Operation Manual: TPL67-C33

Turbocharging
Operation Manual
TPL67-C33
ABB Turbo Systems Ltd
CH 5401 Baden
Type
TPL67-C33
n Mmax 502
HT486060
t
Mmax
620
Bmax
650
1/s
n Bmax 487
1100 kg
Year
C
t
35
50
50
Application according to
the Operation Manual
2007
HZTL2488 English
made in Switzerland

Operating condition and replacement intervals

The operational limits for the turbocharger nBmax, tBmax, nMmax, tMmax, inspection- and replacement intervals for the components 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 current 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
Turbocharging
Operation Manual
TPL67-C33
CH 5401 Baden
Type
TPL67-C33
n Mmax 502
HT486061
t
Mmax
620
Bmax
650
1/s
n Bmax 487
1100 kg
Year
C
t
35
50
50
2007
HZTL2488 English
made in Switzerland


Note:

recycled cardboard.


Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C33
CH 5401 Baden
Type
TPL67-C33
n Mmax 502
HT486103
t
Mmax
620
Bmax
650
1/s
n Bmax 487
1100 kg
Year
C
t
35
50
50
2007
HZTL2488 English
made in Switzerland


Note:

recycled cardboard.


Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C33
CH 5401 Baden
Type
TPL67-C33
n Mmax 502
HT486104
t
Mmax
620
Bmax
650
1/s
n Bmax 487
1100 kg
Year
C
t
35
50
50
2007
HZTL2488 English
made in Switzerland


Note:

recycled cardboard.


Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C33
CH 5401 Baden
Type
TPL67-C33
n Mmax 502
HT486386
t
Mmax
650
Bmax
620
1/s
n Bmax 487
1100 kg
Year
C
t
35
50
50
2007
HZTL2488 English
made in Switzerland


Note:

recycled cardboard.


Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C33
CH 5401 Baden
Type
TPL67-C33
n Mmax 502
HT486387
t
Mmax
650
Bmax
620
1/s
n Bmax 487
1100 kg
Year
C
t
35
50
50
2007
HZTL2488 English
made in Switzerland


Note:

recycled cardboard.


Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C33
CH 5401 Baden
Type
TPL67-C33
n Mmax 502
HT486926
t
Mmax
620
Bmax
650
1/s
n Bmax 487
1100 kg
Year
C
t
35
50
50
2007
HZTL2488 English
made in Switzerland


Note:

recycled cardboard.


Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C33
CH 5401 Baden
Type
TPL67-C33
n Mmax 502
HT486929
t
Mmax
620
Bmax
650
1/s
n Bmax 487
1100 kg
Year
C
t
35
50
50
2007
HZTL2488 English
made in Switzerland


Note:

recycled cardboard.


Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Operation Manual / TPL 6771-C
Version 2.4
HZTL2488_EN
March 2007
List of contents
Page 1
List of contents
1
Preliminary remarks
1.1
Purpose of the manual
1.2
Layout and function
1.3
Correct use of the turbocharger
1.4
Essential information
1.5
Abbreviations and symbols
1.6
Turbocharger rating plate
Safety
2.1
Basic safety instructions
2.2
General safety instructions
2.3
Special safety instructions
2.4
Safety instructions and hazard protection
2.5
Warnings on the turbocharger
Commissioning
3.1
Oil supply
3.2
Inspection work
3.3
Putting into operation after laying up
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
Maintenance
5.1
Foreword to Maintenance
5.2
Cleaning the filter silencer
5.3
Cleaning the compressor during operation
5.4
Cleaning turbine blades and nozzle ring in operation
ABB
6.1
Possible remedies for failures
Removal and installation
7.1
Turbocharger weights
7.2
Remove the turbocharger
7.3
Installing the turbocharger
Disassembly and assembly
8.1
Module weights
8.2
Removing and fitting the filter silencer or air suction branch
8.3
Axial clearance
8.4
Removing cartridge group
8.5
Dismantling and installing the turbine diffuser and nozzle ring
8.6
Installing the cartridge group
8.7
Table of tightening torques
Taking out of operation temporarily
9.1
Possibilities for emergency repair
9.2
Locking the rotor
9.3
Fitting the cover plate
9.4
Blocking the inlets and outlets
9.5
Bypass the turbocharger
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
March 2007
Troubleshooting
HZTL2488_EN
Page 2
Version 2.4
List of contents
ABB

Preliminary remarks
Purpose of the manual
1.1
Page 1
March 2007
1 Preliminary remarks
1.1 Purpose of the manual
Operation manual
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.
Target group
The content of this operation manual is intended for persons such as engineers, marine mechanics and service technicians who are responsible
for the running of the engine and the turbocharger installed thereon.
Content of operation manual
This operation manual includes helpful information on the following topics:

Information on the operation of the turbocharger and ways to prolong
HZTL2488_EN
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.
NOTE
An operation manual must be available at all times at the site where the
turbocharger is used. It is essential that this operation manual is read
before beginning work by all persons working with or on the turbocharger. Personnel who only work occasionally on the machine (e.g.
during installation and maintenance) must also have read and fully understood the operating manual before beginning work.
Version 2.4
The instructions included in this operation manual must be followed under

all circumstances.
WARNING
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 equipment.
In the event of doubt, consult the officer for safety and accident protection
responsible for your area.
ABB

Preliminary remarks
Layout and function
1.2
Page 2
1.2 Layout and function
HZTL2488_EN
March 2007
TPL 67/71-C
Filter silencer
Nozzle ring
Radial plain bearing
Turbine wheel
Thrust bearing
10
Bearing casing
Bearing bush
11
Diffuser
Radial plain bearing
12
Compressor wheel
Gas outlet casing
13
Air outlet casing
Gas inlet casing
Version 2.4
L_00219
ABB

Preliminary remarks
Layout and function
1.2
Page 3
March 2007
Mode of operation
The turbocharger is a turbo-machine and consists of the following main
components:
Turbine
Compressor
These are both mounted on a common shaft.
The exhaust gases from the diesel engine flow through the gas inlet casing (7) and nozzle ring (8) to the turbine wheel.
The turbine wheel (9) uses the energy contained in the exhaust gas to
drive the compressor wheel (12), whereby the compressor draws in fresh
air, and the compressed air is forced into the cylinders.
HZTL2488_EN
The exhaust gases escape through the exhaust pipe which is connected
to the gas outlet casing (6).
The air which is necessary for the operation of the diesel engine and
which is compressed in the turbocharger is drawn through the suction
branch or the filter silencer (1) into the compressor wheel (12). It then
passes through the diffuser (11) and leaves the turbocharger through the
air outlet casing (13).
The rotor runs in two radial plain bearings (2/5). One plain bearing is situated in the bearing bush (4) and one plain bearing is situated in the axial
thrust bearing (3) at the compressor side.
Version 2.4
The plain bearings are connected to a central lubricating oil feed which is
supplied by the oil lubrication circuit of the engine. The oil outlet is always
at the lowest point of the bearing casing (10).
ABB

Preliminary remarks
Correct use of the turbocharger
1.3
Page 4
This turbocharger supplied by ABB Turbo Systems has been developed

for use on diesel engines to generate the volume of air and the charging pressure required to operate the engine.
NOTE
March 2007
1.3 Correct use of the turbocharger
The engine manufacturer has provided ABB Turbo Systems with information regarding the intended purpose of the engine, from which the
operating parameters specific to the turbocharger (such as rotating
speeds, temperatures, replacement periods / exchange intervals) have
been derived and are indicated on the rating plate.
If it is used in conjunction with a gas engine, the engine must not be installed in a potentially explosive environment, and precautionary measures must be taken to ensure that the machine room as a whole is classified as not potentially explosive.
Latest technology
WARNING
This turbocharger was built according to state-of-the-art technology and is

operationally safe according to prevailing safety regulations.
HZTL2488_EN
Any other usage shall be regarded as a special application which must

be discussed with ABB Turbo Systems. The manufacturer accepts no
liability for other applications. If it is used otherwise, ABB Turbo Systems reserves the right to reject all claims under the warranty.
Improper operation and maintenance of the turbocharger can result in

danger to life and limb of the user or third parties. In addition, improper
use may cause damage to the machine. The machine may only be operated by trained personnel.
Perfect condition
The turbocharger must only be installed in a technically perfect condition,

corresponding to its intended purpose and following the instructions in the
Engine Manufacturers' Manual, and must be operated and used in compliance with the Operation Manual.
X Defects which could affect safety must be eliminated immediately.
The manufacturer shall not accept liability for damages resulting from unauthorised alterations to the turbocharger.
ABB
Version 2.4
Correct use of the turbocharger also includes observation of the assembly, disassembly, operating, maintenance and repair conditions specified
by the manufacturer. Regulations set out by local authorities must be observed when disposing of the turbine.

Preliminary remarks
1.4
Page 5
March 2007
1.4 Essential information

Organisational measures
In addition to this manual, the general, statutory regulations applicable in
the respective country for the prevention of accidents and the protection of
the environment must be observed.
This also applies to the provision and wearing of personnel protection equipment.
The safety and risk consciousness of the personnel working on and
with the turbocharger must be checked regularly with reference to this
manual.
NOTE
X The turbocharger must be shut down immediately in the event of alHZTL2488_EN
terations affecting safety or of corresponding operating behaviour. The

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

could compromise safety require the prior approval of ABB Turbo Systems.
Version 2.4
NOTE
ABB

Preliminary remarks
1.4
Page 6
March 2007
Original parts and safety

Original parts and accessories are especially designed for the turbocharger 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 technical design specifications of the turbocharger.
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.
HZTL2488_EN
WARNING
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
Version 2.4
It must be ensured that only authorised personnel work on the turbocharger.
ABB

Preliminary remarks
1.4
Page 7
March 2007
After-sales service
The Contact Information brochure contains an overview of official ABB
Turbo Systems Ltd. service stations worldwide.
Design variants
This operating manual is valid for various turbocharger design variants.
This means that some sections and component descriptions in this operating manual do not apply to your turbocharger.
Our service stations and agencies will gladly answer your questions relating specifically to your model.
HZTL2488_EN
Accuracy of illustrations
The graphics and images shown in this manual are of a general nature
and are intended to assist understanding of the work steps and instructions. Differences may exist in certain details.
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 storage area is dry with humidity of 40-70% and free of
condensation.
X After 6 months, rust-proofing oil should be sprayed on exposed surVersion 2.4
faces and all accessible areas of the turbocharger.

X To do this, the insulating materials must be removed.
Repeat the steps described for rust-proofing your turbocharger every 6

months.
NOTE
ABB

Preliminary remarks
Abbreviations and symbols
1.5
Page 8
1.5 Abbreviations and symbols

March 2007
The following abbreviations are used in this document:

Z Prerequisite
X Work step
D Result
9 Positive checkpoint (activity that must be carried out without fail)

U Negative checkpoint (activity that must not be carried out under any
circumstances)
Basic Instructions
HZTL2488_EN
The following symbol is used for notes in this manual:

This note provides suggestions and tips to make work on the turbocharger easier.
NOTE
The note provides further essential information.
ABB Turbo Systems
Official ABB Turbo Systems service station

The term used in this manual Official ABB Turbo Systems service station
signifies ABB Turbocharger service stations, that have been tested and
certified by ABB Turbo Systems Ltd.
ABB
Version 2.4
The term ABB Turbo Systems used in this manual signifies ABB Turbo
Systems Ltd.

Preliminary remarks
1.6
Page 9
HZTL2488_EN
March 2007
1.6 Turbocharger rating plate
L_00012
Operational limits
Version 2.4
Recommended replacement periods / exchange

intervals for turbocharger
components
3
4
5
Turbocharger operational limits at engine overload (110 %).

In test rig operation only, unless otherwise agreed with the
engine manufacturer.
Turbocharger operational limits in service.
Replacement interval for the plain bearings in 1000 h

Exchange interval for the compressor in 1000 h (no data for
100,000 h)
Exchange interval for the turbine in 1000 h (no data for
100,000 h)
ABB

1
1.6
6
7
8
9
10
11
12
Page 10
Customer part number

Field for special design designation
Weight of the turbocharger in kg
CE = Conformit Europenne
Turbocharger type
Series number
Year of construction of the turbocharger
March 2007
Additional specifications:
Preliminary remarks
Explanations of the rating plate
CAUTION
Continuous running above the indicated nBmax, tBmax values may considerably reduce the recommended exchange intervals. In such cases, we
recommend you contact the nearest official service station of ABB
Turbo Systems Ltd.
nMmax , tMmax normally apply only when running at overload (110 %) during 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.
HZTL2488_EN
The recommended exchange intervals and the corresponding operation

limits are defined together with the engine builder. These specifications
are system-specific.
Version 2.4
Non-compliance with the recommended exchange intervals may increase the risk of unpredictable component failure.
ABB

Safety
Basic safety instructions
2.1
Page 1
2 Safety
March 2007
2.1 Basic safety instructions

The following symbols and terms are used for the safety instructions in
this manual:
Failure to follow work steps and operating instructions marked with this
symbol completely and rigorously may result in serious personal injury
or even fatal accidents.
WARNING
Warning signs must be strictly observed at all times.
CAUTION
Caution signs must be strictly observed at all times.
Version 2.4
HZTL2488_EN
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.
ABB

Safety
General safety instructions
2.2
Page 2
The instructions listed here are designed to ensure your safety and to
promote safe handling of the turbocharger and its associated operating
materials.
March 2007
2.2 General safety instructions
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.
Version 2.4
Helmet
Ear protection
Protective glasses
Protective suit
Oil and petrol resistant gloves
Protective shoes
Attach individual parts and larger component modules carefully to suitable 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.
HZTL2488_EN
Wear protective clothing at all times.
ABB

Safety
2.3
Page 3
March 2007
2.3 Special safety instructions

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 person/department responsible immediately.
In the event of damage, shut down the turbocharger immediately and
secure it against inadvertent or unauthorized use.
Version 2.4
HZTL2488_EN
ABB

Safety
2.3
Page 4
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.
March 2007
Safety when cleaning
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
circulation. Before beginning cleaning work in confined spaces, extinguish naked flames (including cigarettes!) due to the risk of explosion.
WARNING
Version 2.4
operation materials.
You must wear protective clothing (see section General safety instructions).
Handle operation materials and detergents with utmost caution.
When handling solvents, wear protective clothing and observe the following 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.
HZTL2488_EN
Before cleaning, protect the floor against unintended leaks of oil and
ABB

Safety
2.3
Page 5
HZTL2488_EN
March 2007
Safety during disassembly, assembly, maintenance and troubleshooting

Follow the prescribed maintenance and inspection schedules for all ad-
justment, maintenance and inspection work.
Inform operating personnel about special work and repairs before start-
ing.
Ensure that absorbent materials are available to clean up any operation materials that escape accidentally.
Ensure safe and environmentally-friendly drainage, collection and disposal 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 rotors, must only be performed by qualified fitters from an official service
station of ABB Turbo Systems.
CAUTION
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 2.4
ABB

Safety
Safety instructions and hazard

protection
2.4
Page 6
Associated hazards may arise during operation of and work on the turbocharger:
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.
March 2007
2.4 Safety instructions and hazard protection
Mechanical influences
Mechanical influences can cause serious injury or even fatal injury.
Unconsciousness and injury due to:
Causes
crushing
shearing
cutting
winding
smashing
drawing in
knocking
stabbing
rubbing
Escape of liquids under high pressure and / or at high temperature
slipping
tripping
falling
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 / or gases under pressure/in a
vacuum
slippery, oily work area, obstacles on the floor
ABB
Version 2.4
Personal injury
HZTL2488_EN
WARNING
March 2007
Protective measures
Safety

protection
2.4
Page 7
Wear leather protective gloves

Wear close-fitting protective clothing
Tie up long hair and beards (wear hair protection)
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
9 Eliminate leaks
9
9
9
9
9
9
9
Operation and process materials

Operation and process materials refer to chemical and hazardous substances:
HZTL2488_EN
Oils
Grease
Coolants
Detergents and solvents
Acids
Note that operation and process materials are harmful to the environment if they penetrate soil or water.
CAUTION
Personal injury
The following injuries can be caused by operation and process materials:
Version 2.4
Causes
Allergies
Skin disease
Loss of consciousness
Poisoning or nausea after inhalation
Inhalation of toxic gases, smoke and vapours

Skin contact with aggressive fluids
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
ABB

2

protection
2.4
9
9
9
9
9
9
9
9
9
Page 8
Utmost caution when handling process and operation materials

Protective clothing must be worn
Avoid skin contact and inhalation under all circumstances
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 prescribed, and disposed of as special waste in a technically and environmentally 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 compatible manner as special waste
March 2007
Protective measures
Safety
9
9
9
9
9
9
9
Version 2.4
9
9
9
9
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
HZTL2488_EN
Handling insulating materials
ABB

Safety

protection
2.4
Page 9
March 2007
Noise
The effects of noise above a legally permitted level can cause personal injury.
Loss of hearing
Deafness
Impaired hearing
Health disorders such as loss of balance or of consciousness
Cardiac and circulatory disturbances
Personal injury
Causes
Machine noise level above 85 dB (A)
Protective measures
9 Wear ear protection
When the turbocharger is operated, surfaces become very hot.

Personal injury
Burns
Causes
Missing or incorrectly fitted insulation.
Protective measures
9 Wear leather protective gloves.
Version 2.4
HZTL2488_EN
Heat hazard
ABB

Safety
Warnings on the turbocharger
2.5
Page 10
HZTL2488_EN
Warnings that have been applied to turbochargers by ABB Turbo Systems

must not be removed, painted over or obscured with other stickers. Missing or illegible warnings must be replaced by new warnings.
March 2007
2.5 Warnings on the turbocharger
L_00227
Apply warnings so that they are clearly visible in the positions intended
for that purpose. Please contact an official ABB Turbo Systems service
station for further information.
Version 2.4
NOTE
ABB

Commissioning
Oil supply
3.1
Page 1
3 Commissioning
March 2007
3.1 Oil supply

A carefully designed oil supply, which functions under all operating conditions, is an important precondition for trouble-free operation of the turbocharger.
Lubrication of the turbocharger is normally carried out with oil from the
engine oil circuit.
Regarding the oil supply, follow the engine manufacturer's instructions
concerning selection of lubricating oil, oil change intervals, oil filtration,
and oil pressure and temperature.
NOTE
HZTL2488_EN
Oil filtration
A lubrication oil filter system with a mesh size 0.034 mm is adequate for
TPL67-C turbochargers, and 0.050 mm is adequate for TPL71-C turbochargers.
This filter system can also be achieved by using an additional selfcleaning fine filter.
Version 2.4
NOTE
ABB

Commissioning
Oil supply
3.1
Page 2
The oil pressure before the bearings must be maintained precisely to ensure fault-free operation.
The permissible oil pressures are specified in the following tables depending on the lubrication (Engine lubrication).
Kinetic viscosity 12 - 170 cST
Oil pressure [bar]
Impermissible oil-pressure range ->

Engine Shut Down (without delay)
0.0 1.1
Short-term (<1h) permissible oil-pressure range ->

Alarm
1.1 1.3
Permissible oil-pressure range for normal operation
1.3 - 2.5
Permissible oil-pressure range during engine warmup phase
1.3 - 5.0
Oil temperature during normal operation

Oil inlet
temperature
[ C ]
Engine load
[%]
Oil inlet pressure

[ bar ]
Oil outlet
temperature
[ C ]
70
100
1.5 - 2
90 - 110
90
100
1.5 - 2
110 - 130
Version 2.4
Engine lubrication
HZTL2488_EN
Engine lubrication
March 2007
Oil pressure
ABB

Commissioning
Inspection work
3.2
Page 3
3.2 Inspection work

March 2007
This inspection work includes preventive visual controls, as well as monitoring and measurement to ensure the correct functioning of the turbocharger. 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.
HZTL2488_EN
3.2.1 Inspection before commissioning

Monitoring equipment
X To be checked for correct functioning.
Air filter mat
X Inspect for damage.
Lubricating system
X Check oil filter for cleanliness before commissioning.
It is urgently recommended that the entire lubrication system be flushed

thoroughly with warm oil using a bypass pipe before commissioning and
after every servicing operation on the lubrication system.
CAUTION
We strongly recommend the use of a starting filter when running the

engine in and after every servicing operation on the lubrication system.
Version 2.4
X Check oil pressure in oil supply lines.
ABB

Commissioning
Inspection work
3.2
Page 4
March 2007
3.2.2 Inspection after commissioning

Lubricating system
X Check oil pressure in oil supply lines.
Charger speed
X Measuring
Charger pressure
X Measuring
Temperatures
X Measure upstream/downstream from turbine, compressor and oil feed
Gas, air, and oil lines
X After the engine has been started up, check all gas, air and oil lines for
leaks.
HZTL2488_EN
for various engine speeds
Further must be observed:
NOTE
X Measure the speed, oil pressure, charging pressure and temperatures
before and after the turbine and the compressor at various engine
speeds.
X Compare the measured values with those of the inspection report, taking into account the different operating conditions.
3.2.3 Inspection after 100 service hours

Clean or replace lubricating oil filters after the first 100 service hours.
ABB
Version 2.4
Lubricants and pastes are liquefied or vaporised during assembly of the

turbocharger and may escape as an oily liquid in the first few hours after commissioning. If oily liquid continues to escape 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 turbocharger for leaks. If
this is not in order, contact an official ABB Turbo Systems service station.

Commissioning
Putting into operation after laying up
3.3
Page 5
March 2007
3.3 Putting into operation after laying up

If provided
X Remove the cover plates (blind flanges) between the compressor cas-
ing outlet and charge-air receiver, upstream of the gas inlet, downstream of the gas outlet.
X Inspect the exhaust pipe before and after the turbine for any combusX
X
X
Version 2.4
HZTL2488_EN
tion residue, clean / remove foreign bodies or residual water.

Inspect air supply line or filter silencer for any foreign bodies, clean /
remove.
Start up the turbocharger's engine end oil circulation system.
Prepare the turbocharger for operation as instructed in the section Inspection work before commissioning in the chapter entitled Commissioning.
Start up the turbocharger.
ABB

Operation
Servicing work
4.1
Page 1
4 Operation
March 2007
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 carried out at the intervals indicated.
The pertinent safety instructions must be observed during all servicing
work.
HZTL2488_EN
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
X must be recorded
X Enter in the machine logbook
X 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.
Version 2.4
CAUTION
ABB

4
Servicing work
4.1
Page 2
4.1.2 Entries in the machine logbook

Monitoring of the machine plant provides information about the performance of the turbocharger.
March 2007
Operation
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
Exhaust temperature before and after the turbine
Pressure of the charge-air
Pressure drop in the charge-air cooler
Lubricating oil pressure, lubricating oil temperature
Air temperature after compressor and after the charge-air cooler

Speed of the turbocharger
Pressure loss in the air filter
If provided
4.1.3 Servicing work according to the engine manufacturer's instructions

X With the engine at standstill clean or replace oil filters
Version 2.4
Oil filters
HZTL2488_EN
ABB

Operation
Servicing work
4.1
Page 3
March 2007
4.1.4 Servicing work every 8,000 - 12,000 hours

X Dismantle the turbocharger
X Clearance measurement
X Clean turbine- and compressor casings and check for any cracks and
erosion / corrosion.
X Clean bearing casing, blow through oil ports
X Clean nozzle ring and check for cracks and erosion
X Inspection and assessment of the rotor and bearing parts
The inspection and assessment of the rotor and bearing parts must be
performed by an official ABB Turbo Systems service station.
HZTL2488_EN
NOTE
4.1.5 Servicing work every 36,000 hours

X Dismantle the turbocharger
X Clearance measurement
X Clean turbine- and compressor casings and check for any cracks and
X
X
X
X
erosion / corrosion.
Clean bearing casing, blow through oil ports
Clean nozzle ring and check for cracks and erosion
Inspection and assessment of the rotor
Replacement of the plain bearings with original parts from ABB Turbo
Systems
Version 2.4
The replacement of the bearing parts as well as the inspection and assessment of the rotor must be carried out by an official ABB Turbo Systems service station.
NOTE
ABB

Operation
Monitoring
4.2
Page 4
March 2007
4.2 Monitoring
HZTL2488_EN
4.2.1 Speed measurement
Bearing casing
Connecting cable
Axial bearing
Line amplifier (option)
Guide in the axial bearing
Speed transmitter
Gasket ring
Installation variant of the

speed transmitter
Screw plug
ABB
Version 2.4
L_278

Operation
Monitoring
4.2
Page 5
March 2007
The speed transmitter system for the measurement of the turbocharger

speed also permits, in conjunction with the corresponding measuring instruments and/or monitoring systems (not included in the scope of delivery), a constant remote monitoring of the turbocharger speed. With continuous monitoring of the machine installation, the turbocharger speed can
be used as a suitable control parameter. The line amplifier can be purchased as an optional addition to the described speed measuring system.
Possible reasons for failure of the speed indicator:
Defects in the speed transmitter, the connecting cable and plug to the
measuring unit, in the measuring unit itself or the power supply.
Turbocharger damage.
Failure of the speed indicator
HZTL2488_EN
CAUTION
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.
We recommend that subsequent assembly or replacement of the speed

transmitter system should be carried out only by an official ABB Turbo
Systems service station.
NOTE
A reduction in speed of a charger can signify:
Version 2.4
Damaged turbine or bearing

Defects in the connected pulse charging cylinders
Severe soiling of the turbine
Increased turbocharger speed

NOTE
With 4-stroke applications, heavy fouling of the turbine can also be a

cause of an increase in the turbocharger speed.
We recommend that subsequent assembly or replacement of the speed
transmitter system should only be carried out by an official service station of ABB Turbo Systems Ltd.
ABB

Operation
Surging of turbocharger
4.3
Page 6
Surging of the turbocharger can occur with certain engine operating 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 turbocharger.
March 2007
4.3 Surging of turbocharger
Prolonged or periodic surging
Action to be taken:
Version 2.4
The operating safety of the turbocharger is no longer ensured with continuous or periodically recurring surging. The operator must take immediate steps to correct the surging together with the closest official ABB
Turbo Systems service station.
The components listed above must be inspected for damage by an official
ABB Turbo Systems service station, and replaced in cases of doubt.
HZTL2488_EN
CAUTION
If surging is prolonged or occurs periodically, the following components

may be damaged:
- Compressor wheel (vibration fractures, ...)
- Turbine blades (cracks)
- Bearing (overheating)
- Filter silencer
ABB

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

March 2007
Mild, uniform wear around the circumference of rotor components, caused

by slight local grazing against adjacent components, is non-hazardous
and permissible. This slightly reduces the length of the blades in the compressor and/or the turbine. Certain tolerances must be observed to avoid
significant loss of efficiency.
X A check on dimensions must be carried out by an official ABB Turbo
Version 2.4
HZTL2488_EN
Systems service station.
ABB

Operation
Shutting the engine down
4.5
Page 8
Before shutting the engine down, it must be allowed to idle for 5 to 10

minutes longer so that the circulating lubricating oil can dissipate the
heat in the turbocharger bearings.
March 2007
4.5 Shutting the engine down
Version 2.4
HZTL2488_EN
CAUTION
ABB

Maintenance
Foreword to Maintenance
5.1
Page 1
March 2007
5 Maintenance
5.1 Foreword to Maintenance
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 specified in this chapter must be established by visual checks at

the intervals indicated.
The safety instructions must be observed during all cleaning work.
HZTL2488_EN
The cleaning points described in the following are:
Version 2.4
Filter silencer
Compressor
Turbine and nozzle ring
ABB

Maintenance
5.2
Page 2
March 2007
5.2 Cleaning the filter silencer
HZTL2488_EN
5.2.1 Filter silencer with tension band
81265
Filter ring (if provided)
81138
Cover panel
81270
Tension band
81005
Screw plug
38271
Trap cover
81006
Gasket
81136
Fleece segment
81135
Filter silencer body
81137
Cover panel
Ribs
Slide-in module = fleece segment + cover panel installed
Version 2.4
L_00209
ABB

Maintenance
5.2
Page 3
March 2007
Disassembling and cleaning the filter silencer

X Remove filter ring (81265).
X Rinse the filter ring (81265) with water using detergent or, if very dirty,
If provided
soak it. Squeeze out carefully. Rinse in cold water. Avoid high mechanical stress (water jet).
The dirt in the filter ring (81265) depends on the cleanness of the air
drawn in. Wash or replace the filter ring as necessary or every 500 service hours.
NOTE
X Loosen the tension bands (81270) on the trap covers (81271) and ca-
HZTL2488_EN
refully remove the cover grid (81266) from the connecting strips
(81268).
NOTE
In the case of a slide-in module (E), the water injection line must first be
removed with a cleaning container attached to on the filter silencer (available as option depending on turbocharger type) (see also following
section Disassembling the cleaning line).
X Pull the slide-in modules (E) out, bend the cover panels (81137 &
81138) open, and then take out the fleece segments (81136).
X Clean fleece segment (81136).
Version 2.4
When cleaning, ensure that the fleece segments (81136) are cleaned
only with a mild jet of compressed air and a soft brush or damp cloth.
Otherwise the segments may be damaged or lose their shape.
Heavily soiled fleece segments and filter ring as well should be replaced with original parts from ABB Turbo Systems.
NOTE
ABB

Maintenance
5.2
Page 4
March 2007
Assembling the filter silencer
X Assemble the slide-in modules (E) by inserting fleece segments
(81136) in the cover panels (81137).
X Bend the cover panels (81137) back to their original shape.

X Insert slide-in modules (E) in the grooves in the filter silencer body
(81135).
When assembling, mount the extended cover panels (81138) over the
three ribs (A).
NOTE
The water injection line must now be re-installed with a cleaning container attached to on the filter silencer (available as option depending
on turbocharger type) (see also following section Assembling the cleaning line).
HZTL2488_EN
NOTE
X Fit tension bands (81270) and tighten them on the trap covers (81271).
X Fit filter ring (81265).
Version 2.4
If provided
ABB

Maintenance
5.2
Page 5
HZTL2488_EN
March 2007
5.2.2 Filter silencer and connecting rod
Version 2.4
L_00185
81265
Filter ring (if provided)
81136
Fleece segment
81269
Connecting rods
81137
Cover panel
81266
Cover grids
81135
Filter silencer body
81272
Screw
81273
Locknut
Slide-in module = fleece segment + cover panel
ABB

Maintenance
5.2
Page 6
X Remove filter ring (81265).
If provided
Rinse filter ring (81265) with water using detergent or, if very dirty, soak it. Squeeze out carefully. Rinse in cold water. Avoid high mechanical stress (water jet).
March 2007
Disassembling and cleaning the filter silencer
The dirt in the filter ring (81265) depends on the cleanness of the air
drawn in. Wash or replace the filter ring as necessary or every 500 service hours.
X
X
X
X
NOTE
Loosen and remove locknuts (81273).

Loosen and remove screws (81272) to the connecting rods (81269).
Remove connecting rods (81269).
Carefully remove the cover grid (81266).
In the case of a slide-in module (E), with a cleaning container attached

to the filter silencer (available as option depending on turbocharger type) the water injection line must first be removed (see also following
section Disassembling the cleaning line).
HZTL2488_EN
NOTE
X Withdraw the slide-in modules (E), bend open the cover panels
Heavily soiled fleece segments and filter ring as well as damaged connecting rods should be replaced with original parts from ABB Turbo
Systems Ltd.
NOTE
ABB
Version 2.4
(81137) and then take out the fleece segments (81136).

X Clean fleece segment (81136).
When cleaning, ensure that the fleece segments (81136) are cleaned
only with a mild jet of compressed air and a soft brush or damp cloth.
Otherwise the segments may be damaged or lose their shape.

Maintenance
5.2
Page 7
March 2007
Assembling the filter silencer

X Assemble the slide-in modules (E) by inserting fleece segments
(81136) in the cover panels (81137).
X Bend cover panels (81137) back to their original shape.

X Insert slide-in modules (E) in the grooves in the filter silencer body
(81135).
With a cleaning container fitted to the filter silencer (available as option

depending on turbocharger type) the water injection line must now be
re-installed (see also following section Assembling the cleaning line).
NOTE
X Place cover grids (81266) evenly in the correct position.

X Push the connecting rods (81269) through the clips on the cover grids
HZTL2488_EN
(81266).
If the connecting rods (81269) are not located correctly in their recesses
on the filter silencer body (81135), the cover grid (81266) can twist and
shift. This can allow foreign bodies and dirt to get into the compressor.
Version 2.4
CAUTION
L_00232
ABB

5
5.2
Page 8
March 2007
Maintenance
L_00234
tightening the screws (81272), ensure that the connecting rods (81269)
are located correctly in the recesses in the filter silencer body (81135).
Now tighten the screws (81272) alternately to the following max. tightening torque:
Screw
Tightening torque
81272
20 Nm
HZTL2488_EN
X Connect the connecting rods (81269) with the screws (81272). While
X Fit locknuts (81273) onto screw (81272) and tighten to the following
torque:
Tightening torque
81273
40 Nm
X Fit filter ring (81265).
Version 2.4
If provided
Locknut
ABB

Maintenance
Cleaning the compressor during

operation
5.3
Page 9
March 2007
5.3 Cleaning the compressor during operation

These guidelines for wet cleaning apply exclusively for cleaning with
clean water and are subject to permission for the procedure being obtained from the engine manufacturer.
NOTE
The dirt in the compressor stage (compressor wheel and diffuser) depends 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:
HZTL2488_EN
Oil or saline mist

Solid combustion residues
Dust of various kinds
Soiling of the compressor stage has a negative effect on compressor efficiency and charging pressure, particularly for smaller turbochargers.
This results in higher exhaust temperatures and increased fuel consumption by the engine. Contamination of the compressor also increases the
rotor imbalance.
Periodic cleaning of the compressor in operation prevents or retards a severe increase in soiling, but in no way replaces the regular servicing work,
during which the turbocharger is completely dismantled.
Version 2.4
Interval between cleanings
The interval between periodic cleaning depends in large measure on the

operating conditions. In general, cleaning should be carried out every 25
to 100 operating hours.
Should the prescribed cleaning intervals prove incompatible with the
operation of the ship, please contact ABB Turbo Systems.
NOTE
ABB

Maintenance

operation
5.3
Page 10
The compressor is cleaned while operating using the cleaning method described in the following. This method has been tested and is approved by
ABB Turbo Systems:
Wet cleaning
Principle of wet cleaning
March 2007
Cleaning method
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.
Due to the danger of corrosion, only clean water may be used, and on
no account salt water. The water should also contain no cooling additives, which could form deposits in the flow ducts.
CAUTION
For V-engines with several turbochargers on each engine, we recommend

parallel cleaning of the compressors. This cleaning process is faster and
avoids the risk of engine surging.
Register supercharging
With register supercharging it must be ensured that both turbocharger

compressors are cleaned regularly, especially following periods of operation in the lower performance range.
Version 2.4
V-engines
HZTL2488_EN
The water does not act as a solvent in the process, but the deposit is removed by the mechanical impact of the drops. The process is ideal, provided the soiling is not too advanced.
ABB

Maintenance

operation
5.3
Page 11
March 2007
5.3.1 Wet cleaning the compressor with external pressurised water container (XC3)
Operating state preconditions for cleaning compressors with XC3
In order to carry out a successful cleaning procedure that has been

tested and is recommended by ABB Turbo Systems, the following preconditions must be met:
NOTE
Z Engine warm from running (engine under full loading as far as possi-
Version 2.4
HZTL2488_EN
ble)
Z High turbocharger speed
X Cleaning cycle started according to the following description in Procedure for wet cleaning with XC3.
ABB

Maintenance

operation
5.3
Page 12
HZTL2488_EN
March 2007
Procedure for compressor wet cleaning with XC3
L_00198
Valve lever
X The Operating state preconditions for cleaning compressors with XC3

X
X
X
X
X
Screw plug
must be met before cleaning can begin.

Remove the screw plug (X).
Fill the vessel with pure water.
Tighten screw plug (X).
Actuate valve lever (Y) against the spring and hold it for 10 to 15 seconds until all the water has been injected.
After cleaning, a waiting time of at least 5 minutes is necessary to allow
the turbocharger to dry.
ABB
Version 2.4
Operating the pressure

water vessel
March 2007

Maintenance

operation
5.3
Page 13
If the cleaning operation is unsuccessful, it can be repeated up to 2 times.

NOTE
If cleaning is still unsuccessful after three attempts and the engine operating values are unsatisfactory, we recommend that the turbocharger
be checked and cleaned by an official ABB Turbo Systems service station.
Cleaning parameters for each turbocharger compressor

Turbocharger
speed
Contents of the
dosing vessel
[dm3]
Water
Injection time
t1 [s]
TPL 67/71-C
If possible
nBmax
0.4
4 ... 15
Version 2.4
HZTL2488_EN
Turbocharger type
ABB

5
Cleaning turbine blades and nozzle ring

in operation
5.4
Page 14
5.4 Cleaning turbine blades and nozzle ring in

operation
Combustion of heavy fuel oil in diesel engines causes soiling of the turbine blades and nozzle rings of the turbochargers. The deposits on the
turbine components are caused by the following products of combustion:
March 2007
Maintenance
Soot
Molten ash
Cinders
Incompletely burned fuel
Sodium vanadyl vanadate
We recommend the use of fuels with a mass ratio of vanadium to sodium less than 3:1, so that the melting point of the sodium vanadyl vanadate is as high as possible.
NOTE
HZTL2488_EN
Therefore, it is advantageous to use fuels with a low content of ash, sulphur, sodium and vanadium. The fuel must also be stored, prepared and
handled correctly.
Soiling increases with time, so that regular and properly performed cleaning is important to remove the accumulated deposits.
The charging pressure can rise somewhat if the turbine profile is constricted due to fouled turbine components. Contamination causes loss of
performance in the turbine and the engine temperature after the cylinders
can increase. This may mean that the engine output has to be reduced.
Experience in operation has shown that despite periodic cleaning during

operation, it is impossible to dispense with overhauls during which the turbine and nozzle ring are mechanically cleaned. However, if cleaning is
performed correctly and the cleaning system is properly dimensioned, the
intervals between overhauls can be extended.
ABB
Version 2.4
A soiled turbine also results in rotor unbalance. Severe soiling can lead to
impermissibly high rotor imbalance.

5

in operation
5.4
Page 15
The interval between periodic cleaning depends in large measure on the

operating conditions. In general, cleaning should be carried out every 50
to 500 operating hours.
March 2007
Wet cleaning interval
Maintenance
Cleaning method
The turbine and nozzle ring are cleaned while operating using the cleaning method described in the following. This method has been tested and is
approved by ABB Turbo Systems:
Partial load wet cleaning
HZTL2488_EN
Principle of wet cleaning
During wet cleaning using droplets of water, the water does not act as a
solvent. Instead, the deposit is removed by the mechanical impact of the
drops.
Due to the danger of corrosion, only clean water may be used, and on
no account salt water. The water should also contain no cooling additives, which could form deposits in the flow ducts.
CAUTION
Should the prescribed cleaning intervals prove incompatible with the

operation of the ship, please contact ABB Turbo Systems.
Version 2.4
NOTE
Stabilising and drying time
NOTE
Cleaning of the turbine-side components begins after engine start or

reduction of engine load. The exhaust temperature must not exceed the
value specified in the corresponding cleaning instructions (see the respective section Operating state preconditions).
ABB
V-engines

in operation
5.4
Page 16
Failure to maintain the prescribed exhaust temperature upstream of the

turbine, and to allow the minimum stabilising time before and between
cleaning procedures and the drying time after cleaning in accordance
with the pertinent cleaning instructions will shorten the expected service
life of the components significantly.
For V-engines with several turbochargers on each engine, we recommend
parallel cleaning of both turbochargers. This cleaning process is faster
and avoids the risk of engine surging. We recommend conducting tests to
find the most suitable method.
With register supercharging it must be ensured that both turbocharger turbines and nozzle rings are cleaned regularly, especially following periods
of operation in the lower performance range.
Version 2.4
HZTL2488_EN
Register supercharging
March 2007
CAUTION
Maintenance
ABB

Maintenance

in operation
5.4
Page 17
March 2007
5.4.1 Wet cleaning the turbine and nozzle ring during operation <TTE
430C
The maximum exhaust gas temperature specified by the engine manufacturer and the TMmax temperature as shown on the turbocharger rating plate
must not be exceeded under any circumstances. During wet cleaning, the
turbine is braked and the turbocharger operates at reduced speed. As a
result, less air is supplied to the engine and the temperature after the engine cylinder and exhaust valve rises.
For the partial load cleaning the following described operating state of
the turbine is a precondition.
HZTL2488_EN
NOTE
Operating state preconditions for wet cleaning <TTE 430C
In order to carry out a successful cleaning procedure that has been

tested and is recommended by ABB Turbo Systems, the following preconditions must be met:
NOTE
Z Reduction of engine loading to the lowest possible level

X The best cleaning effect is achieved at a loading level of 20 to 30%.
Z Wait 10 to 15 minutes (stabilising time) until the turbine inlet tem-
Version 2.4
perature is stable and less than 430C.

X Cleaning cycle started according to the following description in Procedure for wet cleaning
ABB

Maintenance

in operation
5.4
Page 18
Procedure for wet cleaning the turbine and nozzle ring during operation
March 2007
<TTE 430C
HZTL2488_EN
In engines with one turbocharger (TL 1)
L_00200
Version 2.4
In V-engines with two

turbochargers (TL 1 and
2)
L_00201
ABB
March 2007
Use of cleaning container
Maintenance

in operation
5.4
Water supply (freshwater only)
other turbochargers
Regulating valve
Injection pipe
Manometer
Drainage line
Air supply with 3-way-valve
Drain cock
Water pipe made from stainless 10

steel
Outflow
X The operating state preconditions must be met before cleaning can

X
X
X
X
X
X
HZTL2488_EN
Page 19
X
X
X
begin!
Ensure that the water supply (1) is connected, turned on and constant.
Open the drainage line (8,9).
Open the 3-way-valve (4) first, then open the regulating valve (2) slowly until the pressure gauge (3) indicates a pressure of 5 bar.
Inject water for 10 minutes. Check whether the exhaust gas temperature falls after the turbine.
Close the regulating valve (2).
This completes the cleaning process. The water supply must be disconnected from the gas inlet casing.
Switching the 3-way-valve (4) for the water supply to blow-out mode
with compressed air.
Close drain hole (at 8) above drainage line (8,9).
After cleaning, wait at least 10 minutes with the engine running to allow
turbocharger to dry.
The repeating of cleaning cycles directly one after the other is to be avoided, since this can lead to a high mechanical load and consequently
to a reduction in the service life of the components.
Version 2.4
NOTE
If the cleaning process is unsuccessful, the time of this can be extended. With an extension of the injection time it must be ensured, that
no unacceptable quantity of water collects in the gas outlet casing. For
this purpose, a drainage system for the gas outlet casing must be installed and be open during the cleaning. If no drainage system is present, the injected quantity of water can be controlled with a flow meter
in the water supply. What maximum quantity of water is permitted in individual cases, is to be established with an official ABB Turbo Systems
service station. The influence of the cleaning water on the peripheral
aggregates (such as e.g. Boiler) must be clarified by the operator.
ABB

5

in operation
5.4
Page 20
cleaning.
The exhaust-gas temperature after the turbocharger falls significantly
during cleaning (by 50 to 150C).
Outflow can (but need not) take place through the drain-pipe, depending on the engine load. This outflow might not start for 2 - 3 minutes, or
it may not occur at all.
If draining is not carried out, the turbocharger speed and / or gas inlet
temperature must be monitored closely during the washing operation. If
the load is too low, water can collect in the gas outlet casing. Signs of
this are a sudden fall in the turbocharger speed or very rapid increase
in the gas inlet temperature. In either of these cases, the washing operation must be terminated and the washing cycle begun again with a
lower water pressure or higher engine loading.
March 2007
The gas outlet casing should be drained via the drainage line (8) during
Version 2.4
HZTL2488_EN
Points to remember when

cleaning
Maintenance
ABB

Troubleshooting
6.1
Page 1
6 Troubleshooting
March 2007
6.1 Possible remedies for failures

Exhaust temperature too high
Engine output and speed unchanged
Z Malfunction in the injection system

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

X Clean
HZTL2488_EN
Engine
Z Compressor / turbine soiled

X Clean
Z Exhaust counterpressure too high
X Clean or repair boiler or exhaust silencer
Z Turbine damaged or worn
X Contact an official ABB Turbo Systems service station.
Charge-air cooler
Z Cooler soiled
X Clean
Z Insufficient coolant water quantity
X Replenish
Version 2.4
Z Coolant water inlet temperature too hot

X Clean/inspect cooling system
Z Ventilation inadequate
X Improve ventilation
ABB

Troubleshooting
6.1
Page 2
March 2007
Charge-air pressure too low

Intake condition normal
Engine
Z Air receiver leaking

X Repair
Z Gas line between engine and turbine leaking
X Repair
Z Injection misadjusted
X Correct adjustment
Turbocharger
HZTL2488_EN
Z Valve control misadjusted

Z Manometer display faulty

X Replace manometer
Z Leak in line to the manometer
X Repair leak
Z Air filter dirty, causing excessive loss of pressure
X Clean
Z Compressor / turbine soiled
X Clean
Version 2.4
Z Compressor / turbine damaged

Z Excessive exhaust counterpressure
X Clean boiler or exhaust silencer
ABB

Troubleshooting
6.1
Page 3
March 2007
Charge-air pressure too high

Intake condition normal
Engine
Z Malfunction in the injection system

Z Engine output higher than expected
X Check engine output
HZTL2488_EN
Z Injection misadjusted
Turbocharger
Z Manometer display faulty

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

Turbine or compressor damaged
Bearing defective
Contact an official ABB Turbo Systems service station.
Noises during run-out
Version 2.4
Turbocharger
Z Turbocharger dirty
X Clean
Z
Z
Z
X
Bearing damaged
Rotor grazing
Foreign bodies in the turbocharger
ABB

Troubleshooting
6.1
Page 4
Turbocharger
March 2007
Run-out time too short

X Clean
Z
Z
Z
X
Bearing damaged
Rotor grazing
Sluggish start-up
X Clean
Z
Z
Z
X
Bearing damaged
Rotor grazing
HZTL2488_EN
Turbocharger
Lubricating oil pressure too low

Engine
Z Oil filter heavily soiled

X Clean
Z Oil pump in the lubricating system defective
X Inspect
Z Manometer provides false reading
X Replace manometer
Z Axial clearance of the rotor too big

Version 2.4
Turbocharger
ABB

Troubleshooting
6.1
Page 5
March 2007
Constant surging of the turbocharger

Z Exhaust pressure after the turbine elevated because boiler or exhaust
Engine
silencer is dirty
Z Trap dirty
X Clean
Turbocharger
Z Charge-air cooler or silencer dirty

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

official ABB Turbo Systems service station.
Version 2.4
HZTL2488_EN
NOTE
ABB

7.1
Page 1
7 Removal and installation

March 2007
7.1 Turbocharger weights

WARNING
Loads that are not suspended in accordance with the regulations during
disassembly and assembly may fall and can cause serious or even fatal
injury.
Version 2.4
HZTL2488_EN
X Select a suitable rope taking into account the weight of the load.
X Hang rope crossed over on the crane hook
X Do not stand under suspended loads.
L_00082
ABB

7.1
Page 2
Weights [kg]
TPL 67-C
TPL 71-C
1081
1771
March 2007
Turbocharger complete unit without filter silencer/air suction branch
Turbocharger complete unit with filter silencer

Weights [kg]
TPL 67-C
TPL 71-C
1194
1957
Turbocharger complete unit with radial air suction branch

TPL 67-C
TPL 71-C
1128
1840
Version 2.4
HZTL2488_EN
Weights [kg]
ABB

7.2
Page 3
7.2 Remove the turbocharger

March 2007
X Disconnect all gas, air, and oil lines in accordance with the engine ma-
nufacturers instructions.
NOTE
The two oil supply channels in the bearing casing are fitted with one orifice each. In order to obtain the required oil pressure, the diameter of
the orifice plate holes in the oil-supplying oil inlet channel has been adjusted individually by the manufacturer. Whenever these orifices are
removed, or if the bearing casing or the complete turbocharger is replaced, it is essential to ensure that the orifice with the correct orifice
diameter is fitted into the oil supplying oil-inlet channel
Version 2.4
HZTL2488_EN
Suspending the turbhocharger
L_00181
ABB

7
7.2
Page 4
At least the two suspension lugs on the bearing casing and the two suspension lugs on the gas inlet casing are to be used (observe labelling on
the insulation). The two suspension lugs on the gas inlet casing are helpful for aligning the turbocharger horizontally.
X Remove insulating shell (S) from the bearing casing and the insulation
from the gas inlet casing. The rest of the insulation can remain fitted on
the turbocharger.
X Check the lifting equipment.
X Attach the lifting equipment to the suspension lugs on the bearing casing and the gas inlet casing.
March 2007
Observe weight of the turbocharger.
HZTL2488_EN
CAUTION
During removal, a turbocharger that is not lifted in compliance with

regulations may fall, and can cause serious or even fatal injury.
WARNING
Z The filter silencer must not be used for the lifting of the complete tur-
bocharger.
X Select a suitable rope taking into account the weight of the turbocharger.
X Suspend the complete turbocharger using the attachment points
provided for this purpose.
If the support for the turbocharger is missing or defective, the turbocharger may tip over during installation and removal and can cause serious or even fatal injury.
WARNING
X Support turbocharger in a suitable location.

X Cover oil connector.
ABB
Version 2.4
X Release the fixing screws on the foot.

X Lift the turbocharger from the engine and place it aside.

Installing the turbocharger
7.3
Page 5
March 2007
7.3 Installing the turbocharger

During installation, a turbocharger that is not lifted in compliance with
regulations may fall, and can cause serious or even fatal injury.
WARNING
Z The filter silencer must not be used to lift the turbocharger!

X Select a suitable rope taking into account the weight of the turbo-
charger.
X Suspend the complete turbocharger using the attachment points
provided for this purpose and transport horizontally.
HZTL2488_EN
X Remove cover from the oil connector.

X Check the lifting equipment.
X Secure lifting equipment to the suspension lugs on the bearing casing.
Observe weight of the turbocharger.

CAUTION
X Mate turbocharger with the engine.

X Tighten the fixing screws on the foot, in accordance with the engine
Version 2.4
manufacturer's instructions.
X Mate the insulating shell with the bearing casing and secure.
X Secure all gas, air, and oil lines in accordance with the engine manufacturers instructions.
ABB

Module weights
8.1
Page 1
8 Disassembly and assembly

March 2007
8.1 Module weights

WARNING
Loads that are not suspended in accordance with the regulations during
disassembly and assembly may fall and can cause serious or even fatal
injury.
Version 2.4
HZTL2488_EN
X Select a suitable rope taking into account the weight of the load.
X Hang rope crossed over on the crane hook
X Do not stand under suspended loads.
L_00082
ABB

Module weights
8.1
Page 2
HZTL2488_EN
March 2007
Assembly units
Version 2.4
L_00190
ABB

Module weights
8.1
HZTL2488_EN
March 2007
Weights [kg]
Page 3
TPL 67-C
TPL 71-C
Filter silencer
113
186
Air suction branch,

radial
44
73
Compressor casing
(one-piece)
172
282
Wall insert
48
79
Diffuser
17
27
Cartridge group
282
463
Turbine diffuser
31
51
Nozzle ring
13
Gasket
0.07
0.07
10
Gas inlet casing
90
138
11
Segment
11.5
Compressor casing complete

Weight [kg]
TPL 67-C
TPL 71-C
237
388
The total weight of the complete compressor casing unit is made up of

the combined weights of the compressor casing, the diffuser, and the
wall insert.
Version 2.4
NOTE
ABB

8
Removing and fitting the filter silencer or 8.2

air suction branch
Page 4
8.2 Removing and fitting the filter silencer or air

suction branch
Not all tools are identified with a part number. The identification of the
tools is ensured with the tools list (included in the toolbox).
March 2007
NOTE
X Disconnect all air ducts in accordance with the engine manufacturers
instructions.
X Release nuts (72027) with Verbus washers (72028) and remove the fil-
HZTL2488_EN
ter silencer or air suction branch.
Filter silencer
X Fit a safety ring bolt (90231) on the filter silencer.

X Sling lifting gear through the loops at the rear and secure in the safety
ring bolt with a shackle .
ABB
Version 2.4
81000_004

Axial clearance
8.3
Page 5
HZTL2488_EN
March 2007
8.3 Axial clearance
L_00218
Version 2.4
Z The axial clearance A must be measured before the cartridge group is
removed and after it has been fitted.

X Measure and note the axial clearance (A).
Clearance A [mm]
TPL 67-C
TPL 71-C
0.31 0.49
0.33 0.50
If the axial clearance A is out of tolerance, an official service station of

ABB Turbo Systems Ltd. must be contacted.
CAUTION
ABB

8.4
Page 6
Not all tools are identified with a part number. The identification of the
tools is ensured with the tools list (included in the toolbox).
March 2007
8.4 Removing cartridge group
NOTE
X Remove insulations.
X Disconnect the oil lines in accordance with the engine manufacturer's
instructions.
HZTL2488_EN
Remove compressor
casing complete
X Attach compressor casing clamp (90190) and secure the compressor

X
X
X
X
casing (72000) to the crane with a shackle (90195).

Loosen nuts (61037).
Press off compressor casing (72000) evenly with the three press-off
nuts (61037) fitted at the bearing casing side.
Lift compressor casing (72000) slightly and withdraw a little.
Attach second shackle (90195) for TPL-71-C or (90213) for TPL-67-C
to the flange of the compressor casing (72000).
ABB
Version 2.4
00000_010

8.4
Page 7
March 2007
X Withdraw compressor casing (72000) completely.

X Remove O-ring gasket (42012).
X Place the compressor casing (72000) with wall insert and diffuser with
the flange (F) on shims.
Ensure that the shim does not slip.

X Maximum working load for shackle (90213) is 300kg.
X Only rest the compressor casing on flange (F).
X Check shim and adjust as necessary.
Version 2.4
HZTL2488_EN
WARNING
ABB

8.4
Page 8
HZTL2488_EN
March 2007
Completely disassemble
compressor casing
X
X
X
X
Version 2.4
79000_002
Remove three screws (72002).

Remove diffuser (79000) by means of ring bolts (90235).
Remove wall insert (77000) by means of ring bolts (90235).
Dismantle O-Ring gasket (77005) from the wall insert.
ABB

8.4
Page 9
HZTL2488_EN
March 2007
21000_003
X Unplug cable (86515) and screw out speed sensor (86505) with O-ring
If provided:
seal (86506).
X Disconnect cable (86515) to line amplifier (86525).
Version 2.4
X Check lifting equipment and secure to bearing casing (42001).

X Loosen the three screws (61059).
During removal, a cartridge group that is not lifted in compliance with

regulations might fall and could cause serious or even fatal injury.
CAUTION
X Select a rope suitable for weight of cartridge group.
ABB

8.4
Page 10
X Press down cartridge group evenly using jack screws (90900) in holes
If the blades on the rotor have insufficient or no clearance, this might

cause damage to the blades and the casing.
CAUTION
March 2007
provided.
Turn rotor to check that turbine blades do not touch turbine diffuser.
X Extract the cartridge group.
X Attach the supports (90450) with the screws and set the cartridge
Work that exceeds the scope of the description in this chapter must only be performed by a trained fitter from an official ABB Turbo Systems
service station.
CAUTION
HZTL2488_EN
group down.
X Cover oil connections.
service station.
Version 2.4
CAUTION
ABB
Dismantling and installing the turbine

diffuser and nozzle ring
8.5
Page 11
8.5 Dismantling and installing the turbine diffuser

and nozzle ring
Release turbine diffuser
HZTL2488_EN
March 2007
56000_007
Version 2.4
X Place clamp (90921) over the threaded pin (61036).

X Insert extension (A) of torque spanner (B) through the hole of the
clamp (90921) and release the torque of screws (61056) in succession.

X Do not yet remove the screws (61056) with the Verbus washers
(61057).
ABB


8.5
Page 12
HZTL2488_EN
March 2007
Removing the turbine

diffuser
56000_006
X Replace two screws (61056) and Verbus washers (61057) with guide
Version 2.4
bolts (90320).
X Remove the remaining screws (61056) and Verbus washers (61057).
X Press off turbine diffuser (63000) with puller screws (90901) and withdraw the diffuser a little.
X Fix turbine diffuser (63000) to the lifting gear and remove as a complete unit.
ABB


8.5
Page 13
HZTL2488_EN
March 2007
Remove the nozzle ring
56000_008
After the removal of the turbine diffuser, the nozzle ring (56001) is only
clamped lightly with the gas outlet casing. By pulling it forward, the nozzle ring (56001) is released and can fall down.
CAUTION
Version 2.4
X Pull nozzle ring (56001) forwards and remove.
ABB


8.5
Page 14
X Fit the nozzle ring and the turbine diffuser by reversing the sequence
Fitting
for removal.
X Align the nozzle ring with the holes in the gas inlet casing and assem-
ble with screws, nuts and bushings.
March 2007
Fitting the turbine diffuser and nozzle ring
Smear all screws in and on the gas casings with Anti Scuff Paste 868
from SPANJAARD.
NOTE
HZTL2488_EN
service station.
Version 2.4
CAUTION
ABB

8.6
Page 15
HZTL2488_EN
March 2007
8.6 Installing the cartridge group
21000_003
X Remove cover from oil connector.

X Check lifting equipment and secure it to bearing casing (42001) so that
Version 2.4
cartridge group hangs straight.
When it is being fitted, a cartridge group that is not suspended in compliance with regulations may fall, and can cause serious or even fatal
injury.
CAUTION
X Select a rope suitable for weight of cartridge group.

X Remove supports (90450) and carefully insert cartridge group.
ABB

8
8.6
Page 16
If the blades on the rotor have insufficient or no clearance, the blades

and the casing could be damaged.
CAUTION
X Turn rotor to check that turbine blades do not touch turbine diffuser.
March 2007
X Tighten the three screws (61059) with Verbus washers (61058) evenly.
X Remove lifting equipment.
If provided:
X Connect cable (86515) to line amplifier (86525).

X Screw in the speed measuring transmitter (86505) with O-ring gasket
HZTL2488_EN
(86506) and connect cable (86515).
00000_009
X Fit all oil lines in accordance with the engine manufacturer's instruc-
Version 2.4
tions.
ABB

8.6
Page 17
HZTL2488_EN
March 2007
Fit compressor casing

complete
Version 2.4
79000_002
X Fit O-Ring gasket (77005) on the wall insert (77000).

X Screw ring bolts (90235) into the holes in the wall insert (77000).
X Align the wall insert (77000) so that the pins on the ring bolts (90235)
centre the wall insert (77000) in the three threaded holes.

X Lower the wall insert (77000).
X Release ring bolts (90235).
X Mount the diffuser (79000) with ring bolts (90235).
ABB

8.6
Page 18
March 2007
X Remove ring bolts (90235).

X Fit screws (72002).
HZTL2488_EN
Install compressor casing

complete
00000_010
X Fit O-ring gasket (42012).

X Attach compressor casing clamp (90190) and secure the compressor
casing (72000) to the crane with a shackle (90195).

X Attach second shackle (90195) for TPL-71-C or (90213) for TPL-67-C
to the flange of the compressor casing (72000).
When lifting the complete compressor assembly, take care to ensure
that the shim does not slip.
X Maximum working load for shackle (90213) is 300kg.
X Only rest the compressor casing on flange (F).
X Check shim and adjust as necessary.
Version 2.4
WARNING
X Fit the three press-off nuts (61037), distributed evenly around the cir-
cumference.
ABB

8.6
Page 19
X Push the compressor casing (72000) onto the studs on the cartridge
March 2007
group and remove only the one shackle (90195) on the flange.
X Push the compressor casing (72000) fitting snugly onto the cartridge
group and secure with nuts (61037).
X Measure and note the axial clearance A.

Clearance A [mm]
TPL 67
TPL 71
0.31 0.49
0.33 0.50
If the axial clearance A is out of tolerance, an official service station of

ABB Turbo Systems Ltd. must be contacted.
CAUTION
HZTL2488_EN
X Connect oil lines and all air lines in accordance with engine manufac-
turers instructions.
X Mount filter silencer or air suction branch and secure with nuts (72027)
and Verbus washers (72028).

X Fit insulation.
service station.
Version 2.4
CAUTION
ABB

8.7
Page 20
HZTL2488_EN
March 2007
8.7 Table of tightening torques
00000_001
Version 2.4
The following tightening torques must be maintained for the specified

screwed connections:
ABB
HZTL2488_EN
March 2007
Tightening torques [Nm]
8.7
Page 21
Item
No.
Part No.
TPL 67-C
TPL 71-C
82005
M16x1.5
45
M16x1.5
45
72027
M14
75
M16
95
72026
M14
30
M16
30
61037
M16
110
M18
160
61036
M16
30
M18
40
61059
M16
200
M18
280
42059
M12
45
M16
105
17
61044
M12-T
80
M14-T
130
21
61056
M12-T
130
M14-T
205
23
72002
M10
50
M12
80
86505
M18x1.5
150
M18x1.5
150
Version 2.4
86505
L_00228
ABB

Possibilities for emergency repair
9.1
Page 1
9 Taking out of operation temporarily

March 2007
9.1 Possibilities for emergency repair

Lubricating oil leaks are a fire hazard.
WARNING
The instructions of the engine manufacturer for operation of the engine

with locked / isolated turbocharger must be followed precisely in all cases!
CAUTION
HZTL2488_EN
If the diesel engine must be capable of operation again as soon as possible after damage to the turbocharger (emergency repair), the following
possibilities are available:
Lock the turbocharger rotor
Version 2.4
ABB

Locking the rotor
9.2
Page 2
A locked rotor must be disassembled following turbocharger repair and

given an imbalance check.
March 2007
9.2 Locking the rotor
CAUTION
NOTE
The only exceptions are test rig runs up to a maximum of 25% engine
load on new engines with one or a number of turbochargers, which are
requested by some customers. Since in these cases operation with a
locked rotor is brief and the loads are small, subsequent disassembly of
the rotor is unnecessary.
CAUTION
During operation of the engine with a locked turbocharger, the lubrication oil system must also remain connected to this turbocharger and turned on if the gas inlet cannot be blocked (see section Further measures
and information for operation with a locked rotor for 4-stroke engines).
Otherwise components that are still intact can be damaged by overheating.
Version 2.4
The supply of lubricating oil to the turbocharger must be shut off in the
event of a lubricating oil leak on the turbocharger.
HZTL2488_EN
U Once unscrewed, balancing screws must not be screwed in again.
ABB

Locking the rotor
9.2
Page 3
HZTL2488_EN
March 2007
Locking rotor with screwed connection
94000_001
Tightening torques table
Part no.
TPL67-C
TPL71-C
72027
M14
75 Nm
M16
95 Nm
94007
M8
25 Nm
M8
25 Nm
Version 2.4
X Remove the silencer or air suction branch.
These operations must be carried out as described in the chapter Disassembly and assembly.
NOTE
X Insert locking flange (94003) in the compressor wheel.

X Place screws (94007) in the unoccupied threaded holes in the com-
pressor wheel and tighten to the values shown in the Tightening

torques table.
ABB

9
Locking the rotor
9.2
Page 4
Do not remove the balancing screws on the compressor wheel. Use only free threaded holes to assemble the trunnion.
CAUTION
X Position assembly-/disassembly device (90020) over studs (72026)
March 2007
and locking flange (94003).
X Turn the compressor wheel, so that locking flange hexagon is aligned
Version 2.4
HZTL2488_EN
with the hexagon in the assembly-/disassembly device (90020).

X Fasten the assembly-/disassembly device (90020) on the compressor
housing by tightening the nuts (72027) on the studs (72026) to the values shown in the preceding Tightening torques table.
94000_002
It must be ensured that all components are clean and free from grease.
CAUTION
ABB

Locking the rotor
9.2
Page 5
Further measures and information for operation with a locked rotor for 4March 2007
stroke engines
4-stroke engine with one turbocharger

No further measures are necessary. The engine can be operated as naturally aspirated engine according to the instructions of the manufacturer.
4-stroke engine with several turbochargers

No further measures are necessary on engines with separate air and exhaust receivers. The engine can be operated as naturally aspirated engine according to the instructions of the manufacturer.
Common air receiver
If the engine is equipped with a common air receiver and separate exhaust-gas receivers, the compensator at the compressor outlet of the damaged turbocharger must be dismantled and the air line on the engine side must be isolated. Otherwise the undamaged turbocharger can spin
"unloaded" and overspeed.
HZTL2488_EN
Separate receivers
More or less powerful pulses from the exhaust-gas system are applied to
the locked rotor, depending on the engine turbocharging system. Particularly with pulse supercharging (turbine casing with more than one gas inlet) the locking device is then subjected to heavy loading. The following
operating limits should therefore not be exceeded:
In systems similar to those with constant pressure (1 gas inlet) the en-
Version 2.4
gine can be operated up to a maximum of 25% engine load. The pressure in the charge-air receiver must not exceed 0.9 bar overpressure.
With pulse supercharging (2...4 gas inlets) the engine can be operated
up to a maximum of 20% engine load. The pressure in the charge-air
receiver must not exceed 0.5 bar overpressure.
Attention must be paid to the speed of the undamaged turbocharger in
all cases. Rotating speed limit nBmax as indicated on the rating plate
must not be exceeded.
CAUTION
ABB

9.3
Page 6
The cover plate (material: General structural steel, in accordance with

DIN EN 10025-2) must be produced in-house according to the drawing.
March 2007
9.3 Fitting the cover plate
HZTL2488_EN
NOTE
Cover plate dimensions

[mm]
Type
B1
B2
B3
B4
B5
B6
B7
B8
TPL 67-C
13
325
30
30
10
70
TPL 71-C
13
385
30
30
10
84
Type
5 min.
6 min
TPL 67-C 616
694
660
16
22
15
TPL 71-C 726
818
779
18
25
15
ABB
Version 2.4
90000_001
9.3
Page 7
Type
TPL 67-C
4 x 90
37.5
24 x 15
TPL 71-C
4 x 90
37.5
24 x 15
HZTL2488_EN
March 2007
00000_004
Version 2.4
These operations must be carried out as described in the chapter Disassembly and assembly.
NOTE
X Removing cartridge group
ABB

9
9.3
Page 8
HZTL2488_EN
March 2007
61000_003
X Block the opening in the gas outlet casing with the cover plate.
X Secure cover plate with spacer sleeves and nuts (61037).
Shut off the supply of lubricating oil to the turbocharger.
Version 2.4
CAUTION
ABB

9.3
Page 9
Further measures and information for operation with a turbocharger with

March 2007
cover plate in 4-stroke engines
4-stroke engine with one turbocharger

No further measures are necessary. The engine can be operated as naturally aspirated engine according to the instructions of the manufacturer.
4-stroke engine with several turbochargers

No further measures are necessary on engines with separate air and exhaust receivers. The engine can be operated as naturally aspirated engine according to the instructions of the manufacturer.
Common receiver
The air line must be blocked on the engine side, since the undamaged
turbochargers develop a receiver pressure.
HZTL2488_EN
Separate receivers
Version 2.4
CAUTION
The engine can be operated according to the instructions of the engine

manufacturer. Attention must be paid to the speed of the undamaged
turbocharger in all cases. Rotating speed limit nBmax as indicated on the
rating plate must not be exceeded.
ABB

9.4
Page 10
March 2007
9.4 Blocking the inlets and outlets

CAUTION
X Block the compressor casing outlet, gas inlet and gas outlet by fitting
cover plates.
For information about how to do this, see the manufacturer's instructions.
Version 2.4
HZTL2488_EN
NOTE
ABB

9.5
Page 11
March 2007
9.5 Bypass the turbocharger

CAUTION
Z For engines with one turbocharger only:

Z The connections are ready and pipes for the bypass are to hand.
X Fit the bypass around the turbocharger.
For information about how to do this, see the manufacturer's instructions.
Version 2.4
HZTL2488_EN
NOTE
ABB

10
Taking out of operation for up to 12

months
10.1
Page 1
March 2007
10 Mothballing the turbocharger

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 protective oil must be applied to the naked parts.
If the turbocharger is left mounted on the engine, and the engine oil is replaced 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 turbocharger. The remains of the old engine oil will be washed away and the
sensitive bearing parts will be largely protected against corrosion.
Version 2.4
HZTL2488_EN
If the rotor turns due to a draught from the flue, fit a blind flange between
the compressor casing and the charge-air duct.
ABB

10
Taking out of operation for more than 12 10.2

months
Page 2
10.2 Taking out of operation for more than 12

months
If the turbocharger has to be removed from the engine and stored for a
prolonged period of time, disassembly and mothballing of the turbocharger must be done by an official ABB Turbo Systems service station.
March 2007
Ensure that the storage area 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.
Version 2.4
HZTL2488_EN
NOTE
ABB

11
11.1
Page 1
11 Reserve and spare parts

March 2007
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.
X 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.
HZTL2488_EN
Spare-parts set
Spare-parts set (97070) is required for the work described in this manual. The parts included in the spare-parts set are only available as part
of the complete set.
NOTE
Version 2.4
Spare parts set (97070)
Quantity
Description
Part number
O-ring gasket
42012
Gasket
42041
Gasket
42045
Verbus washer
42058
Hexagon head screw
42059
Hexagon nut
61037
12
Hexagon head screw
61056
12
Verbus washer
61057
Verbus washer
61058
Hexagon head screw
61059
Gasket
77005
O-ring gasket (SpeedSensor)
86506
ABB

11
11.1
Page 2
All spare parts that have been ordered with the turbocharger should be
kept complete and serviceable.
CAUTION
X Rusty parts should be carefully cleaned and greased.
March 2007
X Dispose of parts that have been exchanged and are no longer usable
Version 2.4
HZTL2488_EN
in a technically and environmentally compatible manner.
ABB

11
11.2
Page 3
The following part numbers and descriptions must be used in ALL correspondence or orders:
Turbocharger
Part number
Description
42012 (in spare parts set)
O-ring gasket
51001
Gas inlet casing
56001
Nozzle ring
61001
Gas outlet casing
61044
Hexagon head screw
61050
Gasket
61056
Hexagon head screw
61057
Verbus washer
63000
Turbine diffuser
68001
Foot on the compressor side
68002
Foot at the turbine end
68006
Cup spring
68007
Bushing
72000
Compressor casing
77000
Wall insert
O-ring gasket
79000
Diffuser
81000
Filter silencer
82000
Air suction branch, radial
Version 2.4
HZTL2488_EN
March 2007
11.2 Directory of part numbers
ABB
11.2
Page 4
Part number
Description
21000
Shaft
25000
Compressor wheel
Thrust bearing
Radial bearing, compressor end
Radial bearing, turbine end
Auxiliary bearing
Floating disc
Axial bearing
32107
Bearing bush
42001
Bearing casing
42002
Hood
O-ring gasket
42015
Sealing cover
Gasket
Gasket
Verbus washer
Hexagon head screw
42063
Verbus washer
42064
Hexagon head screw
43001
Partition wall
O-ring gasket
O-ring gasket
86505
Speed sensor
O-ring gasket
March 2007
HZTL2488_EN
11
Version 2.4
Cartridge group screwed

connection
ABB

11
General view of turbocharger
11.3
Page 5
Version 2.4
HZTL2488_EN
March 2007
11.3 General view of turbocharger
L_00186
ABB

11
General view of cartridge group
11.4
Page 6
Version 2.4
HZTL2488_EN
March 2007
11.4 General view of cartridge group
L_00187
ABB
ABB

Bruggerstrasse 71a
CH-5400 Baden
Switzerland

Operation Manual: TPL67-C33

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Turbocharging

ABB Turbo Systems Ltd

Operating condition and replacement intervals

Copyright by ABB TURBO SYSTEMS Ltd 2004

ABB Turbo Systems AG

ABB Turbo Systems Ltd

Operating condition and replacement intervals

Copyright by ABB TURBO SYSTEMS Ltd 2004

ABB Turbo Systems AG

ABB Turbo Systems Ltd

Operating condition and replacement intervals

Copyright by ABB TURBO SYSTEMS Ltd 2004

ABB Turbo Systems AG

ABB Turbo Systems Ltd

Operating condition and replacement intervals

Copyright by ABB TURBO SYSTEMS Ltd 2004

ABB Turbo Systems AG

ABB Turbo Systems Ltd

Operating condition and replacement intervals

Copyright by ABB TURBO SYSTEMS Ltd 2004

ABB Turbo Systems AG

ABB Turbo Systems Ltd

Operating condition and replacement intervals

Copyright by ABB TURBO SYSTEMS Ltd 2004

ABB Turbo Systems AG

ABB Turbo Systems Ltd

Operating condition and replacement intervals

Copyright by ABB TURBO SYSTEMS Ltd 2004

ABB Turbo Systems AG

ABB Turbo Systems Ltd

Operating condition and replacement intervals

Copyright by ABB TURBO SYSTEMS Ltd 2004

ABB Turbo Systems AG

Operation Manual / TPL 6771-C

Purpose of the manual

Layout and function

Correct use of the turbocharger

Abbreviations and symbols

Turbocharger rating plate

Basic safety instructions

General safety instructions

Special safety instructions

Safety instructions and hazard protection

Warnings on the turbocharger

Putting into operation after laying up

Contact with rotating parts

Shutting the engine down

Cleaning the filter silencer

Cleaning the compressor during operation

Cleaning turbine blades and nozzle ring in operation

ABB Turbo Systems Ltd

Operation Manual / TPL 6771-C

Possible remedies for failures

Removal and installation

Remove the turbocharger

Installing the turbocharger

Disassembly and assembly

Removing and fitting the filter silencer or air suction branch

Removing cartridge group

Dismantling and installing the turbine diffuser and nozzle ring

Installing the cartridge group

Table of tightening torques

Taking out of operation temporarily