Turbocharger ABB

ABB Turbo Systems Ltd

Turbocharger
Type TPL69-A30 HT 472190-91
n Mmax 409 tMmax 650
1/s °C
n Bmax 388 tBmax 620

SISO06 1558 kg 35 100 100

Application according to
the Operation Manual
made in Switzerland

Operation Manual
List of contents Page 1
List of contents
April 2006
1 Preliminary remarks
1.1 Purpose of the manual
1.2 Layout and function
1.3 Correct use of the turbocharger
1.4 Essential information
1.5 Abbreviations and symbols
1.6 Turbocharger rating plate
2 Safety
2.1 Basic safety instructions
HZTL2493_EN (TPL 69-A)
2.2 General safety instructions

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

Operation Manual
List of contents Page 2
6 Troubleshooting
6.1 Possible remedies for failures
April 2006
7 Removal and installation
7.1 Turbocharger weights
7.2 Remove the turbocharger
7.3 Installing the turbocharger
8 Disassembly and assembly

8.1 Module weights
8.2 Removing and fitting the filter silencer or air suction branch
8.3 Removing cartridge group
8.4 Axial clearance
8.5 Dismantling and installing the turbine diffuser and nozzle ring
8.6 Installing the cartridge group

8.7 Turbine-end removal / fitting of the nozzle ring
8.8 Table of tightening torques
9 Taking out of operation temporarily

9.1 Possibilities for emergency repair
9.2 Locking the rotor
9.3 Fitting the cover plate
9.4 Blocking the inlets and outlets
9.5 Bypass the turbocharger
10 Mothballing the turbocharger

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

11.1 Ordering spare parts
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11.2 Directory of part numbers

11.3 General view of turbocharger
11.4 General view of cartridge group

Operation Manual
Preliminary remarks 1
Purpose of the manual 1.1 Page 1
1 Preliminary remarks
1.1 Purpose of the manual
April 2006
Operation manual This operation manual will help you to become familiar with your ABB
Turbo Systems Ltd turbocharger and to use it to full effect in its intended
application. You will find important instructions as to the safe, correct, and
economical operation of the turbocharger.
Target group The content of this operation manual is intended for persons such as en-
gineers, marine mechanics and service technicians who are responsible
for the running of the engine and the turbocharger installed thereon.
Content of operation ma- This operation manual includes helpful information on the following topics:
nual
Information on the operation of the turbocharger and ways to prolong
the turbocharger's service life.
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 turbochar-
NOTE ger. 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 sa-
Version 2.4
fety instructions can lead to serious personal injury and damage to e-

WARNING quipment.
In the event of doubt, consult the officer for safety and accident protection
responsible for your area.

Operation Manual
Layout and function 1.2 Page 2
1.2 Layout and function
April 2006
00000_001
1 Filter silencer 8 Nozzle ring

2 Radial plain bearing 9 Turbine wheel
3 Thrust bearing 10 Bearing casing
4 Bearing bush 11 Diffuser
Version 2.4
5 Radial plain bearing 12 Compressor wheel

6 Gas outlet casing 13 Air outlet casing
7 Gas inlet casing

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

components:
April 2006
Turbine
Compressor
These are both mounted on a common shaft.
The exhaust gases from the diesel engine flow through the gas inlet ca-
sing (7) and nozzle ring (8) to the turbine wheel.
The turbine wheel (9) uses the energy contained in the exhaust gas to
drive the compressor wheel (12), whereby the compressor draws in fresh
air, and the compressed air is forced into the cylinders.
The exhaust gases escape through the exhaust pipe which is connected
to the gas outlet casing (6).
The air which is necessary for the operation of the diesel engine and
which is compressed in the turbocharger is drawn through the suction
branch or the filter silencer (1) into the compressor wheel (12). It then
passes through the diffuser (11) and leaves the turbocharger through the
compressor outlet on the air outlet casing (13).
The rotor runs in two radial plain bearings (2/5) which are located in the
bearing bush (4) between the compressor and the turbine. The axial thrust
bearing (3) is on the compressor side.
The plain bearings are connected to a central lubricating oil feed which is
supplied by the oil lubrication circuit of the engine. The oil outlet is always
at the lowest point of the bearing casing (10).
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Operation Manual
Correct use of the turbocharger 1.3 Page 4
1.3 Correct use of the turbocharger
April 2006
This turbocharger supplied by ABB Turbo Systems has been developed
for use on diesel engines to generate the volume of air and the char-
ging pressure required to operate the engine.
NOTE The engine manufacturer has provided ABB Turbo Systems with infor-
mation regarding the intended purpose of the engine, from which the
operating parameters specific to the turbocharger (such as rotating
speeds, temperatures, replacement periods / exchange intervals) have
been derived and are indicated on the rating plate.
If it is used in conjunction with a gas engine, the engine must not be in-
stalled in a potentially explosive environment, and precautionary mea-
sures must be taken to ensure that the machine room as a whole is
classified as not potentially explosive.
Any other usage shall be regarded as a special application which must
be discussed with ABB Turbo Systems. The manufacturer accepts no
liability for other applications. If it is used otherwise, ABB Turbo Sys-
tems reserves the right to reject all claims under the warranty.

Latest technology This turbocharger was built according to state-of-the-art technology and is
operationally safe according to prevailing safety regulations.
Improper operation and maintenance of the turbocharger can result in

danger to life and limb of the user or third parties. In addition, improper
use may cause damage to the machine. The machine may only be ope-
WARNING rated by trained personnel.
Correct use of the turbocharger also includes observation of the as-

sembly, disassembly, operating, maintenance and repair conditions speci-
fied by the manufacturer. Regulations set out by local authorities must be
observed when disposing of the turbine.
Perfect condition The turbocharger must only be installed in a technically perfect condition,
Version 2.4
corresponding to its intended purpose and following the instructions in the

Engine Manufacturers' Manual, and must be operated and used in
compliance with the Operation Manual.
X Defects which could affect safety must be eliminated immediately.
The manufacturer shall not accept liability for damages resulting from u-
nauthorised alterations to the turbocharger.

Operation Manual
Essential information 1.4 Page 5
1.4 Essential information

April 2006
Organisational measures
In addition to this manual, the general, statutory regulations applicable in

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

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

with the turbocharger must be checked regularly with reference to this
manual.
NOTE
X The turbocharger must be shut down immediately in the event of alte-

rations affecting safety or of corresponding operating behaviour. The

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

could compromise safety require the prior approval of ABB Turbo Sys-
tems.
NOTE
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Operation Manual
Original parts and safety
April 2006
Original parts and accessories are especially designed for the turbochar-
ger supplied by ABB Turbo Systems Ltd.
We herewith expressly state that parts and accessories not supplied by

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

Turbo Systems are used, this may have a negative effect on the techni-
cal design specifications of the turbocharger.
WARNING Moreover, the active and/or passive safety of the turbocharger may be
compromised by the use of non-original parts. Note that such improper

use may endanger personnel and the machine.
ABB Turbo Systems shall not be liable for any damage caused by using
non-original parts and accessories.
Qualification of personnel
The turbocharger must only be operated and maintained by trained and

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

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

Version 2.4
ger.

Operation Manual
After-sales service
The Contact Information brochure contains an overview of official ABB

April 2006
Turbo Systems Ltd. service stations worldwide.
Design variants
This operating manual is valid for various turbocharger design variants.
This means that some sections and component descriptions in this opera-
ting manual do not apply to your turbocharger.
Our service stations and agencies will gladly answer your questions rela-
ting specifically to your model.
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 in-
structions. Differences may exist in certain details.
Storage of new turbochargers
New turbochargers supplied by ABB Turbo Systems Ltd. can be stored

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

ces and all accessible areas of the turbocharger.
X To do this, the insulating materials must be removed.
Version 2.4
Repeat the steps described for rust-proofing your turbocharger every 6

months.
NOTE

Operation Manual
Abbreviations and symbols 1.5 Page 8
1.5 Abbreviations and symbols

The following abbreviations are used in this document:
April 2006
Z Prerequisite
X Work step
D Result
9 Positive checkpoint (activity that must be carried out without fail)

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

This note provides suggestions and tips to make work on the turbo-
charger easier.
The note provides further essential information.
NOTE
ABB Turbo Systems
The term used in this manual ABB Turbo Systems signifies ABB Turbo
Systems Ltd.
Official ABB Turbo Systems service station

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

Operation Manual
Turbocharger rating plate 1.6 Page 9
1.6 Turbocharger rating plate

April 2006
L_00012
Operational limits 1 Turbocharger operational limits at engine overload (110 %).

In test rig operation only, unless otherwise agreed with the
engine manufacturer.
2 Turbocharger operational limits in service.
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Recommended replace- 3 Replacement interval for the plain bearings in 1000 h

ment periods / exchange
4 Exchange interval for the compressor in 1000 h (no data for
intervals for turbocharger
100,000 h)
components
5 Exchange interval for the turbine in 1000 h (no data for
100,000 h)

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

7 Field for special design designation
8 Weight of the turbocharger in kg
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9 CE = Conformité Européenne
10 Turbocharger type
11 Series number
12 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 consi-
derably reduce the recommended exchange intervals. In such cases,
we recommend you contact the nearest official service station of ABB
CAUTION Turbo Systems Ltd.
nMmax , tMmax normally apply only when running at overload (110 %) du-
ring 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 inc-
rease the risk of unpredictable component failure.
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Operation Manual
Safety 2
Basic safety instructions 2.1 Page 1
2 Safety
2.1 Basic safety instructions
April 2006
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.
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.
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Operation Manual
Safety 2
General safety instructions 2.2 Page 2
2.2 General safety instructions

The instructions listed here are designed to ensure your safety and to
April 2006
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 sui-
table 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.
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Operation Manual
Safety 2
Special safety instructions 2.3 Page 3
2.3 Special safety instructions

April 2006
Safety when connecting
Work only on those connections for which you are qualified.
Safety when commissioning and during operation
Before starting work, make a visual inspection of the working area.

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

son/department responsible immediately.
In the event of damage, shut down the turbocharger immediately and
secure it against inadvertent or unauthorized use.
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Operation Manual
Safety 2
Safety when cleaning
When handling detergents, solvents, acids and alkalis be sure to observe
April 2006
the respective safety directions on the manufacturers' labels.
Follow directions regarding the environmentally compatible collection, sto-

rage and disposal of these liquids.
Explosion hazard
Cleaning work should be carried out outdoors due to explosion hazard.
If this is not possible, ensure that there is adequate ventilation and air
WARNING circulation. Before beginning cleaning work in confined spaces, extingu-
ish naked flames (including cigarettes!) due to the risk of explosion.
Before cleaning, protect the floor against unintended leaks of oil and
operation materials.

You must wear protective clothing (see section General safety instruc-
tions).
Handle operation materials and detergents with utmost caution.
When handling solvents, wear protective clothing and observe the fol-
lowing rules:
Avoid skin contact with solvents.
Avoid inhaling vapours under all circumstances.
Do not allow solvents to soak protective clothing.
After cleaning, check electric cables for signs of wear or damage.
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Operation Manual
Safety 2
Safety during disassembly, assembly, maintenance and troubleshooting
Follow the prescribed maintenance and inspection schedules for all ad-
April 2006
justment, maintenance and inspection work.

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

personnel. Work on mechanical components, such as bearings or ro-
tors, must only be performed by qualified fitters from an official service
CAUTION station of ABB Turbo Systems.
Safety when taking out of operation or putting into storage
Secure the rotor against turning.

Clean the turbocharger before mothballing.
Wear protective clothing when mothballing the turbocharger.
Keep the work area clean and free of oil and operating materials.
Remove any obstacles lying around on the floor.
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Operation Manual
Safety 2
Safety instructions and hazard 2.4 Page 6

protection
2.4 Safety instructions and hazard protection

Associated hazards may arise during operation of and work on the turbo-
April 2006
charger:
from the turbocharger and its accessories.

from the operating materials used.
due to failure to comply with the safety instructions.
from inadequate performance of maintenance and inspection work.
Mechanical influences
Mechanical influences can cause serious injury or even fatal injury.
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
Version 2.4
Causes sharp edges, pointed parts

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

Operation Manual
Safety 2

protection
Protective measures 9 Wear leather protective gloves

9 Wear close-fitting protective clothing
9 Tie up long hair and beards (wear hair protection)
9 Wear face and eye protection
April 2006
9 Wear protective shoes

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

stances:
Oils
Grease
Coolants
Detergents and solvents

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

Version 2.4
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

Operation Manual
Safety 2

protection
Protective measures 9 Utmost caution when handling process and operation materials
9 Protective clothing must be worn
9 Avoid skin contact and inhalation under all circumstances
9 Ensure that the workroom is properly ventilated
April 2006
9 Observe the hazard indications on the containers for operation and
process materials
9 Immediately after use, seal the hazardous substance container tight
9 Used operation materials must be collected safely in accordance with
the legal provisions, stored separately in suitable containers as presc-
ribed, and disposed of as special waste in a technically and environ-
mentally compatible manner
9 Ensure that containers for new / used operation materials are sealed
tight
9 In the event of leaks or spills immediately apply a suitable absorbent
material and dispose of this in a technically and environmentally com-
patible manner as special waste
Handling insulating materials

9 Ensure that the work area is well ventilated
9 Keep the work area clean
9 Avoid disturbing dust
9 Dust-suppressing tools and processing steps
9 Remove from packaging only in the work area
9 Exercise particular care when removing old insulating materials
9 Dispose of insulating materials in a technically and environmentally
compatible manner
9 If large quantities of dust are created, wear protective glasses
9 Use half or quarter masks
9 Wear suitable work clothing and gloves
9 For sensitive skin, apply moisturising, protective barrier cream
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Operation Manual
Safety 2

protection
Noise
The effects of noise above a legally permitted level can cause personal in-
April 2006
jury.
Personal injury Loss of hearing

Deafness
Impaired hearing
Health disorders such as loss of balance or of consciousness
Cardiac and circulatory disturbances
Causes Machine noise level above 85 dB (A)
Protective measures 9 Wear ear protection
Heat hazard
When the turbocharger is operated, surfaces become very hot.
Personal injury Burns
Causes Missing or incorrectly fitted insulation.
Protective measures 9 Wear leather protective gloves.

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Operation Manual
Safety 2
Warnings on the turbocharger 2.5 Page 10
2.5 Warnings on the turbocharger
April 2006
Warnings that have been applied to turbochargers by ABB Turbo Systems
must not be removed, painted over or obscured with other stickers. Mis-
sing or illegible warnings must be replaced by new warnings.

L_00227
Apply warnings so that they are clearly visible in the positions intended
for that purpose. Please contact an official ABB Turbo Systems service
station for further information.
NOTE
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Operation Manual
Commissioning 3
Oil supply 3.1 Page 1
3 Commissioning
3.1 Oil supply
April 2006
A carefully designed oil supply, which functions under all operating condi-
tions, is an important precondition for trouble-free operation of the turbo-
charger.
Lubrication of the turbocharger is normally carried out with oil from the
engine oil circuit.
Regarding the oil supply, follow the engine manufacturer's instructions

concerning selection of lubricating oil, oil change intervals, oil filtration,
and oil pressure and temperature.
NOTE
3.1.1 Oil filtration
A lubrication oil filter system with a mesh size ≤ 0.050 mm is adequate for
TPL 69-A turbochargers.
3.1.2 Oil pressure
The oil pressure before the bearings (measuring point in blind connection)
must be exactly maintained to ensure fault-free operation.
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Operation Manual
Commissioning 3
Inspection work 3.2 Page 2
3.2 Inspection work

This inspection work includes preventive visual controls, as well as moni-
April 2006
toring and measurement to ensure the correct functioning of the turbo-
charger. These serve as an aid to detecting anomalies before and during
commissioning, thus preventing possible damage to the machine.
The safety instructions must be followed before and during all inspecti-
on work.
3.2.1 Inspection before commissioning
Monitoring equipment X To be checked for correct functioning.
Air filter mat X Inspect for damage.

Lubricating system X Check oil filter for cleanliness before commissioning.
It is urgently recommended that the entire lubrication system be flushed

thoroughly with warm oil using a bypass pipe before commissioning and
after every servicing operation on the lubrication system.
CAUTION We strongly recommend the use of a starting filter when running the
engine in and after every servicing operation on the lubrication system.
X Check oil pressure in oil supply lines.
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Operation Manual
Commissioning 3
Inspection work 3.2 Page 3
3.2.2 Inspection after commissioning

April 2006
Lubricating system X Check oil pressure in oil supply lines.
Charger speed X Measuring
Charger pressure X Measuring
Temperatures X Measure upstream/downstream from turbine, compressor and oil feed

for various engine speeds
Gas, air, and oil lines X After the engine has been started up, check all gas, air and oil lines for
leaks.
Further must be observed:
Lubricants and pastes are liquefied or vaporised during assembly of the

turbocharger and may escape as an oily liquid in the first few hours af-
ter commissioning. If oily liquid continues to escape after this period,
NOTE the cause must be treated as an oil leak and located. The first step in
this process is to check the oil supply to the turbocharger for leaks. If
this is not in order, contact an official ABB Turbo Systems service stati-
on.
X Measure the speed, oil pressure, charging pressure and temperatures

Version 2.4
before and after the turbine and the compressor at various engine
speeds.
X Compare the measured values with those of the inspection report, ta-
king into account the different operating conditions.
3.2.3 Inspection after 100 service hours
Clean or replace lubricating oil filters after the first 100 service hours.

Operation Manual
Commissioning 3
Putting into operation after laying up 3.3 Page 4
3.3 Putting into operation after laying up

If provided X Remove the cover plates (blind flanges) between the compressor ca-
April 2006
sing outlet and charge-air receiver, upstream of the gas inlet,
downstream of the gas outlet.
X Inspect the exhaust pipe before and after the turbine for any combusti-
on residue, clean / remove foreign bodies or residual water.
X Inspect air supply line or filter silencer for any foreign bodies, clean /
remove.
X Start up the turbocharger's engine end oil circulation system.
X Prepare the turbocharger for operation as instructed in the section In-
spection work before commissioning in the chapter entitled Commissi-
oning.
X Start up the turbocharger.

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Operation Manual
Operation 4
Servicing work 4.1 Page 1
4 Operation
4.1 Servicing work
April 2006
Servicing work during operation includes visual checks, monitoring and

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

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

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

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

official ABB Turbo Systems service station.
CAUTION
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Operation Manual
Operation 4
4.1.2 Entries in the machine logbook
April 2006
Monitoring of the machine plant provides information about the perfor-
mance of the turbocharger.
The following operation data and measurement values must be entered

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

Air intake temperature
Exhaust temperature before and after the turbine
Pressure of the charge-air
Pressure drop in the charge-air cooler
Lubricating oil pressure, lubricating oil temperature
If provided Air temperature after compressor and after the charge-air cooler

Speed of the turbocharger
Pressure loss in the air filter
4.1.3 Servicing work according to the engine manufacturer's instructions
Oil filters X With the engine at standstill clean or replace oil filters
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Operation Manual
Operation 4
4.1.4 Servicing work every 8,000 - 12,000 hours

April 2006
X Dismantle the turbocharger

X Clearance measurement
X Clean turbine- and compressor casings and check for any cracks and
erosion / corrosion.
X Clean bearing casing, blow through oil ports
X Clean nozzle ring and check for cracks and erosion
X Inspection and assessment of the rotor and bearing parts
The inspection and assessment of the rotor and bearing parts must be
performed by an official ABB Turbo Systems service station.
NOTE
4.1.5 Servicing work every 35,000 hours
X Dismantle the turbocharger

X Clearance measurement
X Clean turbine- and compressor casings and check for any cracks and
erosion / corrosion.
X Clean bearing casing, blow through oil ports
X Clean nozzle ring and check for cracks and erosion
X Inspection and assessment of the rotor
X Replacement of the plain bearings with original parts from ABB Turbo
Systems
The replacement of the bearing parts as well as the inspection and as-
sessment of the rotor must be carried out by an official ABB Turbo Sys-
tems service station.
NOTE
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Operation Manual
Operation 4
Monitoring 4.2 Page 4
4.2 Monitoring
April 2006
4.2.1 Speed measurement

L_278
1 Bearing casing 6 Connecting cable

2 Axial bearing 7 Line amplifier (option)
3 Guide in the axial bearing 8 Speed transmitter
4 Gasket ring 9 Installation variant of the
speed transmitter
Version 2.4
5 Screw plug

Operation Manual
Operation 4
Monitoring 4.2 Page 5
The speed transmitter system for the measurement of the turbocharger

speed also permits, in conjunction with the corresponding measuring in-
struments and/or monitoring systems (not included in the scope of delive-
ry), a constant remote monitoring of the turbocharger speed. With conti-
April 2006
nuous monitoring of the machine installation, the turbocharger speed can

be used as a suitable control parameter. The line amplifier can be purcha-
sed as an optional addition to the described speed measuring system.
Possible reasons for failure of the speed indicator:
Defects in the speed transmitter, the connecting cable and plug to the
measuring unit, in the measuring unit itself or the power supply.
Turbocharger damage.
Failure of the speed indicator

If the speed indication fails, it is recommended that the engine output
be reduced to idling speed and the engine stopped. The cause of the
CAUTION failure should then be determined.
We recommend that subsequent assembly or replacement of the speed

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

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

Version 2.4
With 4-stroke applications, heavy fouling of the turbine can also be a

cause of an increase in the turbocharger speed.
NOTE

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

Surging of the turbocharger can occur with certain engine operating sta-
April 2006
tes, such as rapid load removal or while manoeuvring. The direction of
flow in the compressor is then briefly reversed. However, sporadic surging
of this kind does not generally affect the safe operation of the turbochar-
ger.
Prolonged or periodic surging

If surging is prolonged or occurs periodically, the following components
may be damaged:
CAUTION - Compressor wheel (vibration fractures, ...)
- Turbine blades (cracks)
- Bearing (overheating)
- Filter silencer

Action to be taken:
The operating safety of the turbocharger is no longer ensured with conti-

nuous or periodically recurring surging. The operator must take immediate
steps to correct the surging together with the closest official ABB Turbo
The components listed above must be inspected for damage by an official
ABB Turbo Systems service station, and replaced in cases of doubt.
Version 2.4

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

Mild, uniform wear around the circumference of rotor components, caused
April 2006
by slight local grazing against adjacent components, is non-hazardous

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

Version 2.4

Operation Manual
Operation 4
Shutting the engine down 4.5 Page 8
4.5 Shutting the engine down
April 2006
Before shutting the engine down, it must be allowed to idle for about 3
minutes longer so that the circulating lubricating oil can dissipate the
heat in the turbocharger bearings.
CAUTION

Version 2.4

Operation Manual
Maintenance 5
Foreword to Maintenance 5.1 Page 1
5 Maintenance
5.1 Foreword to Maintenance
April 2006
Cleaning work includes regular visual checks and washing to ensure the
correct functioning of the turbocharger and its auxiliary appliances.
The external condition and the degree of contamination of the cleaning

points specified in this chapter must be established by visual checks at
the intervals indicated.
The safety instructions must be observed during all cleaning work.
The cleaning points described in the following are:

Filter silencer
Compressor
Turbine and nozzle ring
Version 2.4

Operation Manual
Maintenance 5
Cleaning the filter silencer 5.2 Page 2
5.2 Cleaning the filter silencer
April 2006
5.2.1 Filter silencer with tension band

L_00209
81265 Filter ring (if provided) 81138 Cover panel

81270 Tension band 81005 Screw plug
38271 Trap cover 81006 Gasket
81136 Fleece segment 81135 Filter silencer body
81137 Cover panel A Ribs
E Slide-in module = fleece segment + cover panel installed
Version 2.4

Operation Manual
Maintenance 5
Disassembling and cleaning the filter silencer
X Remove filter ring (81265).

April 2006
If provided
X Rinse the filter ring (81265) with water using detergent or, if very dirty,
soak it. Squeeze out carefully. Rinse in cold water. Avoid high mecha-
nical stress (water jet).
The dirt in the filter ring (81265) depends on the cleanness of the air
drawn in. Wash or replace the filter ring as necessary or every 500 ser-
vice hours.
NOTE
X Loosen the tension bands (81270) on the trap covers (81271) and ca-
refully remove the cover grid (81266) from the connecting strips
(81268).
In the case of a slide-in module (E), the water injection line must first be
removed with a cleaning container attached to on the filter silencer (a-
vailable as option depending on turbocharger type) (see also following
NOTE section Disassembling the cleaning line).
X Pull the slide-in modules (E) out, bend the cover panels (81137 &
81138) open, and then take out the fleece segments (81136).
X Clean fleece segment (81136).
When cleaning, ensure that the fleece segments (81136) are cleaned
only with a mild jet of compressed air and a soft brush or damp cloth.
Otherwise the segments may be damaged or lose their shape.
Heavily soiled fleece segments and filter ring as well should be repla-
Version 2.4
ced with original parts from ABB Turbo Systems.
NOTE

Operation Manual
Maintenance 5
Assembling the filter silencer
April 2006
X Assemble the slide-in modules (E) by inserting fleece segments
(81136) in the cover panels (81137).
X Bend the cover panels (81137) back to their original shape.
X Insert slide-in modules (E) in the grooves in the filter silencer body
(81135).
When assembling, mount the extended cover panels (81138) over the
three ribs (A).
NOTE

The water injection line must now be re-installed with a cleaning contai-
ner attached to on the filter silencer (available as option depending on
turbocharger type) (see also following section Assembling the cleaning
NOTE line).
X Fit tension bands (81270) and tighten them on the trap covers (81271).
If provided X Fit filter ring (81265).

Version 2.4

Operation Manual
Maintenance 5
5.2.2 Removing / installing the cleaning line

April 2006
L_00192
1 Injection pipe 2 Pipe

3 Guide tube
Removing the cleaning line
X Disconnect the line (2) at the injection pipe (1) and remove the screw
coupling from the pipe.
X Withdraw the pipe (2) from the guide tube (3).
Version 2.4

Operation Manual
Maintenance 5
Punch out the guide tube
April 2006
L_00193
X Punch the guide tube (3) out of the caulking with a bolt (diameter = 16
mm) and withdraw it.
Heavily soiled components of the cleaning line must be replaced with

original parts from ABB Turbo Systems.
NOTE
Version 2.4

Operation Manual
Maintenance 5
Installing the cleaning line

April 2006
L_00194
X After fitting the slide-in modules (E), re-fit the guide tube (3) and re-
caulk it.
X Fit the pipe (2) and screw to the injection pipe (1).
Version 2.4

Operation Manual
Maintenance 5
Cleaning the compressor during 5.3 Page 8

operation
5.3 Cleaning the compressor during operation
April 2006
These guidelines for wet cleaning apply exclusively for cleaning with
clean water and are subject to permission for the procedure being ob-
tained from the engine manufacturer.
NOTE
The dirt in the compressor stage (compressor wheel and diffuser) de-
pends on the cleanness of the air drawn in and the operating point.
A deposit of dirt in the flow ducts will be formed if the following substances
are present in the intake air:
Oil or saline mist

Solid combustion residues

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

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

tion by the engine. Contamination of the compressor also increases the
rotor imbalance.
Periodic cleaning of the compressor in operation prevents or retards a se-

vere increase in soiling, but in no way replaces the regular servicing work,
during which the turbocharger is completely dismantled.
Interval between clea- The interval between periodic cleaning depends in large measure on the
nings operating conditions. In general, cleaning should be carried out every 25
to 100 operating hours.
Should the prescribed cleaning intervals prove incompatible with the

Version 2.4
operation of the ship, please contact ABB Turbo Systems.
NOTE

Operation Manual
Maintenance 5

operation
Cleaning method
The compressor is cleaned while operating using the cleaning method

described in the following. This method has been tested and is approved
April 2006
by ABB Turbo Systems:
Wet cleaning
Principle of wet cleaning Water is injected before the compressor wheel via an injection pipe fitted
in the filter silencer or the suction branch in order to clean the compressor
stage in operation.
The water does not act as a solvent in the process, but the deposit is re-
moved by the mechanical impact of the drops. The process is ideal, provi-
ded the soiling is not too advanced.
Due to the danger of corrosion, only clean water may be used, and on
no account salt water. The water should also contain no cooling additi-
ves, which could form deposits in the flow ducts.
CAUTION
Cleaning more than one If several turbochargers are installed on one engine, we recommend clea-
turbocharger compressor ning the turbocharger compressors one after the other.
V-engines For V-engines with several turbochargers on each engine, we recommend

parallel cleaning of the compressors. This cleaning process is faster and
avoids the risk of engine surging.
Register supercharging With register supercharging it must be ensured that both turbocharger
Version 2.4
compressors are cleaned regularly, especially following periods of opera-

tion in the lower performance range.

Operation Manual
Maintenance 5

operation
5.3.1 Wet cleaning the compressor with external pressurised water con-
tainer (XC3)
April 2006
The water feed with the externally mounted dosing vessel is only sui-
table for applications with underpressure upstream of the compressor
wheel (cannot be used for: Blower connected upstream of the
NOTE compressor or high-pressure compressor stage in the case of two-
stage charging).
Operating state preconditions for cleaning compressors with XC3
In order to carry out a successful cleaning procedure that has been

tested and is recommended by ABB Turbo Systems, the following pre-
conditions must be met:

NOTE
Z Engine warm from running (engine under full loading as far as pos-
sible)
Z High turbocharger speed
X Cleaning cycle started according to the following description in Pro-
cedure for wet cleaning with XC3.
Version 2.4

Operation Manual
Maintenance 5

operation
Procedure for compressor wet cleaning with XC3

April 2006
L_00198
X Screw plug
Y Valve lever
Operating the pressure X The Operating state preconditions for cleaning compressors with XC3
water vessel must be met before cleaning can begin.
X Remove the screw plug (X).
X Fill the vessel with pure water.
Version 2.4
X Tighten screw plug (X).

X Actuate valve lever (Y) against the spring and hold it for 10 to 15 se-
conds until all the water has been injected.
X After cleaning, a waiting time of at least 5 minutes is necessary to allow
the turbocharger to dry.

Operation Manual
Maintenance 5

operation
If the cleaning operation is unsuccessful, it can be repeated up to 2 ti-

mes.
April 2006
If cleaning is still unsuccessful after three attempts and the engine ope-
NOTE rating values are unsatisfactory, we recommend that the turbocharger
be checked and cleaned by an official ABB Turbo Systems service sta-
tion.
Cleaning parameters for XC3 for each turbocharger compressor
Turbocharger type Turbocharger Contents of the Water injection

speed dosing vessel time
[dm3] t1 [s]
TPL65-A If possible 0.4 4…15
TPL69-A nBmax

TPL73-A 1.0
TPL77-A 1.0
TPL80-A 2.0
Version 2.4

Operation Manual
Maintenance 5

operation
5.3.2 Wet cleaning compressors with water vessel (XC4)

April 2006
Operating state preconditions for cleaning compressors with XC4

NOTE
Z Engine warm from running (engine under full loading as far as pos-
sible)
Z High turbocharger speed
cedure for wet cleaning with XC4.
Version 2.4

Operation Manual
Maintenance 5

operation
Procedure for compressor wet cleaning with XC4
April 2006
L_00197
1 Cleaning container 2 Pipe

3 Injection pipe 4 Cleaning instructions
5 Cover 6 Valve
If the cleaning container on the filter silencer is used, the detailed clea-
ning instructions provided on the plate (4) fitted to the filter silencer
should be followed.
NOTE
Version 2.4
Use of cleaning container X The Operating state preconditions for cleaning compressors with XC4
must be met before cleaning can begin.
X Open filling cap (5) on cleaning container (1).
X Fill with clean water.
X Screw filling cap (5) back into place.
X Open valve (6) for about 3 minutes.
X Close valve (6) and check that all the water has been sucked out.
X After cleaning, a waiting time of at least 5 minutes with the engine run-
ning must be allowed so that the turbocharger can dry.

Operation Manual
Maintenance 5

operation
If the cleaning operation is unsuccessful, it can be repeated up to 2 ti-

mes.
April 2006
If cleaning is still unsuccessful after three attempts and the engine ope-
NOTE rating values are unsatisfactory, we recommend that the turbocharger
be checked and cleaned by an official ABB Turbo Systems service sta-
tion.
Cleaning parameters for XC4 for each turbocharger compressor
Turbocharger type Turbocharger Contents of the Water injection

speed dosing vessel time
[dm3] t1 [s]
TPL65-A If possible 0.4 4…15
TPL69-A nBmax
TPL73-A 2
TPL77-A
TPL80-A 3
Version 2.4

Operation Manual
Maintenance 5
Cleaning turbine blades and nozzle ring 5.4 Page 16

in operation
5.4 Cleaning turbine blades and nozzle ring in

operation
April 2006
Combustion of heavy fuel oil in diesel engines causes soiling of the turbi-
ne blades and nozzle rings of the turbochargers. The deposits on the tur-
bine components are caused by the following products of combustion:
Soot
Molten ash
Cinders
Incompletely burned fuel
Sodium vanadyl vanadate
Therefore, it is advantageous to use fuels with a low content of ash,

sulphur, sodium and vanadium. The fuel must also be stored, prepared
and handled correctly.

We recommend the use of fuels with a mass ratio of vanadium to sodi-
um less than 3:1, so that the melting point of the sodium vanadyl vana-
date is as high as possible.
NOTE
Soiling increases with time, so that regular and properly performed clea-
ning is important to remove the accumulated deposits.
The charging pressure can rise somewhat if the turbine profile is constric-
ted due to fouled turbine components. Contamination causes loss of per-
formance in the turbine and the engine temperature after the cylinders can
increase. This may mean that the engine output has to be reduced.
A soiled turbine also results in rotor unbalance. Severe soiling can lead to
impermissibly high rotor imbalance.
Experience in operation has shown that despite periodic cleaning during

operation, it is impossible to dispense with overhauls during which the tur-
Version 2.4
bine and nozzle ring are mechanically cleaned. However, if cleaning is

performed correctly and the cleaning system is properly dimensioned, the
intervals between overhauls can be extended.

Operation Manual
Maintenance 5

in operation
Wet cleaning interval The interval between periodic cleaning depends in large measure on the
operating conditions. In general, cleaning should be carried out every 50
to 500 operating hours.
April 2006
Cleaning method
The turbine and nozzle ring are cleaned while operating using the clea-
ning method described in the following. This method has been tested and
is approved by ABB Turbo Systems:
Wet cleaning
The dry cleaning method may be used as an alternative to wet clea-

ning. However, this is not the preferred method, and must be approved
by an official ABB Turbo Systems service station.
NOTE
Principle of wet cleaning
During wet cleaning using droplets of water, the water does not act as a
solvent. Instead, the deposit is removed by the mechanical impact of the
drops.
Due to the danger of corrosion, only clean water may be used, and on
no account salt water. The water should also contain no cooling additi-
ves, which could form deposits in the flow ducts.
CAUTION
Should the prescribed cleaning intervals prove incompatible with the

Version 2.4
operation of the ship, please contact ABB Turbo Systems.
NOTE

Operation Manual
Maintenance 5

in operation
Stabilising and drying time
Cleaning of the turbine-side components begins after engine start or
April 2006
reduction of engine load. The exhaust temperature must not exceed the
value specified in the corresponding cleaning instructions (see the
NOTE respective section Operating state preconditions).
Failure to maintain the prescribed exhaust temperature upstream of the

turbine, and to allow the minimum stabilising time before and between
cleaning procedures and the drying time after cleaning in accordance
CAUTION with the pertinent cleaning instructions will shorten the expected service
life of the components significantly.
V-engines

For V-engines with several turbochargers on each engine, we recommend
parallel cleaning of both turbochargers. This cleaning process is faster
and avoids the risk of engine surging. We recommend conducting tests to
find the most suitable method.
Register supercharging With register supercharging it must be ensured that both turbocharger tur-
bines and nozzle rings are cleaned regularly, especially following periods
of operation in the lower performance range.
Version 2.4

Operation Manual
Maintenance 5

in operation
5.4.1 Wet cleaning the turbine and nozzle ring during operation
April 2006
The maximum exhaust gas temperature specified by the engine manufac-

turer and the TMmax temperature as shown on the turbocharger rating plate
must not be exceeded under any circumstances. During wet cleaning, the
turbine is braked and the turbocharger operates at reduced speed. As a
result, less air is supplied to the engine and the temperature after the en-
gine cylinder and exhaust valve rises.
Operating state preconditions for wet cleaning the turbine and nozzle ring
during operation


NOTE
Z After the engine is started up or the engine load has been reduced to
the lowest possible level
Z Wait 10 to 15 minutes (stabilising time) until the turbine inlet tempe-
rature is stable and less than 430°C.
cedure for wet cleaning
Version 2.4

Operation Manual
Maintenance 5

in operation
Procedure for wet cleaning the turbine and nozzle ring (1 nozzle)
In engines with one turbo-
April 2006
charger (TL 1)

L_00203
In V-engines with two

turbochargers (TL 1 and
2)
Version 2.4
L_00204

Operation Manual
Maintenance 5

in operation
1 Water supply (freshwater only) 6 Other turbochargers

2 Regulating valve 7 Injection pipe
3 Manometer 8 Drainage line
April 2006
4 Air supply with 3-way-valve 9 Drain cock

5 Stainless steel piping 10 Outflow
11 Baffle (optional, can be integrated in the nozzle)
Operating the wet clea- Z The Operating state preconditions must have been fulfilled before
ning system cleaning is begun!
X Check that the water supply (1) is connected, open and reliable.
X Open the drain pipe (8, 9) on the gas outlet casing.
X Connect the water supply (1) to the regulating valve (2) upstream of
the turbocharger.
X 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.
X Inject water for 10 minutes.

X Check whether the exhaust-gas temperature after the turbine drops.
X Close the regulating valve (2) and the 3-way-valve (4).
X Close the drain pipe (8, 9) on the gas outlet casing.
X The water supply connection (1) must be isolated at the regulating val-
ve (2).
X 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 a-

voided, 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 exten-
ded. 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
Version 2.4
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 wa-
ter 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 aggrega-
tes (such as e.g. Boiler) must be clarified by the operator.

Operation Manual
Maintenance 5

in operation
Points to remember when The gas outlet casing must be drained of water via the drain pipe (8)
cleaning when cleaning.
The exhaust-gas temperature after the turbocharger falls significantly
during cleaning (by 50 to 150°C).
April 2006
Outflow can (but need not) take place through the drain-pipe, depen-
ding 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 begin-
ning with lower water pressure or higher engine load.

Version 2.4

Operation Manual
Maintenance 5

in operation
Procedure for wet cleaning the turbine and nozzle ring (2 nozzles)
April 2006
In engines with one turbo-

charger (TL 1)
L_00252
In V-engines with two

turbochargers (TL 1 and
2)
Version 2.4
L_00253

Operation Manual
Maintenance 5

in operation
1 Water supply (freshwater 6 Other turbochargers

only)
2 Regulating valve 7 Injection pipe
April 2006
3 Manometer 8 Drainage line
4 Air supply with 3-way-valve 9 Drain cock
5 Stainless steel piping 10 Outflow
11 Baffle (optional, can be integrated in the nozzle)
Operating the wet clea- Z The Operating state preconditions must have been fulfilled before
ning system cleaning is begun!
X Check that the water supply (1) is connected, open and reliable.
X Open the drain pipe (8, 9) on the gas outlet casing.
X Connect the water supply (1) to the regulating valve (2) upstream of
the turbocharger.
X 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.
X Inject water for 10 minutes.
X Check whether the exhaust-gas temperature after the turbine drops.
X Close the regulating valve (2) and the 3-way-valve (4).
X Close the drain pipe (8, 9) on the gas outlet casing.
X The water supply connection (1) must be isolated at the regulating val-
ve (2).
X 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 a-

voided, 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 exten-
ded. 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
Version 2.4
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 wa-
ter 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 aggrega-
tes (such as e.g. Boiler) must be clarified by the operator.

Operation Manual
Maintenance 5

in operation
Points to remember when The gas outlet casing must be drained of water via the drain pipe (8)
cleaning when cleaning.
The exhaust-gas temperature after the turbocharger falls significantly
during cleaning (by 50 to 150°C).
April 2006
Outflow can (but need not) take place through the drain-pipe, depen-
ding 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 begin-
ning with lower water pressure or higher engine load.
Version 2.4

Operation Manual
Troubleshooting 6
Possible remedies for failures 6.1 Page 1
6 Troubleshooting
6.1 Possible remedies for failures
April 2006
Exhaust temperature too high
Engine output and speed unchanged
Engine Z Malfunction in the injection system

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

X Clean
Z Compressor / turbine soiled

X Clean
Z Exhaust counterpressure too high

X Clean or repair boiler or exhaust silencer
Z Turbine damaged or worn

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

X Clean
Z Insufficient coolant water quantity

X Replenish
Z Coolant water inlet temperature too hot

Version 2.4
X Clean/inspect cooling system
Z Ventilation inadequate
X Improve ventilation

Operation Manual
Troubleshooting 6
Charge-air pressure too low
April 2006
Intake condition normal
Engine Z Air receiver leaking

X Repair
Z Gas line between engine and turbine leaking

X Repair
Z Injection misadjusted
X Correct adjustment
Z Valve control misadjusted

Turbocharger Z Manometer display faulty

X Replace manometer
Z Leak in line to the manometer

X Repair leak
Z Air filter dirty, causing excessive loss of pressure

X Clean
Z Compressor / turbine soiled

X Clean
Z Compressor / turbine damaged

Version 2.4
Z Excessive exhaust counterpressure

X Clean boiler or exhaust silencer

Operation Manual
Troubleshooting 6
Charge-air pressure too high

April 2006
Intake condition normal
Engine Z Malfunction in the injection system

Z Engine output higher than expected

X Check engine output
Z Injection misadjusted
Turbocharger Z Manometer display faulty

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

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

X Clean
Version 2.4
Z Bearing damaged
Z Rotor grazing
Z Foreign bodies in the turbocharger

Operation Manual
Troubleshooting 6
Run-out time too short
Z Turbocharger dirty
April 2006
Turbocharger
X Clean
Z Bearing damaged
Z Rotor grazing
Sluggish start-up
Turbocharger Z Turbocharger dirty

X Clean
Z Bearing damaged

Z Rotor grazing
Lubricating oil pressure too low
Engine Z Oil filter heavily soiled

X Clean
Z Oil pump in the lubricating system defective

X Inspect
Z Manometer provides false reading

X Replace manometer
Turbocharger Z Axial clearance of the rotor too big

Version 2.4

Operation Manual
Troubleshooting 6
Constant surging of the turbocharger
Z Exhaust pressure after the turbine elevated because boiler or exhaust

April 2006
Engine
silencer is dirty
Z Trap dirty
X Clean
Turbocharger Z Charge-air cooler or silencer dirty

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

official ABB Turbo Systems service station.
NOTE
Version 2.4

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

7.1 Turbocharger weights
April 2006

WARNING
Turbocharger parts that are not suspended in accordance with the re-
gulations during disassembly and assembly may fall and can cause se-
rious or even fatal injury.
X Select a suitable rope taking into account the weight of the turbo-
charger parts.
X Cross and loop the rope over the crane hook
X Do not stand under suspended loads.
Version 2.4
L_00082
For the safety of loads on the crane hook, the ropes must be suspen-
ded crossed over each other. See also previous illustration.
WARNING

Operation Manual
Turbocharger weights 7.1 Page 2
Turbocharger complete unit without silencer/air suction branch
Weights [kg] TPL 69
April 2006
1415
Turbocharger complete unit with silencer
Weights [kg] TPL 69

1555
Turbocharger complete unit with air suction branch
Weights [kg] TPL 69

1495
Version 2.4

Operation Manual
Remove the turbocharger 7.2 Page 3
7.2 Remove the turbocharger

X Disconnect all gas, air, and oil lines in accordance with the engine ma-
April 2006
nufacturer’s instructions.
The two oil supply channels in the bearing casing are fitted with one ori-
fice each. In order to obtain the required oil pressure, the ∅ of this orifi-
ce has been individually adjusted by the engine builder. Whenever the-
NOTE se orifices are removed, or if the bearing casing or the complete turbo-
charger is replaced, it is essential to ensure that the orifice with the cor-
rect ∅ is fitted into the oil-conducting oil-inlet channel.
X Remove the insulating shell from the bearing casing.

X Check the lifting equipment.
X Secure lifting equipment to the suspension lugs on the bearing casing.
Observe weight of the turbocharger.
CAUTION
Version 2.4

Operation Manual
Turbocharger without
reinforced suspension lug
April 2006
L_00052
During removal, a turbocharger that is not lifted in compliance with re-

gulations may fall, and can cause serious or even fatal injury.
WARNING Z If the bearing casing is not provided with a reinforced suspension lug
Version 2.4
(lugs are flush with external diameter of the flange), the complete
charger must be secured by the air outlet casing and gas inlet ca-
sing. See following illustration.
charger.

Operation Manual
Turbocharger with reinfor-

ced suspension lug
April 2006
L_00051
X Release the fixing screws on the foot.

X Lift the turbocharger from the engine and place it aside.
If the support for the turbocharger is missing or defective, the turbo-

charger may tip over during installation and removal and can cause se-
WARNING
X Support turbocharger in a suitable location.

X Cover oil connector.
Version 2.4

Operation Manual
Installing the turbocharger 7.3 Page 6
7.3 Installing the turbocharger
April 2006
During installation, a turbocharger that is not lifted in compliance with
regulations may fall, and can cause serious or even fatal injury.
WARNING Z If the bearing casing is not provided with a reinforced suspension

lug, the complete charger must be secured by the air outlet casing
and gas inlet casing.
charger.
X Suspend the complete turbocharger using the two ribs provided for
this purpose.
X Remove cover from the oil connector.

X Check the lifting equipment.

X Secure lifting equipment to the suspension lugs on the bearing casing.
If provided X Secure the lifting equipment to the suspension lugs on the gas inlet ca-
sing (see illustration under Removing the turbocharger).
Observe weight of the turbocharger.
CAUTION
X Mate turbocharger with the engine.

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

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

8.1 Module weights
April 2006

WARNING
Turbocharger parts that are not suspended in accordance with the re-
gulations during disassembly and assembly may fall and can cause se-
charger parts.
X Cross and loop the rope over the crane hook
X Do not stand under suspended loads.
Version 2.4
L_00082
For the safety of loads on the crane hook, the ropes must be suspen-
ded crossed over each other. See also previous illustration.
WARNING

Operation Manual
Modules
April 2006
L_00048
Weights [kg] Description TPL 69

1 Air suction branch, radial 80
2 Air suction branch, axial -
3 Filter silencer 140
4 Compressor casing, internal part 83
5 Wall insert 85
Version 2.4
6 Diffuser 36
7 Compressor casing external part 180
8 Cartridge group 356
9 Turbine diffuser 46
10 Nozzle ring 17

Operation Manual
Compressor casing complete
Weights [kg] TPL 69

204
April 2006
The total weight of the complete internal part of the compressor casing
includes the internal part of the compressor casing, the diffuser and the
wall insert.
NOTE
Version 2.4

Operation Manual
Removing and fitting the filter silencer or 8.2 Page 4

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

suction branch
April 2006
Not all tools are identified with a part number. The identification of the
tools is ensured with the tools list (included in the toolbox).
NOTE
X Disconnect all air ducts in accordance with the engine manufacturer’s

instructions.
X Release nuts (74027) with Verbus washers (74028) and remove the fil-
ter silencer or air suction branch.
81000_003
Filter silencer X Fit ring bolts (90231) on the filter silencer.

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

X Remove the filter silencer.
Assembly X Mount filter silencer or air suction branch with nuts (74027) and Verbus
washers (74028).
X Install insulating shell.
X Fit all air lines in accordance with the engine manufacturer’s instructi-
ons.

Operation Manual
Removing cartridge group 8.3 Page 5
8.3 Removing cartridge group

April 2006
Not all tools are identified with a part number. The identification of the
tools is ensured with the tools list (included in the toolbox).
NOTE
00000_005
X Disconnect the oil lines in accordance with the engine manufacturer's

instructions.
X Release and remove nuts (74027) and discs (74028).
X Remove six studs (74026) in the upper section and and fit four guide
Version 2.4
bolts (90320).
X Leave 2 holes free for fitting the lifting device (90190).
X 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.
X Raise internal part of compressor casing slightly with wall insert and
diffuser, remove guide bolts (90320) and then withdraw.
X Fit support angle (90025).
X Place internal part of compressor casing with wall insert and diffuser on
support bracket and shim.
X Remove O-ring gasket (76040).

Operation Manual
Compressor casing, inter-

nal part
April 2006
L_00047
X Refit the lifting device on the other side of the flange (F).
X 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.
Ensure that the shim does not slip.

Version 2.4
X Check shim and adjust as necessary.

CAUTION

Operation Manual
Diffuser
April 2006
L_00053
Version 2.4
For the turbocharger sizes up to and including TPL 73-A, the diffuser is
positioned by hand and therefore has no threaded holes in the diffuser
for the safety ring bolt 90230.
NOTE
X Remove screws (76002) and diffuser (79000).

Operation Manual
Compressor casing exter-

nal part
April 2006
74000_002
X Secure lifting device (90190) with shackle (90195) to external part of

compressor casing (74000) and attach securely to the crane.
X Loosen nuts (61037), press off external part of compressor casing e-
venly with the three press-off nuts (61037) and remove.
Version 2.4

Operation Manual
Cartridge group
April 2006
L_00054
X Withdraw cable (86515) and unscrew speed measuring transmitter

(86505) with O-ring gasket (86506).
If provided: X Disconnect cable to line amplifier (86525).

Version 2.4
X Remove the three screws (61059) and Verbus washers (61058).

X Check lifting equipment and secure to bearing casing (42001).

Operation Manual
During removal, a cartridge group that is not lifted in compliance with

regulations may fall, and can cause serious or even fatal injury.
April 2006
X Select a suitable rope taking into account the weight of the cartridge
CAUTION
group.
X Press cartridge group down evenly with jack screws (90900) into the
holes provided.
If the turbine blades on the rotor have too little or no clearance, this may
damage the blades and the casing.
X By turning the rotor, check that the turbine blades do not touch the
CAUTION
turbine diffuser.

X Extract the cartridge group and fit supports (90450).
X Cover oil connections.
Work that exceeds the scope of the description in this chapter must on-
ly be performed by a trained fitter from an official ABB Turbo Systems
service station.
CAUTION
Version 2.4

Operation Manual
Axial clearance 8.4 Page 11
8.4 Axial clearance

April 2006
01000_001
Z Axial clearance A must be measured after the cartridge group is remo-

ved and before it is fitted.
X Measure and note the axial clearance A.
Clearance A [mm] TPL 69

0.33 - 0.50
Version 2.4
If the axial clearance (A) is out of tolerance, an official service station of

ABB Turbo Systems must be contacted.
CAUTION

Operation Manual
Dismantling and installing the turbine 8.5 Page 12

diffuser and nozzle ring
8.5 Dismantling and installing the turbine diffuser

and nozzle ring
April 2006
L_00055
X Place clamp (90921) over stud (61036) until it lies flush with the inner
radius of the gas outlet casing.
X Insert extension (A) of torque spanner (B) through the clamp hole and
release the torque of screws (61056) and Verbus washers (61057) in
succession.
X Do not yet remove the screws (61056) and Verbus washers (61057).
Version 2.4

Operation Manual

Removing the turbine

diffuser
April 2006
56001_001
X In the upper section of the turbine diffuser (63000), replace the two
screws (61056) and Verbus washers (61057) with two guide bolts
(90320). Pass the guide bolts through the holes in clamps (90921).
X To secure, fit hexagon nuts (90178).
Version 2.4

Operation Manual

Secure diffuser
April 2006
61000_002
X Before dismantling the turbine diffuser, if possible the nozzle ring

should be secured against falling with a clamping set and a wooden
block.
X Loosen the remaining screws (61056) and Verbus washers (61057).
X Push back the turbine diffuser (63000) with extraction screws (90901)
and withdraw the turbine diffuser until clamp (90921) contacts the hex-
headed nut (90178).
If the nozzle ring is not secured when the turbine diffuser is withdrawn,
it may fall. Note that the nozzle ring (56001) hangs loosely from the po-
sitioning pins.
CAUTION
X Fix turbine diffuser (63000) to the lifting gear and remove.

Version 2.4

Operation Manual

Remove diffuser
April 2006
56001_002
X Fix the holder (90490) on gas outlet casing.

Version 2.4

Operation Manual

April 2006
56001_003
X Draw the nozzle ring (56001) forward, fix the nozzle ring to the lifting
gear and remove.
Version 2.4

Operation Manual

Fitting the turbine diffuser and nozzle ring
X Fit the nozzle ring and the turbine diffuser by reversing the sequence
April 2006
Fitting
for removal.
X Align the nozzle ring with the holes in the gas inlet casing and as-
semble with screws, nuts and bushings.
Smear all screws in and on the gas casings with Anti Scuff Paste 868
from SPANJAARD.
NOTE
service station.
CAUTION
Version 2.4

Operation Manual
Installing the cartridge group 8.6 Page 18
8.6 Installing the cartridge group
April 2006
L_00054
X Remove cover from the oil connector.

X Check the lifting equipment and secure it to the bearing casing (42001)
so that the cartridge group is hanging straight.
X Remove supports (90450) and carefully insert cartridge group.
X Tighten screws (61059) and the Verbus washers (61058) evenly.
Version 2.4
If the blades on the rotor have too little or no clearance, this may dama-
ge the blades and the casing.
X By turning the rotor, check that the turbine blades do not touch the
CAUTION
turbine diffuser.
X Remove lifting equipment.

Operation Manual
If provided: X Connect cable to line amplifier (86525).

April 2006
X Screw in the speed measuring transmitter (86505) with O-ring gasket

(86506) and connect cable (86515).
21000_001
X Secure lifting device (90190) and shackle (90195) to external part of

compressor casing (74000) and attach securely to the crane.
X Assemble the external part of the compressor casing (74000) and se-
cure with nuts (61037).
Before fitting the external part of the compressor casing, screw three
press-off nuts (61037) to the end of the thread on the studs provided for
this purpose.
Version 2.4
NOTE

Operation Manual
April 2006
L_00053
Version 2.4
For the turbocharger sizes up to and including TPL 73-A, the diffuser is
positioned by hand and therefore has no threaded holes in the diffuser
for the safety ring bolt 90230.
NOTE
X Mount diffuser (79000) and secure with the screws (76002).

Operation Manual

April 2006
L_00047
X Attach the lifting device (90190) and shackle (90195) securely to the
back side of flange (F).
X 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.
Version 2.4

Operation Manual
April 2006
00000_005
X Attach the lifting device (90190) and shackle (90195) securely to the
front side of flange (F).
X Fit O-ring gasket (76040).
X Remove the support angle. (90025)
X Fit four guide bolts (90320).
X Carefully place the internal part of the compressor casing together with
the wall insert and the diffuser over the guide bolts.
Version 2.4

Operation Manual
X Measure and note the axial clearance
Clearance A [mm] TPL 69

0.33 - 0.50
April 2006
If the axial clearance (A) is out of tolerance, an official service station of

ABB Turbo Systems Ltd. must be contacted.
CAUTION
X Connect the oil lines and all air lines in accordance with the engine
manufacturer’s instructions.
X Mount filter silencer or air suction branch and secure with nuts (72027)
and Verbus washers (74028).
X Fit insulation again.
service station.
CAUTION
Version 2.4

Operation Manual
Turbine-end removal / fitting of the 8.7 Page 24

nozzle ring
8.7 Turbine-end removal / fitting of the nozzle

ring
April 2006
If only the nozzle ring has to be removed, it is possible to dismantle it at
the turbine end.
NOTE
L_00057
Version 2.4
Disassembly of the nozzle X Remove the insulation on the gas inlet casing (51001).
ring X Secure the gas inlet casing with shackle (90195) and a suspension ro-
pe.
X Remove the two hexagon head screws (61044) and Verbus washers
(61043) from the lower section and replace them with two studs
(90177).
X To secure, fit hexagon nuts (90178) onto the studs (90177).
X Release and remove the remaining flange screws on the gas inlet ca-
sing (61001).

Operation Manual
Turbine-end removal / fitting of the 8.7 Page 25

nozzle ring
X 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).
X Release the hexagon nuts (90178) from the studs.
April 2006
X Withdraw gas inlet casing fully and remove.
When positioning the gas inlet casing, use suitable shims and take care
to avoid damaging the brackets for the insulation.
CAUTION
X Release holder (90175) and remove the nozzle ring.
Assembly of the nozzle X Fit nozzle ring and tighten holder (90175) with screw (61044) and Ver-
ring bus washer (61043).
X Assemble the gas inlet casing and secure by placing hexagon nuts
(90178) on studs (90177).
X Remove holder (90175) and screw (61044) and Verbus washers

(61043).
X Assemble the gas inlet casing with the nozzle ring on the gas outlet
casing.
X Fit and tighten the flange screws.
X Remove hexagon nuts (90178) from studs (90177).
X Replace the studs (91077) with hexagon head screws (61044) and
Verbus washers (61043).
X Remove shackle (90195) and suspension rope from gas inlet casing
(51001).
X Secure the insulation on the gas inlet casing (51001).
service station.
CAUTION
Version 2.4

Operation Manual
Table of tightening torques 8.8 Page 26
8.8 Table of tightening torques
April 2006
L_00044
The following tightening torques must be maintained for the specified

screwed connections:
Version 2.4

Operation Manual
Table of tightening torques 8.8 Page 27
Tightening torques [Nm] Part no. TPL 69

42059 M16
105
April 2006
61036 M16
30
61037 M16
105
61044 M16
260
61056 M16
260
61059 M16
260
74026 M16
30
74027 M16
105
76002 M12
– 1)
82005 M16 x 1.5
50
86505 M18 x 1.5
150
1) Tighten so that the diffuser can still be moved.

Version 2.4
L_00228

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

9.1 Possibilities for emergency repair
April 2006
Lubricating oil leaks are a fire hazard.
WARNING
The instructions of the engine manufacturer for operation of the engine

with locked / isolated turbocharger must be followed precisely in all ca-
ses!
CAUTION
If the diesel engine must be capable of operation again as soon as pos-

sible after damage to the turbocharger (emergency repair), the following
possibilities are available:
Lock the turbocharger rotor

Fitting the cover plate
Blocking the inlets and outlets
Bypass the turbocharger
Version 2.4

Operation Manual
Locking the rotor 9.2 Page 2
9.2 Locking the rotor
April 2006
A locked rotor must be disassembled following turbocharger repair and
given an imbalance check.
CAUTION
The only exceptions are test rig runs up to a maximum of 25% engine
load on new engines with one or a number of turbochargers, which are
requested by some customers. Since in these cases operation with a
NOTE locked rotor is brief and the loads are small, subsequent disassembly of
the rotor is unnecessary.
U Once unscrewed, balancing screws must not be screwed in again.

Various intermediate rings are provided with the locking device for diffe-
rent compressor wheels. The compressor wheel type ”CV” (for the ba-
lancing screw holes) must be noted. The space between the locking
NOTE flange (94003) and the assembly-disassembly device (90020) must be
compensated by the intermediate rings (94001 and/or 94002) depen-
ding on the version of compressor wheel.
During operation of the engine with a locked turbocharger, the lubricati-

on oil system must also remain connected to this turbocharger and tur-
ned on if the gas inlet cannot be blocked (see section Further measures
CAUTION and information for operation with a locked rotor for 4-stroke engines).
Otherwise components that are still intact can be damaged by overhea-
ting.
The supply of lubricating oil to the turbocharger must be shut off in the
event of a lubricating oil leak on the turbocharger.
Version 2.4

Operation Manual
Locking rotor with screwed connection

April 2006
L_00225
Table of tightening tor- Part no. TPL69-A

ques [Nm]
74027 M16
105
These operations must be carried out as described in the chapter Di-

sassembly and assembly.
Version 2.4
NOTE
X Remove the silencer or air suction branch and the compressor casing
internal part together with the wall insert and the diffuser.
X Remove screw plug (25005).

X Fit studs (74026) as needed for the locking device on the compressor
casing.
X Mount the assembly-disassembly device (90020) and tighten nuts
(74027) to the torques indicated in theTable of tightening torques.

Operation Manual
X Block the rotor with lock (90480).

X Cut a thread (M12 or 1/2") in the existing hole and secure the lock with
a screw (A).
April 2006
Version 2.4

Operation Manual
Locking rotor with polygon connection

April 2006
L_00046
Table of tightening tor- Part no. TPL69-A

ques [Nm]
74027 M16
105
94006 M8
Version 2.4
25
94007 M8
15

NOTE

Operation Manual
X Remove the silencer or air suction branch and the compressor casing
internal part together with the wall insert and the diffuser.
April 2006
X Fit partition wall clamp (94005) with screws (90442).
X Fit locking flange (94003) to the compressor wheel hub with the screws
(94007) according to the values shown in the Table of tightening tor-
ques.
D For engines with three or four turbochargers, the balancing screws

should be removed from the compressor wheel concerned.
D For engines with one or two turbochargers, eight screws are sufficient
for secure fixing of the locking flange.
Locking rotor with polygon connection

Compressor type CV10
Version 2.4
94000_002

Operation Manual
Compressor type CV 20
April 2006
94000_003
It must be ensured that all components are clean and free from grease.
CAUTION
X Push the intermediate rings (94001 and/or 94002) and assembly-

disassembly device (90020) onto the locking flange (94003) in the cor-
rect sequence.
X Now push on the other remaining intermediate rings (94001 and/or
94002).
X Tighten intermediate rings, assembly-disassembly device (90020) and
locking flange (94003) with the screws (94006) according to the values
Version 2.4
shown in the preceding Table of tightening torques.

X 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.

Operation Manual
Further measures and information for operation with a locked rotor for 4-
stroke engines
April 2006
4-stroke engine with one turbocharger
No further measures are necessary. The engine can be operated as natu-

rally aspirated engine according to the instructions of the manufacturer.
4-stroke engine with several turbochargers
Separate receivers No further measures are necessary on engines with separate air and ex-
haust receivers. The engine can be operated as naturally aspirated engi-
ne according to the instructions of the manufacturer.

Common air receiver If the engine is equipped with a common air receiver and separate ex-
haust-gas receivers, the compensator at the compressor outlet of the da-
maged turbocharger must be dismantled and the air line on the engine si-
de must be isolated. Otherwise the undamaged turbocharger can spin
"unloaded" and overspeed.
More or less powerful pulses from the exhaust-gas system are applied to
the locked rotor, depending on the engine turbocharging system. Particu-
larly with pulse supercharging (turbine casing with more than one gas in-
let) the locking device is then subjected to heavy loading. The following
operating limits should therefore not be exceeded:
In systems similar to those with constant pressure (1 gas inlet) the en-
gine can be operated up to a maximum of 25% engine load. The pres-
sure in the charge-air receiver must not exceed 0.9 bar overpressure.
With pulse supercharging (2...4 gas inlets) the engine can be operated
up to a maximum of 20% engine load. The pressure in the charge-air
receiver must not exceed 0.5 bar overpressure.
Version 2.4
Attention must be paid to the speed of the undamaged turbocharger in

all cases. Rotating speed limit nBmax as indicated on the rating plate
must not be exceeded.
CAUTION

Operation Manual
Fitting the cover plate 9.3 Page 9
9.3 Fitting the cover plate

April 2006
The cover plate (material: General structural steel, in accordance with

DIN EN 10025-2) must be produced in-house according to the drawing.
NOTE
90000_001
Version 2.4
Cover plate dimensions Type B1 B2 B3 B4 B5 B6 B7 B8

[mm]
TPL 65 13 325 30 30 8 10 6 70
TPL 69 385 8 10 84

Operation Manual
Type Ø1 Ø2 Ø3 Ø4 Ø5 Ø6
TPL 65 616 694 660 16 22 15
TPL 69 726 818 779 18 25
April 2006
Type α1 α2 α3
TPL 65 - 69 4 x 90° 37.5° 24 x 15°
20000_003
Version 2.4

NOTE
X Removing cartridge group

Operation Manual

April 2006
61000_003
X Block the opening in the gas outlet casing with the cover plate.
X Secure cover plate with spacer sleeves and nuts (61037).
Shut off the supply of lubricating oil to the turbocharger.
CAUTION
Version 2.4

Operation Manual
Further measures and information for operation with a turbocharger with
April 2006
cover plate in 4-stroke engines
4-stroke engine with one turbocharger
No further measures are necessary. The engine can be operated as natu-

rally aspirated engine according to the instructions of the manufacturer.
4-stroke engine with several turbochargers
Separate receivers No further measures are necessary on engines with separate air and ex-
haust receivers. The engine can be operated as naturally aspirated engi-
ne according to the instructions of the manufacturer.

Common receiver The air line must be blocked on the engine side, since the undamaged
turbochargers develop a receiver pressure.
The engine can be operated according to the instructions of the engine

manufacturer. Attention must be paid to the speed of the undamaged
turbocharger in all cases. Rotating speed limit nBmax as indicated on the
CAUTION rating plate must not be exceeded.
Version 2.4

Operation Manual
Blocking the inlets and outlets 9.4 Page 13
9.4 Blocking the inlets and outlets

April 2006
CAUTION
X Block the compressor casing outlet, gas inlet and gas outlet by fitting
cover plates.
For information about how to do this, see the manufacturer's instructi-

ons.
NOTE
Version 2.4

Operation Manual
Bypass the turbocharger 9.5 Page 14
9.5 Bypass the turbocharger
April 2006
CAUTION
Z For engines with one turbocharger only:

Z The connections are ready and pipes for the bypass are to hand.
X Fit the bypass around the turbocharger.
For information about how to do this, see the manufacturer's instructi-

ons.
NOTE

Version 2.4

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

months
10 Mothballing the turbocharger

10.1 Taking out of operation for up to 12 months
April 2006
If a turbocharger has to be laid up for up to 12 months, the decision

whether the turbocharger needs special protection or not depends mainly
on the condition of the lubricating oil before laying up.
If the Total Acid Number (TAN) is lower than 2 mg KOH/g no special

measures need to be taken. However, if the neutralisation factor is higher
the turbocharger must be dismantled after laying up, cleaned and protec-
tive oil must be applied to the naked parts.
If the turbocharger is left mounted on the engine, and the engine oil is
replaced by a protective oil which is circulated with a pre-lubrication pump
prior to laying up, no measures need to be taken in respect of the turbo-
charger. The remains of the old engine oil will be washed away and the
sensitive bearing parts will be largely protected against corrosion.
If the rotor turns due to a draught from the flue, fit a blind flange between
the compressor casing and the charge-air duct.
Version 2.4

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

months
10.2 Taking out of operation for more than 12

months
April 2006
If the turbocharger has to be removed from the engine and stored for a
prolonged period of time, disassembly and mothballing of the turbochar-
ger must be done by an official ABB Turbo Systems service station.
Ensure that the storage area is dry with humidity of 40-70% and free of
condensation.
Check mothballed turbochargers yearly for corrosion.

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

Version 2.4

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

11.1 Ordering spare parts
April 2006
When making inquiries or ordering spare parts, the following data should
be specified:
Turbocharger type
HT number
Description and part number
Our service stations and agents accept orders for spare parts.
X If special variants/cases are not addressed in these general instructi-

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

15 Hexagon head screw 42059 / 42064 / 61044 /
61056 / 61059
15 Verbus washer 42058 / 42063 / 61043 /
61057 / 61058
3 Hexagon nut 61037
1 Gasket 42041
Version 2.4
1 Gasket 42045
2 O-ring gasket 42012 / 76040
2 O-ring gasket 77005 / 77006
1 O-ring gasket 86506

Operation Manual
Ordering spare parts 11.1 Page 2
All spare parts that have been ordered with the turbocharger should be
kept complete and serviceable.
April 2006
X Rusty parts should be carefully cleaned and greased.
CAUTION
X Dispose of parts that have been exchanged and are no longer usable
in a technically and environmentally compatible manner.

Version 2.4

Operation Manual
Directory of part numbers 11.2 Page 3
11.2 Directory of part numbers

The following part numbers and descriptions must be used in ALL cor-
April 2006
respondence or orders:
Turbocharger Part number Description

– Cartridge group
51001 Gas inlet casing
56001 Nozzle ring
61001 Gas outlet casing
61043 (in spare parts set) Verbus washer
61044 (in spare parts set) Hexagon headed screw
61037 (in spare parts set) Hex.-headed nut

63000 Turbine diffuser
68000 Foot
74027 Hex.-headed nut
74000 Compressor casing external part
76000 Compressor casing, internal part
76040 (in spare parts set) O-ring gasket
77000 Wall insert
79000 Diffuser
81000 Silencer
82000 Air suction branch, radial
82000 Air suction branch, axial
Version 2.4

Operation Manual
Cartridge group – screwed Part number Description

connection
21000 Shaft
25000 Compressor wheel
April 2006
25005 Screw plug
32001 Cam bearing
32101 Radial bearing, compressor side
32102 Radial bearing, turbine side
32104 Auxiliary bearing
32105 Float disc
32106 Axial bearing
32107 Bearing bush
42001 Bearing casing
42002 Cowling
42011 O-ring gasket

42015 Gasket cover
42041 (in spare parts set) Gasket
43001 Partition wall
43005 O-ring gasket
86505 Speed sensor
Version 2.4

Operation Manual
Cartridge group - polygon Part number Description

connection
21000 Shaft
25000 Compressor wheel
April 2006
25008 Threaded pin

25009 Ring nut
32001 Cam bearing
32101 Radial bearing, compressor side
32102 Radial bearing, turbine side
32104 Auxiliary bearing
32105 Float disc
32106 Axial bearing
32107 Bearing bush
42001 Bearing casing
42002 Cowling
42011 O-ring gasket

42015 Gasket cover
43001 Partition wall
43005 O-ring gasket
86505 Speed sensor
Version 2.4

Operation Manual
General view of turbocharger 11.3 Page 6
11.3 General view of turbocharger
April 2006
Version 2.4
L_00038

Operation Manual
General view of cartridge group 11.4 Page 7
11.4 General view of cartridge group

April 2006
Version 2.4
L_00039

Turbocharger ABB

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ABB Turbo Systems Ltd

SISO06 1558 kg 35 100 100

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List of contents Page 1

2.2 General safety instructions

4.5 Shutting the engine down

ABB Turbo Systems Ltd ABB

List of contents Page 2

8 Disassembly and assembly

HZTL2493_EN (TPL 69-A)

9 Taking out of operation temporarily

10 Mothballing the turbocharger

11 Reserve and spare parts

11.2 Directory of part numbers

ABB Turbo Systems Ltd ABB

Purpose of the manual 1.1 Page 1

 Minimising repair costs and failure times.

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

The instructions included in this operation manual must be followed under

This applies especially to the general and special safety instructions

fety instructions can lead to serious personal injury and damage to e-

ABB Turbo Systems Ltd ABB

Layout and function 1.2 Page 2

1.2 Layout and function

1 Filter silencer 8 Nozzle ring

5 Radial plain bearing 12 Compressor wheel

ABB Turbo Systems Ltd ABB

Layout and function 1.2 Page 3

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

These are both mounted on a common shaft.

to the gas outlet casing (6).

ABB Turbo Systems Ltd ABB

Correct use of the turbocharger 1.3 Page 4

1.3 Correct use of the turbocharger

HZTL2493_EN (TPL 69-A)

Improper operation and maintenance of the turbocharger can result in

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

corresponding to its intended purpose and following the instructions in the

X Defects which could affect safety must be eliminated immediately.

ABB Turbo Systems Ltd ABB

Essential information 1.4 Page 5

1.4 Essential information

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

This also applies to the provision and wearing of personnel protection e-

The safety and risk consciousness of the personnel working on and

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

rations affecting safety or of corresponding operating behaviour. The

Additions and alterations to, and conversions of the turbocharger that

ABB Turbo Systems Ltd ABB

Essential information 1.4 Page 6

Original parts and safety

We herewith expressly state that parts and accessories not supplied by

If components and assemblies not manufactured and tested by ABB

HZTL2493_EN (TPL 69-A)

The turbocharger must only be operated and maintained by trained and

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

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

ABB Turbo Systems Ltd ABB

Essential information 1.4 Page 7

The Contact Information brochure contains an overview of official ABB

Turbo Systems Ltd. service stations worldwide.

This operating manual is valid for various turbocharger design variants.

Storage of new turbochargers

Minimising repair costs and failure times.

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

Work only on those connections for which you are qualified.

Before starting work, make a visual inspection of the working area.

Report any damage or changes in operational performance to the per-

Secure the rotor against turning.

from the turbocharger and its accessories.

Causes sharp edges, pointed parts

Detergents and solvents

Causes Inhalation of toxic gases, smoke and vapours

Skin contact with aggressive fluids