TPS44 61F维修说明书

ABB JiangJin Turbo Systems Co., Ltd.
重庆 ABB 江津涡轮增压系统有限公司
TPS44-F..-TPS61-F
Operation Manual
操作手册
ABB JiangJin Turbo Systems Co., Ltd.

Operation Manual / TPS44-F.. - TPS61-F..
目录页1
目录
September 2016
1 序言
1.1 手册的目的
1.2 结构与性能
1.3 正当使用涡轮增压器
1.4 新涡轮增压器和备件的存放
1.5 需要注意的提示
1.6 符号和定义
1.7 涡轮增压器铭牌
1.8 联系方式
2 安全
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2.1 介绍
2.2 CE 认证
2.3 强制性标志的含义
2.4 安全指令的含义
2.5 涡轮增压器上的警告牌
2.6 安全操作和维保
2.7 运行和维保期间的危害
2.8 燃气发动机的爆燃
2.9 定期检查压力容器
2.10 起重负荷
3 投入使用
3.1 机油供应
3.2 检验流程
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3.3 停止运行后的调试
4 运行
4.1 噪音排放
4.2 服务工作
4.3 预计的更换周期
4.4 测量转数
4.5 停止发动机
© Copyright 2016 ABB. All rights reserved.

目录页2
5 保养
5.1 维保的前言
September 2016
5.2 在运行过程中清洗压缩机
5.3 在使用中清洗涡轮机
5.4 机械清洁组件
6 故障排除
6.1 起动时故障
6.2 涡轮增压器的喘振
6.3 运行时出现故障
6.4 停止时发生故障
6.5 测速系统
7 拆卸与安装
7.1 运输
7.2 涡轮增压器的重量
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7.3 拆卸涡轮增压器
7.4 安装涡轮增压器
8 拆卸和装配
8.1 介绍
8.2 装配组件重量
8.3 拆卸和安装涡轮增压器
8.4 轴向间隙 A 和径向间隙 B
8.5 径向间隙 N 与 R
8.6 拧紧扭矩列表
9 停机
9.1 关停涡轮增压器
10 封存涡轮增压器
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10.1 发动机停运最多 12 个月
10.2 发动机停止运行，超过 12 个月
11 处理涡轮增压器部件
12 备件
12.1 订购备件
12.2 带零件编号的涡轮增压器示图
12.3 带零件编号的转子总成示图

序言 1
手册的目的 1.1 页3
1 序言
September 2016
1.1
1.1 手册的目的
本操作手册属于带有同一 HT 号(01)的涡轮增压器，参见操作手册首页和涡
轮增压器机器铭牌。
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操作手册
本操作手册能帮助您熟悉 ABB 涡轮系统出品的涡轮增压器，并提供如何将

其用于预期目的的信息。
本操作手册说明了有关安全、适当及经济地运营涡轮增压器的重要条件。
本操作手册是对现有的职业安全和事故预防国家法规的补充与扩展说明。
目标群体
本操作手册面向对发动机及连接的涡轮增压器正常运营负责的工程师、机
械师以及服务人员。
操作手册的可用性
在使用涡轮增压器的地方，无论何时都应该备置一本《操作手册》以供使
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用。
所有操作涡轮增压器或在其上作业的人员，均必须阅读且理解本操作手
册。

序言 1
结构与性能 1.2 页4
1.2
1.2 结构与性能
September 2016
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1 抽气套管 / 消音滤器 8 气体出口法兰
2 压缩机外壳 9 喷嘴环
3 扩散器 10 涡轮机壳
4 轴承壳 11 涡轮侧的轴承凸缘
5 轴向止推轴承 12 压缩机侧的轴承凸缘
6 径向滑动轴承（只能在涡轮机侧看 13 压缩机叶轮
到）
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7 涡轮

序言 1
结构与性能 1.2 页5
工作原理
本涡轮增压器是一个涡轮机，由下列主要部件组成：
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¡ 涡轮
¡ 压缩机
这两个部分由同一个轴连接。
柴油机或燃气发动机的废气通过涡轮机壳（10）和喷嘴环（9）流向涡轮
（7）。
涡轮（7）利用废气中含有的能量来驱动压缩机叶轮（13）；凭借此动力，
压缩机抽进新鲜空气，并且把预压缩的空气压入发动机气缸。
废气从连接在排气法兰（8）上的废气排放管被排出。
发动机运转所需要的、并在涡轮增压器中被压缩的空气，通过抽气套管或
消音滤器（1）进入压缩机叶轮（13）。然后流经扩散器（3）后，通过压
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缩机外壳（2）上的出口离开涡轮增压器。
转子在位于压缩机和涡轮之间的轴承凸缘（11/12）之间的两个径向滑动轴
承（6）之间转动。轴向止推轴承（5）位于两个径向滑动轴承之间。
轴承与中央润滑油路连接，该油路由发动机的润滑油环路供应。出油口总
是位于轴承套（4）的最低点。
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序言 1
正当使用涡轮增压器 1.3 页6
1.3
1.3 正当使用涡轮增压器
September 2016
这个由 ABB Turbo Systems 提供的涡轮增压器是为柴油发动机研制的，
用途是产生发动机运转所需要的空气量和压力。
至于发动机的指定用途，发动机制造商已经向 ABB 提供了信息，由此确
警示定了涡轮增压器铭牌上标注的运行极限值（例如转数、温度、置换时间/
更换间隔等）。
在使用燃气发动机时，注意不得将发动机安装在有潜在爆炸危险的环
境中，同时应采取相应措施，确保整个机房达到不受爆炸危害的安全
等级。
任何其它用途均被视为特殊应用，必须事先与 ABB Turbo Systems 协
商。制造商对其它用途的应用不承担责任。如果用于其它目的，ABB
Turbo Systems 拒绝承担一切担保责任。
技术状态此涡轮增压器是依据当前的技术和公认的安全规程而制造的，操作安全可
靠。
如果涡轮增压器的操作和维护不当，可能会给操作员或者第三方的身体
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甚或生命带来危险。另外，不适当的使用可能损害机器。
u 仅可由经过培训的专业人员操作此机器。
警告
正确应用涡轮增压器也包括遵守制造商规定的安装、拆卸、操作、保养和
维修条件。垃圾处理必须遵循当地政府的规定。
正常状态只能在技术状态良好、并按照规定用途和发动机制造商的手册进行安装，
遵守本操作手册的情况下才可以操作和使用本涡轮增压器。
u 影响安全的故障应立即排除。
若未经授权而对涡轮增压器进行改造，制造商不为此行为所造成的损害承
担责任。
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序言 1
新涡轮增压器和备件的存放 1.4 页7
1.4
1.4 新涡轮增压器和备件的存放
September 2016
新的涡轮增压器和备件存放至 6 个月
在未采取额外防锈措施的情况下，由 ABB Turbo Systems 供应的新涡轮增

压器和备件自发货之日起，可在封闭的包装内存放 6 个月（在包装上通过
VCI 标签标记）。
Volatile Corrosion Inhibitor（VCI 防锈物料）
适合存放的地点只能为湿度仅为大气湿度 40…70% 且不会形成冷凝水的干

燥房间。
新的涡轮增压器和备件存放长于 6 个月(VCI)
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使用 VCI 时的健康保护
根据相关危险品条例，VCI 产品为非危险产品。虽说如此，在接触 VCI
产品时必须注意下列事项：
警告
u 确保房间通风良好。
u 使用 VCI 时不得进食、饮水或在工作区域放置食品。
u 佩戴防护手套。
u 使用 VCI 后须清洗双手和面部。
u 进一步信息参见 www.branopac.com。
佩戴安全手套防止化学危害。
每 6 个月须进行下列防锈处理:
u 打开包装。
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u 除去旧的 VCI 防锈物料，换上新的同一型号的 VCI 防锈物料。新 VCI

防锈物料可在 www.branopac.com 订购。
u 旧 VCI 防锈物料必须符合环保与专业要求以及当地现行法规进行回收处
理。
u 封闭包装。外包装封闭越好，保护性能越佳。

序言 1
新涡轮增压器和备件的存放 1.4 页8
备用涡轮增压器和备件的长时间存放
ABB Turbo Systems 可根据客户要求，对涡轮增压器和转子总成进行长时
September 2016
间存放的准备。外包装将装有一个湿度测量和显示仪表（见图）。
每 6 个月必须执行下列措施:
u 从观察窗中检查湿度显示计（02）。在木箱上有一个开孔（01），用来
进行检查。如果显示区的 70% 已被染色，则表示已超出了允许的最大
空气湿度。这种情况下必须通过 ABB Turbocharging 服务站的专业人员
进行检查并重新包装涡轮增压器和转子。
u 检查包装是否损坏。如果包装损坏，则必须由 ABB Turbocharging 服务
站检查涡轮增压器或转子总成，并重新封装。
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每 3 年必须通过 ABB Turbocharging 服务站进行下列处理：
¡ 检查各组件情况
¡ 更换干燥剂
¡ 重新封装部件。
备件运行就绪
如果湿度显示仪表 (02) 的 70% 区域已染色且包装未损坏时，则可以无
需通过 ABB Turbocharging 服务站的事先检查而运行备用涡轮增压器或
警示
备用转子总成。
拆开备用涡轮增压器或备件包装
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拆开材料的 VCI 包装之后，将不再有防腐蚀保护。
为避免形成冷凝水，拆卸包装时必须使包装内容的温度与外界环境温度相
同。

序言 1
需要注意的提示 1.5 页9
1.5
1.5 需要注意的提示
September 2016
组织措施
除了本手册之外，也应遵守各国有关事故预防和环境保护的一般条例和法
律规定。
这一点也适用于准备与穿戴人身防护装备。
应根据本手册定期检查涡轮增压器操作和使用人员的安全意识和危险意
识。
警示
u 在涉及改变安全性或有类似的运行情况下，必须立即通过关停发动机来
关闭涡轮增压器。并立即向负责人或部门报告故障。
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对涡轮增压器的改造、扩充和改装会产生安全隐患，要获得 ABB Turbo

Systems Ltd 的事先批准方可实施。
警示
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序言 1
需要注意的提示 1.5 页 10
原装零件和安全
原配零件和附件是专为 ABB 涡轮系统提供的涡轮增压器而设计的。
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使用原装零件
使用非原厂配件运行涡轮增压器会损害涡轮增压器的安全，造成严重财
产损失和人员受伤。
警告
u 仅使用 ABB 涡轮系统出品的原装零件。
针对因使用非原装零件及相应附件而造成的损坏，ABB 涡轮系统概不负
责。
人员资格
只允许经过培训和授权的人员在本涡轮增压器进行操作和服务。要求具备
机械方面的基础知识。
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序言 1
需要注意的提示 1.5 页 11
设计类型
本文献适用于涡轮增压器的不同设计类型。可能有某些部分或部件的描述
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说明不适用于某些特定的涡轮增压器型号。
对于有关型号方面的问题，ABB Turbocharging 服务站乐意为您提供帮助

(参见信息 www.abb.com/turbocharging)。
图示的精度
本文献中的图示均为一般性图解，其目的是为了便于理解。因此可能在细
节上存在差异。
注册商标
本文件中使用了外部公司的商标。这些商标 ® 以标记。

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序言 1
符号和定义 1.6 页 12
1.6
1.6 符号和定义
September 2016
本文献中使用以下符号：
w 前提
u 工作步骤
¡ 列举项，第一级
－列举项，第二级
[➙ ] 参阅页码
注意事项的含义
提示
注意事项中包含了方便使用本产品工作的提示。
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警示
强制性标志的含义
强制性标志表示作业时必须穿戴的保护装备。强制性标志在安全一章中进
行了描述，必须遵守此类要求。
小心/警告的含义
有关注意事项和警示在“安全”一章有说明。
ABB 涡轮系统
在本文献中，ABB 涡轮系统有限公司简称 ABB 涡轮系统。

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ABB Turbo Systems 的特约服务站
特约服务站在本文件中被称作 ABB Turbocharging 服务站。该服务部门受

到 ABB 涡轮系统的定期审核和认证。参见章节联系方式 [➙ 15]。

序言 1
涡轮增压器铭牌 1.7 页 13
1.7
1.7 涡轮增压器铭牌
September 2016
运行限制
01 在发动机超负荷（110％）时涡轮增压器的运行极限值。
除非与发动机制造商另有约定，否则仅适用于试验运行。
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02 运行过程中涡轮增压器的运行限制
涡轮增压器部件的建议检
03 滑动轴承的检查周期为 1000 小时
查周期和更换周期
04 压气机的更换间隔为 1000 小时
05 涡轮的更换间隔为 1000 小时
其他数据
06 客户部件编号
07 特种型号名称
08 涡轮增压器的重量，单位为 kg
09 涡轮增压器型号
10 系列号
11 涡轮增压器的制造年份
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序言 1
涡轮增压器铭牌 1.7 页 14
1.7.1 关于铭牌的说明
September 2016
建议的更换间隔以及相应的运行限制均与发动机制造商共同制定。此信息
适用于各系统。
若运行时超出给定数值 nBmax、tBmax，则会大大缩短建议的更换间隔。我们建议在
这种情况下与最近的 ABB Turbocharging 服务站取得联系。
nMmax , tMmax 一般来说只适用于在发动机测试台上进行的超负荷（110%）测试时
使用。这些极限值有时也允许用于特殊用途。不允许使用高于 nMmax 和 tMmax 的值
运行。
不遵守建议的更换间隔会提高部件意外损坏的风险。
1.7.2 铭牌的位置
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在涡轮增压器轴承壳的左右两侧各有一个铭牌（01）。
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序言 1
联系方式 1.8 页 15
1.8
1.8 联系方式
September 2016
联系方式
可在线查看 ABB 涡轮系统有限公司的官方服务部门联系方式。
u 请扫描二维码调用我们的网页。
ABB Turbo Systems Ltd

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
www.abb.com/turbocharging
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安全 2
介绍 2.1 页 17
2 安全
September 2016
2.1
2.1 介绍
ABB 涡轮系统有限公司制造的涡轮增压器是最先进的涡轮增压器，该设备
符合制造时的健康与安全标准。这可确保涡轮增压器的安全运行。不过，
在其操作过程中以及在涡轮增压器上工作时，仍可能存在一些风险：
¡ 由涡轮增压器本身或其配件带来的风险。
¡ 由所使用的运行设备、运行及辅助材料带来的风险。
¡ 由于未遵守安全说明而造成的后果。
¡ 由于维护与检查工作的不足和不当而引发的后果。
运营商负责规定涡轮增压器的使用权限以及制定规范其工作人员安全操作
涡轮增压器的组织性措施。
在涡轮增压器上进行所有工作时，都必须遵守本章内包含的所有指示，以
便能安全无误地操作涡轮增压器。
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同时也要遵守本手册中每个章节中特别标名的其他安全提示（参见“安全提
示的定义”一章）。
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安全 2
CE 认证 2.2 页 18
2.2
2.2 CE 认证
September 2016
信息
ABB 涡轮增压器符合机械设备标准 2006/42/EG，并根据条款 2g 为非完成

机器。
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Revision F

安全 2
强制性标志的含义 2.3 页 19
2.3
2.3 强制性标志的含义
必须始终穿戴
September 2016
防护服装安全鞋可防止机械损伤和跌
倒危险
根据作业类型必须佩戴
护目镜封闭式护目镜
防护手套防护面具，防止
－机械危险 - 灰尘
－化学品危害 - 气体
－高温危害
安全头盔听力保护
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Revision F

安全 2
安全指令的含义 2.4 页 20
2.4
2.4 安全指令的含义
September 2016
本《操作手册》中使用下列符号和术语用于安全提示以及对可能出现的危
险进行提示：
警告的含义
如未遵守或未严格遵守带有本符号的工作与操作指示和警告，则可能造
成严重的人身损伤甚至死亡事故。
警告
u 务必时刻遵守警告说明。
注意的定义
如未遵守或未严格遵守带有本符号小心的工作与操作指示，则可能会对
机器或者其它财产造成严重损害。
小心
u 务必时刻遵守警告说明。
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Revision F

安全 2
涡轮增压器上的警告牌 2.5 页 21
2.5
2.5 涡轮增压器上的警告牌
September 2016
在涡轮增压器的以下部位上安装了警示牌：
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如果在规定的位置没有警示牌或不可读，则必须按如下操作：
u 在 ABB Turbocharging 订购新警示牌

u 拆除不可读警示牌
u 将规定的警示牌位置清洁并去除油污
u 安装新警示牌。
未绝缘的涡轮增压器
对于以未绝缘方式发货给发动机制造商的涡轮增压器，必须将警告牌后补
安置在绝缘上。此项工作属于发动机制造商的责任范围。
Revision F

安全 2
安全操作和维保 2.6 页 22
2.6
2.6 安全操作和维保
September 2016
这里所列的说明是为了确保人身的安全，并与本章中“运行与维护时的危险”
章节中的提示一道用于保证涡轮增压器的安全运转。
职业安全与工作场所的安全
坠落危险
在涡轮增压器上作业时有跌落危险。
警告 u 禁止登攀涡轮增压器或其附属机器部件，禁止将其作为登高辅助件使
用。
u 如果工作高度高于身高，应使用适合的登高辅助件和工作台。
u 务必遵守一般性事故预防规定。
u 仅可在稳定的身体状况和精神状态下操作涡轮增压器。
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u 执行工作时仅可使用适合的工具和完好无损的仪器及工作材料。
u 电动工具必须完好无误地接地，连接电缆不能有破损。
u 保持工作区域清洁，整理零散物体，清除地面障碍物。
u 保持地面、设备和涡轮增压器的清洁。
u 准备好油污吸附材料，准备或者放好集油盘。
u 排除泄漏。
u 准备好防火保护材料和灭火材料。
涡轮增压器附近的焊接作业
u 在涡轮增压器附近进行焊接工作时，请始终遮住消音器以保护滤垫不被
损坏。
u 易燃物品和物质应远离飞溅火花的可及范围。
u 必须盖上涡轮增压器上的所有接口，以防止异物进入涡轮增压器。
Revision F
u 穿戴个人防护装备（PPE）。

安全 2
September 2016
试车时和运行期间的安全
ABB Turbo Systems 供货的 TPS44-F 涡轮机外壳绝缘也作为爆裂保护

如果拆除 ABB Turbo Systems 供货的 TPS44-F 的涡轮机外壳绝缘，可
能造成人身严重伤害或者导致死亡事故。在 ABB Turbo Systems 供货的
警告
TPS44-F 的涡轮机外壳绝缘中内带有爆裂保护。
对于未向 ABB Turbo Systems 订购外壳绝缘的 TPS44-F 型号涡轮机另
外安装有单独的爆裂保护。
u 配有 ABB Turbo Systems 绝缘的 TPS44-F 涡轮增压器严禁在没有

ABB Turbo Systems 绝缘的情况下运行。
u 严禁在没有爆裂保护的情况下运行涡轮增压器。如果没有安装 ABB
Turbo Systems 绝缘，则必须在安装单独的爆裂保护(57200) 后才能
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运行（参见带零件编号的涡轮增压器示图 [➙ 126]）。
u 在开始工作前，对工作区进行目测检查。
u 清除障碍物和散放物件。
u 开始试车前，检查涡轮增压器的所有进出管道是否有损伤或泄漏。
u 严禁任何可能影响涡轮增压器工作安全的活动。
u 每运行 12 个小时左右或至少每天一次对涡轮增压器进行外部损伤和故
障检查。
u 操作性能如有任何故障或变化，应立即向负责部门报告。
u 发生故障时，应立即关闭涡轮增压器，并避免其被意外的或未经许可的
使用。
u 启动辅助能源（液压、气动、电力、水）时，必须注意由于该类能源的
接通可能发生的危险。
Revision F
清洁时的安全
如果使用清洁剂或溶剂进行清洗，必须遵守相关安全数据表中的说明以及
“因运行材料和用品而导致的伤害”一节中的安全提示。
u 遵守清洁剂或溶剂的安全数据表说明。

安全 2
u 穿戴符合安全数据表的个人防护装备（PPE）。
u 清洁工作开始前、结束后都应检查电缆是否磨损及损坏。
September 2016
拆卸、装配、保养和修理时的安全
u 遵守设置、服务以及维修工作和检查间隔的规定。
u 开始任何服务或修理工作前应通知所有操作人员。
u 从涡轮增压器上取走任何罩盖或移走任何安全设备前，必须关闭发动机
并等待直到涡轮增压器静止。
u 请确保已中断供油，特别是外部供油。
u 在所有部件均正确地安装好后，才能启动发动机。
涡轮增压器上的机械操作
涡轮增压器上的部件可能损伤或毁坏。
小心 u 仅限执行本手册中所描述的工作。
u 仅可执行经过培训的工作。
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停止运行或准备封存时的安全
u 保护转子以防止转动。仅烟道抽风就可能使转子转动。
u 封存前清洁涡轮增压器。
u 遵守清洁剂和防腐剂的安全数据表说明。
Revision F

安全 2
运行和维保期间的危害 2.7 页 25
2.7
2.7 运行和维保期间的危害
September 2016
运行期间的机械伤害
正常运行时，如果涡轮增压器安装正确且符合规定的话，就不会发生来自
涡轮增压器本身的机械危险。
人员受伤危险
接触转动的部件可能导致严重的人员受伤。在没有消音器或吸气支管的
情况下，绝不允许使用涡轮增压器。发动机处于静止状态时，转子会由
警告
于抽风自行旋转。
u 涡轮增压器的运行操作须符合相应规定。
u 进行维护工作时，须确保转子不会意外转动。
在涡轮增压器上工作时的机械伤害
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维护工作时，可能因为部件处理的不当、无视工作安全规定、粗心或欠缺
的技术培训而带来各种风险。
机械危险
由具有危险性的和不当的工作方式引发的机械事故会造成严重的人身伤
害，甚至导致死亡。
警告
u 遵守关于工作安全的一般性规则。
u 保证工作场所的安全。
u 仅限执行本文档中所描述的工作。
u 仅可执行经过培训的工作。
Revision F

安全 2
噪音危害
涡轮增压器运行过程中的形成的噪音受到设备安装及运行条件的影响。噪
September 2016
音级高于 85dB(A)时具有伤害性。
因噪音导致的危险
噪音会造成听力损伤、健康和精神状态恶化，并且注意力不集中以及情
绪不稳定。
警告
u 发动机运行时请始终佩戴听力保护用具。
u 噪音电平高于 85 dB(A) 时务必佩戴耳塞。
佩戴听力保护用具.
由热表面和物体造成的伤害
涡轮增压器及其附属部件的表面以及运行材料（润滑油）在运行过程中将
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会发热。其表面温度取决于现有的隔热功效。温度上升到可能会烫伤的程
度。
烫伤危险
与炙热表面或炙热工作材料的接触可能导致严重烧伤。
警告 u 禁止触摸炙热表面，注意涡轮增压器上的警告牌。
u 应穿戴防高温的防护手套和防护服装。
u 开始作业前应首先冷却涡轮增压器。
佩戴安全手套可防止高温伤害。
Revision F

安全 2
无隔热涡轮增压器上的炙热表面
无隔热涡轮增压器可能会造成后果严重的人身损伤（烧伤）。
September 2016
警告根据发动机制造商的订货要求，ABB Turbo Systems 的涡轮增压器在交

货时可能无隔热罩。在这种情况下，发动机制造商负责对涡轮增压器进
行合理正确的绝缘，尤其是对炙热表面接触的防护。
u 必须严格遵守发动机制造商关于涡轮增压器高温表面的说明和规定。
因运行材料和辅助用品而导致的伤害
运行材料和辅助品是指用于涡轮增压器运行或用于维保工作的物品。机
油、油脂、冷却剂、清洁剂和溶剂以及酸都可能是危险物质。运行材料
和用品可能为可燃和易燃性。
处理运行材料及辅助材料
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摄入或吸入运行材料及辅助材料的有毒烟雾或与其接触都可能造成健康
损害。
警告
u 避免皮肤接触或吸入。
u 确保通风良好。
u 遵守运行材料和辅助用品的安全数据表说明。
u 遵守当地法律。
佩戴封闭式护目镜。
佩戴防护面具防止有毒气体。
Revision F

安全 2
火灾或爆炸危险
可燃和易燃运行材料和用品可能导致火灾或产生导致爆炸的蒸汽。
September 2016
警告 u 遵守运行材料和辅助用品的安全数据表说明。
u 遵守当地法律。
u 进行清洁工作时禁止明火或点火源。
u 在室外或在通风充足的情况下进行清洁工作。
破坏环境的危险
工作材料及辅助材料直接排放到大气中或因处理不当而引起的土壤和水
域污染均可能造成环境损害。
小心
u 使用工作材料及辅助材料时务必谨慎操作。
u 遵守运行材料和辅助材料容器上的所有使用说明、材料安全数据表以及
危险信息。
u 穿戴适当的防护服。
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u 避免皮肤接触或吸入。
u 确保工作空间的适当通风。
u 使用后将容器密封并拿走。
u 安全地收集使用后的运行材料及辅助材料，分别存放在相应容器内并根
据法律规定采取正确而且环保的方式进行处理。
u 若有泄漏或溢出发生，则立即使用相应的吸附材料吸除，并根据法律规
定采取正确而且环保的方式进行处理。
Revision F

安全 2
因操作隔热材料而导致的危害
September 2016
隔热材料带来的危险
隔热材料的粉尘和纤维可能给健康带来伤害或干扰。不合适且可燃的隔
热材料将会带来火灾危险。
警告
u 仅使用适当的、不可燃的隔热材料。
u 确保工作区域通风良好。
u 避免扬起灰尘。
u 使用避免扬尘的工具和工作方法。
u 只在工作区域移去包装。
u 去除旧绝热材料时须特别小心谨慎。
u 按照当地有效的法律，专业和无害化地处理隔热材料。
佩戴防护面具防止灰尘。
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u 仅使用适当的、不可燃的隔热材料。
u 确保工作区域通风良好。
u 穿戴适宜的防护服装（护目镜、呼吸系统防护）。
u 避免扬起灰尘。
u 使用避免扬尘的工具和工作方法。
u 只在工作区域移去包装。
u 去除旧绝热材料时须特别小心谨慎。
u 按照当地有效的法律，专业和无害化地处理隔热材料。
Revision F

安全 2
因电子部件而导致的伤害
September 2016
因电子部件而导致的危险
电气部件运行时使用的电压可以造成人员险。
警告 u 所有在电气部件上执行的工作，以及所有使用电气部件所执行的工作
必须由经过专门培训的专业人员进行。
u 必循遵守相应国家地区的要求与规定。
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Revision F

安全 2
燃气发动机的爆燃 2.8 页 31
2.8
2.8 燃气发动机的爆燃
September 2016
ABB 涡轮增压器能够承受瞬时压力增量为 12 bar 的爆燃情况。
ABB 涡轮系统有限公司建议发生爆燃事件后对涡轮增压器下列方面进行检
查：
¡ 涡轮壳体和压气机壳与轴承壳的相对位置
¡ 轴承壳的移位是否与支架成比例
¡ 外壳是否损坏
若发现外观异常，或有剧烈燃爆现象，则建议在下一次启动机器之前对涡
轮增压器的轴承进行检查。这些检查和评估工作必须由 ABB 涡轮增压系统
服务部门来完成。
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Revision F

安全 2
定期检查压力容器 2.9 页 32
2.9
2.9 定期检查压力容器
September 2016
ABB 涡轮系统所使用的压力容器，如在干洗、湿洗中使用的，是所谓的“简
单压力容器”。
¡ 必须遵守当地适用的、有关压力容器定期检查的法律法规。
¡ 运营公司应对压力容器的安全操作负责。
因压力容器导致的危险
运营公司必须确保压力容器处于适当的工作状态并对其进行监控。必须
正确执行必要的修理服务或维保工作，且必须采取必须的安全措施。
警告
u 在出现故障的情况下不能操作压力设备。
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Revision F

安全 2
起重负荷 2.10 页 33
2.10
2.10 起重负荷
September 2016
悬挂负荷
未按规定固定的负荷可能会导致带来人员受伤或死亡事故。
警告 u 仅可将负载固定在完好且具有足够负载能力的起重设备上。
u 注意将重物正确地挂在吊钩上。
u 任何人员不得驻留在吊载下方。
佩戴安全手套防止机械损伤。
佩戴安全帽。
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如果有两个或以上的悬吊点，则固定角度不允许超过 45°。这可以防止因斜
拉而导致负荷过度。
u 按各行动步骤中的描述固定涡轮增压器的部件。
u 在缠绑固定之前，请使涡轮增压器的部件冷却（最高 80 °C）。
u 如果有尖锐的边缘，则请使用合适的边缘保护件进行保护。
Revision F
u 必须完全拧紧装配工具，且在使用过程中不得拧开。
u 将装配装置仅用于描述的应用环境。
u 放置拆下的涡轮增压器部件时应保证其不会翻倒。

投入使用 3
机油供应 3.1 页 35
3 投入使用
September 2016
3.1
3.1 机油供应
一个在任何运行状态下都正常工作的、认真设计的机油供应系统是涡轮增
压器顺利运行的重要前提。
一般来说，涡轮增压器的润滑使用的是发动机机油循环中的润滑油。如果
使用分离式的润滑系统，则应该另外添加一个紧急润滑机构。
u 请遵守发动机制造商关于选择润滑油和换油周期的规定。
油过滤
为了避免轴承部件磨损发生的危险，无论涡轮技术指标如何以及使用什
么样的轴承，都必须滤除润滑油中的较大杂质。
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小心
涡轮增压器标准的润滑油过滤细度规定为 34 微米。就是说，尺度大于
0.034 毫米的杂质必须从润滑油中以 > 99% 的滤除度过滤出去。
u 如果发动机滤器不能足够滤清润滑油，应该使用辅助过滤器。
u 如果在冷起动时或者由于辅助滤器内污物沉淀而使流动阻力超过
0.5 巴，此时必须有一个旁通相应，从而绕过滤器，保证涡轮增压器得
到足够的润滑油供应。
u 在第一次投入使用之前，请检查滤清器的清洁程度。
同时请注意发动机生产商对滤器细度和滤除度的有关规定。
警示
Revision F

投入使用 3
机油供应 3.1 页 36
润滑剂
September 2016
可以使用所有的发动机润滑油。
警示
机油的进油粘度和温度
进油温度不得超过 105 °C 。从下文中可以获悉允许的进油粘度和进油温

度。
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1) 运动粘度 (mm2/s = cSt)
2) 进油温度(°C)
A 允许范围
Revision F
低于最低进油温度
油的粘度过高以及由此引发的轴承内油量不足会对机器或者其它财产造
成严重损害。
小心
u 发动机启动时进油温度不得低于 30 ºC。
u 进油温度不得低于 10 °C。

投入使用 3
机油供应 3.1 页 37
油压
严格遵守涡轮增压器油压以保证其无故障运行。
September 2016
运行时的状态涡轮增压器前的油压
[巴]
正常运行 2.0 … 4.5
发动机起动：冷油，允许最多 15 分钟 ≤ 8.0
发动机空转 ≥ 0.2
预润滑和后润滑（发动机停止运行） ≤ 1.0
预润滑
如果在电机启动时涡轮增压器没有润滑油的话，则可能造成下列机器或
其它财产损失。
小心
u 每次起动发动机前都要开动润滑。
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Revision F

投入使用 3
机油供应 3.1 页 38
进油口的润滑油温
September 2016
机器损坏
如果进油口的油温超出允许范围，则可能会造成机器损坏。
小心 u 按照下面表格中的数据设定进油口的油温。
运行状态进油口油温
T 进油口
允许 30 … 105 °C
短时间允许（<1 小时）→ 警报 > 105 °C
不允许 → 发动机停机 > 110 °C
不允许 → 发动机不起动（起动前：油预热） < 30 °C
出油口的润滑油温
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出油口油温主要取决于：
¡ 进油口的润滑油温和压力
¡ 发动机负荷和涡轮增压器转速
¡ 废气温度
出油口的最高允许油温在下面的表中列出。必须所给出的温度值视为涡轮
增压器运行时的报警值，要根据现行规定对其进行监控。
运行状态出油口油温
T 出油口
允许 ≤ 160 °C
短时间允许 → 警报 > 160 °C
不允许 → 发动机停机 > 180 °C
允许 ≤ T 进油口 + 55 K
短时间允许 → 警报 > T 进油口 + 55 K
Revision F
如果涡轮增压器长时间在允许范围以外运行，ABB Turbo Systems 建议通

过 ABB 涡轮增压器服务站对涡轮增压器进行检查。

投入使用 3
检验流程 3.2 页 39
3.2
3.2 检验流程
September 2016
检验工作包括预防性目检、投入运行之前及过程中的监控和测量工作。通
过检验工作可查出涡轮增压器上的变化。由此能够避免损坏机器。
3.2.1 投入使用前的检查
监控设备 u 检查性能。
滤垫 u 检查有否损坏。
润滑系统 u 在投入使用前检查机油滤器是否干净。
脏污油
油中的脏污成分和固体颗粒可能会对机器或其它财产造成严重损害。
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小心 u 在首次投入运行之前和每次服务工作之后，均须使用干净暖油对整个
润滑系统彻底冲刷。
u 在发动机试机时，每次服务工作之后必须使用试机过滤器。
u 检查输油管内的油压。
预润滑
如果在电机启动时涡轮增压器没有润滑油的话，则可能造成下列机器或
其它财产损失。
小心
u 每次起动发动机前都要开动润滑。
涡轮增压器上的警告牌 u 检查警告牌是否存在及是否可读。
u 检查是否取下了保护膜。
Revision F

投入使用 3
检验流程 3.2 页 40
3.2.2 投入运行后的检查（发动机空转）
September 2016
润滑系统
u 检查供油管路中的油压
u 检查进油口温度。
供油一章中列出了规定的允许数值。
燃气、空气和油的管路
u 发动机起动后，请检查所有的燃气、空气和油的管路是否有泄漏。
3.2.3 起动发动机时检查
u 在不同的发动机功率下测量转速、油压、增压压力
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u 在涡轮前和涡轮后测量废气温度
u 在压气机前和后测量空气温度。
必须将测得的值与验收记录中的值进行比较；在此必须考虑不同的运行条
件。
安装涡轮增压器时所使用的滑润剂和油膏会变稀或者蒸发，也可能在投
入运行之后的头几个小时内作为一种油质液体而泄漏。如果这段时间之
后油质液体继续泄漏，则必须作为油泄漏查找原因。此过程的第一个步
骤是检查涡轮增压器机油进油管的密封情况。如果发现问题，请与 ABB
警示
Turbocharging 服务站联系。
3.2.4 运行 100 小时后的检查

Revision F
运行首次达到 100 小时之后请清洁或者更换润滑油滤器。

投入使用 3
停止运行后的调试 3.3 页 41
3.3
3.3 停止运行后的调试
September 2016
如有 u 在气体入口前，在气体出口后去掉压气机壳出口和增压空气管之间的盖
板（备用法兰）。
u 检查、清洁/除去涡轮机之前和之后的废气管上的燃烧残渣、异物或者水
垢。
u 检查、清洁/除去进气管或者消音器上的异物。
u 起动到涡轮增压器的发动机侧润滑油循环。
u 按照 “投入使用一章” 的 “投入使用前的检查工作” 一节的说明准备好涡
轮增压器。
u 涡轮增压器的投入使用。
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Revision F

运行 4
噪音排放 4.1 页 43
4 运行
September 2016
4.1
4.1 噪音排放
因噪音导致的危险
噪音会造成听力损伤、健康和精神状态恶化，并且注意力不集中以及情
绪不稳定。
警告
u 发动机运行时请始终佩戴听力保护用具。
u 噪音电平高于 85 dB(A) 时务必佩戴耳塞。
佩戴听力保护用具.
噪音排放声级（A 级评定）是在距离涡轮增压器 1 米的位置测量得到的。
噪音排放声级的最高值 1)在消音器范围内以及在整个转速范围内最高可以达
到 105dB(A) 。
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涡轮增压器必须满足下列条件才能确保这一极限值：
¡ 空气进气系统已安装
¡ 所有按照系列标准所要求的消音措施均已经安装 2)
¡ 出气口上的波纹管已经由发动机制造商完好无误地进行了隔音处理。发
动机制造商也负责增压空气管道/清洗空气管道的隔音以及增压空气冷却
器的隔音。
1) 指令 2006/42/EC，1.7.4.2 / u / 条款 5 + 7：
A 级评定的噪音排放声级
Revision F
2) 在没有隔音保护的情况下，发动机制造商必须提供类似的听觉保护措施

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噪音排放 4.1 页 44
波纹管降噪隔音的建议
September 2016
01 压气机壳 04 隔音囊
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02 波纹管 05 隔音垫（至少 15mm）
03 增压空气槽/净化空气槽 06 金属板盖
Revision F

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服务工作 4.2 页 45
4.2
4.2 服务工作
September 2016
运行过程中的服务工作包括目视检查、监控、测量和检验以及功能检查。
如此即可及时发现涡轮增压器上的变化并予以排除。以确保涡轮增压器的
正常运行。
维护间隔
对涡轮增压器不进行维护或太迟的维护都可能造成导致过度脏污、磨损
以及运行中断。
小心
u 务必按照规定的时间间隔进行维护工作。
缩短的服务间隔
即使按正常周期保养，不正常的负荷冲击，如每天多次开机停机、恶劣
的环境条件、燃料质量不佳或强烈的设备震动等因素也会导致机器提前
小心
损坏。
u 应该和 ABB 涡轮系统商定缩短维护周期。
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5 年后的维修服务检查
为避免机器因老化及停机造成损坏，建议最后一次保养服务完毕最多 5
年之后由 ABB 涡轮增压器服务部门进行一次检修。
警示
4.2.1 每 25 … 50 小时进行的维修工作
u 目视检查空气、废气、水和油是否有泄露。
u 采集运行数据并填写到发动机日志中。
u 如果数值有偏差，要查明原因。
Revision F
原因不明的运行情况变化
会影响运行甚至造成运行故障。
小心 u 必须由 ABB Turbocharging 服务站查明未知原因。

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服务工作 4.2 页 46
September 2016
4.2.2 根据发动机制造商的说明进行服务工作
机油滤器 u 在发动机停止时清洁或者更换涡轮增压器进油管道内的油滤器。
4.2.3 根据铭牌上的说明需要进行的维护工作
（一般来说在 8000 - 12000 个运行小时后）
转子和轴承零件必须由 ABB Turbocharging 服务站进行检查和评估。作为

准备可以进行以下工作。
u 按照“安装与拆卸”一章的说明拆卸转子总成。
u 测量间隙。
u 清洗涡轮壳体总成和压气壳体总成，并检查有无任何裂缝和腐蚀情况出
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现。
u 清洁轴承箱，用吹气的方法通开油孔。
u 清洁喷嘴环并且检查有无裂纹和腐蚀。
Revision F

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服务工作 4.2 页 47
4.2.4 发动机日志中的条目
September 2016
通过对发动机系统的监控可得出有关涡轮增压器性能好坏的结论。
必须在发动机制造商的发动机运行日志里定期记录下列运行数据和测量值:
¡ 发动机的功率和速度
¡ 进气温度
¡ 涡轮前后的废气温度
¡ 增压空气压力
¡ 增压空气冷却器中的压力损失
¡ 润滑油压力、润滑油温度
如有 ¡ 压气机后和增压空气冷却器后的空气温度
¡ 涡轮增压器的转速
¡ 空气滤清器里的压降
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Revision F

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预计的更换周期 4.3 页 48
4.3
4.3 预计的更换周期
September 2016
转动的部件
所建议的压缩机叶轮与涡轮叶片的更换周期是根据运行条件和转动部件的
安全方案（SIKO）计算得出的。周期数据写在涡轮增压器的铭牌上。
非转动部件
根据设备特有的运行条件区分下列两种情况：
¡ 轴承零件更换周期和
¡ 带炙热气体压力的非转动部件的更换周期。
起决定性意义的是那些在极端情况下可能大幅缩短此类部件更换周期的各
种相关参数。
在根据规定进行周期保养工作时，要检查每个部件的磨损情况，必要时予
以更换。
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预计的更换周期 [小时]
气 / MDO HFO
涡轮机壳 25000 … 50000 25000 … 50000
喷嘴环 50000 10000 … 25000
气体出口法兰 50000 35000 … 50000
隔板 50000 35000 … 50000
转子部件见铭牌上的数据
轴承零件 12000 … 24000 12000 … 24000
其它外壳 50000 50000
GAS = 天然气 MDO = 船用柴油 HFO = 重油
所列的数值为参考值,不是保证值（参见下面的影响因素章节）。
Revision F

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预计的更换周期 4.3 页 49
影响参数
所列的数值为参考值，不是保证值。下列影响可能造成实际值与参考值的
September 2016
较大偏差：
¡ 燃料质量和燃料加工
¡ 负荷性质（热负荷的变化，也包括开机/停机，紧急关机）
¡ 进气温度
¡ 清洗涡轮和压缩机的频繁程度与执行情况
¡ 涡轮增压器规格。
¡ 系统特定运行条件（运行点、燃烧质量、废气成份）
对于轴承零件
¡ 润滑油质量（润滑油的过滤、状态和监控）
¡ 负荷性质（转数、压力比、温度）
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¡ 转子不平度（脏污程度）。
Revision F

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测量转数 4.4 页 50
4.4
4.4 测量转数
September 2016
测速系统可持续监控涡轮增压器的速度。
不要将电缆用做攀爬辅助工具
猛力拉拽速度传感器的电缆会撕裂触点。
小心 u 不要使速度传感器的电缆承受拉力。
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86505(A) 转速传感器（电缆没有装入） 86526 F/I 互感器

Revision F
86505(B) 转速传感器（电缆已装入） 86528 转速计

86515(A) 连接 86505(A) 的电缆接线器 01 闷塞
86515(B) 连接 86505(B) 的电缆接线器 02 垫片

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测量转数 4.4 页 51
4.4.1 发动机带有多个涡轮增压器时的转速差异
September 2016
安装在一个发动机上的多个涡轮增压器的转速在正常运行中只有很小区
别。
相对速度极限 nBmax，涡轮增压器的最高速度和最低速度之间的差异不可超
过 3 %。
如果超过允许的差异范围，则必须执行以下步骤：
u 立即降低发动机功率，直到涡轮增压器转速不超过 Bmax 值的 70%。

u 如果无法停止发动机，可继续以降低的发动机功率或涡轮增压器转速驱
动发动机。
u 如果涡轮增压器持续喘振，则必须继续降低发动机功率。
u 测量进出涡轮增压器的空气管道和燃气管道内的温度，并将测量值与标
准值进行比较。
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如果可以暂时停止发动机：
u 检查空气管路、燃气管路和涡轮增压器并排除故障。
u 不管情况如何都建议联系附近的 ABB Turbocharging 服务站。
Revision F

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测量转数 4.4 页 52
4.4.2 更换转速传感器
September 2016
电缆插头发烫、转数传感器发烫
烫伤危险。运行时，电缆接线器和转速传感器的温度可能达到 100 ℃ 以
上。
警告
u 取下电缆插头和速度传感器时，请佩戴安全手套。
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u 将发动机功率降低到空转速度，然后使发动机停止运行。
u 关闭涡轮增压器的进油口。
u 将电缆接线器和转速传感器分开。
u 把损坏的转速传感器拧下来。
u 将新的转速传感器拧至止挡。
u 遵守扭矩。
零件编号 TPS44 TPS48 TPS52 TPS57 TPS61

Revision F
86505 15 Nm 15 Nm 15 Nm 15 Nm 15 Nm

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测量转数 4.4 页 53
转速传感器的密封
September 2016
转速传感器带有一个密封沿，安装时无需另外的垫片。
警示
u 将电缆连接器与转速传感器连接起来。
u 打开涡轮增压器的进油口。
4.4.3 测速系统故障
在排除故障一章中说明了测速系统故障的可能原因。
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Revision F

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停止发动机 4.5 页 54
4.5
4.5 停止发动机
September 2016
油冷却涡轮增压器情况下的发动机停止运行
必须通过仍然在循环中的润滑油将涡轮增压器的热量散掉。
小心 u 15 … 20 分钟后续润滑。
u 后续润滑时保证 0.5 … 1.0 巴油压。
水冷却涡轮增压器情况下的发动机停止运行
必须将涡轮增压器的热量散掉。
小心 u 在发动机停止后还要运行涡轮增压器的水冷却系统 15 … 20 分钟。
u 继续进行油润滑，直到转子静止。无需进行后续润滑，也不建议进
行。
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Revision F

保养 5
维保的前言 5.1 页 55
5 保养
September 2016
5.1
5.1 维保的前言
维护工作包括定期目测检查和清洁，以确保涡轮增压器的正确运行。
此处描述各维保点的下列区别：
¡ 运行过程中进行清洁：
– 压气机
– 涡轮和喷嘴环。
¡ 机械清洁各个组件：
– 过滤式消声器
– 壳体、扩压器、喷嘴环
– 芯座组件：压气机、涡轮
机械清洁过程中的损坏风险
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过度频繁地进行机械清洁可能会造成部件的损坏或腐蚀。
小心 u 如果运行中的清洁尚不足以满足热应力要求和发动机性能，则可进行
局部的机械清洁。
u 机械清洁，尤其是芯座组件处的机械清洁，在每个服务周期仅可进行
一次。
清洁方法
为能确保定期维修服务周期以及保持涡轮增压器的高效率，ABB Turbo
Systems 建议在运行中进行清洁。由此可将发动机的热应力保持最低，
警示
而燃料的燃烧效率则发挥最高。
u 污水和清洁剂必须以环保、专业以及符合当地现行法规的方式进行回收
处理。
Revision F

保养 5
在运行过程中清洗压缩机 5.2 页 56
5.2
5.2 在运行过程中清洗压缩机
September 2016
综述压气机侧（压气叶轮、叶轮罩壳和扩压器）的脏污程度取决于吸入空气的
纯净度。
如果吸入的空气中有盐、油雾或灰尘，则可能在气流通道中形成积淀。
脏污带来的后果：
¡ 影响压气机效率
¡ 废气温度升高
¡ 增大燃料消耗
¡ 增加转子失衡情况
在运行期间定期清洁压气机可避免或延缓污染严重程度。但这并不能取代
完全拆解涡轮增压器并对压气机进行机械式清洁的常规保养服务。
如果污垢很厚、很硬，则只能完全拆开压缩机进行手工清洗。清洗工作
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应由 ABB Turbocharging 服务站执行。
警示
清洗周期间隔清洁工作的间隔时间在很大程度上取决于运行条件。一般来说，应该每运
行 25 … 100 小时进行一次清洁工作。
如果规定的清洁间隔时间与发动机运行不匹配，请您与 ABB Turbo

Systems 联系。
Revision F

保养 5
清洁方法
压缩机运行时的清洁采用湿清洁法进行。本清洁方法经过了 ABB Turbo

September 2016
Systems Ltd 的检验和许可。
湿洗原理用过滤式消音器或者进气岐管里的喷射管在压气叶轮前喷射水，以此清洗
运行中的压气端。
在此过程中水并不是作为一种溶剂，但大量堆积的污垢却因为水滴的机械
影响而被清除。如果污垢形成的时间不太长，此方法是理想的。
清洗时的腐蚀与附垢
盐水与冷却水处理剂对涡轮增压器部件的损坏与影响。
小心 u 不能使用盐水，只许使用纯净水进行清洗。
决不能用水龙头将喷射管直接连接到水管或者更大的计量容器上。这会
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防止大量水毫无控制地进入涡轮增压器和发动机从而导致重大损坏。
小心
V 型发动机如果每个 V 型发动机带多个涡轮增压器，我们建议对压缩机采取并行清洁

方法。这样，清洁工作较快，同时减小涡轮增压器喘振。
串联增压必须确保对串联增压的涡轮增压器压缩机进行定期清洁工作，尤其是在低
性能范围的运行周期之后。
Revision F

保养 5
5.2.1 使用外部压力水箱（XC1）湿洗压缩机
September 2016
发动机生产商的许可本湿洗操作说明仅适用于纯水清洗，同时必须是发动机制造商所许可的清
洗方法。
使用外部安装的计量罐作为水供应源仅适用于在压气叶轮前的欠压方式
（不适用于：在压缩机前接通的吹风机或者两级压缩的压缩机高压
档）。
警示
带 XC1 的压缩机清洗时有关运行状态的前提条件
为了能够成功进行经过 ABB Turbo Systems 检验过并推荐的清洗，必须

满足下列前提条件：
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u 发动机负荷为 50 … 85 %
警示 u 按照下面使用 XC1 的湿洗操作说明启动清洗过程。
Revision F

保养 5
使用 XC1 的压缩机湿洗操作
September 2016
X 密封塞 D 压缩空气
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Y 阀门手柄 W 水
Z 箱
操作压力水箱 u 旋出密封塞 (X) 。

u 向水箱(Z)中注满纯净水。
u 将密封塞旋回位置。
u 把阀门手柄(Y) 推压到弹簧上并保持 10 至 15 秒钟，直至全部水量喷完
为止。
u 必须至少等待 10 分钟的稳定时间才可以重复清洗过程。
可以从增压器或者排气压力中看出，或者也可以从废气温度中看出清洗
是否成功。如果清洁不成功，则最多可以重复清洁 2 次。
如果三次尝试后清洁还是不成功，并且发动机操作值不令人满意，我们
警示推荐请一个授权的 ABB Turbocharging 服务站检查和清洁涡轮增压器。
Revision F
每台涡轮增压器压缩机的
产品发动机负载计量管的水的
清洗参数
容量喷入时间
[分米 3] t1 [秒]
TPS 50 … 85 % 0.4 10

保养 5
在使用中清洗涡轮机 5.3 页 60
5.3
5.3 在使用中清洗涡轮机
September 2016
在柴油发动机中燃油的燃烧，例如重油（HFO）会污染涡轮增压器的涡轮
部件。劣质燃料加上排气高温会导致特别坚硬的污垢沉积在喷嘴环上，尤
其是气体出口法兰上。
因此，ABB Turbo Systems 建议使用含较低的灰、硫、钠和钒的燃料。
脏污的后果：
¡ 涡轮机效率低
¡ 排气温度升高
¡ 涡轮增压器转速上升时，增压和点火压力上升
¡ 发动机功率减小。
¡ 发动机停止之后转子可能会停留在污垢沉积处。
工作经验表明，运行中定期清洁会延长维修期的间隔。在 4 冲程机器上可
以使用下述湿洗方法清除涡轮上的顽固污垢（例如使用 HFO 的情况）。
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运行中涡轮的定期清洗不能代替正常的服务工作，在正常的服务工作中要
完全拆卸涡轮增压器。
脏污严重的涡轮无法采用这种方式达到清洁目的。在这种情况下，必须由
ABB Turbocharging 特约服务站进行机械式清洁。
定期清洁
使用过程中经常清洁涡轮能够避免或者延迟严重的脏污。
警示
清洁间隔时间
清洁工作的间隔时间在很大程度上取决于运行条件。一般来说，应该每运
行 50 至 200 小时进行一次清洁工作。
Revision F

保养 5
清洗周期间隔
如果上述的清洁间隔时间与发动机运行不匹配，请您与 ABB Turbo
September 2016
Systems 联系。
警示
清洁方法
对涡轮部件在使用中的清洁工作要按照下述的湿洗清洁方法进行。这个方
法通过了 ABB Turbo Systems 的验证和许可。
选择清洁方法的关键在于涡轮机外壳的类型和涡轮机外壳密封方式。
发动机生产商的许可
湿洗清洁的前提是发动机生产商许可采用这种方法，而且必须遵守他的
规定。
警示
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5.3.1 湿洗清洁方法
短时喷水清洁法（3 x 30 秒)
短时喷水清洁法适合应用在无附加 C 形密封环的涡轮增压器上。
这种方法基于热振原理，之后进行冲洗。
长时喷水清洁法（10 分钟清洁法）
长时喷水清洁法适合应用在带附加 C 形密封环的涡轮增压器上。
本方法经过 10 分钟的喷水，利用污垢的水解性达到清洁目的。
Revision F

保养 5
清洁方法的选择
如果您需要有关选择（长/短）清洁方法的信息，请与发动机厂家或者与
September 2016
ABB Turbo Systems 特约经销商联系。
警示
5.3.2 前提条件
锈蚀与积垢危险
盐水与水管中的冷却水添加剂会对涡轮增压器性能造成不良影响或者损
坏增压器。
小心
u 不能使用盐水，只许使用纯净水进行清洗。
u 避免外壳内侧发生锈蚀。
u 湿洗清洁后，要继续运行发动机 10 分钟。
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清洁时涡轮前的最高温度
在清洁过程中，涡轮前的温度会上升，因而对涡轮部件带来影响。涡轮
进口的温度可能比气缸之后的废气温度高出 100 °C。这一点要在清洁前
小心
设定操作点时予以考虑。
u 清洁时不要使涡轮前的温度超过最高温度值。
禁止的温差应力与涡轮淹没
如果水太少，则达不到清洗效果。水量太大会给涡轮部件带来过大的温
差应力，可能造成涡轮淹没。
小心
u 一定要遵守涡轮清洗参数。
V 型发动机
Revision F
如果每个 V 型发动机带多个涡轮增压器，我们建议对涡轮增压器采取并

行清洁。这样，清洁工作较快，同时减小涡轮增压器喘振。
警示

保养 5
涡轮湿洗所建议的运行状态
下面的运行状态已通过了 ABB Turbo Systems 的验证和许可。

September 2016
特性/部件条件
短长
喷水时间喷水时间
发动机负荷（参考值） 20 … 40 %
喷水之前涡轮入口温度 TTE 350 … 400 °C 350 … 430 °C
进水保证
水压（高于大气压的压力）pWT 2.0 巴 1.5 巴
有时必须降低发动机功率，以满足这些条件。
现在可以按照下面的说明启动清洗过程。
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Revision F

保养 5
5.3.3 使用短时喷水法的步骤
September 2016
w 已满足前提条件。
u 发动机降低负荷后等待 10 分钟的稳定过程。
u 打开阻断阀门。
u 用流量测量装置根据清洗参数表调节所需要的水流量并喷水 30 秒钟。
u 遵守清洗参数表中规定的 3 或者 5 分钟的间停。
u 重复两次 30 秒钟的喷水。
u 关闭阻断阀。
u 在提高发动机负荷前，等待 10 分钟的稳定过程。
涡轮的清洗结束。
运行时的清洗参数
涡轮清洗前的温度水喷水时间喷水的间歇时间
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[ °C ] 流量 1) [分] [分]
TPS [分米 3/分]
44 ≤ 450 4.5 0.5 3
48 6 (3 x)
52 8
57 11
61 17 5
1) 相对于 pWT 2.0 巴水压（高于大气压的压力）
小心
Revision F

保养 5
September 2016
5.3.4 使用长时喷水法的步骤
w 已满足前提条件。
u 发动机降低负荷后等待 10 分钟的稳定过程。
u 打开阻断阀门。
u 用流量测量装置根据清洗参数表调节所需要的水流量并喷水 10 分钟。
u 关闭阻断阀。
u 在提高发动机负荷前，等待 10 分钟的稳定过程。
涡轮的清洗结束。
运行时的清洗参数
涡轮清洗前的温度水喷水时间喷水前、后的稳定

[ °C ] 流量 1) [分] 过程
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TPS [分米 3/分] [分]

44 ≤ 530 2.5 10 10
48 4
52 5.5
57 8.5
61 12
1) 相对于 pWT 1.5 巴水压（高于大气压的压力）
小心
Revision F

保养 5
机械清洁组件 5.4 页 66
5.4
5.4 机械清洁组件
September 2016
5.4.1 介绍
选择清洁工具
涡轮增压器部件对机械损坏很敏感。使用诸如针式喷枪或其他冲击工具
会损坏部件。根据规格不同，喷嘴环或涡轮机外壳会有保护层，该层也
小心
会被损坏。
u 仅可使用柔软的工具，如抹布、毛刷或金属丝刷。
u 严重脏污的情况下可重复进行所描述的清洁方法，如浸渍等，直到达
到满意效果。
u 污水和清洁剂必须以环保、专业以及符合当地现行法规的方式进行回收
处理。
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拆卸和装配
组件的拆卸和装配在拆卸和装配一章中进行了描述。
警示
Revision F

保养 5
5.4.2 清洁消音器
September 2016
81135 过滤式消声器主体 81266 保护栅网

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81136 吸收段 81270 张紧带

81137 金属板盖 81271 锁环
81265 过滤环
拆卸和安装
拆装消音滤器的说明在拆卸和安装一章中进行了描述。
警示
清洁滤器环（如有）
u 取下滤器环（81265）。
u 若有需要或每运行 500 个小时应清洁滤器环（81265），并最晚应在五
次清洁过程之后将其进行更换。
滤器环的脏污取决于所抽吸空气的清洁程度。
Revision F
u 用加入了柔性清洗剂的水冲洗滤器环（81265），如果脏污严重，则需
浸泡，并小心将水挤出。在冷水中冲净。要避免产生机械冲击（例如水
射流）。
u 安装之前彻底干燥过滤环。
u 污水和柔性清洗剂须以符合当地现行法规的方式进行回收处理。

保养 5
清洁减震段
u 松开绷带（81270）。
September 2016
u 取下网罩（81266）。
u 拉出外套板（81137），将其掀开并取出减震段（81136）。
u 清洁减震段（81136）。
注意，仅可使用压缩空气、软刷或者湿抹布清洁减震段（81136）。
u 严重脏污的减震段则由 ABB Turbocharging 服务站进行更新。
安装消音滤器
u 将减震段 (81136) 插入外套板 (81137) 中。

u 将外套板 (81137) 恢复原有形状并插入消音器 (81135) 中的导缝内。
u 安装网罩 (81266)。
u 放上绷带 (81270)，并绷紧在搭扣 (81271) 上。
u 损坏的绷带必须更换。
u 安装滤器环 (81265)（如有）。
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Revision F

保养 5
5.4.3 压气机端部，非转动部件
September 2016
关于运行材料和辅助用品
吞咽或吸入运行材料和辅助用品的蒸汽或与其接触，均有可能危害健
康。
警告
u 请勿吸入这些物质并避免皮肤接触。
u 遵守本地法律规定。
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下列性能相关部件可按照以下说明进行清洁。
72000 压缩机外壳
77000 插隔板
79000 扩散器
u 使用蒸汽清洗上述部件，或将上述部件浸泡在柴油或含有家用清洁剂的
水中。浸泡后使用软刷清除污物。
Revision F
u 彻底干燥部件。
u 在清洗后的表面喷洒渗透油。不得喷洒在涡轮增压器外壳上。
u 根据安全数据信息上的说明处理废水和清洁剂。

保养 5
September 2016
5.4.4 涡轮端部，非转动部件
康。
警告
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涡轮侧上会有例如重油或焦化油的烧焦污垢层。下列性能相关的部件可按
照下面描述进行清洁。
51000 涡轮壳 56001 喷嘴环

52400 燃排法兰
Revision F
u 脏污部件置入热水或除碳剂溶液中，软化脏污。
u 刷下污物，或用蒸汽清洁器将其清除。
u 如果需要则重复浸泡软化和刷洗过程。
u 将部件用净水完全洗净清洁液。
u 将部件完全晾干。

保养 5
u 已清洁的表面喷上润滑油。不要喷涂涡轮增压器的外表面。
u 按照安全数据表的说明处理污水和清洁剂。
September 2016
5.4.5 芯座组件
引言
腐蚀
清洗后，转子总成如未立刻投入运行，则可能出现部件腐蚀。
小心 u 清洗后须立刻安装和使用转子总成。
压缩机叶轮或涡轮可能因重油或焦化油而严重脏污。该污物可能无法通过
开机清洗进行清除，因此必须在正常维护周期时通过机械方式清洁（参见
章保养工作）。
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u 从发动机上拆卸涡轮增压器（参见章节拆卸与安装 [➙ 85]）。

u 拆下转子总成（参见章节拆卸和装配 [➙ 91]）。
根据下列说明首先清洗压缩机侧，然后清洗涡轮机侧。
Revision F

保养 5
清洗压缩机侧
September 2016
选择清洁剂
含氯清洁剂会侵蚀金属。
小心 u 仅可使用 pH 值为中性且不会侵蚀金属的清洁剂。
u 注意安全数据信息。
转子芯座组件中的水和污物
如果有水或污物进入转子芯座组件中，则会影响涡轮增压器的功能，并
损坏转子芯座组件中的部件。
小心
u 确保不会有水或灰尘进入转子芯座。
u 将抹布或软刷浸在含有家用清洁剂的水中，然后清洁压缩机侧。不得使
用钢丝刷！
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u 使用较弱的压缩空气干燥压缩机叶轮以及压缩机和轴承箱之间的间隙。
u 在压缩机叶轮以及压缩机和轴承箱之间的间隙喷洒少量渗透油。
u 根据安全数据信息处理废水和清洁剂。
Revision F

保养 5
清洁涡轮机侧
September 2016
软化污垢涡轮机侧会出现由重油或焦化油导致的烧结污垢。该污垢可通过软化和洗
刷去除。污垢层的软化及涡轮机的清洁请参见下文。
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产品 A [mm] B [mm] C [mm]

TPS44 91 15 173
TPS48 108 17 205
TPS52 128 20 245
TPS57 157 25 300
TPS61 187 30 357
为了浸泡涡轮机上的污垢层，可将转子总成垂直浸入一个含有液体的容器
（02）中。
u 将该容器（02）置于一个更大的容器（03）中，以便收集溢出的液体。
选择清洁剂
Revision F
含氯清洁剂会侵蚀金属。
小心 u 仅可使用 pH 值为中性且不会侵蚀金属的清洁剂。
u 注意安全数据信息。
u 向容器（02）中加入浸泡液体。

保养 5
加热液体
为了缩短浸泡时间，可将液体加热至最高 60 ºC。
September 2016
警示
加热清洁剂和运行材料
加热清洁剂和运行材料时可能会产生对健康有害以及有爆炸危险的气
体。
警告
u 注意安全数据表中的数据说明。
按照安全数据表佩戴防护面具。
转子总成中的水和污物
如果水或污物进入转子总成中，则可能会影响涡轮增压器的功能并损坏
转子总成中的部件。
小心
u 将转子总成置于合适的木质或金属底座（01）上。
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u 注意底座（01）的尺寸（B），避免转子总成没入过深。
u 浸泡涡轮上的污垢层四小时。
Revision F

保养 5
清除污物
碳黑颗粒影响健康
September 2016
如果碳黑颗粒进入眼睛或呼吸道，会对健康造成损害。
警告 u 避免形成灰尘。
u 用合适的吸尘器抽吸灰尘。
u 佩戴防灰尘的防护面具（P1 或 P2 面具）。
u 佩戴封闭式护目镜。
u 抬起转子总成并水平对齐。
u 使用软刷或钢丝刷手动清除污物。
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Revision F

保养 5
转子总成中的水和污物
September 2016
如果水或污物进入转子总成中，则可能会影响涡轮增压器的功能并损坏
转子总成中的部件。
小心
u 避免水和污物进入隔板和涡轮之间的间隙。
清洗后出现不允许的转子不平衡现象
分布不均匀的残留污垢会导致转子不平衡。可能会损坏轴承和涡轮增压
器。
小心
u 彻底清除涡轮机上的污垢沉积。
u 洗刷污物后向容器（02）中注入清水，不得使用盐水。
u 将转子总成的涡轮浸入清水中，彻底溶解松散的污物。
u 抬起转子总成并水平对齐。
u 用轴承箱卡住隔板。
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u 使用较弱的压缩空气干燥涡轮以及涡轮和隔板之间的间隙。
u 在涡轮以及涡轮和隔板之间的间隙喷洒少量渗透油。
u 根据安全数据信息上的说明处理废水和清洁剂。
Revision F

故障排除 6
起动时故障 6.1 页 77
6 故障排除
September 2016
6.1
6.1 起动时故障
延时起动
可能原因排除
涡轮增压器涡轮增压器脏污清洁
轴承损坏联系 ABB Turbocharging 服务站
转子磨损
涡轮增压器中有异物
振动
可能原因排除
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涡轮增压器转子失衡联系 ABB Turbocharging 服务站

涡轮或者压气机损坏
轴承损坏
转动部件的摩擦
正常现象，并非故障
涡轮增压器转子部件周围出现的、因转子部件与相邻部件轻微摩擦而造成的细
微且均匀的磨损是允许的。这将导致压气机或涡轮叶片缩短一定程
度。为防止效率重大损失，必须满足特定的公差。
¡ 如果对于磨损的程度有任何疑问，请联系 ABB Turbocharging 服
务站。
¡ 请 ABB Turbocharging 服务站进行尺寸校验。
Revision F

故障排除 6
涡轮增压器的喘振 6.2 页 78
6.2
6.2 涡轮增压器的喘振
September 2016
涡轮增压器的喘振
可能原因排除
发动机涡轮增压器前的防护栅栏脏污或损坏清洁/更换
涡轮增压器消音器或扩压器脏污清洁
涡轮或喷嘴环内有严重灰尘沉积
增压空气冷却器冷却器脏污清洁
增压空气槽堵塞
持续或周期性喘振
可能造成组件损坏，如压气叶轮、涡轮叶片、轴承和消音器等。
小心 u 一旦出现此情况则立即通知 ABB Turbocharging 服务站采取措施。
u 由 ABB Turbocharging 服务站检查部件是否损坏，必要的话予以更
换。
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阵发性振荡气流
在发动机的某种运行状态下，如高负荷下发动机功率的快速降低会造成涡
轮增压器的喘振。同时压气机内的空气流向暂时逆转。这类阵发性振荡气
流不会影响涡轮增压器的安全运行。
¡ 泵送式振动振荡气流伴随着响声和热空气从过滤式消音器中逸出的现
象。
Revision F

故障排除 6
运行时出现故障 6.3 页 79
6.3
6.3 运行时出现故障
September 2016
润滑油压过低
可能原因排除
发动机滤油器严重脏污清洁
润滑系统中的油泵损坏检查/更换
压力计显示不正确更换压力计
涡轮增压器转子轴向间隙过大联系 ABB Turbocharging 服务站
转速下降
可能原因排除
发动机脉冲增压气缸损坏联系发动机制造商
涡轮增压器涡轮严重脏污清洁
转子部件或轴承损坏联系 ABB Turbocharging 服务站
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管道废气或增压空气管道的损坏，例修理
如油泄漏
转速上升
可能原因排除
涡轮增压器喷嘴环严重脏污（在 4 冲程应用联系 ABB Turbocharging 服务站
时）
Revision F

故障排除 6
废气温度过高
发动机功率和速度未发生变化
September 2016
可能原因排除
发动机喷射系统故障修理或联系制造商
涡轮增压器空气不足，例如过滤器的消音清洁
器被污垢堵塞
压气机/涡轮脏污
废气背压过高清洁或修理锅炉或废气消声器
涡轮损坏或锈蚀联系 ABB Turbocharging 服务站
增压空气冷却冷却器脏污清洁
器冷却水流量过低注满
冷却水进水温度过高检查/清洁冷却系统
通风不足改善通风
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Revision F

故障排除 6
增压空气压力过低
发动机功率及速度未变，进气状态正常
September 2016
可能原因排除
发动机储气室未密封修理
发动机和涡轮之间的气体通路不
密封
喷射失调正确设定
阀门失调
涡轮增压器压力计显示不正确更换压力计
至压力计的供气管道未密封修理泄露
消音器脏污，因此压力下降过快清洁
压气机/涡轮脏污
压气机/涡轮损坏联系 ABB Turbocharging 服务站
废气背压过高清洁或修理锅炉或废气消声器
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增压空气压力过高
发动机功率及速度未变，进气状态正常
可能原因排除
发动机喷射系统故障修理或联系制造商
喷射失调正确设定
发动机功率高出预期检查发动机功率
涡轮增压器压力计显示不正确更换压力计
Revision F

故障排除 6
通风气的引入对压缩机造成的脏污
压缩机功率/压气叶轮效率的降低，进而造成发动机功率的损失
September 2016
可能原因排除
涡轮增压压缩机组件的严重脏污清洗压缩机
器优化油排放
震荡的提高，压缩机叶片功能的根据发动机制造商的说明调整通
可能损坏风气的引入。
压缩机叶轮的持续抗震荡能力降低，压缩机叶片断裂。
可能原因排除
涡轮增压压缩机叶轮材料受损检查燃料及其腐蚀性成分，必要
器的话更换燃料。
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Revision F

故障排除 6
停止时发生故障 6.4 页 83
6.4
6.4 停止时发生故障
September 2016
滑行噪音
可能原因排除
转子磨损
滑行时间太短
可能原因排除
转子磨损
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Revision F

故障排除 6
测速系统 6.5 页 84
6.5
6.5 测速系统
可能原因排除
September 2016
没有信号振幅安装错误传感器密封螺栓采用附加密封（铜密封环）
或信号振幅不进行安装。
好安装转速传感器时，必须先取出这个密封
圈。如果这个密封圈被无意安装上，则传感
器探头与发出信号的密封垫片之间的距离将
扩大。这导致转速信号电压振幅的减小，可
能给数据分析电气系统带来问题。
取出密封圈，既能解决这个问题。
传感器损坏联系 ABB 涡轮增压器服务站
所测得的转速传感器探头脏污因为传感器探头有磁性，所以可能吸附材料
过高粉尘。这样与发出信号的密封垫片之间的距
离就会减小，这可能造成噪音分量的加强，
进而导致错误触发。
将传感器拆装，清洁传感器探头，然后用所
给扭矩安装。
所测得的转速 -- 联系 ABB 涡轮增压器服务站
过低
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其他故障原因 -- 如果采用了上述方法依然不能排除故障，建
议由 ABB Turbocharging 器服务站对转速测
量系统进行检查。
Revision F

拆卸与安装 7
运输 7.1 页 85
7 拆卸与安装
September 2016
7.1
7.1 运输
未绝缘涡轮增压器的吊起
带油冷却轴承箱的涡轮增压器带排气外壳的整套涡轮增压器
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绝缘涡轮增压器的吊起
带油冷却轴承箱的涡轮增压器带排气外壳的整套涡轮增压器
Revision F

拆卸与安装 7
涡轮增压器的重量 7.2 页 86
7.2
7.2 涡轮增压器的重量
September 2016
安装和拆卸涡轮增压器时，必须使用具有足够承重能力的起吊工具。下列
重量值为最重可能性。该参考值可能与铭牌上的说明规格有偏差。
TPS44 TPS48 TPS52 TPS57 TPS61

[kg] [kg] [kg] [kg] [kg]
120 180 250 410 650
涡轮增压器的重量
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Revision F

拆卸与安装 7
拆卸涡轮增压器 7.3 页 87
7.3
7.3 拆卸涡轮增压器
September 2016
u 根据发动机制造商的说明断开所有废气和空气管路。
带水冷式轴承壳的款型：
u 根据发动机制造商的说明断开水管。
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如果有，按以下方式去除硬绝缘件：
u 去除轴承壳绝缘件螺栓和板（B）。
u 去除轴承壳绝缘件（A）剩余的螺栓。
u 向上拔下轴承壳绝缘件。为了便于去除，可以将轴承壳绝缘件压到一
起。
u 拔出转速传感器的电缆接头。
u 将起重设备固定在轴承壳上。
u 如果有排气弯管，必须另外将它缠起，或者使用万向垂重环（C）固定
在起重工具上。
Revision F
u 松开涡轮壳上的固定螺栓（D）。
u 抬起并放下涡轮增压器。
u 油接口罩盖。

拆卸与安装 7
安装涡轮增压器 7.4 页 88
7.4
7.4 安装涡轮增压器
September 2016
u 去除油接口的盖子。
u 目视检查油流入和流出管的 O 型密封圈（发动机端的 O 型密封圈不包
含在 ABB 涡轮系统有限公司的供货范围内）。
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**）将涡轮增压器安装到发动机支架上时，必须稍微润滑螺栓的螺纹和螺栓
头（假设拧紧扭矩摩擦系数 µ = 0.12）
产品轴承壳中的通孔螺纹尺寸拧紧扭矩

[mm] [mm] [Nm] 依据
DIN/ISO 898 的
性能等级
TPS44 17 M16 230 10.9/12.9
TPS48 17 M16 230 10.9/12.9
TPS52 21 M20 455 10.9/12.9
TPS57 21 M20 455 10.9/12.9
TPS61 25 M24 780 10.9/12.9
u 将起重设备固定在轴承壳上。
Revision F
u 如果有排气弯管，必须另外将它缠起，或者使用万向垂重环（C）固定
在起重工具上（另请参见运输/重量一节）。
u 抬起涡轮增压器，放到支架上并对齐。
u 根据上表将固定螺栓（D）拧到轴承壳上。
u 根据发动机制造商的说明固定所有燃气、水和空气管道。

拆卸与安装 7
安装涡轮增压器 7.4 页 89
如果有，则：
September 2016
u 安装转速传感器，插入电缆接头。
u 调整并安装轴承壳绝缘件（A）。
u 调整并安装轴承壳绝缘件的板（B）。
带水冷式轴承壳的款型：
u 取下水管接头上的闷塞，并根据发动机制造商的说明安装水管。
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Revision F

拆卸和装配 8
介绍 8.1 页 91
8 拆卸和装配
September 2016
8.1
8.1 介绍
下述工作的前提条件是涡轮增压器已从发动机上拆卸（参见拆卸和安装章
节）。
进一步工作
使用本操作手册只能进行手册中所描述的工作。转子总成的错误拆卸与
安装可能导致机器的严重损坏。
小心
u ABB Turbo Systems 建议进一步的工作只能由受过训练的 ABB
Turbocharging 服务站人员进行。
标记壳体位置以进行安装
ABB 涡轮系统建议在拆卸前标记好壳体的位置。
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警示
安装工具的识别
并非所有的安装工具都标记有部件编号。其标记在工具清单中确定。该清
单包括在工具箱内。
使用安装工具
使用前后都应检查安装工具是否损坏。
警告 u 目视检查是否有腐蚀、裂纹、变形或磨损。
u 不允许使用损坏的安装工具，必须将其更换。
Revision F

拆卸和装配 8
介绍 8.1 页 92
客户备件套件
开始工作前，请确认有所需的客户备件套件可供使用。
September 2016
u 参看“备品与备件” 一节。
油孔
u 拆卸涡轮增压器时，不能去掉已安装的油孔。
涡轮增压器部件的拧紧扭矩
必须遵守所规定的用于涡轮增压器组件的紧固螺栓扭矩（参见“扭矩表”
一节）。
ABB 涡轮系统装配装置的拧紧扭矩
如果没有其他说明，装配装置的螺栓和螺母必须紧密相邻地拧紧固定。
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悬挂负荷
如未按照规定吊装重物可能会造成严重的人身损伤，甚至导致死亡。
警告 u 涡轮增压器、组件或单个部件仅可固定在完好且具有足够负载能力的
起重设备上。
u 注意应将负荷正确地固定在起重机吊钩上。
u 任何人员不得驻留在吊载下方。
佩戴安全帽。
名称定义
Revision F
¡ 起吊点
零件或组件上已定义的受力点（盲孔螺纹、吊环、鱼尾板）。
¡ 装配装置
安装在涡轮增压器上的、以便获得起吊点的装置。装配装置是专门为其
已经定义的应用目的而设计，安装装置非贸易商品。装配装置仅用于所
描述的用途。

拆卸和装配 8
介绍 8.1 页 93
¡ 起吊工具
用于提升和运输重物的器械（绳缆、链式滑车组、吊车）。ABB Turbo
Systems AG 不随货提供起吊工具。
September 2016
必须采用的旋转吊环
为了安全提升重物需要使用旋转吊环（不属于供货范围）。
旋转吊环产品螺纹长度最低承重能力
M L
TPS44 M8 13 mm 150 kg
TPS48 M10 17 mm 250 kg
TPS52 M10 17 mm 250 kg
TPS57 M12 21 mm 350 kg
TPS61 M12 21 mm 500 kg
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Revision F

拆卸和装配 8
装配组件重量 8.2 页 94
8.2
8.2 装配组件重量
September 2016
单个部件或装配组件的给定重量均为化整的标准值。
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名称 [公斤] [公斤] [公斤] [公斤] [公斤]
1 消音滤器 15 19 30 40 65
2 抽气套管，径向 5 6 8 11 21
3 抽气套管，轴向 3 4 4 6 9
4 压缩机外壳 17 24 35 55 90
5 插隔板 4 7 10 13 30
6 扩散器 2 2 3 6 10
7 转子总成 25 35 50 85 140
8 喷嘴环 1 1 2 3 6
9 爆裂环 1 2 3 5 12
10 带外部爆裂保护 1 个进口 30 35 50 80 130
装置的涡轮机外 2 个进口
Revision F
30 35 50 90 150
壳
3 个进口 - - 55 95 170
4 个进口 - - - 95 170
11 气体出口法兰 4 4 8 16 30
12 气体排放弯管 16 18 25 40 60

拆卸和装配 8
拆卸和安装涡轮增压器 8.3 页 95
8.3
8.3 拆卸和安装涡轮增压器
September 2016
拆下压缩机外壳
烫伤危险
u 根据发动机制造商的说明断开所有空气输送管。
如有 u 去掉压缩机外壳绝缘上的螺栓，拆下绝缘。
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Revision F
u 松开 V 形带(72020)并且去掉消音滤器(81000)或者抽气套管(82000)。

拆卸和装配 8
拆卸绝缘
September 2016
如有 u 松开绝缘板（1，2）上的螺栓并取下。
u 如有：拆卸绝缘板（1，2）。
u 去掉绝缘（3）上的剩余螺栓。
u 取下绝缘（3）。
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Revision F

拆卸和装配 8
u 轻微松开螺栓(72011)，转动压缩机外壳(72000)，直至能够在起吊工具
上固定旋转吊环为止。
September 2016
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(77006* 仅在有安装插隔板和使用加速扳手时具备)
如果不能轻易拧松压缩机外壳，可以使用顶压工具(90042)顶压涡轮机外
壳把压缩机外壳撬下来。为此必须去掉涡轮机外壳硬绝缘上的两个盖板
（1, 2）。
警示
轴向力
使用顶压工具会产生很大的轴向力，如果操作不当（单侧顶压力过大）
会损坏转子。
小心
u 因此必须两侧交替顶压，每侧都不要用力过大。
Revision F
u 松开螺栓(72011)并使用紧固夹片(72012)取下。
u 小心地水平移开压缩机外壳(72000)和插板(77000)。
u 用尼龙锤把插板(77000)从压缩机外壳钟敲出来，去掉 O 形圈(77005)。

拆卸和装配 8
拆卸插隔板 TPS61
u 将起吊横梁(90258)固定到插隔板上。
September 2016
u 将旋转吊环(a)固定在起吊横梁上。
u 借助起吊工具取下插隔板(77000)。
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拆卸扩散器
TPS..-F31/32 / FV31/32
Revision F
u 松开螺栓(72041)并且与固定板(72040)和扩散器(79000)一起从压缩机
外壳(72000)上取下来。

拆卸和装配 8
压缩机外壳的安装
u 按照相反顺序安装插板(77000)和 O 型圈(77005)。
September 2016
O 形圈
应始终用新的 O 形圈替换用过的 O 形圈。O 形圈仅可成套订购（参见备
件一章）。
警示
扩压器的安装 u 按照相反顺序安装扩压器。
TPS..-F31/32 / FV31/32
u 按照相反顺序安装压缩机壳。
u 安装前彻底清洁固定用夹片(72012)。
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Revision F

拆卸和装配 8
拆卸转子总成
u 检查吊具并且固定到轴承箱（42001）上。
September 2016
如果有的话 u 按照发动机制造商的要求断开所有的管线，去掉绝缘，拆下涡轮增压
器，取下压缩机外壳及过滤式消音器（参考前面的章节）。
烫伤危险
w 轴承套不易松动。
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u 使用顶压工具（90042）顶压涡轮机外壳把轴承套撬下来（参看下图）。
轴向力
使用顶压工具会产生很大的轴向力，如果操作不当（单侧顶压力过大）
会损坏转子。
小心
u 因此必须两侧交替顶压，每侧都不要用力过大。
Revision F

拆卸和装配 8

September 2016
u 借助这两个拉卸机构(90070)和服务支架(90012)把喷嘴环(56001)拉出
来。
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如果有的话 u 取下 C 形圈(51105)。
拆卸扩散器
TPS..-F33
Revision F
u 把转子总成放到服务支架(90012)上并拧紧。
u 松开螺栓(42008)，然后取下扩散器(79000)和 O 形圈(42012)。
u 测量轴向和径向间隙（参考轴向与径向间隙一节）。

拆卸和装配 8
安装转子总成
September 2016
O 形圈
应始终用新的 O 形圈替换用过的 O 形圈。O 形圈仅可成套订购（参见备
件一章）。
警示
探出的绝缘
在涡轮外壳上绝缘可能在气体出口侧探出。可以使用螺丝刀将其顶回。
警示
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u 将迷宫密封隔环（56005，如果有）装入正确的槽内（参见细节图 A）。
同时请确保迷宫密封隔环的正确卷绕（参见细节图 B）。
u 使用密封带固定迷宫密封隔环。
Revision F
u 将带凸轮的喷嘴环（56001）朝前插入涡轮壳中，直到止挡位置。将喷嘴
环上的凸轮推到涡轮壳的凹槽上，直到涡轮壳（51000）的止挡位置。请
勿移除密封带（01）。
如果有，则 u 将 C 形圈（51105）插入涡轮壳中，使用高真空润滑脂固定。

拆卸和装配 8
为了使喷嘴环在工作中保持固定，必须将其卡在隔板和涡轮外壳之间。
September 2016
警示
单进口涡轮外壳喷嘴环压 u 压力 (PD) 可通过计算得出。

力
如果计算出的数值（PD）小于 0.1 mm ，则必须与 ABB Turbocharging

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特约服务站联系。
警示

Revision F

拆卸和装配 8
多进口涡轮外壳喷嘴环压 u 压力 (PD) 可通过计算得出。

力
September 2016
如果计算出的数值（PD）在 ±0.2 mm 范围以外，则必须与 ABB
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Turbocharging 特约服务站联系。
警示
Revision F

拆卸和装配 8
安装扩散器
TPS..-F33
September 2016
u 用螺栓(42008)固定扩散器(79000)和 O 形圈(42012)。
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u 检查吊具并且固定到轴承箱（42001）上。
u 拧开转子总成并从服务支架(90012)上提起。
u 用高温油脂给定中座和螺栓的螺纹润滑。
u 取下机油接口的临时盖子。
Revision F
安装转子总成时不要损坏或者移动固定支架内的密封环(A)。密封圈
（A）属于发动机制造商的供货范围。
小心
如果在一个发动机上安装两个分别有左右进油口的增压器，那么为了避
免安装出错，可以在底座内用一个销子作为安装标记。这个销子(B)恰好
与轴承箱底座对应的凹槽配合。
警示

拆卸和装配 8
September 2016
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u 用紧固夹片(51002)、Verbus Ripp®垫片(51003)和螺母(51007)固定转
子总成（参考紧固扭矩表一章）。
u 用紧固螺栓(C)固定轴承箱(42001)。
u 按照下表所列的紧固扭矩拧紧紧固螺栓 (C)。
**) 将涡轮增压器安装到发动机底座上时，必须在螺栓的螺纹上和螺栓头上
涂油（摩擦系数 µ = 0.12 除外）。
产品轴承座内的孔紧固螺栓 C [mm] 紧固扭矩 [Nm] **)

[mm]
TPS44 Ø 17 M16 230
TPS48 Ø 17 M16 230
TPS52 Ø 21 M20 455
Revision F
TPS57 Ø 21 M20 455

TPS61 Ø 25 M24 780
如有

拆卸和装配 8

September 2016
u 插上转速测量传感器(86505)的电缆插头(86515)，安装绝缘板(1, 2)
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（如果有的话）。
拆卸排气弯管和气体出口法兰
如果有的话 u 按照发动机制造商的要求断开所有的管线，去掉绝缘（参考前面的章
节）。
Revision F
u 把吊具缠绕在排气弯管(51100)上。
u 拆卸排气弯管(51100)并取下密封(52406)。只有 ABB Turbo Systems
的排气弯管有密封(52406)。
u 取下气体出口法兰(52400)和 C 形圈(52408)（如果有的话）。

拆卸和装配 8
安装气体出口法兰和排气弯管
September 2016
u 如果有的话，安装 C 形圈(52408)。
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u 安装气体出口法兰(52400) 。
u 如果是 ABB Turbo Systems 的排气弯管（51100）：
一定要更换密封（52406）（参阅“备用件与替换件”一章）。
u 用高温油脂涂抹接触面和螺栓螺纹。
u 涡轮机外壳用螺母（52433）按照紧固扭矩表一章所规定的紧固扭矩安
装。
如有 u 固定绝缘
u 根据制造商的说明固定管线。 Revision F

拆卸和装配 8
轴向间隙 A 和径向间隙 B 8.4 页 109
8.4
8.4 轴向间隙 A 和径向间隙 B
September 2016
u 拆出转子总成之后和安装之前须测量并记录轴向间隙 A 和径向间隙 B。
为了正确测量轴向间隙 A，须稍微提起涡轮。
警示
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压缩机叶轮上的锐利边缘存在受伤危险
压缩机叶轮具有锐利边缘，可能导致受伤。
警告 u 穿戴防护手套。
轴向间隙 A 和径向间隙 B
[mm]
A 最小值 0.08 0.08 0.10 0.12 0.15
A 最大值 0.16 0.16 0.18 0.21 0.25
B 最小值* 0.51 0.50 0.61 0.72 0.81
B 最大值* 1.00 1.00 1.15 1.31 1.55
* 标准径向轴承的允许 B 间隙。如果在 TPS57 或 TPS61 上所测得的间

Revision F
隙在允许范围外，那么可以采用特殊几何尺寸的径向轴承标准对其进行
评估。对于特殊几何尺寸的径向轴承适用其他允许数值（见下表）。

拆卸和装配 8
轴向间隙 A 和径向间隙 B 8.4 页 110
识别特殊几何尺寸的径向
轴承
September 2016
轴承类型可以通过测量转子滑行时间确定。测量时手动将转子分别向左
（L）和向右（R）转到止档，尽量用力均匀。所设定的滑行至转子静止
的时间分别在左右测量并进行比较。标准径向轴承的左右转子滑行时间
是相等的。
如果一侧的滑行时间至少比另一侧多出 1.5 倍，那么该径向轴承即是特

殊几何尺寸的径向轴承。对于此类特殊几何尺寸的径向轴承适用下列 B
间隙。
TPS57 TPS61
B 最小值 0.46 0.52
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B 最大值 0.73 0.82
间隙超出公差范围
间隙超出公差范围以及过度磨损的部件会导致发动机严重损坏或财产严
重损失。
小心
u 请 ABB Turbocharging 服务站对部件做出评估，必要时由其进行更
换。
Revision F

拆卸和装配 8
径向间隙 N 与 R 8.5 页 111
8.5
8.5 径向间隙 N 与 R
September 2016
N与R
这些是压气叶轮和插隔板之间以及涡轮和气体出口法兰之间的理论值。
最小和最大值取决于压气叶轮和涡轮以及插隔板和气体出口法兰的加工误
差。
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间隙塞尺
同时用两个间隙塞尺分别测量 N1 和 N2
或者 R1 和 R2。
测量 N1 和 N2 时，必须将塞尺无间隙地
分别插到上下插隔板与压缩机叶轮之间。
测量 R1 和 R2 时，必须将塞尺无间隙地
分别插到上下气体出口法兰与涡轮之间。
Revision F

拆卸和装配 8
径向间隙 N 与 R 8.5 页 112
测量 N 与 R
September 2016
测出的平均值必须在径向间隙 N 或 R 的允许值以内。
径向间隙 N 与 R
产品 N [mm] R [mm]
TPS44 0.15 … 0.49 0.36 … 0.67
TPS48 0.22 … 0.58 0.47 … 0.77
TPS52 0.30 … 0.67 0.59 … 0.92
TPS57 0.40 … 0.86 0.75 … 1.11
TPS61 0.50 … 0.94 0.90 … 1.32
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间隙超出公差范围
间隙超出公差范围以及过度磨损的部件会导致发动机严重损坏或财产严
重损失。
小心
u 请 ABB Turbocharging 服务站对部件做出评估，必要时由其进行更
换。
Revision F

拆卸和装配 8
拧紧扭矩列表 8.6 页 113
8.6
8.6 拧紧扭矩列表
September 2016
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固定螺栓时必须遵守以下拧紧扭矩：
拧紧扭矩 [Nm]
项号部件编号 TPS44 TPS48 TPS52 TPS57 TPS61
1 72020 60 60 60 60 60
2 42008 6 10 10 20 20
5 52433 20 20 40 65 65
6 51007 25 25 45 75 75
9 72011 35 35 70 105 170
10 86505 15 15 15 15 15
Revision F

停机 9
关停涡轮增压器 9.1 页 115
9 停机
September 2016
9.1
9.1 关停涡轮增压器
在涡轮增压器损坏情况下如果为了紧急修理只能短时间停止发动机，应该
如下操作：
u 安装盖板。
在任何情况下都必须遵循发动机制造商关于带有锁定/隔离涡轮增压器的
发动机的操作说明。
小心
拆卸涡轮增压器
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u 拆卸涡轮增压器（参见涡轮增压器的拆卸与安装一节）。
Revision F
u 不要拆下喷嘴环。

停机 9
安装终端盖板
September 2016
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u 用盖板（A）堵塞涡轮外壳的开口。
u 用紧固夹片（51002）、Verbus Ripp®垫片（51003）和螺母
（51007）把盖板固定到涡轮外壳（51000）上，并拧紧到支撑上。
安装前彻底清洁固定用夹片（51002）。用高温油脂涂抹双头螺栓
(51006) 的螺纹。
警示
Revision F

停机 9
终端盖板的图纸
盖板不属于 ABB Turbo Systems 的供货范围，必须由运营商根据图纸

September 2016
制造。
材料：普通结构钢，DIN EN 10025-2
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产品 B1 B2 B3 B4 B5 B6
±0.5 ±0.2
TPS44 62.6 54 110 11.0 1 144
TPS48 65.7 60 130 11.7 1.5 150
TPS52 79.6 78 155 14.2 1.5 180
TPS57 98.2 100 190 17.2 2 220
TPS61 116.8 120 226 20.5 2.4 260
产品 B7 ØD1 ØD1* ØD2 R1 M

±0.2 ±0.2
Revision F
TPS44 191.3 191.3 17 ≤88 M8

TPS48 35.7 222.7 227.7 17 ≤105 M8
TPS52 39.6 265.7 271.7 21 ≤125 M8
TPS57 48.2 325.7 332.5 21 ≤153 M10
TPS61 56.8 387.7 395.9 25 ≤182 M10
尺寸 [mm]

停机 9
*) 带备选 C 形密封环的涡轮机外壳直径
September 2016
有关涡轮机外壳类型（带或不带 C 形密封环）的信息，可以向 ABB
Turbocharging 服务站索取。
警示
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Revision F

封存涡轮增压器 10
发动机停运最多 12 个月 10.1 页 119
10 封存涡轮增压器
September 2016
10.1
10.1 发动机停运最多 12 个月
发动机润滑油的状态
一般来说涡轮增压器安装在发动机内。涡轮增压器的防锈处理取决于润滑
油状态：
¡ 如果中和数 (TAN) 低于 2 mg KOH/g，则无需采取任何措施。

¡ 如果在停止发动机运行前已用防护油替换了润滑油、且已使用预润滑泵
使防护油在发动机内循环流动，则也无需采取任何措施。通过这种方式
可以冲洗掉旧的发动机油，并且可为轴承部件在很大程度上提供防腐蚀
保护。
封存的准备
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康。
警告
Revision F

发动机停运最多 12 个月 10.1 页 120
如果中和数（TAN）大于 2 mg KOH/g，则停运之后需要采取下列措施以便
保存：
September 2016
u 拆卸涡轮增压器。
u 转子和轴承零件必须由 ABB Turbocharging 服务站拆卸和再安装。
u 清洁所有零件。
u 给加工过的光面的钢零件或铸铁零件涂上防锈油。
u 完全安装涡轮增压器。
由于抽力引起的转子转动
如果转子因抽风而转动：
u 请在压气机壳出口法兰和增压空气管之间安装一个无孔法兰盘。
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Revision F

发动机停止运行，超过 12 个月 10.2 页 121
10.2
10.2 发动机停止运行，超过 12 个月
September 2016
如果发动机停用，可对涡轮增压器采取以下措施：
¡ 涡轮增压器保留安装在发动机上
¡ 涡轮增压器的机壳保留安装在发动机上，转子和轴承零件被 ABB
Turbocharging 服务站拆下并单独保存
¡ 拆下整个涡轮增压器，保留其整体单元状态或拆成单个部件
对于涡轮增压器封存准备必须采取的措施，请参见章节发动机停止运行最
多 12 个月，封存的准备这一部分。
如果将涡轮增压器留在发动机上，请参见章节发动机停止运行最多 12 个
月，抽风导致转子转动这一部分。
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如果拆下整台涡轮增压器或由单个部件再次装配成涡轮增压器：
u 请将涡轮增压器的所有开口用石蜡纸和木盖板封闭。
适合存放的地点只能为湿度仅为大气湿度 40 … 70% 且不会形成冷凝水的

干燥房间。
封存的涡轮增压器的状态
u 每年检查涡轮增压器零件是否有锈蚀迹象。
u 出现生锈情况时：将零件进行彻底清洁并重新进行防锈保护处理。
Revision F

处理涡轮增压器部件 11
发动机停止运行，超过 12 个月 10.2 页 123
11 处理涡轮增压器部件
September 2016
处理损坏的隔热罩
隔热罩可能致使部件暴露于粉尘之中。玻璃纤维可能会引发眼睛、皮肤
和呼吸道的机械性刺激。
警告
u 避免形成灰尘。
u 用合适的吸尘器抽吸灰尘。
u 佩戴防灰尘的防护面具（P1 或 P2 面具）。
u 佩戴皮质工作手套。
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废物处理过程必须根据当地现行法规、按照环保方式进行。
涡轮增压器主要由金属（铸铁材料、钢、镍钢合金、铝和轴承黄铜）组
成。
其他部件为：非金属材料（由毛毡制成和聚乙烯的过滤器组件）、润滑剂
（发动机油）、电子元件（转数传感器和相关组件）、隔热罩。
u 将金属作为金属废料进行回收处理。
u 将非金属材料作为垃圾处理。
u 将润滑油残余作为废油处理。
u 电子部件作为电器废料处理。
u 将隔热罩作为有害垃圾处理。
Revision F

备件 12
订购备件 12.1 页 125
12 备件
September 2016
12.1
12.1 订购备件
查询及订购备件时请注明以下数据：
¡ 涡轮增压器型号
¡ 系列号 (HT……)
¡ 名称和部件编号。
备件可在 ABB Turbocharging 服务站订购。
u 对于上述文件中未考虑到的特殊情况，请与 ABB Turbocharging 服务站

联系。
备件的存储
与涡轮增压器一起订购的所有备件必须保持完整且随时可用。
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小心 u 必须认真仔细地对生锈零件进行清洁和涂油。
u 要采取正确的和符合环保的方式处理换下来的且无法再继续使用的零
件。
客户备件套件 (97070)
操作手册所描述的工作需要客户备件套件 (97070)。
数量名称零件编号
1 内六角螺栓 42008
1 O 形圈 42012
1 密封圈 52406 *
1 O 形圈 77005
2 埋头螺钉 72041
Revision F
1 O 形圈 81010/ 82010
* 该密封圈只有在使用 ABB Turbo Systems 排气外壳时才能使用。

备件 12
带零件编号的涡轮增压器示图 12.2 页 126
12.2
12.2 带零件编号的涡轮增压器示图
September 2016
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Revision F

备件 12
带零件编号的涡轮增压器示图 12.2 页 127
零件编号名称
10900 转子总成
September 2016
42008 (包括在客户备件套件内) 内六角螺栓

42012 (包括在客户备件套件内) O 形圈
51000 涡轮机壳
51002 固定用夹片
51100 气体排放弯管
51105* 金属 C 形圈
52400 气体出口法兰
52406 (包括在客户备件套件内) 密封圈
52408* 金属 C 形圈
56001 喷嘴环
57200 爆裂保护
57210 爆裂环
72000 压缩机外壳
72011 内六角螺栓
HZTL2412_ZH
72012 固定用夹片
72020 V 形带
72041 (包括在客户备件套件内) 带十字槽的埋头螺钉
77000 插隔板
79000 扩散器
81000 消音滤器
82000 抽气套管，轴向
86505(A)* 转速传感器（电缆没有装入）
86505(B)* 转速传感器（电缆已装入）
86515(A)* 连接 86505(A) 的电缆接线器
86515(B)* 连接 86505(B) 的电缆接线器
Revision F
86526* F/I 互感器

86528* 速度仪
* 取决于涡轮增压器的规格。

备件 12
带零件编号的转子总成示图 12.3 页 128
12.3
12.3 带零件编号的转子总成示图
September 2016
HZTL2412_ZH
Revision F

备件 12
带零件编号的转子总成示图 12.3 页 129
零件编号名称
21000 轴
September 2016
21002 活塞环
25000 压缩机叶轮
32101 滑动轴承轴颈箱
32103 保险环
32105 止推环
32106 止推轴承
32108 活塞环
32109 密封垫片
32110 轴承凸缘
32111 辅助轴承
32112 轴承凸缘
32221 轴承盖
HZTL2412_ZH
32222 O 形圈
42001 轴承套
42008 (包括在客户备件套件内) 内六角螺栓
43001 隔板
43012* 金属 C 形圈
* 取决于涡轮增压器的规格。
Revision F

Table of contents Page 1
Table of contents
September 2016
1 Preliminary remarks
1.1 Purpose of this manual
1.2 Layout and function
1.3 Intended use of the turbocharger
1.4 Storage of new turbochargers and spare parts
1.5 Essential information
1.6 Symbols and definitions
1.7 Turbocharger rating plate
1.8 Contact information
2 Safety
HZTL2412_EN
2.1 Introduction
2.2 CE conformity
2.3 Definition of mandatory signs
2.4 Definition of Safety instructions
2.5 Warning plates on the turbocharger
2.6 Safe operation and maintenance
2.7 Hazards during operation and maintenance
2.8 Deflagration on gas engines
2.9 Periodic checking of the pressure vessel
2.10 Lifting loads
3 Start-up
3.1 Oil supply
3.2 Inspection work
Revision F
3.3 Commissioning after taking out of operation
4 Operation
4.1 Noise emissions
4.2 Servicing work
4.3 Expected exchange intervals
4.4 Speed measurement
4.5 Stopping the engine

Table of contents Page 2
5 Maintenance
5.1 Foreword to Maintenance
September 2016
5.2 Cleaning the compressor during operation
5.3 Turbine cleaning during operation
5.4 Cleaning components mechanically
6 Troubleshooting
6.1 Malfunctions when starting
6.2 Surging of the turbocharger
6.3 Malfunctions during operation
6.4 Malfunctions when stopping
6.5 Speed measurement system
7 Removal and installation

7.1 Transport
7.2 Turbocharger weights
HZTL2412_EN
7.3 Remove the turbocharger
7.4 Installing the turbocharger
8 Disassembly and assembly

8.1 Introduction
8.2 Module weights
8.3 Disassembling and assembling turbocharger
8.4 Axial clearance A and radial clearance B
8.5 Radial clearances N and R
8.6 Table of tightening torques
9 Taking out of operation

9.1 Shutting down the turbocharger
10 Mothballing the turbocharger

Revision F
10.1 Taking the engine out of operation for up to 12 months

10.2 Taking the engine out of operation for more than 12 months
11 Disposing of turbocharger components
12 Spare parts
12.1 Ordering spare parts
12.2 View of turbocharger showing part numbers
12.3 View of cartridge group showing part numbers

Preliminary remarks 1
Purpose of this manual 1.1 Page 3
1 Preliminary remarks
September 2016
1.1
1.1 Purpose of this manual
This operation manual belongs to the turbocharger with the identical HT

number (01), see the cover sheet of the operation manual and the turbo-
charger rating plate.
HZTL2412_EN
Operation Manual
This Operation Manual enables you to familiarize yourself with the turbo-
charger supplied by ABB Turbo Systems and to use it as intended.
It provides important information in order that the turbocharger can be op-

erated safely, correctly and efficiently.
This Operation Manual complements and expands existing national regu-

lations concerning work safety and accident prevention.
Target group
This Operation Manual is intended for engineers and qualified mechanics

who are responsible for operating the engine and the turbocharger in-
stalled on it.
Revision F
Availability of operation manual
An operation manual must be available at all times at the place where the
turbocharger is used.
Everyone who operates or works on the turbocharger must have first read
and understood the operation manual.

Layout and function 1.2 Page 4
1.2
1.2 Layout and function
September 2016
HZTL2412_EN
1 Suction branch / filter silencer 8 Gas outlet flange
2 Compressor casing 9 Nozzle ring
3 Diffuser 10 Turbine casing
4 Bearing casing 11 Turbine-end bearing flange
5 Axial thrust bearing 12 Compressor-end bearing flange
6 Radial plain bearing (visible only 13 Compressor wheel
at turbine end)
Revision F
7 Turbine

Layout and function 1.2 Page 5
Mode of operation
The turbocharger is a turbomachine consisting of the following main com-

September 2016
ponents:
¡ Turbine
¡ Compressor
These are mounted on a common shaft.
Exhaust gases from the diesel or gas engine flow through the turbine cas-
ing (10) and the nozzle ring (9) to impinge on the turbine (7).
The turbine (7) uses the energy contained in the exhaust gas to drive the
compressor wheel (13). The compressor draws in fresh air, compresses it
and then forces it into the engine's cylinders.
The exhaust gases escape into the ambient air through the exhaust gas
pipe, which is connected to the gas outlet flange (8).
HZTL2412_EN
The air, which is necessary for operation of the diesel or gas engine and
is compressed in the turbocharger, is drawn into the compressor wheel
(13) through the suction branch or filter silencer (1). It then passes
through the diffuser (3) and leaves the turbocharger through the outlet on
the compressor casing (2).
The rotor runs in two radial plain bearings (6), which are located in the
bearing flanges (11/12) between the compressor and the turbine. The axi-
al thrust bearing (5) is located between the two radial plain bearings.
The bearings are connected to a central lubricating oil duct which is sup-
plied by the engine's lubricating oil circuit. The oil outlet is always at the
lowest point of the bearing casing (4).
Revision F

Intended use of the turbocharger 1.3 Page 6
1.3
1.3 Intended use of the turbocharger
September 2016
This turbocharger supplied by ABB Turbo Systems has been developed
for use on diesel engines to generate the volume of air and the charg-
ing pressure required to operate the engine.
NOTICE The engine builder has provided ABB Turbo Systems with information
regarding the intended use of the engine, from which the operating lim-
its specific to the turbocharger shown on the rating plate (such as oper-
ating speeds, temperatures, exchange intervals / replacement intervals)
have been derived.
If it is used in conjunction with a gas engine, the engine must not be in-
stalled in a potentially explosive environment, and precautionary
measures must be taken to ensure that the machine room as a whole is
classified as not potentially explosive.
Any other use will be regarded as a special application which must first
be discussed with ABB Turbo Systems. The manufacturer accepts no
liability for other applications. If it is used otherwise, ABB Turbo Sys-
tems reserves the right to reject all warranty claims.
State of the art This turbocharger was built according to state-of-the-art technology and is
HZTL2412_EN
operationally safe according to recognised safety regulations.
Improper operation and maintenance of the turbocharger can result in

danger to life and limb of the user or third parties. In addition, improper
use may cause damage to the machine.
WARNING u The machine may be operated only by trained personnel.
Use of the turbocharger as intended also includes observance of the in-

stallation / fitting, disassembly / removal, operating, maintenance / servic-
ing and repair conditions specified by the manufacturer. Disposal regula-
tions set down by local authorities must be observed.
Perfect condition The turbocharger may be installed only when in technically perfect condi-
tion while observing the instructions given in the engine builder's manual.
It may be used only for the intended purpose and operated in compliance
Revision F
with the operation manual.
u Malfunctions which could affect safety must be eliminated immediately.
The manufacturer accepts no liability for any damage resulting from unau-
thorised alterations to the turbocharger.

Storage of new turbochargers and 1.4 Page 7

spare parts
1.4 Storage of new turbochargers and spare

parts
September 2016
1.4
Storage of new turbochargers and spare parts up to 6 months
New turbochargers and spare parts from ABB Turbo Systems can be stored
in sealed packaging without additional mothballing measures for up to 6
months from the date of delivery (marked by the VCI label on the package).
Volatile Corrosion Inhibitor (VCI)
Only dry rooms in which the relative humidity is between 40…70 % and
no condensation can form are suitable for storage.
Storage of new turbochargers and spare parts for more than 6 months (VCI)
HZTL2412_EN
Protection of health when handling VCIs

VCI products are not hazardous in the sense of the Hazardous Sub-
stances Ordinance. Nevertheless, the following points are to be ob-
WARNING
served when handling VCIs:
u Ensure good room ventilation.
u Do not eat, drink or keep food at the workplace while working with
VCIs.
u Wear safety gloves.
u Clean hands and face after working with VCIs.
u For further information refer to www.branopac.com.
Wear safety gloves to protect against chemical hazards.
The following mothballing measures are required every 6 months:

Revision F
u Open the package.

u Remove the VCI corrosion protection emitter from the package and
replace it with a new, identical VCI corrosion protection emitter. New
VCI corrosion protection emitters can be obtained at
www.branopac.com.
u Dispose of the old VCI corrosion protection emitter in an environmen-
tally compatible manner, professionally and in accordance with local
regulations.
u Seal the package. The better the external seal is designed, the more
permanent the protection.

Storage of new turbochargers and 1.4 Page 8

spare parts
Long-term storage of replacement turbochargers or spare parts
Per order, turbochargers or cartridge groups will be prepared by ABB Tur-
September 2016
bo Systems for prolonged storage. The package is equipped with a
hygrometer (see illustration).
The following measures are required every 6 months:
u Check the hygrometer (02) in the sight-glass. There is an opening (01)

in the wooden crate which allows this check to be carried out. When
the display field has changed colour at the 70% level, the maximum
permissible humidity has been exceeded. In this case the turbocharger
or rotor must be inspected by an ABB Turbocharging Service Station
HZTL2412_EN
and repacked.
u Inspect the package for damage. If the package is damaged, the tur-
bocharger or cartridge group must be inspected by an ABB Turbo-
charging Service Station and repacked.
After every 3 years the following work steps must be performed by an

ABB Turbocharging Service Station:
¡ Inspect the components

¡ Exchange the desiccant agent
¡ Repackage the components.
Replacement components ready for operation

If the 70% display field of the hygrometer (02) has not changed colour
and the package is undamaged, the replacement turbocharger or re-
NOTICE
placement cartridge group can be placed into operation without any pri-
or testing by an ABB Turbocharging Service Station.
Revision F
Unpacking replacement turbochargers or spare parts
The corrosion protection effect ends after the material is unpacked from
the VCI package.
To avoid the formation of condensation, the surroundings and the content

of the package must have the same temperature during unpacking.

Essential information 1.5 Page 9
1.5
1.5 Essential information
September 2016
Organisational measures
In addition to this manual, the general, statutory regulations applicable in

the respective country for the prevention of accidents and the protection of
the environment must be observed.
This also applies to the provision and wearing of personnel protection

equipment.
The safety and risk consciousness of the personnel working on and

with the turbocharger must be checked regularly with reference to this
manual.
NOTICE
u The turbocharger must be shut down immediately by stopping the en-

HZTL2412_EN
gine in the event of alterations affecting safety or of corresponding op-

erating behaviour. The fault must be reported to the person or depart-
ment responsible.
Additions and alterations to, and conversions of the turbocharger that

could compromise safety require the prior approval of ABB Turbo Sys-
tems.
NOTICE
Revision F

Original parts and safety
Original parts and accessories are specially designed for the turbocharger
September 2016
supplied by ABB Turbo Systems.
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
WARNING
and injury to personnel.
u Only use original parts from ABB Turbo Systems.
ABB Turbo Systems accepts no liability for any damage resulting from the
use of non-original parts and corresponding accessories.
Competence of personnel
The turbocharger must only be operated and serviced by trained and au-
HZTL2412_EN
thorised personnel. Basic mechanical training is a prerequisite.
Revision F

Design variants
This document is valid for different design variants of turbochargers.

September 2016
There may be sections and descriptions of components that are not rele-
vant for a specific turbocharger variant.
ABB Turbocharging Service Stations will be happy to provide information

on 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.
Registered Trademarks
Registered trademarks of external companies are used in this document.

The trademarks are marked with ®.
HZTL2412_EN
Revision F

Symbols and definitions 1.6 Page 12
1.6
1.6 Symbols and definitions
September 2016
The following symbols are used in the documents:
w Prerequisite
u Step of a procedure
¡ List, first level
- List, second level
[➙ ] Refers to a page number
Definition of notes
Note
A note provides suggestions which facilitate the work on the product.
HZTL2412_EN
NOTICE
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
The caution and warning signs are described in the chapter Safety.
ABB Turbo Systems
In this document, ABB Turbo Systems Ltd is abbreviated to ABB Turbo

Revision F
Systems.
Official ABB Turbo Systems Service Stations
In this document, official service stations are referred to as ABB Turbo-

charging Service Stations. They are inspected and certified regularly by
ABB Turbo Systems. See also chapter Contact information [➙ 15].

Turbocharger rating plate 1.7 Page 13
1.7
1.7 Turbocharger rating plate
September 2016
Operating limits
01 Turbocharger operating limits at engine overload (110%).
Only when operating in the test rig unless otherwise agreed with the
HZTL2412_EN
enginebuilder.
02 Turbocharger operating limits during operation
Recommended inspection
03 Inspection interval of plain bearings in 1000 h
and replacement intervals
of turbocharger compo- 04 Replacement interval of compressor in 1000 h
nents 05 Replacement interval of turbine in 1000 h
Further data
06 Customer part number
07 Designation of the special design
08 Weight of turbocharger in kg
09 Turbocharger type
10 Serial number
11 Year of construction of turbocharger
Revision F

Turbocharger rating plate 1.7 Page 14
1.7.1 Explanation of the rating plate
September 2016
The recommended replacement intervals and the corresponding opera-
tional limits are jointly defined with the engine manufacturer. This
information is specific to the system.
Operation above the indicated values nBmax, tBmax can considerably shorten the
recommended replacement intervals. In such cases, we recommend that you
contact the nearest official ABB Turbocharging service station.
nMmaxand tMmax normally apply only when running at overload (110%) during tri-
als on the engine test bed. These limits can also be permitted during operation
for special applications. Operation above nMmax and tMmax is not permitted.
Non-observance of the recommended replacement intervals can increase the
risk of unpredictable component failures.
1.7.2 Positions of the rating plates
HZTL2412_EN
One rating plate (01) each is attached on the left and the right side of the
turbocharger bearing casing. Revision F

Contact information 1.8 Page 15
1.8
1.8 Contact information
September 2016
Contact information
Contact information for the official service stations of ABB Turbo Systems
is available online.
u Scan the QR code to access our website.
ABB Turbo Systems Ltd

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
HZTL2412_EN
Revision F

Safety 2
Introduction 2.1 Page 17
2 Safety
September 2016
2.1
2.1 Introduction
Turbochargers manufactured by ABB Turbo Systems are state of the art
and comply with the pertinent safety and health-protection requirements
that applied when the turbocharger was manufactured. Consequently, the
turbocharger is safe to operate. Nevertheless, during turbocharger opera-
tion and when working on the turbocharger, residual risks can exist which:
¡ originate from the turbocharger itself and its accessories

¡ originate from the operating and auxiliary materials used
¡ are the consequence of insufficient observance of the safety instruc-
tions
¡ are the consequence of unsatisfactory and improper execution of
maintenance and inspection work
The operator is responsible for access to the turbocharger as well as the

organisational measures which regulate the safe handling of the turbo-
HZTL2412_EN
charger by his personnel.
All instructions in this chapter must be observed to ensure safe and trou-
ble-free turbocharger operation and during work on the turbocharger.
In the same vein, all other specially marked safety instructions in every
chapter of this manual must be observed (see the section entitled Defini-
tion of safety instructions).
Revision F

Safety 2
CE conformity 2.2 Page 18
2.2
2.2 CE conformity
September 2016
Information
ABB turbochargers fulfil Directive 2006/42/EC on machinery and are con-

sidered partly completed machinery in the sense of Article 2 g.
HZTL2412_EN
Revision F

Safety 2
Definition of mandatory signs 2.3 Page 19
2.3
2.3 Definition of mandatory signs
To be worn at all times
September 2016
Protective clothing Safety footwear to protect

against mechanical hazard
and risk of falling
To be worn according to the specific work

Safety glasses Safety goggles
Safety gloves to protect Respiratory mask to protect

against against
- Mechanical hazard - Dusts
- Chemical hazard - Gases
- Thermal hazard
Safety helmet Ear protection
HZTL2412_EN
Revision F

Safety 2
Definition of Safety instructions 2.4 Page 20
2.4
2.4 Definition of Safety instructions
September 2016
The following symbols and terms used in this manual concern safety or
refer to possible hazards:
Definition of warning
Serious personal injuries and even accidents with fatal consequences
may occur if work and operating instructions marked with this symbol and
WARNING
the word WARNING are either not followed or not followed precisely.
u Warning signs must be observed at all times.
Definition of caution
Serious machine or property damage may occur if work and operating
instructions marked with this symbol and the word CAUTION are either
CAUTION
not followed or not followed precisely.
u Caution signs must be observed at all times.
HZTL2412_EN
Revision F

Safety 2
Warning plates on the turbocharger 2.5 Page 21
2.5
2.5 Warning plates on the turbocharger
September 2016
Warning plates are attached to the turbocharger at the following places:

HZTL2412_EN
If warning plates are not present at the intended places or are not legible,
then proceed as follows:
u Order new warning plates from ABB Turbocharging Service Stations.

u Remove unreadable warning plates.
u Clean and degrease surfaces provided for warning plates.
u Attach new warning plates.
Uninsulated turbochargers
When uninsulated turbochargers are delivered to the engine builder, the

warning plates must be subsequently attached to the insulation. This is
the responsibility of the engine builder.
Revision F

Safety 2
Safe operation and maintenance 2.6 Page 22
2.6
2.6 Safe operation and maintenance
September 2016
The instructions specified in this section are for the safety of personnel.
Together with the instructions in the Hazards during operation and
maintenance section, they allow the user to safely use the turbocharger.
Work safety and work area safety
Risk of falling
There is the risk that someone can fall when working on the turbo-
charger.
WARNING
u Do not climb on the turbocharger or on parts attached to it or use
these as climbing aids.
u When working at levels above the head, use climbing aids and work
platforms suitable for this purpose.
HZTL2412_EN
u Observe all general regulations for the prevention of accidents.
u Do not work on the turbocharger if you are under physical or mental
stress.
u Work only with suitable tools as well as equipment and working mate-
rials that are in perfect condition.
u Electric tools must be solidly earthed, and connecting cables may not
be damaged.
u Keep the workplace clean, clear away loose objects and remove ob-
stacles on the floor.
u Keep the floor, equipment and the turbocharger clean.
u Have oil binding materials ready at hand and keep oil catch pans
ready or in position
u Eliminate leaks.
u Keep fire-protection materials and fire-extinguishing equipment ready.
Revision F
Welding work in the vicinity of the turbocharger
u When performing welding work in the vicinity of the turbocharger, al-

ways cover the filter silencer to prevent the filter mat from being dam-
aged.
u Keep flammable objects and substances out of the range of flying
sparks.
u Cover all connections on the turbocharger so that no foreign objects
can enter the turbocharger.
u Wear personal protective equipment (PPE) for welding operations.

Safety 2
Safety during start-up / commissioning and operation

September 2016
The turbine casing insulation of the TPS44-F supplied by ABB Turbo

Systems is also burst protection.
WARNING Serious personal injuries or fatal accidents can occur, if the turbine cas-
ing insulation of the TPS44-F supplied by ABB Turbo Systems is re-
moved. The burst protection is integrated into the turbine casing insula-
tion of the TPS44-F supplied by ABB Turbo Systems.
Separate burst protection is fitted to TPS44-F turbochargers without in-
sulation that have been ordered from ABB Turbo Systems.
u Never operate TPS44-F turbochargers that have been supplied by

ABB Turbo Systems with insulation if this insulation from ABB Turbo
Systems is not in place.
u Never operate turbochargers without burst protection. If the insula-
tion from ABB Turbo Systems is not in place, the separate burst pro-
tection (57200) must be fitted before operation. (See View of
turbocharger showing part numbers [➙ 126].)
HZTL2412_EN
u Before starting work, carry out visual inspection of working area.

u Remove any obstacles and objects lying around.
u Before start-up / commissioning, check all pipes from and to turbo-
charger for damage and leaks.
u Don't work in any way that could impair safety when working on turbo-
charger.
u After about every 12 hours of operation or at least once a day, inspect
turbocharger for visible damage and defects.
u Immediately report any damage or changes in operational perfor-
mance to person responsible.
u If damage is discovered, immediately shut down turbocharger and se-
cure it against inadvertent or unauthorized use.
u When switching on auxiliary power sources (hydraulics, pneumatics,
electricity, water), keep an eye open for any hazards resulting from
Revision F
supplying these power sources.
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 and auxiliary materials" must be observed.
u Observe the material safety data sheet for the cleaning agent or solvent.

Safety 2
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
September 2016
your cleaning work.
Safety during disassembly, assembly, maintenance and troubleshooting
u Always perform the specified adjustments, servicing as well as inspec-

tion work and observe inspection intervals.
u Inform operating personnel about all service and repair work before
beginning.
u Before opening a cover or removing a protective device on a turbo-
charger, the engine must be switched off and the turbocharger must
have come to a standstill.
u Ensure that the supply of oil is interrupted, especially with an external
oil supply.
u Put the engine into operation only after all parts have been refitted
properly.
HZTL2412_EN
Mechanical work on the turbocharger
Possible damage to or destruction of components on the turbocharger.
CAUTION u Perform only those tasks that are described in this manual.
u Perform work only for which training has been carried out.
Safety when taking out of operation or preparing for mothballing
u Secure the rotor so it cannot turn. The rotor can turn on its own from
the force of the stack draught.
u Clean the turbocharger before mothballing it.
u Observe the material safety data sheet for the cleaning and mothball-
ing agents.
Revision F
safety data sheet.

Safety 2
Hazards during operation and 2.7 Page 25

maintenance
2.7
2.7 Hazards during operation and maintenance
September 2016
Mechanical hazards during operation
During normal operation, no mechanical hazards emanate from the turbo-

charger if it has been installed properly.
Risk of injury
Contact with rotating parts can lead to serious injuries. The turbo-
charger must never be operated without a filter silencer or an air suction
WARNING
branch. When the engine is at a standstill, the rotor can turn on its own
because of stack draught.
u Operate the turbocharger in accordance with instructions.
u During maintenance work, secure the rotor against unintentional ro-
tation.
HZTL2412_EN
Mechanical hazards when working on the turbocharger
During maintenance work, various risks can occur through the improper
handling of components, through the non-observance of work instructions,
due to inadequate care or as a consequence of insufficient training.
Mechanical hazards
Severe injuries to personnel or fatal accidents can be caused by me-
chanical influences as a consequence of hazardous and inadequate
WARNING
operational procedures.
u Observe the general rules for occupational safety and prevention of
accidents.
u Ensure workplace safety.
u Only perform operations that are described in this document.
u Only perform operations for which you have previously received in-
struction or training.
Revision F

Safety 2

maintenance
Hazards due to noise
The development of noise during operation is influenced by the installation
September 2016
and operating conditions. Noise with a sound pressure level exceeding
85 dB(A) is harmful.

Noise can cause impaired hearing, damage to health, mental disturb-
ances, diminished attention and irritation.
WARNING
u Always wear ear protection when the engine is running.
u When the sound pressure level is above 85 dB(A), always wear ear
protection.
Wear ear protection.
Hazards due to hot surfaces and substances
HZTL2412_EN
During operation, turbocharger surfaces and attached parts as well as op-
erating materials (lubricating oil) become hot. The surface temperature is
dependent on the effectiveness of the insulation being used. The tem-
perature can become high enough so that it falls into ranges where burns
are possible.
Risk of burning
Touching hot surfaces or contact with hot operating materials can lead
to serious burns.
WARNING
u Do not touch hot surfaces and heed the warning plate on the turbo-
charger.
u Wear heat-resistant safety gloves and protective clothing.
u Allow the turbocharger to cool down before carrying out any work.
Wear safety gloves to protect against thermal hazards.

Revision F

Safety 2

maintenance
Hot surfaces on the non-insulated turbocharger

Non-insulated turbochargers can cause serious injuries to personnel
September 2016
(burns).
WARNING
The turbocharger is supplied by ABB Turbo Systems without insulation
depending on the order from the enginebuilder. If supply is without insu-
lation, 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.
Hazards due to operating and auxiliary materials
Operating and auxiliary materials are substances used for operation or the
execution of maintenance work. Oils, greases, coolants, cleaning agents
and solvents, acids, etc. can be regarded as hazardous materials. Operat-
HZTL2412_EN
ing and auxiliary materials can be combustible and easily ignited.
Handling operating and auxiliary materials

Ingestion or inhalation of vapours of operating and auxiliary materials or
contact with such can cause damage to health.
WARNING
u Avoid inhalation and contact with the skin.
u Ensure good ventilation.
u Observe details in the safety data sheets of the operating and auxil-
iary materials.
u Observe local laws.
Wear safety goggles.
Wear a respiratory mask to protect against gases.

Revision F

Safety 2

maintenance
Risk of fire, explosion

Flammable and combustible operating materials and supplies can catch
September 2016
fire or resulting vapours can lead to an explosion.
WARNING
u Observe the details in the material safety data sheets of the operat-
ing and auxiliary materials.
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 aeration and ven-
tilation.
Risk of environmental damage

The escape of operating and auxiliary materials into the atmosphere or
contamination of the ground and water due to improper disposal can
CAUTION
lead to environmental damage.
u Handle operating and auxiliary materials carefully.
HZTL2412_EN
u Heed the instructions for use, safety data sheets and hazard notices
on the containers of the operating and auxiliary materials.
u Wear appropriate protective clothing.
u Avoid inhalation and contact with the skin.
u Ensure that the work space is adequately ventilated.
u Seal containers tightly immediately after use and put them away.
u Collect used working and auxiliary materials safely, store them sepa-
rately in suitable containers and dispose of them properly and in an
environmentally compatible manner in accordance with statutory regu-
lations.
u In the event of leaks or after spilling, immediately spread a suitable
binding agent and dispose of it properly and in an environmentally
compatible manner in accordance with statutory regulations.
Revision F

Safety 2

maintenance
Hazards when handling insulating materials

September 2016
Hazards due to insulating materials

Dust and fibres from insulating materials can cause damage to health
or irritations. Unsuitable, combustible insulating materials signify a fire
WARNING
hazard.
u Use only suitable, non-combustible insulating materials.
u Ensure that the work area is well ventilated.
u Avoid stirring up dust.
u Use tools and processes which keep dust to a minimum.
u Remove packing materials only in the work area.
u Take particular care when removing old insulating materials.
u Dispose of insulating materials properly and in an environmentally
compatible way in accordance with applicable local regulations.

HZTL2412_EN
Wear a respiratory mask to protect against dusts.
u Use only suitable, non-combustible insulating materials.

u Ensure that the work area is well ventilated.
u Wear suitable work clothing (safety glasses, respiratory mask).
u Avoid stirring up dust.
u Use tools and processes which keep dust to a minimum.
u Remove packing materials only in the work area.
u Take particular care when removing old insulating materials.
u Dispose of insulating materials properly and in an environmentally
compatible way in accordance with applicable local regulations.
Revision F

Safety 2

maintenance
Hazards due to electrical components
September 2016
Hazards due to electrical components
Electrical components operate with voltages which can present hazards
to humans.
WARNING
u All work on or with electrical components may only be performed by
trained specialists.
u Heed any country-specific regulations.
HZTL2412_EN
Revision F

Safety 2
Deflagration on gas engines 2.8 Page 31
2.8
2.8 Deflagration on gas engines
September 2016
ABB turbochargers can tolerate a deflagration with a transient pressure

increase of 12 bar.
After a deflagration event ABB Turbo Systems recommends verifying the

following points on the turbocharger:
¡ Position of the turbine and compressor casings to the bearing casing

¡ Shifting of the bearing casing in relation to the bracket
¡ Cracks in casings
If during external inspection anomalies are found or if a particularly strong

deflagration event has taken place, it is also recommended to check the
bearings of the turbochargers before the next start. This inspection and
evaluation must be carried out by an ABB Turbocharging Service Station.
HZTL2412_EN
Revision F

Safety 2
Periodic checking of the pressure 2.9 Page 32

vessel
2.9
2.9 Periodic checking of the pressure vessel
September 2016
The pressure vessels used by ABB Turbo Systems, such as those for wet
or dry cleaning, are so-called "simple pressure vessels".
¡ The local, statutory regulations covering periodic checks of pressure

vessels must be observed.
¡ The operator is responsible for the safe operation of the pressure ves-
sel.
Hazards from pressure vessels

The operator must keep the pressure vessel in a proper condition and
monitor it. Necessary repair or maintenance work must be carried out
WARNING
without delay and the required safety precautions must be taken.
u Pressure equipment must not be operated if it has defects.
HZTL2412_EN
Revision F

Safety 2
Lifting loads 2.10 Page 33
2.10
2.10 Lifting loads
September 2016
Suspended loads
Loads not suspended in compliance with regulations may lead to per-
sonal injury or accidents with fatal consequences.
WARNING
u Loads must always be fastened to technically perfect lifting gear with
sufficient loading capacity.
u Make sure the load is suspended properly on the crane hook.
u Do not let anyone stand beneath a suspended load.
Wear safety gloves to protect against mechanical hazards.
Wear safety helmet.

HZTL2412_EN
In the case of two or more suspension points, the slinging angle must not
exceed 45°. This avoids excessive loading due to inclined tensile loading.
u Fasten turbocharger assemblies / components as described in respec-

tive handling steps.
Revision F
u Before attaching slings, allow turbocharger components to cool down

(maximum 80°C).
u Use suitable protection at sharp edges.
u Completely screw in assembly / fitting devices without fail so that they
cannot work loose during use.
u Use assembly / fitting devices only for applications described.
u Make sure removed turbocharger components stand safely and se-
curely.

Start-up 3
Oil supply 3.1 Page 35
3 Start-up
September 2016
3.1
3.1 Oil supply
A carefully designed and installed oil supply, which functions in all possi-
ble operational conditions, is an important prerequisite for trouble-free tur-
bocharger operation.
The turbocharger is normally lubricated with oil from the engine oil circuit.
If a separate lubricating system is used, then emergency lubrication is al-
so to be provided.
u Heed the instructions of the engine builder when selecting the lubricat-
ing oil and oil-change intervals.
Oil filtration
Depending on the turbine specifications and bearings used, varying

HZTL2412_EN
amounts of contaminants have to be filtered out of the lubricating oil to

avoid dangerous wear of the bearing parts.
CAUTION
The standard oil filter specification for the turbocharger is 34 µm. This
means that contaminants larger than 0.034 mm must be filtered out of the
oil with a separation efficiency > 99%.
u Fit an accessory filter if engine oil filter is not efficient enough.

u If the engine is started cold and the flow resistance rises to above 0.5
bar due to deposits of dirt in the accessory filter, a bypass must open
which ensures that oil flows to the turbocharger by circumventing the
filter.
u Check that oil filters are clean before commissioning.
Revision F
Also follow the enginebuilder's instructions regarding filter mesh and

separation efficiency.
NOTICE

Start-up 3
Lubricant
September 2016
All lubricating oils used for engines are admissible.
NOTICE
Oil inlet viscosity and temperature
The oil-inlet temperature must not exceed 105°C. Permissible oil-inlet vis-
cosities and oil-inlet temperatures are shown in the following chart.
HZTL2412_EN
1) Kinematic viscosity (mm2/s = cSt)
2) Oil-inlet temperature (°C)
A Permissible range
Revision F
Falling below the minimum oil inlet temperature

Serious machine or property damage can be caused by excessively
high oil viscosity and the resulting lack of oil in the bearings.
CAUTION
u Do not allow the oil inlet temperature to fall below the minimum 30 ºC
when starting the engine.
u The oil inlet temperature must never be less than 10 °C.

Start-up 3
Oil pressure
The oil pressure in front of the turbocharger must be maintained precisely

September 2016
to ensure trouble-free operation.
Status for operation Oil pressure in front of

turbocharger
[bar]
Normal operation 2.0 … 4.5
Engine start: cold oil, permissible for maximum ≤ 8.0
15 minutes
Engine idling ≥ 0.2
Pre- and post-lubrication (engine stopped) ≤ 1.0
Prelubrication
Serious machine or property damage might result if the turbocharger is
not supplied with oil when the engine is starting.
CAUTION
u Activate prelubrication device before starting engine.
HZTL2412_EN
Revision F

Start-up 3
Lubricating oil temperature at the inlet
September 2016
Machine damage
Machine damage may result if the oil temperature at the oil inlet ex-
ceeds the permissible range.
CAUTION
u Keep the oil temperature at the oil inlet as specified in the following
table.
Status for operation Oil temperature at inlet

Toil,inlet
Permissible 30 … 105 °C
Temporarily permissible (< 1 h) → alarm > 105 °C
Not permissible → stop engine > 110 °C
Not permissible → do not start engine (before < 30 °C
starting: preheat oil)
HZTL2412_EN
Lubricating oil temperature at the outlet
The oil temperature at the outlet depends mainly on:
¡ lubricating oil temperature and pressure at the oil inlet

¡ engine load and turbocharger speed
¡ exhaust gas temperature
The maximum permissible oil temperature at the outlet is listed in the fol-
lowing table. The specified oil outlet temperature must be regarded as an
alarm value for turbocharger operation and be monitored in accordance
with standard regulations.
Status for operation Oil temperature at outlet

Toil,outlet
Permissible ≤ 160 °C
Revision F
Temporarily permissible → alarm > 160 °C

Not permissible → stop engine > 180 °C
Permissible ≤ Toil,inlet + 55 K
Temporarily permissible → alarm > Toil,inlet + 55 K
If the turbocharger has been operated outside the permissible range for a
prolonged period of time, ABB Turbo Systems recommends having the
turbocharger inspected by an ABB Turbocharging Service Station.

Start-up 3
Inspection work 3.2 Page 39
3.2
3.2 Inspection work
September 2016
Inspection work includes preventive visual controls plus monitoring and

measuring work before and during commissioning. Inspections help detect
changes to the turbocharger. Machine damage can be avoided.
3.2.1 Inspection before commissioning
Monitoring devices u Check for correct functioning.
Filter mat u Inspect for damage.
Lubricating system u Check oil filter for cleanliness before commissioning.
Contaminated oil
HZTL2412_EN
Particles of dirt and solid matter in the oil can cause serious damage to
the machine or property.
CAUTION
u During initial commissioning and after all service work, the complete
lubricating system must be flushed thoroughly with warm oil.
u When running in the engine and after all service work on the lubricat-
ing system, special running-in filters must be used.
u Check oil pressure in oil supply lines.
Prelubrication
Serious machine or property damage might result if the turbocharger is
not supplied with oil when the engine is starting.
CAUTION
u Activate prelubrication device before starting engine.
Revision F
Warning plates on u Check whether the warning plates are present and legible.
turbocharger
u Check whether the protective sheets have been removed.

Start-up 3
Inspection work 3.2 Page 40
3.2.2 Check after start-up (engine at idling speed)
September 2016
Lubricating system
u Check oil pressure in oil supply lines.

u Check oil inlet temperature.
The permissible values are listed in the section Oil supply.
Gas, air and oil lines
u Check all gas, air and oil lines for leaks after starting the engine.
3.2.3 Check when running up engine
u Measure speed, oil pressure and charging pressure at various engine
HZTL2412_EN
performance levels.
u Measure exhaust gas temperature in front of and behind turbine.
u Measure air temperature in front of and behind compressor.
The measured values must be compared with the values in the acceptance
test report, while taking different operating conditions into account.
Lubricants and pastes used during assembly of the turbocharger liquefy

or vaporise and might escape as an oily liquid in the first few hours after
commissioning. If oily liquid continues to escape after this period, an oil
leak must be suspected. The first step is to check for leakage of the oil
NOTICE
supply to the turbocharger. If this is leaky, contact an official ABB Tur-
bocharging service station.
Revision F
3.2.4 Inspection after 100 service hours
Clean or replace lubricating oil filters after the first 100 service hours.

Start-up 3
Commissioning after taking out of 3.3 Page 41

operation
3.3
3.3 Commissioning after taking out of operation
September 2016
If provided u Remove cover plates (blind flanges) between compressor casing out-
let and charge air duct, before gas inlet and after gas outlet.
u Inspect exhaust gas duct / line in front of and after turbine for any
combustion deposits, foreign matter or residual water. Clean and re-
move.
u Inspect air supply line or filter silencer for any foreign matter. Clean
and remove.
u Start up turbocharger oil circulation system at engine end.
u Prepare turbocharger for operation as instructed in section "Inspection
work before start-up / commissioning" of chapter headed "Start-up /
commissioning".
u Start up turbocharger.
HZTL2412_EN
Revision F

Operation 4
Noise emissions 4.1 Page 43
4 Operation
September 2016
4.1
4.1 Noise emissions

Noise can cause impaired hearing, damage to health, mental disturb-
ances, diminished attention and irritation.
WARNING
u Always wear ear protection when the engine is running.
u When the sound pressure level is above 85 dB(A), always wear ear
protection.
Wear ear protection.
The sound pressure level (A-weighted) of emissions is measured at a dis-

tance of 1 metre from the turbocharger.
HZTL2412_EN
The highest sound pressure level of emissions1) reaches a maximum of

105 dB(A) near the filter silencer and over the entire speed range.
The following prerequisites must be fulfilled on the turbocharger in order

to observe this limit value:
¡ Fitted air-inlet system

¡ All standard, noise-reducing measures have been taken 2).
¡ The bellows at the air outlet have been perfectly insulated acoustically
by the engine builder. He is also responsible for insulating the charge
air / scavenging air line and the charge air cooler.
Revision F
1) Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 :

A-weighted emission sound pressure level
2) In the event of divergent insulation designs, the engine builder must en-
sure that equivalent acoustic insulating measures are taken.

Operation 4
Noise emissions 4.1 Page 44
Suggestion for noise insulation of the bellows
September 2016
01 Compressor casing 04 Insulation pads
HZTL2412_EN
02 Bellows 05 Insulation mat (at least 15 mm)
03 Charge air duct / scavenging 06 Sheet metal cover
air line
Revision F

Operation 4
Servicing work 4.2 Page 45
4.2
4.2 Servicing work
September 2016
Service work to be carried out during operation involves visual checks,

monitoring, measuring, inspection work and functional checks. It is then
possible for changes to the turbocharger to be identified and rectified. In
this way, it can be ensured that the turbocharger remains in full working
order.
Service intervals
Service work on the turbocharger that is neglected or carried out too
late can lead to excessive contamination and wear as well as operating
CAUTION
failures.
u Carry out service work at specified time intervals.
Shortened service intervals

Despite observance of the service intervals, unusual loads, such as
HZTL2412_EN
several start-stops a day, harsh environmental factors, poor fuel quality

CAUTION
or heavy installation vibration can lead to premature machine damage.
u A shortened service interval must be arranged with ABB Turbo Sys-
tems.
Service inspection after 5 years

To prevent age- and stoppage-related machine damage, an inspection
by an ABB Turbocharging Service Station is recommended at the latest
NOTICE
5 years after the last service.
4.2.1 Service work every 25 … 50 hours
u Visual inspection for air, exhaust gas, water and oil leaks.
u Record operating data and enter it in the engine logbook.
Revision F
u Clarify the cause of any variances.
Unknown changes during operation

The consequences can range from an impairment to a breakdown.
CAUTION u Have unknown causes clarified by an ABB Turbocharging service
station.

Operation 4
September 2016
4.2.2 Servicing work according to the engine manufacturer's instructions
Oil filter u Clean or replace oil filter in supply line to turbocharger when engine is
not running.
4.2.3 Service work in accordance with instructions on rating plate
(In general, after 8000 - 12000 hours of operation)
Rotor and bearing parts must be inspected and assessed by an ABB Turbo-
charging Service Station. The following work can be carried in preparation.
u Remove cartridge group as described in chapter Disassembly and as-

sembly.
u Measure clearances.
HZTL2412_EN
u Clean turbine and compressor casings and check them for cracks and
erosion / corrosion.
u Clean bearing casing and blow air through oil ports / holes.
u Clean nozzle ring and check for cracks and erosion.
Revision F

Operation 4
4.2.4 Entries in engine logbook

September 2016
By monitoring the engine, conclusions can be drawn about the turbo-

charger performance.
The following operating data and measured values must be entered regu-
larly in the engine manufacturer's engine logbook:
¡ Engine performance and speed

¡ Air intake temperature
¡ Exhaust gas temperature in front of and behind the turbine
¡ Pressure of charge air
¡ Pressure drop in charge air cooler
¡ Lubricating oil pressure and lubricating oil temperature
If provided ¡ Air temperature behind compressor and charge air cooler

¡ Turbocharger speed
HZTL2412_EN
¡ Pressure loss in air filter

Revision F

Operation 4
Expected exchange intervals 4.3 Page 48
4.3
4.3 Expected exchange intervals
September 2016
Rotating components
The recommended replacement intervals for compressor wheels and tur-

bine wheels are defined depending on the operating conditions and based
on the safety concept (SiKo) for rotating parts. These intervals can be
found on the turbocharger rating plate.
Non-rotating components
Depending on the system-specific operating conditions, a distinction is

made between:
¡ the replacement interval for the bearing parts and

¡ the replacement interval for those non-rotating components that are
exposed to hot gases.
Decisive in this respect are various influencing parameters, which can
HZTL2412_EN
drastically shorten the replacement intervals of these parts in extreme
cases.
During the specified periodic service work, the individual components are
inspected for wear and, if necessary, replaced.
Expected replacement intervals [h]
GAS / MDO HFO

Turbine casing 25000 … 50000 25000 … 50000
Nozzle ring 50000 10000 … 25000
Gas outlet flange 50000 35000 … 50000
Partition wall 50000 35000 … 50000
Rotor components See the data on the rating plate
Bearing parts 12000 … 24000 12000 … 24000
Revision F
Other casings 50000 50000

GAS = Natural gas MDO = Marine diesel oil HFO = Heavy fuel oil
The specified values are a guide only and not guaranteed (see following
section Influencing parameters).

Operation 4
Expected exchange intervals 4.3 Page 49
Influencing parameters
The specified values are only guide values and not guaranteed. The actu-
September 2016
al values can deviate considerably from the guide values due, for example,
to the following influences:
¡ Fuel quality and preparation

¡ Load profile (thermal load cycles, also starts / stops, emergency shut-
downs)
¡ Gas inlet temperature
¡ Frequency and execution of turbine and compressor cleaning
¡ Turbocharger specification
¡ System-specific operating conditions (operating point, combustion
quality, composition of exhaust gas)
For bearing parts

HZTL2412_EN
¡ Lubricating oil quality (oil filtration, condition of lubricating oil, oil moni-
toring)
¡ Load profile (rpm / speed, pressure conditions, temperature)
¡ State of rotor unbalance (degree of contamination)
Revision F

Operation 4
Speed measurement 4.4 Page 50
4.4
4.4 Speed measurement
September 2016
A speed measuring system permits continuous monitoring of the turbo-
charger speed.
Do not use cables as a climbing aid

If you pull the speed measurement cables too hard, contacts can be
pulled out.
CAUTION
u Do not tension the speed measurement cables.
HZTL2412_EN
Revision F
86505(A) Speed sensor (cable not integrated) 86526 F/I converter

86505(B) Speed sensor (cable integrated) 86528 Tachometer
86515(A) Cable connector to 86505(A) 01 Screw plug
86515(B) Cable connector to 86505(B) 02 Gasket

Operation 4
4.4.1 Speed differences with multiple turbochargers per engine

September 2016
The speeds of all turbochargers on one engine differ only slightly from
each other in normal operation.
The difference between the highest and the lowest turbocharger speed
must not be more than 3 % relative to the speed limit n Bmax.
If this permissible range of difference is exceeded, the following steps

must be carried out:
u Reduce engine performance immediately until the highest turbo-

charger speed no longer exceeds 70% of n Bmax.
u If the engine cannot be stopped, continue to run at this reduced engine
performance or turbocharger speed.
u If the turbocharger surges continuously, engine performance must be
reduced further.
u Measure the temperatures in the air and gas lines to and from the tur-
bochargers and compare them with standard values.
HZTL2412_EN
If the engine can be stopped for a short time:
u Inspect the air and gas lines as well as the turbocharger and eliminate
any problems.
u In any event, it is recommended that you contact the nearest ABB
Turbocharging Service Station.
Revision F

Operation 4
4.4.2 Replacing the speed sensor
September 2016
Hot cable connector and hot speed sensor
Risk of burning. During operation, the cable connector and the speed
sensor can reach temperatures exceeding 100 °C.
WARNING
u Wear safety gloves when removing the cable connector and speed
sensor.
HZTL2412_EN
u Reduce engine performance to the idling speed, then stop the engine.
u Switch off the lubricating oil supply to the turbocharger.
u Disconnect the cable connector from the speed sensor.
u Screw out defective speed sensor.
u Screw in a new speed sensor up to the limit block.

u Adhere to tightening torque.
Part number TPS44 TPS48 TPS52 TPS57 TPS61

Revision F
86505 15 Nm 15 Nm 15 Nm 15 Nm 15 Nm

Operation 4
Sealing the speed sensor

September 2016
The speed sensor is designed with a sealing lip and does not require an
additional gasket when fitted.
NOTICE
u Connect cable connector to speed sensor.

u Switch on lubricating oil supply to turbocharger.
4.4.3 Failure of speed measuring system
Possible reasons for failure of the speed measuring system are described
in the chapter Troubleshooting.
HZTL2412_EN
Revision F

Operation 4
Stopping the engine 4.5 Page 54
4.5
4.5 Stopping the engine
September 2016
Stopping the engine of oil-cooled turbocharger version
Heat in the turbocharger must be dissipated by the further circulating
lubricating oil.
CAUTION
u Post-lubricate for 15 … 20 minutes.
u Maintain oil pressure of 0.5 … 1.0 bar for post-lubrication.
Stopping the engine of water-cooled turbocharger version

Heat in the turbocharger must be dissipated.
CAUTION u Allow turbocharger cooling water to run for 15 … 20 minutes after
stopping engine.
u Allow oil lubrication to continue running until rotor comes to a stop.
Further post-lubrication is not required and not recommended.
HZTL2412_EN
Revision F

Maintenance 5
Foreword to Maintenance 5.1 Page 55
5 Maintenance
September 2016
5.1
5.1 Foreword to Maintenance
General maintenance work involves regular visual checks and cleaning
tasks which are intended to ensure the trouble-free functioning of the tur-
bocharger.
The maintenance points described here are differentiated as follows:
¡ Cleaning during operation:

– Compressor
– Turbine and nozzle ring.
¡ Mechanical cleaning of individual components:
– Filter silencer
– Casings, diffuser, nozzle ring
– Cartridge group: Compressor, turbine
HZTL2412_EN
Risk of damage during mechanical cleaning

If mechanical cleaning is carried out too often, this can lead to damage
and corrosion on the components.
CAUTION
u If cleaning during operation is not sufficient to achieve acceptable
values regarding thermal load and engine performance, mechanical
cleaning of certain spots can be carried out.
u Perform mechanical cleaning, especially of the cartridge group, only
once within the service interval.
Cleaning method
To allow you to observe the standard service intervals and to maintain a
high turbocharger efficiency, ABB Turbo Systems recommends that the
NOTICE
cleaning procedure be carried out during operation. This allows the
thermal load of the engine to be kept low while ensuring maximum fuel
efficiency.
Revision F
u Dispose of dirty water and cleaning agents in an environmentally com-

patible manner, professionally and in accordance with valid local regu-
lations.

Maintenance 5
Cleaning the compressor during 5.2 Page 56

operation
5.2
5.2 Cleaning the compressor during operation
September 2016
General The contamination of the compressor stage (compressor wheel, wall in-
sert and diffuser) depends on the degree of purity of the taken-in air.
Deposits can form in the flow channels if salt, oil mist, exhaust gas or dust
are sucked in with the air.
Consequences of contamination:
¡ Impaired compressor efficiency

¡ Higher exhaust gas temperatures
¡ Increased fuel consumption
¡ Increased rotor unbalance
Periodic cleaning of the compressor during operation prevents or delays

any major increase in contamination. But it never replaces the regular
service work where the turbocharger is completely dismantled and the
compressor is mechanically cleaned.
HZTL2412_EN
If the coating of dirt is very thick and hard, the compressor can only be
cleaned manually when disassembled. This cleaning must be carried
out by an ABB Turbocharging Service Station.
NOTICE
Cleaning interval The interval between periodic cleaning is very dependent on the operating
conditions. In general, cleaning should be carried out every 25 ... 100 op-
erating hours.
Should the specified cleaning intervals prove incompatible with engine

operation, please contact ABB Turbo Systems.
Revision F

Maintenance 5

operation
Cleaning method
Cleaning the compressor while in operation is carried out as wet cleaning.

September 2016
This cleaning method has been tested and approved by ABB Turbo Sys-
tems.
Principle of wet cleaning To clean the compressor stage during operation, water is injected in front
of the compressor wheel through an injection pipe fitted in the filter silenc-
er or the suction branch.
The water does not act as a solvent, but the dirt deposit is removed by the
mechanical impact of the droplets. This is a very suitable process, provid-
ed that the degree of contamination is not too high.
Corrosion and deposits when cleaning

Damage and impairment of turbocharger parts due to salt water and
cooling water additives
CAUTION
u Don't use salt water for cleaning, but only clean fresh water.
HZTL2412_EN
The injection pipe must on no account be connected directly via a cock

to a water pipe or a dosing vessel larger than the one supplied. This
prevents uncontrolled volumes of water entering the turbocharger and
engine, which can lead to serious damage.
CAUTION
V-engines In the case of V-engines with several turbochargers on each engine, we

recommend parallel cleaning of the compressors. This cleaning process is
faster and the risk of turbocharger surging is reduced.
Sequential charging In the case of sequential charging, care must be taken to ensure that tur-
bocharger compressors are cleaned regularly, especially after periods of
operation in the lower performance range.
Revision F

Maintenance 5

operation
5.2.1 Wet cleaning compressor using external water pressure vessel (XC1)
September 2016
Approval by enginebuilder These instructions for wet cleaning only apply when cleaning is carried out
with clean water and under the precondition that the enginebuilder ap-
proves the process.
Supplying water from the externally mounted water vessel is suitable

only for those applications where a negative pressure exists in front of
the compressor wheel (not used for: blowers connected in front of the
compressor or high-pressure compressor stages with two-stage charg-
NOTICE
ing).
Operating state prerequisites for cleaning compressor with XC1
To be able to carry out a satisfactory cleaning process that has been
HZTL2412_EN
tested and is recommended by ABB Turbo Systems, the following pre-
requisites must be fulfilled:
NOTICE u Run engine at load from 50 … 85 %.
u Start cleaning cycle according to following description Wet cleaning
operation with XC1.
Revision F

Maintenance 5

operation
Procedure for wet cleaning the compressor with XC1

September 2016
X Sealing plug D Compressed air

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Y Valve activator W Water

Z Vessel
Operating the water u Remove sealing plug (X).

pressure vessel
u Fill the vessel (Z) with clean water.
u Screw in the sealing plug.
u Push the valve activator (Y) against the spring and hold for 10 to
15 seconds until the entire volume of water has been injected.
u Do not repeat the cleaning cycle until a stabilisation period of at least
10 minutes has elapsed.
Whether or not cleaning has been successful can be seen from the
charging or flushing pressure and also from the exhaust gas tempera-
tures. If the cleaning process is unsatisfactory, it can be repeated up to
2 times.
NOTICE
If the cleaning result is still not satisfactory after three attempts and the
Revision F
engine values are also unsatisfactory, we recommend that you have the
turbocharger inspected and cleaned by an official ABB Turbocharging
Service Station.
Cleaning parameters per

Product Engine load Contents Water
turbocharger compressor
of cleaning medium vessel injection time
[dm3] t1 [s]
TPS 50 … 85 % 0.4 10

Maintenance 5
Turbine cleaning during operation 5.3 Page 60
5.3
5.3 Turbine cleaning during operation
September 2016
The combustion of fuels such as heavy fuel oil (HFO) in diesel engines
produces contamination of the turbocharger's turbine components. In
combination with a high exhaust gas temperature, poor quality fuel can
lead to particularly hard deposits on the nozzle ring and especially on the
gas outlet flange.
ABB Turbo Systems recommends using fuels with a low ash, sulphur, so-
dium and vanadium content.
Consequences of contamination:
¡ Poor turbine efficiency

¡ elevated exhaust gas temperatures
¡ higher charging and ignition pressures as turbocharger speed rises
¡ lower engine performance.
¡ After stopping the engine, the rotor can become stuck in contamination
deposits.
HZTL2412_EN
Experience with turbocharger operation shows that the intervals between
overhauls can be extended if cleaning while in operation is carried out pe-
riodically. Wet cleaning the turbine, as described below, should be used
for 4-stroke applications when there are heavy deposits from, for example,
HFO.
Under no circumstances is periodic cleaning of the turbine during opera-

tion a substitute for the service work carried out when the turbocharger is
completely dismantled and cleaned mechanically.
Turbines which are very heavily contaminated cannot be cleaned this way
any longer. In this case, the contaminated components must be mechani-
cally cleaned by an ABB Turbocharging Service Station.
Regular cleaning
Regular turbine cleaning during operation prevents or delays excessive
Revision F
build-up of contamination.
NOTICE
Cleaning intervals
The interval between periodic cleaning is very dependent on the operating

conditions. In general, cleaning should be carried out every 50 to 200 op-
erating hours.

Maintenance 5
Cleaning intervals
Should the specified cleaning intervals prove incompatible with engine
September 2016
operation, please contact ABB Turbo Systems.

NOTICE
Cleaning method
Turbine components are cleaned during operation using the wet cleaning
processes described in the following. These have been tested and are
approved by ABB Turbo Systems.
The turbine casing design and the type of turbine casing sealing are deci-
sive for the choice of cleaning method.
Approval by engine manufacturer

The prerequisite for wet cleaning is that the engine manufacturer ap-
proves the method and his instructions are followed.
NOTICE
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5.3.1 Wet cleaning methods
Process with short water injection time (3 x 30 seconds cleaning)
The cleaning process with short water injection time is used for turbo-
charger designs without additional sealing by means of C-rings.
The process is based on the principle of thermal shock in combination

with a subsequent flushing phase.
Process with long water injection time (10 minutes cleaning)
The cleaning process with a long water injection time is used for turbo-
Revision F
charger designs with additional sealing by means of C-rings.
Based on a 10-minute injection phase, this cleaning process utilises the

water solubility of the dirty deposits.

Maintenance 5
Choice of cleaning method

If you need information about the choice of cleaning method (short /
September 2016
long), you can contact the engine builder or an official ABB Turbo-
NOTICE
charger service station.
5.3.2 Prerequisites
Risk of corrosion and deposits

Impairment and damage of turbocharger by salt water and cooling wa-
ter additives in flow ducts
CAUTION
u Don't use salt water for cleaning, but only clean fresh water.
u Avoid corrosion on casing inner surfaces.
u Let engine run for 10 minutes after wet cleaning.
HZTL2412_EN
Maximum temperature in front of turbine during cleaning
When cleaning, the temperature in front of the turbine will rise and can
heavily stress the material of turbine components. The temperature at
CAUTION
the turbine inlet can be up to 100 °C higher than the exhaust gas tem-
perature after the cylinder. This should be taken into consideration
when setting the operating point before cleaning.
u Don't exceed maximum temperature in front of turbine when clean-
ing.
Impermissible thermal stressing and flooding of the turbine

Smaller volumes of water can result in poor cleaning. Larger volumes of
water lead to impermissible thermal stressing of the turbine compo-
CAUTION
nents and can cause flooding of the turbine.
u Be absolutely sure to observe turbine cleaning parameters.
Revision F
V-engines
In the case of V-engines with several turbochargers on each engine, we
recommend parallel cleaning of both turbochargers. This cleaning pro-
NOTICE
cess is faster and the risk of turbocharger surging is reduced.

Maintenance 5
Recommended operating state for turbine wet cleaning
The following operating state has been tested and is approved by ABB
September 2016
Turbo Systems:
Characteristic / component Conditions

short long
water injection time water injection time
Engine load (guide value) 20 … 40 %
Turbine inlet temperature 350 - 400 °C 350 - 430 °C
TTE before water injection
Water supply ensured
Water pressure (overpres- 2.0 bar 1.5 bar
sure over atmosphere) pWT
If necessary, engine performance must be reduced to maintain these

conditions.
The cleaning cycle can now be started based on the following description.
HZTL2412_EN
Revision F

Maintenance 5
5.3.3 Procedure for method with short water injection time
September 2016
w Prerequisites have been fulfilled.
u Wait 10 minutes during a stabilising phase after reducing the engine
load.
u Open the shut-off valve.
u Set the required water flow rate as specified in the table of cleaning
parameters using the flowmeter and inject for 30 seconds.
u Observe a pause of 3 or 5 minutes as specified in the table.
u Repeat the 30-second water injection two times.
u Close the shut-off valve.
u Wait 10 minutes during a stabilising phase before increasing engine
load again.
This completes the turbine cleaning process.
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Cleaning parameters during the process
Temperature in Water Injection time Pause between

front of the turbine volume flow 1) [min] injections
TPS during cleaning [dm3/min] [min]
[°C]
44 ≤ 450 4.5 0.5 3
48 6 (3 x)
52 8
57 11
61 17 5
1) corresponds to a water pressure pWT of 2.0 bar (overpressure over at-

mosphere)
Revision F

CAUTION
u Don't exceed maximum temperature in front of turbine when cleaning.

Maintenance 5

September 2016
5.3.4 Procedure for method with long water injection time
w Prerequisites have been fulfilled.

u Wait 10 minutes as a stabilising phase after reducing the engine load.
u Open the shut-off valve.
u Set the required water flow rate as specified in the table of cleaning
parameters using a flowmeter and inject for 10 minutes.
u Close the shut-off valve.
u Wait 10 minutes as a stabilising phase before increasing the engine
load again.
This completes the turbine cleaning process.
Cleaning parameters during the process

HZTL2412_EN
Temperature in Water Injection time Stabilising phase

front of the turbine volume flow 1) [min] before / after water
TPS during cleaning [dm /min]
3 injection
[°C] [min]
44 ≤ 530 2.5 10 10
48 4
52 5.5
57 8.5
61 12
1) corresponds to a water pressure pWT of 1.5 bar (overpressure over at-

mosphere)

Revision F

CAUTION
u Don't exceed maximum temperature in front of turbine when cleaning.

Maintenance 5
Cleaning components mechanically 5.4 Page 66
5.4
5.4 Cleaning components mechanically
September 2016
5.4.1 Introduction
Choosing cleaning tools

Turbocharger components are sensitive to mechanical damage. The
use of needle guns or other impact tools, for example, damages the
CAUTION
components. Depending on the specification, nozzle rings and turbine
casings have protective coatings, which can also be damaged.
u Only use soft tools such as cloths, brushes or wire brushes.
u In the event of heavy contamination, the cleaning methods that have
been described such as soaking can be repeated until a satisfactory
result has been achieved.
u Dispose of dirty water and cleaning agents in an environmentally com-

patible manner, professionally and in accordance with valid local regu-
HZTL2412_EN
lations.
Disassembly and assembly

The disassembly and assembly of the components is described in
chapter Disassembly and assembly.
NOTICE
Revision F

Maintenance 5
5.4.2 Cleaning the filter silencer

September 2016
81135 Filter silencer body 81266 Cover grid

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81136 Absorption segment 81270 Tension band

81137 Sheet-metal covering 81271 Lock
81265 Filter ring
Disassembly and assembly

The procedure for disassembly and assembly of the filter silencer is de-
scribed in the chapter entitled Disassembly and Assembly.
NOTICE
Cleaning the filter ring (if provided)
u Remove filter ring (81265).

u Clean filter ring (81265) as required or every 500 operating hours, and
replace after the fifth cleaning operation at the latest.
The degree of contamination of the filter ring depends on the cleanli-
Revision F
ness of the air that is drawn in.

u Wash filter ring (81265) using water containing light-duty detergent or,
if very heavily contaminated, soak it while squeezing carefully. Rinse
in cold water. Avoid rough handling (do not use a water jet).
u Allow the filter ring to dry out completely before assembly.
u Dispose of dirty water and gentle detergents in accordance with valid
local regulations.

Maintenance 5
Cleaning the absorption segments
u Loosen the tension bands (81270).
September 2016
u Remove the cover grid (81266).
u Pull out the sheet-metal coverings (81137), bend them up and remove
the absorption segments (81136).
u Clean the absorption segments (81136).
During cleaning, ensure that the absorption segments (81136) are only
cleaned with a mild jet of compressed air, soft brush or a damp cloth.
u Have absorption segments which are heavily contaminated replaced
by an official ABB Turbocharging Service Station.
Fitting the filter silencer
u Insert the absorption segments (81136) into the sheet-metal coverings

(81137).
u Bend the sheet-metal coverings (81137) back into their original shape
and insert them into the slot guides in the silencer body (81135).
HZTL2412_EN
u Fit the cover grid (81266).
u Fit the tension bands (81270) and apply tension at the locks (81271).
u Damaged tension bands must be replaced with new ones.
u If provided, fit the filter ring (81265).
Revision F

Maintenance 5
5.4.3 Compressor-end, non-rotating parts

September 2016
Handling operating materials and supplies

Swallowing or inhaling vapours of operating materials and supplies or
contact with them may be harmful to health.
WARNING
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 op-
erating materials and supplies.
safety data sheet.

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The following performance-relevant parts can be cleaned according to the

following description.
72000 Compressor casing

77000 Wall insert
79000 Diffuser
Revision F
u Clean the components specified above with steam or allow to soak in

diesel oil or water with household detergent. After soaking, remove the
dirt with a brush.
u Dry components completely.
u Spray cleaned surfaces with penetrating oil. Do not spray the outer
surfaces of the turbocharger.
u Dispose of dirty water and cleaning agent in accordance with the spec-
ifications in the safety data sheet.

Maintenance 5
September 2016
5.4.4 Turbine-end, non-rotating parts

WARNING
safety data sheet.
HZTL2412_EN
Baked layers of contamination, for example, from heavy fuel oil or coked
oil occur at the turbine end. The following parts, which are relevant in
terms of performance, can be cleaned in accordance with the description
below.
Revision F
51000 Turbine casing 56001 Nozzle ring

52400 Gas outlet flange
u Place contaminated parts in hot water or in a liquid such as carbon

remover to soften the contamination.
u Brush away the contamination or remove with a steam cleaner.
u Repeat the soaking and brushing if necessary.
u Use clean water to completely clean parts of any solvents.
u Dry components completely.

Maintenance 5
u Spray cleaned surfaces with penetrating oil. Do not spray the outer
surfaces of the turbocharger.
u Dispose of contaminated water and cleaning agents in accordance
September 2016
with the information in the material safety data sheet.
5.4.5 Cartridge group
Introduction
Corrosion
If the cartridge group is not put into operation again immediately after
cleaning, parts may corrode.
CAUTION
u Re-install and use the cartridge group immediately after cleaning.
HZTL2412_EN
Compressor wheels or turbines may be heavily contaminated due to

heavy fuel oil operation or coked oil. Such contamination may possibly no
longer be removed through cleaning during operation and must be
cleaned mechanically during the standard service intervals (see chapter
entitled Service work).
u Remove turbocharger from the engine (see chapter Removal and in-
stallation [➙ 85]).
u Remove cartridge group (see chapter Disassembly and assembly
[➙ 91]).
First clean the compressor end and then the turbine end in accordance
with the following description.
Revision F

Maintenance 5
Cleaning the compressor end
September 2016
Selection of the cleaning agent
Cleaning agents which contain chlorine attack metals.
CAUTION u Use only pH-neutral cleaning agents which do not attack metals.
u Observe safety data sheet.
Water and contamination in the cartridge group

If water or contamination penetrates the cartridge group, this can impair
the function of the turbocharger and damage parts inside the cartridge
CAUTION
group.
u Make sure that no water or contamination can enter into the cartridge
group.
u Clean compressor wheel with a cloth or soft brush soaked in water
HZTL2412_EN
with household detergent. Do not use any wire brushes!
u Dry the compressor wheel and the gap between the compressor and
the bearing casing with a weak jet of compressed air.
u Lightly spray the compressor wheel and the gap between the com-
pressor and the bearing casing with penetrating oil.
u Dispose of dirty water and cleaning agent in accordance with the safe-
ty data sheet.
Revision F

Maintenance 5
Cleaning the turbine end

September 2016
Soaking the dirt Baked-on layers of dirt from heavy fuel oil or coked oil, occur at the tur-
bine end. The contamination can be removed by soaking and brushing.
The soaking of the layers of dirt as well as the cleaning of the turbine are
described below.
HZTL2412_EN
Product A [mm] B [mm] C [mm]

TPS44 91 15 173
TPS48 108 17 205
TPS52 128 20 245
TPS57 157 25 300
TPS61 187 30 357
To soak the layers of dirt on the turbine, the cartridge group can be sub-
merged vertically in a tank (02) with liquid.
u Place the tank (02) in a larger container (03), so that the excess liquid
can be collected.
Revision F
Selection of the cleaning agent

Cleaning agents which contain chlorine attack metals.
CAUTION u Use only pH-neutral cleaning agents which do not attack metals.
u Observe safety data sheet.
u Fill the tank (02) with soaking liquid.

Maintenance 5
Heat the liquid

To shorten the soaking time the liquid can be heated to maximum 60 ºC.
September 2016
NOTICE
Heating up of cleaning agents and operating fluids

When cleaning agents or operating fluids are heated up, explosive va-
pours can be produced which are hazardous to health.
WARNING
u Observe the information in the material safety data sheet.
Wear a respiratory mask according to material safety data sheet.
Water and dirt in the cartridge group

If water or dirt gets into the cartridge group, the turbocharger function
may be impaired and parts in the cartridge group may be damaged.
CAUTION
u Place the cartridge group on suitable wooden or metal supports (01).
HZTL2412_EN
u Maintain dimension (B) for the supports (01), so that the cartridge
group does not submerge too deep.
u Allow the layers of dirt on the turbine to soak for four hours.
Revision F

Maintenance 5
Removing the dirt
Health hazard due to soot particles

September 2016
If soot particles enter the eyes or respiratory tract, this can be harmful
to health.
WARNING
u Avoid the formation of dust.
u Vacuum up dust with a suitable vacuum cleaner.
u Wear a respiratory mask to protect against particles (P1 or P2 mask).
u Wear safety goggles.
u Raise the cartridge group and align horizontally.

u Remove dirt manually with a soft brush or wire brush.
HZTL2412_EN
Revision F

Maintenance 5
Water and dirt in the cartridge group
September 2016
If water or dirt gets into the cartridge group, the turbocharger function
may be impaired and parts in the cartridge group may be damaged.
CAUTION
u Make sure that water or dirt does not get into the gap between the
partition wall and turbine.
Non-permissible rotor unbalance after cleaning

Unevenly distributed residual contamination deposits lead to rotor un-
balance. This can result in bearing or turbocharger damage.
CAUTION
u Remove all traces of contamination from the turbine.
u After brushing off the contamination, fill the tank (02) with clean water,
not salt water.
u Submerge the turbine of the cartridge group in clean water, so that
loose particles of dirt detach completely.
HZTL2412_EN
u Raise the cartridge group and align horizontally.
u Clamp the partition wall with the bearing casing.
u Dry the turbine and the gap between the turbine and partition wall with
a weak jet of compressed air.
u Lightly spray the turbine and the gap between the turbine and partition
wall with penetrating oil.
u Dispose of dirty water and cleaning agent in accordance with the spec-
ifications in the safety data sheet.
Revision F

Troubleshooting 6
Malfunctions when starting 6.1 Page 77
6 Troubleshooting
September 2016
6.1
6.1 Malfunctions when starting
Sluggish start-up
Possible causes Elimination

Turbocharger Turbocharger contaminated Clean it
Damaged bearing Contact an ABB Turbocharg-
Rubbing rotor ing Service Station
Foreign object in turbocharger
Vibrations

HZTL2412_EN
Turbocharger Rotor unbalance Contact an ABB Turbocharg-

Damaged turbine or compressor ing Service Station
Damaged bearing
Rubbing of rotating parts
Normal behaviour, no malfunction

Turbocharger Minor uniform wear around the periphery of rotor components,
caused by slight local rubbing of adjacent components, is per-
missible. The compressor blades and turbine blades are then
shortened somewhat. Certain tolerances must be observed to
avoid a significant loss of efficiency.
¡ If there is any doubt about the extent of rubbing, then an ABB
Turbocharging Service Station must be contacted.
¡ Have a dimension check carried out by an ABB Turbocharg-
ing Service Station.
Revision F

Troubleshooting 6
Surging of the turbocharger 6.2 Page 78
6.2
6.2 Surging of the turbocharger
September 2016
Turbocharger surging

Engine Guard in front of the turbo- Clean / replace it
charger is contaminated or
damaged
Turbocharger Filter silencer or diffuser con- Clean it
taminated
Heavy deposits of dirt in the
turbine or nozzle ring
Charge air Cooler contaminated Clean it
cooler Charge air duct blocked
Prolonged or periodic surging
HZTL2412_EN
Possible damage to components, such as the compressor wheel, tur-
bine blades, bearings and filter silencer
CAUTION
u Have the cause clarified immediately by an ABB Turbocharging ser-
vice station and rectified.
u Have components inspected for damage and, if necessary, replaced
by an ABB Turbocharging service station.
Sporadic surge blows
Surging of the turbocharger can occur during certain operating conditions

such as when reducing the engine performance quickly when manoeu-
vring. At the same time, the flow direction in the compressor is momentari-
ly reversed. Such sporadic surge blows do not impair the safe operation of
the turbocharger.
¡ A surge blow is accompanied by a loud bang and escape of hot air

from the filter silencer.
Revision F

Troubleshooting 6
Malfunctions during operation 6.3 Page 79
6.3
6.3 Malfunctions during operation
September 2016
Lubricating oil pressure too low

Engine Oil filter heavily contaminated Clean it
Defective oil pump in lubricat- Check / replace it
ing system
Manometer display wrong Replace the manometer
Turbocharger Rotor axial clearance too large Contact an ABB Turbocharging
Service Station
Reduction in speed

Engine Defects of connected cylin- Contact the enginebuilder
HZTL2412_EN
ders when pulse charging

Turbocharger Heavy contamination of the Clean it
turbine
Damaged rotor components or Contact an ABB Turbocharging
bearing Service Station
Pipes Defects such as leaks in the Make repairs
exhaust gas pipes or charge
air ducts
Increase in speed

Turbocharger Heavily contaminated nozzle Contact an ABB Turbocharging
ring (with 4-stroke application) Service Station
Revision F

Troubleshooting 6
Exhaust gas temperature too high
Engine performance and engine speed unchanged
September 2016
Engine Malfunctioning injection system Repair it or contact the manu-
facturer
Turbocharger Air starvation, for example filter Clean it
silencer clogged with dirt
Compressor / turbine
contaminated
Exhaust counterpressure too Clean or repair the boiler or
high exhaust silencer
Damaged or eroded turbine Contact an ABB Turbocharg-
ing Service Station
Charge air Cooler contaminated Clean it
cooler Cooling water volume too low Top up the water
Entry temperature of cooling Inspect / clean the cooling
HZTL2412_EN
water too high system
Inadequate ventilation Improve the ventilation
Revision F

Troubleshooting 6
Charge air pressure too low
Engine performance and engine speed unchanged, air intake condition

September 2016
normal

Engine Air receiver leaking Make repairs
Gas piping between the engine
and the turbine leaking
Poorly adjusted injection system Correct it
Poorly adjusted valve control
Turbocharger Manometer display wrong Replace the manometer
Line to manometer leaking Repair the leak
Contaminated filter silencer caus- Clean it
ing excessive loss of pressure
Compressor / turbine
contaminated
Damaged compressor / turbine Contact an ABB Turbocharg-
HZTL2412_EN
ing Service Station

Exhaust counterpressure too high Clean or repair the boiler or
exhaust silencer
Charge air pressure too high
Engine performance and engine speed unchanged, air intake condition

normal

Engine Malfunctioning injection system Repair it or contact the man-
ufacturer
Poorly adjusted injection system Correct it
Engine performance higher than Check engine performance
expected
Turbocharger Manometer display wrong Replace the manometer
Revision F

Troubleshooting 6
Fouling of the compressor due to the feeding in of ventilation gases
Reduced compressor performance/efficiency, hence engine performance
September 2016
losses
Possible causes Remedy

Turbocharger Heavy fouling of the com- Clean compressor
pressor components Optimize oil separation
Increased vibrations, com- Correct the feed of ventilation
pressor blade damage gases according to instructions
of enginebuilder.
Reduced fatigue strength of the compressor wheel, compressor blade

failure.
Possible causes Remedy

Turbocharger Material of compressor Check the fuel and its corrosive
HZTL2412_EN
wheel corroded components, and change fuel if
necessary.
Revision F

Troubleshooting 6
Malfunctions when stopping 6.4 Page 83
6.4
6.4 Malfunctions when stopping
September 2016
Noises during run-down

Run-down time too short

HZTL2412_EN

Revision F

Troubleshooting 6
Speed measurement system 6.5 Page 84
6.5
6.5 Speed measurement system
September 2016
No signal or Fitting error The screw plug for the sensor is fitted with
amplitude is an additional gasket (copper ring).
poor When fitting the speed sensor, this gasket
must be removed. If the gasket is fitted by
mistake, the distance from the sensor tip to
the signal-generating sealing disc increases.
As a result, the voltage amplitude of the
speed signal decreases, which can cause
problems for the evaluation electronics.
This problem is eliminated by removing the
gasket.
Defective sensor Contact an ABB Turbocharging Service Sta-
tion
Measured Contaminated The sensor tip is magnetic and can thus at-
speeds too sensor tip tract metal particles. As a result, the dis-
high tance to the signal-generating sealing disc is
reduced, which can lead to amplification of
HZTL2412_EN
the noise component and consequently to
faulty triggering.
Dismantle the sensor, clean its tip and refit
the sensor using the specified tightening
torque.
Measured -- Contact an ABB Turbocharging Service Sta-
speed too low tion
Other sources -- If none of the above measures eliminates
of errors the malfunction, we recommend that you
have the speed measuring system inspected
by an ABB Turbocharging Service Station.
Revision F

Removal and installation 7
Transport 7.1 Page 85
7 Removal and installation

September 2016
7.1
7.1 Transport
Suspension of uninsulated turbocharger
Turbocharger with oil-cooled bearing Complete turbocharger with gas outlet

casing casing
HZTL2412_EN
Suspension of insulated turbocharger
Turbocharger with oil-cooled bearing Complete turbocharger with gas outlet

casing casing
Revision F

Turbocharger weights 7.2 Page 86
7.2
7.2 Turbocharger weights
September 2016
Lifting gear with a sufficient load limit must be used for removing and in-
stalling the turbocharger. The following weight specification is the heaviest
possibility. This guide value can differ from data on the rating plate, de-
pending on the specification.

[kg] [kg] [kg] [kg] [kg]
120 180 250 410 650
Turbocharger weights
HZTL2412_EN
Revision F

Remove the turbocharger 7.3 Page 87
7.3
7.3 Remove the turbocharger
September 2016
u Disconnect all exhaust gas and air lines according to the instructions
of the enginebuilder.
Version with water-cooled bearing casing:
u Disconnect the water pipes according to the instructions of the en-

ginebuilder.
HZTL2412_EN
If present, remove hard insulation as follows:
u Remove screws and sheet metal (B) from the bearing casing insula-
tion.
u Remove the remaining screws from the bearing casing insulation (A).
u Pull the bearing casing insulation up and off. The bearing casing insu-
lation can be compressed to facilitate the removal process.
u Unplug the cable connector from the speed sensor.

u Attach lifting gear to bearing casing.
Revision F
u If a gas outlet bend is present, sling lifting gear around it or secure it to

the lifting gear with a swivel lifting eye (C).
u Loosen the fixing screws (D) on the bearing casing.
u Lift the turbocharger from the engine and put it down.
u Cover oil connections.

Installing the turbocharger 7.4 Page 88
7.4
7.4 Installing the turbocharger
September 2016
u Remove covers from oil connections.
u Visually inspect O-ring gaskets of oil supply and drain pipe (O-ring
gaskets for engine are not delivered by ABB Turbo Systems).
HZTL2412_EN
**) When the turbocharger is mounted on the engine support, the bolt
threads and screw heads must be lightly oiled (assumed friction coeffi-
cient µ = 0.12 for tightening torque)
Product Through hole in Thread size Tightening Strength class

bearing casing [mm] torque in acc. with
[mm] [Nm] DIN/ISO 898
TPS44 17 M16 230 10.9/12.9
TPS48 17 M16 230 10.9/12.9
TPS52 21 M20 455 10.9/12.9
TPS57 21 M20 455 10.9/12.9
TPS61 25 M24 780 10.9/12.9
u Attach lifting gear to bearing casing.

Revision F
u If a gas outlet manifold is provided, sling lifting gear around it addition-

ally or fasten it to lifting gear using a swivel lifting eye (C) (see also
section Transport / Weights).
u Lift turbocharger, place on bracket and align.
u Tighten fixing screws (D) to the bearing casing in accordance with the
table above.
u Fasten all gas, water and air lines in accordance with the enginebuild-
er's instructions.

Installing the turbocharger 7.4 Page 89
If present:
September 2016
u Fit speed sensor and plug in cable connector.

u Adapt and fit bearing casing insulation (A).
u Adapt and fit sheet metal (B) of bearing casing insulation.
Version with water-cooled bearing casing:
u Remove the screw plugs from the water connections and fit the water
pipes in accordance with the enginebuilder's instructions.
HZTL2412_EN
Revision F

Disassembly and assembly 8
8 Disassembly and assembly

September 2016
8.1
8.1 Introduction
Precondition for the work described below is a turbocharger removed from
the engine (refer to the chapter entitled Removal and Installation).
Further work
Only the work described in this Operation Manual may be carried out.
Incorrectly performed disassembly and assembly of the cartridge group
CAUTION
can lead to serious machine damage.
u ABB Turbo Systems recommends having further work carried out on-
ly by trained personnel from an ABB Turbocharging Service Station.
Marking casing positions for assembly

HZTL2412_EN
ABB Turbo Systems recommends that the casing positions are marked
before disassembling the turbocharger.
NOTICE
Identifying assembly devices
Not all assembly devices are marked with a part number. They can be
identified using the tool list. This list is enclosed in the toolbox.
Maintaining assembly devices

Assembly devices must be checked for damage before and after use.
WARNING u Visually check for corrosion, cracks, deformation and wear.
u Don't use damaged assembly devices, but replace them.
Revision F

Customer spare parts set
Before beginning work, ensure that the required customer spare parts
September 2016
sets are available.
u See chapter Spare parts.
Oil orifice
u When disassembling the turbocharger, a fitted oil orifice must not be

removed.
Tightening torques for turbocharger components
The specified tightening torques of screw connections for turbocharger

components must be observed. (See section Table of tightening torques.)
Tightening torques for assembly devices of ABB Turbo Systems
HZTL2412_EN
If nothing else is described, the screws and nuts of the assembly devices
must be tightened down firmly.
Suspended loads
Loads not suspended in compliance with regulations may lead to per-
sonal injury or accidents with fatal consequences.
WARNING
u Attach turbochargers, assemblies or individual components only to
lifting gear which is in technically perfect condition and has sufficient
load capacity.
u Make sure the load is suspended properly on the crane hook.
u Do not let anyone stand beneath a suspended load.
Wear safety helmet.

Revision F
Definition of terms
¡ Suspension point
Defined load carrying point on a component or an assembly (blind hole
thread, eye, lug).
¡ Assembly device
Devices mounted on the turbocharger to create a suspension point.
Assembly devices are calculated and designed especially for the de-

fined application. They are not commercially available products. Use

assembly / fitting devices only for the applications described.
¡ Lifting gear
September 2016
Equipment for lifting and transporting loads (ropes, chain hoists,

cranes). Lifting gear is not supplied by ABB Turbo Systems.
Swivel lifting eye to be used
A swivel lifting eye is required to lift loads safely (not supplied by ABB).
Swivel lifting eye Product Thread Length Minimum

M L load limit
(loading
capacity)
TPS44 M8 13 mm 150 kg
TPS48 M10 17 mm 250 kg
TPS52 M10 17 mm 250 kg
TPS57 M12 21 mm 350 kg
HZTL2412_EN
TPS61 M12 21 mm 500 kg

Revision F

Module weights 8.2 Page 94
8.2
8.2 Module weights
September 2016
The specified weights of individual parts or assemblies are guides round-
ed off to the next highest value.
HZTL2412_EN
Description [kg] [kg] [kg] [kg] [kg]
1 Filter silencer 15 19 30 40 65
2 Radial air suction branch 5 6 8 11 21
3 Axial air suction branch 3 4 4 6 9
4 Compressor casing 17 24 35 55 90
5 Wall insert 4 7 10 13 30
6 Diffuser 2 2 3 6 10
7 Cartridge group 25 35 50 85 140
8 Nozzle ring 1 1 2 3 6
9 Burst ring 1 2 3 5 12
10 Turbine casing 1 inlet 30 35 50 80 130
Revision F
with external 2 inlets 30 35 50 90 150

burst protection
3 inlets - - 55 95 170
4 inlets - - - 95 170
11 Gas outlet flange 4 4 8 16 30
12 Exhaust manifold 16 18 25 40 60

Disassembling and assembling 8.3 Page 95

turbocharger
8.3
8.3 Disassembling and assembling turbocharger
September 2016
Removing the compressor casing
Risk of burning
to serious burns.
WARNING
charger.
u Disconnect all air lines in accordance with the enginebuilder’s instruc-

tions.
HZTL2412_EN
If provided u Remove the screws for the compressor casing insulation and disman-
tle the insulation.
Revision F
u Undo the V-clamp (72020) and remove the filter silencer (81000) or air
suction branch (82000).


turbocharger
Removing the insulation
September 2016
If provided u Loosen and remove the screws for the insulation plates (1, 2).
u If provided: Remove the insulation plates (1, 2).
u Remove the remaining screws for the insulation (3).
u Remove the insulation (3).
HZTL2412_EN
Revision F


turbocharger
u Slightly loosen the screws (72011) and turn the compressor casing
(72000) until the swivel lifting eye can be fastened to the lifting gear.
September 2016
HZTL2412_EN
(77006* only provided with the wall insert with acceleration aid.)
If the compressor casing cannot be removed easily, it can be pressed

off using the press-off tool (90042) against the turbine casing. To do
this, the two cover plates (1, 2) must be removed from the hard insula-
tion on the turbine casing.
NOTICE
Axial force
The press-off tool can generate a high axial force and, if it is not used
properly (too much pressure on one side), it can damage the rotor.
CAUTION
u It should thus be used alternately on both sides while avoiding ex-
Revision F
cessive pressure on either side.
u Loosen the screws (72011) and remove them together with the fas-
tening strips (72012).
u Move the compressor casing (72000) with the wall insert (77000) care-
fully away, doing so horizontally.
u Tap the wall insert (77000) out of the compressor casing using a nylon
hammer and remove the O-ring seal (77005).


turbocharger
TPS61 wall insert removal
u Fasten lifting beam (90258) to wall insert.
September 2016
u Fasten swivel lifting eye (a) to lifting beam.
u Remove wall insert (77000) using lifting gear.
HZTL2412_EN
Disassembly of diffuser
TPS..-F31/32 / FV31/32
Revision F
u Loosen screws (72041) and remove them together with lockwashers

(72040) and diffuser (79000) from compressor casing (72000).


turbocharger
September 2016
Installing compressor casing
u Refit wall insert (77000) and O-ring (77005) in the reverse order.
O-rings
Used O-rings must always be replaced with new ones. O-rings are only
available as a set (see chapter Spare parts).
NOTICE
Fitting the diffuser u Refit diffuser in reverse order.

TPS..-F31/32 / FV31/32
u Fit compressor housing in reverse order.

HZTL2412_EN
u Thoroughly clean fastening strips (72012) before fitting them.

Revision F


turbocharger
Removing the cartridge group
u Check the lifting gear and fasten it to bearing casing (42001).
September 2016
If provided u Disconnect all lines in accordance with the engine builder's instruc-
tions, remove the insulation, remove the turbocharger and compressor
casing together with the filter silencer (also see the previous chapter).
Risk of burning
to serious burns.
WARNING
charger.
HZTL2412_EN
w The bearing casing is difficult to loosen.
u Use the press-off tool (90042) against the turbine casing to press off
the bearing casing (see the following illustration).
Axial force
The press-off tool can generate a high axial force and, if it is not used
properly (too much pressure on one side), it can damage the rotor.
CAUTION
u It should thus be used alternately on both sides while avoiding ex-
cessive pressure on either side.
Revision F


turbocharger
September 2016
u Withdraw nozzle ring (56001) using two extraction devices (90070)

and withdraw bottom part of service support (90012).
HZTL2412_EN
If provided u Remove C-ring (51105).

Disassembly of diffuser
TPS..-F33
Revision F
u Mount the cartridge group on the service support (90012) and bolt
it down firmly.
u Loosen screw (42008) and remove diffuser (79000) complete with
O-ring (42012).
u Measure the axial and radial clearances (see the section Axial and
radial clearances).


turbocharger
Installing the cartridge group
September 2016
O-rings
Used O-rings must always be replaced with new ones. O-rings are only
available as a set (see chapter Spare parts).
NOTICE
Protruding insulation
The insulation on the turbine casing may protrude at the gas outlet side.
This can be pushed back in with a screw driver.
NOTICE
HZTL2412_EN
u Fit the lamellar sealing ring (56005, if present) in the correct slot (see
detail A). When doing this, pay attention to correct winding of the la-
mellar sealing ring (see detail B).
u Secure the lamellar sealing ring with adhesive tape.
Revision F
u Insert the nozzle ring (56001) (with the cam facing forwards) into the
turbine casing as far as it will go. Align the cam on the nozzle ring with
the recesses of the turbine casing and insert it into the turbine casing
(51000) as far as it will go. Do not remove the adhesive tape (01).
If present u Insert the C-ring (51105) into the turbine casing and secure with high-
vacuum grease.


turbocharger
To ensure the nozzle ring is held in place during operation, it must be

clamped between the partition wall and the turbine casing.
September 2016
NOTICE
Nozzle ring press fit for u Calculate the press fit (PD) as shown.
single inlet turbine casing
If the calculated value (PD) is less than 0.1 mm, an official ABB Turbo-
HZTL2412_EN
charging Service Station must be contacted.
NOTICE
u Measure the axial and radial clearances (see the section Axial and ra-
dial clearances).
Revision F


turbocharger
Nozzle ring press fit for u Calculate the press fit (PD) as shown.
multiple inlet turbine cas-
September 2016
ing
If the calculated value (PD) is outside ±0.2 mm, an official ABB Turbo-
HZTL2412_EN
charging Service Station must be contacted.
NOTICE
u Measure the axial and radial clearances (see the section Axial and ra-
dial clearances).
Revision F


turbocharger
Assembly of diffuser
TPS..-F33
September 2016
u Fasten diffuser (79000) and O-ring (42012) using screw (42008).

HZTL2412_EN
u Check lifting gear and fasten to bearing casing (42001).

u Unscrew the cartridge group and lift it out of the service support
(90012).
u Apply high-temperature grease to the centering points and screw
threads.
Revision F
u Remove temporary covers from oil connections.
Don't damage or shift gasket rings (A) in the mounting support when
fitting the cartridge group. The gasket rings (A) are supplied by the en-
gine builder.
CAUTION


turbocharger
If two turbochargers are mounted on an engine, one with a left-hand

and one with a right-hand oil inlet, a pin can be fitted in the bracket as a
precaution against incorrect positioning. This pin (B) locates in a corre-
September 2016
spponing groove in the foot of the bearing casing.
NOTICE
HZTL2412_EN
u Fasten the cartridge group using fastening strips (51002), Verbus
Ripp® washers (51003) and nuts (51007) (also see the chapter enti-
tled Table of tightening torques).
u Fasten the bearing casing (42001) using the fixing screws (C).
u Tighten the fixing screws (C) to the torques listed in the following table.
**) For the assembly of the turbocharger on the engine support, the
threads of the screws and screw heads must be lightly oiled (assumed
coefficient of friction µ = 0.12 for the tightening torque).
Revision F
Product Hole in the bearing casing Fixing screws Tightening torques

[mm] C [mm] [Nm] **)
TPS44 Ø 17 M16 230
TPS48 Ø 17 M16 230
TPS52 Ø 21 M20 455
TPS57 Ø 21 M20 455
TPS61 Ø 25 M24 780


turbocharger
If provided
September 2016
u Plug in the cable connector (86515) for the speed sensor (86505) and
HZTL2412_EN
(if provided) fit the insulation plates (1, 2).
Removing gas outlet bend and gas outlet flange
If provided u Disconnect all lines in accordance with engine builder's instructions

and remove insulation. (See also preceding chapter.)
Revision F
u Loop lifting gear around gas outlet bend (51100).

u Remove gas outlet bend (51100) and gasket (52406). Only gas outlet
bends from ABB Turbo Systems have the gasket (52406).
u Remove gas outlet flange (52400) and, if fitted, C-ring (52408).


turbocharger
Fitting the gas outlet flange and gas outlet bend
September 2016
u If provided, fit the C-ring (52408).
HZTL2412_EN
u Fit the gas outlet flange (52400).
u In the case of gas outlet bends (51100) from ABB Turbo Systems:
always replace the gasket (52406) (see the chapter entitled Spare
parts).
u Apply high-temperature grease to contacting surfaces and threads.
u Fit the turbine casing using the nuts (52433) while observing tightening
torques specified in the table of tightening torques.
If provided u Fasten the insulation.
u Attach pipes in accordance with the enginebuilder's instructions.

Revision F

Axial clearance A and radial clearance 8.4 Page 109

B
8.4
8.4 Axial clearance A and radial clearance B
September 2016
u Following removal and before installation of the cartridge group, the axi-
al clearance A and radial clearance B must be measured and noted.
In order to correctly measure the axial clearance A, the turbine must be

raised slightly.
HZTL2412_EN
NOTICE
Risk of injury due to sharp edges on the compressor wheel

The compressor wheel has sharp edges which can cause injuries.
WARNING u Wear safety gloves.
Axial clearance A and

radial clearance B [mm]
A minimum 0.08 0.08 0.10 0.12 0.15
A maximum 0.16 0.16 0.18 0.21 0.25
B minimum * 0.51 0.50 0.61 0.72 0.81
B maximum * 1.00 1.00 1.15 1.31 1.55
Revision F
* Permissible B clearances for standard radial bearings. If the clearances

measured on TPS57 or TPS61 are outside the permissible range, this can
indicate radial bearings with a special bearing geometry. Different permis-
sible values are valid for radial bearings with a special bearing geometry
(see the table below).

Axial clearance A and radial clearance 8.4 Page 110

B
Identifying radial bearings

with a special bearing
geometry
September 2016
The type of bearing can be determined by measuring the rotor run-out
time. To do so, the rotor must be pushed by hand, once to the left (L) and
once to the right (R), with a force as close to the same in both directions.
The resulting run-out times until the rotor comes to a stop are measured
for the anticlockwise and clockwise rotations and then compared. With
standard radial bearings, the run-out time for anticlockwise and clockwise
rotating rotors is the same.
If one run-out time is at least 1.5 times longer than the other, then radial
bearings with a special bearing geometry are installed. The following B
clearances are valid for these special bearings.
HZTL2412_EN
TPS57 TPS61
B minimum 0.46 0.52
B maximum 0.73 0.82
Clearances out of tolerance

Clearances out of tolerance and excessively worn components can be
the cause of serious damage to machinery and property.
CAUTION
u Have components assessed and, if necessary, replaced by an ABB
Revision F

Radial clearances N and R 8.5 Page 111
8.5
8.5 Radial clearances N and R
September 2016
N and R
These are the theoretical values of the radial clearance between the com-
pressor wheel and the wall insert and / or turbine wheel and the gas outlet
flange.
The minimum and maximum values result from the manufacturing toler-
ances of the compressor wheel and turbine wheel or the wall insert and
HZTL2412_EN
gas outlet flange.
Feeler gauge
N1 and N2 as well as R1 and R2 are
each measured at the same time using
two feeler gauges.
To measure N1 and N2, the feeler gaug-
es must be pushed between the wall in-
sert and the compressor wheel free of
play, in each case above and below.
To measure R1 and R2, the feeler gaug-
es must be pushed between the gas out-
let flange and the turbine free of play, in
each case above and below.
Revision F

Radial clearances N and R 8.5 Page 112
Measuring N and R
September 2016
The mean values measured must be within the permissible values of the
radial clearance N and R.
Radial clearances N and

Product N [mm] R [mm]
R
TPS44 0.15 … 0.49 0.36 … 0.67
TPS48 0.22 … 0.58 0.47 … 0.77
TPS52 0.30 … 0.67 0.59 … 0.92
TPS57 0.40 … 0.86 0.75 … 1.11
HZTL2412_EN
TPS61 0.50 … 0.94 0.90 … 1.32
Clearances out of tolerance

Clearances out of tolerance and excessively worn components can be
the cause of serious damage to machinery and property.
CAUTION
u Have components assessed and, if necessary, replaced by an ABB
Revision F

Table of tightening torques 8.6 Page 113
8.6
8.6 Table of tightening torques
September 2016
HZTL2412_EN
The following tightening torques must be observed for the specified screw
connections:
Tightening torques [Nm]

Position Part number TPS44 TPS48 TPS52 TPS57 TPS61
1 72020 60 60 60 60 60
2 42008 6 10 10 20 20
5 52433 20 20 40 65 65
6 51007 25 25 45 75 75
9 72011 35 35 70 105 170
10 86505 15 15 15 15 15
Revision F

Taking out of operation 9
Shutting down the turbocharger 9.1 Page 115
9 Taking out of operation

September 2016
9.1
9.1 Shutting down the turbocharger
If the turbocharger is damaged and the engine can be shut down for only
a short time for emergency repairs, proceed as follows:
u Fit the cover plate.
Always heed precisely the engine builder's instructions in case of en-

gine operation with a blocked / throttled turbocharger!
CAUTION
Dismantling the turbocharger

HZTL2412_EN
u Dismantle the turbocharger (see the section Dismantling and fitting the
turbocharger).
Revision F
u Do not dismantle the nozzle ring.

Fitting the cover plate
September 2016
HZTL2412_EN
u Close the opening in the turbine casing using the cover plate (A).
u Fasten the cover plate on the turbine casing (51000) using the fas-
tening strips (51002), Verbus Ripp® Verbusripp washers (51003) and
nuts (51007) and screw it down securely on the support.
Thoroughly clean the fastening strips (51002) before fitting them. Apply
high-temperature grease to the stud threads (51006).
NOTICE
Revision F

Cover plate drawing
The cover is not supplied by ABB Turbo Systems and must be manufac-
September 2016
tured by the operator according to the following drawing.
Material: Common structural steel, according to DIN EN 10025-2

HZTL2412_EN
Product B1 B2 B3 B4 B5 B6
±0.5 ±0.2
TPS44 62.6 54 110 11.0 1 144
TPS48 65.7 60 130 11.7 1.5 150
TPS52 79.6 78 155 14.2 1.5 180
TPS57 98.2 100 190 17.2 2 220
TPS61 116.8 120 226 20.5 2.4 260
Product B7 ØD1 ØD1* ØD2 R1 M

±0.2 ±0.2
Revision F
TPS44 191.3 191.3 17 ≤88 M8

TPS48 35.7 222.7 227.7 17 ≤105 M8
TPS52 39.6 265.7 271.7 21 ≤125 M8
TPS57 48.2 325.7 332.5 21 ≤153 M10
TPS61 56.8 387.7 395.9 25 ≤182 M10
Dimensions in [mm]

*) Diameter for turbine casing designs for optional C-ring sealing
September 2016
Information about the turbine casing design (with / without C-ring seal-
ing) can be requested from an ABB Turbocharging Service Station.
NOTICE
HZTL2412_EN
Revision F

Mothballing the turbocharger 10
Taking the engine out of operation for 10.1 Page 119

up to 12 months
10 Mothballing the turbocharger

September 2016
10.1 Taking the engine out of operation for up to

10.1
12 months
Condition of engine lubricating oil
The turbocharger normally remains mounted on the engine. Mothballing a

turbocharger depends on the condition of the lubricating oil:
¡ If the total acid number (TAN) is lower than 2 mg KOH/g, no measures

have to be taken.
¡ If the engine lubricating oil is replaced by preserving oil before taking
the engine out of operation and this is circulated by the pre-lubrication
pump, no measures have to be taken. Any remaining old engine oil will
therefore be flushed away and the bearing sections largely protected
against corrosion.
HZTL2412_EN
Mothballing measures

WARNING
safety data sheet.

Revision F


up to 12 months
If the total acid number (TAN) is greater than 2 mg KOH/g, the following
mothballing measures are necessary after taking an engine out of operation:
September 2016
u Dismantle the turbocharger.
u The rotor and the bearing parts must be removed by an official ABB
Turbocharging service station and refitted afterwards.
u Clean all parts.
u Machined, bright surfaces of steel and cast parts must be oiled with
anticorrosive oil.
u Reassemble complete turbocharger.
Rotor turning in stack draught
If the rotor turns as a result of the stack draught:
u Install blind flange between compressor casing outlet flange and

charge air duct.
HZTL2412_EN
Revision F


more than 12 months
10.2 Taking the engine out of operation for more

than 12 months
September 2016
10.2
If the engine is taken out of service, the following alternatives are possible
with the turbocharger:
¡ The turbocharger remains mounted on the engine.

¡ The turbocharger casing remains mounted on the engine, but the rotor
and the bearing parts are removed and stored separately by an ABB
¡ The turbocharger is removed completely, either as a whole or in indi-
vidual parts.
See the section Taking out of operation for up to 12 months, under Moth-
balling measures, for the measures always necessary when mothballing
turbocharger parts.
HZTL2412_EN
If the turbocharger remains mounted on the engine, refer to the section

Taking out of operation for up to 12 months, under Rotating the rotor in
stack draught.
If the entire turbocharger is removed, or if the turbocharger is re-

assembled from the individual components thereof:
u Close all turbocharger openings using wooden covers and paraffin paper.
Suitable storage locations are only dry rooms where the relative humidity
is between 40 … 70 % and no condensation can form.
Condition of the mothballed turbocharger

Revision F
u Check the mothballed turbocharger parts for corrosion once per an-
num.
u If there are signs of rust: Clean parts thoroughly and renew protection
against corrosion.

Disposing of turbocharger components 11

more than 12 months
11 Disposing of turbocharger components

September 2016
Handling damaged thermal insulation

Damaged thermal insulation can lead to dust exposure. The glass fibres
can cause mechanical irritation of the eyes, skin, and respiratory tracts.
WARNING
u Avoid the formation of dust.
u Vacuum up dust with a suitable vacuum cleaner.
u Wear a respiratory mask to protect against particles (P1 or P2 mask).
u Wear work gloves made of leather.

HZTL2412_EN
Disposal must be environmentally compatible, professional, and in com-

pliance with locally applicable regulations.
The turbocharger consists largely of metal (cast iron materials, steel,

nickel-steel alloys, aluminium and bearing brass).
Further components are: Non-metallic materials (filter components of felt

and polyethylene), lubricants (engine oil), electronic parts (speed sensor
and associated components), and thermal insulation.
u Dispose of metals as scrap metal for recycling.

u Dispose of non-metallic materials as waste.
u Dispose of residues of lubricants as waste oil.
u Dispose of electronic components as electronic waste.
u Dispose of thermal insulation as hazardous waste.
Revision F

Spare parts 12
Ordering spare parts 12.1 Page 125
12 Spare parts
September 2016
12.1
12.1 Ordering spare parts
When making inquiries or ordering spare parts, the following data must be
specified:
¡ Turbocharger type
¡ Serial number (HT……)
¡ Description and part number
Spare parts can be ordered from an official ABB Turbocharging Service

Station.
u If different design versions have not been taken into consideration in

this document, please contact an ABB Turbocharging Service Station.
Storage of spare parts

HZTL2412_EN
All spare parts ordered with the turbocharger must be kept complete
and ready for use.
CAUTION
u Parts showing signs of rust should be carefully cleaned and greased.
u Dispose of replaced and unusable parts in a professional and envi-

ronmentally compatible way.
Customer spare part set (97070)
The customer spare part set (97070) is required for the work described in
this manual.
Quantity Description Part number

1 Socket screw 42008
1 O-ring 42012
Revision F
1 Gasket 52406 *
1 O-ring 77005
2 Counter-sunk screw 72041
1 O-ring 81010 / 82010
* This gasket can be used only when using a gas outlet casing from ABB
Turbo Systems.

Spare parts 12
View of turbocharger showing part 12.2 Page 126

numbers
12.2
12.2 View of turbocharger showing part numbers
September 2016
HZTL2412_EN
Revision F

Spare parts 12
View of turbocharger showing part 12.2 Page 127

numbers
Part number Description

10900 Cartridge group
September 2016
42008 (in customer spare part set) Socket screw

42012 (in customer spare part set) O-ring
51000 Turbine casing
51002 Fastening strips
51100 Exhaust bend
51105* Metal C-ring
52400 Gas outlet flange
52406 (in customer spare part set) Gasket
52408* Metal C-ring
56001 Nozzle ring
57200 Burst protection
57210 Burst ring
72000 Compressor casing
72011 Socket screw
HZTL2412_EN
72012 Fastening strips

72020 V-clamp
72041 (in customer spare part set) Counter-sunk screw with cross slotted
head
77000 Wall insert
79000 Diffuser
81000 Filter silencer
82000 Axial air suction branch
86505(A)* Speed sensor (cable not integrated)
86505(B)* Speed sensor (cable integrated)
86515(A)* Cable connector for 86505(A)
Revision F
86515(B)* Cable connector for 86505(B)

86526* F/I converter
86528* Tachometer
* depends on the turbocharger specification.

Spare parts 12
View of cartridge group showing part 12.3 Page 128

numbers
12.3 View of cartridge group showing part num-

bers
September 2016
12.3
HZTL2412_EN
Revision F

Spare parts 12
View of cartridge group showing part 12.3 Page 129

numbers
Part number Description

21000 Shaft
September 2016
21002 Piston ring

25000 Compressor wheel
32101 Plain bearing bush
32103 Locking ring
32105 Thrust ring
32106 Thrust bearing
32108 Piston ring
32109 Sealing disc
32110 Bearing flange
32111 Auxiliary bearing
32112 Bearing flange
32113 Socket screw
32114 Socket screw
32221 Bearing cover
HZTL2412_EN
32222 O-ring
42001 Bearing casing
42002 Socket screw
42008 (in customer spare part set) Socket screw
43001 Partition wall
43012* Metal C-ring
Revision F

ABB
Service stations
ABB Turbocharging ABB
ABB Jiangjin Turbo Systems Co. Ltd. Shanghai Branch
No. 4528,Kangxin Highway, Pudong New District, 4528
Shanghai 201319 P.R.China 201319

Tel No.: (86) 21 5069 5177 : (86) 21 5069 5177
Fax No.: (86) 21 5069 5226 : (86) 21 5069 5226
24 Hour Hot Line: (86) 189 1820 3500 24 : (86) 189 1820 3500
E.Mail: turbo.sh@cn.abb.com : turbo.sh@cn.abb.com
ABB Jiangjin Turbo Systems Co. Ltd. Guangzhou Branch
A Building,NO.3,5,7 Lianda Road

Huangpu District,
Guangzhou510760,P.R.China 510760
Tel No.: (86) 20 8211 7088 : (86) 20 8211 7088
Fax No.: (86) 20 8211 7188 : (86) 20 8211 7188
24 Hour Hot Line: (86) 139 0240 9901 24 : (86) 139 0240 9901
E.Mail: turbo.gz@cn.abb.com : turbo.gz@cn.abb.com
ABB Jiangjin Turbo Systems Co. Ltd. Tianjin Branch
West Part,No.1Standard Factory Building,19 Xin Ye San

Jie, TEDA West 19
Tianjin,300462,P.R.China 300462
Tel No.: (86) 22 6632 0532 : (86) 22 6632 0532
Fax No.: (86) 22 6632 0535 : (86) 22 6632 0535
24 Hour Hot Line: (86) 136 0208 6208 24 : (86) 136 0208 6208
E.Mail: turbo.tj@cn.abb.com : turbo.tj@cn.abb.com
ABB Jiangjin Turbo Systems Co. Ltd. Dalian Branch
Building 14-3 No.39,Gangxing Street,

39 14-3
Economic and Development Area
Dalian 116600 P.R.China 116600
Tel No.: (86) 411 8758 8222 : (86) 411 8758 8222
Fax No.: (86) 411 8758 8288 : (86) 411 8758 8288
24 Hour Hot Line: (86) 136 0408 9900 24 : (86) 136 0408 9900
E-Mail turbo.dl@cn.abb.com : turbo.dl@cn.abb.com
ABB Visit ABB Turbocharging on line at

ABB
Service stations
ABB Turbocharging ABB
ABB Jiangjin Turbo Systems Co. Ltd. Qingdao Branch
Building 1, No. 19, Mao Shan Road, Huangdao District , 19

Qingdao 266500,PRC 266500
Tel No.: 86 532 8691 7106 86 532 86917106
Fax No.: 86 532 8691 8030 : 86 532 8691 8030
24 Hour Hot Line: 86 13963990710 24 : 86 13963990710
E-Mail turbo.qd@cn.abb.com : turbo.qd@cn.abb.com
ABB Turbo Systems (HongKong) Limited ABB Turbo Systems (HongKong) Limited
No.3 Dai Hei Street

Tai Po Industrail Estate
Tai Po N.T
HongKong,P.R.China
Tel No.: (852)2929 3630 : (852)2929 3630
(852)2929 3651 (852)2929 3651
(852)2929 3638 (852)2929 3638
(852)2929 3665 (852)2929 3665
Fax No.: (852) 2929 3501 : (852) 2929 3501
24 Hour Hot Line: (852) 9103 5163 24 : (852) 9103 5163
E-Mail turbo.hk@cn.abb.com : turbo.hk@cn.abb.com
ABB Visit ABB Turbocharging on line at

Power and productivity
TM
for a better world

TPS44 61F维修说明书

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TPS44 61F维修说明书

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ABB JiangJin Turbo Systems Co., Ltd.

ABB JiangJin Turbo Systems Co., Ltd.

© Copyright 2016 ABB. All rights reserved.

© Copyright 2016 ABB. All rights reserved.

本操作手册能帮助您熟悉 ABB 涡轮系统出品的涡轮增压器，并提供如何将

© Copyright 2016 ABB. All rights reserved.

© Copyright 2016 ABB. All rights reserved.

© Copyright 2016 ABB. All rights reserved.

© Copyright 2016 ABB. All rights reserved.

在未采取额外防锈措施的情况下，由 ABB Turbo Systems 供应的新涡轮增

Volatile Corrosion Inhibitor（VCI 防锈物料）

适合存放的地点只能为湿度仅为大气湿度 40…70% 且不会形成冷凝水的干

u 除去旧的 VCI 防锈物料，换上新的同一型号的 VCI 防锈物料。新 VCI

© Copyright 2016 ABB. All rights reserved.

ABB Turbo Systems 可根据客户要求，对涡轮增压器和转子总成进行长时

拆开材料的 VCI 包装之后，将不再有防腐蚀保护。

© Copyright 2016 ABB. All rights reserved.

对涡轮增压器的改造、扩充和改装会产生安全隐患，要获得 ABB Turbo

© Copyright 2016 ABB. All rights reserved.

原配零件和附件是专为 ABB 涡轮系统提供的涡轮增压器而设计的。

© Copyright 2016 ABB. All rights reserved.

对于有关型号方面的问题，ABB Turbocharging 服务站乐意为您提供帮助

本文件中使用了外部公司的商标。 这些商标 ® 以标记。

© Copyright 2016 ABB. All rights reserved.

在本文献中，ABB 涡轮系统有限公司简称 ABB 涡轮系统。

ABB Turbo Systems 的特约服务站

特约服务站在本文件中被称作 ABB Turbocharging 服务站。该服务部门受

© Copyright 2016 ABB. All rights reserved.

© Copyright 2016 ABB. All rights reserved.

© Copyright 2016 ABB. All rights reserved.

可在线查看 ABB 涡轮系统有限公司的官方服务部门联系方式。

ABB Turbo Systems Ltd

© Copyright 2016 ABB. All rights reserved.

© Copyright 2016 ABB. All rights reserved.

ABB 涡轮增压器符合机械设备标准 2006/42/EG，并根据条款 2g 为非完成

© Copyright 2016 ABB. All rights reserved.

© Copyright 2016 ABB. All rights reserved.

© Copyright 2016 ABB. All rights reserved.

u 在 ABB Turbocharging 订购新警示牌

© Copyright 2016 ABB. All rights reserved.

© Copyright 2016 ABB. All rights reserved.

ABB Turbo Systems 供货的 TPS44-F 涡轮机外壳绝缘也作为爆裂保护

u 配有 ABB Turbo Systems 绝缘的 TPS44-F 涡轮增压器严禁在没有

© Copyright 2016 ABB. All rights reserved.

© Copyright 2016 ABB. All rights reserved.

© Copyright 2016 ABB. All rights reserved.

© Copyright 2016 ABB. All rights reserved.

警告 根据发动机制造商的订货要求，ABB Turbo Systems 的涡轮增压器在交

© Copyright 2016 ABB. All rights reserved.

© Copyright 2016 ABB. All rights reserved.

© Copyright 2016 ABB. All rights reserved.

© Copyright 2016 ABB. All rights reserved.

ABB 涡轮增压器能够承受瞬时压力增量为 12 bar 的爆燃情况。

© Copyright 2016 ABB. All rights reserved.

© Copyright 2016 ABB. All rights reserved.

© Copyright 2016 ABB. All rights reserved.

© Copyright 2016 ABB. All rights reserved.

进油温度不得超过 105 °C 。从下文中可以获悉允许的进油粘度和进油温

© Copyright 2016 ABB. All rights reserved.

© Copyright 2016 ABB. All rights reserved.

如果涡轮增压器长时间在允许范围以外运行，ABB Turbo Systems 建议通

© Copyright 2016 ABB. All rights reserved.

© Copyright 2016 ABB. All rights reserved.

本文件中使用了外部公司的商标。这些商标 ® 以标记。

警告根据发动机制造商的订货要求，ABB Turbo Systems 的涡轮增压器在交

转子和轴承零件必须由 ABB Turbocharging 服务站进行检查和评估。作为

压缩机运行时的清洁采用湿清洁法进行。本清洁方法经过了 ABB Turbo

V 型发动机如果每个 V 型发动机带多个涡轮增压器，我们建议对压缩机采取并行清洁

如果每个 V 型发动机带多个涡轮增压器，我们建议对涡轮增压器采取并

涡轮清洗前的温度水喷水时间喷水的间歇时间

涡轮清洗前的温度水喷水时间喷水前、后的稳定

u 从发动机上拆卸涡轮增压器（参见章节拆卸与安装 [➙ 85]）。

涡轮增压器转子失衡联系 ABB Turbocharging 服务站