Vol. 2

Turbocharging
Operation Manual
TPS48-61D/E/F
ABB Turbo Systems Ltd

CH 5401 Baden
Type TPS48-61D/E/F HT
n Mmax t Mmax
1/s °C
n Bmax t Bmax
kg
Application according to
Year 2005 the Operation Manual
made in Switzerland
HZTL2410 English
ABB Turbo Systems Ltd

Operating condition and replacement intervals
The operational limits for the turbocharger nBmax, tBmax, nMmax, tMmax, inspection- and replacement intervals for the compon-
ents concerned on the rating plate are valid for the operational mode and compressor inlet condition, which has been agreed upon
between the engine builder and ABB.
Note: Replacement intervals of components depends on the load profile, turbine inlet temperature, suction air temperature and
turbocharger speed. In case the operation conditions differs significantly from what is considered to be normal for the cur-
rent application, it is recommended to contact ABB for a re-calculation of replacement intervals. Frequent load alterations,
high temperatures and high speed lower the life of components.
Unless otherwise agreed, the application limits nMmax, tMmax are valid for the test operation for a limited time.
We herewith confirm that this Operation Manual has been drawn up orientated towards the Product Liability Law 1/1/90 as well as to
the „European Machinery Directives“.
We reserve all rights in this document and in the information contained herein.
Reproduction, use or disclosure to third parties without express authority by ABB Turbo Systems Ltd is strictly forbidden.
© Copyright by ABB TURBO SYSTEMS Ltd 2004

Design and specifications are subject to change without notice.
Printed on naturally white paper, bleached free from chlorine and environmentally acceptable.
The CD is made of polycarbonate and contains in addition aluminium, lacquer, dye stuffs and materials of the adhesive label. The CD-cover is made of
recycled cardboard.
These materials may be disposed with the domestic wastes or at a specialised collecting centre.

ABB Turbo Systems AG
Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Operation Manual (TPS48-61)
Table of Contents Page 1
Table of Contents
September 2005
1 Preliminary remarks
1.1 Foreword
1.2 Layout and function
1.3 Correct application
1.4 Essential information
1.5 Abbreviations and symbols
1.6 Turbocharger rating plate
2 Safety
2.1 Basic safety instructions
HZTL2410_EN (TPS48-61)
2.2 General safety instructions

2.3 Special safety instructions
2.4 Safety instructions and hazard protection
3 Commissioning
3.1 Oil supply
3.2 Inspection work
3.3 Putting into operation after out of service period
4 Operation
4.1 Servicing work
4.2 Monitoring
4.3 Surging of turbocharger
4.4 Contact with rotating parts
4.5 Shutting the engine down
Version 2
5 Maintenance
5.1 Outline of cleaning work
5.2 Cleaning the filter silencer
5.3 Cleaning the compressor during operation
5.4 Cleaning turbine blades and nozzle ring in operation
5.5 Maintenance work
ABB Turbo Systems Ltd ABB

Table of Contents Page 2
6 Troubleshooting
September 2005
6.1 Possible remedies for failures
7 Removal and installation

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

8.1 Module weights
8.2 Disassembling and assembling turbocharger (with V-band
connection)
8.3 Disassembling and assembling turbocharger (with strap
connection)
8.4 Axial and radial clearances
8.5 Table of tightening torques
9 Taking out of operation

9.1 Turbocharger shut down (with V-band connection)
9.2 Turbocharger shut down (with strap connection)
10 Mothballing the turbocharger

10.1 Taking out of operation for up to 12 months
10.2 Taking out of operation for more than 12 months
11 Reserve and spare parts

11.1 Ordering spare parts
11.2 Directory of part numbers
11.3 General view of turbocharger
11.4 General view of cartridge group
Version 2

Preliminary remarks 1
Foreword 1.1 Page 1
1 Preliminary remarks
September 2005
1.1 Foreword
This operation manual will help you to become familiar with your ABB
Turbo Systems Ltd turbocharger and to use it to full effect in its intended
application. You will find important instructions as to the safe, correct, and
economical operation of the turbocharger.
This operation manual includes helpful information on the following topics:
Information on the operation of a turbocharger and ways to prolong the

turbocharger's service life.
Early awareness and avoidance of hazards.
Minimising repair costs and failure times.
This operation manual is a complement to, and an extension of, existing

national regulations on accident protection and prevention.
At least one operation manual must be available at all times at the site
where the turbocharger is used. It is essential that this operation man-
ual is read before beginning work by all persons working with or on the
NOTE turbocharger. Personnel only working occasionally on the turbocharger
(e.g. during installation and maintenance) must also have read and fully
understood the operating manual before working on the turbocharger.
The instructions included in this operation manual must be followed under

all circumstances.
This applies especially to the general and special safety instructions

preceding and in the respective chapters. Ignoring hazards and the
safety instructions can lead to serious personal injury and damage to
NOTE equipment.
Version 2
In the event of doubt, consult the officer for safety and accident protection
responsible for your area.

Layout and function 1.2 Page 2
1.2 Layout and function
September 2005
S_00095
1 Suction branch / Filter silencer 8 Gas outlet flange

2 Compressor casing 9 Nozzle ring
3 Diffuser 10 Turbine casing
Version 2
4 Bearing casing 11 Turbine-end bearing flange

5 Axial thrust bearing 12 Compressor-end bearing flange
6 Radial plain bearing (only visible 13 Compressor wheel
turbine-end)
7 Turbine

Layout and function 1.2 Page 3
Mode of operation
The turbocharger is a turbo-machine and consists of the following main

September 2005
components:
Turbine
Compressor
These are both connected with a common shaft.
The exhaust gases from the diesel or gas engine flow through the turbine
casing (10) and nozzle ring (9) to the turbine (7).
The turbine (7) uses the energy contained in the exhaust gas to drive the
compressor wheel (13), whereby the compressor draws in fresh air, and
the compressed air is forced into the cylinders.
The exhaust gases escape through the exhaust pipe which is connected
to the gas outlet flange (8).
The air which is necessary for the operation of the diesel or petrol engine
and which is compressed in the turbocharger, is drawn through the suc-
tion branch or the filter silencer (1) into the compressor wheel (13). 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 ax-
ial thrust bearing (5) is located between the two radial plain bearings.
The bearings are connected to a central lubricating oil feed which is sup-
plied by the oil lubrication circuit of the engine. The oil outlet is always at
the lowest point of the bearing casing (4).
Version 2

Correct application 1.3 Page 4
1.3 Correct application
September 2005
This turbocharger supplied by ABB Turbo Systems has been developed
exclusively for use on diesel and gas engines to generate the volume of
air and the charging pressure necessary for the operation of such en-
NOTE gines. Any other usage shall be regarded as a special application which
must be discussed with ABB Turbo Systems. The manufacturer ac-
cepts no liability for other applications.
The turbocharger has been designed for the diesel or petrol engine de-
scribed, including speed and output. If it is used otherwise ABB Turbo
Systems reserves the right to reject all claims under the warranty.
This turbocharger was built in accordance with state of the art technology
and is operationally safe according to prevailing safety regulations.
The turbocharger may be hazardous to life and limb of the user or third
parties. In addition, improper use may cause damage to the machine.
The machine may only be operated by trained personnel.
NOTE
Correct use of the turbocharger also includes observation of the assem-

bly, disassembly, operating, maintenance and repair conditions specified
by the manufacturer. Regulations set out by local authorities must be ob-
served when disposing of the turbine.
The turbocharger should only be operated and used in a technically per-

fect condition, for its intended purpose and in compliance with the opera-
tion manual.
Defects which could affect safety must be eliminated immediately.
The manufacturer shall not accept liability for damages resulting from un-
authorised alterations to the turbocharger.
Version 2

Essential information 1.4 Page 5
1.4 Essential information

September 2005
Organizational 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.
NOTE
The turbocharger must be shut down immediately in the event of al-

terations affecting safety or of corresponding operating behaviour. The

fault should be reported to the person or department responsible.
Additions to, and alterations and conversions of the turbocharger that

could compromise safety require the prior approval of ABB Turbo Sys-
tems.
NOTE
Version 2

Original parts and safety
September 2005
Original parts and accessories are especially designed for the turbo-
charger supplied by ABB Turbo Systems Ltd .
We herewith expressly state that parts and accessories not supplied by

us have also not been tested and approved by us.
NOTE
If components and assemblies not manufactured and tested by ABB

Turbo Systems are used, this may have a negative effect on the techni-
cal design specifications of the turbocharger.
WARNING Moreover, the active and/or passive safety of the turbocharger may be
compromised by the use of non-original parts. Note that such improper
use may endanger personnel and the machine.
ABB Turbo Systems shall not be liable for any damage caused by using
non-original parts and accessories.
Qualification of personnel
The turbocharger must only be operated and maintained by trained and

authorised personnel.
Work on mechanical components, such as bearings or rotors, must only

be performed by qualified fitters from an official service station of ABB
Turbo Systems Ltd !
CAUTION
It must be ensured that only authorised personnel work on the turbo-

charger.
Version 2

After-sales service
September 2005
The Contact Information brochure contains an overview of official ABB

Turbo Systems Ltd service stations worldwide.
Design variants
This instruction manual is valid for various turbocharger design variants.
This means that some sections and component descriptions in this oper-
ating manual do not apply to your turbocharger.
Our service stations and agencies will gladly answer your questions relat-
ing specifically to your model.
Storage of new turbochargers

New turbochargers supplied by ABB Turbo Systems Ltd can be stored

without additional safeguarding measures for a period of 6 months after
the delivery date.
Ensure that the area where the turbocharger is to be stored is dry with
humidity of 40-70% and free of condensation.
After 6 months, rust-proofing oil should be sprayed on exposed sur-

faces and all accessible areas of the turbocharger.
To do this, the insulating materials must be removed.
Repeat the steps described for rust-proofing your turbocharger every 6

months.
NOTE
Version 2

Abbreviations and symbols 1.5 Page 8
1.5 Abbreviations and symbols

The following abbreviations are used in this document:
September 2005
Prerequisite
Work step
Result
Positive checkpoint (activity which must be performed without fail)

Negative Checkpoint (activity which may not be performed under any
circumstances)
Version 2

Turbocharger rating plate 1.6 Page 9
1.6 Turbocharger rating plate

September 2005
L_00012
Operational limits 1 Turbocharger operational limits at engine overload (110%).

In test rig operation only, unless otherwise agreed with the en-
gine manufacturer.
2 Turbocharger operational limits in service.
Version 2
Inspection and exchange 3 Inspection interval for plain bearings in 1000 h

intervals for turbocharger
4 Exhange interval for the compressor in 1000 h (no values
components
100,000 h)
5 Exchange interval for the turbine in 1000 h (no values 100,000
h)

Turbocharger rating plate 1.6 Page 10
Additional specifications: 6 Customer part number

7 Field for special design designation
September 2005
8 Weight of the turbocharger in kg
9 CE = Conformité Européenne
10 Turbocharger type
11 Series number
12 Year of construction of the turbucharger
Explanations of the rating plate
The conditions agreed with the engine manufacturer apply to the values
indicated on the rating plate with regard to operational limits, inspection in-
tervals and replacement intervals.
Continuous running above the indicated values nBmax , tBmax can consid-
erably reduce the recommended exchange intervals. In such cases,
you should contact the nearest official service station of ABB Turbo
CAUTION Systems Ltd.
nMmax , tMmax normally apply only when running at overload (110%) dur-
ing trials on the engine test bed. These limits may also be permitted in
service for special applications. The operation over nMmax , tMmax is not
permitted.
Non-compliance with the recommended exchange intervals may in-
crease the risk of unpredictable component failure.
The inspection intervals and replacement intervals for the turbocharger

components specified must be observed without fail!
Turbocharger components whose permissible operating times have ex-

pired may not be used again under any circumstances!
Version 2

Safety 2
Basic safety instructions 2.1 Page 1
2 Safety
September 2005
2.1 Basic safety instructions

The following symbols and terms are used for the safety instructions in
this operation manual:
Serious injury or fatal accident may result if the working and operation
instructions marked with this symbol are not, or only partly observed.
Warning signs must be strictly observed at all times.
WARNING
Serious damage to the machine or to other property may result if the

working and operation instructions marked with this symbol are not, or
only partly, observed.
CAUTION Caution signs must be strictly observed at all times.

Version 2

Safety 2
General safety instructions 2.2 Page 2
2.2 General safety instructions

The instructions listed here are designed to ensure your safety and to
September 2005
promote safe handling of the turbocharger and its associated operating
materials.
The following safety instructions must be followed when operating and

when working on the turbocharger.
WARNING
Do not work on the turbocharger if you are under physical or mental

stress.
Wear protective clothing at all times.
Helmet
Ear protection
Protective glasses
Protective suit
Oil and petrol resistant gloves
Protective shoes
Attach individual parts and larger component modules carefully to suit-
able hoists/lifting devices which are in technically perfect condition and
which have adequate load-bearing capacity.
Do not stand under suspended loads.
If welding work is to be carried out above the turbocharger, the air filter
must be covered to prevent damage to the filter mat.
When working on the turbocharger, be aware of the risk of it falling.
For overhead assembly work, use the steps and platforms provided for
this purpose.
Version 2

Safety 2
Special safety instructions 2.3 Page 3
2.3 Special safety instructions

September 2005
Safety when connecting
Work only on those connections for which you are qualified.
Safety when commissioning and during operation
Before starting work, make a visual inspection of the working area.

Remove obstacles and any objects lying around from the work area.
Before commissioning check the turbocharger for damage and leaks.
Refrain from any activity which could compromise safety while working
with the turbocharger.
Inspect the turbocharger after about 12 hours of operation or at least
once a day for visible damage and defects.
Report any damage or changes in operational performance to the per-

son/department responsible immediately.
In the event of damage, shut down the turbocharger immediately and
secure it against inadvertent or unauthorized use.
Version 2

Safety 2
Safety when cleaning
September 2005
When handling detergents, solvents, acids and alkalis be sure to observe
the respective safety directions on the manufacturers' labels.
Follow directions regarding the environmentally compatible collection,

storage and disposal of these liquids.
Explosion hazard
Cleaning work should be carried out outdoors due to explosion hazard.
If this is not possible, ensure that there is adequate ventilation and air
WARNING circulation. Before beginning cleaning work in confined spaces, extin-
guish naked flames (including cigarettes!) due to the risk of explosion.
Before cleaning, protect the floor against unintended leaks of oil and
operation materials.
You must wear protective clothing (see section General safety instruc-
tions).
Handle operation materials and detergents with utmost caution.
When handling solvents, wear protective clothing and observe the fol-
lowing rules:
Avoid skin contact with solvents.
Avoid inhaling vapours under all circumstances.
Do not allow solvents to soak protective clothing.
After cleaning, check electric cables for signs of wear or damage.
Version 2

Safety 2
Safety during disassembly, assembly, maintenance and troubleshooting

September 2005
Perform the prescribed adjustment, maintenance and inspection work

at the specified intervals.
Inform operating personnel about special work and repairs before start-
ing.
Ensure that absorbent materials are available to clean up any opera-
tion materials that escape accidentally.
Ensure safe and environmentally-friendly drainage, collection and dis-
posal of operating and auxiliary materials.
Before opening a cover or removing a protective component on the
turbocharger, the engine must have been switched off and must not be
started up again until all parts have been properly re-assembled.
Assembly and disassembly work must only be performed by trained

personnel. Work on mechanical components, such as bearings or ro-
tors, must only be performed by qualified fitters from an official service

CAUTION station of ABB Turbo Systems.
Safety when taking out of operation or putting into storage
Secure the rotor against turning.

Clean the turbocharger before mothballing.
Wear protective clothing when mothballing the turbocharger.
Keep the work area clean and free of oil and operating materials.
Remove any obstacles lying around on the floor.
Version 2

Safety 2
Safety instructions and hazard 2.4 Page 6

protection
2.4 Safety instructions and hazard protection

Associated hazards may arise during operation of and work on the turbo-
September 2005
charger:
from the turbocharger and its accessories.

from the operating materials used.
due to failure to comply with the safety instructions.
from inadequate performance of maintenance and inspection work.
Mechanical influences
Mechanical influences can cause serious or even fatal injury:
Personal injury Unconsciousness and injury due to:
crushing
shearing
cutting
winding
smashing
drawing in
knocking
stabbing
rubbing
escape of liquids under high pressure and at high temperature
slipping
tripping
falling
Causes sharp edges, pointed parts

crush, shear and winding areas
fragmentation / ejection of parts
fracture or rupture of parts due to overload
Elastic elements (springs), liquids and gases under pressure/in a vac-
Version 2
uum
slippery, oily work area, obstacles on the floor

Safety 2

protection
Protective measures Wear leather protective gloves

Wear close-fitting protective clothing
Tie up long hair and beards (wear hair protection)
September 2005
Wear face and eye protection

Wear protective shoes
Keep floor, equipment and the turbocharger clean
Ensure the availability of oil absorbing materials and have oil collector
basins ready or in position
Eliminate leaks
Operation and process materials
Operation and process materials refer to chemical and hazardous sub-

stances:
Oil
Grease
Coolants
Detergents and solvents

Acids
Note that operation and process materials are harmful to the environ-
ment if they penetrate soil or water.
CAUTION
Personal injury The following injuries can be caused by operation and process materials:
Allergies
Skin disease
Loss of consciousness
Poisoning or nausea after inhalation
Causes Inhalation of toxic gases, smoke and vapours

Skin contact with aggressive fluids
Version 2
Clothing wet or soaked with hazardous substances

Spilling and tipping over of vessels containing substances used during
operation
Escape due to leakage
Tanks and collectors which are not gas-tight and which do not comply
with the regulations on hazardous substances
Burning cigarettes or open flame in the proximity of operation materials

Safety 2

protection
Protective measures Utmost caution when handling process and operation materials
Protective clothing must be worn
Avoid skin contact and inhalation under all circumstances
September 2005
Ensure that the workroom is properly ventilated
Observe the hazard indications on the containers for operation and
process materials
Immediately after use, seal the hazardous substance container tight
Used operation materials must be collected safely in accordance with
the legal provisions, stored separately in suitable containers as pre-
scribed, and disposed of as special waste in a technically and envi-
ronmentally compatible manner
Ensure that containers for new / used operation materials are sealed
tight
In the event of leaks or spills immediately apply a suitable absorbent
material and dispose of this in a technically and environmentally com-
patible manner as special waste
Handling insulating materials
Ensure that the work area is well ventilated
Keep the work area clean
Avoid disturbing dust
Dust-suppressing tools and processing steps
Remove from packaging only in the work area
Exercise particular care when removing old insulating materials
Dispose of insulating materials in a technically and environmentally
compatible manner
If large quantities of dust are created, wear protective glasses
Use half or quarter masks
Wear suitable work clothing and gloves
For sensitive skin, apply moisturising, protective barrier cream
Version 2

Safety 2

protection
Noise
September 2005
The effects of noise above a legally permitted level can cause personal in-
jury.
Personal injury Loss of hearing

Deafness
Impaired hearing
Health disorders such as loss of balance or of consciousness
Cardiac and circulatory disturbances
Causes Machine noise level above 85 dB (A)
Protective measures Wear ear protection
Heat hazard
When the turbocharger is operated, surfaces become very hot.
Personal injury Burns
Causes Missing or incorrectly fitted insulation.
Protective measures Wear leather protective gloves.

Version 2

Commissioning 3
Oil supply 3.1 Page 1
3 Commissioning
September 2005
3.1 Oil supply

A carefully designed oil supply, which functions under all operating condi-
tions, is an important precondition for trouble-free operation of the turbo-
charger.
Lubrication of the turbocharger is normally carried out with oil from the
engine oil circuit.
If a separate lubrication system is used, then standby lubrication is also to

be proved.
The engine manaufacturer's recommendations regarding oil selection

and oil change intervals are to be observed.
NOTE
Oil filtration
To prevent dangerous wear to the bearing parts, depending on the tur-

bine specification and bearing used, different-sized impurities must be
filtered out of the lubrication oil.
CAUTION
As standard, for the turbocharger an oil filtration of 34 µm is prescribed.

That means, impurities which are larger than 0.034 mm, must be filtered
out of the oil with a filtration efficiency of > 99%.
If the oil is not sufficiently filtered through the engine filter, an additional
filter is to be installed.
During a cold start and, if due to deposits of dirt in the additional filter,
the flow resistance rises above 0.5 bar, a bypass must respond, which
guarantees the oil supply of the turbocharger by bypassing the filter.
Version 2
Before putting into operation for the first time, check that the oil filters
are clean.
Also observe the specifications of the engine manufacturer concerning

filter fineness and filtration efficiency.
NOTE

Commissioning 3
Lubricants
September 2005
All lubricating oils used for engines are permissible.
NOTE
Oil inlet viscosity and temperature
The oil inlet temperature must not exceed 105°C. The permissible oil inlet
viscosities and temperatures are shown in the following diagram.
S_00132
1) Kinetic viscosity (mm2/s = cSt)

2) Oil inlet temperature (°C)
Version 2
A Permissible range
During engine start, the lower temperature limit may be temporarily un-
dershot.
The oil inlet temperature however should thereby not fall below 10 °C.
NOTE

Commissioning 3

September 2005
Oil pressure
The oil pressure before the bearings must be exactly maintained to en-
sure fault-free operation.
The oil pressure (overpressure) before the turbocharger with the engine
under load should be 2.0 ... 4.5 bar and at idling speed at least 0.2 bar .
With cold oil, during the starting phase, temporarily a higher oil pressure
of up to 8 bar is permissible. During pre- and post-lubrication, the oil pres-
sure must not exceed 1.0 bar .
Pre-lubrication
Before every engine start, actuate pre-lubrication device. The turbo-

charger must be supplied with oil from the very first moment the engine
is started.
CAUTION
Version 2

Commissioning 3
Inspection work 3.2 Page 4
3.2 Inspection work

This inspection work includes preventive visual controls, as well as moni-
September 2005
toring and measurement to ensure the correct functioning of the turbo-
charger. These serve as an aid to detecting anomalies before and during
commissioning, thus preventing possible damage to the machine.
The safety instructions must be followed before and during all inspec-
tion work.
3.2.1 Inspection before commissioning
Monitoring equipment To be checked for correct functioning.
Oil filters Check cleanliness before commissioning.
Manometers on oil lines Check oil pressure in oil supply lines.
Air filter mat Inspect for damage.
It is urgently recommended that the entire lubrication system is bridged

using a bypass pipe, in order to be flushed thoroughly with warm, clean
oil before commissioning and after every servicing operation on the lu-
CAUTION brication system.
We strongly recommend the use of a starting filter when running the
engine in and after every servicing operation on the lubrication system.
Version 2
Pre-lubrication
Before every engine start, actuate pre-lubrication device. The turbo-

charger must be supplied with oil from the very first moment the engine
is started.
CAUTION

Commissioning 3
Inspection work 3.2 Page 5
3.2.2 Inspection after commissioning
Charger speed Measuring (optional, charger speed counter not included as standard
September 2005
with all turbocharger types)
Charger pressure Measuring
Temperatures Measure upstream/downstream from turbine, compressor and oil feed

for various engine speeds
Gas, air, and oil lines After the engine has been started up, check all gas, air and oil lines for
leaks.
Lubricants and pastes used during assembly of the turbocharger are

liquefied or vaporised and may escape as an oily liquid or smoke in the
first few hours after commissioning. If oily liquid continues to escape
NOTE after this period, the cause must be treated as an oil leak and located.
The first step in this process is to check the oil supply to the turbo-
charger for leaks. If this is not in order, contact an official ABB Turbo
Systems service station.
Measure the speed, oil pressure, charging pressure and temperatures

before and after the turbine and the compressor at various engine
speeds.
Compare the measured values with those of the inspection report, tak-
ing into account the different operating conditions.
3.2.3 Inspection after 100 service hours

Version 2
Clean or replace lubricating oil filters after the first 100 service hours.

Commissioning 3
Putting into operation after out of 3.3 Page 6

service period
3.3 Putting into operation after out of service pe-

riod
September 2005
Inspect the exhaust pipe before and after the turbine for possible com-
bustion residues, foreign bodies or residual water and clean if neces-
sary.
Start up the engine end oil circulation system.
Inspect air supply lines or filter segments for possible foreign bodies
and clean if necessary.
Version 2

Operation 4
Servicing work 4.1 Page 1
4 Operation
September 2005
4.1 Servicing work

Servicing work during operation includes visual checks, monitoring and
measuring as well as inspection and function checks in order to ensure
correct functioning of the turbocharger. It serves as an aid to detecting
anomalies during operation, thus preventing damage to the machine.
The inspection, measurement and servicing operations listed must be car-
ried out at the intervals indicated.
The pertinent safety instructions must be observed during all servicing

work.
WARNING
Servicing work must be carried out at the prescribed intervals in order

to avoid damage to and malfunctioning of the turbocharger.
CAUTION
4.1.1 Servicing work every 25 to 50 hours
Operation data must be recorded

Enter in the machine logbook
In the event of significant anomalies, establish the cause
If you are unable to establish the cause of the anomalies, contact an

official ABB Turbo Systems service station.
CAUTION
Visual check for air, exhaust gas, water and oil leaks.
Version 2

Operation 4
Servicing work 4.1 Page 2
4.1.2 Servicing work according to the engine manufacturer's instructions
September 2005
Oil filters With the engine at standstill clean or replace oil filters
4.1.3 Servicing work every 8,000 -12,000 hours
Dismantle the turbocharger

Clearance measurement
Clean turbine- and compressor casings and check for any cracks and
erosion / corrosion.
Clean bearing casing, blow through oil ports
Clean nozzle ring and check for cracks and erosion
Inspection and assessment of the rotor and bearing parts
Inspection and assessment of the rotor
The first inspection and assessment of the bearing parts has to be car-
ried out in acc. with the rating plate or between 8,000 and 12,000 ser-
NOTE vice hours.
The inspection and assessment of the rotor and the bearing parts must
be carried out by an official service station of ABB Turbo Systems.
4.1.4 Entries in the machine logbook
Monitoring of the machine plant provides information about the perform-

ance of the turbocharger.
The following operation data and measurement values must be entered

regularly in the engine manufacturer's machine log book:
Output and speed of the engine

Air intake temperature
Version 2
Exhaust gas temperature before and after the turbine

Pressure of the charge-air
Pressure drop in the charge-air cooler
Lube oil pressure, lube oil temperature
If provided Air temperature after compressor and after the charge-air cooler
Speed of the turbocharger
Pressure loss in the air filter

Operation 4
Monitoring 4.2 Page 3
4.2 Monitoring
September 2005
4.2.1 Speed measurement

S_00096
1 Line amplifier 7 Cable plug

2 Installation variants (right or left) 8 Gasket
3 Bearing casing 9 Screw plug
4 Sealing disc with cam or groove 10 Voltage limiting module
5 Speed transmitter 11 Connecting cable
Version 2
6 Flange plug

Operation 4
TPS turbochargers can be optionally fitted with a speed transmitter sys-

tem for measuring the turbocharger speed. This speed transmitter, in
connection with the corresponding measuring units or monitoring systems
September 2005
(not part of the delivery), permits continuous remote monitoring of the tur-
bocharger speed. With continuous monitoring of the engine installation,
the turbocharger speed can be used as a suitable control parameter.
If required, the line amplifier can be purchased as an optional addition to

the described speed measuring system.
A reduction in speed of a charger can signify:
Damaged rotor components or bearing.

Defects in the connected pulse charging cylinders.
Defects or leaks on the exhaust gas pipes or on the charge-air lines.
With 4-stroke applications, heavy fouling of the turbine can also be a
cause of an increase in the turbocharger speed.
NOTE
Possible reasons for failure of the speed indicator:
Defects on the speed transmitting system, on the connecting cable, on

the measuring unit or in the power supply. (if applicable on the line
amplifier or the line amplifier power supply).
Turbocharger damage.
If the speed indication fails, it is recommended that the engine output

be reduced to idling speed and the engine stopped. The cause of the
failure should then be determined.
CAUTION
Version 2

Operation 4
Installation:
September 2005
If the speed transmitter system is not assembled on the turbocharger at

the time of delivery, it will be in a separate package together with its cable.
To assemble, the transmitter system must be screwed into the left or right
threaded hole on the bearing casing, depending on the desired position.
The screw plug which is in this threaded hole and its seal must first be
removed. It should be noted that the sensor is screwed in completely and
to the correct tightening torque without a gasket (see chapter Tightening
torques table).
Exchange or subsequent assembly of the speed sensor:
We recommend that subsequent assembly or replacement of the speed

transmitter system should be carried out only by an official ABB Turbo

NOTE
Version 2

Operation 4
Surging of turbocharger 4.3 Page 6
4.3 Surging of turbocharger

Surging of the turbocharger can occur with certain engine operating
September 2005
states, such as rapid load removal or while manoeuvring. The direction of
flow in the compressor is then briefly reversed. However, sporadic surging
of this kind does not generally affect the safe operation of the turbo-
charger.
Prolonged or periodic surging

If surging is prolonged or occurs periodically, the following components
may be damaged:
CAUTION - Compressor wheel (vibration fractures, ...)
- Turbine blades (cracks)
- Bearing (overheating)
- Filter silencer
Action to be taken:
The operating safety of the turbocharger is no longer ensured with con-

tinuous or periodically recurring surging. The operator must take immedi-
ate steps to correct the surging together with the closest official ABB
Turbo Systems service station.
The above mentioned components are to be examined for damage by an
official service station of ABB Turbo Systems and replaced in cases of
doubt.
Version 2

Operation 4
Contact with rotating parts 4.4 Page 7
4.4 Contact with rotating parts

Mild, uniform wear around the circumference of rotor components, caused
September 2005
by slight local grazing against adjacent components, is non-hazardous

and permissible. This slightly reduces the length of the blades in the com-
pressor and/or the turbine. Certain tolerances must be observed to avoid
significant loss of efficiency.
A check on dimensions must be carried out by an official ABB Turbo

Version 2

Operation 4
Shutting the engine down 4.5 Page 8
4.5 Shutting the engine down
September 2005
Before shutting the engine down, it must be allowed to idle for a further
5 to 10 Minutes, so that the circulating oil can dissipate the heat in the
turbocharger bearings.
CAUTION
Version 2

Maintenance 5
Outline of cleaning work 5.1 Page 1
5 Maintenance
September 2005
5.1 Outline of cleaning work

Cleaning work includes regular visual checks and washing to ensure the
correct functioning of the turbocharger and its auxiliary appliances.
The external condition and the degree of contamination of the cleaning

points listed below must be established by visual checks at the inter-
vals indicated.
The safety instructions must be observed during all cleaning work.
Filter silencer Filter ring must be cleaned wet

Dismantle the filter silencer
Felt segments in the cover panels are to be cleaned dry
Compressor Wet clean with fresh water in accordance with the engine manufac-
turer's instructions
Engine warm from running
High compressor speed
Turbine Wet clean with fresh water in accordance with the engine manufac-
turer's instructions
High engine load
Gas inlet temperature before turbine may not exceed 450°C
Version 2

Maintenance 5
Cleaning the filter silencer 5.2 Page 2
5.2 Cleaning the filter silencer
September 2005
S_00116
If provided The filter ring (81265) can be replaced or cleaned by washing.
To ensure perfect operation during washing it is advisable to replace

Version 2
the filter ring with another (filter rings available in packs of two).
NOTE
Wash or replace the filter ring every 500 service hours. The filter ring is
not to be washed more than five times.
CAUTION

Maintenance 5
Cleaning the filter silencer 5.2 Page 3
Washing the filter ring Rinse filter ring with water (up to 40°C) using fine washing powder or, if
September 2005
very dirty, soak it and squeeze out carefully. Rinse in cold water. Avoid
high mechanical stress (wringing, strong water jet).
Allow the filter ring to dry completely before assembly.
Cleaning the silencer Loosen the tension bands (81270) and withdraw cover grid (81266).
Withdraw the cover panels (81137), bend them upwards and remove
the felt segments (81136).
During cleaning take care that the felt segments do not get wet!
CAUTION
Remove dirt with a cloth, a soft brush or compressed air.

Have heavily soiled felt segments replaced by an ABB Turbo Systems

service station.
Damaged tension bands must be replaced with new ones.
CAUTION
Version 2

Maintenance 5
Cleaning the compressor during 5.3 Page 4

operation
5.3 Cleaning the compressor during operation

The dirt in the compressor stage (compressor wheel and diffuser) de-
September 2005
pends on the cleanness of the air drawn in and the operating point.
A deposit of dirt in the flow ducts will be formed if the following substances
are present in the intake air:
Oil or saline mist

Solid combustion residues
Dust of various kinds
Soiling of the compressor stage has a negative effect on compressor effi-

ciency and charging pressure, particularly for smaller turbochargers.
This results in higher exhaust temperatures and increased fuel consump-

tion by the engine. Contamination of the compressor also increases the
rotor unbalance.
Periodic cleaning of the compressor in operation prevents or retards an
increase in soiling, but in no way replaces the regular servicing work, dur-
ing which the turbocharger is completely dismantled.
If the coating of dirt is very thick and hard, the compressor can only be
cleaned manually when dismantled. This cleaning should be carried out
by an official ABB Turbo Systems service station.
NOTE
Principle of wet cleaning Water is injected before the compressor wheel via an injection pipe fitted
in the filter silencer or the suction branch in order to clean the compressor
stage in operation.
The water does not act as a solvent in the process, but the deposit is re-
moved by the mechanical impact of the drops. The process is ideal, pro-
vided the soiling is not too advanced.
Version 2

Maintenance 5

operation
5.3.1 Wet cleaning of the compressor

September 2005
These guidelines for wet cleaning the compressor apply exclusively for
cleaning with water and are subject to the approval of the engine manu-
facturer.
NOTE
Due to the danger of corrosion, only fresh watermay be used, and on

no account salt water. The water should also not contain any cooling
additives or solvents, which could form deposits in the flow ducts.
CAUTION 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.
Cleaning interval The interval between periodic cleanings depends in large measure on the
operating conditions. In general, cleaning should be carried out every 24
to 72 operating hours.
Engine load during wet Cleaning of the compressor stage must be performed with the engine
cleaning warm from running and as fully loaded as possible (i.e. at high turbo-
charger speed).
The success of the cleaning can be seen from the charging or scavenging
pressure or also from the exhaust gas temperatures. If cleaning is unsuc-
cessful, it can be repeated up to 2 times.
An unsuccessful cleaning should be repeated after a stabilisation period

of 10 minutes at the earliest.
If cleaning is still unsuccessful after three attempts, and if the engine

operating values are unsatisfactory, we recommend that the turbo-
Version 2
charger be checked and cleaned by an official ABB Turbo Systems

NOTE service station.
After cleaning the compressor stage, the engine must be run under load
for at least another 5 minutes.
Cleaning more than one If several turbochargers are installed on one engine, we recommend
turbocharger compressor cleaning the turbocharger compressors one after the other.

Maintenance 5

operation
5.3.2 Wet cleaning with external pressurised water container
September 2005
The supply of water from the externally mounted dosing vessel is not
suitable for applications where underpressure is not present before the
compressor wheel (e.g.: Blower connected upstream of the compressor
NOTE or high-pressure compressor stage in the case of two-stage charging).
S_00097
X Screw plugs D Compressed air

Y Valve lever W Water
Version 2
Z Container

Maintenance 5

operation
Cleaning parameters for Turbocharger type Turbocharger Contents of the Water injection
each turbocharger com- speed dosing vessel time
pressor [dm3] t1 [s]
September 2005
TPS 48 roughly nBmax 0.4 10

TPS 52
TPS 57
TPS 61
Operating the pressure Remove the screw plug (X).

water vessel Fill the vessel with pure water.
Screw the screw plug back in place.
Actuate valve lever(Y) against the spring and hold it for 10 to 15 sec-
onds until all the water has been injected.
Version 2

Maintenance 5
Cleaning turbine blades and nozzle ring 5.4 Page 8

in operation
5.4 Cleaning turbine blades and nozzle ring in

operation
September 2005
Combustion of heavy fuel oil in diesel engines causes soiling of the tur-
bine blades and nozzle rings of the turbochargers. Heavy fuel oil of par-
ticularly poor quality in combination with a high exhaust gas temperature,
as occurs with a 4-stroke engine, can lead to particularly hard deposits,
above all on the nozzle ring.
Poor turbine efficiency, increased exhaust gas temperatures, higher

charging and ignition pressures and a lower engine output are the result.
Experience in operation shows, that with periodical cleaning during opera-

tion, the interval between overhauls can be extended. The wet cleaning of
the turbine blades and the nozzle ring described in the following can be
applied with 4-stroke applications with heavy fuel oil and gas engines with
heavy deposits (e.g. waste dump gas).
For the other applications, in general no turbine cleaning is necessary.
Regular cleaning of the turbine during operation prevents or retards a
severe increase in soiling.
NOTE
This cleaning does not replace the normal maintenance work, during
which the turbocharger is to be completely dismantled.
Very heavily soiled turbochargers are not to be cleaned with this

method. In this case, the rotor must be cleaned by an official ABB
Turbo Systems service station.
NOTE
Version 2

Maintenance 5

in operation
Wet cleaning
September 2005
Wet cleaning is used for TPS turbochargers.
To clean the turbine components during operation, the thermal shock

principle is applied in combination with a subsequent flushing phase. Dur-
ing the cleaning process, the layer of dirt on the material surface of the
turbine components loosens.
Only clean fresh water without cleaning agents or solvents may be

used for the wet cleaning.
CAUTION
The instructions of the engine manufacturer for wet cleaning are to be

observed.
NOTE
To achieve the required thermal shock effect for wet cleaning, the tem-
perature before the turbine TTI must lie between 400°C (673 K) and 450°C
(723 K).
For reasons of material strength, during the cleaning process the tem-
perature before the turbine TTI must not exceed 450°C (723 K).
If the exhaust gas temperature can be reduced for wet cleaning, we
CAUTION recommend this should be done as far as possible, to reduce stress on
the material, but the exhaust gas temperature must not be reduced be-
low 400°C (673 K).
The prescribed water injection pressure and the duration of water injec-
Version 2
tion must be observed without fail.

Smaller volumes of water can lead to an inadequate cleaning effect.
Larger volumes of water lead to impermissible thermal stresses.
Clean fresh water free from cleaning agents and solvents must be
used.

Maintenance 5

in operation
Cleaning more than one If on a single engine, more than one turbocharger is mounted feeding into
turbocharger turbine the same air receiver, the turbochargers are to be cleaned one after the
other.
September 2005
The cleaning of all turbochargers at the same time causes a greater drop
in performance.
To avoid corrosion on the inner surfaces of the casing, the engine must be
run for a further 10 minutes after the wet cleaning operation is completed.
Cleaning interval The frequency of the cleaning depends on the extent of soiling. As a
guidance value, the turbine components are to be cleaned approx. every
200 service hours.
If required, this cleaning interval can be shortened after consultation with

ABB Turbo Systems.
Requirement for water supply
During the injection, the absolute static water pressure pWT before the wa-
ter connection on the turbine casing must be at least 1.5 bar above the
absolute turbine inlet pressure (pWT – pTi ≥ 1.5 bar).
If necessary, the engine load must be lowered during cleaning.
pWT = absolute static pressure before water connection on turbine cas-

ing
pTi = absolute static pressure before the turbine
The water supply line to the turbine casing must on no account be con-
nected to a water pipe directly via a cock.
Version 2
CAUTION

Maintenance 5

in operation
Wet cleaning procedure

September 2005
Check that the temperature before the turbine TTi is between 400°C (673
K) and 450°C (723 K). If necessary the engine output is to be adapted.
The engine output must also be lowered if pWT – pTi ≥ 1.5 bar.
If TTi = 400°C can not be achieved (TTi < 400°C), then the temperature
should be set as high as possible.
NOTE
Check that the water supply is ensured.

Open shut-off valve
Inject water with pressure pWT for 15 to 30 seconds
(As standard 15 seconds are recommended. Extend the injection pe-

riod if cleaning effect with 15 seconds is unsatisfactory and if engine
operation permits this.)
Reheating phase of the turbocharger components over a time th ac-
cording to the following table „Cleaning parameters“.
Repeat the last 2 previous points until water has been injected three
times.
This completes the turbine cleaning process. The shut-off valve must
be closed.
If an engine is charged by more than one turbocharger, to save time the

turbines should be cleaned sequentially. That means, that during the
reheating phase of one turbocharger, the water injection can take place
NOTE at the next one.
Version 2

Maintenance 5

in operation
Cleaning parameters
September 2005
Type Temperature Water Injection period
before turbine [°C] Absolute pressure 1) per injection
[ bar ] [s]
TPS 48 400 … 450 3,5 … 6,0 15 … 30
TPS 52 400 … 450 3,5 … 6,0 15 … 30
TPS 57 400 … 450 3,5 … 6,0 15 … 30
TPS 61 400 … 450 3,5 … 6,0 15 … 30
Type Water volume Pause between Number of water

per injection 2) the injections injections
[l] [min]
TPS 48 1,5 … 3,5 3 3
TPS 52 2,0 … 5,0 3 3
TPS 57 3,5 … 8,0 3 3
TPS 61 5,0 … 12,0 5 3
1) Before the water connection on the turbine casing during
cleaning
2) Water volume depending on pressure before turbine, water
injection pressure and injection period
The specified water volume is per turbocharger.
CAUTION
Version 2

Maintenance 5
Maintenance work 5.5 Page 13
5.5 Maintenance work

Maintenance work includes inspection and function checks of wearing
September 2005
parts with or without changing process materials, parts or modules. It

must be carried out in accordance with the intervals as set out in the Out-
line of Maintenance work.
Failure to conduct scheduled maintenance work

Failure to carry out the maintenance work at the prescribed intervals
can lead to damage and malfunction of the turbocharger.
CAUTION The safety instructions in the respective chapters must be observed for
all maintenance work.
Keep lubrication and auxiliary materials ready
Overview of maintenance work
Completely replace bearings in accordance with the instructions on the

rating plate and/or as indicated by the service station or in case of
damage.
Replace compressor wheel in accordance with the instructions on the
rating plate and/or as indicated by the service station or in case of
damage.
Replace turbine in accordance with the instructions on the rating plate
and/or as indicated by the service station or in case of damage.
These operations must be carried out by an authorised ABB Turbo Sys-

tems service station.
NOTE
Version 2

Troubleshooting 6
Possible remedies for failures 6.1 Page 1
6 Troubleshooting
September 2005
6.1 Possible remedies for failures
6.1.1 Exhaust temperature too high
Engine output and speed unchanged
Engine Malfunction in the injection system

Repair, or contact the manufacturer.
Turbocharger Air starvation, e.g. air filter clogged with dirt

Clean
Compressor / turbine soiled

Clean
Exhaust counterpressure too high

Clean or repair boiler or exhaust silencer
Turbine damaged or worn

Contact an official ABB Turbo Systems service station.
Charge-air cooler Cooler soiled

Clean
Insufficient coolant water quantity

Replenish
Coolant water inlet temperature too hot

Version 2
Clean/inspect cooling system
Ventilation inadequate
Improve ventilation

Troubleshooting 6
6.1.2 Charge-air pressure too low
September 2005
Intake condition normal
Engine Air receiver leaking

Repair
Gas line between engine and turbine leaking

Repair
Injection misadjusted
Correct adjustment
Valve control misadjusted
Correct adjustment
Turbocharger Manometer display faulty

Replace manometer
Leak in line to the manometer

Repair leak
Air filter dirty, causing excessive loss of pressure

Clean
Compressor / turbine soiled

Clean
Compressor / turbine damaged

Version 2
Excessive exhaust counterpressure

Clean boiler or exhaust silencer

Troubleshooting 6
6.1.3 Charge-air pressure too high

September 2005
Intake condition normal
Engine Malfunction in the injection system

Correct adjustment
Engine output higher than expected

Check engine output
Injection misadjusted
Correct adjustment
Turbocharger Manometer display faulty

Replace manometer
6.1.4 Vibrations
Turbocharger Rotor imbalance due to heavy fouling of compressor/turbine

Turbine or compressor damaged
Bearing defective
6.1.5 Noises during run-out
Turbocharger Turbocharger dirty

Clean
Version 2
Bearing damaged
Rotor grazing
Foreign bodies in the turbocharger

Troubleshooting 6
6.1.6 Run-out time too short
September 2005
Clean
Bearing damaged
Rotor grazing
6.1.7 Sluggish start-up

Clean
Bearing damaged
Rotor grazing
6.1.8 Lubricating oil pressure too low
Engine Oil filter heavily soiled

Clean
Oil pump in the lubricating system defective

Inspect
Manometer provides false reading

Replace manometer
Version 2
Turbocharger Axial clearance of the rotor too big


Troubleshooting 6
6.1.9 Constant surging of the turbocharger

September 2005
Engine Exhaust pressure to the turbine elevated because boiler or exhaust si-
lencer is dirty
Trap dirty
Clean
Turbocharger Charge-air cooler or silencer dirty

Heavy deposits of contamination in the turbine
Clean
If it is not possible to determine the reason for the surging, contact an

official ABB Turbo Systems service station.
NOTE
Version 2

Removal and installation 7
Turbocharger weights 7.1 Page 1
7 Removal and installation

September 2005
7.1 Turbocharger weights

WARNING
Turbocharger parts that are not suspended in accordance with the
regulations during disassembly and assembly may fall and can cause
serious or even fatal injury.
Select a suitable rope taking into account the weight of the turbo-
charger parts.
Version 2
L_00082
To ensure the safety of loads on the crane hook, the ropes must be
crossed for suspending. See also the illustration above.
NOTE

Turbocharger weights 7.1 Page 2
Turbocharger complete without silencer / air suction branch and without

gas outlet manifold
September 2005
Weight [kg] TPS 48 TPS 52 TPS 57 TPS 61
110 160 260 450
Turbocharger complete without gas outlet manifold and with silencer

129 187 300 512
Turbocharger complete without gas outlet manifold and with air suction
branch (radial)
116 168 271 471
Version 2

Remove the turbocharger 7.2 Page 3
7.2 Remove the turbocharger

Disconnect all gas and air lines in accordance with the engine manu-
September 2005
facturer’s instructions.
If provided Remove insulation as follows:

S_00098
Remove screws and plate (A) of the bearing casing insulation.

Remove remaining screws of the bearing casing insulation (B).
Withdraw bearing casing insulation upwards. For more simple removal,
Version 2
the bearing casing insulation can be compressed.

Unplug cable on the speed measurement (C).
Check the lifting equipment.

Turbocharger without gas

outlet manifold
September 2005
S_00099
Secure lifting equipment to bearing casing.
Turbocharger with gas

outlet manifold without
insulation:
Version 2
S_00100
Sling lifting equipment around the gas outlet manifold and secure to the
bearing casing.


outlet manifold and with
insulation:
September 2005
S_00101
Secure lifting equipment with a ring bolt and nut to the flange of the gas
outlet mainfold and to the bearing casing.
During removal, a turbocharger that is not lifted in compliance with

regulations may fall, and can cause serious or even fatal injury.
WARNING
charger.
Loosen securing screws (D) on the bearing casing.

Version 2
Lift the turbocharger from the engine and place it aside.

Cover oil connections.

Installing the turbocharger 7.3 Page 6
7.3 Installing the turbocharger
September 2005
During installation, a turbocharger that is not lifted in compliance with
regulations may fall, and can cause serious or even fatal injury.
WARNING
charger.
Remove covers from the oil connections.

Visual inspection of the O-ring gaskets of oil supply- and drain pipe
(the engine-end O-ring gaskets are not part of the scope of delivery of
ABB Turbo Systems).
Check the lifting equipment.
Turbocharger without gas
outlet manifold
S_00099
Version 2
Secure lifting equipment to bearing casing


outlet manifold without
insulation:
September 2005
S_00100
Sling lifting equipment around the gas outlet manifold and secure to the
bearing casing.

outlet manifold and with
insulation:
Version 2
S_00101

Secure lifting equipment with a ring bolt and nut to the flange of the gas
outlet mainfold and to the bearing casing.
Mate turbocharger with the engine.
September 2005
Tighten securing screws (D) on the bearing casing.
Plug in cable for the speed measurrement (C).
If provided: Secure insulation as follows:
Mate bearing casing insulation.
S_00098
Version 2
Tighten screws of the bearing casing insulation (B).

Mate screws and plate (A) of the bearing casing insulation.
Secure all gas and air lines in accordance with the engine manufac-
turer’s instructions.

Disassembly and assembly 8
Module weights 8.1 Page 1
8 Disassembly and assembly

September 2005
8.1 Module weights

WARNING
Turbocharger parts that are not suspended in accordance with the
charger parts.
Version 2
L_00082
To ensure the safety of loads on the crane hook, the ropes must be
crossed for suspending. See also the illustration above.
NOTE

Modules
September 2005
Version 2
S_00102
A Strap connection B V-band connection

Weights [kg] Description TPS 48 TPS 52 TPS 57 TPS 61

1 Silencer 19 27 40 62
September 2005
2 Air suction branch, radial 6 8 11 21

3 Air suction branch, axial 4 4 6 9
4 Compressor casing 24 35 51 89
5 Wall insert 7 10 13 30
6 Diffuser 2 3 6 10
7 Cartridge group 32 48 83 136
8 Nozzle ring 1 2 3 6
9 Rupture ring 2 3 5 12
10 Turbine casing 1 inlet 32 47 77 130
with external 2 inlets 35 50 86 145
rupture protec-
tion 3 inlets - 53 96 162
4 inlets - - 93 162
11 Gas outlet flange 4 8 16 30
12 Gas outlet manifold 18 25 40 56

Version 2

Disassembling and assembling 8.2 Page 4

turbocharger (with V-band connection)
8.2 Disassembling and assembling turbocharger

(with V-band connection)
September 2005
Not all tools are identified with a part number. The identification of the
tools is ensured with the tools list (included in the toolbox).
NOTE
During removal and assembly, turbocharger components that have not

been suspended in compliance with regulations may fall, and can
cause serious or even fatal injury.
WARNING
charger parts.
Removing compressor casing
Disconnect all air ducts in accordance with the engine manufacturer’s

instructions.
If provided: Remove screws of the compressor casing insulation and dismantle in-
sulation.
Loosen V-band (72020) and remove filter silencer or air suction
branch.
Version 2


September 2005
S_00103
1 Filter silencer 2 Air suction branch
Slightly loosen V-band (72030) and turn compressor casing (72000),

until the ring bolt (90230) on the lifting equipment can be secured.
Completely loosen V-band (72030) and travel compressor casing
(72000) away horizontally with wall insert (77000).
Knock wall insert (77000) out of the compressor casing with nylon
hammer and remove O-ring gasket (77005).
Version 2


September 2005
S_00104
If the compressor casing can not be easily released, it can be pushed

off against the turbine casing with the press-off tool (90042). For this,
the two cover plates (A+B) of the turbine casing insulation must be re-
NOTE moved.
If provided
Version 2
S_00105


Axial force
September 2005
A high axial force can be generated with the press-off tool and with im-
proper handling (pressing off too strongly at one side) the rotor can be
CAUTION damaged.
Therefore always engage at both sides alternately and do not press
off too much at each side.
Version 2


Installing compressor casing
September 2005
Install the compressor casing following these instructions in the reverse
order.
Always replace O-ring gaskets (see section Spare parts)
NOTE
Clean V-bands (72020/72030) thoroughly before assembly.

Grease V-band thread and inside of the profile with Antiscuff (or similar
high-temperature lubricating paste).
Check lifting equipment and secure to bearing casing (42001).
Work that exceeds the scope of the description in this chapter must
only be performed by a trained fitter from an official ABB Turbo Sys-
CAUTION
Version 2


Removing cartridge group

September 2005
If provided Disconnect all lines according to engine manufacturer's specifications,

remove insulation, dismantle turbocharger and remove compressor
casing as well as filter silencer (see also previous chapter).
S_00105
Remove screws on both plates (A+B) of the turbine casing insulation

and dismantle the plates.
Version 2
S_00106
If provided Disconnect plug to speed measuring transmitter (86505).


Treat screw thread of the V-band (52410) with rust dissolver and allow
September 2005
to act.
Loosen V-band (52410) with hexagon insert (90400) and remove.
Loosen fastening screws (C) of the bearing casing (42001) and re-
move.
Carefully withdraw cartridge group and remove gasket (42013).
Bearing casing is not easy to remove.

Press off bearing casing with press-off tool (90042) against the turbine
casing (see following diagram).
Axial force
CAUTION damaged.
Version 2
S_00128
The V-band (52410) is always to be replaced by a new one. (see sec-

tion Spare parts)
NOTE


September 2005
S_00107
Press off nozzle ring (56001) with the two withdrawal devices (90070)
and the service support bracket (90012) and remove.
If provided: Remove lamellar sealing ring (56005).
Place cartridge group on the service support (90012) and screw tight.
Version 2


Diffusor disassembly
TPS…D/E/F33
September 2005
S_00110
Loosen screws (42008), remove diffuser (79000) and O-ring gasket

(42012).
Measure axial and radial clearances (see section Axial and Radial
Clearances).
Version 2


Installing the cartridge group

September 2005
NOTE
S_00109
If provided: Fit lamellar sealing ring (56005).

Version 2
Ensure the correct coiling of the lamellar sealing ring (56005).
NOTE
Push in nozzle ring (56001) up to the stop in the turbine casing

(51000).
Pay attention to the position of the cam.


So that the nozzle ring is fixed during operation, it must be clamped be-
tween the partition wall and the turbine casing.
September 2005
NOTE
The pressing (PD) must be calculated.
S_00129
If the calculated value is less than 0.1 mm, an official service station of
ABB Turbo Systems must be contacted.
NOTE
Version 2


September 2005
S_00110
Measuring axial and radial clearances (see section Axial and Radial
Clearances).
Secure diffuser (79000) and O-ring gasket (42012) with screws
(42008).
Unscrew cartridge group and lift from the service support (90012).
Version 2


September 2005
S_00111
Grease centering seats, inside of the V-band profile and screw threads
with Antiscuff (or similar high-temperature lubricating paste).
Remove provisional covers at the oil connections.
Assemble cartridge group and gasket (42013) as far as possible by
hand.
During assembly of the cartridge group, do not damage or move gasket

rings (A) in the securing support. The gasket rings (A) are engine side
and are not included in the scope of supply of ABB Turbo Systems.
CAUTION
Version 2


September 2005
S_00112
If two turbochargers, each with a left and right oil inlet, are mounted on
one engine, as a precaution against mistaken, incorrect assembly, a pin
can be fitted in the bracket as assembly security device. This pin (B) fits
NOTE in the respective groove on the foot of the bearing casing.
Fit V-band (52410) and tighten using hexagon insert (90400) to the
specified torque. (use torque spanner!).
Loosen V-band and remove.
Measure the distance between the V-band flanges at several points
with a feeler gauge. This distance must not be greater than the calcu-
Version 2
lated value (PD).
Correct positioning of the turbine casing

Operation of the TPS turbocharger with axially incorrect positioned tur-
bine casing leads to damage to the nozzle ring and turbine casing.
CAUTION


If the calculated value is not nicht achieved, repeat tightening proce-

dure with V-band (do not tighten V-band with more than the specified
September 2005
torque) or separate casing with press-off tool and start from the begin-
ning.
Fit V-band and tighten with the specified torque.
An optimal seating of the V-band is achieved through gentle taps on the

cover band with a nylon hammer.
NOTE
Retighten V-band with torque spanner (see chapter Tightening torques
table).
Version 2
S_00113
Assemble bearing casing (42001) with fixing screws (C).

Tighten fixing screws with the torques specified in the following table.


TPS Fixing screws C [mm] Tightening torques [Nm]

48 M16 230
September 2005
52 M20 455
57 M20 455
61 M24 780
Fit speed sensor (86505).
If provided:
S_00105
Fit insulation plates (A+B).
CAUTION
Version 2


turbocharger (with strap connection)
8.3 Disassembling and assembling turbocharger

(with strap connection)
September 2005
Not all tools are identified with a part number. The identification of the
tools is ensured with the tools list (included in the toolbox).
NOTE

WARNING Turbocharger parts that are not suspended in accordance with the
charger parts.
Removing compressor casing
Disconnect all air ducts in accordance with the engine manufacturer’s

instructions.
If provided Remove screws of the compressor casing insulation and dismantle in-
sulation.
Version 2
Loosen V-band (72020) and remove silencer or air suction branch.


September 2005
S_00103
1 Silencer 2 Air suction branch
Slightly loosen screws (72011) and turn compressor casing (72000),

until the ring bolt (90230) on the lifting equipment can be secured.
Version 2


September 2005
S_00114
If provided
Version 2
S_00105
If the compressor casing can not be easily released, it can be pushed

off against the turbine casing with the press-off tool (90042). For this,
the two cover plates (A+B) of the turbine casing insulation must be re-
NOTE moved.


September 2005
Axial force
CAUTION damaged.
Loosen screws (72011) and remove with securing straps (72012).

Carefully travel compressor casing (72000) away horizontally with wall
insert (77000).
TPS.. –F31/F32
Version 2
S_00115
Release screws (72040) and remove from compressor casing (72000)

with fixing washers (72041) and diffuser (79000).
Knock wall insert (77000) out of the compressor casing with nylon
hammer and remove O-ring gasket (77005).
TPS 61 To lift the wall insert (77000) use the ring bolts (90255).


Installing compressor casing
September 2005
Diffusor assembly TPS.. – Install wall insert (77000) and O-ring gasket (77005) analogously in the
F31/F32 reverse order.
Install diffuser analogously in the reverse order.
Fit the compressor casing analogously in the reverse order.
Always replace O-ring gaskets. (see section Spare parts)
NOTE
Thoroughly clean securing straps (72012) and V-band (72020) before
assembly. Grease V-band thread and inside of the profile with Antiscuff
(or similar high-temperature lubricating paste).
CAUTION
Version 2


Removing cartridge group

September 2005
If provided
Disconnect all lines according to engine manufacturer's specifications,

remove insulation, dismantle turbocharger and remove compressor
casing as well as filter silencer (see also previous chapter).
S_00105
Remove screws on both plates (A+B) of the turbine casing insulation

and remove the plates.
Version 2


September 2005
S_00117
If provided Disconnect plug to speed measuring transmitter (86505)
Treat screw thread of the studs (51006) with creep oil and allow to re-
act.
Release nuts (51007) and remove Verbus washers (51003) with secur-
ing straps (51002).
Loosen fastening screws (C) of the bearing casing (42001) and re-
move.
Remove cartridge group.
Bearing casing is not easy to remove.

Version 2


Press off bearing casing with press-off tool (90042) against the turbine
casing (see following diagram)
September 2005
Axial force
CAUTION damaged.
S_00128

Version 2


September 2005
S_00107
Withdraw nozzle ring (56001) with the two withdrawal devices (90070)
and the service support bracket (90012).
If provided Remove lamellar sealing ring (56005).
TPS.. D/E/F33 Version 2


September 2005
S_00110
Place cartridge group on the service support (90012) and screw tight.
Loosen screw (42008) and remove diffuser (79000) and O-ring gasket
(42012).
Clearances).
Version 2


Installing the cartridge group
September 2005
NOTE
S_00109
If provided Fit lamellar sealing ring (56005).

Version 2
Ensure the correct coiling of the lamellar sealing ring (56005).
NOTE
Push in nozzle ring (56001) up to the stop in the turbine casing

(51000).
Pay attention to the position of the cam.


So that the nozzle ring is fixed during operation, it must be clamped be-
tween the partition wall and the turbine casing.
September 2005
NOTE
The pressing (PD) must be calculated.
S_00133
If the calculated value (PD) is less than 0.1 mm, an official service sta-
tion of ABB Turbo Systems must be contacted.
NOTE
Clearances).
Version 2


Diffusor assembly
TPS…D/E/F33
September 2005
S_00110
Secure diffuser (79000) and O-ring gasket (42012) with screw (42008).
See section Removing Rotor.
NOTE

Unscrew cartridge group and lift from the service support (90012).
Version 2
Grease centering seats and screw threads with Antiscuff (or similar
high-temperature lubricating paste).
Remove provisional covers at the oil connections.


September 2005
S_00134
Fit cartridge group as far as possible by hand

Version 2


September 2005
S_00118
During assembly of the cartridge group, do not damage or move gasket

rings (A) in the securing support. The gasket rings (A) are engine side
and are not included in the scope of supply of ABB Turbo Systems.
CAUTION
If two turbochargers, each with a left and right oil inlet, are mounted on
one engine, as a precaution against mistaken, incorrect assembly, a pin
can be fitted in the bracket as assembly security device. This pin (B) fits
Version 2
NOTE in the respective groove on the foot of the bearing casing.


September 2005
S_00113
Secure cartridge group with the securing straps (51002), the Verbus
washers (51003) and nuts (51007) (see also chapter Tightening
torques table).
Secure bearing casing (42001) with fixing screws (C).
Tighten fixing screws (C) with the tightening torques according to the
following table.
TPS Fixing screws C [mm] Tightening torques [Nm]

48 M16 230
52 M20 455
57 M20 455
61 M24 780
Version 2


If provided
September 2005
S_00105
Plug in connector for speed measuring transmitter (86505) and fit the
insulation plates (A/B).
CAUTION
Version 2

Axial and radial clearances 8.4 Page 37
8.4 Axial and radial clearances

September 2005
S_00119
After removal and before the installation of the cartridge group, the
axial clearance A and the radial clearance B are to be measured and
noted.
Version 2
To correctly measure the axial clearance A, raise the turbine slightly.
NOTE

Axial and radial clearances 8.4 Page 38
Axial and radial clearance TPS 48 TPS 52 TPS 57 TPS 61

[mm]
A at least 0.08 0.10 0.12 0.15
September 2005
A maximum 0.16 0.18 0.21 0.25
B at least 0.50 0.61 0.72 0.81
B maximum 0.99 1.15 1.31 1.55
If the clearances are outside the tolerance, an official ABB Turbo Sys-
tems service station must be contacted.
CAUTION
Version 2

Table of tightening torques 8.5 Page 39
8.5 Table of tightening torques

September 2005
S_00120
If provided
Version 2
S_00121

Table of tightening torques 8.5 Page 40
The tightening torques listed must be observed for the screwed connec-
tions listed in the following table.
September 2005
Tightening torques [Nm] Part no. TPS 48 TPS 52 TPS 57 TPS 61
32113 10 10 20 40
32114 10 10 20 40
42002 20 40 65 65
42008 10 10 20 40
51007 25 45 75 75
52410 60 1) 60 1) 60 1) -
52432 20 40 65 65
72011 35 70 105 105
72020 60 60 60 60
72030 60 1) 60 1) - -
86505 15 15 15 15
1) V-band connection only
Version 2

Taking out of operation 9
Turbocharger shut down (with V-band 9.1 Page 1

connection)
9 Taking out of operation

September 2005
9.1 Turbocharger shut down (with V-band con-

nection)
If with a damaged turbocharger, the Diesel engine can only be shut down
temporarily for an emergency repair, then the following procedure should
be adopted:
Fit cover plate.
The instructions of the engine manufacturer for operation of the engine

with locked / isolated turbocharger must be followed precisely in all
cases!
CAUTION
Fitting the cover plate

Version 2
S_00122


connection)
Dismantle turbocharger. (See section Disassembling and assembling

turbocharger with V-band connection)
September 2005
Do not disassemble nozzle ring.
NOTE
S_00123
Block the opening in the turbine casing with the cover plate (A).
Secure cover plate to turbine casing (51000) with V-band (52410) and
Version 2
screw tight on support.
Clean V-band (52410) thoroughly with a steel brush before assembly.

Grease thread and inside of the profile with Antiscuff (or similar high-
temperature lubricating paste).
NOTE


connection)
Cover plate drawing

September 2005
The cover plate (material: general structural steel, in accordance with

DIN EN 10025-2) must be produced in-house according to the drawing.
NOTE
Version 2
S_00124
Cover plate with V-band TPS B1 [mm] B2 [mm] B3 [mm] B4 [mm]

connection
48 65.7 ± 0.4 60 19.1 ± 0.1 130
52 79.6 ± 0.4 78 20.1 ± 0.1 155


connection)
TPS B5 [mm] ØD1 [mm] ØD2 [mm] ØD3 [mm] R1 [mm]

48 150 258 ± 0.2 222.7 ± 0.2 17 115
September 2005
52 180 307 ± 0.2 265.7 ± 0.2 21 135
Version 2

Turbocharger shut down (with strap 9.2 Page 5

connection)
9.2 Turbocharger shut down (with strap connec-

tion)
September 2005
If with a damaged turbocharger, the Diesel engine can only be shut down
temporarily for an emergency repair, then the following procedure should
be adopted:
Fit cover plate.
The instructions of the engine manufacturer for operation of the engine

with locked / isolated turbocharger must be followed precisely in all
cases!
CAUTION
Fitting the cover plate

Version 2
S_00125
Turbocharger disassembly (see section Disassembling and assembling

turbocharger with strap connection).


connection)
Do not disassemble nozzle ring.
September 2005
NOTE
S_00126
Block the opening in the turbine casing with the cover plate (A).
Secure cover plate to the turbine casing (51000) with securing straps
(51002), Verbus washers (51003) and nuts (51007) and screw tight on
support.
Version 2
Clean securing straps (51002) thoroughly before assembly. Grease

thread of studs (51006) with Antiscuff (or similar high-temperature lubri-
cating paste).
NOTE


connection)
Cover plate drawing

September 2005
The cover plate (material: general structural steel, in accordance with

DIN EN 10025-2) must be produced in-house according to the drawing.
NOTE
S_00127
Cover plate with strap TPS B1 [mm] B2 [mm] B3 [mm] B4 [mm] B5 [mm]
connection
48 65.7 ± 0.5 60 130 11.7 ± 0.2 1.5
52 79.6 ± 0.5 78 155 14.2 ± 0.2 1.5
Version 2
57 98.2 ± 0.5 100 190 17.2 ± 0.2 2

61 116.8 ± 0.5 120 226 20.5 ± 0.2 2.4


connection)
TPS B6 [mm] ØD1 [mm] ØD2 [mm] R1 [mm] M

48 150 222.7 ± 0.2 17 maximum M8
150
September 2005
52 180 265.7 ± 0.2 21 maximum M8
125
57 220 325.7 ± 0.2 21 maximum M10
153
61 260 387.7 ± 0.2 25 maximum M10
182
Version 2

Mothballing the turbocharger 10
Taking out of operation for up to 12 10.1 Page 1

months
10 Mothballing the turbocharger

September 2005
10.1 Taking out of operation for up to 12 months

If a turbocharger has to be laid up for up to 12 months, the decision
whether the turbocharger needs special protection or not depends mainly
on the condition of the lubricating oil before laying up.
If the Total Acid Number (TAN) is lower than 2 mg KOH/g no special

measures need to be taken. However, if the neutralisation factor is higher
the turbocharger must be dismantled after laying up, cleaned and protec-
tive oil must be applied to the naked parts.
If the turbocharger is left mounted on the engine, and the engine oil is re-
placed by a protective oil which is circulated with a pre-lubrication pump
prior to laying up, no measures need to be taken in respect of the turbo-
charger. The remains of the old engine oil will be washed away and the
sensitive bearing parts will be largely protected against corrosion.
If the rotor turns due to a draught from the flue, fit a blind flange between
the compressor casing and the charge-air duct.
Version 2

Mothballing the turbocharger 10
Taking out of operation for more than 12 10.2 Page 2

months
10.2 Taking out of operation for more than 12

months
September 2005
If the turbocharger has to be removed from the engine and stored for a
prolonged period of time, disassembly and mothballing of the turbo-
charger must be done by an official ABB Turbo Systems service station.
Ensure that the area where the turbocharger is to be stored is dry with
humidity of 40-70% and free of condensation.
Check mothballed turbochargers yearly for corrosion.

In the event of rust, clean and renew the corrosion protection.
NOTE
Version 2

Reserve and spare parts 11
Ordering spare parts 11.1 Page 1
11 Reserve and spare parts

September 2005
11.1 Ordering spare parts

When making inquiries or ordering spare parts, the following data should
be specified:
Turbocharger type
HT number
Description and part number
Our service stations and agents accept orders for spare parts.
If special variants/cases are not addressed in these general instruc-

tions, contact an official ABB Turbo Systems Ltd. service station or an
ABB agent.
Spare-parts set
Spare-parts set (97070) is required for the work described in this man-
ual. The parts included in the spare-parts set are only available as part
of the complete set.
NOTE
Spare parts set (97070) Quantity Description Part number

1 Socket head screw 42008
2 O-ring gasket 42012/ 81010/ 82010
1 O-ring gasket 77005
11) Gasket 42013
1 Gasket 52406
Version 2
11) V-Band 52410
1) Only TPS with bearing casings with V-band connection

Ordering spare parts 11.1 Page 2
All spare parts that have been ordered with the turbocharger should be
kept complete and serviceable.
September 2005
Rusty parts should be carefully cleaned and greased.
CAUTION
Dispose of parts that have been exchanged and are no longer usable
in a technically and environmentally compatible manner.
Version 2

Directory of part numbers 11.2 Page 3
11.2 Directory of part numbers

The following part numbers and descriptions must be used in ALL corre-
September 2005
spondence or orders:
Turbocharger Part no. Description

51000 Turbine casing
51002 Securing straps
51100 Gas outlet manifold
52400 Gas outlet flange
56001 Nozzle ring
57200 Rupture protection
57210 Rupture ring
72000 Compressor casing
72011 Socket head screw
72012 Securing straps
72020 V-Band
77000 Wall insert
79000 Diffuser
81000 Filter silencer
82000 Air suction branch, axial
Version 2

Directory of part numbers 11.2 Page 4
Cartridge group Part no. Description

21000 Shaft
September 2005
21002 Piston ring
25000 Compressor wheel
32101 Plain bearing bush
32103 Seeger circlip
32105 Thrust ring
32106 Thrust bearing
32108 Piston ring
32109 Sealing disc
32110 Compressor-end bearing flange
32111 Auxiliary bearing
32112 Turbine-end bearing flange
32221 Bearing cap
32222 O-ring gasket
42001 Bearing casing
42008 Socket head screws
43001 Interior wall
Version 2

General view of turbocharger 11.3 Page 5
11.3 General view of turbocharger

September 2005
Version 2
S_00130

General view of cartridge group 11.4 Page 6
11.4 General view of cartridge group
September 2005
Version 2
S_00131

ABB
ABB Turbo Systems AG
Bruggerstrasse 71a
CH-5400 Baden
Switzerland

6(59,&(0$18$/
$,567$57(56

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+2:7286(7+,60$18$/

0$1'$725<5(48,5(0(17 ANY INSTALLATION OF THE STARTER THAT DOES

NOT COMPLY WITH THIS REQUIREMENT SHALL BE CONSIDERED NON-
CONFORMING.
5(&200(1'$7,21TO OBTAIN MAXIMUM LIFETIME AND BEST OPERATION OF

THE STARTER.

Mkb - 2
5311027
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The GALI air starters are devices generally installed as auxiliary units of thermal motors or turbines, for
their start-up.
These starters are based on the principle of two geared rotors, which are turned through the action of
compressed air. This movement is subjected to the appropriate reduction to obtain a determined torque
on the output shaft. To this shaft the appropriate pinion is fitted and the movement thereof pulls the motor
that is desired to start. This pulling action is achieved engaging the pinion of the starter with a crown
wheel usually fitted on the flywheel of the motor.
The starters have internal mechanisms to achieve the engagement and avoid their start-up until it has
been carried out successfully. They are also provided with a device that avoids reengagement.
7(&+1,&$/'$7$
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TORQUE-POWER AND AIR FLOW DIAGRAM FLOW
0$;,08032:(5 N:
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lb.ft TORQUE POWER HP sft /s
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FRECUENCIA DE ROTACION min 1(rpm)

SPEED
(*) Medium value for standard configuration. Different accessories may change these values.
Mkb - 3
5311027
'(6,*1$7,21
All starters have the following data marked on the body:
GALI
30 BAR MAX G S30 X (turning direction X: R - right , CW / L – left, CCW)
NUMBER OF BASE
ROTATION (indicated by an arrow, according to turning direction)
Each starter comes with its corresponding identification plate (mounted on the head), which includes the
following data:
SERIAL NUMBER / YEAR OF MANUFACTURE----- Æ

UNIT REFERENCE----------------------- -Æ
ADDRESS OF THE MANUFACTURER -----------------Æ
Designation of the turning sense on an internal combustion engine: follow the one on the ISO 1204:1990
standard, which consider a viewer lloking at the engine from the output shaft of it; it’s said as clockwise
the direction that the hands of a clock move and counter clockwise the opposite sense.
Designation of the turning sense on a GALI air starter: follow the same standard, looking the starter from
the pinion. It’s showed clockwise as (R) and counter clockwise as (L).
Mkb - 4
5311027
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We,

GALI INTERNACIONAL, S.A.
Polígono Industrial Mas d’en Cisa
C/ Josep Tura, 5
08181-Sentmenat - BARCELONA
SPAIN

declare that the unit:
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is in conformity with the following European Directives:
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In the design and construction thereof the following harmonised European standards have been applied:
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Basic terminology, methodology. Part 2: Basic principles and specifications.
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IT IS FORBIDDEN TO PUT THIS MACHINE IN SERVICE BEFORE IT HAS BEEN INSTALLED

FOLLOWING THE DIRECTIONS OF THE SERVICE MANUAL AND BEFORE THE INSTALLATION AS A
WHOLE HAS BEEN DECLARED CONFORMING TO THE PRECEDING DIRECTIVES

Sentmenat, march the 1st 2007.
Llorenç Gali
Mkb - 5
5311027
75$163257$1'6725$*($66(0%/<$1'',60$17/,1*

75$163257$1'6725$*(
The reduced weight of the GALI starters allows their handling by a single operative for the jobs of
maintenance, assembly and dismantling.
The geometry of the starter is such that it is easy to locate fastening elements, which allows its transport,
or lifting.
The packing which they are provided with for delivery facilitates transport and storage, at the same time
as it protects the starter from possible blows or surface damages.
The starters leave the factory with anti-rust grease that protects the internal mechanisms.
Nevertheless, it is recommended to store them in a dry place.
$66(0%/<
Completely remove the packing material. Remove the plastic caps that plug the holes corresponding to
the inlet nozzle and to the air outlets for accessories. The unique function of these plugs is to avoid dirt
penetration to the interior of the starter before its final assembly.
In case any of the holes foreseen for reading the pressure are not used for this purpose,
close them in a secure manner by means of the corresponding threaded caps and
gaskets.
',60$17/,1*
Cover the access holes to the interior of the starter appropriately, avoiding the possible
entry of dirt or particles of any type. Take particular care with the caps themselves, which
could introduce or release loose particles into the interior.
In the event of the starter incorporating an electro valve, protect this particularly from
impact. If the starter will remain dismantled a long time, protect the pinion and output
shaft of the starter by means of oil or grease to prevent rusting.
Mkb - 6
5311027
,167$//$7,21
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It is recommended the starter to be fixed to the engine by means of a front flange.
GALI can supply standard flanges, or tailored according to order requirements.
The starter can be mounted on any position on the motor, the most recommendable
being to locate the silencer below the drive pinion shaft.
If the coupling has to be made unavoidably by cylindrical cradle, it is necessary to check

that this adapts perfectly without producing local stress, assisting it if necessary with an
annular clamp.
It should be verified that there is adequate gap (Jn) between drive pinion and crown
wheel, and that it is constant over the length of the tooth edge. Check if the front distance
of the gearing follows the indications. Also respect the screw tightening torques of the
following diagram.
m (DP) alfa Jn (mm)
2.540 (10)
2.75
0.3 – 0.6
3
20º
Jn 3.175 (8)
3.5
4.233 (6) 0.4 – 0.7
3
15º
3.5 0.7 - 1
2.117 (12) 0.3 – 0.5

12º
8 FIXATION SCREWS M12

TORQUE 70 Nm
6 ± 1.5 24
The starter has to be firmly joined to the motor body (not to the bed or other attached
elements). To avoid vibrations between the starter and the connection pipe, the
installation is recommended near the starter of a straight length of flexible pipe of at least
300 mm, which complies with the regulations relative to pipes under pressure (97/23/EC).
Mkb - 7
5311027
If it is not possible to secure the starter to the body of the motor, make sure that in the
operation thereof no vibrations are produced which affect the distance between the drive
pinion and the crown wheel of the motor flywheel.
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The starter is designed to deliver its maximum torque at 3MPa (435 psi, 30 bar), although this pressure
will not always be necessary to carry out start-up. The minimum pressure necessary to achieve motor
start-up will depend on each specific application. GALI guarantees that all S30 starters carry out the
engaging movement and main valve opening at least up to 0.6 MPa.
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The air should arrive at the starter clean and dry (ISO 8573-1:2001 maximum diameter of
particles 800 microns; maximum humidity 30 g/m3). It is recommended to fit an automatic
purge in the tank and a GALI air filter connected immediately before the starter. The
installation should foresee a horizontal stretch to install the filter.
Unless expresely recommended otherwise, the inside diameter of the feeding pipe
should not at any point be less than 36 mm or 1 3/8”.
In case of long pipes, the inside diameter should be greater than the minimum
recommended. The feeding pipe should be as short as possible and have a minimum of
direction changes.
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The starters have two couplers for 6 mm pipe diameter, G1/8” threaded, one for taking the pressure and
the other one for the start signal input. If the starter incorporates a solenoid valve, the couplers are
replaced with a coupling socket. When the starter is delivered, these sockets are plugged with the
corresponding airtight cap.
It is recommended to use the free pressure socket to fit a pressure gauge, 0-4 MPa.
Mkb - 8
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In the cases where the control system incorporates a solenoid valve directly assembled on the starter, it
will be necessary to connect the supply voltage, according to the indications for the same.
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The pipe should be cleaned with compressed air before being coupled to the starter,
taking particular care to prevent loose particles reaching the interior, due to welding of
the pipes or for any other reason.
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Check that the installation has been made in accordance with the general instructions provided above. In
particular, verify that the line has no restrictions, with regard to that indicated in point 3.2.
Check the fastening of all elements and the installation of the necessary gaskets to guarantee air-
tightness in the unions between elements.
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DOZD\VEHGLVFKDUJHGIURPLW
Once the installation is finished, open the air feed valve carefully, observing if there is any leak; in such a
case, close it again, empty the pipe slowly and solve the problem.
Apply short low-pressure bursts manually. Ensure the meshing between the pinion and crown wheel of
the engine is correct.
Mkb - 9
5311027
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The installation of a pressure gauge connected to the pipe in the air intake to the starter
allows you to make sure that there is no air remaining in the circuit and, when the starter
is working, it will be possible to determine the effective air feed pressure.
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5.- OPERATION

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The starter has two successive operations:
- First action: in which the pinion carries out an approach movement to the crown wheel and
simultaneously a double turn that favours the engage of both elements. Only when it has been
completed successfully it’s possible to proceed to the second movement.
- Second movement: the main valve is opened, giving to the motor body the possibility to develop
its maximum power.
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Once the second movement has been carried out, the starter accelerates the motor very quickly, thereby
reducing losses in the cylinders to the maximum until the compression is achieved under appropriate
conditions for producing ignition if the fuel feed is correct.

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The shutdown can take place for different reasons:
5.3.1.- FOR ABSENCE OF SIGNAL
If the signal fed by the solenoid valve or the air plunger is cut off, the starter is stopped and disengages.
Control of the signal time can contribute to reduce the consumption of start-up air and
length the useful life of the starter.
5.3.2.- FOR BACKWARD MOTION OF THE DRIVE PINION
At the moment when the motor comes into operation on its own, its torque, greater than starter’s one,
causes disengagement and an internal mechanism produces starter shutdown.
Mkb - 10
5311027
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When shutdown takes place for any of the reasons indicated in point 5.3, the drive pinion is automatically
withdrawn to the idle position.
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When the starter has been stopped, it will remain immobile until the control air pressure disappears
(solenoid valve or plunger), for which reason, in order to operate the starter again, it is necessary to cease
acting on the plunger or to disable the solenoid valve briefly.
Since the actual starter mechanisms are unable to detect whether the motor is working or it has stopped
after a start-up intent, this operation prevents the starter from insisting on another engage action while the
person in charge of controlling the same is not sure that the motor is totally at rest, preventing the drive
pinion from attempting to engage if the crown wheel of the motor is still in motion, which could lead to
serious damage.
Before attempting a new start-up always make sure that the gear rim of the motor has
stopped.
Mkb - 11
5311027
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Always close the shutoff valve with a padlock when carrying out any kind of maintenance task on the
installation. Discharge the air remaining in the pipe by activating the electrically controlled valve (the
starter will try to work, pay attention to the movements that take place), or else allow this air to discharge
smoothly by slowly loosening any plug. ,IWKHUHLVDSUHVVXUHJDXJHDWWKHLQOHWWRWKHVWDUWHUXVHLWWR
FKHFNWKHDEVHQFHRISUHVVXUH
Always use original GALI spare parts. The spare parts that are not GALI originals can
generate hazards or malfunctioning of the starter.
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The preventive maintenance of the GALI starters greatly depends on the use that the corresponding user
makes thereof, both for the frequency of start-ups and for the type of motor. Indeed, a starter that never
works deteriorates more quickly than one which does so with a certain frequency (for example, once a
week).
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RIPDLQYDOYHVKRXOGEHUHPRYHGEHVXUHWRUHDVVHPEO\LWDJDLQSURSHUO\$Q
LQFRUUHFWDVVHPEO\RIWKHVDPHFRXOGFDXVHWKDWVRPHHOHPHQWVFDPHRXWDWJUHDW
VSHHGVKRW(Until serial number 070736 only).
To achieve maximum duration and reliability in the operation of the GALI starter, the
maintenance program should be carried out which is detailed next.
7.2.1.-MONTHLY CHECK
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Observe if there are leaks in the Visual Close the corresponding general
1 installation. shutoff valve, empty the pipe and
replace deteriorated element.
Observe if there are cracks in flexible Visual Close the corresponding general
2 pipe shutoff valve, empty the pipe and
replace flexible pipe.
Close the general shutoff valve with Manually
3
padlock and empty the pipe slowly.
Observe wear in flanks of the drive Visual Remove lock nut, fit new pinion and
4 pinion replace the nut with the corresponding
torque (10.1)
Mkb - 13
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Observe cracks or marks of the drive Visual Remove lock nut, fit new pinion and
5 pinion replace the nut with the corresponding
torque (10.1)
Rotate the pinion manually Manually Carry out starter internal inspection
6
M05.
Verify tightness of front securing screws Torque Set torque 70 Nm
7
wrench
0 &/($1,1*(;7(51$/),/7(5
1
padlock and empty the pipe slowly. As per M01.3
2 Loosen the drainage plug of the filter Set key 13 Permit accumulated water to drain.
3 Tighten the drainage filter plug Set key 13
7.2.2.- ANNUAL CHECK
Be sure to have at hand a SET OF SEALS 5290036. (from serial number 070737)
0 *(1(5$/&+(&.&+$1*(6(72)*$6.(76
1
Disassembly the main valve. Follow disassembly instructions – main
2
valve.
3 Remove all o-rings and membranes. Replace by new parts from set of seals.
4 Assembly all parts in the opposite way.
5 Open general shutoff valve.
6 Pay attention to air leakages. Tighten any needed part.
Be sure to have at hand a SET OF SEALS 5290036.
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1
2 Loosen the 4 nuts 01. Set key 16 Change the gasket 02
3 Loosen the 4 screws 03. Allen key 10 Change the gasket 04
4 Remove the elastic ring 05 Pliers for ring
5 Remove cover 06 Allen key M5 Change gasket 07
6 Remove membrane 08 Manual Change membrane
7 Remove screw 09 Allen key 04
8 Remove cover 10 Change gasket 11
9 Remove 4 screw 12 Allen key 06
10 Remove 4 screw 13 Allen key 06 Change gasket 14
Hold valve rod 16 and loosen nut 15 Two set key Change gasket 17 and 18
11
17 Change membrane 19
Re-assemby the valve rod 16 with a Two set key
12 new 17
nut 15
Re-install the 4 screws 12 with its Allen key 06 Change gasket 20
13
washers
Re-install the 4 screws 13 with its Allen key 06
14 washers.
Correctly assembly 2 union pipes 21
15 Re-install membrane 08
16 Re-install cover 06 Allen key M5
Mkb - 14
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17 Re-install elastic ring 05 Pliers for ring

18 Re-install screws 03 with its washers Allen key 06
19 Re-install cover 10 and screw 09 Allen key 04
20 Install 4 new nuts 01 Set key 13
21 Open general shutoff valve

Be sure to have at hand a REPAIR KIT 5290831 (from serial number 070737).
0 *(1(5$/&+(&.&+(&.2)527256$1'/8%5,&$7,21
Close the general shutoff valve with As per M01.3
1
padlock and empty the pipe.
Disassembly the Motor body Follow disassembly instructions –
2 motor body (usually, it will be not a
need to extract closing rings).
Examine state of rotors (wear, cracks, Visual Replace with new rotors from repair kit
3
etc.)
4 Examine state of bearings Manual Replace with new bearings
Grease bearings Grease
5 KLUBERPLEX
BEM 34-132
Grease the outer toothed axle of main Grease
6 rotor KLUBER KL
COMPLEX
7 Assembly the body, in the oppsite way.
9 Pay attention to air leakages. Tighten any needed part.
Be sure to have at hand a REPAIR KIT 5290826 (until serial number 070736).
0 *(1(5$/5(9,6,215(9,6,212)527256$1'/8%5,&$7,21 VHHGLDJUDPEHORZ

Close the general shutoff valve with As per M01.3
1
padlock and empty the pipe.
Loosen the four nuts 01 Flat star key
2
22
Mkb - 15
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3 Remove head and 4 washers 02 Manual

Withdraw main rotor 03 and secondary Manual
4
04
Examine state of rotors (wear, cracks, Visual Replace with new rotors
5
etc.)
6 Examine state of bearings Manual Replace with new
Grease bearings Grease
7 KLUBERPLEX
BEM 34-132
Grease the outer toothed axle of main Grease
9 rotor KLUBER KL
COMPLEX
10 Re-install head and washer 02 Manual
11 Re-install nuts 01 01 Set key 19

For lubrication always use the grease and oil indicated below:
O-rings: TELLUS 32 oil.

Bearings and rollers: KLUBERPLEX BEM 34-132 grease.
Main rotor and splined shaft : KRAFFT KL COMPLEX grease
Main valve (except membrane 12): KLUBER ISOFLEX SUPER LDS grease
Mkb - 16
5311027
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1.- With a fix key, remove the self-locking nut and take-off the pinion.
2.- With allen kay, loose the four screws M12, keeping the cover on his
position.
3.- Holding from the fillet of the splined shaft (fixation of the pinion), take out
the frontal cover as assembly.
4.- Place the assembly over a flat surface and loose the splined shaft.
5.- Remove the frontal cover to have access to the internal parts. Pay
special attention to the loss of small bearing cylinders, that will become
separated.
6.- Disassembly the internal parts of the assembly. On the frontal cover stay
several elements; to make them out:
7.- Disassembly the retaining ring at the end, inserted at pressure.
8.- With pliers for internal ring, loose the stopping ring of the needle
bearing.
9.- Take out the needle bearing, inserted at pressure.
10.- Disassembly the outer ring of rotation of the rollers, inserted at

pressure.
Mkb - 17
5311027

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1.- With allen key, loose the four screws M8.
2.- With fix key, loose the banjo raccord, placed on the inferior position.
3.- Hold the assembly onwards.
4.- Pay attention to the losse of the small o-ring between this subassembly
and the rear cover of the starter.
5.- Loosing the four screws M8 at each end of the subassembly with allen
key, to divide this in three parts: inlet, main valve body and fast exhaust.
6.- Loosing the elastic ring with long-nose pliers, to take out the exhaust
part. Disassemble the o-ring placed on it.
7.- With long-nose pliers, take out the membrane of her place. It could be
neccesary to blow from the lower hole of the part.
8.- To introduce a flat kay by the lower side, locking the shaft by the flat
sides of it. By means of a pipe kay, loose the nut at the end.
9.- With allen key, take out the plug on the upper hole.
10.- Slide the shaft to take out the piston from his place. The internal
elemens of the valve will be separated, with the needed o-rings.
11.- With fix key, hold the shaft between the flat sides and loose the
threaded part.
12.- Take out the membrane, placed at pressure.

Mkb - 18
5311027
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2.- With fix key, loose the banjo raccord, placed on the inferior position.
3.- Hold the assembly onwards.
4.- Pay attention to the losse of the small o-ring between this subassembly
and the rear cover of the starter.
5.- Loosing the four screws M8 at each end of the subassembly with allen
key, to divide this in three parts: inlet, main valve body and fast exhaust.
6.- By means of the holes on the upper face, turn the exhaust part to take it
out; to make it it’s possible to use long-nose pliers. Disassemble both o-
rings placed on it.
7.- With long-nose pliers, take out the membrane of her place. It could be
neccesary to blow from the lower hole of the part.
8.- To introduce a flat kay by the lower side, locking the shaft by the flat
sides of it. By means of a pipe kay, loose the nut at the end.
9.- With allen key, take out the plug on the upper hole.
10.- Slide the shaft to take out the piston from his place. The internal
elemens of the valve will be separated, with the needed o-rings.
11.- With fix key, hold the shaft between the flat sides and loose the
threaded part.
12.- Take out the membrane, placed at pressure.

Mkb - 19
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(;+$867 XQWLOVHULDOQXPEHU
2.- By means of two keys, loose both nuts at the end of the
assembly.
3.- Slide the differents parts to the full dismantling of the

assembly.

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2.- By means of two allen keys, loose both screws at the

end of the assembly.
3.- Slide the differents parts to the full dismantling of the

assembly.
Mkb - 20
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6(592/2&.(5
1.- With allen key, loose four screws M6.
2.- Take out the subassembly, throwing outside.
4.- Remove the rear cover.
5.- Take out the piston.
6.- Take out the o-rings from his places.
7.- With allen key, loose two screws M4, keeping the parts in
his position by hand.
8.- Loose the parts slowly, to avoid jumping parts by the

action of internal springs.
9.- Extract the ring of the piston, assembled by pressure on it.
10.- With universal key, loose the frontal cover. Pay attention,
because of the internal spring that could make jump the parts.
11.- Dismantle the o-rings from his palces.
12.- Hold the square part on a workbenck.
13.- By means of a screwdriver, disassembly the inside part.
14.- Extract the o-ring.
Mkb - 21
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1.- With fix key, loose the four self-locking nuts M12.
2.- Stricking slowly with nylon hammer, disassembly the set.
3.- By means of nut and counter-nut M12, disassembly the

stud from the reductor body.
4.- Take the special GALI keys rep. 5905810 y 5905812.
5.- Put firmly the key 5905810 en the closing ring of the main
rotor, matching the position of both parts. Turn slowly the key
clockwise if the starter is L and counter clockwise if the starter
is R.
6.- Put firmly the key 5905812 en the closing ring of the
secundary rotor, matching the position of both parts. Turn
slowly the key counter clockwise if the starter is L and
clockwise if the starter is R.
7.- Extract the o-rings from his place in the closing rings.
8.- Extract the external ring of the bearings. The internal ring
should be fixed on the rotors. To disassembly this ring, if it
where a need to insert some part from the rear side, be
careful to not to damage the balls of the bearing.
10.- Throw from the pusher guide to disassembly the internal

parts.
11.- With allen key, extract strainer G1/8” placed on the lower
side.
Mkb - 22
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12.- In a similar way, dismount the closing rings of the rear

cover, but turning in the opposite way to the rings of the
reductor body.
13.- Extract the o-rings, the outer ring of the bearings an the
strainer, in the same way than the reductor body.
14.- By means of a M5 crew, extract the retention valve.
15.- Disassembly the o-rings, extract the elastic pin sticking

with a punch by one of his ends and extract the closing ball.
Mkb - 23
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Pressing push-button, • Empty air receiver (s) • Charge receiver (s)
starter does not respond
and not airflow seems to • Flow valve (s) closed. • Open flow valve (s)
• •
exist in control circuit. Control circuit blocked. Disconnect and clean out
• There is not signal for the • Control signal
electro valve
Pressing push-button, • Leak in control duct. • Repair or replace.

starter does not respond,
although air flows through • Insufficient air pressure • Increase pressure in receiver
control circuit • Servolocker sticking in closed • Remove and check both,

position smoothen guides or change
parts.
• Push-button stuck. • Remove and clean the same
• Excessive length on main air • Approach push-button to starter
pipe work or install a solenoid valve near
the latter
Pinion revolves and • Ring gear and/or pinion have • Clean burrs or replace if
advances, but does not burrs or are damaged necessary. Replace pinion by a
engage the ring gear. more adequate one.
• Lack of clearance between • Check by distortion of ring gear.
pinion and ring gear
Pinion revolves but does • Push-rod (spare part 06) • Disassemble, check, smoothen
not advance inoperative guide diameter, clean or replace
if rusted
• Insufficient air pressure • Increase pressure in receiver.
• Splined shaft (spare part 15) • Disassemble and clean, check
sticking spring (spare part 14) and
reassemble.
• Excessive length of control • Approach push-button to starter
pipe. or install a solenoid valve near
the latter
Pinion advances but does • Pneumatic motor inoperative • Disassemble; inspect rotors for
not rotate. foreign matters between teeth
and for possible wear of gears,

spindles and bearing. Clean, oil
and reassemble. Replace worn
parts.
• Check valve (spare part 29) • Disassemble, clean, oil and
stuck of blocked. reassemble.
Pinion engages gear ring, • Main valve (spare part 79) • Disassemble, clean, oil and
but will not turn engine. blocked. reassemble or replace main
valve.
• Rotors worn or blocked. • Disassemble, clean, oil and

reassemble or replace rotors.
• Insufficient air pressure • Increase pressure in receiver.
• Main air pipe work restricted or • Check all pipe work and replace
insufficient bore. joint it if necessary.
• Membrane (spare part 104) • Replace it.
broken.
Starter starts working • Incorrect connection of control • Connect control pipes as per
upon opening the flow pipes. installations instructions.
valve of the feed line,
although push-button (or
Mkb - 24
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although push-button (or • Main valve (spare part 79) • Disassemble, clean oil and
solenoid valve) are not blocked and open, solenoid replace joint if needed.
actuated. valve or servolocker bloqued
or broken.
Lack of starter power.. • Main pipe work chocked or its • Check all the piping , and
bore is less than stipulated for replace if the inside diameter is
the starter. not correct.
• Insufficient air pressure. • Increase pressure in receiver.

• Badly worn rotors. • Replace them.
• Incorrect bore of main pipe • Check entire pipe work for
work. correct bore and replace if
incorrect.
• Idling of main valve (spare part • Disassemble, clean, oil and
79). reassemble.
After starting the engine, • Servolocker blocked. • Disassemble, clean, oil and
pinion tries to-reengage reassemble. replace if needed.

and hits the ring gear,
which results in damage
to both.
Starter don’t stop. • Main valve (spare part 79) • Disassemble, clean, oil and
blocked reassemble.
• Servolocker defective. • Disassemble, clean, oil and
reassemble. Replace if needed.
• Valve (spare part 29) does not • Disassemble, check for correct
close properly closing of the ball and the plug,
press the valve against its seat.
• Splined shaft (spare part 15) • Disassemble, clean, check
blocked. spring 14
Mkb - 25
5311027

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(from serial number 070737)
Mkb - 26
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Mkb - 27
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10.1.- PINION
Fitting of pinion must be made with the self-locking nut, with the indicated torque:

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10.2.- FRONTAL FLANGE
The optional flange is suitable for differents assembly positions thanks to the holes on the frontal cover of
the starter. It should be fitted with four screws M12, tighten torque 70 Nm.
10.3.- SOLENOID VALVE AND PUSH BUTTON
The command system has solenoid valve 3/2 NC (24V DC) assembled directly over the starter. The
solenoid valve has a push button to operate in case of absence of electric signal. The push button is
provided of protection against accidental operation.
The electric installation should follow the indications of the solenoid valve.
The electric installation must accomplish the International Regulations for Low Tension.
Mkb - 28
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11.1.- FROM SERIAL NUMBER 070737 AHEAD
,' 5(3 '(6,*1$7,21 47< 2%6

01 0276202 ELASTIC RING 1
02 0071255 ALLEN BOLT 4
03 1251001 WASHER 4
04 51306101.001 FRONTAL COVER 1
05 0820808 ROLLER DIAM 8x8 28
07 0384204 RETAINING RING 1 SET OF SEALS
08 51307108 CROWN 1
10 0925025 NEEDLE BEARING 1
11 51306104 EXTERNAL RING 1
12 51306105 CENTER RING 1
14 51307106 SPRING 1
15 51307110 SPLINED SHAFT 1
,' 5(3 '(6,*1$7,21 47< 2%6

16 0070415 ALLEN BOLT 4
17 1250405 WASHER 4
18 5290306 REDUCTOR BODY ASSEMBLY 1
19 51306245 MAIN ROTOR ASSEMBLY 1 REPAIR KIT
20 5290307 MOTOR BODY ASSEMBLY 1
21 51307247 REAR COVER 1
22 51306206 STUD 4
23 0151225 WASHER 4
24 0121275 SELFLOCKING NUT 4
25 5290712 PUSHER GUIDE ASSEMBLY 1
26 0302015 O-RING 1 SET OF SEALS
27 51306246 SECUNDARY ROTOR ASSEMBLY 1 REPAIR KIT
29 5290726 RETENTION VALVE ASSEMBLY 1
31 5290309 PIPE ASSEMBLY 1
112 51306232 SECUNDARY CLOSE RING 1
114 51306229 PRIMARY CLOSE RING 1
Mkb - 29
5311027
,' 5(3 '(6,*1$7,21 47< 2%6

108 5290310 EXHAUST ASSEMBLY 1
109 0070800 ALLEN BOLT 4
110 1250808 WASHER 4
111 51306602 EXHAUST BRACKET 1
,' 5(3 '(6,*1$7,21 47< 2%6

69 0070880 ALLEN BOLT 8
70 1250808 WASHER 12
71 51306403 AIR INLET 1
72 51306412 SPRING 1
73 0121012.30 NUT 1
74 0151002.30 WASHER 1
76 51306405 SOCKET 1
78 51307401 BODY 1
79 51306402.1 VALVE SHAFT 1
80 51306414 SEALER RING 1 SET OF SEALS
85 0070845 ALLEN BOLT 4
95 51306406 SEALER BRACKET 1
97 0639710 PLUG 1
98 51306402.2 VALVE BRACKET 1
103 5290311 FAST EXHAUST BODY 1
104 51206404 MEMBRANE 1 SET OF SEALS
106 51306424 PLUG 1
Mkb - 30
5311027
,' 5(3 '(6,*1$7,21 47< 2%6

44 51306554 SERVOLOCKING COVER 1
45 51306559 SERVOLOCKING VALVE GUIDE 1
46 51306560 SERVOLOCKING SEALER BRACKET 1
48 5290824 SERVOCOMMAND BODY ASSEMBLY 1
49 51306562 SPRING 1
50 51306558 PISTON 1
51 51306557 VALVE SUPPORT 1
52 51306556 VALVE 1
54 1250607 WASHER 4
55 0070650 ALLEN BOLT 4
56 1250506 WASHER 4
57 51306561 SPRING 1
60 0070415 ALLEN BOLT 2
61 0311503 RING 1 SET OF SEALS
62 51306563 SPRING 1
63 5290823 SERVOLOCKER BODY 1
64 51306555 SERVOLOCKER PISTON 1
67 51306553 REAR COVER SERVOLOCKER 1
68 0070515 ALLEN BOLT 4
83 51206413 CONNECTION PIPE ASSEMBLY 1 SET OF SEALS
Mkb - 31
5311027
,' 5(3 '(6,*1$7,21 47< 2%6

65 51307462 CONNECTION PIPE 1
98 51206461 BRACKET 1
99 0070525 SCREW 4
124 1911544 SOLENOID VALVE 1
125 0300412 O-RING 2
126 94800247 CONECTOR 1
127 1250506 WASHER 4
REPAIR KIT (includes set of seals) 5290831
SET OF SEALS 5290036
Mkb - 32
5311027
11.2.- UNTIL SERIAL NUMBER 070736
,' 5(3 '(6,*1$7,21 47< 2%6

02 0071255 ALLEN BOLT 4
03 1251001 WASHER 4
04 51306101.001 FRONTAL COVER 1
05 0820808 ROLLER DIAM 8x8 28
08 51307108 CROWN 1
10 0925025 NEEDLE BEARING 1
11 51306104 EXTERNAL RING 1
12 51306105 CENTER RING 1
14 51307106 SPRING 1
15 51307110 SPLINED SHAFT 1
,' 5(3 '(6,*1$7,21 47< 2%6

16 0070415 ALLEN BOLT 4
17 1250405 WASHER 4
18 5290349 REDUCTOR BODY ASSEMBLY 1
19 51306245 MAIN ROTOR ASSEMBLY 1 REPAIR KIT
20 5290307 MOTOR BODY ASSEMBLY 1
21 51307247 REAR COVER 1
22 51306206 STUD 4
23 0151225 WASHER 4
24 0121275 SELFLOCKING NUT 4
25 5290712 PUSHER GUIDE ASSEMBLY 1
27 51306246 SECUNDARY ROTOR ASSEMBLY 1 REPAIR KIT
29 5290726 RETENTION VALVE ASSEMBLY 1
30 0502147 EXHAUST G ½” 1
31 5290308 PIPE ASSEMBLY 1
32 51306312 COVER 1
33 0070620 ALLEN BOLT 4
56 1250607 WASHER 4
Mkb - 33
5311027
,' 5(3 '(6,*1$7,21 47< 2%6

108 5290528 EXHAUST ASSEMBLY 1
109 0070800 ALLEN BOLT 4
110 1250808 WASHER 4
111 51306602 EXHAUST BRACKET 1
,' 5(3 '(6,*1$7,21 47< 2%6

69 0070880 ALLEN BOLT 8
70 1250808 WASHER 12
71 51306403 AIR INLET 1
72 51306412 SPRING 1
73 0121012.30 NUT 1
74 0151002.30 WASHER 1
76 51306405 SOCKET 1
78 51307401 BODY 1
79 51306402.1 VALVE SHAFT 1
80 51306414 SEALER RING 1 SET OF SEALS
85 0070845 ALLEN BOLT 4
95 51306406 SEALER BRACKET 1
97 0639710 PLUG 1
98 51306402.2 VALVE BRACKET 1
103 51307420 FAST EXHAUST BODY 1
104 51206404 MEMBRANE 1 SET OF SEALS
106 51306411 PLUG 1
Mkb - 34
5311027
,' 5(3 '(6,*1$7,21 47< 2%6

44 51306554 SERVOLOCKING COVER 1
45 51306559 SERVOLOCKING VALVE GUIDE 1
46 51306560 SERVOLOCKING SEALER BRACKET 1
48 5290824 SERVOCOMMAND BODY ASSEMBLY 1
49 51306562 SPRING 1
50 51306558 PISTON 1
51 51306557 VALVE SUPPORT 1
52 51306556 VALVE 1
54 1250607 WASHER 4
55 0070650 ALLEN BOLT 4
56 1250506 WASHER 4
57 51306561 SPRING 1
60 0070415 ALLEN BOLT 2
61 0311503 RING 1 SET OF SEALS
62 51306563 SPRING 1
63 5290823 SERVOLOCKER BODY 1
64 51306555 SERVOLOCKER PISTON 1
67 51306553 REAR COVER SERVOLOCKER 1
68 0070515 ALLEN BOLT 4
83 51206413 CONNECTION PIPE ASSEMBLY 1 SET OF SEALS
Mkb - 35
5311027
,' 5(3 '(6,*1$7,21 47< 2%6

98 51206461 BRACKET 1
99 0070525 SCREW 4
124 1911544 SOLENOID VALVE 1
125 0300412 O-RING 2
126 94800247 CONECTOR 1
127 1250506 WASHER 4
REPAIR KIT (includes set of seals) 5290826
SET OF SEALS 5290036
Mkb - 36
5311027
63(&,)<&63$5(6

6HHILJXUH(;7(51$/',0(16,216IURPVHULDOQXPEHU
326 5()1 '(6,*1$&,21 &$17 2%6(59

01 5290030 S30LM STARTER WITH SOLENOID VALVE 1
02 5302209 FRONTAL FLANGE 1
03 5301263 PINION 1
04 0071240 ALLEN BOLT 4
05 1251201 WASHER 4
06 0121412 NUT 1
07 51306111 WASHER 1
6HHILJXUH(;7(51$/',0(16,216XQWLOVHULDOQXPEHU
326 5()1 '(6,*1$&,21 &$17 2%6(59

01 S30LBASEM S30L BASE AIRSTARTER MET. 1
02 5302209 FRONTAL FLANGE 1
03 5301263 PINION 1
04 0071240 ALLEN SCREW 4
05 1251201 WASHER 4
06 0121412 NUT 1
07 51306111 WASHER 1
08 51307110 SHAFT 1
09 1150205 RIVEKLE 4
10 0353528 IDENTIFICATION PLATE 1
12 0070525 SCREW 4
13 1250506 WASHER 4
14 0721024 SOLENOID VALVE 24V DC 1
15 51206461 BRACKET 1
16 0639710 PLUG 1
17 0304735 O-RING 1
18 5400049 CAUTION PLATE 1
19 5400048 EMERGENCY START PLATE 1
Mkb - 37
5311027
',675,%87,21$1'6(59,&(

*5832*$/,

(63$f$
GALI INTERNACIONAL, S.A.
Polígono Industrial Mas d’en Cisa
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Apartado 11
Tel. 93 715 31 11
Fax 93 726 43 85 / 715 07 51

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DISTRIMAR, S.L.
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SAMSAWON, INC.
ADEX ZONEX PTE. LTD. VM DIESELS (NZ) LIMITED
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628623 SINGAPORE 118-120 NELSON STREET
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Mkb - 38
Viscous Torsional Vibration Dampers
Procedure for taking samples of Silicone fluid
Méthode de
prélèvement
d’échantillons
de silicone
Anleitung zur
Entnahme von
Silikonöl-Proben
Procediminento
para toma de
muestras del
fluido silicona
FORMERLY
Procedure for taking Méthode de prélèvement
samples of silicone fluid d’échantillons de silicone
Fluid samples may be taken from dampers equipped Un prélèvement de fluide silicone peut être effectué
with removable filling plugs. In most cases two of sur les dampers pourvus de bouchons de
these are positioned diametrically opposite each other remplissage. Dans la plupart des cas, deux de ces
in the damper cover. bouchons sont situés dans le couvercle du damper, et
If reasonable access to one of these plugs is possible, diamétralement opposés.
the damper may remain on the engine during this Dans la mesure où il est possible d’accéder à l’un de
procedure. In other cases, the damper must stand in ces bouchons, le prélèvement de fluide pourra
the normal vertical position during sampling. s’effectuer sans dépose préalable du damper. Si le
It is recommended that the damper is rotated until the damper doit être déposé du moteur, le prélèvement
• Sampling Container two plugs are approximately horizontal and that the de fluide s’effectuera en plaçant le damper en position
• Tube de Prélèvement damper remains in this position for a minimum period verticale.
• Proberöhrchen of one hour before the sampling procedure begins. Il est conseillé de faire tourner le damper pour placer
• Contenedor de muestra In general, two sizes of thread are used for the filling les 2 bouchons approximativement l’horizontale. Le
holes, therefore the sample containers are threaded damper restera dans cette position au moins d’une
differently at each end. heure avant de procéder au prélèvement.
En général, il y a deux tailles de filetage pour les trous
de remplissage, et les éprouvettes de prélèvement ont
donc un filetage différent à chaque extrémité.
1 2 3 4
Assuming the thread Remove filling plug Screw sample Remove the other
size in the damper is keeping container container into filling cap nut.
known, prepare sample ready for immediate hole.
container by removing insertion.
English the cap nut from the
end to be inserted in
the damper.
Si on connaît le type de Enlever le bouchon de Visser le tube de Enlever l’autre

filetage dans le damper, remplissage; le tube de prélèvement dans le bouchon écrou.
préparer le tube de prélèvement doit être trou de remplissage.
prélèvement en ôtant le prêt à le remplacer.
bouchon écrou de
Français l’extrémité à introduire
dans le couvercle du
damper.
Je nach Gewinde Verschlußschraube Proberöhrchen sofort Andere Schließkappe

Proberöhrchen durch herausdrehen, dabei in Entnahmebohrung abnehmen.
Abnehmen der Röhrchen bereithalten. schrauben.
Schließkappe für das
Deutsch Einschrauben in den
Dämpfer vorbereiten.
Considerando que el Quitar el tapón de Roscar Quitar el otro tapón

tamaño de rosca en el llenado de la tapa del completamente el roscado del
amortiguador es amortiguador, teniendo contenedor en el contenedor.
conocido, preparar el el contenedor agujero de dicho
Español contenedor de muestra
quitando su tapón
preparado para su
inmediata inserción.
tapón de llenado.
roscado del extremo a

insertar en el
amortiguador.
Anleitung zur Entnahme von Procedimiento para tomar
Silikonöl-Proben muestras del fluido de silicona a)
Flüssigkeitsproben können Dämpfern mit Pueden tomarse muestras del fluido del amortiguador,
abnehmbaren Verschlußschrauben entnommen en los aparatos equipados con tapón de ilenado
werden. Meistens sind zwei solcher Schrauben desmontable.
gegenüberliegend im Deckel des Dämpfers En muchos casos dos de estos tapones están
angebracht. situados, diametralmente opuestos, en la tapa del
Wenn eine der Schrauben einigermaßen zugänglich amortiguador. b)
ist, kann der Dämpfer am Motor bleiben. Im anderen Si se dispone de un acceso razonable a uno de estos
Fall muß der Dämpfer demontiert und die tapones, el amortiguador puede quedar en el motor
Probeentnahme am senkrecht stehenden Dämpfer durante la toma de muestras. En otros casos, el
vorgenommen werden. amortiguador debe situarse en posición vertical • Types of filling plug
Es wird empfohlen, den Dämpfer zu drehen, bis die normal durante dicha operación. • Types de bouchons de
dieden Schrauben ungefähr waagrecht sind, und Se recomienda situar el amortiguador, de forma que remplissage
mindestens eine Stunde so stehen zu lassen, bevor los dos tapónes de ilenado esten aproximadamente • Verschlußschrauben
mit der Probeentnahme begonnen wird. en posición horizontal, dejandolo en esta posición por • Tipos detapones de
Es sind zwei verschiedene Gewinde in den un periodo minimo de una hora antes de comenzar la ilenado
Entnahmebohrungen üblich. Das Proberöhrchen hat toma de muestras.
deshalb unterschiedliche Gewinde an beiden Seiten. En general se utilizan dos diferentes tamaños de rosca
para los agujeros, por tanto los contenedores de
muestra están roscados diferentes en cada extremo.
5 6 .7 8 9
Allow fluid to reach Immediately fluid flows Keeping a filling Immediately fit new plug. Tighten Fit cap nut to container
the open end of the from the open end of plug ready for to 18lb ft (2.5kgm) and lock by and ensure both cap
container. This may the container, replace immediate insertion, disturbing cover material into the nuts are fully screwed
occur within seconds the cap nut. unscrew the slot of the plug using a punch. on but not over-
or over an hour * Important container from the For Plug Type A, it is tightened.
dependent upon fluid The container must be filling hole. recommended that the old plug (Do not use spanners).
conditions and other at least 75% full, to is re-used with a new seal and the
factors. enable Metaldyne plug tightened to match existing
Industries to analyse the peining marks.
sample.
Faire venir le fluide Dès que le fluide Tenir un bouchon Insérer immédiatement le nouveau Remettre le bouchon
silicone à l’extrémité s’écoule par l’extrémité écrou prêt au bouchon, le serrer à 2.5kgm et écrou sur le tube et
ouverte du tube. Cette ouverte du tube, revissage et l’immobiliser en utilisant un pointeau s’assurer que les 2
opération peut durer revisser le bouchon dévisser le tube de ou un chassegoupille qui permet de bouchons écrous sont
quelques secondes écrou. l’orifice de repousser le matériau du couvercle bien vissés mais pas
ou plus d’une heure, * Attention remplissage. dans la fente du bouchon. Pour un trop (ne pas utiliser de
selon la nature du Afin de pouvoir analyser bouchon du type A, il est conseillé pinces).
fluide et en fonction l’échantillon, le tube de de réutiliser l’ancien bouchon avec
un joint d’étanchéité neuf et de
d’autres facteurs. prélèvement doit être
serrer le bouchon jusqu’ à la
remplit de 75% disparition des traces de fatigue.
minimum.
Flüssigkeit bis zum Sobald Flüssigkeit Röhrchen aus Neue Schraube sofort Andere Schließkappe
offenen Ende des austritt, Röhrchen mit Entnahme bohrung einschrauben. Anziehen mit 2.5 auf Röhrchen
Röhrchens kommen- Schließkappe herausschrauben, kpm (18lb ft) und durch schrauben und
lassen. Dies kann in verschließen. dabei Verstemmen von sicherstellen, daß beide
Sekunden erfolgen * Achtung Versclußschraube Deckelwerkstoff in den Kappen gut hand-fest
oder wesentlich Um die Analyse zu bereithalten. Stopfenschlitz sichern. Für Type angezogen sind. (Keine
länger dauern je nach ermöglichen, muß das A wird empfohlen, den alten Schrauben schlüssel
Beschaffenheit der Proberöhrchen Stopfen mit neuer Dichtung benutzen).
Flüssigkeit und mindestens zu 75% wiederzuverwenden und bis zu
den vorhandenen
sonstigen Einflüssen. gefüllt sein. Anzugsspuren anzuziehen.
Dejar que el fluido Inmediatamente que el Tomando un tapón Inmediatamente poner de Poner el otro tapón
alcance el extremo fluido salga por el de llenado neuvo el tapon de llenado, roscado en el extremo
abierto del extremo abierto del dispuesto para su aprentando con un par de del contenedoy
contenedor. Esto contenedor, montar el inmediata inserción 2.5kgm (18lb ft) y precintando asegurar que ambos
puede ocurrir en tapón roscado en la tapa del con punzón, aportando materia tapones están
segundos o en horas, * Atencion amortiguador, de la tapa dentro de la muesca roscados
dependiendo de las Para realizar el analisis de desenroscar el del tapón tipo A, se recomienda completamente pero
condiciones del fluido la muestra de silicona, el contenedor. usar una nueva junta tórica no forzados. (No usar
y otros factores. contenedor debe estar apretando el tapón hasta ajuste llaves).
con las marcas anteriores.
lleno al menos en el 75%
Dampers Mounted with Filling Dämpfer mit Verschlußschraube
Plug Facing the Engine zur Motorseite
These dampers may be sampled if reasonable access Flüssigkeitsproben können entnommen werden, wenn
to the filling plugs is available from crankcase, die Verschlußschrauben vom Kurbelgehäuse
proceeding as follows:- einigermaßen zugänglich sind.
1 Turn engine to determine which plug will provide
1 Dämpfer drehen und feststellen, welche Schraube
best access for removal.
am besten zugänglich ist.
2 Loosen the plug to break peining but allow plug to
remain slightly tight. 2 Schraube lösen, jedoch dicht anliegen lassen.
3 Turn engine until the plug is at the lowest part and 3 Dämpfer drehen bis diese Schraube ganz unten ist
leave for a minimum period of two hours. und mindestens zwei Stunden so stehen lassen.
4 Turn engine until plug is accessible; remove plug 4 Dämpfer drehen bis Schraube zugänglich ist und
and sample as previously described. Probe entnehmen wie zuvor beschrieben.
Important Wichtig
Cleanliness of sample containers, filling plugs and Sauberkeit von Proberöhrchen, Verschlußschraube
the damper surfaces adjacent to the filling holes und Dämpferoberfläche um die Entnahmebohrung ist
is essential. unbedingt erforderlich.
It is important to restrict the escape of fluid to an
Der Verlust von Flüssigkeit ist so gering wie möglich zu
absolute minimum during these operations.
Excessive loss of fluid could affect the further halten. Übermäßiger Verlust kann die Dämpferwirkung
performance of the damper or limit the number of beeinflussen bzw. die Zahl weiterer Probeentnahmen
further samples which may be required. einschränken.
However, provided care is taken whilst sampling, at Bei Verwendung eines Holset Proberöhrchens (1 cm3)
least 10 samples may be taken using our standard und Vermeidung von Flüssigkeitsverlust können
1cm3 containers. mindestens zehn Proben entnommen werden.
Dampers montés avec bouchons Amortiguadores montados con

de remplissage face au moteur los tapones en el lado motor
On pourra réaliser des prélèvements sur ces dampers, La toma de muestras en estos amortiguadores puede
sous réserve d’accéder par le carter moteur aux efectuarse siempre que se disponga de acceso a los
bouchons de remplissage, comme suit: tapones de llenado desde el cárter, procediendo
1 Faire tourner le moteur pour positionner un des como sigue:
bouchons en son point le plus accessible. 1 Girar el motor hasta determinar que tapón es el que
2 Desserrer le bouchon, sans toutefois le dégager quedará con mejor acceso.
complètement du filetage du couvercle du damper. 2 Aflojar el tapón de llenado para romper su precinto
3 Faire ensuite tourner le moteur de sorte que le pero permitiendo permanezca ligeramente roscada.
bouchon se trouve maintenant en son point le plus 3 Girar el motor hasta que este tapón quede en la
bas possible, et laisser le damper au moins deux parte de abajo y mantener esta posición durante un
heures dans cette position. periodo minimo de dos horas.
4 Faire de nouveau tourner le moteur pour accéder au 4 Girar de nuevo el motor hasta que el tapón quede
mieux au bouchon, enlever celui ci et procéder alors otra vez accesible; quitar finalmente dicho tapón y
au prélèvement comme décrit en page précédente. extraer de la forma que se ha descrito
anteriormente.
Important
Il est essentiel que les tubes de prélèvement, les Importante
bouchons de remplissage et les faces du damper Es essencial la limpieza del contenedor, tapones de
voisines des orifices de remplissage soient propres. llenado y superficies del amortiguador adyacentes al
Il est important, pendant ces opérations, de réduire au orifico del Ilenado.
strict minimum la quantité de fluide silicone extraite du Es muy importante evitar las fugas de fluido al minimo
damper. Une perte excessive de fluide pourrait nuire posible durante estas operaciones. Excesiva pérdida
aux performances futures du damper, et aux podria afectar las caracteristicas del amortiguador o
prélèvements pourraient être necessaires. limitar la posibilidad de obtener nuevas muestras en
Toutefois, sous réserve qu’on fasse beaucoup el futuro.
d’attention avec le fluide silicone, on peut procéder au Consiguiendose evitar cualquier perdida de fluido, por
moins à 10 prélèvements en utilisant nos tubes lo menos pueden ser tomades 10 muestras, si se usan
standard (1cm3) nuestros contenedores “Standard” de 1 c.c.
Metaldyne International (UK) Ltd
Service Department
131 Parkinson Lane, Halifax, West Yorkshire, HX1 3RD, England
Tel: +44 (0)1422 357234 Fax: +44 (0)1422 354432
Homepage: [email protected]
[email protected]
H21/32
ALBANISA
OFFICIAL SHOP TEST RESULT FOR DIESEL ENGINE Project Owner ALBANISA
122MW PPS
Eng. Type 9H21/32 Class -
SPECIFICATION OF Eng. No. BF0239 Test Date 2008.01.20/23
ENGINE & ACCESSORIES Eng. MCR 1800㎾ Evaluated by J.H.Choi
Gen. MCR 1701㎾ Operated by C.K.Lee
Description
Eng.No. BF0239-1 BF0239-2 BF0239-3 BF0239-4
Type 9H21/32
Engine
Power × rpm 1800 ㎾ x 900 rpm
Firing Order 1-3-5-7-9-8-6-4-2
Model HSR7 637-8P
Output & Volt 2127kVA 1701㎾ × 4160V
Generator Current & Hz 295A 60㎐
Pole & PF 8P 3PHA 0.8PF
Ser.No. 61951RBH12003 61951RBH12004 20071356RBH04602 20071356RBH04604
Type TPS 57D01
Max. rpm & Temp. 40680 rpm 620 ℃
Turbocharger
Maker ABB
Ser.No. HT487620 HT487623 HT487622 HT487621
Type UG-8
Governor Maker WOODWARD
Ser.No. 15359085 15359086 15319087 15319088
Cooling Surface 64.8 ㎡
Air Cooler Maker DONGHWA ENTEC
Ser.No. DHH79810-A DHH79810-B DHH79810-C DHH79810-D
Cooling Surface 27.75 ㎡
Lub.Oil Cooler Maker KPHE CORPORATION
Ser.No. KPHE-2072199 KPHE-2072200 KPHE-2072201 KPHE-2072202
USED OIL AT SHOP TEST

Description Fuel Oil Lub.Oil
Kind of Oil Bunker - A Gadinia 40
Specific Gravity (15/4℃) 0.906 0.8932
Flash Point (℃) 72 -
50℃/cSt 7.69 -
Viscosity
100℃/cSt - 14.32
Carbon Residue (wt%) 1.4 -
Ash (wt%) 0.006 -
Water & Sediment (vol%) 0.05 -
Sulfur (wt%) 0.24 -
Net.Cal.Value (kcal/kg) 10027 -
- 1 -
H21/32
ALBANISA
OFFICIAL SHOP TEST RESULT FOR DIESEL ENGINE Project 122MW PPS
Owner ALBANISA
Eng. No. BF0239 -1 Test Date 2008.01.20
MEASURING RECORD(NO.1 D/G)
Eng. MCR 1800㎾ Evaluated by J.H.Choi
Time hh:mm - 09:00~09:30 09:30~10:00 10:00~11:00 11:00~11:30

Ambient Press. / Temp. mbar/℃ - - 1027.0 10.3 1027.0 11.0 1027.0 11.5 1027.0 13.8
Load Point % 25% 50% 75% 100% 110%
Engine Speed rpm 900 900 900 900 900
Generator Load ㎾ 424.4 867.3 1305.9 1739.5 1911.5
Generator Efficiency % 94.30 96.37 96.73 96.64 96.54
Engine Load ㎾ 450.0 900.0 1350.0 1800.0 1980.0
Fuel oil consumption ㎏/h - - - 343.800 -
specific consumption g/kW.h - - - 191.000 -
at ISO conditions g/kW.h - - - 187.988 -
Governor Indicator Position % - 5.1 6.3 7.7 8.0
Turbocharger Speed rpm - 27,310 33,730 38,530 40,500
Lub. Oil Press. Inlet Filter ㎏/㎠ - 5.20 5.00 4.80 4.80
Lub. Oil Press. Inlet Engine ㎏/㎠ - 4.60 4.50 4.40 4.30
Lub. Oil Temp. Inlet engine ℃ - 65.5 66.0 66.0 66.5
H.T. Water Press. Inlet Engine ㎏/㎠ - 3.20 3.20 3.20 3.20
H.T. Water Temp. Inlet/Outlet Engine ℃ - - 79.0 81.0 77.0 80.0 76.0 80.0 76.0 80.0
L.T. Water Press. Inlet Air Cooler ㎏/㎠ - 3.40 3.60 3.50 3.50
L.T. Water Temp. Inlet/Outlet Engine ℃ - - 38.0 40.0 36.0 40.0 36.0 42.0 35.0 42.0
Lub. Oil Press. Inlet Turbocharger ㎏/㎠ - 3.50 3.20 3.00 2.90
Fuel Oil Press. Inlet Engine ㎏/㎠ - 5.80 4.70 5.00 5.10
Fuel Oil Temp. Inlet Engine ℃ - 16 15 15 18
Charge Air Press. After A/C ㎏/㎠ - 1.20 2.00 2.80 3.00
Charge Air Temp. After A/C ℃ - 40.0 42.0 44.0 47.0
Exh. Gas Temp. T/C Outlet ℃ - 320 305 290 290
Exh. Gas Temp. T/C Intlet A/B ℃ - 378 398 427 444
Exh.gas Pump Firing BRG.
Temp Index Press Temp
Cyl.No. ℃ mm bar ℃ ℃ mm bar ℃ ℃ mm bar ℃ ℃ mm bar ℃ ℃ mm bar ℃
Cylinder Unit No.1 - - - - 290 15.0 127 - 315 20.0 163 - 335 24.0 190 - 355 26.0 198 -
No.2 - - - - 285 15.0 128 - 305 20.0 162 - 320 24.0 191 - 340 26.0 200 -
No.3 - - - - 280 15.0 125 - 300 20.0 162 - 315 24.0 190 - 335 26.0 198 -
No.4 - - - - 280 14.5 129 - 300 20.0 165 - 320 24.0 193 - 335 26.0 201 -
No.5 - - - - 280 15.0 126 - 300 20.0 163 - 320 24.0 190 - 335 26.0 198 -
No.6 - - - - 285 15.0 128 - 305 20.0 163 - 320 24.0 191 - 330 26.0 200 -
No.7 - - - - 290 15.0 126 - 310 20.0 163 - 320 24.0 190 - 335 26.0 199 -
No.8 - - - - 280 15.0 126 - 305 20.0 163 - 315 24.0 190 - 335 26.0 200 -
No.9 - - - - 285 15.0 126 - 310 20.0 163 - 320 24.0 190 - 335 26.0 198 -
mean - - - -- 284 14.9 126.8 -- 306 20.0 163.0 -- 321 24.0 190.6 -- 337 26.0 199.1 --
Gen. Brg Temp. ℃ - - - - -
★Safety Device Test

1. Overspeed Stop 1013/1035 rpm
2. Lub. Oil Low Pressure Stop 2.95 bar
3. H.T-Water High Temperature Stop 92.1 ℃
★Overhaul Inspection - Cyl. - Main Brg.
- 2 -
H21/32
ALBANISA
Owner ALBANISA
Time hh:mm - 09:00~09:30 09:30~10:00 10:00~11:00 11:00~11:30

Load Point % 25% 50% 75% 100% 110%
Engine Speed rpm 900 900 900 900 900
Generator Load ㎾ 424.4 867.3 1305.9 1739.5 1911.5
Engine Load ㎾ 450.0 900.0 1350.0 1800.0 1980.0
Cylinder Unit No.1 - - - - 295 15.0 129 - 315 20.0 165 - 340 25.0 194 - 360 27.0 202 -
No.2 - - - - 290 15.0 127 - 305 20.0 163 - 335 25.0 192 - 350 27.0 200 -
No.3 - - - - 275 15.0 126 - 330 20.0 162 - 310 25.0 192 - 340 27.0 200 -
No.4 - - - - 315 15.0 126 - 315 20.0 162 - 340 25.0 190 - 360 27.0 198 -
No.5 - - - - 275 14.5 129 - 290 19.5 163 - 315 24.5 193 - 335 27.0 201 -
No.6 - - - - 280 15.0 129 - 290 20.0 163 - 315 25.0 192 - 325 27.0 200 -
No.7 - - - - 275 15.0 126 - 285 20.0 162 - 300 25.0 190 - 325 27.0 198 -
No.8 - - - - 275 15.0 126 - 285 20.0 163 - 310 25.0 191 - 335 27.0 199 -
No.9 - - - - 300 15.0 126 - 310 20.0 163 - 330 25.0 190 - 365 27.0 200 -
mean - - - -- 287 14.9 127.1 -- 303 19.9 162.9 -- 322 24.9 191.6 -- 344 27.0 199.8 --
Gen. Brg Temp. ℃ - - - - -

- 3 -
H21/32
ALBANISA
Owner ALBANISA
Time hh:mm - 09:15~09:45 09:45~10:15 10:15~11:15 11:15~11:45

Load Point % 25% 50% 75% 100% 110%
Engine Speed rpm 900 900 900 900 900
Generator Load ㎾ 424.4 867.3 1305.9 1739.5 1911.5
Engine Load ㎾ 450.0 900.0 1350.0 1800.0 1980.0
Cylinder Unit No.1 - - - - 280 14.0 124 - 315 19.5 160 - 340 24.5 189 - 365 26.5 197 -
No.2 - - - - 270 14.0 125 - 295 19.0 161 - 320 24.0 192 - 340 26.0 198 -
No.3 - - - - 275 14.0 125 - 300 19.0 161 - 325 24.0 192 - 345 26.0 198 -
No.4 - - - - 280 14.5 126 - 310 19.0 162 - 330 24.0 193 - 350 26.0 198 -
No.5 - - - - 265 14.0 125 - 295 19.0 161 - 320 24.0 190 - 335 26.0 198 -
No.6 - - - - 275 14.0 127 - 300 19.5 163 - 325 24.5 193 - 345 26.5 200 -
No.7 - - - - 295 14.5 124 - 315 19.5 162 - 335 24.5 191 - 350 26.0 199 -
No.8 - - - - 270 14.5 126 - 295 19.5 163 - 320 24.5 191 - 335 26.5 200 -
No.9 - - - - 270 14.5 126 - 300 19.5 163 - 320 24.5 190 - 335 26.5 200 -
mean - - - -- 276 14.2 125.3 -- 303 19.3 161.8 -- 326 24.3 191.2 -- 344 26.2 198.7 --
Gen. Brg Temp. ℃ - - - - -

- 4 -
H21/32
ALBANISA
Owner ALBANISA
Time hh:mm - 09:15~09:45 09:45~10:15 10:15~11:15 11:15~11:45

Load Point % 25% 50% 75% 100% 110%
Engine Speed rpm 900 900 900 900 900
Generator Load ㎾ 424.4 867.3 1305.9 1739.5 1911.5
Engine Load ㎾ 450.0 900.0 1350.0 1800.0 1980.0
Cylinder Unit No.1 - - - - 285 14.0 126 - 305 19.0 162 - 335 24.0 191 - 355 26.0 198 -
No.2 - - - - 285 14.0 125 - 300 19.0 162 - 325 24.0 191 - 345 26.0 198 -
No.3 - - - - 285 14.0 124 - 310 19.0 161 - 330 24.0 191 - 350 26.0 199 -
No.4 - - - - 290 14.0 125 - 305 19.0 161 - 325 24.0 193 - 345 26.0 201 -
No.5 - - - - 285 14.0 124 - 300 19.0 160 - 325 24.0 190 - 340 26.0 198 -
No.6 - - - - 280 14.0 124 - 290 19.0 160 - 315 24.0 190 - 330 26.0 198 -
No.7 - - - - 300 14.5 124 - 305 19.5 160 - 325 24.0 192 - 340 26.0 198 -
No.8 - - - - 275 14.5 125 - 290 19.5 162 - 315 24.0 190 - 330 26.0 198 -
No.9 - - - - 295 14.5 126 - 305 19.5 162 - 325 24.0 193 - 340 26.0 198 -
mean - - - -- 287 14.2 124.8 -- 301 19.2 161.1 -- 324 24.0 191.2 -- 342 26.0 198.4 --
Gen. Brg Temp. ℃ - - - - -

- 5 -
H21/32
ALBANISA
OFFICIAL SHOP TEST RESULT FOR DIESEL ENGINE Project
122MW PPS
Owner ALBANISA
SETTING TABLE Eng. No. BF0239 -1 Test Date 2008.01.20
(NO.1 D/G) Eng. MCR 1800㎾ Evaluated by J.H.Choi

Dwg. No. : B93-013932-5.1
Atomizer Mark No. : H21FV1
Injection Hole : 10 Holes X φ 0.32 mm X 148˚
Clearance of Inlet Valve : 0.5 ㎜ (Cold Condition)

Valves Exhaust Valve : 0.5 ㎜ (Cold Condition)
[UNIT : mm]
Cylinder No. 1 2 3 4 5 6 7 8 9
Adjustment of Thrust Plate 13.20 13.20 13.20 13.30 13.20 13.10 13.30 13.10 13.20
Fuel Injection
Pump Shim 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Index by Maximum Supply of F.O 26.0 26.0 26.0 26.0 26.0 26.0 26.0 26.0 26.0
Index with Handle Stop 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Coupling Type Between Engine and Generator [UNIT : 1/100mm]
Cylinder No. 1 2 3 4 5 6 7 8 9
Near Bottom X 0 0 0 0 0 0 0 0 0
Exhaust Side P -1.0 -1.0 0 +1.0 +2.0 +3.0 +1.0 -4.0 -12.0
Cold
Top T -2.0 -1.0 -1.0 +2.0 +4.0 +5.0 +2.0 -9.0 -24.0
Condition
Crankshaft Camshaft Side S -1.0 -1.0 0 +1.0 +2.0 +3.0 +1.0 -4.0 -12.0
Deflection Near Bottom Y 0 0 0 0 0 0 0 0 0
Near Bottom X 0 0 0 0 0 0 0 0 0
Exhaust Side P 0 -1.0 -1.0 0 +1.0 +2.0 -1.0 -5.0 -13.0
Hot
Top T -1.0 -1.0 -2.0 -2.0 +1.0 +3.0 -1.0 -11.0 -25.0
Condition
Camshaft Side S 0 -1.0 -1.0 0 +1.0 +2.0 -1.0 -5.0 -13.0
Near Bottom Y 0 0 0 0 0 0 0 0 0
Reference Temperature Data for Hot Condition Room Temperature : 14 ℃
Lub. Oil Temperature in Oil Sump : 66 ℃
"Closing" of The Locking Aft.
Crankthrow is Start in Position X.
Considered Negative. Turn Counter Clockwise.
- 6 -
H21/32
ALBANISA
122MW PPS
Owner ALBANISA

Dwg. No. : B93-013932-5.1

[UNIT : mm]
Cylinder No. 1 2 3 4 5 6 7 8 9
Fuel Injection
Pump Shim 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Cylinder No. 1 2 3 4 5 6 7 8 9
Near Bottom X 0 0 0 0 0 0 0 0 0
Exhaust Side P +1.0 -1.0 0 +1.0 +2.0 +3.0 +1.0 -4.0 -11.0
Cold
Top T +1.0 -1.0 +1.0 +1.0 +4.0 +5.0 +2.0 -8.0 -23.0
Condition
Crankshaft Camshaft Side S +1.0 -1.0 0 +1.0 +2.0 +3.0 +1.0 -4.0 -11.0
Near Bottom X 0 0 0 0 0 0 0 0 0
Exhaust Side P 0 0 -1.0 -1.0 +1.0 +1.0 -1.0 -6.0 -14.0
Hot
Top T -1.0 -1.0 -4.0 -3.0 +1.0 +1.0 -1.0 -10.0 -24.0
Condition
Camshaft Side S 0 0 -1.0 -1.0 0 +1.0 -1.0 -6.0 -14.0
Near Bottom Y 0 0 0 0 0 0 0 0 0
- 7 -
H21/32
ALBANISA
122MW PPS
Owner ALBANISA


Dwg. No. : B93-013932-5.1

[UNIT : mm]
Cylinder No. 1 2 3 4 5 6 7 8 9
Fuel Injection
Pump Shim 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Cylinder No. 1 2 3 4 5 6 7 8 9
Near Bottom X 0 0 0 0 0 0 0 0 0
Exhaust Side P -1.0 -1.0 +1.0 +1.0 +1.0 +3.0 +1.0 -4.0 -12.0
Cold
Top T -2.0 -1.0 +1.0 +1.0 +3.0 +6.0 +2.0 -9.0 -24.0
Condition
Crankshaft Camshaft Side S -1.0 -1.0 0 +1.0 +1.0 +4.0 +1.0 -5.0 -12.0
Near Bottom X 0 0 0 0 0 0 0 0 0
Exhaust Side P -1.0 0 0 0 +1.0 +2.0 -1.0 -5.0 -12.0
Hot
Top T -2.0 -1.0 -1.0 -3.0 0 +2.0 -1.0 -11.0 -24.0
Condition
Camshaft Side S -1.0 0 0 0 +1.0 +2.0 -1.0 -5.0 -12.0
Near Bottom Y 0 0 0 0 0 0 0 0 0
- 8 -
H21/32
ALBANISA
122MW PPS
Owner ALBANISA

Dwg. No. : B93-013932-5.1

[UNIT : mm]
Cylinder No. 1 2 3 4 5 6 7 8 9
Fuel Injection
Pump Shim 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Cylinder No. 1 2 3 4 5 6 7 8 9
Near Bottom X 0 0 0 0 0 0 0 0 0
Exhaust Side P 0 0 -1.0 0 +2.0 +4.0 +1.0 -4.0 -11.0
Cold
Top T 0 0 -1.0 0 +3.0 +6.0 +3.0 -7.0 -22.0
Condition
Crankshaft Camshaft Side S 0 0 -1.0 0 +2.0 +4.0 +1.0 -3.0 -12.0
Near Bottom X 0 0 0 0 0 0 0 0 0
Exhaust Side P 0 +1.0 +1.0 -1.0 +1.0 +1.0 0 -6.0 -12.0
Hot
Top T -1.0 -1.0 +3.0 -5.0 +1.0 +1.0 -1.0 -11.0 -25.0
Condition
Camshaft Side S 0 -1.0 +1.0 -1.0 +1.0 +1.0 0 -6.0 -12.0
Near Bottom Y 0 0 0 0 0 0 0 0 0
- 9 -
H21/32
ALBANISA
122MW PPS
Owner ALBANISA
GOVERNOR TEST Eng. No. BF0239 Test Date 2008.01.20
& GENERATOR PARALLEL RUNNING TEST Eng. MCR 1800㎾ Evaluated by J.H.Choi
1.GOVERNOR TEST
No. 1 D/G
LOAD % SPEED VARIATION GOV. TYPE UG-8
GOV' SETTING
FROM TO BEF.Hz MOM.Hz DIFF. % PER.Hz DIFF. % TIME SERIAL NO. 15359085
100 0 60.0 64.0 6.67% 62.4 4.00% 3.6sec SPEED DROOP 50
0 38 62.4 58.9 5.61% 61.6 1.28% 5.0sec NEEDLE V/V 7/8
38 66 61.6 58.8 4.55% 60.8 1.30% 4.6sec COMPENSATION -5
66 100 60.8 57.9 4.77% 60.0 1.32% 4.4sec - -
No. 2 D/G
GOV' SETTING
100 0 60.0 64.3 7.17% 62.3 3.83% 3.8sec SPEED DROOP 48
0 38 62.3 58.9 5.46% 61.6 1.12% 5.0sec NEEDLE V/V 7/8
66 100 61.0 58.0 4.92% 60.0 1.64% 4.4sec - -
No. 3 D/G
GOV' SETTING
100 0 60.0 64.2 7.00% 62.3 3.83% 3.3sec SPEED DROOP 50
0 38 62.3 59.7 4.17% 61.5 1.28% 4.5sec NEEDLE V/V 4/4
66 100 60.8 57.3 5.76% 60.0 1.32% 4.1sec - -
No. 4 D/G
GOV' SETTING
100 0 60.0 64.0 6.67% 62.2 3.67% 3.0sec SPEED DROOP 52
0 38 62.2 59.8 3.86% 61.4 1.29% 4.1sec NEEDLE V/V 4/4
66 100 60.8 57.5 5.43% 60.0 1.32% 3.9sec - -
2. PARALLEL RUNNING TEST

LOAD % 75 100 80 60 40 20 40 60 80 100 75
D/G
VOLTAGE V 4139 4136 4142 4143 4145 4146 4144 4142 4140 4137 4141
NO.
FREQUENCY ㎐ 60 59 60 60 61 61 61 60 60 59 60
NO.1 OUTPUT ㎾ 1256 1683 1329 1007 671 340 671 998 1347 1674 1261
NO.2 OUTPUT ㎾ 1261 1701 1356 1002 662 322 658 993 1356 1696 1261
LOAD % 75 100 80 60 40 20 40 60 80 100 75

D/G
VOLTAGEV 4155 4152 4153 4155 4156 4158 4156 4154 4152 4150 4152
NO.
FREQUENCY ㎐ 60 60 60 60 61 61 61 61 60 60 60
NO.3 OUTPUT ㎾ 1261 1683 1347 1012 680 336 671 1007 1347 1683 1256
NO.4 OUTPUT ㎾ 1261 1678 1347 1016 676 349 671 1007 1338 1674 1261
- 10 -
H21/32
ALBANISA
122MW PPS
Owner ALBANISA
MECHANICAL VIBRATION Eng. No. BF0239 Test Date 2008.01.20/23
MEASUREMENT Eng. MCR 1800㎾

Measured by
C.S.Choi
Gen. MCR 1701㎾ /QM
Measurement Equipment
Manufacture Type Mechanical connection Measured value Recored value Measurement Equipment
RION VM - 61 magnetic velocity velocity -
RION VM - 82 magnetic velocity velocity O
Vibration Measurement Location and Limit Value

Measuring Points (ISO 8528-9) Direction Limit Value Remarks
B1 Front End Top Edge X,Y,Z
B2 Back End Top Edge X,Y,Z
≤ 28 ㎜/s (Vrms) ISO 10816-6
B3 Front End of Base Frame X,Y,Z
B4 Front End of Generator Base Frame X,Y,Z
G1 Rear End of Generator Base Frame X,Y,Z
≤ 18 ㎜/s (Vrms) ISO 8528-9
G2 Generator Bearing X,Y,Z
Measurement points
B1 B2
G2
B3 Z
Y
G1
B4
X
UNIT : V rms (mm/s)

Item axial transverse vertical
Measuring Point Remarks
D/G (X) (Y) (Z)
B1 6.4 7.2 4.2 ▶Coupling : Disc coupled
B2 5.1 7.6 6.7 [with Generator]
B3 4.7 4.8 5.4 ▶Erection : Rubber Mount
NO.1 D/G
B4 9.6 4.4 8.5 Type : 214 SH65
G1 4.9 7.8 14.0 ▶Load % : 100%
G2 7.7 6.5 12.0 ▶Running hours : 1 Hr
B1 5.6 6.3 6.5
B2 5.2 7.0 6.5
B3 4.5 4.8 5.1
NO.2 D/G
B4 8.7 4.1 7.9
G1 4.8 6.7 14.0
G2 6.9 5.7 10.6
B1 6.2 6.6 4.9
B2 5.4 6.8 6.5
B3 5.0 5.4 5.2
NO.3 D/G
B4 4.9 4.1 6.5
G1 4.4 8.2 15.0
G2 7.3 7.7 12.6
B1 6.7 6.3 4.3
B2 5.4 7.4 6.7
B3 4.3 5.5 5.0
NO.4 D/G
B4 4.4 4.1 6.8
G1 4.0 8.6 16.0
G2 7.2 7.9 14.0
- 11 -
H21/32
ALBANISA
122MW PPS
HEIGHT OF RESILIENT SUPPORTS IN Eng. No. BF0239 Test Date 2008.01.20/23
LOADED CONDITION Eng. MCR 1800㎾ Evaluated by J.H.Choi

Mount Type : 214 SH65
1A 2A 3A 4A 5A 6A 7A 8A 9A
Front alternator
end
1B 2B 3B 4B 5B 6B 7B 8B 9B
HL = Height of resilient support in loaded

condition
Note ! This flexible elements must be loaded for

at least 48 hours, before measurements are taken
1A 2A 3A 4A 5A 6A 7A 8A 9A
Resilient support NO. Remarks
1B 2B 3B 4B 5B 6B 7B 8B 9B
166.0 167.0 167.0 167.0 - - - - -
No. 1 D/G
167.0 166.5 167.0 167.0 - - - - -
166.0 167.0 166.0 166.0 - - - - -
No. 2 D/G
166.5 167.5 167.0 167.0 - - - - -
HL (㎜)
167.0 167.0 167.0 167.0 - - - - -
No. 3 D/G
166.0 166.5 167.0 167.0 - - - - -
167.0 168.0 167.0 167.0 - - - - -
No. 4 D/G
166.5 167.0 167.0 167.5 - - - - -
REMARK.:
- 12 -
H21/32
ALBANISA
122MW PPS
Eng. No. BF0239 Test Date 2008.01.20/23

CALCULATION SHEET OF F.O.
Description
Engine No. NO.1 D/G NO.2 D/G NO.3 D/G NO.4 D/G -
Load % 100% 100% 100% 100% -
Engine Speed rpm 900 900 900 900 -
Generator Output ㎾ 1739.5 1739.5 1739.5 1739.5 -

Output
Generator Efficiency % 96.64 96.64 96.64 96.64 -
㎾ 1800.0 1800.0 1800.0 1800.0 -

Engine Output
BHP 2447.3 2447.3 2447.3 2447.3 -
Time min/sec 20min 0.00sec 20min 0.00sec 30min 0.00sec 30min 0.00sec - -
kg 114.600 115.200 173.800 173.600 -

Actual F.O. Consumption
kg/h 343.800 345.600 347.600 347.200 -
Measurement
g/㎾.h 191.000 192.000 193.111 192.889 -
SFOCamb
g/BHP.h 140.481 141.216 142.033 141.870 -
Ambient Air Temp. ℃ 11.5 11.5 12.8 12.8 -
(Ta-25)×0.05 % -0.675 -0.675 -0.61 -0.61 -
Ambient Air Press. mbar 1027.0 1027.0 1019.0 1019.0 -
(Pa-1000)×0.007 % 0.1890 0.1890 0.1330 0.1330 -
C.W. to Air Cooler ℃ 36 36 36 35 -

ISO (Tcw-25)×0.07 % 0.77 0.77 0.77 0.7 -
Convers.
Factor Low Calorific Value kcal/kg 10027 10027 10027 10027 -
(LCV-10200)/102 % -1.69608 -1.69608 -1.69608 -1.69608 -

dSFOC
[100+(Ta-25)×0.05
-(Pa-1000)×0.007 1.0160 1.0160 1.0172 1.0165 -
+(Tcw-25)×0.07
-(LCV-10200)/102]/100
S.F.O.C(ISO) g/㎾.h 187.988 188.973 189.840 189.752 -
= SFOCamb / dSFOC g/BHP.h 138.265 138.989 139.627 139.563 -

All values based on ISO 3046/1 conditions
Ambient air temperature : 25 ℃
Ambient air pressure : 1000 mbar
Cooling water for air cooler : 25 ℃
Marine diesel oil(MDO). Lower calorific value : 42,700 kJ/kg (10,200 kcal/kg)
For other reference conditions, the SFOC is to be corrected by :
Ambient air temperature rise 10℃ rise 10℃ 0.5 %
Ambient air pressure rise 10mbar rise 10mbar -0.07 %
Cooling water for air cooler rise 10℃ rise 10℃ 0.7 %
Lower calorific value rise 1% rise 1% -1.0 %
- 13 -

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Turbocharging

ABB Turbo Systems Ltd

ABB Turbo Systems Ltd 

© Copyright by ABB TURBO SYSTEMS Ltd 2004

Table of Contents Page 1

2.2 General safety instructions

ABB Turbo Systems Ltd ABB

Table of Contents Page 2

7 Removal and installation

8 Disassembly and assembly

9 Taking out of operation

10 Mothballing the turbocharger

11 Reserve and spare parts

ABB Turbo Systems Ltd ABB

Foreword 1.1 Page 1

This operation manual includes helpful information on the following topics:

Information on the operation of a turbocharger and ways to prolong the

This operation manual is a complement to, and an extension of, existing

The instructions included in this operation manual must be followed under

This applies especially to the general and special safety instructions

ABB Turbo Systems Ltd ABB

Layout and function 1.2 Page 2

1.2 Layout and function

1 Suction branch / Filter silencer 8 Gas outlet flange

4 Bearing casing 11 Turbine-end bearing flange

ABB Turbo Systems Ltd ABB

Layout and function 1.2 Page 3

The turbocharger is a turbo-machine and consists of the following main

These are both connected with a common shaft.

ABB Turbo Systems Ltd ABB

Correct application 1.3 Page 4

1.3 Correct application

Correct use of the turbocharger also includes observation of the assem-

The turbocharger should only be operated and used in a technically per-

Defects which could affect safety must be eliminated immediately.

ABB Turbo Systems Ltd ABB

Essential information 1.4 Page 5

1.4 Essential information

In addition to this manual, the general, statutory regulations applicable in

This also applies to the provision and wearing of personnel protection

The safety and risk consciousness of the personnel working on and

The turbocharger must be shut down immediately in the event of al-

terations affecting safety or of corresponding operating behaviour. The

Additions to, and alterations and conversions of the turbocharger that

ABB Turbo Systems Ltd ABB

Essential information 1.4 Page 6

Original parts and safety

We herewith expressly state that parts and accessories not supplied by

If components and assemblies not manufactured and tested by ABB

The turbocharger must only be operated and maintained by trained and

Work on mechanical components, such as bearings or rotors, must only

It must be ensured that only authorised personnel work on the turbo-

ABB Turbo Systems Ltd ABB

Essential information 1.4 Page 7

The Contact Information brochure contains an overview of official ABB

This instruction manual is valid for various turbocharger design variants.

Storage of new turbochargers

New turbochargers supplied by ABB Turbo Systems Ltd can be stored

ABB Turbo Systems Ltd