surfaces or contact with hot operating fluids can cause burns.  
u Do not touch hot surfaces. Observe the warning plate on the turbochar-  
ger.  
u Wear heat-resistant safety gloves and protective clothing.  
u Wait for the turbocharger to cool down before carrying out any work.  
Wear safety gloves to protect against thermal hazards.  
© Copyright 2018 ABB. All rights reserved.  
HZTL4027_EN  
Revision A  
April 2018  
 
Operation Manual / 2 Safety / TPS-R  
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 in-  
sulation, the enginebuilder is responsible for providing the turbocharger  
with proper insulation and for providing protection against contact with hot  
surfaces.  
u Compliance with the instructions and specifications given by the en-  
ginebuilder to protect against hot turbocharger surfaces is compulsory.  
Wear safety gloves to protect against thermal hazards.  
Hazards due to rotating parts  
WARNING  
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.  
© Copyright 2018 ABB. All rights reserved.  
HZTL4027_EN  
Revision A  
April 2018  
Operation Manual / 2 Safety / TPS-R  
1 Safety / 1.11 Safe operation  
1.11  
Safe operation  
Mechanical hazards during operation  
During standard operation, no mechanical hazards are caused by the turbocharger itself if it  
has been properly installed.  
Safety during commissioning and operation  
u Visually inspect your working environment before starting work.  
u Remove any obstacles and objects littering the workplace.  
u Check all pipes to and from the turbocharger for damage and leaks before commission-  
ing.  
u Check turbocharger for recognisable damage or defects every 12 hours of operation or at  
least once a day.  
u Report any damage and any alterations of operational characteristics to the responsible  
department immediately.  
u In case of damage, take the turbocharger out of operation immediately and safeguard  
against accidental/unauthorised use.  
u When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay at-  
tention to the risks that may occur as a consequence of this energy input.  
© Copyright 2018 ABB. All rights reserved.  
HZTL4027_EN  
Revision A  
April 2018  
 
Operation Manual / 2 Safety / TPS-R  
1 Safety / 1.12 Safe maintenance  
1.12  
Safe maintenance  
Occupational safety  
WARNING  
Injuries to persons  
Severe injuries to personnel or fatal accidents can be caused by mechanical  
influences as a consequence of hazardous and inadequate operational pro-  
cedures or non-compliance with safety and health standards.  
u When working on the turbocharger always wear safety footwear and pro-  
tective clothing to protect against mechanical hazards.  
u Keep personal protective equipment in perfect condition.  
u Obey mandatory signs.  
u Observe the general rules for occupational safety and prevention of acci-  
dents.  
u Only perform operations that are described in this 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 fall-  
ing.  
Wear protective clothing.  
WARNING  
Risk of falling  
When working on the turbocharger, there is a risk of falling.  
u Do not climb onto the turbocharger or onto attached parts and do not  
use them as climbing aids.  
u Use suitable climbing aids and working platforms for work above body  
height.  
u 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.  
u Keep the floor, equipment, and turbocharger clean.  
u Have oil binding agents ready and provide or keep oil pans at hand.  
u Clean up any spills.  
u Have fire protection means and extinguishing agents available.  
© Copyright 2018 ABB. All rights reserved.  
HZTL4027_EN  
Revision A  
April 2018  
 
Operation Manual / 2 Safety / TPS-R  
1 Safety / 1.12 Safe maintenance  
Use of assembly devices  
Assembly devices are specially constructed and designed for the defined use; they are not  
commercially available products.  
u Use assembly devices only for the described applications.  
Welding work in the vicinity of the turbocharger  
u When performing welding work in the vicinity of the turbocharger, always cover the filter  
silencer to prevent the filter mat from being damaged.  
u Keep flammable objects and substances out of the vicinity of flying sparks.  
u Cover all connections on the turbocharger so that no foreign objects can enter the tur-  
bocharger.  
u Wear personal protective equipment (PPE) for welding operations.  
Safety during cleaning  
If cleaning agents or solvents are used for cleaning, the corresponding material safety data  
sheet and the safety instructions in section Hazards due to operating materials and supplies  
must be observed.  
u Observe the material safety data sheet for the cleaning agent or solvent.  
u Wear personal protective equipment (PPE) according to the material safety data sheet.  
u Inspect the electric cables for abrasion and damage before and after your cleaning work.  
Safety during disassembly, assembly, maintenance and repair  
u Observe the procedures for set-up, service and inspection work and the inspection inter-  
vals.  
u Inform the operating staff before starting any service or repair work. Make sure the en-  
gine is not started while work is being conducted on the turbocharger.  
u Before taking off any cover or removing any guard from the turbocharger, switch off the  
engine and wait until the turbocharger has come to a standstill.  
u Make sure that the oil supply is interrupted, especially with an external oil supply.  
u Only restart the engine after all parts have been properly fitted again and oil supply is en-  
sured.  
CAUTION  
Mechanical operations on the turbocharger  
Components of the turbocharger can be damaged or destroyed as a result  
of improper procedures.  
u Only perform operations that are described in this chapter.  
u Only perform operations for which you have received instruction or train-  
ing.  
© Copyright 2018 ABB. All rights reserved.  
HZTL4027_EN  
Revision A  
April 2018  
Operation Manual / 2 Safety / TPS-R  
1 Safety / 1.12 Safe maintenance  
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 pro-  
cedures.  
u Observe the general rules for occupational safety and prevention of acci-  
dents.  
u Ensure workplace safety.  
u Only perform operations that are described in this chapter.  
u Only perform operations for which you have previously received instruc-  
tion or training.  
© Copyright 2018 ABB. All rights reserved.  
HZTL4027_EN  
Revision A  
April 2018  
 
Operation Manual / 2 Safety / TPS-R  
1 Safety / 1.12 Safe maintenance  
Hazards due to operating materials and supplies  
Operating materials and supplies are substances required for the operation of the tur-  
bocharger or for the performance of maintenance work. Oils, greases, coolants, detergents  
and solvents, acids and similar substances can be classified as hazardous substances.  
WARNING  
Handling operating materials and supplies  
Swallowing or inhaling vapours of operating materials and supplies or con-  
tact with them may be harmful to health.  
u Do not breathe in these substances and avoid contact with the skin.  
u Ensure proper ventilation.  
u Observe the information in the material safety data sheet for the operat-  
ing materials and supplies.  
u Wear personal protective equipment (PPE) according to the material  
safety data sheet.  
u Comply with local legislation.  
Wear safety goggles.  
Wear safety gloves to protect against chemical hazards.  
Wear a respiratory mask to protect against gases.  
WARNING  
Danger of fire or explosion  
Flammable and combustible operating materials and supplies can catch fire  
or resulting vapours can lead to an explosion.  
u Observe the information in the material safety data sheet for the operat-  
ing materials and supplies.  
u Comply with local legislation.  
u Do not allow any exposed flame or ignition source during cleaning work.  
u Carry out cleaning in the open or provide sufficient ventilation.  
CAUTION  
Environmental hazard  
Improper handling of operating materials and supplies can lead to environ-  
mental damage.  
u Observe the information in the material safety data sheet for the operat-  
ing materials and supplies.  
u Comply with local legislation.  
© Copyright 2018 ABB. All rights reserved.  
HZTL4027_EN  
Revision A  
April 2018  
Operation Manual / TPS61-R / Safety data sheet  
Page 1 / 1  
Safety data sheet  
TPS61-R  
HT591545  
TPS61-R  
511  
HT591545  
650  
511  
620  
TPS61R35-162850A  
720  
12  
50  
50  
2019  
© Copyright 2019 ABB. All rights reserved.  
HT591545  
October 2019  
Operation Manual / 4 Product description / TPS61-R  
Table of contents  
Product description  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
Operation Manual / 4 Product description / TPS61-R  
1 Introduction / 1.1 Essential information  
1
Introduction  
1.1  
Essential information  
Design variants  
This document is valid for different design variants of turbochargers. There may be sections  
and descriptions of components that are not relevant for a specific turbocharger variant.  
Please contact an ABB Turbocharging Service Station if you have any questions regarding a  
design variant (see Contact information at www.abb.com/turbocharging).  
Accuracy of illustrations  
The illustrations in this document are general in nature and intended for ease of understand-  
ing. Differences in detail are therefore possible.  
1.2  
Registered trademarks  
The trademarks of outside companies are used in this document. These are marked with the  
® symbol.  
1.3  
Related documents  
Chapter  
Operation Manual / 1 Introduction  
Operation Manual / 2 Safety  
Document number  
HZTL4005  
HZTL4027  
Operation Manual / 3 Safety data sheet *)  
Table 1: Related documents  
Serial number of the turbocharger  
*) This chapter is only present in serialised operation manuals.  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
         
Operation Manual / 4 Product description / TPS61-R  
1 Introduction / 1.4 Layout and function of the turbocharger  
1.4  
Layout and function of the turbocharger  
Fig. 1: Layout and function of TPS61-R  
01 Air suction branch  
02 Compressor casing  
03 Diffuser  
04 Bearing casing  
05 Axial thrust bearing  
06 Plain bearing bush  
07 Turbine  
08 Turbine casing  
09 Nozzle ring  
10 Compressor wheel  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
     
Operation Manual / 4 Product description / TPS61-R  
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  
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 com-  
pressor 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 cas-  
ing (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 cas-  
ing (04).  
1.5  
Locations of the rating plates  
Fig. 2: Locations of the rating plates  
One rating plate (01) each is attached on the left and the right side of the turbocharger bear-  
ing casing.  
Explanations regarding the rating plate can be found in the chapter dealing with safety.  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
   
Operation Manual / 4 Product description / TPS61-R  
1 Introduction / 1.6 Warning plates on the turbocharger  
1.6  
Warning plates on the turbocharger  
Warning plates are affixed at the following locations:  
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 insula-  
tion. This is the responsibility of the enginebuilder.  
If warning plates are not present in the designated locations or not readable, proceed as fol-  
lows:  
u Order new warning plates (72080) from ABB Turbocharging Service Stations (see chapter  
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.  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
   
Operation Manual / 4 Product description / TPS61-R  
2 Removing and Installing / 2.1 Turbocharger weight and transporta-  
tion  
2
Removing and Installing  
2.1  
Turbocharger weight and transportation  
Lifting gear with a sufficient load limit must be used for removing and installing the tur-  
bocharger. The following weight specification applies to the heaviest variant possible. De-  
pending 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 des-  
troyed during turbocharger transport if they are fitted.  
u Never transport turbocharger with bellows fitted.  
Fig. 4: Turbocharger transport  
Product  
Weights [kg]  
TPS61-R  
720  
Table 2: Weight of the turbocharger  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
       
Operation Manual / 4 Product description / TPS61-R  
2 Removing and Installing / 2.2 Removing the turbocharger  
2.2  
Removing the turbocharger  
WARNING  
Danger of burns  
Touching hot surfaces or contact with hot operating fluids can cause burns.  
u Do not touch hot surfaces. Observe the warning plate on the turbochar-  
ger.  
u Wear heat-resistant safety gloves and protective clothing.  
u Wait for the turbocharger to cool down before carrying out any work.  
Wear safety gloves to protect against thermal hazards.  
CAUTION  
Do not 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.  
u Disconnect all pipes according to the instructions of the enginebuilder.  
u Unplug the cable connector at the speed sensor (86505).  
Fig. 5: Removing the turbocharger  
1. Ensure that the oil connections have been dismantled.  
2. Remove the bellows.  
3. Attach lifting gear to the turbocharger.  
4. Loosen and remove screws.  
5. Lift turbocharger from engine support vertically upwards.  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
   
Operation Manual / 4 Product description / TPS61-R  
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.  
2.3  
Installing 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.  
Fig. 7: Requirements for fixing screws  
Product Diameter  
Hole in  
Screw size  
Length  
L1 [mm]  
Length  
L2 [mm]  
Material  
DIN / ISO 898  
(Part 1)  
Tightening  
torque  
bracket  
[mm]  
TPS61-  
R
Ø18 / M16  
M16  
30  
120  
10.9  
300 Nm  
Table 3: Requirements for fixing screws  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
       
Operation Manual / 4 Product description / TPS61-R  
2 Removing and Installing / 2.3 Installing the turbocharger  
2.3.1  
Attaching the turbocharger to the bracket  
CAUTION  
Damage to bellows  
If the axes of the flanges of the turbine casing do not align with the piping,  
the bellows can be damaged or destroyed.  
u 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.  
Fig. 8: Placing the turbocharger on the bracket  
Product  
Screw position  
Tightening torque  
(assumed friction coefficient  
µ = 0.12)  
TPS61-R  
TPS61-R  
01  
02  
M16  
300 Nm  
M16  
325 Nm  
Table 4: Tightening torque for turbocharger fixing screws  
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. Ob-  
serve the tightening torque.  
4. Tighten hexagon-head screws (01). Observe the tightening torque.  
5. Connect the oil supply. Ensure that the connection is tight.  
6. Connect cable to speed sensor (86505).  
7. Remove the lifting gear.  
u Connect all the gas pipes and air lines according to the enginebuilder's instructions.  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
   
Operation Manual / 4 Product description / TPS61-R  
3 Commissioning / 3.1 Oil supply  
3
Commissioning  
3.1  
Oil supply  
3.1.1  
Introduction  
In all operating states, a functioning and carefully executed oil supply is an important pre-  
requisite for trouble-free operation of the turbocharger.  
The lubrication of the turbocharger is usually carried out with oil from the engine oil circula-  
tion.  
u Comply with the enginebuilder's specifications regarding the selection of lubricating oil  
and the oil change intervals.  
3.1.2  
Pre-lubrication  
Pre-lubrication must be carried out as follows:  
u Switch on the oil pump.  
u Build up oil pressure &.  
u Do not exceed a pre-lubrication time of 2 minutes.  
u Start the engine.  
u Let the oil pump run until the pump driven by the engine generates sufficient pressure.  
3.1.3  
Oil filtering  
Filtering the lubricating oil with a filter mesh width of 0.034 mm is sufficient for this tur-  
bocharger.  
3.1.4  
Oil pressure  
Comply precisely with the oil pressure before the turbocharger for trouble-free operation.  
The admissible values are specified in chapter Monitoring operation 15.  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
   
Operation Manual / 4 Product description / TPS61-R  
3 Commissioning / 3.2 Inspection procedures  
3.2  
Inspection procedures  
3.2.1  
Introduction  
Inspection procedures include preventative visual controls, monitoring and measuring work  
before and during commissioning. Inspection procedures enable changes to the turbochar-  
ger to be detected. Machine damage can be prevented.  
3.2.2  
Checks before commissioning  
Lubricating system  
CAUTION  
Contaminated oil  
Serious damage to engine or property can be caused by dirt and solid ma-  
terial particles in the oil.  
u For the initial commissioning phase and after all service work, flush the  
complete lubricating system with warm oil.  
u Use special running-in filters when running in the engine and after all ser-  
vice work on the lubricating system.  
u Check that the oil filter is clean before commissioning.  
u Adhere to lubricating oil pressure at the inlet.  
u Adhere to lubricating oil temperature at the inlet.  
u For permissible values, see chapter Monitoring operation 15.  
Warning plates  
u Check whether warning plates are present and legible.  
u Check whether the protective sheets have been removed.  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
 
Operation Manual / 4 Product description / TPS61-R  
3 Commissioning / 3.2 Inspection procedures  
3.2.3  
Checks after commissioning (engine in idle mode)  
Lubricating system  
u Keep to the lubricating oil pressure at the inlet.  
u Keep to the lubricating oil temperature at the inlet.  
u Refer to chapter Monitoring operation 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.  
3.2.4  
Checks when starting up the engine  
If present:  
u Measure speed, oil pressure and charging pressure at various engine performances.  
u Measure the exhaust gas temperature before and after the turbine.  
u Measure the air temperature before and after the compressor.  
u Compare the measured values with the values of the acceptance report. Different operat-  
ing conditions indicate a malfunction (see chapter Eliminating malfunctions 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.  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
Operation Manual / 4 Product description / TPS61-R  
3 Commissioning / 3.3 Commissioning after taking out of operation  
3.3  
Commissioning after taking out of operation  
If present  
u Remove cover plates (blind flanges) from the compressor casing, the gas inlet and the  
gas outlet.  
General  
u Check the exhaust gas pipe before and after the turbine for combustion residues or wa-  
ter residues and clean it. Remove any foreign objects that may be present.  
u Check and clean the air supply system, and remove any foreign objects that may be  
present.  
u Put engine-side oil circulation to the turbocharger into operation.  
u Prepare the turbocharger for operation according to section "Checks before commission-  
ing".  
u The turbocharger is now ready for operation.  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
 
Operation Manual / 4 Product description / TPS61-R  
4 Monitoring operation / 4.1 Oil pressure, oil temperature  
4
Monitoring operation  
4.1  
Oil pressure, oil temperature  
Lubricating oil pressure, oil inlet  
To limit the oil flow rate through the turbocharger to the admissible values with the engine  
at full load, an oil orifice is mandatory or already fitted at the turbocharger oil inlet if the oil  
inlet pressure is > 3 bar.  
CAUTION  
Assuring lubricating oil pressure  
Serious damage to the engine or property can result from a missing or insuf-  
ficient lubricating oil supply.  
u The lubricating oil pressure must be monitored during operation and the  
necessary pressure assured at the oil inlet.  
Status for operation  
Pressure at oil inlet upstream of  
the turbocharger  
[bar] Overpressure  
Normal operation  
2.0 < poil 4.5  
Engine start: Cold oil, admissible for a maximum of 15  
< 8.0  
minutes  
Engine idling, admissible for a maximum of 1 hour  
Pre-lubrication and post-lubrication (engine stopped)  
0.2 < poil 2.5  
0.2 < poil 1.0  
< 1.25  
Warning signal: (n 0.5 x nBmax  
)
Alarm signal: Not admissible. Stop the engine immediately.  
Table 5: Lubricating oil pressure at oil inlet before turbocharger  
< 0.2  
Fig. 9: Arrangement of oil temperature and oil pressure measuring points  
P
T
Oil pressure measuring point  
Oil temperature measuring point  
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.  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
     
Operation Manual / 4 Product description / TPS61-R  
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 ori-  
fices or valves may be attached at the engine side between the measuring point and the tur-  
bocharger 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.  
Status for operation  
Oil temperature at the inlet  
Toil,inlet  
8 … 105 °C  
> 105 °C  
> 110 °C  
< 8 °C  
Admissible  
Temporarily admissible (< 1 h) Alarm  
Not admissible stop engine  
Not admissible do not start engine (before start: preheat  
oil)  
Table 6: 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 op-  
eration and must be monitored according to the current regulations.  
Status for operation  
Oil temperature at the outlet  
Toil,outlet  
Admissible  
160 °C  
Temporarily admissible alarm  
Not admissible stop engine  
Admissible  
Temporarily admissible alarm  
Table 7: Lubricating oil temperature at the outlet  
> 160 °C  
> 180 °C  
Toil,inlet + 55 K  
> Toil,inlet + 55 K  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
   
Operation Manual / 4 Product description / TPS61-R  
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 Tur-  
bocharging Service Station.  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
Operation Manual / 4 Product description / TPS61-R  
4 Monitoring operation / 4.2 Exhaust gas temperature before turbine  
4.2  
Exhaust gas temperature before turbine  
CAUTION  
Factors influencing replacement intervals  
Operation above the operating limits defined on the rating plate can  
shorten the recommended replacement intervals considerably.  
u Measure exhaust gas temperature upstream of turbine.  
u Comply with operating limits on rating plate.  
u 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.  
4.3  
Turbocharger speed  
4.3.1  
Introduction  
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).  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
   
Operation Manual / 4 Product description / TPS61-R  
4 Monitoring operation / 4.3 Turbocharger speed  
4.3.2  
Layout and overview  
Fig. 10: Speed measurement system  
86505 Speed sensor (cable not integrated)  
86515 Cable connector to 86505  
32109 Sealing disc  
01  
02  
Screw plug  
Gasket  
4.3.3  
Malfunctions on the speed measurement system  
In the case of malfunctions of the speed measurement system, refer to the chapter entitled  
Troubleshooting/Speed measurement system 33.  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
 
Operation Manual / 4 Product description / TPS61-R  
4 Monitoring operation / 4.3 Turbocharger speed  
4.3.4  
Replacing the speed sensor  
WARNING  
Hot speed sensor  
Danger of burns. The speed sensor can reach temperatures of more than  
100 °C during operation.  
u Wear safety gloves when disassembling the speed sensor.  
Wear safety gloves to protect against thermal hazards.  
The speed sensor supplied by ABB is equipped with a sealing lip and an O-ring. No additional  
gasket is required during assembly.  
Fig. 11: Fitting the speed sensor  
Part number  
Tightening torque  
86505  
15 Nm  
Table 8: Tightening torque (86505)  
u Reduce the engine performance to idling and then stop the engine. Pay attention to post-  
lubrication (Stopping the engine 27).  
u Switch off the lubricating oil supply to the turbocharger.  
u Disconnect cable connector (86515) from speed sensor (86505).  
u Unscrew and remove defective speed sensor (86505).  
u Screw in new speed sensor (86505) as far as it will go and tighten.  
u Connect cable connector (86515) to speed sensor (86505).  
u Switch on lubricating oil supply to the turbocharger.  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
     
Operation Manual / 4 Product description / TPS61-R  
5 Operation and service / 5.1 Noise emission  
5
Operation and service  
5.1  
Noise emission  
WARNING  
Danger due to noise  
Exposure to noise can harm the hearing system, impair health and the psy-  
chological state and may lead to lack of attention and irritation.  
u When the engine is running, always wear ear protection.  
u Always wear ear protection if the sound pressure level exceeds 85 dB(A).  
Wear ear protection.  
The emission sound pressure level (A-weighted) is measured at a distance of 1 meter from  
the turbocharger.  
The highest value of the emission sound pressure level1) reaches a maximum of 105 dB(A)  
near the filter silencer. The following prerequisites must be fulfilled with regard to the tur-  
bocharger 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:  
The enginebuilder is responsible for insulating the charge air/scavenging air line and the  
charge air cooler.  
1)  
2)  
Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7:  
A-weighted emission sound pressure level  
The enginebuilder must provide acoustically equivalent measures in case of deviating in-  
sulation versions  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
   
Operation Manual / 4 Product description / TPS61-R  
5 Operation and service / 5.1 Noise emission  
Suggestion for noise insulation, bellows  
Fig. 12: Noise insulation, bellows  
01  
02  
03  
04  
05  
06  
Compressor casing  
Bellows  
Charge air duct / scavenging air duct  
Insulation cushion  
Insulation mat (at least 15 mm)  
Sheet metal cover  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
   
Operation Manual / 4 Product description / TPS61-R  
5 Operation and service / 5.2 Service work  
5.2  
Service work  
Service work includes visual controls, monitoring, measuring and inspection as well as func-  
tional checks. Service work enables the detection and rectification of changes to the tur-  
bocharger and ensures full operability of the turbocharger.  
CAUTION  
Service intervals  
Any service work on the turbocharger that is omitted or performed too late  
can cause excessive contamination, wear and operating failures.  
u Carry out the service work at the specified time intervals.  
CAUTION  
Shortened service intervals  
Exceptional stresses such as several starts/stops per day, harsh environ-  
mental conditions, poor fuel quality or high system vibrations can lead to  
untimely machine damage even if the prescribed service intervals are ob-  
served.  
u Agree on a shortened service interval with ABB Turbo Systems.  
To prevent machine damage caused by ageing and downtime, we recommend having an in-  
spection carried out by an ABB Turbocharging Service Station no later than 5 years after the  
last service.  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
 
Operation Manual / 4 Product description / TPS61-R  
5 Operation and service / 5.2 Service work  
5.2.1  
Service work every 24 … 48 hours  
Pipes  
u Check all the inlet and outlet pipes of the turbocharger for leaks.  
Operating data  
CAUTION  
Unknown operational changes  
Impairment to the degree of a possible operating failure can be the con-  
sequence.  
u Have any unknown causes clarified by an ABB Turbocharging Service Sta-  
tion.  
Monitoring the engine's operating data makes it possible to draw conclusions about the op-  
erating behaviour of the turbocharger.  
u The following operating data and measured values must be entered every 24 … 48 hours  
in the engine logbook of the enginebuilder.  
¡
¡
¡
¡
¡
Performance and speed of the engine  
Air intake temperature  
Charging pressure  
Pressure loss in the charge air cooler  
Lubricating oil pressure and lubricating oil temperature.  
If present:  
¡
¡
Speed of the turbocharger  
Pressure in air inlet system  
u In case of different values, determine the cause.  
5.2.2  
Service work at 100 hours after commissioning  
u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en-  
gine is stopped.  
5.2.3  
Service work according to instructions of enginebuilder  
u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en-  
gine is stopped.  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
Operation Manual / 4 Product description / TPS61-R  
5 Operation and service / 5.2 Service work  
5.2.4  
Service work according to data on the rating plate  
WARNING  
Incorrect handling of a cartridge group  
The disassembly and assembly of the cartridge group, as well as the assess-  
ment of the rotor and bearing parts, requires the expertise of an ABB Tur-  
bocharging Service Station. The rotor parts rotate extremely quickly and are  
sensitive to unbalance. Incorrect handling of a cartridge group can damage  
the turbocharger and cause injuries to persons.  
u Ensure that the disassembly and assembly of the cartridge group is only  
carried out by an ABB Turbocharging Service Station.  
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).  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
Operation Manual / 4 Product description / TPS61-R  
5 Operation and service / 5.3 Expected replacement intervals  
5.3  
Expected replacement intervals  
Component  
Operating hours  
Turbine casing  
25000 … 50000  
Nozzle ring  
Gas outlet flange  
Partition wall  
50000  
50000  
50000  
Rotating components  
Bearing parts  
Other casings  
See rating plate information 1)  
12000 … 24000  
50000  
Table 9: Expected replacement intervals [h]  
1)  
The recommended replacement intervals of the compressor and turbine wheels are spe-  
cified with the aid of the safety concept for rotating parts (SIKO) and dependent on the  
operating conditions.  
Influencing parameters  
The specified values are guideline values and are not guaranteed. The actual values can devi-  
ate 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)  
For bearing parts  
¡
¡
¡
¡
Lubricating oil quality (oil filtering, oil condition, oil monitoring)  
Load profile (speed, pressure conditions, temperature)  
Number of starts/stops  
Unbalance of the rotor (degree of contamination).  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
   
Operation Manual / 4 Product description / TPS61-R  
6 Stopping the engine /  
6
Stopping the engine  
CAUTION  
Post-lubrication  
If the heat in the turbocharger is not dissipated after the engine stops, dam-  
age may result.  
u Perform post-lubrication 15 … 20 minutes after stopping the engine.  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
 
Operation Manual / 4 Product description / TPS61-R  
7 Eliminating malfunctions / 7.1 Malfunctions when starting  
7
Eliminating malfunctions  
7.1  
Malfunctions when starting  
Delayed start-up  
Possible causes  
Remedy  
Turbochar-  
ger  
Turbocharger contaminated  
Have cleaning carried out by an ABB  
Turbocharging Service Station.  
Bearing damaged  
Rotor rubbing  
Contact ABB Turbocharging Service Sta-  
tion  
Foreign object in the turbocharger  
Table 10: Malfunctions when starting – Delayed start-up  
Vibrations  
Possible causes  
Remedy  
Turbochar-  
ger  
Rotor unbalance  
Turbine or compressor damaged  
Bearing damaged  
Contact ABB Turbocharging Service  
Station  
Engine  
Vibrations from engine  
Contact enginebuilder  
Table 11: Malfunctions when starting – Vibrations  
Rotating parts rubbing  
Normal behaviour, not a malfunction  
Turbochar-  
ger  
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 com-  
ponents. This causes the compressor or turbine blades to be somewhat  
shortened. To prevent significant loss of efficiency, specific tolerances must be  
fulfilled.  
¡
If there is any doubt about the extent of the rubbing, contact an ABB Tur-  
bocharging Service Station.  
¡
Have a dimension check carried out by an ABB Turbocharging Service Sta-  
tion.  
Table 12: Malfunctions when starting - Rotating parts rubbing  
7.2  
Malfunctions during operation  
Lubricating oil pressure too low  
Possible causes  
Remedy  
Turbochar-  
ger  
Axial clearance of the rotor excessive  
Contact ABB Turbocharging Service  
Station  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
           
Operation Manual / 4 Product description / TPS61-R  
7 Eliminating malfunctions / 7.2 Malfunctions during operation  
Possible causes  
Engine Oil filter heavily contaminated  
Remedy  
Clean  
Oil pump in lubricating system defect- Check/replace  
ive  
Manometer displays incorrectly  
Replace manometer  
Table 13: Malfunctions during operation – Lubricating oil pressure too low  
Speed reduces  
Possible causes  
Turbochar-  
ger  
Remedy  
Turbine and/or nozzle ring severely con- Have cleaning carried out by an ABB  
taminated Turbocharging Service Station.  
Rotor components or bearing damaged Contact ABB Turbocharging Service Sta-  
tion  
Engine  
Pipes  
Defects on the connected cylinders in  
pulse charging  
Contact enginebuilder  
Defects, such as leaks, in the exhaust gasRepair  
pipes or charge air ducts  
Table 14: Malfunctions during operation – Speed reduces  
Speed increasing  
Possible causes  
Remedy  
Turbochar-  
Light to medium contamination of the Have cleaning carried out by an ABB  
ger  
turbine and/or nozzle ring Turbocharging Service Station.  
Table 15: Malfunctions during operation – Speed increases  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
     
Operation Manual / 4 Product description / TPS61-R  
7 Eliminating malfunctions / 7.2 Malfunctions during operation  
Exhaust gas temperature too high  
Engine performance and engine speed unchanged  
Possible causes  
Remedy  
Turbocharger  
Compressor/turbine contaminated  
Have cleaning carried out by an ABB  
Turbocharging Service Station.  
Exhaust gas back pressure too high  
Turbine damaged or eroded  
Check the exhaust gas system.  
Contact ABB Turbocharging Service  
Station  
Air inlet system Insufficient air, for example, if the air Clean or replace the air filter.  
filter is blocked  
Engine  
Malfunction in the injection system  
Cooler contaminated  
Cooling water volume too low  
Repair or contact manufacturer  
Clean  
Fill  
Charge air  
cooler  
Inlet temperature of cooling water too Check/clean cooling system  
high  
Insufficient ventilation  
Improve ventilation  
Table 16: Malfunctions during operation – Exhaust gas temperature too high  
Charge air pressure too low  
Engine performance and engine speed unchanged, suction condition normal  
Possible causes  
Remedy  
Turbochar-  
ger  
Compressor end and/or turbine end  
Have cleaning carried out by an ABB  
contaminated  
Turbocharging Service Station.  
Compressor/turbine damaged  
Contact ABB Turbocharging Service Sta-  
tion  
Air inlet sys- Insufficient air, for example, if the air fil- Clean or replace the air filter.  
tem  
ter is blocked  
Engine  
Air receiver not sealed  
Repair  
Gas piping between engine and turbine  
leaking  
Injection mistimed  
Set correctly  
Valve control misadjusted  
Pipes  
Pipes downstream to the compressor  
Repair.  
outlet not sealed.  
Exhaust gas back pressure too high  
Check the exhaust gas system.  
Table 17: Malfunctions during operation – Charge air pressure too low  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
   
Operation Manual / 4 Product description / TPS61-R  
7 Eliminating malfunctions / 7.2 Malfunctions during operation  
Charge air pressure too high  
Engine performance and engine speed unchanged, suction condition normal  
Possible causes  
Engine Malfunction in the injection system  
Injection mistimed  
Remedy  
Repair or contact manufacturer  
Set correctly  
Engine performance higher than indic- Check engine performance  
ated  
Table 18: Malfunctions during operation – Charge air pressure too high  
Reduced compressor performance/efficiency and therefore engine performance  
losses  
CAUTION  
Compressor damage  
A severely contaminated or corroded compressor wheel can reduce the com-  
pressor wheel’s fatigue endurance limit and result in the turbocharger being  
damaged.  
u Rectify malfunction in accordance with the following table.  
Possible causes  
Remedy  
Turbochar-  
ger  
Compressor components severely con- Have cleaning carried out by an ABB  
taminated by the ventilation gases that Turbocharging Service Station.  
have been fed in  
Optimize oil separation  
Increased blade vibration, compressor Correct the feed of ventilation gases ac-  
blade damage due to the ventilation  
gases that have been fed in  
cording to instructions of engineb-  
uilder.  
Material of the compressor wheel cor-  
Correct the feed of ventilation gases ac-  
roded due to the feeding in of ventilation cording to instructions of enginebuilder.  
gases containing corrosive components  
Material of the compressor wheel cor-  
roded due to intake air containing ex-  
haust gases or salt  
Prevent exhaust gas leakages in the en-  
gine space  
Have cleaning carried out by an ABB Tur-  
bocharging Service Station.  
Table 19: Malfunctions during operation – Engine performance losses  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
   
Operation Manual / 4 Product description / TPS61-R  
7 Eliminating malfunctions / 7.3 Turbocharger is surging  
7.3  
Turbocharger 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 tur-  
bocharger 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.  
Possible causes  
Turbocharger  
Remedy  
Diffuser contaminated  
Have cleaning carried out by an ABB  
Turbocharging Service Station.  
Heavy contamination deposits in the  
turbine or in the nozzle ring  
Air inlet system Air inlet filter contaminated  
Clean  
Clean  
Engine  
Protective grating in front of the tur- Clean/replace  
bocharger contaminated or damaged  
Cooler contaminated  
Charge air  
cooler  
Charge air duct blocked  
Table 20: Malfunction – Turbocharger pumping  
Sporadic surge blows  
Possible causes  
Remedy  
Engine  
Engine load changed quickly.  
- -  
When this happens, the flow direc-  
tion in the compressor is momentar-  
ily reversed. Such sporadic surge  
blows do not impair the safe opera-  
tion of the turbocharger.  
Table 21: Malfunction – Sporadic surge blows  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
     
Operation Manual / 4 Product description / TPS61-R  
7 Eliminating malfunctions / 7.4 Malfunctions when stopping  
7.4  
Malfunctions when stopping  
Runout noises  
Possible causes  
Remedy  
Turbochar-  
ger  
Turbocharger contaminated Have cleaning carried out by an ABB Turbochar-  
ging Service Station.  
Bearing damaged  
Rotor rubbing  
Contact an ABB Turbocharging Service Station.  
Foreign object in the tur-  
bocharger  
Table 22: 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.  
If the runout time is significantly shorter in comparison to a previous measurement, the fol-  
lowing table must be observed.  
Possible causes  
Remedy  
Turbochar-  
ger  
Turbocharger contaminated Have cleaning carried out by an ABB Turbochar-  
ging Service Station.  
Bearing damaged  
Rotor rubbing  
Contact an ABB Turbocharging Service Station.  
Foreign object in the tur-  
bocharger  
Table 23: Malfunctions when stopping – Runout time too short  
7.5  
Speed measurement system  
No signal or poor signal amplitude of the speed measurement  
Possible causes  
Remedy  
Turbochar-  
ger  
The speed sensor was acci-  
The screw plug for the sensor is fitted with an ad-  
dentally fitted with an addi- ditional gasket (copper ring).  
tional gasket.  
For information regarding the disassembly and as-  
sembly of the speed sensor, refer to chapter Re-  
An enlarged distance  
between the sensor tip and  
the signal-emitting sealing  
disc reduces the voltage  
amplitude of the speed sig-  
nal.  
Install the speed sensor without the additional  
gasket (copper ring).  
Sensor or cable defective  
Contact an ABB Turbocharging Service Station.  
Order new speed sensor (86505) (refer to chapter  
Table 24: Malfunction of the speed measurement system – No signal or poor signal amplitude  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
         
Operation Manual / 4 Product description / TPS61-R  
7 Eliminating malfunctions / 7.5 Speed measurement system  
Measured speed too high  
Possible causes  
Remedy  
Turbochar-  
ger  
Sensor tip contaminated,  
For information regarding the disassembly and as-  
since it is magnetic and can sembly of the speed sensor, refer to chapter Re-  
attract metallic particles.  
This reduces the distance to Dismantle the sensor, clean the sensor tip, and fit  
the signal-emitting sealing  
the sensor back on with the specified tightening  
disc, which can lead to ampli- torque.  
fication of the noise com-  
ponent and, hence, to false  
triggering.  
Table 25: Malfunction of the speed measurement system – Measured speed too high  
Measured speed too low  
Possible causes  
Remedy  
Turbochar-  
- -  
Contact ABB Turbocharging Service Station  
ger  
Table 26: Malfunction of the speed measurement system – Measured speed too low  
If none of the measures described above remedy the malfunction, have the speed measure-  
ment system checked by an ABB Turbocharging Service Station.  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
   
Operation Manual / 4 Product description / TPS61-R  
8 Mothballing the turbocharger / 8.1 Taking the engine out of opera-  
tion for up to 12 months  
8
Mothballing the turbocharger  
8.1  
Taking the engine out of operation for up to  
12 months  
State of the engine lubricating oil  
The turbocharger normally remains attached to the engine. The measures to be taken for  
mothballing the turbocharger depend on the state of the lubricating oil. No measures are re-  
quired under the following conditions:  
¡
¡
Acid number (TAN) < 2 mg 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 con-  
tact with them may be harmful to health.  
u Do not breathe in these substances and avoid contact with the skin.  
u Ensure proper ventilation.  
u Observe the information in the material safety data sheet for the operat-  
ing materials and supplies.  
u Wear personal protective equipment (PPE) according to the material  
safety data sheet.  
u Comply with local legislation.  
Wear safety goggles.  
Wear safety gloves to protect against chemical hazards.  
Wear a respiratory mask to protect against gases.  
If the acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures  
are necessary after 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  
Service Station.  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
   
Operation Manual / 4 Product description / TPS61-R  
8 Mothballing the turbocharger / 8.2 Taking the engine out of opera-  
tion for more than 12 months  
8.2  
Taking the engine out of operation for more than  
12 months  
If the engine is taken out of operation, the following variants are possible with regard to the  
turbocharger:  
¡
¡
Turbocharger remains attached to the engine  
The casings of the turbocharger remain attached to the engine, the rotor and bearing  
parts are dismantled by an ABB Turbocharging Service Station and stored separately  
¡
The turbocharger is completely removed, either as a whole unit or in individual parts  
For the measures always necessary for preparing the turbocharger parts for mothballing,  
see section Taking the engine out of operation for up to 12 months, subsection Preparations  
for mothballing.  
If the turbocharger remains attached to the engine, see section Taking the engine out of op-  
eration for up to 12 months 35, subsection Rotor turning in stack draught.  
If the complete turbocharger is removed or the turbocharger is assembled again from the  
individual parts:  
u Seal all openings of the turbocharger with paraffin paper and wooden lids.  
Only dry rooms with 40 ... 70 % atmospheric humidity, in which no water condensation can  
form, are suitable as storage locations.  
State of the mothballed turbocharger  
u Check the turbocharger parts annually for corrosion.  
u If there are signs of rust: Thoroughly clean parts and renew corrosion protection.  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
 
Operation Manual / 4 Product description / TPS61-R  
9 Disposing of turbocharger components /  
9
Disposing of turbocharger components  
Disposal must be environmentally compatible, competent and in compliance with locally ap-  
plicable regulations.  
The turbocharger consists largely of metal (cast iron materials, steel, nickel-steel alloys, alu-  
minium and bearing brass).  
Further components are: Non-metallic materials (gaskets), lubricants (engine oil) and elec-  
tronic parts (speed sensor and associated components).  
u Dispose of metals as scrap metal for recycling.  
u Dispose of non-metallic materials as waste.  
u Dispose of residues of lubricants as waste oil.  
u Dispose of electronic components as electronic waste.  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
 
Operation Manual / 4 Product description / TPS61-R  
10 Spare parts / 10.1 Ordering spare parts  
10  
Spare parts  
10.1  
Ordering spare parts  
CAUTION  
Spare part storage  
All spare parts that were ordered together with the turbocharger must be  
kept intact and ready for use.  
u Carefully clean any rusted parts and grease them.  
Please quote the following data when making queries and ordering spare parts:  
¡
¡
¡
Turbocharger type  
Serial number of the turbocharger  
Designation and part number  
Spare parts can be ordered from any ABB Turbocharging Service Station.  
u If different model variants are not taken into account in this document, contact an ABB  
Turbocharging Service Station.  
u Dispose of placed and unusable parts in an environmentally-friendly and professional  
manner in accordance with the local regulations.  
u Dispose of the packaging of new parts in an environmentally-friendly and professional  
manner in accordance with the local regulations.  
10.2  
Spare parts of the speed measurement system  
Fig. 13: Spare parts of the speed measurement system  
Part number  
86505  
86515  
Designation  
Speed sensor  
Cable connector  
Table 27: Spare parts of the speed measurement system  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Rev.B  
June 2019  
         
Operation Manual / 4 Product description / TPS61-R  
ꢀTables  
Tables  
© Copyright 2019 ABB. All rights reserved.  
HZTL4042_EN  
Revision B  
June 2019  
 

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