Turbo Manual

Turbocharging
Operation Manual
TPL67-C33
ABB Turbo Systems Ltd

CH 5401 Baden
Type TPL67-C33 HT490908

n Mmax 510 t Mmax 650
1/s °C
n Bmax 510 t Bmax 620
1260 kg 35 50 50
Application according to
Year 2008 the Operation Manual
made in Switzerland
HZTL2488 English

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

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

ABB Turbo Systems AG
Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C33

CH 5401 Baden

1/s °C
1260 kg 35 50 50
made in Switzerland
HZTL2488 English


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C33

CH 5401 Baden

1/s °C
1260 kg 35 50 50
made in Switzerland
HZTL2488 English


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C33

CH 5401 Baden

1/s °C
1260 kg 35 50 50
made in Switzerland
HZTL2488 English


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C33

CH 5401 Baden

1/s °C
1260 kg 35 50 50
made in Switzerland
HZTL2488 English


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C33

CH 5401 Baden

1/s °C
1260 kg 35 50 50
made in Switzerland
HZTL2488 English


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C33

CH 5401 Baden

1/s °C
1260 kg 35 50 50
made in Switzerland
HZTL2488 English


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C33

CH 5401 Baden

1/s °C
1260 kg 35 50 50
made in Switzerland
HZTL2488 English


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C33

CH 5401 Baden

1/s °C
1260 kg 35 50 50
made in Switzerland
HZTL2488 English


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C33

CH 5401 Baden

1/s °C
1260 kg 35 50 50
made in Switzerland
HZTL2488 English


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C33

CH 5401 Baden

1/s °C
1260 kg 35 50 50
made in Switzerland
HZTL2488 English


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C33

CH 5401 Baden

1/s °C
1260 kg 35 50 50
made in Switzerland
HZTL2488 English


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Operation Manual / TPL 67÷71-C
Table of contents Page 1
Table of contents
October 2007
1 Preliminary remarks
1.1 Purpose of 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
2.2 General safety instructions
HZTL2488_EN
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 Expected exchange intervals
4.3 Monitoring
4.4 Surging of turbocharger
Version 2.5
4.5 Contact with rotating parts

4.6 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

Table of contents Page 2
6 Troubleshooting
6.1 Possible remedies for failures
October 2007
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 filter silencer or air suction branch
8.3 Axial clearance
8.4 Removing cartridge group
8.5 Dismantling and installing the turbine diffuser and nozzle ring
8.6 Installing cartridge group
8.7 Table of tightening torques
HZTL2488_EN
9 Taking out of operation at short notice
9.1 Possibilities for emergency repair
9.2 Locking the rotor
9.3 Fit cover plate
9.4 Blocking the inlets and outlets
9.5 Bypass the turbocharger
10 Mothballing turbocharger
10.1 Taking out of operation for up to 12 months
10.2 Taking out of operation for more than 12 months
11 Disposal
11.1 Environmentally compatible disposal of turbocharger
components
Version 2.5
12 Reserve and spare parts

12.1 Ordering spare parts
12.2 Directory of part numbers
12.3 General view of turbocharger
12.4 General view of cartridge group
12.5 Cleaning lines for radial gas inlet casing
12.6 Cleaning lines for axial gas inlet casing

Preliminary remarks 1
Purpose of manual 1.1 Page 1
1 Preliminary remarks
1.1 Purpose of manual
October 2007
Operating manual This operation manual will help you to become familiar with your ABB
Turbo Systems turbocharger and to use it to full effect in its intended ap-
plication. 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 operating 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 identification and avoidance of hazards.
Minimizing repair costs and downtime.
HZTL2488_EN
This operating manual complements and extends existing national regula-

tions on protection against accidents and accident 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 turbo-
NOTE charger. Anyone who works only occasionally on the machine, e.g. dur-
ing installation and maintenance, must also read and fully understand
the operating manual before beginning work.
The instructions included in this operating manual must be followed with-

out fail.
This applies especially to the general and special safety instructions

preceding the respective chapters and in them. Ignoring hazards and
Version 2.5
the safety instructions can lead to serious personal injury and damage
WARNING to equipment.
If in doubt, consult the safety officer responsible and the person account-
able for protection against accidents in your domain.

Layout and function 1.2 Page 2
1.2 Layout and function

TPL 67/71-C
October 2007
1 2 3 4 5 6
10
11
HZTL2488_EN
12
13
L_00219
1 Filter silencer 8 Nozzle ring

2 Radial plain bearing 9 Turbine wheel
3 Thrust bearing 10 Bearing casing
4 Bearing bush 11 Diffusor
5 Radial plain bearing 12 Compressor wheel
6 Gas outlet casing 13 Compressor casing
7 Gas inlet casing
Version 2.5

Layout and function 1.2 Page 3
Working principle
October 2007
The turbocharger is a turbo-machine and consists of the following main

components:
Turbine
Compressor
These are both mounted on a common shaft.
The exhaust gases from the diesel engine flow through the gas inlet cas-
ing (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 to free air through the exhaust manifold which
HZTL2488_EN
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 diffusor (11) and leaves the turbocharger through the
compressor casing (13).
The rotor runs in two radial plain bearings (2/5). One plain bearing is situ-
ated in the bearing bush (4) and one plain bearing is situated in the axial
thrust bearing (3) at the compressor side.
The plain bearings are connected to a central lubricating oil channel which
is fed with oil from the engine lubrication circuit. The oil outlet is always at
the lowest point of the bearing casing (10).
Version 2.5

Correct use of the turbocharger 1.3 Page 4
1.3 Correct use of the turbocharger
October 2007
This turbocharger supplied by ABB Turbo Systems has been developed
for use on diesel engines to generate the volume of air and the charg-
ing pressure required to operate the engine.
NOTE The engine manufacturer has provided ABB Turbo Systems with infor-
mation regarding the intended purpose of the engine, from which the
operating parameters specific to the turbocharger (such as rotating
speeds, temperatures, replacement periods / exchange intervals) have
been derived and are indicated on the rating plate.
If it is used in conjunction with a gas engine, the engine must not be in-
stalled in a potentially explosive environment, and precautionary meas-
ures must be taken to ensure that the machine room as a whole is clas-
sified as not potentially explosive.
Any other use will be regarded as a special application which must first
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.
HZTL2488_EN
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 assem-

bly, disassembly, operating, maintenance and repair conditions specified
by the manufacturer. Disposal regulations set down by local authorities
must be observed.
Perfect condition The turbocharger must only be installed in a technically perfect condition,
Version 2.5
corresponding to its intended purpose and following the instructions in the

Engine Manufacturers' Manual, and must be operated and used in com-
pliance with the Operation Manual.
X Malfunctions / defects which could affect safety must be eliminated

immediately.
The manufacturer shall not accept liability for damages resulting from un-
authorised alterations to the turbocharger.

Essential information 1.4 Page 5
1.4 Essential information

October 2007
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 by stopping the en-

gine in the event of alterations affecting safety or of corresponding op-
erating behaviour. The fault must be reported to the person or depart-
HZTL2488_EN
ment responsible.
Additions and alterations to, and conversions of the turbocharger that

could compromise safety require the prior approval of ABB Turbo Sys-
tems.
NOTE
Version 2.5

Original parts and safety
October 2007
Original parts and accessories are especially designed for the turbo-
charger supplied by ABB Turbo Systems.
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.
HZTL2488_EN
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, may only

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

Version 2.5
charger.

After-sales service
October 2007
The Contact Information brochure contains an overview of official ABB

Turbo Systems. 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 oper-
ating manual do not apply to your turbocharger.
Our service stations and agencies will gladly answer your questions relat-
ing specifically to your model.
Accuracy of illustrations
HZTL2488_EN
The graphics and images shown in this manual are of a general nature
and are intended to assist understanding of the work steps and instruc-
tions. Differences may exist in certain details.
Storage of new turbochargers
New turbochargers supplied by ABB Turbo Systems can be stored without

additional safeguarding measures for a period of 6 months after the deliv-
ery date.
Suitable storage locations are dry rooms where the relative humidity is be-
tween 40-70% and no condensation can form.
X After expiry of the 6 months, all surfaces and accessible areas of the
turbocharger should be sprayed with anticorrosive agent.
X To do this, the insulating materials must be removed.
Version 2.5
Repeat the described measures every 6 months to keep your turbo-

charger free from rust.
NOTE

Abbreviations and symbols 1.5 Page 8
1.5 Abbreviations and symbols

The following abbreviations are used in this document:
October 2007
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-
HZTL2488_EN
charger easier.
The note provides further essential information.
NOTE
Reference to safety instructions

The warnings and cautions are described in the chapter Safety .
CAUTION
ABB Turbo Systems
ABB Turbo Systems Ltd is specified in this manual as ABB Turbo Sys-
tems.
Version 2.5
Official ABB Turbo Systems service station
The term Official ABB Turbo Systems service station used in this manual
signifies ABB turbocharger service stations, that have been tested and
certified by ABB Turbo Systems.

Turbocharger rating plate 1.6 Page 9
1.6 Turbocharger rating plate

October 2007
HZTL2488_EN
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.
Version 2.5
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)

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
October 2007
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 consid-
HZTL2488_EN
erably reduce the recommended exchange intervals. In such cases, we
recommend you contact the nearest official service station of ABB
CAUTION Turbo Systems.
nMmax , tMmax normally apply only when running at overload (110 %) dur-
ing trials on the engine test bed. These limits may also be permitted in
service for special applications. The operation over nMmax , tMmax is not
permitted.
Non-compliance with the recommended exchange intervals may in-
crease the risk of unpredictable component failure.
Version 2.5

Safety 2
Basic safety instructions 2.1 Page 1
2 Safety
2.1 Basic safety instructions
October 2007
The following symbols and terms are used for the safety instructions in
this manual:
Failure to follow work steps and operating instructions marked with this
symbol completely and rigorously may result in serious personal injury
or even fatal accidents.
WARNING Warning signs must be strictly observed at all times.
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.
HZTL2488_EN
Version 2.5

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
October 2007
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
HZTL2488_EN
Protective shoes
Attach individual parts and larger component modules carefully to suit-
able hoists/lifting devices which are in technically perfect condition and
which have adequate load-bearing capacity.
Do not stand under suspended loads.
If welding work is to be carried out above the turbocharger, the air filter
must be covered to prevent damage to the filter mat.
When working on the turbocharger, be aware of the risk of it falling.
For overhead assembly work, use the steps and platforms provided for
this purpose.
Version 2.5

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

October 2007
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.
HZTL2488_EN
In the event of damage, shut down the turbocharger immediately and

secure it against inadvertent or unauthorized use.
Version 2.5

Safety 2
Safety when cleaning
October 2007
When handling detergents, solvents, acids and alkalis be sure to observe
the respective safety directions on the manufacturers' labels.
Follow directions regarding the environmentally compatible collection, 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, extin-
guish naked flames (including cigarettes!) due to the risk of explosion.
Before cleaning, protect the floor against unintended leaks of oil and
operation materials.
You must wear protective clothing (see section General safety instruc-
HZTL2488_EN
tions).
Handle operation materials and detergents with utmost caution.
When handling solvents, wear protective clothing and observe the fol-
lowing rules:
Avoid skin contact with solvents.
Avoid inhaling vapours under all circumstances.
Do not allow solvents to soak protective clothing.
After cleaning, check electric cables for signs of wear or damage.
Version 2.5

Safety 2
Safety during disassembly, assembly, maintenance and troubleshooting

October 2007
Follow the prescribed maintenance and inspection schedules for all ad-
justment, maintenance and inspection work.
Inform operating personnel about special work and repairs before start-
ing.
Ensure that absorbent materials are available to clean up any opera-
tion materials that escape accidentally.
Ensure safe and environmentally-friendly drainage, collection and dis-
posal of operating and auxiliary materials.
Before opening a cover or removing a protective component on the
turbocharger, the engine must have been switched off and must not be
started up again until all parts have been properly re-assembled.
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.
HZTL2488_EN
Safety when taking out of operation or putting into storage
Secure the rotor against turning.

Clean the turbocharger before mothballing.
Wear protective clothing when mothballing the turbocharger.
Keep the work area clean and free of oil and operating materials.
Remove any obstacles lying around on the floor.
Version 2.5

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-
October 2007
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
HZTL2488_EN
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 2.5
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

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)
Wear face and eye protection
October 2007
9
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
HZTL2488_EN
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 2.5
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

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
Ensure that the workroom is properly ventilated
October 2007
9
9 Observe the hazard indications on the containers for operation and
process materials
9 Seal the hazardous substance container tight immediately after use
9 Used operation materials must be collected safely in accordance with
the legal provisions, stored separately in suitable containers as pre-
scribed, and disposed of as special waste in an environmentally com-
patible manner
9 Ensure that containers with 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

Keep the work area clean
HZTL2488_EN
9
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
Version 2.5

Safety 2

protection
Noise
October 2007
The effects of noise above a legally permitted level can cause personal in-
jury.
Personal injury Loss of hearing

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

HZTL2488_EN
Personal injury Burns
Causes Missing or incorrectly fitted insulation.
Protective measures 9 Wear leather protective gloves.

Version 2.5

Safety 2
Warnings on the turbocharger 2.5 Page 10
2.5 Warnings on the turbocharger
October 2007
Warnings that have been applied to turbochargers by ABB Turbo Systems
must not be removed, painted over or obscured with other stickers. Miss-
ing or illegible warnings must be replaced by new warnings.
HZTL2488_EN
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
Version 2.5

Commissioning 3
Oil supply 3.1 Page 1
3 Commissioning
3.1 Oil supply
October 2007
A carefully designed oil supply, which functions under all operating condi-
tions, is an important precondition for trouble-free operation of the turbo-
charger.
Lubrication of the turbocharger is normally carried out with oil from the
engine oil circuit.
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
Oil filtration
HZTL2488_EN
Filtration of the lubricating oil using a filter mesh size ≤ 0.034 mm is ade-
quate for TPL67-C turbochargers and a mesh size ≤0.050 mm for TPL71-
C turbochargers.
This filtration can also be carried out using an additional self-cleaning

fine filter.
NOTE
Version 2.5

Commissioning 3
Oil supply 3.1 Page 2
Oil pressure
October 2007
The oil pressure in front of the bearings must be maintained precisely to
ensure trouble-free operation.
The oil pressure at measuring point M, in blind connection on the turbo-

charger, must be within the following permissible range:
HZTL2488_EN
L_00943
Oil pressure range Oil pressure [bar]

Permissible oil pressure range for 1.3 - 2.5
normal operation
To ensure this oil pressure, a regulating orifice is fitted in the oil inlet of
the turbocharger.
NOTE
Version 2.5

Commissioning 3
Inspection work 3.2 Page 3
3.2 Inspection work

This inspection work includes preventive visual controls, as well as moni-
October 2007
toring and measurement to ensure the correct functioning of the turbo-

charger. These serve as an aid to detecting anomalies before and during
commissioning, thus preventing possible damage to the machine.
The safety instructions must be followed before and during all inspec-
tion work.
3.2.1 Inspection before commissioning
Monitoring equipment X Check for correct functioning.
Air filter mat X Inspect for damage.

HZTL2488_EN
Lubrication system X Check that the oil filter is clean 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.

Version 2.5

Commissioning 3
Inspection work 3.2 Page 4
3.2.2 Inspection after commissioning
October 2007
Lubrication system X Check oil pressure in oil supply lines.
Charger speed X Measure
Charger pressure X Measuring
Measure temperatures X upstream/downstream from turbine, compressor and oil feed for vari-
ous engine speeds
Gas, air, and oil lines X Check all gas, air, and oil lines for leaks after the engine has been star-
HZTL2488_EN
ted up.
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 further oily liquid continues to appear after this pe-
NOTE riod, an oil leak must be suspected. Then, the first step is to check for
leakage of the oil supply to the turbocharger. If something wrong is de-
tected, contact an official ABB Turbo Systems service station.
X Measure the speed, oil pressure, charging pressure and temperatures

before and after the turbine and the compressor at various engine
Version 2.5
speeds.
X Compare the measured values with those of the inspection report, tak-
ing into account the different operating conditions.
3.2.3 Inspection after 100 service hours
Clean or replace lubricating oil filters after the first 100 service hours.

Commissioning 3
Putting into operation after laying up 3.3 Page 5
3.3 Putting into operation after laying up

If they are present X Remove the cover plates (blind flanges) between the compressor cas-
October 2007
ing outlet and the charge-air receiver, upstream of the gas inlet, down-
stream of the gas outlet.
X Inspect the exhaust-gas duct before and after the turbine for any com-
bustion residue, clean / remove foreign bodies or residual water.
X Inspect air supply line or filter silencer for any foreign bodies, clean /
remove.
X Start up the turbocharger's engine end oil circulation system.
X Prepare the turbocharger for operation as instructed in the section In-
spection work before commissioning in the chapter entitled Commis-
sioning.
X Commission the turbocharger.
HZTL2488_EN
Version 2.5

Operation 4
Servicing work 4.1 Page 1
4 Operation
4.1 Servicing work
October 2007
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.
HZTL2488_EN
CAUTION
4.1.1 Servicing work every 25 to 50 hours
Operation data X Record

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

official ABB Turbo Systems service station.
CAUTION
Version 2.5

Operation 4
4.1.2 Entries in the machine logbook
October 2007
Monitoring of the machine plant provides information about the perform-
ance of the turbocharger.
The following operation data and measurement values must be entered

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

Air intake temperature
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
HZTL2488_EN
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
4.1.4 Servicing work every 4000 - 6000 hours
Certain specific operating conditions (which mainly depend on the opera-

tion profile and fuel quality) may make it necessary to carry out intermedi-
ate mechanical cleaning before the standard recommended bearing and
component inspection. Whether or not intermediate mechanical cleaning
is necessary is usually determined by the operator based on engine op-
eration parameter deviations. The following components may be affected: Version 2.5
nozzle ring
turbine blades
compressor wheel
insert wall
air diffuser

Operation 4
4.1.5 Inspection work every 12,000 hours

October 2007
X Remove filter silencer or air suction branch

X Clean filter silencer as far as accessible, and inspect for damage
X Remove internal part of compressor casing
X Check clearance A (axial bearing play)
X Clean accessible parts (compressor wheel, diffuser, wall insert), and
inspect for damage
X Visual check of the turbine parts (nozzle ring, turbine diffuser/cover
ring, turbine blades) for possible soiling and damage.
X Refit internal part of compressor casing
X Re-install filter silencer or air suction branch.
For the application with HFO (heavy fuel oil) the reconditioning of tur-
bine blades may already be necessary from 12,000 service hours (see
HZTL2488_EN
also Chapter Expected exchange intervals).

NOTE
This inspection work and checks must be carried out by an official ser-
vice station of ABB Turbo Systems.
NOTE
4.1.6 Servicing work every 36,000 hours
X Dismantle the turbocharger

X Clearance measurement
X Clean turbine and compressor casings and check for any cracks and
erosion / corrosion
Version 2.5
X Clean bearing casing, blow through oil ports

X Clean nozzle ring and inspect for cracks and erosion
X Inspect and assess rotor
X Replace the plain bearings with original parts from ABB Turbo Systems
Replacement of the bearing parts as well as inspection and assessment

of the rotor must be carried out by an official ABB Turbo Systems ser-
vice station.
NOTE

Operation 4
Expected exchange intervals 4.2 Page 4
4.2 Expected exchange intervals

Expected exchange inter- GAS / MDO HFO
October 2007
vals [h]
Gas inlet casing 50'000…100’000 25'000…50’000
Gas outlet casing 50'000…100’000 35'000…100’000
Nozzle ring 35'000…50’000 25'000…50’000
Turbine diffuser / cover 35'000…50’000 25'000…50’000
ring
Turbine blades - ≥ 12’000
(due to wear)
Other housings 100’000 100’000
Rotor components See rating plate for information
Axial bearing compo- 36’000 36’000
nents
Radial bearing compo- 24'000…36’000 24'000…36’000
nents
HZTL2488_EN
GAS = Gas engine
MDO = Marine Diesel Oil
HFO = Heavy Fuel Oil
The values indicated are for guidance only and are not guaranteed val-
ues. These values may vary significantly for example due to inadequate
servicing, frequent emergency stoppages as well as through the use of
NOTE fuel or lubricating oil of inferior quality.
Version 2.5

Operation 4
Monitoring 4.3 Page 5
4.3 Monitoring
October 2007
4.3.1 Speed measurement

HZTL2488_EN
L_278
1 Bearing casing 6 Connecting cable

2 Axial bearing 7 Line amplifier (optional)
3 Guide in the axial bearing 8 Speed transmitter
4 Gasket ring 9 Installation variant of the
speed transmitter
Version 2.5
5 Screw plug

Operation 4
Monitoring 4.3 Page 6
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 deliv-
October 2007
ery), a constant remote monitoring of the turbocharger speed. With con-
tinuous monitoring of the machine installation, the turbocharger speed can
be used as a suitable control parameter. The line amplifier can be pur-
chased as an option to the described speed measuring system.
Possible reasons for failure of the transmitter system are:
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
HZTL2488_EN
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 turbocharger speed can signify:
Damaged turbine or bearing

Defects in the connected pulse charging cylinders
Severe soiling of the turbine
Version 2.5
Increased turbocharger speed

With 4-stroke applications, heavy fouling of the turbine can also be a
cause of an increase in the turbocharger speed.
NOTE
We recommend that subsequent assembly or replacement of the speed
transmitter system should only be carried out by an official service sta-
tion of ABB Turbo Systems Ltd.

Operation 4
Surging of turbocharger 4.4 Page 7
4.4 Surging of turbocharger

Surging of the turbocharger can occur with certain engine operating sta-
October 2007
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 turbo-
charger.
Prolonged or periodic surging

If surging is prolonged or occurs periodically, the following components
may be damaged:
CAUTION - Compressor wheel (vibration fractures, ...)
- Turbine blades (cracks)
- Bearing (overheating)
- Filter silencer
HZTL2488_EN
Action to be taken:
The operating safety of the turbocharger is no longer ensured with con-
tinuous or periodically recurring surging. The operator must take imme-
NOTE diate steps to correct the surging together with the closest official ABB
Turbo Systems service station.
The components listed above must be inspected for damage by an offi-
cial ABB Turbo Systems service station, and replaced in cases of
doubt.
Version 2.5

Operation 4
Contact with rotating parts 4.5 Page 8
4.5 Contact with rotating parts

Slight, uniform wear around the periphery of rotor components, caused by
October 2007
their just touching adjacent components locally, is not hazardous and
permissible. This slightly reduces the length of the blades in the compres-
sor and/or the turbine. Certain tolerances must be observed to avoid a
significant loss of efficiency.
X A check on dimensions must be carried out by an official ABB Turbo

Systems service station.
HZTL2488_EN
Version 2.5

Operation 4
Shutting the engine down 4.6 Page 9
4.6 Shutting the engine down

October 2007
Before shutting the engine down, it must be allowed to idle for 5 to 10

minutes longer so that the circulating lubricating oil can dissipate the
heat in the turbocharger bearings.
CAUTION
HZTL2488_EN
Version 2.5

Maintenance 5
Foreword to Maintenance 5.1 Page 1
5 Maintenance
5.1 Foreword to Maintenance
October 2007
Maintenance and servicing work involves regular visual checks and clean-
ing to ensure that the turbocharger and its attached units function trouble-
free.
The external condition and how dirty the cleaning points specified in
this chapter are, must be established by visual checks at the specified
intervals.
The safety precautions must be observed during all maintenance and
servicing work.
The cleaning points described in the following are:

HZTL2488_EN
Filter silencer
Compressor
Turbine and nozzle ring
Version 2.5

Maintenance 5
Cleaning the filter silencer 5.2 Page 2
5.2 Cleaning the filter silencer
October 2007
5.2.1 Filter silencer with tension band
HZTL2488_EN
L_00209
81265 Filter ring (if provided) 81138 Cover panel

81270 Tension ring 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 2.5

Maintenance 5
Disassembling and cleaning filter silencer

October 2007
If provided X Remove filter ring (81265).

X Rinse filter ring (81265) with water using detergent or, if very dirty, soak
it. Squeeze out carefully. Rinse in cold water. Avoid high mechanical
stress (water jet).
The dirt in the filter ring (81265) depends on how clean the drawn-in air
is. Wash or replace the filter ring as necessary or every 500 service
hours.
NOTE
X Loosen the tension bands (81270) on the trap covers (81271) and ca-
refully remove the cover grid (81266) from the connecting strips
(81268).
HZTL2488_EN
In the case of a slide-in module (E) when a cleaning container is at-

tached to the filter silencer (available as option depending on turbo-
charger type), the water injection line must first be removed (see also
NOTE following section Disassembling 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.
Replace heavily contaminated fleece segments and filter ring with origi-
Version 2.5
nal parts from ABB Turbo Systems.
NOTE

Maintenance 5
Mounting filter silencer
October 2007
X Assemble slide-in modules (E) by inserting fleece segments (81136) in
cover plates (81137).
X Bend the cover panels (81137) back to their original shape.
X Insert slide-in modules (E) in grooves in filter silencer body (81135).
When assembling, mount the extended cover panels (81138) over the
three ribs (A).
NOTE
When the cleaning container is fitted to the filter silencer (available as
HZTL2488_EN
option depending on turbocharger type), the water injection line must be
re-installed (see also following section Assembling cleaning line).
NOTE
X Fit tension bands (81270) and tighten on trap covers (81271).
If provided X Fit filter ring (81265).
Version 2.5

Maintenance 5
5.2.2 Filter silencer and connecting rod

October 2007
HZTL2488_EN
L_00185
81265 Filter ring (if provided) 81136 Fleece segment

81269 Connecting rods 81137 Cover panel
81266 Cover grids 81135 Filter silencer body
Version 2.5
81272 Screw 81273 Locknut

E Slide-in module = fleece segment + cover panel
Disassembling and cleaning filter silencer
If provided X Remove filter ring (81265).

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

Maintenance 5
ak it. Squeeze out carefully. Rinse in cold water. Avoid high mechani-
cal stress (water jet).
October 2007
The dirt in the filter ring (81265) depends on how clean the drawn-in air
is. Wash or replace the filter ring as necessary or every 500 service
hours.
NOTE
X Loosen and remove locknuts (81273).

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

tached to the filter silencer (available as option depending on turbo-
charger type), the water injection line must first be removed (see also
HZTL2488_EN
NOTE following section Disassembling cleaning line).
X Withdraw slide-in modules (E), bend open cover panels (81137) and
then take out 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.
Replace heavily contaminated fleece segments and filter ring as well as

damaged connecting rods with original parts from ABB Turbo Systems.
NOTE
Version 2.5

Maintenance 5
Mounting filter silencer

October 2007
X Assemble slide-in modules (E) by inserting fleece segments (81136) in

cover plates (81137).
X Bend cover panels (81137) back to their original shape.
X Insert slide-in modules (E) in the grooves in the filter silencer body
(81135).
When the cleaning container is fitted to the filter silencer (available as

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

X Push the connecting rods (81269) through the clips on the cover grids
(81266).
HZTL2488_EN
If the connecting rods (81269) are not located correctly in their recesses
on the filter silencer body (81135), the cover grid (81266) can twist and
shift. This can allow foreign bodies and dirt to get into the compressor.
CAUTION
Version 2.5
L_00232

Maintenance 5
October 2007
L_00234
X Connect the connecting rods (81269) with the screws (81272). While
tightening the screws (81272), ensure that the connecting rods (81269)
HZTL2488_EN
are located correctly in the recesses in the filter silencer body (81135).
Now tighten the screws (81272) alternately to the following max. tight-
ening torque:
Screw Tightening torque

81272 20 Nm
X Fit locknuts (81273) onto screw (81272) and tighten to the following
torque:
Locknut Tightening torque

81273 40 Nm
If provided X Fit filter ring (81265).

Version 2.5

Maintenance 5
Cleaning the compressor during 5.3 Page 9

operation
5.3 Cleaning the compressor during operation

October 2007
These guidelines for wet cleaning apply exclusively for cleaning with
clean water and are subject to permission for the procedure being ob-
tained from the engine manufacturer.
NOTE
The contamination of the compressor stage (compressor wheel and dif-

fuser) depends on the cleanness of the air drawn in.
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
HZTL2488_EN
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 considerably on the op-
nings erating conditions. In general, cleaning should be carried out every 25 to
100 operating hours.
Should the prescribed cleaning intervals prove incompatible with the

Version 2.5
operation of the engine, please contact ABB Turbo Systems.
NOTE

Maintenance 5

operation
Cleaning method
The compressor is cleaned while operating using the cleaning method de-
October 2007
scribed in the following. This method has been tested and is approved by
ABB Turbo Systems:
Wet cleaning
Principle of wet cleaning Water is injected before the compressor wheel via an injection pipe fitted
in the filter silencer or the suction branch in order to clean the compressor
stage in operation.
The water does not act as a solvent in the process, but the deposit is re-
moved by the mechanical impact of the drops. The process is ideal, pro-
vided the soiling is not too advanced.
HZTL2488_EN
Due to the danger of corrosion, only clean water may be used, and on
no account salt water. The water should also contain no cooling addi-
tives, which could form deposits in the flow ducts.
CAUTION
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.
Sequential charging With sequential charging it must be ensured that both turbocharger com-
pressors are cleaned, especially following periods of operation in the
lower performance range.
Version 2.5

Maintenance 5

operation
5.3.1 Wet cleaning the compressor with external pressurised water con-
tainer (XC3)
October 2007
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 loading as full as possible
Z High turbocharger speed
X Cleaning cycle started according to the following description in Pro-
cedure for wet cleaning with XC3.
Procedure for compressor wet cleaning with XC3

HZTL2488_EN
Version 2.5
L_00198
X Screw plug
Y Valve activator

Maintenance 5

operation
Operating the pressurised X The Operating state preconditions for cleaning the compressor with
water container XC3 must be met before cleaning can begin.
X Remove screw plug (X).
October 2007
X Fill container with clean water.
X Screw screw plug (X) back in.
X Actuate valve lever (Y) against the spring and hold for 10 to 15 sec-
onds, until all the water has been injected.
X After cleaning, the turbocharger must be allowed to dry for at least 5
minutes before any further activity.
If the cleaning operation was not successful, it can be repeated up to 2

times.
If cleaning is still not successfulafter three attempts and the engine op-
NOTE erating values are unsatisfactory, we recommend that you have the tur-
bocharger checked and cleaned by an official ABB Turbo Systems ser-
vice station.
HZTL2488_EN
Cleaning parameters per turbocharger compressor
Turbocharger type Turbocharger Contents of dos- Water

speed ing vessel injection time
[dm3] t1 [s]
TPL 67/71-C As far as possible 0.4 4 ... 15
nBmax
Version 2.5

Maintenance 5
Cleaning turbine blades and nozzle ring 5.4 Page 13

in operation
5.4 Cleaning turbine blades and nozzle ring in

operation
October 2007
Combustion of heavy fuel oil in diesel engines causes soiling of the tur-
bine blades and nozzle rings of the turbochargers. The deposits on the
turbine 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, sul-

phur, sodium and vanadium. The fuel must also be stored, prepared and
handled correctly.
HZTL2488_EN
We recommend the use of fuels with a mass ratio of vanadium to so-

dium less than 3:1, so that the melting point of the sodium vanadyl va-
nadate is as high as possible.
NOTE
Soiling increases with time, so that regular and properly performed clean-
ing is important to remove the accumulated deposits.
The charging pressure can rise somewhat if the turbine profile is con-
stricted due to fouled turbine components. Contamination causes loss of
performance in the turbine and the engine temperature after the cylinders
can increase. This may mean that the engine output has to be reduced.
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 2.5
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.

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

operation of the ship, please contact ABB Turbo Systems.
NOTE
Stabilising and drying time

Version 2.5
Cleaning of the turbine-side components begins after engine start or

reduction of engine load. The exhaust temperature must not exceed the
value specified in the corresponding cleaning instructions (see the re-
NOTE spective section Operating state preconditions).

Maintenance 5

in operation
Failure to maintain the prescribed exhaust temperature upstream of the

turbine, and to allow the minimum stabilising time before and between
October 2007
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.
HZTL2488_EN
Version 2.5

Maintenance 5

in operation
5.4.1 Wet cleaning of the turbine and nozzle ring during operation up to
October 2007
TTE 430°C
The maximum exhaust gas temperature specified by the engine manufac-

turer and the TMmax temperature shown on the turbocharger rating plate
must not be exceeded under any circumstances. During wet cleaning the
turbine delivers less power to the shaft and the turbocharger speed sinks.
As a result, less air is supplied to the engine and the temperature after the
engine cylinder and exhaust valve rises.
For the partial load cleaning the following described operating state of
the turbine is a precondition.
NOTE
HZTL2488_EN
Operating state preconditions for wet cleaning up to TTE 430°C
In order to carry out a successful cleaning procedure that has been

tested and is recommended by ABB Turbo Systems, the following pre-
conditions must be met:
NOTE
Z After the engine is started up or the engine load has been reduced to
the lowest possible level
X The best cleaning effect is achieved at a loading level of 20 to 30%.
Z Wait 10 to 15 minutes (stabilising time) until the temperature at the

turbine inlet is stable below 430°C.
X Start the cleaning cycle according to the following description in
Procedure for wet cleaning
Version 2.5

Maintenance 5

in operation
Layout of cleaning pipes

October 2007
HZTL2488_EN
L_00200
1 Water supply (freshwater 6 Additional turbocharger

only)
2 Regulating valve 7 Injection pipe
3 Manometer 8 Drainage line
4 Air supply with 3-way-valve 9 Drain cock
5 Water pipe (stainless steel) 10 Outflow
Version 2.5

Maintenance 5

in operation
Wet cleaning turbine and nozzle ring during operation up to TTE 430°C
October 2007
X The operating prerequisites must be met before cleaning can begin!
X Make sure water supply (1) is connected, turned on and flows con-
stantly.
X Open drain pipe (8,9).
X Open 3-way-valve (4) first, then open regulating valve (2) slowly until
pressure gauge (3) indicates following pressure in [bar]:
Type of gas inlet casing No. of injection nozz- Essential

les water pressure [bar]
Single inlet 1 to 2 2.0
Single inlet 3 2.5
Multiple inlets 2 to 4 2.0
X Inject water for 10 minutes. Check whether exhaust gas temperature

drops turbine.
X Close the regulating valve (2).
HZTL2488_EN
X This completes the cleaning process. Make sure water supply is dis-
connected from gas inlet casing.
X Switch over 3-way-valve (4) for water supply to blow-out mode with
compressed air.
X Close drain hole (at 8) above drain pipe (8,9).
X After cleaning, wait at least 10 minutes with engine running to allow
turbocharger to dry.
Version 2.5

Maintenance 5

in operation
Repeating cleaning cycles immediately after each other must be avoi-

ded as this can lead to high mechanical loading and consequently to a
October 2007
reduction in the service life of the components.

NOTE If the cleaning process is unsuccessful, the time of this can be ex-
tended. 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 in-
stalled and be open during the cleaning. If no drainage system is pre-
sent, the injected quantity of water can be controlled with a flow meter
in the water supply. What maximum quantity of water is permitted in in-
dividual cases, is to be established with an official ABB Turbo Systems
service station. The influence of the cleaning water on the peripheral
aggregates (such as e.g. Boiler) must be clarified by the operator.
Points to remember when The gas outlet casing should be drained via the drainage line (8) during
cleaning cleaning.
The exhaust-gas temperature after the turbocharger falls significantly
HZTL2488_EN
during cleaning (by 50 to 150°C).

Outflow can (but need not) take place through the drain-pipe, depend-
ing on the engine load. This outflow might not start for 2 - 3 minutes, or
it may not occur at all.
If draining is not carried out, the turbocharger speed and / or gas inlet
temperature must be monitored closely during the washing operation. If
the load is too low, water can collect in the gas outlet casing. Signs of
this are a sudden fall in the turbocharger speed or very rapid increase
in the gas inlet temperature. In either of these cases, the wet cleaning
operation must be terminated and the wet cleaning cycle begun again
with a lower water pressure or higher engine loading.
Version 2.5

Troubleshooting 6
Possible remedies for failures 6.1 Page 1
6 Troubleshooting
6.1 Possible remedies for failures
October 2007
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
HZTL2488_EN
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 2.5
X Clean/inspect cooling system
Z Ventilation inadequate
X Improve ventilation

Troubleshooting 6
Charge-air pressure too low
October 2007
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

HZTL2488_EN
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 2.5
Z Excessive exhaust counterpressure

X Clean boiler or exhaust silencer

Troubleshooting 6
Charge-air pressure too high

October 2007
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

HZTL2488_EN
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 2.5
Z Bearing damaged
Z Rotor grazing
Z Foreign bodies in the turbocharger

Troubleshooting 6
Run-out time too short
October 2007
X Clean
Z Bearing damaged
Z Rotor grazing
Sluggish start-up

X Clean
Z Bearing damaged
Z Rotor grazing
HZTL2488_EN
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 2.5

Troubleshooting 6
Constant surging of the turbocharger

October 2007
Engine Z Exhaust pressure to the turbine elevated because boiler or exhaust si-
lencer is dirty
Z Trap dirty
X Clean
Turbocharger Z Charge-air filter 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
HZTL2488_EN
Version 2.5

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

7.1 Turbocharger weights
October 2007

WARNING
Loads that are not suspended in accordance with the regulations during
disassembly and assembly may fall and can cause serious or even fatal
injury.
X Select a suitable rope taking into account the weight of the load
X Hang rope crossed over on the crane hook
X Do not stand under suspended loads
HZTL2488_EN
Version 2.5
L_00082

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

1194 1957
Complete turbocharger unit with radial air suction branch

1128 1840
HZTL2488_EN
Version 2.5

Remove the turbocharger 7.2 Page 3
7.2 Remove the turbocharger

X Disconnect all gas, air, and oil lines in accordance with engine manu-
October 2007
facturer’s instructions.
An orifice plate is fitted in each of the two oil inlet channels in the bear-
ing casing. In order to obtain the required oil pressure, the diameter of
the orifice plate holes in the oil-supplying oil inlet channel has been ad-
NOTE justed individually by the manufacturer. Whenever these orifices are
removed, or if the bearing casing or the complete turbocharger is re-
placed, it is essential to ensure that the orifice with the correct orifice
diameter is fitted into the oil supplying oil-inlet channel
Suspending the turbo-

charger
HZTL2488_EN
Version 2.5
L_00181

Remove the turbocharger 7.2 Page 4
At least the two suspension lugs on the bearing casing and the two sus-
pension lugs on the gas inlet casing are to be used (observe labelling on
the insulation). The two suspension lugs on the gas inlet casing are help-
ful for aligning the turbocharger horizontally.
October 2007
X Remove insulating shell (S) from the bearing casing and the insulation
from the gas inlet casing. The rest of the insulation can remain fitted on
the turbocharger.
X Check the lifting equipment.
X Attach the lifting equipment to the suspension lugs on the bearing cas-
ing and the gas inlet casing.
Take into consideration by the choosing of the lifting gear the weight of
the turbocharger.
CAUTION
HZTL2488_EN
During removal, a turbocharger that is not lifted in compliance with
regulations may fall, and can cause serious or even fatal injury.
WARNING Z The filter silencer must not be used for the lifting of the complete tur-
bocharger.
X Select a suitable rope taking into account the weight of the turbo-
charger.
X Suspend the complete turbocharger using the attachment points
provided for this purpose.
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-

Version 2.5
charger might tip over during installation and removal and can cause
serious or even fatal injury.
WARNING
X Support turbocharger in a suitable location.

X Cover oil connector.

Installing the turbocharger 7.3 Page 5
7.3 Installing the turbocharger

October 2007
During installation work, a turbocharger that is not lifted in compliance

with regulations could fall and cause serious personal injuries or even
fatal accidents.
WARNING
Z The filter silencer must not be used to lift the turbocharger!
X Select a suitable rope taking into account the weight of the turbo-
charger.
X Suspend the complete turbocharger using the attachment points
provided for this purpose and transport horizontally.
X Remove cover from oil connector.

X Check the lifting equipment.
X Secure lifting equipment to the suspension lugs on the bearing casing.
HZTL2488_EN
Take into consideration by the choosing of the lifting gear the weight of
the turbocharger.
CAUTION
X Mate turbocharger to engine.

X Tighten the fixing screws on the foot, in accordance with the engine
manufacturer's instructions.
X Adapt insulating shell to suit bearing casing and secure it.
X Secure all gas, air, and oil lines in accordance with the engine manu-
facturer’s instructions.
Version 2.5

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

8.1 Module weights
October 2007

WARNING
Loads that are not suspended in accordance with the regulations during
disassembly and assembly may fall and can cause serious or even fatal
injury.
X Select a suitable rope taking into account the weight of the load
X Hang rope crossed over on the crane hook
X Do not stand under suspended loads
HZTL2488_EN
Version 2.5
L_00082

Assembly units
October 2007
HZTL2488_EN
L_00190
Version 2.5


1 Filter silencer 113 186
2 Air suction branch, 44 73
October 2007
radial
3 Compressor casing 172 282
(one-piece)
4 Insert wall 48 79
5 Air diffuser 17 27
6 Cartridge group 282 463
7 Turbine diffuser 31 51
8 Nozzle ring 8 13
9 Gasket 0.07 0.07
10 Gas inlet casing 90 138
11 Segment 7 11.5
Compressor casing complete

HZTL2488_EN
Weight [kg] TPL 67-C TPL 71-C

237 388
The total weight of the complete compressor casing unit is made up of

the combined weights of the compressor casing, the diffuser, and the
wall insert.
NOTE
Version 2.5

Removing and fitting filter silencer or air 8.2 Page 4

suction branch
8.2 Removing and fitting filter silencer or air suc-

tion branch
October 2007
Not all tools are identified with a part number. The identification of the
tools is ensured with the tools list (included in the toolbox).
NOTE
X Disconnect all air ducts in accordance with engine manufacturer’s in-

structions.
X Unscrew nuts (72027) with Verbusripp washers (72028) and remove fil-
ter silencer or air suction branch.
HZTL2488_EN
81000_004
Filter silencer X Fit a ring bolt (90231) on the filter silencer.

X Pass lifting gear through the lugs at the rear and secure in the ring bolt
Version 2.5
with a shackle .

Axial clearance 8.3 Page 5
8.3 Axial clearance

October 2007
HZTL2488_EN
L_00218
Z The axial clearance A must be measured before the cartridge group is

removed and after it has been fitted.
X Measure and note the axial clearance (A).
Version 2.5
Clearance A [mm] TPL 67-C TPL 71-C

0.31 – 0.49 0.33 – 0.50
If the axial clearance A is out of tolerance, an official service station of

ABB Turbo Systems must be contacted.
CAUTION

Removing cartridge group 8.4 Page 6
8.4 Removing cartridge group
October 2007
Not all tools are identified with a part number. The identification of the
tools is ensured with the tools list (included in the toolbox).
NOTE
X Remove insulations.
X Disconnect the oil lines in accordance with the engine manufacturer's
instructions.
Remove compressor
casing complete
00000_010 HZTL2488_EN
Version 2.5
X Attach compressor casing clamp (90190) and secure the compressor

casing (72000) to the crane with a shackle (90195).
X Loosen nuts (61037).
X Press off compressor casing (72000) evenly with the three press-off
nuts (61037) fitted at the bearing casing side.
X Lift compressor casing (72000) slightly and withdraw a little.
X Attach second shackle (90195) for TPL-71-C or (90213) for TPL-67-C
to the flange of the compressor casing (72000).
X Withdraw compressor casing (72000) completely.
X Remove O-ring seal (42012).

X Place the compressor casing (72000) with wall insert and diffuser with
the flange (F) on shims.
October 2007
Ensure that the underlay does not slip.
X Maximum working load for shackle (90213) is 300kg.

WARNING X Only rest the compressor casing on flange (F).
X Check underlay and adjust if necessary.
HZTL2488_EN
Version 2.5

Completely disassemble
compressor casing
October 2007
HZTL2488_EN
Version 2.5
79000_002
X Remove three screws (72002).

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

Removing cartridge group

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

X Loosen the three screws (61059) and remove together with the Ver-
busripp washers (61058).
Version 2.5
During removal, a cartridge group that is not lifted in compliance with

regulations might fall and could cause serious or even fatal injury.
X Select a rope suitable for weight of cartridge group.
WARNING
X Press down cartridge group evenly using jack screws (90900) in holes
provided.

If the blades have insufficient or no clearance between the rotor and

casing, this can lead to damage to the blades and the casing.
October 2007
Turn rotor to check that turbine blades do not touch turbine diffuser.
CAUTION
X Extract cartridge group.

X Attach the supports (90450) with the screws and set the cartridge
group down.
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
HZTL2488_EN
Version 2.5

Dismantling and installing the turbine 8.5 Page 11

diffuser and nozzle ring
8.5 Dismantling and installing the turbine diffuser

and nozzle ring
October 2007
Release turbine diffuser

HZTL2488_EN
56000_007
X Place clamp (90921) over the threaded pin (61036).

Version 2.5
X Insert extension (A) of torque spanner (B) through the hole of the
clamp (90921) and release the torque of screws (61056) in succession.
X Do not yet remove the screws (61056) with the Verbusripp washers
(61057).


Removing the turbine

diffuser
October 2007
HZTL2488_EN
56000_006
X Replace two screws (61056) and Verbusripp washers (61057) with

guide bolts (90320).
X Remove the remaining screws (61056) and Verbusripp washers
(61057).
X Press off turbine diffuser (63000) with puller screws (90901) and with-
draw the diffuser a little.
X Fix turbine diffuser (63000) to the lifting gear and remove as a com-
plete unit. Version 2.5


Removing nozzle ring

October 2007
HZTL2488_EN
56000_008
After the removal of the turbine diffuser, the nozzle ring (56001) is only
clamped lightly with the gas outlet casing. By pulling it forward, the noz-
zle ring (56001) is released and can fall down.
CAUTION
X Pull nozzle ring (56001) forwards and remove.

Version 2.5


Fitting turbine diffuser and nozzle ring
October 2007
Fitting X Fit nozzle ring and turbine diffuser in reverse order to removing them.
X Align the nozzle ring with the holes in the gas inlet casing and assem-
ble with screws, nuts and bushings.
Smear all screws in and on gas casings with Anti Scuff Paste 868 from
SPANJAARD.
NOTE
service station.
CAUTION
HZTL2488_EN
Version 2.5

Installing cartridge group 8.6 Page 15
8.6 Installing cartridge group

October 2007
HZTL2488_EN
21000_003
X Remove cover from oil connector.

X Check lifting equipment and secure it to bearing casing (42001) so that
cartridge group hangs straight.
Version 2.5
When it is being fitted, a cartridge group that is not suspended in com-

pliance with regulations can fall and cause serious or even fatal injury.
X Select a rope suitable for weight of cartridge group.
WARNING
X Remove supports (90450) and carefully insert cartridge group.

If the blades on the rotor have insufficient or no clearance, the blades

and the casing could be damaged.
October 2007
X Turn rotor to check that turbine blades do not touch turbine diffuser.
CAUTION
X Tighten the three screws (61059) with Verbusripp washers (61058) e-

venly.
X Remove lifting equipment.
If provided: X Connect cable (86515) to line amplifier (86525).

X Screw in speed sensor (86505) fitted with O-ring (86506) and connect
cable (86515).
HZTL2488_EN
00000_009
X Fit all oil lines in accordance with the engine manufacturer's instruc- Version 2.5
tions.

Fit compressor casing

complete
October 2007
HZTL2488_EN
79000_002
Version 2.5
X Fit O-Ring gasket (77005) on the wall insert (77000).

X Screw ring bolts (90235) into the holes in the wall insert (77000).
X Align the wall insert (77000) so that the pins on the ring bolts (90235)
centre the wall insert (77000) in the three threaded holes.
X Lower the wall insert (77000).
X Release ring bolts (90235).
X Mount the diffuser (79000) with ring bolts (90235).
X Remove ring bolts (90235).
X Fit screws (72002).

Install compressor casing

complete
October 2007
HZTL2488_EN
00000_010
X Fit O-ring seal (42012).

X Attach compressor casing clamp (90190) and secure the compressor
casing (72000) to the crane with a shackle (90195).
X Attach second shackle (90195) for TPL-71-C or (90213) for TPL-67-C
to the flange of the compressor casing (72000).
When lifting the complete compressor assembly, take care to ensure

that the shim does not slip.
WARNING X Maximum working load for shackle (90213) is 300kg.

X Only rest the compressor casing on flange (F).
X Check underlay and adjust if necessary.
Version 2.5
X Fit the three press-off nuts (61037), distributed evenly around the cir-
cumference.

X Push the compressor casing (72000) onto the studs on the cartridge
group and remove only the one shackle (90195) on the flange.
X Push the compressor casing (72000) fitting snugly onto the cartridge
October 2007
group and secure with nuts (61037).
X Measure and note axial clearance A.
Clearance A [mm] TPL 67 TPL 71

0.31 – 0.49 0.33 – 0.50
If the axial clearance A is out of tolerance, an official service station of

ABB Turbo Systems must be contacted.
CAUTION
X Connect oil lines and all air ducts in accordance with engine manufac-
HZTL2488_EN
turer’s instructions.
X Mount filter silencer or air suction branch and secure with nuts (72027)
and Verbusripp washers (72028).
X Fit insulation.
service station.
CAUTION
Version 2.5

Table of tightening torques 8.7 Page 20
8.7 Table of tightening torques
October 2007
1 3 6 7 8
45
46
19
28 26
27
HZTL2488_EN
4 5 23 9 21 17
L_01118
29
9
Version 2.5
L_00558
The following tightening torques must be maintained for the specified

screwed connections:

Table of tightening torques 8.7 Page 21
Tightening torques [Nm] Item Part No. TPL 67-C TPL 71-C
No.
1 82005 M16x1.5 M16x1.5
October 2007
45 45
3 72002 M10 M12
50 80
4 72027 M14 (VR) M16 (VR)
75 95
5 72026 M14 M16
30 30
6 61037 M16 M18
110 160
7 61036 M16 M18
30 40
8 61059 M16 (VR) M18 (VR)
200 280
9 42059 M12 (VR) M16 (VR)
80 180
HZTL2488_EN
17 61044 M12-T M14-T

80 130
19 52206 G3/4 G3/4
75 75
21 61056 M12-T (VR) M14-T (VR)
105 130
23 42086 M10 M10
50 50
26 52204 M12-T (VR) M12-T (VR)
80 80
27 52205 M12-T M12-T
80 80
28 51300 M12-T (VR) M14-T (VR)
130 200
29 86505 M18x1.5 M18x1.5
Version 2.5
150 150
45 52254 M10 (VR) M10 (VR)
55 55
46 52257 M8-T (VR) M8-T (VR)
40 40

Taking out of operation at short notice 9
Possibilities for emergency repair 9.1 Page 1
9 Taking out of operation at short notice

9.1 Possibilities for emergency repair
October 2007
Lubricating oil leakage is 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 possi-

ble after damage to the turbocharger (emergency repair), the following
possibilities are available:
HZTL2488_EN
Lock the turbocharger rotor

Blocking the inlets and outlets
Bypass the turbocharger
Fit cover plate
Version 2.5

Locking the rotor 9.2 Page 2
9.2 Locking the rotor
October 2007
A blocked/ jammed rotor must be disassembled following the turbo-
charger repair and given an imbalance check.
CAUTION
The only exception is a test rig run up to maximum 25% of the engine
load with new engines with one or a number of turbochargers, which
are requested by some customers. Since in these cases operation with
NOTE a blocked rotor is brief and the loads are low, subsequent disassembly
of the rotor is unnecessary.
U Once unscrewed, balancing screws must not be screwed in again.
During operation of the engine with a blocked turbocharger, the lubrica-

tion oil system must also remain connected to this turbocharger and
HZTL2488_EN
turned on if the gas inlet cannot be blocked (see section Further meas-
CAUTION ures and information for operation with a blocked rotor for 4-stroke en-
gines). Otherwise components that are still intact can be damaged by
overheating.
The supply of lubricating oil to the turbocharger must be shut off in the
event of a lubricating oil leak on the turbocharger.
Version 2.5

Locking rotor with screw connection

October 2007
HZTL2488_EN
94000_001
Tightening torques table Part No. TPL67-C TPL71-C

72027 M14 M16
75 Nm 95 Nm
94007 M8 M8
25 Nm 25 Nm
X Remove silencer or air suction branch.

Version 2.5
These operations must be carried out as described in the chapter Dis-

assembly and assembly.
NOTE
X Insert locking flange (94003) in the compressor wheel.

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

Don't remove any balancing screws from the compressor wheel. Use
only free threaded holes to mount the lifting device.
October 2007
CAUTION
X Position assembly-/disassembly device (90020) over studs (72026)

and locking flange (94003).
X Turn the compressor wheel, so that locking flange hexagon is aligned
with the hexagon in the assembly-/disassembly device (90020).
X Fasten the assembly-/disassembly device (90020) on the compressor
housing by tightening the nuts (72027) on the studs (72026) to the val-
ues shown in the preceding Tightening torques table.
HZTL2488_EN
Version 2.5
94000_002
Make sure all components are clean and free from grease.
CAUTION

Further measures and information for operation with blocked rotor for 4-
stroke engines
October 2007
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 en-
gine 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 duct on the engine
HZTL2488_EN
side must be isolated. Otherwise the undamaged turbocharger can spin

"unloaded" and run at 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.
Attention must be paid to the speed of the undamaged turbocharger in

Version 2.5
all cases. Rotating speed limit nBmax as indicated on the rating plate
must not be exceeded.
CAUTION

Fit cover plate 9.3 Page 6
9.3 Fit cover plate
October 2007
The cover plate (material: General structural steel, in accordance with
DIN EN 10025-2) must be manufactured in-house according to the
drawing.
NOTE
HZTL2488_EN
90000_001
Cover plate dimensions Type B1 B2 B3 B4 B5 B6 B7 B8

[mm]
TPL 67-C 13 325 30 30 8 10 6 70
Version 2.5
TPL 71-C 13 385 30 30 8 10 6 84
Type Ø1 Ø2 Ø3 Ø4 Ø 5 min. Ø 6 min

TPL 67-C 616 694 660 16 22 15
TPL 71-C 726 818 779 18 25 15

Type ⍺1 ⍺2 ⍺3
TPL 67-C 4 x 90° 37.5° 24 x 15°
TPL 71-C 4 x 90° 37.5° 24 x 15°
October 2007
HZTL2488_EN
00000_004
These operations must be carried out as described in the chapter Dis-

assembly and assembly.
Version 2.5
NOTE
X Removing cartridge group

October 2007
HZTL2488_EN
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 2.5

Further measures and information for operation with a turbocharger with

cover plate in 4-stroke engines
October 2007
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 en-
gine according to the instructions of the manufacturer.
Common receiver The air line must be blocked on the engine side, since the undamaged
turbochargers develop a receiver pressure.
HZTL2488_EN
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 2.5

Blocking the inlets and outlets 9.4 Page 10
9.4 Blocking the inlets and outlets
October 2007
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 instruc-

tions.
NOTE
HZTL2488_EN
Version 2.5

Bypass the turbocharger 9.5 Page 11
9.5 Bypass the turbocharger

October 2007
CAUTION
Z Only applies for engines with one turbocharger.

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 instruc-

tions.
NOTE
HZTL2488_EN
Version 2.5

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

months
10 Mothballing turbocharger
10.1 Taking out of operation for up to 12 months
October 2007
If a turbocharger has to be laid up for up to 12 months, the decision

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

measures need to be taken. However, if the neutralisation factor is higher
the turbocharger must be dismantled after laying up, cleaned and protec-
tive oil must be applied to the naked parts.
If the turbocharger is left mounted on the engine, and the engine oil is re-
placed by a protective oil which is circulated with a pre-lubrication pump
prior to laying up, no measures need to be taken in respect of the turbo-
charger. The remains of the old engine oil will be washed away and the
sensitive bearing parts will be largely protected against corrosion.
If the rotor turns due to a draught from the flue, fit a blind flange between
HZTL2488_EN
the compressor casing and the charge-air duct.

Version 2.5

Mothballing 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
October 2007
If the turbocharger has to be removed from the engine and stored for a
prolonged period of time, disassembly and mothballing of the turbo-
charger must be done by an official ABB Turbo Systems service station.
Suitable storage locations are dry rooms where the relative humidity is be-
tween 40-70% and no condensation can form.
Check mothballed turbochargers yearly for corrosion.

If there are signs of rust, clean parts and renew means for protection
against corrosion.
NOTE
HZTL2488_EN
Version 2.5

Disposal 11
Environmentally compatible disposal of 11.1 Page 1

turbocharger components
11 Disposal
11.1 Environmentally compatible disposal of tur-
October 2007
bocharger components
Environmentally compatible disposal of turbocharger components

The disposal must be carried out environmentally compatible, properly
and in accordance with locally applicable regulations.
NOTE
The turbocharger mainly consists of metal (cast-iron materials, steel,
nickel-steel alloys, aluminium, bearing brass).
Other components are: nonmetallic materials (filter components made
from felt and polyethylene), lubricants (engine oil), thermal insulation,
electronic components (speed sensor and associated components).
HZTL2488_EN
X Dispose of metals through melting down and recycling.

X Dispose of nonmetallic materials as waste.
X Dispose of lubricant residues as waste oil.
X Dispose of thermal insulation as special waste.
X Dispose of electronic components as electrical scrap.
Version 2.5

Reserve and spare parts 12
Ordering spare parts 12.1 Page 1
12 Reserve and spare parts

12.1 Ordering spare parts
October 2007
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 will take orders for spare parts.
X If special variants/cases are not addressed in these general instruc-

tions, then contact an official ABB Turbo Systems service station or an
ABB agent.
HZTL2488_EN
Spare parts set
The spare-parts set (97070) is required for the work described in this
manual. The parts included in the spare parts set are available only as
part of the complete set.
NOTE
Spare parts set (97070) Quantity Description Part number

1 O-ring seal 42012
1 Gasket 42041
2 Gasket 42045
2 Verbusripp washer 42058
2 Hexagon-head screw 42059
Version 2.5
3 Hexagon nut 61037

1 Gasket 77005
1 O-ring gasket (Speed- 86506
Sensor)

Ordering spare parts 12.1 Page 2
All spare parts that have been ordered with the turbocharger should be
kept complete and serviceable.
October 2007
X Rusty parts should be carefully cleaned and greased.
CAUTION
X Dispose of replaced parts that are no longer usable in a technically and

environmentally compatible manner.
HZTL2488_EN
Version 2.5

Directory of part numbers 12.2 Page 3
12.2 Directory of part numbers

The following part numbers and descriptions must be used in ALL corre-
October 2007
spondence or orders:
turbochargers Part number Description

42012 (in spare parts set) O-ring seal
51001 Gas inlet casing
51012 Segment
56001 Nozzle ring
61001 Gas outlet casing
61044 Hexagon-head screw
61050 Gasket
61057 Verbusripp washer
63000 Turbine diffuser
68001 Foot on the compressor side
HZTL2488_EN
68002 Foot at the turbine end

68003 Slide plate
68006 Cup spring
68007 Bushing
72000 Compressor casing
76040 O-ring seal
77000 Insert wall
79000 Air diffuser
81000 Filter silencer
82000 Radial air suction branch
Version 2.5

Cartridge group – screwed Part number Description

connection
21000 Shaft
25000 Compressor wheel
October 2007
32001 (in spare parts set) Thrust bearing
32101 (in spare parts set) Radial bearing, compressor end
32102 (in spare parts set) Radial bearing, turbine end
32104 (in spare parts set) Auxiliary bearing
32105 (in spare parts set) Floating disc
32106 (in spare parts set) Thrust bearing
32107 Bearing bush
42001 Bearing casing
42002 Hood
42015 Sealing cover
42041 (in spare parts set) Gasket
42045 (in spare parts set) Gasket
HZTL2488_EN
42058 (in spare parts set) Verbusripp washer
42059 (in spare parts set) Hexagon-head screw
43001 Partition wall
86505 Speed sensor
Version 2.5

Cleaning lines Part number Description

51006 Blind flange
51007 Gasket
October 2007

51169 Screw plug
51229 Water supply pipe
51255 Locking plate
51257 Expansion bushing
52200 Gasket
52202 Flange
52206 Screw plug
52208 Jet
52209 Jet
HZTL2488_EN
52210 Jet
52213 Locking plate
52250 Bracket
52251 Block
52252 Plate
52254 Hexagon nut
52255 Half-shell bottom part
52256 Half-shell top part
Version 2.5

General view of turbocharger 12.3 Page 6
12.3 General view of turbocharger
October 2007
61044
HZTL2488_EN
51012
51001
42012
68003
79000
61050
68002
68006
68007
76040
77000
61001
77005
72000
68001
Version 2.5
56001
81000
63000
82000
61056
61057
L_00186

General view of cartridge group 12.4 Page 7
12.4 General view of cartridge group

October 2007
21000
42015
42011
42002
86505
HZTL2488_EN
86506
42064 42045
32102
42001
42063 42058
42041 42059
43006
32107
43005
43007
32001
32105
43001
Version 2.5
32106
32101
25000
32104
L_00187

Cleaning lines for radial gas inlet casing 12.5 Page 8
12.5 Cleaning lines for radial gas inlet casing
October 2007
52204 51257
51255 52204
52213
51229
52209
52208
52205
52210 52202
52200
52256
52254
HZTL2488_EN
52253 52255 51169
52251
52250 52258
52257
51007
52252
51006
51062
51064
Version 2.5
L_01117

Cleaning lines for axial gas inlet casing 12.6 Page 9
12.6 Cleaning lines for axial gas inlet casing

October 2007
51255
51062 51064 51257 52204
51006
52210 51007
51229
52206
HZTL2488_EN
52209
51169
52256
52255
52200
52258
52202
52257
52205 52252
52208
Version 2.5
L_01119

ABB
Bruggerstrasse 71a
CH-5400 Baden
Switzerland

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Turbocharging

ABB Turbo Systems Ltd

Type TPL67-C33 HT490908

ABB Turbo Systems Ltd 

© Copyright by ABB TURBO SYSTEMS Ltd 2004

ABB Turbo Systems Ltd

Type TPL67-C33 HT490909

ABB Turbo Systems Ltd 

© Copyright by ABB TURBO SYSTEMS Ltd 2004

ABB Turbo Systems Ltd

Type TPL67-C33 HT491153

ABB Turbo Systems Ltd 

© Copyright by ABB TURBO SYSTEMS Ltd 2004

ABB Turbo Systems Ltd

Type TPL67-C33 HT491154

ABB Turbo Systems Ltd 

© Copyright by ABB TURBO SYSTEMS Ltd 2004

ABB Turbo Systems Ltd

Type TPL67-C33 HT491155

ABB Turbo Systems Ltd 

© Copyright by ABB TURBO SYSTEMS Ltd 2004

ABB Turbo Systems Ltd

Type TPL67-C33 HT491156

ABB Turbo Systems Ltd 

© Copyright by ABB TURBO SYSTEMS Ltd 2004

ABB Turbo Systems Ltd

Type TPL67-C33 HT490934

ABB Turbo Systems Ltd 

© Copyright by ABB TURBO SYSTEMS Ltd 2004

ABB Turbo Systems Ltd

Type TPL67-C33 HT490935

ABB Turbo Systems Ltd 

© Copyright by ABB TURBO SYSTEMS Ltd 2004

ABB Turbo Systems Ltd

Type TPL67-C33 HT490936

ABB Turbo Systems Ltd 

© Copyright by ABB TURBO SYSTEMS Ltd 2004

ABB Turbo Systems Ltd

Type TPL67-C33 HT490937

ABB Turbo Systems Ltd 

© Copyright by ABB TURBO SYSTEMS Ltd 2004

ABB Turbo Systems Ltd

Type TPL67-C33 HT490938

ABB Turbo Systems Ltd 

© Copyright by ABB TURBO SYSTEMS Ltd 2004

ABB Turbo Systems Ltd

Type TPL67-C33 HT490939

ABB Turbo Systems Ltd 

© Copyright by ABB TURBO SYSTEMS Ltd 2004

Table of contents Page 1

2.3 Special safety instructions

4.5 Contact with rotating parts

ABB Turbo Systems Ltd ABB

Table of contents Page 2

8 Disassembly and assembly

12 Reserve and spare parts

ABB Turbo Systems Ltd ABB

Purpose of manual 1.1 Page 1

This operating manual complements and extends existing national regula-

The instructions included in this operating manual must be followed with-

This applies especially to the general and special safety instructions

ABB Turbo Systems Ltd ABB

Layout and function 1.2 Page 2

ABB Turbo Systems Ltd

ABB Turbo Systems Ltd

ABB Turbo Systems Ltd

ABB Turbo Systems Ltd

ABB Turbo Systems Ltd

ABB Turbo Systems Ltd

ABB Turbo Systems Ltd

ABB Turbo Systems Ltd

ABB Turbo Systems Ltd

ABB Turbo Systems Ltd

ABB Turbo Systems Ltd

ABB Turbo Systems Ltd

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.