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List of contents
January 2007
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
2 Safety
HZTL2491_EN (TPL85-B14/-B15/-B16)
3 Commissioning
3.1 Oil supply
3.2 Inspection work
3.3 Putting into operation after laying up
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 4
5 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
5.5 Suppliers of materials for dry cleaning
6 Troubleshooting
January 2007
6.1 Possible remedies for failures
HZTL2491_EN (TPL85-B14/-B15/-B16)
8.5 Dismantling gas inlet casing
8.6 Fitting gas inlet casing
8.7 Fitting the internal part of the compressor casing
8.8 Table of tightening torques
1 Preliminary remarks
1.1 Purpose of the manual
January 2007
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 en-
gineers, marine mechanics and service technicians who are responsible
for the running of the engine and the turbocharger installed thereon.
Content of operation ma- This operation manual includes helpful information on the following topics:
nual
Information on the operation of the turbocharger and ways to prolong
the turbocharger's service life.
HZTL2491_EN (TPL85-B14/-B15/-B16)
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 turbo-
NOTE charger. Personnel who only work occasionally on the machine (e.g.
during installation and maintenance) must also have read and fully un-
derstood the operating manual before beginning work.
WARNING quipment.
In the event of doubt, consult the officer for safety and accident protection
responsible for your area.
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
1.2.
Mode of operation
January 2007
Turbine
Compressor
The exhaust gases from the diesel engine flow through the gas inlet cas-
ing (6) and nozzle ring (7) to the turbine wheel (8).
The turbine wheel (8) uses the energy contained in the exhaust gas to
drive the compressor wheel (11), whereby the compressor draws in fresh
HZTL2491_EN (TPL85-B14/-B15/-B16)
The exhaust gases escape through the exhaust pipe which is connected
to the gas outlet casing (5).
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 (11). It then
passes through the diffuser (10) and leaves the turbocharger through the
compressor outlet on the air outlet casing (12).
The rotor runs in two radial plain bearings (2/4), which are located in the
bearing casing (9) between the compressor and the turbine. The axial
thrust bearing (3) is on the compressor side.
The plain bearings are connected to a central lubricating oil feed which is
normally supplied by the oil lubrication circuit of the engine. The oil outlet
is always at the lowest point of the bearing casing (9).
January 2007
This turbocharger supplied by ABB Turbo Systems has been developed
for use on diesel engines to generate the volume of air and the charg-
ing pressure required to operate the engine.
NOTE The engine manufacturer has provided ABB Turbo Systems with infor-
mation 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.
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 Sys-
tems reserves the right to reject all claims under the warranty.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Latest technology This turbocharger was built according to state-of-the-art technology and is
operationally safe according to prevailing safety regulations.
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 com-
pliance with the Operation Manual.
Version 4
The manufacturer shall not accept liability for damages resulting from un-
authorised alterations to the turbocharger.
Organisational measures
January 2007
Original parts and accessories are especially designed for the turbo-
charger supplied by ABB Turbo Systems Ltd.
NOTE
HZTL2491_EN (TPL85-B14/-B15/-B16)
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
charger.
After-sales service
January 2007
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.
HZTL2491_EN (TPL85-B14/-B15/-B16)
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 instruc-
tions. Differences may exist in certain details.
Ensure that the storage area is dry with humidity of 40-70% and free of
condensation.
NOTE
January 2007
Z Prerequisite
X Work step
D Result
Basic Instructions
HZTL2491_EN (TPL85-B14/-B15/-B16)
The following symbol is used for notes in this manual:
This note provides suggestions and tips to make work on the turbo-
charger easier.
The note provides further essential information.
NOTE
The term ABB Turbo Systems used in this manual signifies ABB Turbo
Systems Ltd.
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.
L_00012
January 2007
9 CE = Conformité Européenne
10 Turbocharger type
11 Series number
12 Year of construction of the turbocharger
HZTL2491_EN (TPL85-B14/-B15/-B16)
Continuous running above the indicated nBmax, tBmax values may consid-
erably reduce the recommended exchange intervals. In such cases, we
recommend you contact the nearest official service station of ABB
CAUTION Turbo 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.
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2 Safety
2.1 Basic safety instructions
January 2007
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.
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
promote safe handling of the turbocharger and its associated operating
materials.
WARNING
HZTL2491_EN (TPL85-B14/-B15/-B16)
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 4
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.
Version 4
Before cleaning, protect the floor against unintended leaks of oil and
operation materials.
January 2007
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.
HZTL2491_EN (TPL85-B14/-B15/-B16)
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 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.
January 2007
charger:
Mechanical influences
HZTL2491_EN (TPL85-B14/-B15/-B16)
WARNING
crushing
shearing
cutting
winding
smashing
drawing in
knocking
stabbing
rubbing
Escape of liquids under high pressure and / or at high temperature
slipping
tripping
falling
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Oils
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
Version 4
Personal injury The following injuries can be caused by operation and process materials:
Allergies
January 2007
Skin disease
Loss of consciousness
Poisoning or nausea after inhalation
HZTL2491_EN (TPL85-B14/-B15/-B16)
Protective measures 9 Utmost caution when handling process and operation materials
9 Protective clothing must be worn
9 Avoid skin contact and inhalation under all circumstances
9 Ensure that the workroom is properly ventilated
9 Observe the hazard indications on the containers for operation and
process materials
9 Immediately after use, seal the hazardous substance container tight
9 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
9 Ensure that containers for new / used operation materials are sealed
tight
9 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
Version 4
Noise
HZTL2491_EN (TPL85-B14/-B15/-B16)
The effects of noise above a legally permitted level can cause personal in-
jury.
Heat hazard
January 2007
Warnings that have been applied to turbochargers by ABB Turbo Systems
must not be removed, painted over or obscured with other stickers. Miss-
ing or illegible warnings must be replaced by new warnings.
HZTL2491_EN (TPL85-B14/-B15/-B16)
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.
NOTE
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3 Commissioning
3.1 Oil supply
January 2007
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.
Oil filtration
A lubrication oil filter system with a mesh size ≤ 0.050 mm is adequate for
TPL ..-B turbochargers.
Oil pressure
The oil pressure before the bearings must be maintained precisely to en-
sure fault-free operation.
The permissible oil pressures are specified in the following tables de-
pendent on the lubrication (engine lubrication or separate lubricating sys-
tem).
Alarm
Permissible oil-pressure range for normal operation 0.8 - 2.5
Permissible oil-pressure range during engine warm- 0.8 - 4.0
up phase
Separate lubrication sys- Kinetic viscosity 12 - 170 cST Oil pressure [bar]
tem
Impermissible oil-pressure range -> 0.0 - 0.9
Engine Shut Down (without delay)
January 2007
Short-term (<1h) permissible oil-pressure range -> 0.9 - 1.1
Alarm
Permissible oil-pressure range for normal operation 1.1 - 2.5
Permissible oil-pressure range during engine warm- 1.1 - 4.0
up phase
Engine lubrication Oil inlet Engine load Oil inlet pressure Oil outlet
HZTL2491_EN (TPL85-B14/-B15/-B16)
temperature [%] [ bar ] temperature
[ °C ] [ °C ]
45 100 1.5 - 2 70 - 90
70 100 1.5 - 2 90 - 110
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The safety instructions must be followed before and during all inspec-
tion work.
January 2007
Lubricating system X Check oil pressure in oil supply lines.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Gas, air, and oil lines X After the engine has been started up, check all gas, air and oil lines for
leaks.
before and after the turbine and the compressor at various engine
speeds.
X Compare the measured values with those of the inspection report, tak-
ing into account the different operating conditions.
Clean or replace lubricating oil filters after the first 100 service hours.
ing outlet and charge-air receiver, upstream of the gas inlet, down-
stream of the gas outlet.
X Inspect the exhaust pipe before and after the turbine for any combus-
tion residue, clean / remove foreign bodies or residual water.
X Inspect air supply line or filter silencer for any foreign bodies, clean /
remove.
X Start up the turbocharger's engine end oil circulation system.
X Prepare the turbocharger for operation as instructed in the section In-
spection work before commissioning in the chapter entitled Commis-
sioning.
X Start up the turbocharger.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
4 Operation
4.1 Servicing work
January 2007
WARNING
HZTL2491_EN (TPL85-B14/-B15/-B16)
CAUTION
CAUTION
Version 4
January 2007
Monitoring of the machine plant provides information about the perform-
ance of the turbocharger.
HZTL2491_EN (TPL85-B14/-B15/-B16)
If provided Air temperature after compressor and after the charge-air cooler
Speed of the turbocharger
Pressure loss in the air filter
Oil filters X With the engine at standstill clean or replace oil filters
Version 4
This inspection work and the checks are to be carried out by an official
service station of ABB Turbo Systems Ltd.
NOTE
Version 4
January 2007
X Remove filter silencer or air suction branch
X Clean filter silencer as far as accessible, and inspect for damage
X Remove the internal part of the compressor casing
X Check clearance A (axial bearing clearance)
X Clean accessible parts (diffuser, wall insert), and inspect for damage
X Remove gas inlet casing, and dismantle nozzle ring
X Clean nozzle ring, and check for damage/wear
X Clean turbine diffuser/cover ring, and check for damage/wear
X Replacement of the radial bearing and axial bearing with original parts
from ABB Turbo Systems Ltd.
X Inspection and assessment of the rotor
HZTL2491_EN (TPL85-B14/-B15/-B16)
The replacement of the bearing parts as well as the inspection and as-
sessment of the rotor must be carried out by an official ABB Turbo Sys-
tems service station.
NOTE
Version 4
4.2 Monitoring
January 2007
86505_001
Defects in the speed transmitter, the connecting cable and plug to the
measuring unit, in the measuring unit itself or the power supply.
January 2007
Turbocharger damage.
HZTL2491_EN (TPL85-B14/-B15/-B16)
NOTE
Version 4
A U-tube manometer can be ordered from ABB Turbo Systems Ltd. for
measuring the underpressure at the filter silencer.
U-tube manometer
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
L_00003
L_00004
1 Felt discs
A [mm H2O] Pressure differential / pressure loss
January 2007
The U-tube manometer must be exposed to minimum possible me-
chanical shock or vibration.
NOTE
X Fit the U-tube manometer to the filter silencer as shown in the preced-
ing description.
X For best readability, the U-tube manometer can be filled with slightly
coloured water.
Under as-new conditions (new or clean filter silencer and filter mat), the
maximum pressure loss (A) is 120 mm H2O under full loading.
HZTL2491_EN (TPL85-B14/-B15/-B16)
X Clean the filter as soon as the loss of pressure (A) reaches a value of
200 mm H2O if not before.
For better readability of the pressure differential (A) on the U-tube ma-
nometer, the measuring rod can be withdrawn to the level of the lower
water level indicators.
NOTE
Version 4
Action to be taken:
January 2007
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.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
Before shutting the engine down, it must be allowed to idle for about 3
minutes longer so that the circulating lubricating oil can dissipate the
heat in the turbocharger bearings.
CAUTION
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
5 Maintenance
5.1 Foreword to Maintenance
January 2007
Cleaning work includes regular visual checks and washing to ensure the
correct functioning of the turbocharger and its auxiliary appliances.
Filter silencer
Compressor
Turbine and nozzle ring
Version 4
January 2007
5.2.1 Filter silencer with tension band
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00210
Version 4
X Rinse filter ring (81265) with water using detergent or, if very dirty, so-
ak it. Squeeze out carefully. Rinse in cold water. Avoid high mechani-
cal 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 ser-
vice hours.
NOTE
X Pull the slide-in modules (E) out, bend the cover panels (81137) open,
and then take out the fleece segments (81136).
X Clean fleece segments (81136).
When cleaning, ensure that the fleece segments (81136) are cleaned
only with a mild jet of compressed air, a soft brush or damp cloth. Oth-
erwise the segments may be damaged or lose their shape.
Heavily soiled fleece segments and filter ring as well as damaged con-
necting strips should be replaced with original parts from ABB Turbo
Systems.
Version 4
NOTE
January 2007
X Assemble the slide-in modules (E) by inserting fleece segments
(81136) in the cover panels (81137).
X Bend the cover panels back to their original shape.
X Insert slide-in modules (E) in the grooves in the filter silencer body
(81135).
HZTL2491_EN (TPL85-B14/-B15/-B16)
X When fitting, insert the cover grid (81266) into the connecting strips
(81268).
X Fit the tension bands (81270) and tighten on the trap covers (81271).
Version 4
L_00192
January 2007
X Disconnect the line (2) at the injection pipe (1) and remove the screw
coupling from the pipe.
X Withdraw the pipe (2) from the guide tube (3).
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00193
X Punch the guide tube (3) out of the caulking with a bolt (diameter = 16
mm) and withdraw it.
NOTE
L_00194
X After fitting the slide-in modules (E), re-fit the guide tube (3) and re-
caulk it.
X Fit the pipe (2) and screw to the injection pipe (1).
Version 4
January 2007
These guidelines for wet cleaning apply exclusively for cleaning with
clean water and are subject to permission for the procedure being ob-
tained from the engine manufacturer.
NOTE
The dirt in the compressor stage (compressor wheel and diffuser) de-
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:
HZTL2491_EN (TPL85-B14/-B15/-B16)
Solid combustion residues
Dust of various kinds
Interval between clea- The interval between periodic cleaning depends in large measure on the
nings operating conditions. In general, cleaning should be carried out every 25
to 100 operating hours.
NOTE
Cleaning method
The compressor is cleaned while operating using the cleaning method de-
January 2007
scribed in the following. This method has been tested and is approved by
ABB Turbo Systems:
Wet cleaning
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.
HZTL2491_EN (TPL85-B14/-B15/-B16)
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 addi-
tives, which could form deposits in the flow ducts.
CAUTION
Cleaning more than one If several turbochargers are installed on one engine, we recommend clea-
turbocharger compressor ning the turbocharger compressors one after the other.
Version 4
5.3.1 Wet cleaning the compressor with external pressurised water con-
January 2007
tainer (XC3)
The water feed with the externally mounted dosing vessel is only suit-
able for applications with underpressure upstream of the compressor
wheel (cannot be used for: Blower connected upstream of the com-
NOTE pressor or high-pressure compressor stage in the case of two-stage
charging).
HZTL2491_EN (TPL85-B14/-B15/-B16)
In order to carry out a successful cleaning procedure that has been
tested and is recommended by ABB Turbo Systems, the following pre-
conditions must be met:
NOTE
Z Engine warm from running (engine under full loading as far as possi-
ble)
Z High turbocharger speed
X Cleaning cycle started according to the following description in Pro-
cedure for wet cleaning with XC3.
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L_00198
X Screw plug
Y Valve lever
Operating the pressure X The Operating state preconditions for cleaning compressors with XC3
water vessel must be met before cleaning can begin.
X Remove the screw plug (X).
X Fill the vessel with pure water.
Version 4
January 2007
If cleaning is still unsuccessful after three attempts and the engine op-
NOTE erating values are unsatisfactory, we recommend that the turbocharger
be checked and cleaned by an official ABB Turbo Systems service sta-
tion.
HZTL2491_EN (TPL85-B14/-B15/-B16)
TPL 73-B nBmax 1
TPL 77-B
TPL 80-B 2
TPL 85-B
TPL 91-B
Version 4
L_00197
If the cleaning container on the filter silencer is used, the detailed clean-
ing instructions provided on the plate (4) fitted to the filter silencer
January 2007
should be followed.
NOTE
Use of cleaning container X The Operating state preconditions for cleaning compressors with XC4
must be met before cleaning can begin.
X Open filling cap (5) on cleaning container (1).
X Fill with clean water.
X Screw filling cap (5) back into place.
X Open valve (6) for about 3 minutes.
X Close valve (6) and check that all the water has been sucked out.
X After cleaning, a waiting time of at least 5 minutes with the engine run-
HZTL2491_EN (TPL85-B14/-B15/-B16)
ning must be allowed so that the turbocharger can dry.
TPL 77-B
Version 4
TPL 80-B 3
TPL 85-B
TPL 91-B
Combustion of heavy fuel oil in diesel engines causes soiling of the tur-
bine blades and nozzle rings of the turbochargers.
Soiling increases with time, so that regular and properly performed clean-
ing is important to remove the accumulated deposits.
The exhaust gas temperature downstream of the cylinders can rise and
the charging pressure at the air receiver can fall if turbine components be-
come soiled.
A soiled turbine also results in rotor unbalance. Severe soiling can lead to
impermissibly high rotor imbalance.
Wet cleaning interval 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.
Interval for dry cleaning The interval between periodic cleaning depends in large measure on the
operating conditions. In general, cleaning should be carried out every 20
to 50 operating hours.
Version 4
Cleaning methods
January 2007
Several methods are possible for cleaning the turbine and nozzle ring dur-
ing operation. The cleaning methods described in the following have been
tested and are recommended by ABB Turbo Systems:
Wet cleaning
Dry cleaning
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.
HZTL2491_EN (TPL85-B14/-B15/-B16)
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 addi-
tives, which could form deposits in the flow ducts.
CAUTION
Principle of dry cleaning During dry cleaning using dry solid particles in granulate form, the deposit
is removed by the mechanical impact of the grains hitting the surface.
Wet and dry cleaning are equally effective. However, it may be useful to
apply both methods together.
NOTE
Version 4
CAUTION with the pertinent cleaning instructions will shorten the expected service
life of the components significantly.
Cleaning more than one If several turbochargers are installed on one engine, we recommend clea-
turbocharger turbine ning the turbocharger turbines with nozzle rings one after the other.
Version 4
5.4.1 Wet cleaning the turbine and nozzle ring during operation at partial
January 2007
power
HZTL2491_EN (TPL85-B14/-B15/-B16)
In order to carry out a successful cleaning procedure that has been
tested and is recommended by ABB Turbo Systems, the following pre-
conditions must be met:
NOTE
Z After the engine has been started or during operation, the engine
output must be adjusted until the scavenging air pressure pscav is
within the range of 0.3 – 0.6 bar (gauge pressure).
Z Wait 10 to 15 minutes (stabilising time), until the exhaust tempera-
ture at the turbine inlet is stable and below 430°C, the auxiliary
blower must also be operating.
X Cleaning cycle started according to the following description in Pro-
cedure for wet cleaning.
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L_00394
Operating the wet clea- Z The Operating state preconditions for wet cleaning must be satisfied
ning system before cleaning is begun.
X Check that the water supply (1) is open and ensured, and also con-
nected to the regulating value (2) in front of the turbocharger.
X Set the shut-off valve (9) of the drain pipe (8) on the gas outlet casing
to Position 1 and check whether exhaust gas escapes.
X Firstly, slowly open the 3-way-valve (4) (if fitted), then the regulating
valve (2) until the manometer (3) shows a pressure of 1 ∓ 0.2 bar.
January 2007
X Set drain cock (9) of the drain pipe (8) on the gas outlet casing to Posi-
tion 2, in order to keep the drain pipe clean with air from the compres-
sor casing (21).
X The water supply connection (1) to the regulating valve (2) must be
disconnected.
X After cleaning, a waiting time of at least 10 minutes with the engine
running must be allowed so that the turbocharger can dry.
HZTL2491_EN (TPL85-B14/-B15/-B16)
tion.
Points to remember when The gas outlet casing must be drained of water via the drain pipe (8)
cleaning when cleaning.
The exhaust-gas temperature after the turbocharger falls significantly
during cleaning (by 50 to 150°C).
Outflow can (but need not) take place through the drain-pipe, depend-
ing 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 op-
eration must be terminated and the washing cycle begun again with a
lower water pressure or higher engine loading.
Version 4
5.4.2 Integrated dry cleaning of the turbine and nozzle ring during opera-
January 2007
tion
This cleaning method is not suitable for removing thick dirt deposits and
must therefore be carried out more often (see chapter Cleaning turbine
blades and nozzle ring in operation).
NOTE
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00094
CAUTION
Operation of the dry Z The Operating state preconditions for integrated dry cleaning must be
satisfied before cleaning is begun.
January 2007
cleaning device
X Ensure that the ON/OFF valve (5) is closed.
X Check that the combined air valve/pressure relief valve (7) is in the
pressure relief position.
X Open the trap-cover (2) carefully.
X Fill the container (1) with the prescribed amount of granulate.
X Close and seal the trap-cover (2).
X Open the air valve (7).
X Open the safety valve (6).
X Whilst cleaning the turbine, open the ON/OFF valve (5) and leave it
open for approx. 1 minute.
X Close the ON/OFF valve (5).
X Close the safety valve (6).
HZTL2491_EN (TPL85-B14/-B15/-B16)
X Set the combined air valve/pressure relief valve (7) to the pressure re-
lief position.
X Check whether the exhaust gas temperature has dropped downstream
of the turbine.
January 2007
Selection of materials The following materials are suitable for use in dry cleaning:
The average grain size of the cleaning granulate must be between 1.2
and 2.0 mm.
HZTL2491_EN (TPL85-B14/-B15/-B16)
The specific weight of the cleaning granulate must not exceed 1.2 kg/dm3.
Granulate quantity per TPL 69BA TPL 73-B TPL 77-B TPL 80-B TPL 85-B TPL 91-B
turbocharger [litres]
1.0 1.0 1.5 2.0 3.0 3.5
Version 4
5.4.3 Non-integrated dry cleaning device for the turbine and nozzle ring
January 2007
during opration
NOTE
Z High engine output (50 to 100%) and high turbocharger speed.
Z Gas inlet temperature upstream of the turbine must be below 590°C.
Otherwise, there is considerable danger that the dry cleaning agent
will be burnt off.
X Start the cleaning cycle with reference to the following description
Operating procedure for non-integrated dry cleaning device.
Version 4
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
L_00208
CAUTION
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation of the dry Z The Operating state preconditions for non-integrated dry cleaning de-
cleaning device vice must be satisfied before cleaning is begun.
Z Friction cock or slide controller (5) closed and safety valve with ventila-
tion (7) open.
X Close the safety valve with ventilation (7).
X Tighten the trap-cover (1).
X Open the compressed air shut-off valve (8) so that deposits and any
condensation are blown off.
X Close the compressed air shut-off valve (8) again after about 3 min-
utes.
X Close the friction cock / slide controller (5).
X Open the safety valve with ventilation (7) to blow out the exhaust ga-
ses.
X Open the trap-cover (1) on the granulate container carefully.
X Fill the granulate container with the prescribed quantity of granulate.
X Close and seal the trap-cover (1).
X Close the safety valve with ventilation (7).
X Open the compressed air shut-off valve (8).
X Open the friction cock or slide controller (5) for approx. 1 minute.
X Close the friction cock or slide controller (5).
Version 4
January 2007
The drain openings in the gas outlet casing must remain closed while
NOTE the turbine is being cleaned. Careless handling can cause incompletely
combusted soot particles to escape.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Cleaning parameters for the non-integrated dry cleaning device
NOTE
6 Troubleshooting
6.1 Possible remedies for failures
January 2007
Z Ventilation inadequate
X Improve ventilation
January 2007
Engine output and speed unchanged
Z Injection misadjusted
X Correct adjustment
HZTL2491_EN (TPL85-B14/-B15/-B16)
Z Valve control misadjusted
X Correct adjustment
Z Injection misadjusted
X Correct adjustment
HZTL2491_EN (TPL85-B14/-B15/-B16)
Vibrations
Z Bearing damaged
Version 4
Z Rotor grazing
Z Foreign bodies in the turbocharger
X Contact an official ABB Turbo Systems service station.
January 2007
Turbocharger Z Turbocharger dirty
X Clean
Z Bearing damaged
Z Rotor grazing
Z Foreign bodies in the turbocharger
X Contact an official ABB Turbo Systems service station.
Sluggish start-up
HZTL2491_EN (TPL85-B14/-B15/-B16)
Z Bearing damaged
Z Rotor grazing
Z Foreign bodies in the turbocharger
X Contact an official ABB Turbo Systems service station.
Engine Z Exhaust pressure after the turbine elevated because boiler or exhaust
silencer is dirty
Z Trap dirty
X Clean
NOTE
Version 4
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.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
L_00082
January 2007
9745
HZTL2491_EN (TPL85-B14/-B15/-B16)
10035
Version 4
nufacturer’s instructions.
The two oil supply channels in the bearing casing are fitted with one ori-
fice each. In order to obtain the required oil pressure, the ∅ of this ori-
fice has been individually adjusted by the engine builder. Whenever
NOTE these orifices are removed, or if the bearing casing or the complete tur-
bocharger is replaced, it is essential to ensure that the orifice with the
correct ∅ is fitted into the oil supplying oil-inlet channel.
7.2
January 2007
WARNING X Select a suitable rope taking into account the weight of the turbo-
charger.
X Suspend the complete turbocharger using the two ribs on the bear-
ing casing provided for this purpose.
X The turbocharger must be transported as horizontally as possible.
HZTL2491_EN (TPL85-B14/-B15/-B16)
aside, the turbocharger may tip over and can cause serious or even fa-
tal injury.
WARNING
Version 4
WARNING X Select a suitable rope taking into account the weight of the turbo-
charger.
X Suspend the complete turbocharger using the two ribs on the bear-
ing casing provided for this purpose.
X The turbocharger must be transported as horizontally as possible.
X
X Mate turbocharger with the engine.
X Tighten the fixing screws on the foot, in accordance with the engine
manufacturer's instructions.
X Secure all gas, air, and oil lines in accordance with the engine manu-
facturer’s instructions.
Version 4
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.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
L_00082
Modules
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
8.1
Version 4
The total weight of the complete internal part of the compressor casing
includes the internal part of the compressor casing, the diffuser and the
wall insert.
NOTE
Version 4
January 2007
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
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00011
Version 4
X Fit safety ring bolt (90231) in the bearing plate (P) on the filter silencer.
L_00226
Remove filter silencer X Sling lifting gear through the loops at the rear and secure to the
shackle (90195) or to the safety ring bolt (90231) with a shackle.
X Release nuts (74027) with Verbus washers (74028) and remove the fil-
ter silencer or air suction branch.
Install the filter silencer X The filter silencer or air suction branch is installed in the reverse se-
quence.
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
8.3
X Before disassembly and after assembly of the internal part of the com-
pressor casing, as well as of the gas inlet casing (if dismantled), the
axial clearance (A) must be measured.
X Measure and note the axial clearance A.
CAUTION
Version 4
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
Position of the safety X Take nuts (90458) from the toolbox and fit them on the threaded pins
segments before disas- of the three safety segments (Y) in the internal part of the compressor
sembly casing (76000).
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00269
NOTE
January 2007
Dismantling the internal
part of the compressor
casing
HZTL2491_EN (TPL85-B14/-B15/-B16)
8.4.2
X Press off the internal part of the compressor casing (76000) with press-
off screws (90900) so far, until the lifting device (90190/90195) can be
fitted.
Version 4
X Fit the lifting device to the internal part of the compressor casing
(76000).
X Remove internal part of the compressor casing (76000) with wall insert
and diffuser.
X Fit support angle (90025).
X Set down internal part of compressor casing (76000) in a horizontal
position.
If necessary X Attach two shackles (90195) to the support angle (90025) and fasten a
second lifting gear to the two shackles (90195).
X With lifting device (90190) slightly raise internal part of compressor
January 2007
X Rest the internal part of the compressor casing only on flange (F).
WARNING X Check shim and adjust as necessary.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
Remove diffuser
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
8.4
Work that exceeds the scope of the description in this chapter must on-
ly be performed by a trained fitter from an official ABB Turbo Systems
service station.
CAUTION
X Fix lifting gear to the eyes on the gas inlet casing with shackle (90195).
WARNING
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00022
X Loosen the screws (61044) and remove gas inlet casing (51001) with
nozzle ring (56001).
X Remove screws (56014), bushings (56013) and nozzle ring (56001).
X Loosen and remove screws (57005).
Version 4
Work that exceeds the scope of the description in this chapter must on-
ly be performed by a trained fitter from an official ABB Turbo Systems
service station.
CAUTION
January 2007
fasten tight with screws (57005).
X Remove guide bolts (90320).
X Mount nozzle ring (56001) on the gas inlet casing (51001) with screws
(56014) and bushings (56013).
Smear all screws in and on the gas casings with Anti Scuff Paste 868
from SPANJAARD.
NOTE
HZTL2491_EN (TPL85-B14/-B15/-B16)
X Fit gas inlet casing (51001) with nozzle ring onto the gas outlet casing
(61044) with screws (61009).
X Remove lifting gear with shackle (90195).
Version 4
8.4
Version 4
X Carefully slacken the lifting gear on the support bracket (90025) and
through this bring the internal part of the compressor casing (76000) to
a horizontal position.
January 2007
X Remove support bracket (90025) with shackle (90195).
HZTL2491_EN (TPL85-B14/-B15/-B16)
8.4.2
X Seat O-ring gasket (76040) to the internal part of the compressor cas-
ing (76000).
X Fit guide bolts (90320).
X Carefully insert internal part of the compressor casing (76000) with wall
Version 4
insert and diffuser over the guide bolts (90320) into the external part of
the compressor casing (74000).
X Remove the lifting device (90190/90195).
X Insert the internal part of the compressor casing as far as it will go.
X Remove guide bolts (90320) and fit studs (74026).
X Release the nuts (90458) on the threaded pins of the three safety
segments (Y) on the internal part of the compressor casing (76000).
L_00276
HZTL2491_EN (TPL85-B14/-B15/-B16)
NOTE
CAUTION
Install the filter silencer X Fit the filter silencer or air suction branch and secure with nuts (76027)
and Verbus washers (76028) (see section Removing and installing the
filter silencer or air suction branch).
January 2007
X Connect all air lines in accordance with the engine manufacturer’s in-
structions.
X Install all insulation that has been removed.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
L_00059
January 2007
56014 M16
160
57005 M16
160
61044 M24
480
74026 M24
80
74027 M24
300
76002 M20
- 1)
HZTL2491_EN (TPL85-B14/-B15/-B16)
82005 M16 x 1.5
50
86505 M22 x 1.5
220
90458 M12
30
86505
Version 4
L_00228
WARNING
NOTE
Version 4
January 2007
A locked rotor must be disassembled following turbocharger repair and
given an imbalance check.
CAUTION
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
NOTE locked rotor is brief and the loads are small, subsequent disassembly of
the rotor is unnecessary.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Various intermediate rings are provided with the locking device for dif-
ferent compressor wheels. The compressor wheel type ”CV” (for the
balancing screw holes) must be noted. The space between the locking
NOTE flange (94003) and the assembly-disassembly device (90020) must be
compensated by the intermediate rings (94001 and/or 94002) depend-
ing on the version of compressor wheel.
L_00261
Version 4
January 2007
NOTE
X Remove the filter silencer or air suction branch and the compressor
casing internal part together with the wall insert and the diffuser.
X Fix partition wall with press-off tools (90920).
CAUTION
HZTL2491_EN (TPL85-B14/-B15/-B16)
Table of tightening tor- Part number TPL85-B
ques [Nm]
94006 M12
75
94007 / 94008 M12
60
X Fit the locking flange (94003) with screws (94007 or 94008, using the
longest possible screws) as well as the adjustment ring (94004) and in-
termediate ring (94031).
Version 4
94000_15
It must be ensured that all components are clean and free from grease.
CAUTION
Version 4
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
94000_012
It must be ensured that all components are clean and free from grease.
CAUTION
Further measures and information for operation with a locked rotor for 2-
stroke engines
January 2007
2-stroke engine with one No further measures are necessary. The engine can be operated with the
turbocharger: auxiliary blower according to the instructions of the manufacturer.
9 The lubrication oil system must remain connected and turned on.
2-stroke engine with seve- X The compensator at the compressor outlet must be dismantled and the
ral turbochargers: air duct blocked at the engine end, as undamaged turbochargers de-
velop a receiver pressure.
X The operating limit of the engine can be raised by additionally blocking
the gas inlet, as the exhaust gas is then used to drive the undamaged
turbocharger. The loading and temperature of the locked rotor are also
reduced.
HZTL2491_EN (TPL85-B14/-B15/-B16)
If the gas inlet cannot be blocked, the following operating limits must be
observed:
The pressure in the charge-air receiver must not exceed 1 bar over-
pressure.
Max. permissible engine load: 50%.
January 2007
Shut off the supply of lubricating oil to the turbocharger.
CAUTION
X Block the compressor casing outlet, gas inlet and gas outlet by fitting
cover plates.
NOTE
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
CAUTION
NOTE
Version 4
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
HZTL2491_EN (TPL85-B14/-B15/-B16)
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 4
January 2007
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 storage area is dry with humidity of 40-70% and free of
condensation.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
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.
Spare-parts set
January 2007
To carry out the work described in this manual, you need a set of spare
parts (97070). These spare parts in this set are available only as a
complete set.
NOTE
HZTL2491_EN (TPL85-B14/-B15/-B16)
4 Hexagon nut 61037
1 Gasket 61041
2 O-ring gasket 77005, 77006
1 O-ring gasket 86506
All spare parts that were ordered with the turbocharger should be kept
as a complete set and ready for use.
X Parts showing signs of rust should be carefully cleaned and greased.
CAUTION
X Dispose of parts, which have been replaced and are no longer usable,
in a proper and environmentally compatible manner. Version 4
spondence or orders:
January 2007
25008 Threaded pin
25009 Ring nut
32001 Thrust bearing
32101 Radial bearing, compressor end
32102 Radial bearing, turbine end
32104 Auxiliary bearing
32105 Floating disc
32106 Axial bearing
42001 Bearing casing
42002 Hood
42011 O-ring gasket
HZTL2491_EN (TPL85-B14/-B15/-B16)
42012 (in spare parts set) O-ring gasket
42015 Sealing cover
42041 (in spare parts set) Gasket
42045 (in spare parts set) Gasket
42059 (in spare parts set) Hexagon head screw
42064 (in spare parts set) Hexagon head screw
42295 Non-return valve
43001 Partition wall
43005 O-ring gasket
86505 Speed sensor
86506 (in spare parts set) O-ring gasket
Version 4
11.3_page1
32102
42011
42045 25008
32105
32001
32106
Reserve and spare parts
42002
32101
General view of cartridge group
42001
42295
32104
11
42064
11.4
42012
86506
42041
11.4 General view of cartridge group
43001
42059 86505