Operation Manual

Table of Contents

Page 1

May 2006

Table of Contents
1 1.1 1.2 1.3 1.4 1.5 1.6 2 2.1 2.2 2.3 2.4 2.5 3 3.1 3.2 3.3 4 4.1 4.2 4.3 4.4 Preliminary remarks Purpose of the manual Layout and function Correct use of the turbocharger Essential information Abbreviations and symbols Turbocharger rating plate Safety Basic safety instructions General safety instructions Special safety instructions Safety instructions and hazard protection Warnings on the turbocharger Commissioning Oil supply Inspection work Putting into operation after laying up Operation Servicing work Monitoring Surging of turbocharger Contact with rotating parts Shutting the engine down Maintenance Foreword to Maintenance Cleaning the filter silencer Cleaning the compressor during operation Cleaning turbine blades and nozzle ring in operation

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

4.5 5 5.1 5.2 5.3 5.4

ABB Turbo Systems Ltd

ABB

Operation Manual

Table of Contents

Page 2

6 6.1 7 7.1 7.2 7.3 8 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 9 9.1 9.2 9.3 9.4 9.5 10 10.1 10.2 11 11.1 11.2 11.3 11.4

Troubleshooting Possible remedies for failures Removal and installation Turbocharger weights Remove the turbocharger Installing the turbocharger Disassembly and assembly Module weights Removing and fitting the filter silencer or air suction branch Removing cartridge group Axial clearance Installing the cartridge group Turbine-end removal / fitting of the nozzle ring Table of tightening torques Taking out of operation temporarily Possibilities for emergency repair Locking the rotor Fitting the cover plate Blocking the inlets and outlets Bypass the turbocharger Mothballing the turbocharger Taking out of operation for up to 12 months Taking out of operation for more than 12 months Reserve and spare parts Directory of part numbers General view of turbocharger General view of cartridge group
Version 2.0 HZTL2481_EN (TPL73-A.. - 80-A..) May 2006

Dismantling and installing the turbine diffuser and nozzle ring

Ordering spare parts

ABB Turbo Systems Ltd

ABB

Operation Manual Preliminary remarks Purpose of the manual 1 1.1 Page 1

1 Preliminary remarks
May 2006

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. 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. This operation manual includes helpful information on the following topics:
Information on the operation of the turbocharger and ways to prolong

Target group

Content of operation manual
HZTL2481_EN (TPL73-A.. - 80-A..)

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. 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. The instructions included in this operation manual must be followed under all circumstances. This applies especially to the general and special safety instructions preceding and in the respective chapters. Ignoring hazards and the safety instructions can lead to serious personal injury and damage to equipment. In the event of doubt, consult the officer for safety and accident protection responsible for your area.

NOTE

Version 2.0

WARNING

ABB Turbo Systems Ltd

ABB

) .2 Page 2 1.2 Layout and function May 2006 00000_001 1 2 3 4 5 6 7 Filter silencer Radial plain bearing Thrust bearing Bearing bush Radial plain bearing Gas outlet casing Gas inlet casing 8 9 10 11 12 13 Nozzle ring Turbine wheel Bearing casing Compressor wheel Air outlet casing Version 2. .80-A.0 Diffuser ABB Turbo Systems Ltd ABB HZTL2481_EN (TPL73-A..Operation Manual Preliminary remarks Layout and function 1 1..

. The exhaust gases escape through the exhaust pipe which is connected to the gas outlet casing (6).80-A. The plain bearings are connected to a central lubricating oil feed which is supplied by the oil lubrication circuit of the engine.Operation Manual Preliminary remarks Layout and function 1 1. Version 2. The oil outlet is always at the lowest point of the bearing casing (10). 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).2 Page 3 Mode of operation May 2006 The turbocharger is a turbo-machine and consists of the following main components: Turbine Compressor These are both mounted on a common shaft.0 HZTL2481_EN (TPL73-A. whereby the compressor draws in fresh air. The turbine wheel (9) uses the energy contained in the exhaust gas to drive the compressor wheel (12). and the compressed air is forced into the cylinders.. It then passes through the diffuser (11) and leaves the turbocharger through the compressor outlet on the air outlet casing (13). The axial thrust bearing (3) is on the compressor side. . The rotor runs in two radial plain bearings (2/5) which are located in the bearing bush (4) between the compressor and the turbine.) ABB Turbo Systems Ltd ABB . The exhaust gases from the diesel engine flow through the gas inlet casing (7) and nozzle ring (8) to the turbine wheel.

NOTE May 2006 Version 2. temperatures. disassembly.3 Page 4 1. Any other usage shall be regarded as a special application which must be discussed with ABB Turbo Systems. Correct use of the turbocharger also includes observation of the assembly. If it is used otherwise.. and must be operated and used in compliance with the Operation Manual. and precautionary measures must be taken to ensure that the machine room as a whole is classified as not potentially explosive. from which the operating parameters specific to the turbocharger (such as rotating speeds.Operation Manual Preliminary remarks Correct use of the turbocharger 1 1. The machine may only be operated by trained personnel. the engine must not be installed in a potentially explosive environment. Improper operation and maintenance of the turbocharger can result in danger to life and limb of the user or third parties. improper use may cause damage to the machine.. ABB Turbo Systems reserves the right to reject all claims under the warranty. Regulations set out by local authorities must be observed when disposing of the turbine. . corresponding to its intended purpose and following the instructions in the Engine Manufacturers' Manual. Latest technology This turbocharger was built according to state-of-the-art technology and is operationally safe according to prevailing safety regulations. In addition.) The engine manufacturer has provided ABB Turbo Systems with information regarding the intended purpose of the engine. ABB Turbo Systems Ltd ABB . replacement periods / exchange intervals) have been derived and are indicated on the rating plate. The manufacturer shall not accept liability for damages resulting from unauthorised alterations to the turbocharger. operating. maintenance and repair conditions specified by the manufacturer.80-A.3 Correct use of the turbocharger 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. Defects which could affect safety must be eliminated immediately.0 HZTL2481_EN (TPL73-A. If it is used in conjunction with a gas engine. The manufacturer accepts no liability for other applications. WARNING Perfect condition The turbocharger must only be installed in a technically perfect condition.

80-A. and conversions of the turbocharger that could compromise safety require the prior approval of ABB Turbo Systems.Operation Manual Preliminary remarks Essential information 1 1. HZTL2481_EN (TPL73-A. The safety and risk consciousness of the personnel working on and with the turbocharger must be checked regularly with reference to this manual. statutory regulations applicable in the respective country for the prevention of accidents and the protection of the environment must be observed. The fault should be reported to the person or department responsible. the general. .4 Essential information May 2006 Organisational measures In addition to this manual.0 ABB Turbo Systems Ltd ABB .. This also applies to the provision and wearing of personnel protection equipment..) NOTE The turbocharger must be shut down immediately in the event of al- terations affecting safety or of corresponding operating behaviour.4 Page 5 1. Additions and alterations to. NOTE Version 2.

0 WARNING Moreover.80-A. We herewith expressly state that parts and accessories not supplied by us have also not been tested and approved by us. Note that such improper use may endanger personnel and the machine. . NOTE May 2006 If components and assemblies not manufactured and tested by ABB Turbo Systems are used. Qualification of personnel The turbocharger must only be operated and maintained by trained and authorised personnel. must only be performed by qualified fitters from an official service station of ABB Turbo Systems Ltd...! CAUTION It must be ensured that only authorised personnel work on the turbocharger. such as bearings or rotors. the active and/or passive safety of the turbocharger may be compromised by the use of non-original parts. this may have a negative effect on the technical design specifications of the turbocharger.4 Page 6 Original parts and safety Original parts and accessories are especially designed for the turbocharger supplied by ABB Turbo Systems Ltd.Operation Manual Preliminary remarks Essential information 1 1. ABB Turbo Systems shall not be liable for any damage caused by using non-original parts and accessories. HZTL2481_EN (TPL73-A. Work on mechanical components. ABB Turbo Systems Ltd ABB .) Version 2.

HZTL2481_EN (TPL73-A.0 faces and all accessible areas of the turbocharger.) Accuracy of illustrations The graphics and images shown in this operation manual are of a general nature and are intended to assist understanding of the work steps and instructions. Storage of new turbochargers New turbochargers supplied by ABB Turbo Systems Ltd. After 6 months. To do this.. .4 Page 7 After-sales service May 2006 The Contact Information brochure contains an overview of official ABB Turbo Systems Ltd. Our service stations and agencies will gladly answer your questions relating specifically to your model. rust-proofing oil should be sprayed on exposed surVersion 2. Repeat the steps described for rust-proofing your turbocharger every 6 months. Differences may exist in certain details. Ensure that the storage area is dry with humidity of 40-70% and free of condensation.. NOTE ABB Turbo Systems Ltd ABB . Design variants This operating manual is valid for various turbocharger design variants. service stations worldwide.80-A. the insulating materials must be removed. This means that some sections and component descriptions in this operating manual do not apply to your turbocharger. can be stored without additional safeguarding measures for a period of 6 months after the delivery date.Operation Manual Preliminary remarks Essential information 1 1.

80-A.. Official ABB Turbo Systems service station The term used in this manual Official ABB Turbo Systems service station signifies ABB Turbocharger service stations. Version 2. NOTE HZTL2481_EN (TPL73-A. that have been tested and certified by ABB Turbo Systems Ltd.5 Abbreviations and symbols Prerequisite Work step Result May 2006 The following abbreviations are used in this document: Positive checkpoint (activity that must be carried out without fail) Negative checkpoint (activity that must not be carried out under any circumstances) Basic Instructions The following symbol is used for notes in this manual: This note provides suggestions and tips to make work on the turbocharger easier.5 Page 8 1.. ABB Turbo Systems The term used in this manual ABB Turbo Systems signifies ABB Turbo Systems Ltd.) The note provides further essential information. .Operation Manual Preliminary remarks Abbreviations and symbols 1 1.0 ABB Turbo Systems Ltd ABB .

000 h) ABB Turbo Systems Ltd ABB .6 Page 9 1. Version 2.80-A. ..) L_00012 Operational limits 1 2 Turbocharger operational limits at engine overload (110 %). In test rig operation only. unless otherwise agreed with the engine manufacturer. Turbocharger operational limits in service.000 h) Exchange interval for the turbine in 1000 h (no data for 100..0 Recommended replacement periods / exchange intervals for turbocharger components 3 4 5 Replacement interval for the plain bearings in 1000 h Exchange interval for the compressor in 1000 h (no data for 100.Operation Manual Preliminary remarks Turbocharger rating plate 1 1.6 Turbocharger rating plate May 2006 HZTL2481_EN (TPL73-A.

Operation Manual Preliminary remarks Turbocharger rating plate 1 1.6 Page 10

Additional specifications:

6 7 8 9 10 11 12

Customer part number Field for special design designation Weight of the turbocharger in kg CE = Conformité Européenne Turbocharger type Series number Year of construction of the turbocharger

Explanations of the rating plate The recommended exchange intervals and the corresponding operation limits are defined together with the engine builder. These specifications are system-specific. 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. Non-compliance with the recommended exchange intervals may increase the risk of unpredictable component failure.

CAUTION

ABB Turbo Systems Ltd

ABB

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Operation Manual Safety Basic safety instructions 2 2.1 Page 1

2 Safety
May 2006

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.

HZTL2481_EN (TPL73-A.. - 80-A..)

Serious damage to the machine or to other property may result if the working and operation instructions marked with this symbol are not, or only partly, observed.
CAUTION

Caution signs must be strictly observed at all times.

Version 2.0

ABB Turbo Systems Ltd

ABB

Operation Manual Safety General safety instructions 2 2.2 Page 2

2.2 General safety instructions
May 2006 Version 2.0 HZTL2481_EN (TPL73-A.. - 80-A..)

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

Do not work on the turbocharger if you are under physical or mental

stress.

Wear protective clothing at all times.

­ Helmet ­ Ear protection ­ Protective glasses ­ Protective suit ­ Oil and petrol resistant gloves ­ Protective shoes Attach individual parts and larger component modules carefully to 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.

ABB Turbo Systems Ltd

ABB

Operation Manual Safety Special safety instructions 2 2. Safety when commissioning and during operation Before starting work.0 ABB Turbo Systems Ltd ABB .) Version 2. Inspect the turbocharger after about 12 hours of operation or at least once a day for visible damage and defects. In the event of damage..3 Special safety instructions May 2006 Safety when connecting Work only on those connections for which you are qualified. Refrain from any activity which could compromise safety while working with the turbocharger.. .80-A. Report any damage or changes in operational performance to the person/department responsible immediately. Before commissioning check the turbocharger for damage and leaks.3 Page 3 2. HZTL2481_EN (TPL73-A. shut down the turbocharger immediately and secure it against inadvertent or unauthorized use. make a visual inspection of the working area. Remove obstacles and any objects lying around from the work area.

protect the floor against unintended leaks of oil and operation materials. wear protective clothing and observe the following rules: ­ Avoid skin contact with solvents. Handle operation materials and detergents with utmost caution. After cleaning. You must wear protective clothing (see section General safety instructions). solvents. ABB Turbo Systems Ltd ABB . ­ Do not allow solvents to soak protective clothing.0 HZTL2481_EN (TPL73-A. extinguish naked flames (including cigarettes!) due to the risk of explosion. acids and alkalis be sure to observe the respective safety directions on the manufacturers' labels. Explosion hazard WARNING Cleaning work should be carried out outdoors due to explosion hazard.80-A. . ensure that there is adequate ventilation and air circulation.Operation Manual Safety Special safety instructions 2 2. When handling solvents. ­ Avoid inhaling vapours under all circumstances.3 Page 4 Safety when cleaning May 2006 Version 2. Before beginning cleaning work in confined spaces. If this is not possible. Follow directions regarding the environmentally compatible collection. check electric cables for signs of wear or damage. Before cleaning. storage and disposal of these liquids..) When handling detergents..

.Operation Manual Safety Special safety instructions 2 2. Version 2. HZTL2481_EN (TPL73-A. Clean the turbocharger before mothballing.3 Page 5 Safety during disassembly. Before opening a cover or removing a protective component on the turbocharger. maintenance and troubleshooting May 2006 Follow the prescribed maintenance and inspection schedules for all ad- justment.80-A. Ensure that absorbent materials are available to clean up any operation materials that escape accidentally. Assembly and disassembly work must only be performed by trained personnel. collection and disposal of operating and auxiliary materials. Remove any obstacles lying around on the floor. such as bearings or rotors. maintenance and inspection work. assembly.) CAUTION Safety when taking out of operation or putting into storage Secure the rotor against turning. Wear protective clothing when mothballing the turbocharger. Ensure safe and environmentally-friendly drainage. Inform operating personnel about special work and repairs before start- ing. Work on mechanical components. must only be performed by qualified fitters from an official service station of ABB Turbo Systems. . Keep the work area clean and free of oil and operating materials.. the engine must have been switched off and must not be started up again until all parts have been properly re-assembled.0 ABB Turbo Systems Ltd ABB .

4 Safety instructions and hazard protection May 2006 Version 2. from inadequate performance of maintenance and inspection work. . pointed parts crush. due to failure to comply with the safety instructions. Mechanical influences Mechanical influences can cause serious injury or even fatal injury.4 Page 6 2.80-A.. obstacles on the floor ABB Turbo Systems Ltd ABB .) Associated hazards may arise during operation of and work on the turbocharger: from the turbocharger and its accessories. from the operating materials used. oily work area..0 HZTL2481_EN (TPL73-A. liquids and / or gases under pressure/in a vacuum slippery. WARNING Personal injury Unconsciousness and injury due to: crushing shearing cutting winding smashing drawing in knocking stabbing rubbing Escape of liquids under high pressure and / or at high temperature slipping tripping falling Causes sharp edges.Operation Manual Safety Safety instructions and hazard protection 2 2. shear and winding areas fragmentation / ejection of parts fracture or rupture of parts due to overload Elastic elements (springs).

CAUTION Personal injury The following injuries can be caused by operation and process materials: Allergies Skin disease Loss of consciousness Poisoning or nausea after inhalation Causes Version 2. .Operation Manual Safety Safety instructions and hazard protection Protective measures 2 2.. 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 Turbo Systems Ltd ABB ..0 Inhalation of toxic gases.80-A. equipment and the turbocharger clean Ensure the availability of oil absorbing materials and have oil collector basins ready or in position Eliminate leaks Operation and process materials May 2006 Operation and process materials refer to chemical and hazardous substances: HZTL2481_EN (TPL73-A.) Oils Grease Coolants Detergents and solvents Acids Note that operation and process materials are harmful to the environment if they penetrate soil or water.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.

.0 HZTL2481_EN (TPL73-A.4 Page 8 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.Operation Manual Safety Safety instructions and hazard protection Protective measures 2 2. protective barrier cream ABB Turbo Systems Ltd ABB Version 2. apply moisturising. wear protective glasses Use half or quarter masks Wear suitable work clothing and gloves For sensitive skin. .80-A. 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..) Handling insulating materials May 2006 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. 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 .

Operation Manual Safety Safety instructions and hazard protection 2 2. Wear leather protective gloves. Personal injury Causes Protective measures Burns Missing or incorrectly fitted insulation.80-A.0 ABB Turbo Systems Ltd ABB . surfaces become very hot.) Machine noise level above 85 dB (A) Wear ear protection Heat hazard When the turbocharger is operated. ... Personal injury Loss of hearing Deafness Impaired hearing Health disorders such as loss of balance or of consciousness Cardiac and circulatory disturbances Causes Protective measures HZTL2481_EN (TPL73-A.4 Page 9 Noise May 2006 The effects of noise above a legally permitted level can cause personal injury. Version 2.

May 2006 Version 2. ..80-A.) L_00227 Apply warnings so that they are clearly visible in the positions intended for that purpose..Operation Manual Safety Warnings on the turbocharger 2 2. painted over or obscured with other stickers.5 Page 10 2.5 Warnings on the turbocharger Warnings that have been applied to turbochargers by ABB Turbo Systems must not be removed.0 HZTL2481_EN (TPL73-A. Please contact an official ABB Turbo Systems service station for further information. NOTE ABB Turbo Systems Ltd ABB . Missing or illegible warnings must be replaced by new warnings.

NOTE HZTL2481_EN (TPL73-A. follow the engine manufacturer's instructions concerning selection of lubricating oil. which functions under all operating conditions.1 Oil supply A carefully designed oil supply..050 mmis adequate for TPL 73 .1. .2 Oil pressure The oil pressure before the bearings (measuring point in blind connection) must be exactly maintained to ensure fault-free operation.Operation Manual Commissioning Oil supply 3 3. is an important precondition for trouble-free operation of the turbocharger.1 Page 1 3 Commissioning May 2006 3.1.. oil change intervals. 3.) 3. oil filtration.TPL 80 turbochargers. and oil pressure and temperature.1 Oil filtration A lubrication oil filter system with a mesh size ≤ 0. Lubrication of the turbocharger is normally carried out with oil from the engine oil circuit.80-A. Regarding the oil supply. Version 2.0 ABB Turbo Systems Ltd ABB .

CAUTION We strongly recommend the use of a starting filter when running the engine in and after every servicing operation on the lubrication system.1 Inspection before commissioning Monitoring equipment To be checked for correct functioning.2 Page 2 3. Air filter mat Inspect for damage. ABB Turbo Systems Ltd ABB . These serve as an aid to detecting anomalies before and during 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. Lubricating system Check oil filter for cleanliness before commissioning. 3. Check oil pressure in oil supply lines.Operation Manual Commissioning Inspection work 3 3.0 HZTL2481_EN (TPL73-A. .2.) tion work. as well as monitoring and measurement to ensure the correct functioning of the turbocharger.80-A. The safety instructions must be followed before and during all inspecMay 2006 Version 2..2 Inspection work This inspection work includes preventive visual controls. thus preventing possible damage to the machine.

check all gas. and oil lines After the engine has been started up. oil pressure. the cause must be treated as an oil leak and located. .2 Inspection after commissioning May 2006 Lubricating system Check oil pressure in oil supply lines. If this is not in order. The first step in this process is to check the oil supply to the turbocharger for leaks.3 Inspection after 100 service hours Clean or replace lubricating oil filters after the first 100 service hours. air..2 Page 3 3. taking into account the different operating conditions. contact an official ABB Turbo Systems service station. 3.2. Compare the measured values with those of the inspection report.) Measure upstream/downstream from turbine.80-A. Further must be observed: NOTE 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. ABB Turbo Systems Ltd ABB . If oily liquid continues to escape after this period. charging pressure and temperatures Version 2.. air and oil lines for leaks. compressor and oil feed for various engine speeds Gas. Measure the speed.2.Operation Manual Commissioning Inspection work 3 3.0 before and after the turbine and the compressor at various engine speeds. Charger speed Measuring Charger pressure Measuring Temperatures HZTL2481_EN (TPL73-A.

Start up the turbocharger's engine end oil circulation system. Inspect the exhaust pipe before and after the turbine for any combus tion residue. ABB Turbo Systems Ltd ABB .80-A...3 Page 4 3. clean / remove. Inspect air supply line or filter silencer for any foreign bodies.0 HZTL2481_EN (TPL73-A. clean / remove foreign bodies or residual water. Start up the turbocharger. downstream of the gas outlet. upstream of the gas inlet. .) If provided Remove the cover plates (blind flanges) between the compressor cas- ing outlet and charge-air receiver.Operation Manual Commissioning Putting into operation after laying up 3 3. Prepare the turbocharger for operation as instructed in the section Inspection work before commissioning in the chapter entitled Commissioning.3 Putting into operation after laying up May 2006 Version 2.

1 Servicing work every 25 to 50 hours Operation data must be recorded Enter in the machine logbook In the event of significant anomalies.1 Servicing work Servicing work during operation includes visual checks.. It serves as an aid to detecting anomalies during operation.1 Page 1 4 Operation May 2006 4.) Servicing work must be carried out at the prescribed intervals in order to avoid damage to and malfunctioning of the turbocharger. CAUTION Version 2. measurement and servicing operations listed must be carried out at the intervals indicated.1. The inspection. monitoring and measuring as well as inspection and function checks in order to ensure correct functioning of the turbocharger. The pertinent safety instructions must be observed during all servicing work. contact an official ABB Turbo Systems service station.0 ABB Turbo Systems Ltd ABB . establish the cause If you are unable to establish the cause of the anomalies. WARNING HZTL2481_EN (TPL73-A. ..80-A. CAUTION 4. thus preventing damage to the machine.Operation Manual Operation Servicing work 4 4.

1 Page 2 Monitoring of the machine plant provides information about the performance of the turbocharger.Operation Manual Operation Servicing work 4 4..2 Entries in the machine logbook .. lubricating oil temperature May 2006 4.1.1. .3 Servicing work according to the engine manufacturer's instructions Oil filters With the engine at standstill clean or replace oil filters ABB Turbo Systems Ltd ABB Version 2. The following operation data and measurement values must be entered regularly in the engine manufacturer's machine log book: If provided Air temperature after compressor and after the charge-air cooler Speed of the turbocharger Pressure loss in the air filter 4.0 HZTL2481_EN (TPL73-A.80-A.) 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.

Clean bearing casing.0 NOTE ABB Turbo Systems Ltd ABB . Version 2. 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 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.4 Servicing work every 8. HZTL2481_EN (TPL73-A.12.000 hours Dismantle the turbocharger Clearance measurement Clean turbine.80-A.and compressor casings and check for any cracks and erosion / corrosion. Clean bearing casing.1.000 .) NOTE 4.1 Page 3 4.Operation Manual Operation Servicing work 4 4. ..1.5 Servicing work every 35.000 hours May 2006 Dismantle the turbocharger Clearance measurement Clean turbine.and compressor casings and check for any cracks and erosion / corrosion.. blow through oil ports Clean nozzle ring and check for cracks and erosion 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.

80-A.2 Page 4 4.Operation Manual Operation Monitoring 4 4.0 Installation variant of the speed transmitter ABB Turbo Systems Ltd ABB HZTL2481_EN (TPL73-A.. .1 Speed measurement May 2006 L_278 1 2 3 4 5 Bearing casing Axial bearing Guide in the axial bearing Gasket ring Screw plug 6 7 8 9 Connecting cable Line amplifier (option) Speed transmitter Version 2.2 Monitoring 4.) .2..

a constant remote monitoring of the turbocharger speed. . NOTE A reduction in speed of a charger can signify: Damaged turbine or bearing Defects in the connected pulse charging cylinders Severe soiling of the turbine Version 2. heavy fouling of the turbine can also be a cause of an increase in the turbocharger speed. the turbocharger speed can be used as a suitable control parameter. Failure of the speed indicator HZTL2481_EN (TPL73-A.) CAUTION If the speed indication fails. 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. The line amplifier can be purchased as an optional addition to the described speed measuring system.. Turbocharger damage. in the measuring unit itself or the power supply. The cause of the failure should then be determined. Possible reasons for failure of the speed indicator: Defects in the speed transmitter. in conjunction with the corresponding measuring instruments and/or monitoring systems (not included in the scope of delivery).2 Page 5 The speed transmitter system for the measurement of the turbocharger speed also permits. the connecting cable and plug to the May 2006 measuring unit.Operation Manual Operation Monitoring 4 4.80-A. With continuous monitoring of the machine installation.. ABB Turbo Systems Ltd ABB . it is recommended that the engine output be reduced to idling speed and the engine stopped.0 Increased turbocharger speed NOTE With 4-stroke applications.

Turbine blades (cracks) . The components listed above must be inspected for damage by an official ABB Turbo Systems service station..0 HZTL2481_EN (TPL73-A. Prolonged or periodic surging CAUTION May 2006 Version 2. The direction of flow in the compressor is then briefly reversed.Operation Manual Operation Surging of turbocharger 4 4. The operator must take immediate steps to correct the surging together with the closest official ABB Turbo Systems service station...) .) If surging is prolonged or occurs periodically. .Filter silencer Action to be taken: The operating safety of the turbocharger is no longer ensured with continuous or periodically recurring surging. such as rapid load removal or while manoeuvring. However.3 Surging of turbocharger Surging of the turbocharger can occur with certain engine operating states. ABB Turbo Systems Ltd ABB .3 Page 6 4. sporadic surging of this kind does not generally affect the safe operation of the turbocharger. the following components may be damaged: .80-A.Compressor wheel (vibration fractures.Bearing (overheating) . . and replaced in cases of doubt..

4 Contact with rotating parts Mild. Certain tolerances must be observed to avoid significant loss of efficiency.. This slightly reduces the length of the blades in the compressor and/or the turbine. .0 HZTL2481_EN (TPL73-A.Operation Manual Operation Contact with rotating parts 4 4. Version 2.) ABB Turbo Systems Ltd ABB .4 Page 7 4.. uniform wear around the circumference of rotor components. A check on dimensions must be carried out by an official ABB Turbo May 2006 Systems service station.80-A. is non-hazardous and permissible. caused by slight local grazing against adjacent components.

0 HZTL2481_EN (TPL73-A.) ABB Turbo Systems Ltd ABB .80-A. 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. .5 Shutting the engine down Before shutting the engine down. CAUTION May 2006 Version 2.5 Page 8 4...Operation Manual Operation Shutting the engine down 4 4.

. 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.1 Page 1 5 Maintenance May 2006 5.80-A. .1 Foreword to Maintenance Cleaning work includes regular visual checks and washing to ensure the correct functioning of the turbocharger and its auxiliary appliances..Operation Manual Maintenance Foreword to Maintenance 5 5.) The cleaning points described in the following are: Filter silencer Compressor Turbine and nozzle ring Version 2. The safety instructions must be observed during all cleaning work. HZTL2481_EN (TPL73-A.0 ABB Turbo Systems Ltd ABB .

2 Page 2 5.0 HZTL2481_EN (TPL73-A.80-A.1 Filter silencer with tension band May 2006 L_00210 81265 81270 38271 81268 E Filter ring (if provided) Tension ring Trap cover Connecting strip 81266 81136 81137 81135 Cover grids Fleece segment Cover panel Filter silencer body Slide-in module = fleece segment + cover panel installed ABB Turbo Systems Ltd ABB Version 2...2 Cleaning the filter silencer 5.2.Operation Manual Maintenance Cleaning the filter silencer 5 5. .) .

Operation Manual Maintenance Cleaning the filter silencer 5 5.2 Page 3

Disassembling and cleaning the filter silencer
May 2006

If provided

Remove filter ring (81265). Rinse filter ring (81265) with water using detergent or, if very dirty, so-

ak 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

Loosen tension bands (81270) on trap covers (81271) and carefully
HZTL2481_EN (TPL73-A.. - 80-A..)

remove cover grid (81266) from connecting strips (81268).

NOTE

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).

Pull the slide-in modules (E) out, bend the cover panels (81137) open,

and then take out the fleece segments (81136).

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. Otherwise the segments may be damaged or lose their shape.

Version 2.0

Heavily soiled fleece segments and filter ring as well as damaged connecting strips should be replaced with original parts from ABB Turbo Systems.
NOTE

ABB Turbo Systems Ltd

ABB

Operation Manual Maintenance Cleaning the filter silencer 5 5.2 Page 4

Assembling the filter silencer (81136) in the cover panels (81137).
May 2006 Version 2.0 HZTL2481_EN (TPL73-A.. - 80-A..)

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

When fitting, insert the cover grid (81266) into the connecting strips

(81268). Fit the tension bands (81270) and tighten on the trap covers (81271).

If provided

Fit filter ring (81265).

ABB Turbo Systems Ltd

ABB

Operation Manual Maintenance Cleaning the filter silencer 5 5.2 Page 5

5.2.2 Filter silencer and connecting rod
May 2006 HZTL2481_EN (TPL73-A.. - 80-A..)

L_00185

81265 81269
Version 2.0

Filter ring (if provided) Connecting rods Cover grids Screw

81136 81137 81135 N

Fleece segment Cover panel Filter silencer body Locknut

81266 B E

Slide-in module = fleece segment + cover panel

ABB Turbo Systems Ltd

ABB

Wash or replace the filter ring as necessary or every 500 service hours. Loosen and remove screws (B) on connecting rods (81269).2 Page 6 Disassembling and cleaning the filter silencer If provided Rinse filter ring (81265) with water using detergent or. NOTE NOTE In the case of a slide-in module (E). Heavily soiled fleece segments and filter ring as well as damaged connecting rods should be replaced with original parts from ABB Turbo Systems.. if very dirty.) Loosen and remove locknuts (N). Rinse in cold water. May 2006 Remove filter ring (81265). Squeeze out carefully. 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). . soak it. Withdraw the slide-in modules (E). The dirt in the filter ring (81265) depends on the cleanness of the air drawn in. ensure that the fleece segments (81136) are cleaned only with a mild jet of compressed air and a soft brush or damp cloth. Carefully remove the cover grid (81266)..0 HZTL2481_EN (TPL73-A. Avoid high mechanical stress (water jet).80-A. . Remove connecting rods (81269). When cleaning. Otherwise the segments may be damaged or lose their shape. NOTE ABB Turbo Systems Ltd ABB Version 2. Clean fleece segment (81136).Operation Manual Maintenance Cleaning the filter silencer 5 5. bend open the cover panels (81137) and then take out the fleece segments (81136).

.0 L_00232 ABB Turbo Systems Ltd ABB . 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).) Place cover grids (81266) evenly in the correct position.. If the connecting rods (81269) are not located correctly in their recesses on the filter silencer body (81135). Push the connecting rods (81269) through the clips on the cover grids (81266). Bend cover panels (81137) back to their original shape..80-A.Operation Manual Maintenance Cleaning the filter silencer 5 5. CAUTION Version 2. the cover grid (81266) can twist and shift.2 Page 7 Assembling the filter silencer May 2006 Assemble the slide-in modules (E) by inserting fleece segments (81136) in the cover panels (81137). NOTE HZTL2481_EN (TPL73-A. This can allow foreign bodies and dirt to get into the compressor. Insert slide-in modules (E) in the grooves in the filter silencer body (81135).

) May 2006 .. .2 Page 8 L_00234 Connect the connecting rods (81269) with screws (B).Operation Manual Maintenance Cleaning the filter silencer 5 5.80-A. ensure that the connecting rods (81269) are located correctly in the recesses in the filter silencer body (81135).0 ABB Turbo Systems Ltd ABB HZTL2481_EN (TPL73-A. Version 2. Now tighten screws (B) alternately to the following max. While tightening the screws (B).. tightening torque: Tightening torque 20 Nm Screw B Fit locknuts (N) on screw (B) and tighten to the following torque: Locknut N Tightening torque 40 Nm If provided Fit filter ring (81265).

0 coupling from the pipe.3 Removing / installing the cleaning line May 2006 HZTL2481_EN (TPL73-A.Operation Manual Maintenance Cleaning the filter silencer 5 5..2. .) L_00192 1 3 Injection pipe Guide tube 2 Pipe Removing the cleaning line Disconnect the line (2) at the injection pipe (1) and remove the screw Version 2.2 Page 9 5.. Withdraw the pipe (2) from the guide tube (3).80-A. ABB Turbo Systems Ltd ABB .

) May 2006 ..0 HZTL2481_EN (TPL73-A.80-A. Heavily soiled components of the cleaning line must be replaced with original parts from ABB Turbo Systems.Operation Manual Maintenance Cleaning the filter silencer 5 5. NOTE ABB Turbo Systems Ltd ABB Version 2.2 Page 10 Punch out the guide tube L_00193 Punch the guide tube (3) out of the caulking with a bolt (diameter = 16 mm) and withdraw it. ..

re-fit the guide tube (3) and re- caulk it.2 Page 11 Installing the cleaning line May 2006 HZTL2481_EN (TPL73-A. Version 2. . Fit the pipe (2) and screw to the injection pipe (1)...80-A.0 ABB Turbo Systems Ltd ABB .Operation Manual Maintenance Cleaning the filter silencer 5 5.) L_00194 After fitting the slide-in modules (E).

Should the prescribed cleaning intervals prove incompatible with the operation of the ship. NOTE May 2006 Version 2. This results in higher exhaust temperatures and increased fuel consumption by the engine. A deposit of dirt in the flow ducts will be formed if the following substances are present in the intake air: Oil or saline mist Solid combustion residues Dust of various kinds Soiling of the compressor stage has a negative effect on compressor efficiency and charging pressure. particularly for smaller turbochargers. during which the turbocharger is completely dismantled.3 Page 12 5.) The dirt in the compressor stage (compressor wheel and diffuser) depends on the cleanness of the air drawn in and the operating point. Contamination of the compressor also increases the rotor imbalance. Periodic cleaning of the compressor in operation prevents or retards a severe increase in soiling. .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. Interval between cleanings The interval between periodic cleaning depends in large measure on the operating conditions.80-A. In general. but in no way replaces the regular servicing work.0 HZTL2481_EN (TPL73-A. cleaning should be carried out every 25 to 100 operating hours...Operation Manual Maintenance Cleaning the compressor during operation 5 5. please contact ABB Turbo Systems. NOTE ABB Turbo Systems Ltd ABB .

which could form deposits in the flow ducts. HZTL2481_EN (TPL73-A. only clean water may be used. This cleaning process is faster and avoids the risk of engine surging. especially following periods of operation in the lower performance range. and on no account salt water. ABB Turbo Systems Ltd ABB . we recommend parallel cleaning of the compressors.0 Register supercharging With register supercharging it must be ensured that both turbocharger compressors are cleaned regularly.80-A. The water does not act as a solvent in the process... The process is ideal. The water should also contain no cooling additives. but the deposit is removed by the mechanical impact of the drops. .3 Page 13 The compressor is cleaned while operating using the cleaning method described in the following. provided the soiling is not too advanced. 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. we recommend cleaning the turbocharger compressors one after the other. V-engines For V-engines with several turbochargers on each engine. Version 2. CAUTION Cleaning more than one turbocharger compressor If several turbochargers are installed on one engine.Operation Manual Maintenance Cleaning the compressor during operation Cleaning method May 2006 5 5.) Due to the danger of corrosion.

.Operation Manual Maintenance Cleaning the compressor during operation 5 5.1 Wet cleaning the compressor with external pressurised water container (XC3) The water feed with the externally mounted dosing vessel is only suitable for applications with underpressure upstream of the compressor wheel (cannot be used for: Blower connected upstream of the compressor or high-pressure compressor stage in the case of two-stage charging).3. .3 Page 14 5.0 HZTL2481_EN (TPL73-A.) NOTE 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. ABB Turbo Systems Ltd ABB . the following preconditions must be met: NOTE Engine warm from running (engine under full loading as far as possi- ble) High turbocharger speed Cleaning cycle started according to the following description in Procedure for wet cleaning with XC3.80-A. May 2006 Version 2..

. Remove the screw plug (X). Version 2. Tighten screw plug (X).80-A. Actuate valve lever (Y) against the spring and hold it for 10 to 15 seconds until all the water has been injected.3 Page 15 Procedure for compressor wet cleaning with XC3 May 2006 HZTL2481_EN (TPL73-A. a waiting time of at least 5 minutes is necessary to allow the turbocharger to dry.) L_00198 X Y Screw plug Valve lever Operating the pressure water vessel The Operating state preconditions for cleaning compressors with XC3 must be met before cleaning can begin. Fill the vessel with pure water.0 ABB Turbo Systems Ltd ABB . After cleaning..Operation Manual Maintenance Cleaning the compressor during operation 5 5. .

0 Water injection time t1 [s] 4…15 HZTL2481_EN (TPL73-A. we recommend that the turbocharger be checked and cleaned by an official ABB Turbo Systems service station.4 1.) TPL65-A TPL69-A TPL73-A TPL77-A TPL80-A ABB Turbo Systems Ltd ABB Version 2... NOTE If cleaning is still unsuccessful after three attempts and the engine operating values are unsatisfactory. it can be repeated up to 2 times.3 Page 16 If the cleaning operation is unsuccessful.Operation Manual Maintenance Cleaning the compressor during operation 5 5.0 2.80-A. Cleaning parameters for XC3 for each turbocharger compressor Turbocharger type Turbocharger speed If possible nBmax Contents of the dosing vessel [dm3] 0.0 1. .0 May 2006 .

ABB Turbo Systems Ltd ABB .80-A.) ble) High turbocharger speed Cleaning cycle started according to the following description in Procedure for wet cleaning with XC4.3...3 Page 17 5. .2 Wet cleaning compressors with water vessel (XC4) May 2006 Operating state preconditions for cleaning compressors with XC4 In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems.0 HZTL2481_EN (TPL73-A. the following preconditions must be met: NOTE Engine warm from running (engine under full loading as far as possi- Version 2.Operation Manual Maintenance Cleaning the compressor during operation 5 5.

0 Use of cleaning container The Operating state preconditions for cleaning compressors with XC4 must be met before cleaning can begin.. Close valve (6) and check that all the water has been sucked out. Fill with clean water.80-A. Open filling cap (5) on cleaning container (1). After cleaning.Operation Manual Maintenance Cleaning the compressor during operation 5 5. Screw filling cap (5) back into place.3 Page 18 Procedure for compressor wet cleaning with XC4 May 2006 L_00197 1 3 5 Cleaning container Injection pipe Cover 2 Pipe 4 Cleaning instructions 6 Valve If the cleaning container on the filter silencer is used. ABB Turbo Systems Ltd ABB HZTL2481_EN (TPL73-A. NOTE Version 2.) .. . Open valve (6) for about 3 minutes. a waiting time of at least 5 minutes with the engine running must be allowed so that the turbocharger can dry. the detailed cleaning instructions provided on the plate (4) fitted to the filter silencer should be followed.

we recommend that the turbocharger be checked and cleaned by an official ABB Turbo Systems service station.80-A. Cleaning parameters for XC4 for each turbocharger compressor Turbocharger type Turbocharger speed If possible nBmax Contents of the dosing vessel [dm3] 0..Operation Manual Maintenance Cleaning the compressor during operation 5 5. it can be repeated up to 2 times..0 ABB Turbo Systems Ltd ABB . May 2006 NOTE If cleaning is still unsuccessful after three attempts and the engine operating values are unsatisfactory.3 Page 19 If the cleaning operation is unsuccessful. .4 2 3 Water injection time t1 [s] 4…15 TPL65-A HZTL2481_EN (TPL73-A.) TPL69-A TPL73-A TPL77-A TPL80-A Version 2.

4 Page 20 5.0 HZTL2481_EN (TPL73-A.80-A. the intervals between overhauls can be extended. The fuel must also be stored. We recommend the use of fuels with a mass ratio of vanadium to sodium less than 3:1. sulphur. Severe soiling can lead to impermissibly high rotor imbalance.Operation Manual Maintenance Cleaning turbine blades and nozzle ring in operation 5 5. The charging pressure can rise somewhat if the turbine profile is constricted due to fouled turbine components. . This may mean that the engine output has to be reduced. if cleaning is performed correctly and the cleaning system is properly dimensioned.. prepared and handled correctly. sodium and vanadium. it is advantageous to use fuels with a low content of ash. Experience in operation has shown that despite periodic cleaning during operation. The deposits on the turbine components are caused by the following products of combustion: May 2006 Version 2. it is impossible to dispense with overhauls during which the turbine and nozzle ring are mechanically cleaned.. A soiled turbine also results in rotor unbalance. so that regular and properly performed cleaning is important to remove the accumulated deposits.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. so that the melting point of the sodium vanadyl vanadate is as high as possible.) Soot Molten ash Cinders Incompletely burned fuel Sodium vanadyl vanadate Therefore. ABB Turbo Systems Ltd ABB . NOTE Soiling increases with time. Contamination causes loss of performance in the turbine and the engine temperature after the cylinders can increase. However.

) The dry cleaning method may be used as an alternative to wet cleaning. cleaning should be carried out every 50 to 500 operating hours. and must be approved by an official ABB Turbo Systems service station.80-A. .4 Page 21 The interval between periodic cleaning depends in large measure on the operating conditions. the deposit is removed by the mechanical impact of the drops. This method has been tested and is approved by ABB Turbo Systems: Wet cleaning HZTL2481_EN (TPL73-A. The water should also contain no cooling additives. and on no account salt water. NOTE Principle of wet cleaning During wet cleaning using droplets of water. only clean water may be used. the water does not act as a solvent. NOTE ABB Turbo Systems Ltd ABB ..0 Should the prescribed cleaning intervals prove incompatible with the operation of the ship. this is not the preferred method. Due to the danger of corrosion. May 2006 Cleaning method The turbine and nozzle ring are cleaned while operating using the cleaning method described in the following. In general. Instead.. CAUTION Version 2. which could form deposits in the flow ducts. please contact ABB Turbo Systems.Operation Manual Maintenance Cleaning turbine blades and nozzle ring in operation Wet cleaning interval 5 5. However.

. especially following periods of operation in the lower performance range. With register supercharging it must be ensured that both turbocharger turbines and nozzle rings are cleaned regularly. CAUTION Failure to maintain the prescribed exhaust temperature upstream of the turbine. For V-engines with several turbochargers on each engine. 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. . This cleaning process is faster and avoids the risk of engine surging.4 Page 22 NOTE Cleaning of the turbine-side components begins after engine start or reduction of engine load.) Version 2. we recommend parallel cleaning of both turbochargers.Operation Manual Maintenance Cleaning turbine blades and nozzle ring in operation Stabilising and drying time 5 5.0 V-engines Register supercharging ABB Turbo Systems Ltd ABB May 2006 .. We recommend conducting tests to find the most suitable method. The exhaust temperature must not exceed the value specified in the corresponding cleaning instructions (see the respective section Operating state preconditions).80-A. HZTL2481_EN (TPL73-A.

During wet cleaning.80-A.4 Page 23 5.1 Wet cleaning the turbine and nozzle ring during operation May 2006 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. the following preconditions must be met: NOTE After the engine is started up or the engine load has been reduced to the lowest possible level Wait 10 to 15 minutes (stabilising time) until the turbine inlet tem- perature is stable and less than 430°C.) In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems. Operating state preconditions for wet cleaning the turbine and nozzle ring during operation HZTL2481_EN (TPL73-A. . As a result. less air is supplied to the engine and the temperature after the engine cylinder and exhaust valve rises..4.Operation Manual Maintenance Cleaning turbine blades and nozzle ring in operation 5 5.0 ABB Turbo Systems Ltd ABB . Cleaning cycle started according to the following description in Procedure for wet cleaning Version 2. the turbine is braked and the turbocharger operates at reduced speed..

4 Page 24 Procedure for wet cleaning the turbine and nozzle ring (1 nozzle) May 2006 In engines with one turbocharger (TL 1) L_00203 In V-engines with two turbochargers (TL 1 and 2) L_00204 ABB Turbo Systems Ltd ABB Version 2.0 HZTL2481_EN (TPL73-A.Operation Manual Maintenance Cleaning turbine blades and nozzle ring in operation 5 5..) .80-A. ..

The water supply connection (1) must be isolated at the regulating valve (2). The repeating of cleaning cycles directly one after the other is to be avoided.Operation Manual Maintenance Cleaning turbine blades and nozzle ring in operation 1 2 May 2006 5 5. a drainage system for the gas outlet casing must be installed and be open during the cleaning. For this purpose.0 ABB Turbo Systems Ltd ABB . With an extension of the injection time it must be ensured. Close the drain pipe (8. Connect the water supply (1) to the regulating valve (2) upstream of the turbocharger. open and reliable. 9) on the gas outlet casing.g. 9) on the gas outlet casing. Open the drain pipe (8. Inject water for 10 minutes. Boiler) must be clarified by the operator.80-A. Slowly open the 3-way-valve (4) first. since this can lead to a high mechanical load and consequently to a reduction in the service life of the components.. a waiting time of at least 10 minutes with the engine running must be allowed so that the turbocharger can dry.) cleaning is begun! Check that the water supply (1) is connected. is to be established with an official ABB Turbo Systems service station. NOTE If the cleaning process is unsuccessful.4 Page 25 Water supply (freshwater only) 6 Regulating valve Manometer Air supply with 3-way-valve Stainless steel piping 7 8 9 10 Other turbochargers Injection pipe Drainage line Drain cock Outflow 3 4 5 11 Baffle (optional. Close the regulating valve (2) and the 3-way-valve (4). The influence of the cleaning water on the peripheral aggregates (such as e. the injected quantity of water can be controlled with a flow meter in the water supply.. After cleaning. then the regulating valve (2) until the manometer (3) shows a pressure of 2 ∓ 0. that no unacceptable quantity of water collects in the gas outlet casing. the time of this can be extended. What maximum quantity of water is permitted in individual cases. . Check whether the exhaust-gas temperature after the turbine drops.2 bar. Version 2. can be integrated in the nozzle) Operating the wet cleaning system The Operating state preconditions must have been fulfilled before HZTL2481_EN (TPL73-A. If no drainage system is present.

Operation Manual Maintenance Cleaning turbine blades and nozzle ring in operation
Points to remember when cleaning

5 5.4 Page 26

The gas outlet casing must be drained of water via the drain pipe (8)

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, 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 case, washing must be stopped immediately and the washing cycle repeated from the beginning with lower water pressure or higher engine load.

ABB Turbo Systems Ltd

ABB

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

Operation Manual Maintenance Cleaning turbine blades and nozzle ring in operation 5 5.4 Page 27

Procedure for wet cleaning the turbine and nozzle ring (2 nozzles)
May 2006

In engines with one turbocharger (TL 1)

HZTL2481_EN (TPL73-A.. - 80-A..)

L_00252
In V-engines with two turbochargers (TL 1 and 2)

Version 2.0

L_00253

ABB Turbo Systems Ltd

ABB

Operation Manual Maintenance Cleaning turbine blades and nozzle ring in operation
1 2 3 4 5 11 Water supply (freshwater only) Regulating valve Manometer Air supply with 3-way-valve Stainless steel piping 6 7 8 9 10

5 5.4 Page 28

Other turbochargers Injection pipe Drainage line Drain cock Outflow

Baffle (optional, can be integrated in the nozzle)

Operating the wet cleaning system

The Operating state preconditions must have been fulfilled before

cleaning is begun! Check that the water supply (1) is connected, open and reliable. Open the drain pipe (8, 9) on the gas outlet casing. Connect the water supply (1) to the regulating valve (2) upstream of the turbocharger. Slowly open the 3-way-valve (4) first, then the regulating valve (2) until the manometer (3) shows a pressure of 2 ∓ 0.2 bar. Inject water for 10 minutes. Check whether the exhaust-gas temperature after the turbine drops. Close the regulating valve (2) and the 3-way-valve (4). Close the drain pipe (8, 9) on the gas outlet casing. The water supply connection (1) must be isolated at the regulating valve (2). After cleaning, a waiting time of at least 10 minutes with the engine running must be allowed so that the turbocharger can 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.
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 Turbo Systems Ltd

ABB

Version 2.0

HZTL2481_EN (TPL73-A.. - 80-A..)

May 2006

If draining is not carried out. If the load is too low. Signs of this are a sudden fall in the turbocharger speed or very rapid increase in the gas inlet temperature. The exhaust-gas temperature after the turbocharger falls significantly during cleaning (by 50 to 150°C). .. the turbocharger speed and / or gas inlet temperature must be monitored closely during the washing operation. Version 2. depending on the engine load.80-A.3 minutes. This outflow might not start for 2 . In either of these case.) ABB Turbo Systems Ltd ABB .0 HZTL2481_EN (TPL73-A. water can collect in the gas outlet casing.Operation Manual Maintenance Cleaning turbine blades and nozzle ring in operation Points to remember when cleaning May 2006 5 5.4 Page 29 The gas outlet casing must be drained of water via the drain pipe (8) when cleaning. Outflow can (but need not) take place through the drain-pipe.. washing must be stopped immediately and the washing cycle repeated from the beginning with lower water pressure or higher engine load. or it may not occur at all.

) perature is stable and less than 430°C. Cleaning cycle started according to the following description in Procedure for wet cleaning . ..Operation Manual Maintenance Cleaning turbine blades and nozzle ring in operation 5 5. the following preconditions must be met: NOTE Reduction of engine loading to the lowest possible level The best cleaning effect is achieved at a loading level of 20 to 30%.. Wait 10 to 15 minutes (stabilising time) until the turbine inlet tem- ABB Turbo Systems Ltd ABB Version 2.0 HZTL2481_EN (TPL73-A.80-A.4 Page 30 Operating state preconditions for wet cleaning the turbine and nozzle ring May 2006 (3 nozzles) In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems.

) L_00200 In V-engines with two turbochargers (TL 1 and 2) Version 2.Operation Manual Maintenance Cleaning turbine blades and nozzle ring in operation 5 5.80-A.4 Page 31 Procedure for wet cleaning the turbine and nozzle ring (3 nozzles) May 2006 In engines with one turbocharger (TL 1) HZTL2481_EN (TPL73-A. ..0 L_00201 ABB Turbo Systems Ltd ABB ..

) . What maximum quantity of water is permitted in individual cases. Switching the 3-way-valve (4) for the water supply to blow-out mode with compressed air..5 bar. Inject water for 10 minutes. Boiler) must be clarified by the operator. Close drain hole (at 8) above drainage line (8. For this purpose. is to be established with an official ABB Turbo Systems service station. After cleaning. If no drainage system is present.g. The influence of the cleaning water on the peripheral aggregates (such as e. ABB Turbo Systems Ltd ABB Version 2. the injected quantity of water can be controlled with a flow meter in the water supply. . the time of this can be extended.4 Page 32 other turbochargers 3 injection nozzles Drain cock Outflow May 2006 Drainage line Water pipe made from stainless 10 steel Operating the wet cleaning system The operating state preconditions must be met before cleaning can begin! Ensure that the water supply (1) is connected.Operation Manual Maintenance Cleaning turbine blades and nozzle ring in operation 1 2 3 4 5 Water supply (freshwater only) Regulating valve Manometer Air supply with 3-way-valve 6 7 8 9 5 5. With an extension of the injection time it must be ensured. Open the drainage line (8.9). then open the regulating valve (2) slowly until the pressure gauge (3) indicates a pressure of 2.80-A. Check whether the exhaust gas temperature falls after the turbine. a drainage system for the gas outlet casing must be installed and be open during the cleaning.0 HZTL2481_EN (TPL73-A. that no unacceptable quantity of water collects in the gas outlet casing. First open the 3-way valve (4).. a waiting time of at least 10 minutes with the engine running must be allowed so that the turbocharger can dry. Close the regulating valve (2).9). The repeating of cleaning cycles directly one after the other is to be avoided. turned on and constant. This completes the cleaning process. since this can lead to a high mechanical load and consequently to a reduction in the service life of the components. NOTE If the cleaning process is unsuccessful. The water supply must be disconnected from the gas inlet casing.

Version 2. the turbocharger speed and / or gas inlet temperature must be monitored closely during the washing operation. The exhaust-gas temperature after the turbocharger falls significantly during cleaning (by 50 to 150°C).80-A.3 minutes. This outflow might not start for 2 .4 Page 33 The gas outlet casing should be drained via the drainage line (8) during cleaning. If the load is too low. .0 HZTL2481_EN (TPL73-A. Outflow can (but need not) take place through the drain-pipe. or it may not occur at all.. In either of these cases.. Signs of this are a sudden fall in the turbocharger speed or very rapid increase in the gas inlet temperature. If draining is not carried out.Operation Manual Maintenance Cleaning turbine blades and nozzle ring in operation Points to remember when cleaning May 2006 5 5. water can collect in the gas outlet casing. the washing operation must be terminated and the washing cycle begun again with a lower water pressure or higher engine loading.) ABB Turbo Systems Ltd ABB . depending on the engine load.

.

1 Possible remedies for failures Exhaust temperature too high Engine output and speed unchanged Engine Malfunction in the injection system Repair. HZTL2481_EN (TPL73-A.) Turbocharger Air starvation.g. .Operation Manual Troubleshooting Possible remedies for failures 6 6.80-A. air filter clogged with dirt Clean Compressor / turbine soiled Clean Exhaust counterpressure too high Clean or repair boiler or exhaust silencer Turbine damaged or worn Contact an official ABB Turbo Systems service station.. Charge-air cooler Cooler soiled Clean Insufficient coolant water quantity Replenish Version 2. e..0 Coolant water inlet temperature too hot Clean/inspect cooling system Ventilation inadequate Improve ventilation ABB Turbo Systems Ltd ABB . or contact the manufacturer.1 Page 1 6 Troubleshooting May 2006 6.

.) Turbocharger Manometer display faulty Replace manometer Leak in line to the manometer Repair leak Air filter dirty.1 Page 2 Charge-air pressure too low May 2006 Engine output and speed unchanged Intake condition normal Engine Air receiver leaking Repair Gas line between engine and turbine leaking Repair Injection misadjusted Correct adjustment Valve control misadjusted Correct adjustment HZTL2481_EN (TPL73-A.Operation Manual Troubleshooting Possible remedies for failures 6 6. causing excessive loss of pressure Clean Compressor / turbine soiled Clean Compressor / turbine damaged Contact an official ABB Turbo Systems service station..0 . Excessive exhaust counterpressure Clean boiler or exhaust silencer ABB Turbo Systems Ltd ABB Version 2.80-A..

. Noises during run-out Turbocharger Turbocharger dirty Clean Version 2.0 Bearing damaged Rotor grazing Foreign bodies in the turbocharger Contact an official ABB Turbo Systems service station.Operation Manual Troubleshooting Possible remedies for failures 6 6.) Turbocharger Manometer display faulty Replace manometer Vibrations Turbocharger Rotor imbalance due to heavy fouling of compressor/turbine Turbine or compressor damaged Bearing defective Contact an official ABB Turbo Systems service station..80-A.1 Page 3 Charge-air pressure too high May 2006 Engine output and speed unchanged Intake condition normal Engine Malfunction in the injection system Correct adjustment Engine output higher than expected Check engine output Injection misadjusted Correct adjustment HZTL2481_EN (TPL73-A. ABB Turbo Systems Ltd ABB ..

80-A..Operation Manual Troubleshooting Possible remedies for failures 6 6.) Turbocharger dirty Clean .. . HZTL2481_EN (TPL73-A. Sluggish start-up Turbocharger Bearing damaged Rotor grazing Foreign bodies in the turbocharger Contact an official ABB Turbo Systems service station. Lubricating oil pressure too low Engine Oil filter heavily soiled Clean Oil pump in the lubricating system defective Inspect Manometer provides false reading Replace manometer ABB Turbo Systems Ltd ABB Version 2.0 Turbocharger Axial clearance of the rotor too big Contact an official ABB Turbo Systems service station.1 Page 4 Run-out time too short Turbocharger May 2006 Turbocharger dirty Clean Bearing damaged Rotor grazing Foreign bodies in the turbocharger Contact an official ABB Turbo Systems service station.

0 ABB Turbo Systems Ltd ABB . NOTE Version 2... contact an official ABB Turbo Systems service station.Operation Manual Troubleshooting Possible remedies for failures 6 6.) If it is not possible to determine the reason for the surging. .80-A.1 Page 5 Constant surging of the turbocharger May 2006 Engine Exhaust pressure after the turbine elevated because boiler or exhaust silencer is dirty Trap dirty Clean Turbocharger Charge-air cooler or silencer dirty Heavy deposits of contamination in the turbine Clean HZTL2481_EN (TPL73-A.

.

80-A.1 Turbocharger weights 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.0 HZTL2481_EN (TPL73-A. Version 2. Select a suitable rope taking into account the weight of the turbo- charger parts. See also previous illustration.. WARNING ABB Turbo Systems Ltd ABB ..1 Page 1 7 Removal and installation May 2006 7.) Cross and loop the rope over the crane hook Do not stand under suspended loads. . L_00082 For the safety of loads on the crane hook.Operation Manual Removal and installation Turbocharger weights 7 7. WARNING Turbocharger parts that are not suspended in accordance with the regulations during disassembly and assembly may fall and can cause serious or even fatal injury. the ropes must be suspended crossed over each other.

80-A.. ..0 HZTL2481_EN (TPL73-A.) .Operation Manual Removal and installation Turbocharger weights 7 7.1 Page 2 Turbocharger complete unit without silencer/air suction branch May 2006 Weights [kg] TPL 73 2080 TPL 77 3200 TPL 80 4920 Turbocharger complete unit with silencer Weights [kg] TPL 73 2324 TPL 77 3604 TPL 80 5496 Turbocharger complete unit with air suction branch Weights [kg] TPL 73 2220 TPL 77 3355 TPL 80 5162 ABB Turbo Systems Ltd ABB Version 2.

Secure lifting equipment to the suspension lugs on the bearing casing. it is essential to ensure that the orifice with the correct ∅ is fitted into the oil-conducting oil-inlet channel. Remove the insulating shell from the bearing casing. or if the bearing casing or the complete turbocharger is replaced. Check the lifting equipment. the ∅ of this orifice has been individually adjusted by the engine builder. In order to obtain the required oil pressure. .0 ABB Turbo Systems Ltd ABB . HZTL2481_EN (TPL73-A. CAUTION Version 2.80-A. and oil lines in accordance with the engine ma- nufacturer’s instructions...) Observe weight of the turbocharger. air.Operation Manual Removal and installation Remove the turbocharger 7 7. Whenever these orifices are removed.2 Page 3 7.2 Remove the turbocharger May 2006 Disconnect all gas. NOTE The two oil supply channels in the bearing casing are fitted with one orifice each.

Operation Manual Removal and installation Remove the turbocharger 7 7. the complete charger must be secured by the air outlet casing and gas inlet casing. Select a suitable rope taking into account the weight of the turbocharger.80-A.) . See following illustration. ABB Turbo Systems Ltd ABB Version 2.0 If the bearing casing is not provided with a reinforced suspension lug HZTL2481_EN (TPL73-A.2 Page 4 Turbocharger without reinforced suspension lug May 2006 L_00052 During removal.. . a turbocharger that is not lifted in compliance with regulations may fall. and can cause serious or even fatal injury.. WARNING (lugs are flush with external diameter of the flange).

Cover oil connector. WARNING Version 2..) L_00051 Release the fixing screws on the foot. 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. ABB Turbo Systems Ltd ABB .Operation Manual Removal and installation Remove the turbocharger 7 7.0 Support turbocharger in a suitable location. Lift the turbocharger from the engine and place it aside.2 Page 5 Turbocharger with reinforced suspension lug May 2006 HZTL2481_EN (TPL73-A.80-A.

ABB Turbo Systems Ltd ABB .. Observe weight of the turbocharger. . Secure all gas. If provided Secure the lifting equipment to the suspension lugs on the gas inlet ca- sing (see illustration under Removing the turbocharger). CAUTION Mate turbocharger with the engine. a turbocharger that is not lifted in compliance with regulations may fall.0 HZTL2481_EN (TPL73-A.3 Installing the turbocharger During installation.Operation Manual Removal and installation Installing the turbocharger 7 7. Remove cover from the oil connector. and can cause serious or even fatal injury. the complete charger must be secured by the air outlet casing and gas inlet casing. in accordance with the engine manufacturer's instructions.) If the bearing casing is not provided with a reinforced suspension lug.80-A. Suspend the complete turbocharger using the two ribs provided for this purpose. Check the lifting equipment. Secure lifting equipment to the suspension lugs on the bearing casing. Select a suitable rope taking into account the weight of the turbocharger. Mate the insulating shell with the bearing casing and secure.. and oil lines in accordance with the engine manufacturer’s instructions. air. WARNING May 2006 Version 2. Tighten the fixing screws on the foot.3 Page 6 7.

Operation Manual Disassembly and assembly Module weights 8 8. L_00082 For the safety of loads on the crane hook.80-A. WARNING Turbocharger parts that are not suspended in accordance with the regulations during disassembly and assembly may fall and can cause serious or even fatal injury. See also previous illustration.1 Module weights 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..0 HZTL2481_EN (TPL73-A.. Version 2. the ropes must be suspended crossed over each other.) Cross and loop the rope over the crane hook Do not stand under suspended loads. . Select a suitable rope taking into account the weight of the turbo- charger parts. WARNING ABB Turbo Systems Ltd ABB .1 Page 1 8 Disassembly and assembly May 2006 8.

. .80-A. radial Air suction branch.0 431 ABB Turbo Systems Ltd ABB HZTL2481_EN (TPL73-A.. internal part Wall insert Diffuser Compressor casing external part Cartridge group Turbine diffuser Nozzle ring TPL 73 140 244 148 134 57 290 546 72 25 TPL 77 155 404 260 276 80 475 950 150 44 TPL 80 242 576 355 125 680 1356 250 63 Version 2.) .1 Page 2 Modules May 2006 L_00048 Weights [kg] Description 1 2 3 4 5 6 7 8 9 10 Air suction branch. axial Filter silencer Compressor casing.Operation Manual Disassembly and assembly Module weights 8 8.

complete Weights [kg] May 2006 TPL 73 339 TPL 77 616 TPL 80 911 The total weight of the complete internal part of the compressor casing includes the internal part of the compressor casing.1 Page 3 Compressor casing. NOTE Version 2. the diffuser and the wall insert.) ABB Turbo Systems Ltd ABB .Operation Manual Disassembly and assembly Module weights 8 8.80-A.. .0 HZTL2481_EN (TPL73-A.. internal part.

80-A.2 air suction branch 8...73 81000_003 Fit safety ring bolt (90231) on the filter silencer. . NOTE May 2006 Version 2. The identification of the tools is ensured with the tools list (included in the toolbox).0 HZTL2481_EN (TPL73-A.) Remove insulation where necessary. Disconnect all air ducts in accordance with the engine manufacturer’s instructions. TPL 69 .Operation Manual Disassembly and assembly 8 Page 4 Removing and fitting the filter silencer or 8. ABB Turbo Systems Ltd ABB .2 Removing and fitting the filter silencer or air suction branch Not all tools are identified with a part number.

85 HZTL2481_EN (TPL73-A. TPL 77 – 85 Version 2.. ABB Turbo Systems Ltd ABB .. .2 air suction branch TPL 77 .0 L_00226 Mount shackle (90195) on the fin on the filter silencer.) May 2006 L_00011 Fit safety ring bolt (90231) in the bearing plate (P) on the filter silencer.80-A.Operation Manual Disassembly and assembly 8 Page 5 Removing and fitting the filter silencer or 8.

. .2 air suction branch Remove filter silencer Sling lifting gear through the loops at the rear and secure to the Install the filter silencer The filter silencer or air suction branch is installed in the reverse se- quence..80-A. ABB Turbo Systems Ltd ABB Version 2. Release nuts (74027) with Verbus washers (74028) and remove the filter silencer or air suction branch.) May 2006 shackle (90195) or to the safety ring bolt (90231) with a shackle.Operation Manual Disassembly and assembly 8 Page 6 Removing and fitting the filter silencer or 8..0 HZTL2481_EN (TPL73-A.

. Note control dimension (u).3 Page 7 8.) Position of the safety segments before disassembly Take nuts (90458) out of the toolbox and fit them on the threaded pins of the safety segments (Y) on the internal part of the compressor casing (76000).80-A. NOTE Remove insulation Disconnect the oil lines in accordance with the engine manufacturer's instructions. ..3 Removing cartridge group May 2006 Not all tools are identified with a part number.Operation Manual Disassembly and assembly Removing cartridge group 8 8. The internal part of the compressor casing is now detached from the external part of the compressor casing (74000) and can be removed. NOTE ABB Turbo Systems Ltd ABB .0 Tighten nuts (90458) to a maximum torque of 30 Nm. If provided: HZTL2481_EN (TPL73-A. L_00269 Version 2. The identification of the tools is ensured with the tools list (included in the toolbox).

Raise internal part of compressor casing slightly with wall insert and diffuser. remove guide bolts (90320) and then withdraw..6 TPL77-A 19. ABB Turbo Systems Ltd ABB Version 2.80-A.0 TPL80-A 19.0 HZTL2481_EN (TPL73-A. Fit support angle (90025). Leave 2 holes free for fitting the lifting device (90190). Place internal part of compressor casing with wall insert and diffuser on support bracket and shim. Remove O-ring gasket (76040). .3 Page 8 Control dimension u [mm] Dimension u TPL73-A 18. Remove six studs (74026) in the upper section and and fit four guide bolts (90320). Push back internal part of compressor casing (76000) with extraction screws (90900) until the lifting device (90190) can be attached with shackle (90195) and secured to the crane.6 May 2006 L_00266 Release and remove nuts (74027) and discs (74028)..) .Operation Manual Disassembly and assembly Removing cartridge group 8 8.

Check shim and adjust as necessary. internal part May 2006 HZTL2481_EN (TPL73-A. Turn the internal part of the compressor casing with wall insert and dif- fuser carefully over the support bracket (90025) and set down with the front side of the flange (F) on the shim. ..0 Ensure that the shim does not slip. CAUTION ABB Turbo Systems Ltd ABB .80-A..Operation Manual Disassembly and assembly Removing cartridge group 8 8. Version 2.) L_00047 Refit the lifting device on the other side of the flange (F).3 Page 9 Compressor casing.

HZTL2481_EN (TPL73-A. the diffuser is positioned by hand and therefore has no threaded holes in the diffuser for the safety ring bolt 90230.0 For the turbocharger sizes up to and including TPL 73-A. ..80-A. Remove diffuser (79000). If provided: Fit safety ring bolts (90230) on diffuser (79000). ABB Turbo Systems Ltd ABB Version 2..Operation Manual Disassembly and assembly Removing cartridge group 8 8.) May 2006 .3 Page 10 Diffuser L_00053 NOTE Loosen and remove screws (76002).

Version 2.3 Page 11 HZTL2481_EN (TPL73-A. press off external part of compressor casing evenly with the three press-off nuts (61037) and remove. Loosen nuts (61037). ..80-A.) May 2006 Compressor casing external part 74000_002 Secure lifting device (90190) with shackle (90195) to external part of compressor casing (74000) and attach securely to the crane..0 ABB Turbo Systems Ltd ABB .Operation Manual Disassembly and assembly Removing cartridge group 8 8.

.Operation Manual Disassembly and assembly Removing cartridge group 8 8.0 HZTL2481_EN (TPL73-A. If provided: Disconnect cable to line amplifier (86525). Check lifting equipment and secure to bearing casing (42001). ABB Turbo Systems Ltd ABB Version 2..80-A..3 Page 12 Cartridge group L_00054 Withdraw cable (86515) and unscrew speed measuring transmitter (86505) with O-ring gasket (86506). Remove the three screws (61059) and Verbus washers (61058).) May 2006 .

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. If the turbine blades on the rotor have too little or no clearance. check that the turbine blades do not touch the turbine diffuser. and can cause serious or even fatal injury. .Operation Manual Disassembly and assembly Removing cartridge group 8 8.80-A. HZTL2481_EN (TPL73-A.. CAUTION By turning the rotor.) Extract the cartridge group and fit supports (90450). CAUTION Version 2. Press cartridge group down evenly with jack screws (90900) into the holes provided.3 Page 13 During removal. a cartridge group that is not lifted in compliance with regulations may fall.0 ABB Turbo Systems Ltd ABB . this may damage the blades and the casing. May 2006 CAUTION Select a suitable rope taking into account the weight of the cartridge group.. Cover oil connections.

36 .4 Page 14 8.80-A..42 .) .0. ..53 TPL 77 0. CAUTION ABB Turbo Systems Ltd ABB Version 2.0. Measure and note the axial clearance A. Clearance A [mm] TPL 73 0.0.Operation Manual Disassembly and assembly Axial clearance 8 8.0 HZTL2481_EN (TPL73-A.39 . an official service station of ABB Turbo Systems must be contacted.65 If the axial clearance (A) is out of tolerance.4 Axial clearance May 2006 01000_001 Axial clearance A must be measured after the cartridge group is re- moved and before it is fitted.57 TPL 80 0.

. Version 2. Insert extension (A) of torque spanner (B) through the clamp hole and release the torque of screws (61056) and Verbus washers (61057) in succession.) L_00055 Place clamp (90921) over stud (61036) until it lies flush with the inner radius of the gas outlet casing.0 ABB Turbo Systems Ltd ABB . .. Do not yet remove the screws (61056) and Verbus washers (61057).80-A.5 Page 15 8.5 Dismantling and installing the turbine diffuser and nozzle ring May 2006 HZTL2481_EN (TPL73-A.Operation Manual Disassembly and assembly Dismantling and installing the turbine diffuser and nozzle ring 8 8.

0 HZTL2481_EN (TPL73-A. . Pass the guide bolts through the holes in clamps (90921).) . To secure. replace the two screws (61056) and Verbus washers (61057) with two guide bolts (90320).Operation Manual Disassembly and assembly Dismantling and installing the turbine diffuser and nozzle ring Removing the turbine diffuser May 2006 8 8.. ABB Turbo Systems Ltd ABB Version 2.5 Page 16 56001_001 In the upper section of the turbine diffuser (63000).. fit hexagon nuts (90178).80-A.

Push back the turbine diffuser (63000) with extraction screws (90901) and withdraw the turbine diffuser until clamp (90921) contacts the hexheaded nut (90178). if possible the nozzle ring should be secured against falling with a clamping set and a wooden block. CAUTION Version 2.. If the nozzle ring is not secured when the turbine diffuser is withdrawn. . ABB Turbo Systems Ltd ABB .5 Page 17 Secure diffuser May 2006 HZTL2481_EN (TPL73-A. Note that the nozzle ring (56001) hangs loosely from the positioning pins..0 Fix turbine diffuser (63000) to the lifting gear and remove.) 61000_002 Before dismantling the turbine diffuser.80-A. it may fall. Loosen the remaining screws (61056) and Verbus washers (61057).Operation Manual Disassembly and assembly Dismantling and installing the turbine diffuser and nozzle ring 8 8.

ABB Turbo Systems Ltd ABB Version 2. ..5 Page 18 56001_002 Fix the holder (90490) on gas outlet casing.0 HZTL2481_EN (TPL73-A.80-A.Operation Manual Disassembly and assembly Dismantling and installing the turbine diffuser and nozzle ring Remove diffuser 8 8.) May 2006 ..

5 Page 19 HZTL2481_EN (TPL73-A. fix the nozzle ring to the lifting gear and remove.80-A.) May 2006 56001_003 Draw the nozzle ring (56001) forward. Version 2.Operation Manual Disassembly and assembly Dismantling and installing the turbine diffuser and nozzle ring 8 8..0 ABB Turbo Systems Ltd ABB . ..

nuts and bushings.80-A.5 Page 20 Fitting the turbine diffuser and nozzle ring Fitting for removal.) 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.. ..Operation Manual Disassembly and assembly Dismantling and installing the turbine diffuser and nozzle ring 8 8. May 2006 Fit the nozzle ring and the turbine diffuser by reversing the sequence . NOTE CAUTION ABB Turbo Systems Ltd ABB Version 2.0 HZTL2481_EN (TPL73-A. Smear all screws in and on the gas casings with Anti Scuff Paste 868 from SPANJAARD. Align the nozzle ring with the holes in the gas inlet casing and assem- ble with screws.

0 so that the cartridge group is hanging straight.80-A. ABB Turbo Systems Ltd ABB .6 Page 21 8.. Check the lifting equipment and secure it to the bearing casing (42001) Version 2. Tighten screws (61059) and the Verbus washers (61058) evenly.Operation Manual Disassembly and assembly Installing the cartridge group 8 8.) L_00054 Remove cover from the oil connector..6 Installing the cartridge group May 2006 HZTL2481_EN (TPL73-A. . Remove supports (90450) and carefully insert cartridge group.

6 Page 22 If the blades on the rotor have too little or no clearance..) May 2006 . screw three press-off nuts (61037) to the end of the thread on the studs provided for this purpose. Assemble the external part of the compressor casing (74000) and secure with nuts (61037). this may damage the blades and the casing. check that the turbine blades do not touch the turbine diffuser. Screw in the speed measuring transmitter (86505) with O-ring gasket (86506) and connect cable (86515).0 HZTL2481_EN (TPL73-A. CAUTION By turning the rotor. . 74000_002 Secure lifting device (90190) and shackle (90195) to external part of compressor casing (74000) and attach securely to the crane.Operation Manual Disassembly and assembly Installing the cartridge group 8 8. If provided: Connect cable to line amplifier (86525). NOTE ABB Turbo Systems Ltd ABB Version 2.. Remove lifting equipment. Before fitting the external part of the compressor casing.80-A.

the diffuser is positioned by hand and therefore has no threaded holes in the diffuser for the safety ring bolt 90230. NOTE If provided Transport diffuser (79000) with the fitted safety ring bolts (90230).Operation Manual Disassembly and assembly Installing the cartridge group 8 8.0 For the turbocharger sizes up to and including TPL 73-A. ABB Turbo Systems Ltd ABB . Fit the diffuser with the screws (76002).) May 2006 L_00053 Version 2. Mount diffuser (79000) and align... Remove safety ring bolts. .6 Page 23 HZTL2481_EN (TPL73-A.80-A.

6 Page 24 L_00047 Attach the lifting device (90190) and shackle (90195) securely to the back side of flange (F). ..) May 2006 . Version 2. Turn the internal part of compressor casing with wall insert and diffuser carefully over the support bracket (90025) to the vertical position and set down on the shim and support bracket.80-A..0 ABB Turbo Systems Ltd ABB HZTL2481_EN (TPL73-A.Operation Manual Disassembly and assembly Installing the cartridge group 8 8.

.. Carefully place the internal part of the compressor casing together with the wall insert and the diffuser over the guide bolts.) May 2006 L_00266 Check that the nuts (90348) on the three safety segments are all tight- ened. Attach the lifting device (90190) and shackle (90195) securely to the front side of flange (F).6 Page 25 HZTL2481_EN (TPL73-A. .0 If provided: Position of the safety segments after assembly Loosen nuts (90458) on the threaded pins of the safety segments (Y) on the internal part of the compressor casing (76000) and push the threaded pins together with safety segment (Y) as far as they will go against the external part of the compressor casing (74000). Version 2. (90025) Fit four guide bolts (90320).Operation Manual Disassembly and assembly Installing the cartridge group 8 8.80-A. The internal part of the compressor casing (76000) is now secured a- gainst the external part of the compressor casing (74000). ABB Turbo Systems Ltd ABB . Remove the support angle. Fit O-ring gasket (76040).

0. Safety segments (Y) are in an operating state again.60 TPL 80 0. Measure and note the axial clearance Clearance A [mm] TPL 73 0.6 Page 26 L_00276 Note control dimension (s).0 Connect the oil lines and all air lines in accordance with the engine HZTL2481_EN (TPL73-A.9 Replace the nuts (90458) that were taken from the toolbox. NOTE Control dimension s [mm] Dimension s TPL73-A 12.42 . 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 manufacturer’s instructions.53 TPL 77 0.0.80-A.. CAUTION ABB Turbo Systems Ltd ABB Version 2.) May 2006 . .0.65 If the axial clearance A is out of tolerance.1 TPL77-A 12. an official service station of ABB Turbo Systems Ltd. must be contacted.9 TPL80-A 11.Operation Manual Disassembly and assembly Installing the cartridge group 8 8. Fit insulation again.36 .. Mount filter silencer or air suction branch and secure with nuts (72027) and Verbus washers (74028).39 .

80-A. To secure.) L_00290 Disassembly of the nozzle ring Version 2.0 Remove the insulation on the gas inlet casing (51001).7 Page 27 8..Operation Manual Disassembly and assembly Turbine-end removal / fitting of the nozzle ring 8 8. Release the hexagon nuts (90178) from the studs. Remove the two hexagon head screws (61044) and Verbus washers (61043) from the lower section and replace them with two studs (90177).7 Turbine-end removal / fitting of the nozzle ring May 2006 If only the nozzle ring has to be removed. it is possible to dismantle it at the turbine end. ABB Turbo Systems Ltd ABB . Loosen and remove the remaining screws (61044) and Verbus washers (61043) on the gas inlet casing flange (61001). Secure the gas inlet casing with shackle (90195) and a suspension ro pe. . NOTE HZTL2481_EN (TPL73-A. Withdraw the gas inlet casing with the nozzle ring from the gas outlet casing until holder (90175) can be fitted from outside with screws (61044) and Verbus washers (61043). fit hexagon nuts (90178) onto the studs (90177)..

Tighten holder (90175) with screw (61044) and Verbus washer (61043). . Replace the studs (91077) with hexagon head screws (61044) and Verbus washers (61043). Assembly of the nozzle ring Fit nozzle ring and place the holder (90175) over the nozzle ring. Align the gas inlet casing and secure by fitting hexagon nuts (90178) on the studs (90177). use suitable shims and take care to avoid damaging the brackets for the insulation. Remove holder (90175) and screw (61044) and Verbus washers (61043). Remove shackle (90195) and suspension rope from gas inlet casing (51001). Remove hexagon nuts (90178) from studs (90177).7 Page 28 Withdraw gas inlet casing fully and remove.0 ABB Turbo Systems Ltd ABB HZTL2481_EN (TPL73-A. . Secure the insulation on the gas inlet casing (51001). Fit and tighten the gas inlet casing flange to the gas outlet casing with screws (61044) and Verbus washers (61043).. CAUTION Version 2.Operation Manual Disassembly and assembly Turbine-end removal / fitting of the nozzle ring 8 8.80-A. CAUTION Release holder (90175) and remove the nozzle ring with gasket (61050). Insert gasket (61050) in the groove in the gas inlet casing (61001).) May 2006 When positioning the gas inlet casing.. 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.

80-A...8 Page 29 8. .0 ABB Turbo Systems Ltd ABB .) L_00044 The following tightening torques must be maintained for the specified screwed connections: Version 2.Operation Manual Disassembly and assembly Table of tightening torques 8 8.8 Table of tightening torques May 2006 HZTL2481_EN (TPL73-A.

5 50 M22 x 1.0 HZTL2481_EN (TPL73-A. 42059 61036 61037 61044 61056 61059 74026 74027 76002 82005 86505 90458 TPL 73 M16 105 M18 80 M18 160 M18 370 M18 370 M18 370 M18 80 M18 135 M14 – 1) M16 x 1.5 50 M18 x 1..80-A.5 220 M10 30 1) Tighten so that the diffuser can still be moved.8 Page 30 Tightening torques [Nm] Part no. . L_00228 ABB Turbo Systems Ltd ABB Version 2.5 50 M18 x 1.5 150 M10 30 TPL 77 M20 240 M20 80 M20 210 M20 480 M20 480 M20 480 M20 80 M20 175 M16 – 1) M16 x 1.5 150 M10 30 TPL 80 M20 240 M22 80 M22 280 M22 480 M22 480 M22 480 M22 80 M22 235 M18 – 1) M16 x 1..Operation Manual Disassembly and assembly Table of tightening torques 8 8.) May 2006 .

1 Possibilities for emergency repair Lubricating oil leaks are a fire hazard.) If the diesel engine must be capable of operation again as soon as possible after damage to the turbocharger (emergency repair). WARNING The instructions of the engine manufacturer for operation of the engine with locked / isolated turbocharger must be followed precisely in all cases! CAUTION HZTL2481_EN (TPL73-A. the following possibilities are available: Lock the turbocharger rotor Fitting the cover plate Blocking the inlets and outlets Bypass the turbocharger Version 2..0 ABB Turbo Systems Ltd ABB .80-A. ..Operation Manual Taking out of operation temporarily Possibilities for emergency repair 9 9.1 Page 1 9 Taking out of operation temporarily May 2006 9.

0 HZTL2481_EN (TPL73-A. subsequent disassembly of the rotor is unnecessary.. The supply of lubricating oil to the turbocharger must be shut off in the event of a lubricating oil leak on the turbocharger. . Since in these cases operation with a locked rotor is brief and the loads are small.80-A. ABB Turbo Systems Ltd ABB . Once unscrewed. The compressor wheel type ”CV” (for the balancing screw holes) must be noted. NOTE CAUTION During operation of the engine with a locked turbocharger.2 Locking the rotor A locked rotor must be disassembled following turbocharger repair and given an imbalance check.. Otherwise components that are still intact can be damaged by overheating. which are requested by some customers.) 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. Various intermediate rings are provided with the locking device for different compressor wheels. 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). balancing screws must not be screwed in again.2 Page 2 9.Operation Manual Taking out of operation temporarily Locking the rotor 9 9. The space between the locking flange (94003) and the assembly-disassembly device (90020) must be compensated by the intermediate rings (94001 and/or 94002) depending on the version of compressor wheel. CAUTION May 2006 Version 2.

) L_00225 Table of tightening torques [Nm] Part no.0 These operations must be carried out as described in the chapter Disassembly and assembly. .Operation Manual Taking out of operation temporarily Locking the rotor 9 9. 74027 94006 94007 TPL73-A M18 135 M8 25 M8 15 TPL77-A M20 175 M8 25 M8 15 TPL80-A M22 235 M10 45 M10 35 Version 2. NOTE Remove the silencer or air suction branch and the compressor casing internal part together with the wall insert and the diffuser... ABB Turbo Systems Ltd ABB .2 Page 3 Locking rotor with screwed connection May 2006 HZTL2481_EN (TPL73-A.80-A.

80-A. Block the rotor with lock (90480). ABB Turbo Systems Ltd ABB Version 2.0 HZTL2481_EN (TPL73-A.2 Page 4 Remove screw plug (25005).Operation Manual Taking out of operation temporarily Locking the rotor 9 9. Cut a thread (M12 or 1/2") in the existing hole and secure the lock with a screw (A).. Fit studs (74026) as needed for the locking device on the compressor casing. . (74027) to the torques indicated in theTable of tightening torques.) May 2006 Mount the assembly-disassembly device (90020) and tighten nuts ..

NOTE ABB Turbo Systems Ltd ABB .Operation Manual Taking out of operation temporarily Locking the rotor 9 9..2 Page 5 Locking rotor with polygon connection May 2006 HZTL2481_EN (TPL73-A.80-A. .) L_00046 Table of tightening torques [Nm] Part no.0 These operations must be carried out as described in the chapter Disassembly and assembly.. 74027 94006 94007 TPL73-A M18 135 M8 25 M8 15 TPL77-A M20 175 M8 25 M8 15 TPL80-A M22 235 M10 45 M10 35 Version 2.

the balancing screws should be removed from the compressor wheel concerned. eight screws are sufficient Locking rotor with polygon connection HZTL2481_EN (TPL73-A. . Fit locking flange (94003) with the nuts (74027) and then with the screws (94007 / 94006) according to the Table of tightening torques.Operation Manual Taking out of operation temporarily Locking the rotor 9 9.2 Page 6 Remove the silencer or air suction branch and the compressor casing internal part together with the wall insert and the diffuser. For engines with three or four turbochargers. For engines with one or two turbochargers..80-A. Fit partition wall clamp (94005) with screws (90442)..0 May 2006 .) Compressor type CV10 94000_002 ABB Turbo Systems Ltd ABB Version 2. for secure fixing of the locking flange.

. Now push on the other remaining intermediate rings (94001 and/or 94002). Version 2.Operation Manual Taking out of operation temporarily Locking the rotor 9 9. Tighten intermediate rings.80-A. .2 Page 7 Compressor type CV 20 HZTL2481_EN (TPL73-A. CAUTION Push the intermediate rings (94001 and/or 94002) and assembly- disassembly device (90020) onto the locking flange (94003) in the correct sequence.. Now tighten the assembly-/disassembly device (74027) to the compressor casing with the nuts (74027) and the studs to the values shown in the preceding Tightening torques table.) May 2006 94000_003 It must be ensured that all components are clean and free from grease.0 ABB Turbo Systems Ltd ABB . assembly-disassembly device (90020) and locking flange (94003) with the screws (94006) according to the values shown in the preceding Table of tightening torques.

The engine can be operated as naturally aspirated engine according to the instructions of the manufacturer. .. the compensator at the compressor outlet of the damaged turbocharger must be dismantled and the air line on the engine side must be isolated. The engine can be operated as naturally aspirated engine according to the instructions of the manufacturer.4 gas inlets) the engine can be operated up to a maximum of 20% engine load. Particularly with pulse supercharging (turbine casing with more than one gas inlet) the locking device is then subjected to heavy loading. More or less powerful pulses from the exhaust-gas system are applied to the locked rotor. The pressure in the charge-air receiver must not exceed 0.. With pulse supercharging (2. Otherwise the undamaged turbocharger can spin "unloaded" and overspeed.0 ABB Turbo Systems Ltd ABB HZTL2481_EN (TPL73-A. Rotating speed limit nBmax as indicated on the rating plate must not be exceeded..Operation Manual Taking out of operation temporarily Locking the rotor 9 9.5 bar overpressure. The following operating limits should therefore not be exceeded: In systems similar to those with constant pressure (1 gas inlet) the en- gine can be operated up to a maximum of 25% engine load. CAUTION Version 2. The pressure in the charge-air receiver must not exceed 0. . Attention must be paid to the speed of the undamaged turbocharger in all cases.) No further measures are necessary on engines with separate air and exhaust receivers. 4-stroke engine with several turbochargers Separate receivers Common air receiver If the engine is equipped with a common air receiver and separate exhaust-gas receivers.9 bar overpressure. depending on the engine turbocharging system..80-A.2 Page 8 Further measures and information for operation with a locked rotor for 4May 2006 stroke engines 4-stroke engine with one turbocharger No further measures are necessary.

3 Page 9 9.3 Fitting the cover plate May 2006 The cover plate (material: General structural steel.. in accordance with DIN EN 10025-2) must be produced in-house according to the drawing.) 90000_001 Cover plate dimensions [mm] Version 2.Operation Manual Taking out of operation temporarily Fitting the cover plate 9 9.80-A. NOTE HZTL2481_EN (TPL73-A..0 Type TPL 73 TPL 77 TPL 80 B1 B2 B3 50 B4 50 B5 9 9 11 B6 12 12 15 B7 8 B8 94 107 136 ABB Turbo Systems Ltd ABB . .

3 Page 10 Type TPL 73 TPL 77 TPL 80 Ø1 844 1003 1164 Ø2 948 1124 1300 Ø3 905 1075 1248 Ø4 20 22 24 Ø5 28 30 32 Ø6 20 May 2006 Type TPL 73 .0 These operations must be carried out as described in the chapter Disassembly and assembly... .5° α3 24 x 15° 20000_003 Version 2.80 α1 4 x 90° α2 37.Operation Manual Taking out of operation temporarily Fitting the cover plate 9 9.) . NOTE Removing cartridge group ABB Turbo Systems Ltd ABB HZTL2481_EN (TPL73-A.80-A.

CAUTION Version 2.3 Page 11 HZTL2481_EN (TPL73-A. Secure cover plate with spacer sleeves and nuts (61037).80-A. Shut off the supply of lubricating oil to the turbocharger..) May 2006 61000_003 Block the opening in the gas outlet casing with the cover plate. ..Operation Manual Taking out of operation temporarily Fitting the cover plate 9 9.0 ABB Turbo Systems Ltd ABB .

. Rotating speed limit nBmax as indicated on the rating plate must not be exceeded..80-A.3 Page 12 Further measures and information for operation with a turbocharger with cover plate in 4-stroke engines May 2006 4-stroke engine with one turbocharger No further measures are necessary.) Version 2.0 No further measures are necessary on engines with separate air and exhaust receivers.Operation Manual Taking out of operation temporarily Fitting the cover plate 9 9. 4-stroke engine with several turbochargers Separate receivers HZTL2481_EN (TPL73-A. Common receiver CAUTION ABB Turbo Systems Ltd ABB . . 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. The air line must be blocked on the engine side. since the undamaged turbochargers develop a receiver pressure. The engine can be operated as naturally aspirated engine according to the instructions of the manufacturer. The engine can be operated as naturally aspirated engine according to the instructions of the manufacturer.

NOTE HZTL2481_EN (TPL73-A. see the manufacturer's instructions.0 ABB Turbo Systems Ltd ABB . CAUTION Block the compressor casing outlet. gas inlet and gas outlet by fitting cover plates.Operation Manual Taking out of operation temporarily Blocking the inlets and outlets 9 9..4 Page 13 9. .) Version 2.80-A.4 Blocking the inlets and outlets May 2006 Shut off the supply of lubricating oil to the turbocharger.. For information about how to do this.

Operation Manual Taking out of operation temporarily Bypass the turbocharger 9 9. For information about how to do this.5 Bypass the turbocharger Shut off the supply of lubricating oil to the turbocharger.5 Page 14 9. see the manufacturer's instructions. CAUTION May 2006 For engines with one turbocharger only: The connections are ready and pipes for the bypass are to hand. Fit the bypass around the turbocharger..0 .80-A. HZTL2481_EN (TPL73-A. ..) NOTE ABB Turbo Systems Ltd ABB Version 2.

. fit a blind flange between the compressor casing and the charge-air duct. However. If the turbocharger is left mounted on the engine. if the neutralisation factor is higher the turbocharger must be dismantled after laying up. Version 2.0 HZTL2481_EN (TPL73-A. no measures need to be taken in respect of the turbocharger. If the rotor turns due to a draught from the flue. If the Total Acid Number (TAN) is lower than 2 mg KOH/g no special measures need to be taken.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.1 Page 1 10 Mothballing the turbocharger May 2006 10.Operation Manual Mothballing the turbocharger Taking out of operation for up to 12 months 10 10.. The remains of the old engine oil will be washed away and the sensitive bearing parts will be largely protected against corrosion.80-A.) ABB Turbo Systems Ltd ABB . . cleaned and protective oil must be applied to the naked parts. and the engine oil is replaced by a protective oil which is circulated with a pre-lubrication pump prior to laying up.

Operation Manual Mothballing the turbocharger 10 Page 2 Taking out of operation for more than 12 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. NOTE HZTL2481_EN (TPL73-A.. Ensure that the storage area is dry with humidity of 40-70% and free of condensation.) May 2006 Version 2.80-A. Check mothballed turbochargers yearly for corrosion.0 ABB Turbo Systems Ltd ABB . clean and renew the corrosion protection.2 months 10. . disassembly and mothballing of the turbocharger must be done by an official ABB Turbo Systems service station. In the event of rust.

80-A.1 Ordering spare parts When making inquiries or ordering spare parts. If special variants/cases are not addressed in these general instruc- tions. . The parts included in the spare-parts set are only available as part of the complete set. contact an official ABB Turbo Systems Ltd.. NOTE TPL73-A Quantity 2 2 15 15 Description Hexagon head screw Verbus washer Hexagon head screw Verbus washer Hexagon nut Gasket Gasket O-ring gasket O-ring gasket O-ring gasket O-ring gasket Part number 42059 / 42064 42058 / 42063 61044 / 61056 / 61059 61043 / 61057 / 61058 61037 42041 42045 42012 / 76040 77005 / 77006 86506 25011 Version 2. HZTL2481_EN (TPL73-A.Operation Manual Reserve and spare parts Ordering spare parts 11 11.. service station or an ABB agent.0 3 1 1 2 2 1 1 ABB Turbo Systems Ltd ABB .) Spare-parts set Spare-parts set (97070) is required for the work described in this manual. the following data should be specified: Turbocharger type HT number Description and part number Our service stations and agents accept orders for spare parts.1 Page 1 11 Reserve and spare parts May 2006 11.

ABB Turbo Systems Ltd ABB .Operation Manual Reserve and spare parts Ordering spare parts 11 11. ...1 Page 2 TPL77-A Quantity 15 15 3 1 1 2 2 1 1 Description Hexagon head screw Verbus washer Hexagon nut Gasket Gasket O-ring gasket O-ring gasket O-ring gasket O-ring gasket Part number 42059 / 42064 / 61044 / 61056 / 61059 42058 / 42063 / 61043 / 61057 / 61058 61037 42041 42045 42012 / 76040 77005 / 77006 86506 25011 May 2006 Version 2. Dispose of parts that have been exchanged and are no longer usable in a technically and environmentally compatible manner.0 HZTL2481_EN (TPL73-A.80-A.) TPL80-A Quantity 2 2 15 15 3 1 1 2 2 1 1 Description Hexagon head screw Verbus washer Hexagon head screw Verbus washer Hexagon nut Gasket Gasket O-ring gasket O-ring gasket O-ring gasket O-ring gasket Part number 42059 / 42064 42058 / 42063 61044 / 61056 / 61059 61043 / 61057 / 61058 61037 42041 42045 42012 / 76040 77005 / 77006 86506 25011 All spare parts that have been ordered with the turbocharger should be kept complete and serviceable. CAUTION Rusty parts should be carefully cleaned and greased.

-headed nut Turbine diffuser Foot Hex. radial Air suction branch.Operation Manual Reserve and spare parts Directory of part numbers 11 11. axial HZTL2481_EN (TPL73-A.0 ABB Turbo Systems Ltd ABB .2 Directory of part numbers May 2006 The following part numbers and descriptions must be used in ALL correspondence or orders: Turbocharger Part number – 51001 56001 61001 61043 (in spare parts set) 61044 (in spare parts set) 61050 61056 (in spare parts set) Description Cartridge group Gas inlet casing Nozzle ring Gas outlet casing Verbus washer Hexagon headed screw Gasket Hexagon headed screw Verbus washer Verbus washer Hexagon headed screw Hex.) 61057 (in spare parts set) 61058 (in spare parts set) 61059 (in spare parts set) 61037 (in spare parts set) 63000 68000 74027 74000 76000 76040 (in spare parts set) 76080 77000 77005 (in spare parts set) 77006 (in spare parts set) 79000 81000 82000 82000 Version 2. internal part O-ring gasket Safety segment Wall insert O-ring gasket O-ring gasket Diffuser Silencer Air suction branch.80-A.. .-headed nut Compressor casing external part Compressor casing..2 Page 3 11.

) May 2006 Compressor wheel O-ring gasket ABB Turbo Systems Ltd ABB Version 2.2 Page 4 Cartridge group – screwed connection Part number 21000 25000 25005 32001 32101 32102 32104 32105 32106 32107 42001 42002 42011 42012 (in spare parts set) 42015 42041 (in spare parts set) 42045 (in spare parts set) 42058 (in spare parts set) 42059 (in spare parts set) 42063 (in spare parts set) 42064 (in spare parts set) 43001 43005 86505 86506 (in spare parts set) Description Shaft Screw plug Cam bearing Radial bearing.0 . .Operation Manual Reserve and spare parts Directory of part numbers 11 11. compressor side Radial bearing. turbine side Auxiliary bearing Float disc Axial bearing Bearing bush Bearing casing Cowling O-ring gasket Gasket cover Gasket Gasket Verbus washer Hexagon headed screw Verbus washer Hexagon headed screw Partition wall O-ring gasket Speed sensor O-ring gasket HZTL2481_EN (TPL73-A...80-A.

compressor side Radial bearing.80-A.. .0 HZTL2481_EN (TPL73-A..2 Page 5 Cartridge group . turbine side Auxiliary bearing Float disc Axial bearing Bearing bush Bearing casing Cowling O-ring gasket O-ring gasket Gasket cover Gasket Gasket Verbus washer Hexagon headed screw Verbus washer Hexagon headed screw Partition wall O-ring gasket Speed sensor O-ring gasket Version 2.Operation Manual Reserve and spare parts Directory of part numbers 11 11.) ABB Turbo Systems Ltd ABB .polygon connection May 2006 Part number 21000 25000 25008 25009 32001 32101 32102 32104 32105 32106 32107 42001 42002 42011 42012 (in spare parts set) 42015 42041 (in spare parts set) 42045 (in spare parts set) 42058 (in spare parts set) 42059 (in spare parts set) 42063 (in spare parts set) 42064 (in spare parts set) 43001 43005 86505 86506 (in spare parts set) Description Shaft Compressor wheel Threaded pin Ring nut Cam bearing Radial bearing.

80-A.. ..Operation Manual Reserve and spare parts General view of turbocharger 11 11.3 Page 6 11.) .3 General view of turbocharger May 2006 L_00291 ABB Turbo Systems Ltd ABB Version 2.0 HZTL2481_EN (TPL73-A.

) L_00039 ABB Turbo Systems Ltd ABB .Operation Manual Reserve and spare parts General view of cartridge group 11 11..4 Page 7 11. ..4 General view of cartridge group May 2006 Version 2.80-A.0 HZTL2481_EN (TPL73-A.