ABB

Operation Manual
Table of Contents
Page 1
May 2006
Table of Contents
1 1.1 1.2 1.3 1.4 1.5 1.6 2 2.1 2.2 2.3 2.4 2.5 3 3.1 3.2 3.3 4 4.1 4.2 4.3 4.4 Preliminary remarks Purpose of the manual Layout and function Correct use of the turbocharger Essential information Abbreviations and symbols Turbocharger rating plate Safety Basic safety instructions General safety instructions Special safety instructions Safety instructions and hazard protection Warnings on the turbocharger Commissioning Oil supply Inspection work Putting into operation after laying up Operation Servicing work Monitoring Surging of turbocharger Contact with rotating parts Shutting the engine down Maintenance Foreword to Maintenance Cleaning the filter silencer Cleaning the compressor during operation Cleaning turbine blades and nozzle ring in operation
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4.5 5 5.1 5.2 5.3 5.4
ABB Turbo Systems Ltd
ABB
Operation Manual
Table of Contents
Page 2
6 6.1 7 7.1 7.2 7.3 8 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 9 9.1 9.2 9.3 9.4 9.5 10 10.1 10.2 11 11.1 11.2 11.3 11.4
Troubleshooting Possible remedies for failures Removal and installation Turbocharger weights Remove the turbocharger Installing the turbocharger Disassembly and assembly Module weights Removing and fitting the filter silencer or air suction branch Removing cartridge group Axial clearance Installing the cartridge group Turbine-end removal / fitting of the nozzle ring Table of tightening torques Taking out of operation temporarily Possibilities for emergency repair Locking the rotor Fitting the cover plate Blocking the inlets and outlets Bypass the turbocharger Mothballing the turbocharger Taking out of operation for up to 12 months Taking out of operation for more than 12 months Reserve and spare parts Directory of part numbers General view of turbocharger General view of cartridge group
Version 2.0 HZTL2481_EN (TPL73-A.. - 80-A..) May 2006
Dismantling and installing the turbine diffuser and nozzle ring
Ordering spare parts
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Operation Manual Preliminary remarks Purpose of the manual 1 1.1 Page 1
1 Preliminary remarks
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1.1 Purpose of the manual

Operation manual
This operation manual will help you to become familiar with your ABB Turbo Systems Ltd turbocharger and to use it to full effect in its intended application. You will find important instructions as to the safe, correct, and economical operation of the turbocharger. The content of this operation manual is intended for persons such as engineers, marine mechanics and service technicians who are responsible for the running of the engine and the turbocharger installed thereon. This operation manual includes helpful information on the following topics:
Information on the operation of the turbocharger and ways to prolong
Target group
Content of operation manual

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the turbocharger's service life. Early awareness and avoidance of hazards. Minimising repair costs and failure times.
This operation manual is a complement to, and an extension of, existing national regulations on accident protection and prevention. An operation manual must be available at all times at the site where the turbocharger is used. It is essential that this operation manual is read before beginning work by all persons working with or on the turbocharger. Personnel who only work occasionally on the machine (e.g. during installation and maintenance) must also have read and fully understood the operating manual before beginning work. The instructions included in this operation manual must be followed under all circumstances. This applies especially to the general and special safety instructions preceding and in the respective chapters. Ignoring hazards and the safety instructions can lead to serious personal injury and damage to equipment. In the event of doubt, consult the officer for safety and accident protection responsible for your area.
NOTE
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WARNING
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Operation Manual Preliminary remarks Layout and function 1 1.2 Page 2
1.2 Layout and function

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00000_001
1 2 3 4 5 6 7
Filter silencer Radial plain bearing Thrust bearing Bearing bush Radial plain bearing Gas outlet casing Gas inlet casing
8 9 10 11 12 13
Nozzle ring Turbine wheel Bearing casing Compressor wheel Air outlet casing
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Diffuser
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HZTL2481_EN (TPL73-A.. - 80-A..)
Operation Manual Preliminary remarks Layout and function 1 1.2 Page 3
Mode of operation
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The turbocharger is a turbo-machine and consists of the following main components:

Turbine Compressor
These are both mounted on a common shaft.
The exhaust gases from the diesel engine flow through the gas inlet casing (7) and nozzle ring (8) to the turbine wheel. The turbine wheel (9) uses the energy contained in the exhaust gas to drive the compressor wheel (12), whereby the compressor draws in fresh air, and the compressed air is forced into the cylinders. The exhaust gases escape through the exhaust pipe which is connected to the gas outlet casing (6). The air which is necessary for the operation of the diesel engine and which is compressed in the turbocharger is drawn through the suction branch or the filter silencer (1) into the compressor wheel (12). It then passes through the diffuser (11) and leaves the turbocharger through the compressor outlet on the air outlet casing (13). The rotor runs in two radial plain bearings (2/5) which are located in the bearing bush (4) between the compressor and the turbine. The axial thrust bearing (3) is on the compressor side. The plain bearings are connected to a central lubricating oil feed which is supplied by the oil lubrication circuit of the engine. The oil outlet is always at the lowest point of the bearing casing (10).
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ABB
Operation Manual Preliminary remarks Correct use of the turbocharger 1 1.3 Page 4
1.3 Correct use of the turbocharger

This turbocharger supplied by ABB Turbo Systems has been developed for use on diesel engines to generate the volume of air and the charging pressure required to operate the engine.
NOTE
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The engine manufacturer has provided ABB Turbo Systems with information regarding the intended purpose of the engine, from which the operating parameters specific to the turbocharger (such as rotating speeds, temperatures, replacement periods / exchange intervals) have been derived and are indicated on the rating plate. If it is used in conjunction with a gas engine, the engine must not be installed in a potentially explosive environment, and precautionary measures must be taken to ensure that the machine room as a whole is classified as not potentially explosive. Any other usage shall be regarded as a special application which must be discussed with ABB Turbo Systems. The manufacturer accepts no liability for other applications. If it is used otherwise, ABB Turbo Systems reserves the right to reject all claims under the warranty.
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 operated by trained personnel. Correct use of the turbocharger also includes observation of the assembly, disassembly, operating, maintenance and repair conditions specified by the manufacturer. Regulations set out by local authorities must be observed when disposing of the turbine.
WARNING
Perfect condition
The turbocharger must only be installed in a technically perfect condition, corresponding to its intended purpose and following the instructions in the Engine Manufacturers' Manual, and must be operated and used in compliance with the Operation Manual.
Defects which could affect safety must be eliminated immediately.
The manufacturer shall not accept liability for damages resulting from unauthorised alterations to the turbocharger.
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Operation Manual Preliminary remarks Essential information 1 1.4 Page 5
1.4 Essential information

May 2006
Organisational measures In addition to this manual, the general, statutory regulations applicable in the respective country for the prevention of accidents and the protection of the environment must be observed. This also applies to the provision and wearing of personnel protection equipment. The safety and risk consciousness of the personnel working on and with the turbocharger must be checked regularly with reference to this manual.
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NOTE
The turbocharger must be shut down immediately in the event of al-
terations affecting safety or of corresponding operating behaviour. The fault should be reported to the person or department responsible.
Additions and alterations to, and conversions of the turbocharger that could compromise safety require the prior approval of ABB Turbo Systems.
NOTE
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ABB
Original parts and safety Original parts and accessories are especially designed for the turbocharger supplied by ABB Turbo Systems Ltd. We herewith expressly state that parts and accessories not supplied by us have also not been tested and approved by us.
NOTE
May 2006
If components and assemblies not manufactured and tested by ABB Turbo Systems are used, this may have a negative effect on the technical design specifications of the turbocharger.
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WARNING
Moreover, the active and/or passive safety of the turbocharger may be compromised by the use of non-original parts. Note that such improper use may endanger personnel and the machine. ABB Turbo Systems shall not be liable for any damage caused by using non-original parts and accessories. Qualification of personnel The turbocharger must only be operated and maintained by trained and authorised personnel. Work on mechanical components, such as bearings or rotors, must only be performed by qualified fitters from an official service station of ABB Turbo Systems Ltd.!
CAUTION
It must be ensured that only authorised personnel work on the turbocharger.
ABB
After-sales service
May 2006
The Contact Information brochure contains an overview of official ABB Turbo Systems Ltd. service stations worldwide. Design variants This operating manual is valid for various turbocharger design variants. This means that some sections and component descriptions in this operating manual do not apply to your turbocharger. Our service stations and agencies will gladly answer your questions relating specifically to your model.
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Accuracy of illustrations The graphics and images shown in this operation manual are of a general nature and are intended to assist understanding of the work steps and instructions. Differences may exist in certain details.
Storage of new turbochargers New turbochargers supplied by ABB Turbo Systems Ltd. can be stored without additional safeguarding measures for a period of 6 months after the delivery date. Ensure that the storage area is dry with humidity of 40-70% and free of condensation.
After 6 months, rust-proofing oil should be sprayed on exposed surVersion 2.0
faces and all accessible areas of the turbocharger. To do this, the insulating materials must be removed.
Repeat the steps described for rust-proofing your turbocharger every 6 months.
NOTE
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Operation Manual Preliminary remarks Abbreviations and symbols 1 1.5 Page 8
1.5 Abbreviations and symbols

Prerequisite Work step Result
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The following abbreviations are used in this document:
Positive checkpoint (activity that must be carried out without fail) Negative checkpoint (activity that must not be carried out under any circumstances)
Basic Instructions The following symbol is used for notes in this manual: This note provides suggestions and tips to make work on the turbocharger easier.
NOTE
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The note provides further essential information.
ABB Turbo Systems The term used in this manual ABB Turbo Systems signifies ABB Turbo Systems Ltd. Official ABB Turbo Systems service station The term used in this manual Official ABB Turbo Systems service station signifies ABB Turbocharger service stations, that have been tested and certified by ABB Turbo Systems Ltd.
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Operation Manual Preliminary remarks Turbocharger rating plate 1 1.6 Page 9
1.6 Turbocharger rating plate

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L_00012
Operational limits
1 2
Turbocharger operational limits at engine overload (110 %). In test rig operation only, unless otherwise agreed with the engine manufacturer. Turbocharger operational limits in service.
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Recommended replacement periods / exchange intervals for turbocharger components
3 4 5
Replacement interval for the plain bearings in 1000 h Exchange interval for the compressor in 1000 h (no data for 100,000 h) Exchange interval for the turbine in 1000 h (no data for 100,000 h)
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Operation Manual Preliminary remarks Turbocharger rating plate 1 1.6 Page 10
Additional specifications:
6 7 8 9 10 11 12
Customer part number Field for special design designation Weight of the turbocharger in kg CE = Conformit Europenne Turbocharger type Series number Year of construction of the turbocharger
Explanations of the rating plate The recommended exchange intervals and the corresponding operation limits are defined together with the engine builder. These specifications are system-specific. Continuous running above the indicated nBmax, tBmax values may considerably reduce the recommended exchange intervals. In such cases, we recommend you contact the nearest official service station of ABB Turbo Systems Ltd. nMmax , tMmax normally apply only when running at overload (110 %) during trials on the engine test bed. These limits may also be permitted in service for special applications. The operation over nMmax , tMmax is not permitted. Non-compliance with the recommended exchange intervals may increase the risk of unpredictable component failure.
CAUTION
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Operation Manual Safety Basic safety instructions 2 2.1 Page 1
2 Safety
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2.1 Basic safety instructions

The following symbols and terms are used for the safety instructions in this manual: Failure to follow work steps and operating instructions marked with this symbol completely and rigorously may result in serious personal injury or even fatal accidents.
WARNING
Warning signs must be strictly observed at all times.
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Serious damage to the machine or to other property may result if the working and operation instructions marked with this symbol are not, or only partly, observed.
CAUTION
Caution signs must be strictly observed at all times.
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Operation Manual Safety General safety instructions 2 2.2 Page 2
2.2 General safety instructions

The instructions listed here are designed to ensure your safety and to promote safe handling of the turbocharger and its associated operating materials. The following safety instructions must be followed when operating and when working on the turbocharger.
WARNING
Do not work on the turbocharger if you are under physical or mental
stress.
Wear protective clothing at all times.

Helmet Ear protection Protective glasses Protective suit Oil and petrol resistant gloves Protective shoes Attach individual parts and larger component modules carefully to suitable hoists/lifting devices which are in technically perfect condition and which have adequate load-bearing capacity. Do not stand under suspended loads. If welding work is to be carried out above the turbocharger, the air filter must be covered to prevent damage to the filter mat. When working on the turbocharger, be aware of the risk of it falling. For overhead assembly work, use the steps and platforms provided for this purpose.
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Operation Manual Safety Special safety instructions 2 2.3 Page 3
2.3 Special safety instructions

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Safety when connecting

Work only on those connections for which you are qualified.
Safety when commissioning and during operation Before starting work, make a visual inspection of the working area. Remove obstacles and any objects lying around from the work area. Before commissioning check the turbocharger for damage and leaks. Refrain from any activity which could compromise safety while working with the turbocharger. Inspect the turbocharger after about 12 hours of operation or at least once a day for visible damage and defects. Report any damage or changes in operational performance to the person/department responsible immediately. In the event of damage, shut down the turbocharger immediately and secure it against inadvertent or unauthorized use.

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Safety when cleaning

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

May 2006
Follow the prescribed maintenance and inspection schedules for all ad-
justment, maintenance and inspection work.
Inform operating personnel about special work and repairs before start-
ing. Ensure that absorbent materials are available to clean up any operation materials that escape accidentally. Ensure safe and environmentally-friendly drainage, collection and disposal of operating and auxiliary materials. Before opening a cover or removing a protective component on the turbocharger, the engine must have been switched off and must not be started up again until all parts have been properly re-assembled. Assembly and disassembly work must only be performed by trained personnel. Work on mechanical components, such as bearings or rotors, must only be performed by qualified fitters from an official service station of ABB Turbo Systems.
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CAUTION
Safety when taking out of operation or putting into storage

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

Associated hazards may arise during operation of and work on the turbocharger:

from the turbocharger and its accessories. from the operating materials used. due to failure to comply with the safety instructions. from inadequate performance of maintenance and inspection work.
Mechanical influences
Mechanical influences can cause serious injury or even fatal injury.

WARNING
Personal injury
Unconsciousness and injury due to:

crushing shearing cutting winding smashing drawing in knocking stabbing rubbing Escape of liquids under high pressure and / or at high temperature slipping tripping falling
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

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Operation Manual Safety Safety instructions and hazard protection

Protective measures
2 2.4 Page 7

Wear leather protective gloves Wear close-fitting protective clothing Tie up long hair and beards (wear hair protection) Wear face and eye protection Wear protective shoes Keep floor, equipment and the turbocharger clean Ensure the availability of oil absorbing materials and have oil collector basins ready or in position Eliminate leaks Operation and process materials
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Operation and process materials refer to chemical and hazardous substances:

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Oils Grease Coolants Detergents and solvents Acids Note that operation and process materials are harmful to the environment if they penetrate soil or water.
CAUTION
Personal injury
The following injuries can be caused by operation and process materials:

Allergies Skin disease Loss of consciousness Poisoning or nausea after inhalation
Causes
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Inhalation of toxic gases, smoke and vapours Skin contact with aggressive fluids Clothing wet or soaked with hazardous substances Spilling and tipping over of vessels containing substances used during operation Escape due to leakage Tanks and collectors which are not gas-tight and which do not comply with the regulations on hazardous substances Burning cigarettes or open flame in the proximity of operation materials

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Operation Manual Safety Safety instructions and hazard protection

Protective measures
2 2.4 Page 8

Ensure that the work area is well ventilated Keep the work area clean Avoid disturbing dust Dust-suppressing tools and processing steps Remove from packaging only in the work area Exercise particular care when removing old insulating materials Dispose of insulating materials in a technically and environmentally compatible manner If large quantities of dust are created, wear protective glasses Use half or quarter masks Wear suitable work clothing and gloves For sensitive skin, apply moisturising, protective barrier cream
ABB
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Handling insulating materials
May 2006

Utmost caution when handling process and operation materials Protective clothing must be worn Avoid skin contact and inhalation under all circumstances Ensure that the workroom is properly ventilated Observe the hazard indications on the containers for operation and process materials Immediately after use, seal the hazardous substance container tight Used operation materials must be collected safely in accordance with the legal provisions, stored separately in suitable containers as prescribed, and disposed of as special waste in a technically and environmentally compatible manner Ensure that containers for new / used operation materials are sealed tight In the event of leaks or spills immediately apply a suitable absorbent material and dispose of this in a technically and environmentally compatible manner as special waste
Operation Manual Safety Safety instructions and hazard protection 2 2.4 Page 9
Noise
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The effects of noise above a legally permitted level can cause personal injury.
Personal injury

Loss of hearing Deafness Impaired hearing Health disorders such as loss of balance or of consciousness Cardiac and circulatory disturbances
Causes Protective measures

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Machine noise level above 85 dB (A)
Wear ear protection Heat hazard When the turbocharger is operated, surfaces become very hot.
Personal injury Causes Protective measures
Burns Missing or incorrectly fitted insulation.
Wear leather protective gloves.
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Operation Manual Safety Warnings on the turbocharger 2 2.5 Page 10
2.5 Warnings on the turbocharger

Warnings that have been applied to turbochargers by ABB Turbo Systems must not be removed, painted over or obscured with other stickers. Missing or illegible warnings must be replaced by new warnings.
L_00227
Apply warnings so that they are clearly visible in the positions intended for that purpose. Please contact an official ABB Turbo Systems service station for further information.
NOTE
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Operation Manual Commissioning Oil supply 3 3.1 Page 1
3 Commissioning
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3.1 Oil supply

A carefully designed oil supply, which functions under all operating conditions, is an important precondition for trouble-free operation of the turbocharger. Lubrication of the turbocharger is normally carried out with oil from the engine oil circuit. Regarding the oil supply, follow the engine manufacturer's instructions concerning selection of lubricating oil, oil change intervals, oil filtration, and oil pressure and temperature.
NOTE
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3.1.1 Oil filtration

A lubrication oil filter system with a mesh size 0.050 mmis adequate for TPL 73 - TPL 80 turbochargers.
3.1.2 Oil pressure

The oil pressure before the bearings (measuring point in blind connection) must be exactly maintained to ensure fault-free operation.
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Operation Manual Commissioning Inspection work 3 3.2 Page 2
3.2 Inspection work

This inspection work includes preventive visual controls, as well as monitoring and measurement to ensure the correct functioning of the turbocharger. These serve as an aid to detecting anomalies before and during commissioning, thus preventing possible damage to the machine.
The safety instructions must be followed before and during all inspecMay 2006 Version 2.0 HZTL2481_EN (TPL73-A.. - 80-A..)
tion work.
3.2.1 Inspection before commissioning

Monitoring equipment
To be checked for correct functioning.
Air filter mat
Inspect for damage.
Lubricating system
Check oil filter for cleanliness before commissioning.
It is urgently recommended that the entire lubrication system be flushed thoroughly with warm oil using a bypass pipe before commissioning and after every servicing operation on the lubrication system.
CAUTION
We strongly recommend the use of a starting filter when running the engine in and after every servicing operation on the lubrication system.
Check oil pressure in oil supply lines.
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Operation Manual Commissioning Inspection work 3 3.2 Page 3
3.2.2 Inspection after commissioning

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Lubricating system
Check oil pressure in oil supply lines.
Charger speed
Measuring
Charger pressure
Measuring
Temperatures
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Measure upstream/downstream from turbine, compressor and oil feed
for various engine speeds
Gas, air, and oil lines
After the engine has been started up, check all gas, air and oil lines for
leaks.
Further must be observed:
NOTE
Lubricants and pastes are liquefied or vaporised during assembly of the turbocharger and may escape as an oily liquid in the first few hours after commissioning. If oily liquid continues to escape after this period, the cause must be treated as an oil leak and located. The first step in this process is to check the oil supply to the turbocharger for leaks. If this is not in order, contact an official ABB Turbo Systems service station.
Measure the speed, oil pressure, charging pressure and temperatures
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before and after the turbine and the compressor at various engine speeds. Compare the measured values with those of the inspection report, taking into account the different operating conditions.
3.2.3 Inspection after 100 service hours

Clean or replace lubricating oil filters after the first 100 service hours.
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Operation Manual Commissioning Putting into operation after laying up 3 3.3 Page 4
3.3 Putting into operation after laying up

If provided
Remove the cover plates (blind flanges) between the compressor cas-
ing outlet and charge-air receiver, upstream of the gas inlet, downstream of the gas outlet.
Inspect the exhaust pipe before and after the turbine for any combus
tion residue, clean / remove foreign bodies or residual water. Inspect air supply line or filter silencer for any foreign bodies, clean / remove. Start up the turbocharger's engine end oil circulation system. Prepare the turbocharger for operation as instructed in the section Inspection work before commissioning in the chapter entitled Commissioning. Start up the turbocharger.
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Operation Manual Operation Servicing work 4 4.1 Page 1
4 Operation
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4.1 Servicing work

Servicing work during operation includes visual checks, monitoring and measuring as well as inspection and function checks in order to ensure correct functioning of the turbocharger. It serves as an aid to detecting anomalies during operation, thus preventing damage to the machine. The inspection, measurement and servicing operations listed must be carried out at the intervals indicated. The pertinent safety instructions must be observed during all servicing work.
WARNING
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Servicing work must be carried out at the prescribed intervals in order to avoid damage to and malfunctioning of the turbocharger.
CAUTION
4.1.1 Servicing work every 25 to 50 hours

Operation data
must be recorded Enter in the machine logbook In the event of significant anomalies, establish the cause
If you are unable to establish the cause of the anomalies, contact an official ABB Turbo Systems service station.
CAUTION
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Monitoring of the machine plant provides information about the performance of the turbocharger. The following operation data and measurement values must be entered regularly in the engine manufacturer's machine log book:

If provided
Air temperature after compressor and after the charge-air cooler Speed of the turbocharger Pressure loss in the air filter
4.1.3 Servicing work according to the engine manufacturer's instructions

Oil filters
With the engine at standstill clean or replace oil filters
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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
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4.1.2 Entries in the machine logbook
4.1.4 Servicing work every 8,000 - 12,000 hours

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

Dismantle the turbocharger Clearance measurement Clean turbine- and compressor casings and check for any cracks and
erosion / corrosion. Clean bearing casing, blow through oil ports Clean nozzle ring and check for cracks and erosion Inspection and assessment of the rotor Replacement of the plain bearings with original parts from ABB Turbo Systems
The replacement of the bearing parts as well as the inspection and assessment of the rotor must be carried out by an official ABB Turbo Systems service station.
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NOTE
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Operation Manual Operation Monitoring 4 4.2 Page 4
4.2 Monitoring
4.2.1 Speed measurement
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L_278
1 2 3 4 5
Bearing casing Axial bearing Guide in the axial bearing Gasket ring Screw plug
6 7 8 9
Connecting cable Line amplifier (option) Speed transmitter

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Installation variant of the speed transmitter
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Operation Manual Operation Monitoring 4 4.2 Page 5
The speed transmitter system for the measurement of the turbocharger speed also permits, in conjunction with the corresponding measuring instruments and/or monitoring systems (not included in the scope of delivery), a constant remote monitoring of the turbocharger speed. With continuous monitoring of the machine installation, the turbocharger speed can be used as a suitable control parameter. The line amplifier can be purchased as an optional addition to the described speed measuring system. Possible reasons for failure of the speed indicator:
Defects in the speed transmitter, the connecting cable and plug to the
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measuring unit, in the measuring unit itself or the power supply.
Turbocharger damage.
Failure of the speed indicator

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CAUTION
If the speed indication fails, it is recommended that the engine output be reduced to idling speed and the engine stopped. The cause of the failure should then be determined.
We recommend that subsequent assembly or replacement of the speed transmitter system should be carried out only by an official ABB Turbo Systems service station.
NOTE
A reduction in speed of a charger can signify:

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

NOTE
With 4-stroke applications, heavy fouling of the turbine can also be a cause of an increase in the turbocharger speed.
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Operation Manual Operation Surging of turbocharger 4 4.3 Page 6
4.3 Surging of turbocharger

Surging of the turbocharger can occur with certain engine operating states, such as rapid load removal or while manoeuvring. The direction of flow in the compressor is then briefly reversed. However, sporadic surging of this kind does not generally affect the safe operation of the turbocharger. Prolonged or periodic surging
CAUTION
If surging is prolonged or occurs periodically, the following components may be damaged: - Compressor wheel (vibration fractures, ...) - Turbine blades (cracks) - Bearing (overheating) - Filter silencer
Action to be taken: The operating safety of the turbocharger is no longer ensured with continuous or periodically recurring surging. The operator must take immediate steps to correct the surging together with the closest official ABB Turbo Systems service station. The components listed above must be inspected for damage by an official ABB Turbo Systems service station, and replaced in cases of doubt.
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Operation Manual Operation Contact with rotating parts 4 4.4 Page 7
4.4 Contact with rotating parts

Mild, uniform wear around the circumference of rotor components, caused by slight local grazing against adjacent components, is non-hazardous and permissible. This slightly reduces the length of the blades in the compressor and/or the turbine. Certain tolerances must be observed to avoid significant loss of efficiency.
A check on dimensions must be carried out by an official ABB Turbo
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Systems service station.
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Operation Manual Operation Shutting the engine down 4 4.5 Page 8
4.5 Shutting the engine down

Before shutting the engine down, it must be allowed to idle for about 3 minutes longer so that the circulating lubricating oil can dissipate the heat in the turbocharger bearings.
CAUTION
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Operation Manual Maintenance Foreword to Maintenance 5 5.1 Page 1
5 Maintenance
May 2006
5.1 Foreword to Maintenance

Cleaning work includes regular visual checks and washing to ensure the correct functioning of the turbocharger and its auxiliary appliances.
The external condition and the degree of contamination of the cleaning
points specified in this chapter must be established by visual checks at the intervals indicated. The safety instructions must be observed during all cleaning work.
HZTL2481_EN (TPL73-A.. - 80-A..)
The cleaning points described in the following are:
Filter silencer Compressor Turbine and nozzle ring
Version 2.0
ABB
Operation Manual Maintenance Cleaning the filter silencer 5 5.2 Page 2
5.2 Cleaning the filter silencer

5.2.1 Filter silencer with tension band
May 2006
L_00210
81265 81270 38271 81268 E
Filter ring (if provided) Tension ring Trap cover Connecting strip
81266 81136 81137 81135
Cover grids Fleece segment Cover panel Filter silencer body
Slide-in module = fleece segment + cover panel installed
ABB
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
Disassembling and cleaning the filter silencer

May 2006
If provided
Remove filter ring (81265). Rinse filter ring (81265) with water using detergent or, if very dirty, so-
ak it. Squeeze out carefully. Rinse in cold water. Avoid high mechanical stress (water jet).
The dirt in the filter ring (81265) depends on the cleanness of the air drawn in. Wash or replace the filter ring as necessary or every 500 service hours.
NOTE
Loosen tension bands (81270) on trap covers (81271) and carefully

HZTL2481_EN (TPL73-A.. - 80-A..)
remove cover grid (81266) from connecting strips (81268).
NOTE
In the case of a slide-in module (E), with a cleaning container attached to the filter silencer (available as option depending on turbocharger type) the water injection line must first be removed (see also following section Disassembling the cleaning line).
Pull the slide-in modules (E) out, bend the cover panels (81137) open,
and then take out the fleece segments (81136).
Clean fleece segments (81136).
When cleaning, ensure that the fleece segments (81136) are cleaned only with a mild jet of compressed air, a soft brush or damp cloth. Otherwise the segments may be damaged or lose their shape.
Version 2.0
Heavily soiled fleece segments and filter ring as well as damaged connecting strips should be replaced with original parts from ABB Turbo Systems.
NOTE
ABB
Assembling the filter silencer (81136) in the cover panels (81137).

Assemble the slide-in modules (E) by inserting fleece segments Bend the cover panels back to their original shape. Insert slide-in modules (E) in the grooves in the filter silencer body
(81135).
With a cleaning container fitted to the filter silencer (available as option depending on turbocharger type) the water injection line must now be re-installed (see also following section Assembling the cleaning line).
NOTE
When fitting, insert the cover grid (81266) into the connecting strips
(81268). Fit the tension bands (81270) and tighten on the trap covers (81271).
If provided
Fit filter ring (81265).
ABB
5.2.2 Filter silencer and connecting rod

May 2006 HZTL2481_EN (TPL73-A.. - 80-A..)
L_00185
81265 81269
Version 2.0
Filter ring (if provided) Connecting rods Cover grids Screw
81136 81137 81135 N
Fleece segment Cover panel Filter silencer body Locknut
81266 B E
Slide-in module = fleece segment + cover panel
ABB
Disassembling and cleaning the filter silencer

If provided
Rinse filter ring (81265) with water using detergent or, if very dirty, soak it. Squeeze out carefully. Rinse in cold water. Avoid high mechanical stress (water jet).
The dirt in the filter ring (81265) depends on the cleanness of the air drawn in. Wash or replace the filter ring as necessary or every 500 service hours.
NOTE
NOTE
In the case of a slide-in module (E), with a cleaning container attached to the filter silencer (available as option depending on turbocharger type) the water injection line must first be removed (see also following section Disassembling the cleaning line).
Withdraw the slide-in modules (E), bend open the cover panels
(81137) and then take out the fleece segments (81136). Clean fleece segment (81136). When cleaning, ensure that the fleece segments (81136) are cleaned only with a mild jet of compressed air and a soft brush or damp cloth. Otherwise the segments may be damaged or lose their shape. Heavily soiled fleece segments and filter ring as well as damaged connecting rods should be replaced with original parts from ABB Turbo Systems.
NOTE
ABB
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)

Loosen and remove locknuts (N). Loosen and remove screws (B) on connecting rods (81269). Remove connecting rods (81269). Carefully remove the cover grid (81266).
May 2006
Remove filter ring (81265).
Assembling the filter silencer

May 2006
Assemble the slide-in modules (E) by inserting fleece segments
(81136) in the cover panels (81137).
Bend cover panels (81137) back to their original shape. Insert slide-in modules (E) in the grooves in the filter silencer body
(81135).
With a cleaning container fitted to the filter silencer (available as option depending on turbocharger type) the water injection line must now be re-installed (see also following section Assembling the cleaning line).
NOTE
HZTL2481_EN (TPL73-A.. - 80-A..)
Place cover grids (81266) evenly in the correct position. Push the connecting rods (81269) through the clips on the cover grids
(81266).
If the connecting rods (81269) are not located correctly in their recesses on the filter silencer body (81135), the cover grid (81266) can twist and shift. This can allow foreign bodies and dirt to get into the compressor.
CAUTION
Version 2.0
L_00232
ABB
L_00234
Connect the connecting rods (81269) with screws (B). While tightening
the screws (B), ensure that the connecting rods (81269) are located correctly in the recesses in the filter silencer body (81135). Now tighten screws (B) alternately to the following max. tightening torque:
Tightening torque 20 Nm
Screw B
Fit locknuts (N) on screw (B) and tighten to the following torque: Locknut N Tightening torque 40 Nm
If provided
Fit filter ring (81265).

Version 2.0
ABB
HZTL2481_EN (TPL73-A.. - 80-A..)
May 2006
5.2.3 Removing / installing the cleaning line

May 2006 HZTL2481_EN (TPL73-A.. - 80-A..)
L_00192
1 3
Injection pipe Guide tube
Pipe
Removing the cleaning line

Disconnect the line (2) at the injection pipe (1) and remove the screw
Version 2.0
coupling from the pipe. Withdraw the pipe (2) from the guide tube (3).
ABB
Punch out the guide tube
L_00193
Punch the guide tube (3) out of the caulking with a bolt (diameter = 16
mm) and withdraw it.
Heavily soiled components of the cleaning line must be replaced with original parts from ABB Turbo Systems.
NOTE
ABB
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
May 2006
Installing the cleaning line

May 2006 HZTL2481_EN (TPL73-A.. - 80-A..)
L_00194
After fitting the slide-in modules (E), re-fit the guide tube (3) and re-
caulk it. Fit the pipe (2) and screw to the injection pipe (1).
Version 2.0
ABB
Operation Manual Maintenance Cleaning the compressor during operation 5 5.3 Page 12
5.3 Cleaning the compressor during operation

These guidelines for wet cleaning apply exclusively for cleaning with clean water and are subject to permission for the procedure being obtained from the engine manufacturer.
NOTE
The dirt in the compressor stage (compressor wheel and diffuser) depends on the cleanness of the air drawn in and the operating point. A deposit of dirt in the flow ducts will be formed if the following substances are present in the intake air:
Oil or saline mist Solid combustion residues Dust of various kinds
Soiling of the compressor stage has a negative effect on compressor efficiency and charging pressure, particularly for smaller turbochargers. This results in higher exhaust temperatures and increased fuel consumption by the engine. Contamination of the compressor also increases the rotor imbalance. Periodic cleaning of the compressor in operation prevents or retards a severe increase in soiling, but in no way replaces the regular servicing work, during which the turbocharger is completely dismantled.
Interval between cleanings
The interval between periodic cleaning depends in large measure on the operating conditions. In general, cleaning should be carried out every 25 to 100 operating hours. Should the prescribed cleaning intervals prove incompatible with the operation of the ship, please contact ABB Turbo Systems.
NOTE
ABB
Operation Manual Maintenance Cleaning the compressor during operation Cleaning method
May 2006
5 5.3 Page 13
The compressor is cleaned while operating using the cleaning method described in the following. This method has been tested and is approved by ABB Turbo Systems:
Wet cleaning
Principle of wet cleaning
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 removed by the mechanical impact of the drops. The process is ideal, provided the soiling is not too advanced.
HZTL2481_EN (TPL73-A.. - 80-A..)
Due to the danger of corrosion, only clean water may be used, and on no account salt water. The water should also contain no cooling additives, which could form deposits in the flow ducts.
CAUTION
Cleaning more than one turbocharger compressor
If several turbochargers are installed on one engine, we recommend cleaning the turbocharger compressors one after the other.
V-engines
For V-engines with several turbochargers on each engine, we recommend parallel cleaning of the compressors. This cleaning process is faster and avoids the risk of engine surging.
Version 2.0
Register supercharging
With register supercharging it must be ensured that both turbocharger compressors are cleaned regularly, especially following periods of operation in the lower performance range.
ABB
5.3.1 Wet cleaning the compressor with external pressurised water container (XC3)
The water feed with the externally mounted dosing vessel is only suitable for applications with underpressure upstream of the compressor wheel (cannot be used for: Blower connected upstream of the compressor or high-pressure compressor stage in the case of two-stage charging).
NOTE
Operating state preconditions for cleaning compressors with XC3
In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following preconditions must be met:
NOTE
Engine warm from running (engine under full loading as far as possi-
ble) High turbocharger speed Cleaning cycle started according to the following description in Procedure for wet cleaning with XC3.
ABB
Procedure for compressor wet cleaning with XC3

May 2006 HZTL2481_EN (TPL73-A.. - 80-A..)
L_00198
X Y
Screw plug Valve lever
Operating the pressure water vessel
The Operating state preconditions for cleaning compressors with XC3
must be met before cleaning can begin. Remove the screw plug (X). Fill the vessel with pure water. Tighten screw plug (X). Actuate valve lever (Y) against the spring and hold it for 10 to 15 seconds until all the water has been injected. After cleaning, a waiting time of at least 5 minutes is necessary to allow the turbocharger to dry.
Version 2.0
ABB
If the cleaning operation is unsuccessful, it can be repeated up to 2 times.

NOTE
If cleaning is still unsuccessful after three attempts and the engine operating values are unsatisfactory, we recommend that the turbocharger be checked and cleaned by an official ABB Turbo Systems service station.
Cleaning parameters for XC3 for each turbocharger compressor

Turbocharger type Turbocharger speed If possible nBmax Contents of the dosing vessel [dm3] 0.4 1.0 1.0 2.0 Water injection time t1 [s] 415
HZTL2481_EN (TPL73-A.. - 80-A..)
TPL65-A TPL69-A TPL73-A TPL77-A TPL80-A
ABB
Version 2.0
May 2006
5.3.2 Wet cleaning compressors with water vessel (XC4)

May 2006
Operating state preconditions for cleaning compressors with XC4
NOTE
Engine warm from running (engine under full loading as far as possi-
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
ble) High turbocharger speed Cleaning cycle started according to the following description in Procedure for wet cleaning with XC4.
ABB
Procedure for compressor wet cleaning with XC4

May 2006
L_00197
1 3 5
Cleaning container Injection pipe Cover
2 Pipe 4 Cleaning instructions 6 Valve
If the cleaning container on the filter silencer is used, the detailed cleaning instructions provided on the plate (4) fitted to the filter silencer should be followed.
NOTE
Version 2.0
Use of cleaning container
The Operating state preconditions for cleaning compressors with XC4
must be met before cleaning can begin. Open filling cap (5) on cleaning container (1). Fill with clean water. Screw filling cap (5) back into place. Open valve (6) for about 3 minutes. Close valve (6) and check that all the water has been sucked out. After cleaning, a waiting time of at least 5 minutes with the engine running must be allowed so that the turbocharger can dry.
ABB
HZTL2481_EN (TPL73-A.. - 80-A..)
If the cleaning operation is unsuccessful, it can be repeated up to 2 times.

May 2006
NOTE
If cleaning is still unsuccessful after three attempts and the engine operating values are unsatisfactory, we recommend that the turbocharger be checked and cleaned by an official ABB Turbo Systems service station.
Cleaning parameters for XC4 for each turbocharger compressor

Turbocharger type Turbocharger speed If possible nBmax Contents of the dosing vessel [dm3] 0.4 2 3 Water injection time t1 [s] 415
TPL65-A
HZTL2481_EN (TPL73-A.. - 80-A..)
TPL69-A TPL73-A TPL77-A TPL80-A
Version 2.0
ABB
Operation Manual Maintenance Cleaning turbine blades and nozzle ring in operation 5 5.4 Page 20
5.4 Cleaning turbine blades and nozzle ring in operation

Combustion of heavy fuel oil in diesel engines causes soiling of the turbine blades and nozzle rings of the turbochargers. The deposits on the turbine components are caused by the following products of combustion:

Soot Molten ash Cinders Incompletely burned fuel Sodium vanadyl vanadate
Therefore, it is advantageous to use fuels with a low content of ash, sulphur, sodium and vanadium. The fuel must also be stored, prepared and handled correctly. We recommend the use of fuels with a mass ratio of vanadium to sodium less than 3:1, so that the melting point of the sodium vanadyl vanadate is as high as possible.
NOTE
Soiling increases with time, so that regular and properly performed cleaning is important to remove the accumulated deposits. The charging pressure can rise somewhat if the turbine profile is constricted due to fouled turbine components. Contamination causes loss of performance in the turbine and the engine temperature after the cylinders can increase. This may mean that the engine output has to be reduced. 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 turbine and nozzle ring are mechanically cleaned. However, if cleaning is performed correctly and the cleaning system is properly dimensioned, the intervals between overhauls can be extended.
ABB
Operation Manual Maintenance Cleaning turbine blades and nozzle ring in operation
Wet cleaning interval
5 5.4 Page 21
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.
May 2006
Cleaning method The turbine and nozzle ring are cleaned while operating using the cleaning method described in the following. This method has been tested and is approved by ABB Turbo Systems:
Wet cleaning
HZTL2481_EN (TPL73-A.. - 80-A..)
The dry cleaning method may be used as an alternative to wet cleaning. However, this is not the preferred method, and must be approved by an official ABB Turbo Systems service station.
NOTE Principle of wet cleaning
During wet cleaning using droplets of water, the water does not act as a solvent. Instead, the deposit is removed by the mechanical impact of the drops.
Due to the danger of corrosion, only clean water may be used, and on no account salt water. The water should also contain no cooling additives, which could form deposits in the flow ducts.
CAUTION
Version 2.0
Should the prescribed cleaning intervals prove incompatible with the operation of the ship, please contact ABB Turbo Systems.
NOTE
ABB
Stabilising and drying time
5 5.4 Page 22
NOTE
Cleaning of the turbine-side components begins after engine start or reduction of engine load. The exhaust temperature must not exceed the value specified in the corresponding cleaning instructions (see the respective section Operating state preconditions).
CAUTION
Failure to maintain the prescribed exhaust temperature upstream of the turbine, and to allow the minimum stabilising time before and between cleaning procedures and the drying time after cleaning in accordance with the pertinent cleaning instructions will shorten the expected service life of the components significantly. For V-engines with several turbochargers on each engine, we recommend parallel cleaning of both turbochargers. This cleaning process is faster and avoids the risk of engine surging. We recommend conducting tests to find the most suitable method. With register supercharging it must be ensured that both turbocharger turbines and nozzle rings are cleaned regularly, especially following periods of operation in the lower performance range.
V-engines
Register supercharging
ABB
May 2006
5.4.1 Wet cleaning the turbine and nozzle ring during operation
May 2006
The maximum exhaust gas temperature specified by the engine manufacturer and the TMmax temperature as shown on the turbocharger rating plate must not be exceeded under any circumstances. During wet cleaning, the turbine is braked and the turbocharger operates at reduced speed. As a result, less air is supplied to the engine and the temperature after the engine cylinder and exhaust valve rises.
Operating state preconditions for wet cleaning the turbine and nozzle ring during operation
HZTL2481_EN (TPL73-A.. - 80-A..)
NOTE
After the engine is started up or the engine load has been reduced to
the lowest possible level
Wait 10 to 15 minutes (stabilising time) until the turbine inlet tem-
perature is stable and less than 430C. Cleaning cycle started according to the following description in Procedure for wet cleaning
Version 2.0
ABB
Procedure for wet cleaning the turbine and nozzle ring (1 nozzle)
May 2006
In engines with one turbocharger (TL 1)
L_00203
In V-engines with two turbochargers (TL 1 and 2)
L_00204
ABB
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
1 2
May 2006
5 5.4 Page 25
Water supply (freshwater only) 6 Regulating valve Manometer Air supply with 3-way-valve Stainless steel piping 7 8 9 10
Other turbochargers Injection pipe Drainage line Drain cock Outflow
3 4 5 11
Baffle (optional, can be integrated in the nozzle)
Operating the wet cleaning system
The Operating state preconditions must have been fulfilled before
HZTL2481_EN (TPL73-A.. - 80-A..)

cleaning is begun! Check that the water supply (1) is connected, open and reliable. Open the drain pipe (8, 9) on the gas outlet casing. Connect the water supply (1) to the regulating valve (2) upstream of the turbocharger. Slowly open the 3-way-valve (4) first, then the regulating valve (2) until the manometer (3) shows a pressure of 2 0.2 bar. Inject water for 10 minutes. Check whether the exhaust-gas temperature after the turbine drops. Close the regulating valve (2) and the 3-way-valve (4). Close the drain pipe (8, 9) on the gas outlet casing. The water supply connection (1) must be isolated at the regulating valve (2). After cleaning, a waiting time of at least 10 minutes with the engine running must be allowed so that the turbocharger can dry.
The repeating of cleaning cycles directly one after the other is to be avoided, since this can lead to a high mechanical load and consequently to a reduction in the service life of the components.
NOTE
If the cleaning process is unsuccessful, the time of this can be extended. With an extension of the injection time it must be ensured, that no unacceptable quantity of water collects in the gas outlet casing. For this purpose, a drainage system for the gas outlet casing must be installed and be open during the cleaning. If no drainage system is present, the injected quantity of water can be controlled with a flow meter in the water supply. What maximum quantity of water is permitted in individual cases, is to be established with an official ABB Turbo Systems service station. The influence of the cleaning water on the peripheral aggregates (such as e.g. Boiler) must be clarified by the operator.
Version 2.0
ABB
Points to remember when cleaning
5 5.4 Page 26
The gas outlet casing must be drained of water via the drain pipe (8)
when cleaning. The exhaust-gas temperature after the turbocharger falls significantly during cleaning (by 50 to 150C). Outflow can (but need not) take place through the drain-pipe, depending on the engine load. This outflow might not start for 2 - 3 minutes, or it may not occur at all. If draining is not carried out, the turbocharger speed and / or gas inlet temperature must be monitored closely during the washing operation. If the load is too low, water can collect in the gas outlet casing. Signs of this are a sudden fall in the turbocharger speed or very rapid increase in the gas inlet temperature. In either of these case, washing must be stopped immediately and the washing cycle repeated from the beginning with lower water pressure or higher engine load.
ABB
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
May 2006
Procedure for wet cleaning the turbine and nozzle ring (2 nozzles)
May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)
L_00252
Version 2.0
L_00253
ABB
1 2 3 4 5 11 Water supply (freshwater only) Regulating valve Manometer Air supply with 3-way-valve Stainless steel piping 6 7 8 9 10
5 5.4 Page 28
Other turbochargers Injection pipe Drainage line Drain cock Outflow
Baffle (optional, can be integrated in the nozzle)
The Operating state preconditions must have been fulfilled before
cleaning is begun! Check that the water supply (1) is connected, open and reliable. Open the drain pipe (8, 9) on the gas outlet casing. Connect the water supply (1) to the regulating valve (2) upstream of the turbocharger. Slowly open the 3-way-valve (4) first, then the regulating valve (2) until the manometer (3) shows a pressure of 2 0.2 bar. Inject water for 10 minutes. Check whether the exhaust-gas temperature after the turbine drops. Close the regulating valve (2) and the 3-way-valve (4). Close the drain pipe (8, 9) on the gas outlet casing. The water supply connection (1) must be isolated at the regulating valve (2). After cleaning, a waiting time of at least 10 minutes with the engine running must be allowed so that the turbocharger can dry.
NOTE
ABB
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
May 2006
May 2006
5 5.4 Page 29
The gas outlet casing must be drained of water via the drain pipe (8)
when cleaning. The exhaust-gas temperature after the turbocharger falls significantly during cleaning (by 50 to 150C). Outflow can (but need not) take place through the drain-pipe, depending on the engine load. This outflow might not start for 2 - 3 minutes, or it may not occur at all. If draining is not carried out, the turbocharger speed and / or gas inlet temperature must be monitored closely during the washing operation. If the load is too low, water can collect in the gas outlet casing. Signs of this are a sudden fall in the turbocharger speed or very rapid increase in the gas inlet temperature. In either of these case, washing must be stopped immediately and the washing cycle repeated from the beginning with lower water pressure or higher engine load.
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
ABB
Operating state preconditions for wet cleaning the turbine and nozzle ring
May 2006
(3 nozzles)
NOTE
Reduction of engine loading to the lowest possible level The best cleaning effect is achieved at a loading level of 20 to 30%. Wait 10 to 15 minutes (stabilising time) until the turbine inlet tem-
ABB
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
perature is stable and less than 430C. Cleaning cycle started according to the following description in Procedure for wet cleaning
Procedure for wet cleaning the turbine and nozzle ring (3 nozzles)
May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)
L_00200
Version 2.0
L_00201
ABB
1 2 3 4 5 Water supply (freshwater only) Regulating valve Manometer Air supply with 3-way-valve 6 7 8 9
5 5.4 Page 32
other turbochargers 3 injection nozzles Drain cock Outflow

May 2006
Drainage line
Water pipe made from stainless 10 steel
The operating state preconditions must be met before cleaning can
begin! Ensure that the water supply (1) is connected, turned on and constant. Open the drainage line (8,9). First open the 3-way valve (4), then open the regulating valve (2) slowly until the pressure gauge (3) indicates a pressure of 2.5 bar. Inject water for 10 minutes. Check whether the exhaust gas temperature falls after the turbine. Close the regulating valve (2). This completes the cleaning process. The water supply must be disconnected from the gas inlet casing. Switching the 3-way-valve (4) for the water supply to blow-out mode with compressed air. Close drain hole (at 8) above drainage line (8,9). After cleaning, a waiting time of at least 10 minutes with the engine running must be allowed so that the turbocharger can dry.
NOTE
ABB
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
May 2006
5 5.4 Page 33
The gas outlet casing should be drained via the drainage line (8) during
cleaning. The exhaust-gas temperature after the turbocharger falls significantly during cleaning (by 50 to 150C). Outflow can (but need not) take place through the drain-pipe, depending on the engine load. This outflow might not start for 2 - 3 minutes, or it may not occur at all. If draining is not carried out, the turbocharger speed and / or gas inlet temperature must be monitored closely during the washing operation. If the load is too low, water can collect in the gas outlet casing. Signs of this are a sudden fall in the turbocharger speed or very rapid increase in the gas inlet temperature. In either of these cases, the washing operation must be terminated and the washing cycle begun again with a lower water pressure or higher engine loading.
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
ABB
Operation Manual Troubleshooting Possible remedies for failures 6 6.1 Page 1
6 Troubleshooting
May 2006
6.1 Possible remedies for failures

Exhaust temperature too high Engine output and speed unchanged
Engine
Malfunction in the injection system Repair, or contact the manufacturer.
HZTL2481_EN (TPL73-A.. - 80-A..)
Turbocharger
Air starvation, e.g. air filter clogged with dirt Clean Compressor / turbine soiled Clean Exhaust counterpressure too high Clean or repair boiler or exhaust silencer Turbine damaged or worn Contact an official ABB Turbo Systems service station.
Charge-air cooler
Cooler soiled Clean Insufficient coolant water quantity Replenish
Version 2.0
Coolant water inlet temperature too hot Clean/inspect cooling system Ventilation inadequate Improve ventilation
ABB
Charge-air pressure too low

May 2006
Engine output and speed unchanged Intake condition normal
Engine
Air receiver leaking Repair Gas line between engine and turbine leaking Repair Injection misadjusted Correct adjustment Valve control misadjusted Correct adjustment
HZTL2481_EN (TPL73-A.. - 80-A..)
Turbocharger
Manometer display faulty Replace manometer Leak in line to the manometer Repair leak Air filter dirty, causing excessive loss of pressure Clean Compressor / turbine soiled Clean Compressor / turbine damaged Contact an official ABB Turbo Systems service station. Excessive exhaust counterpressure Clean boiler or exhaust silencer
ABB
Version 2.0
Charge-air pressure too high

May 2006
Engine output and speed unchanged Intake condition normal
Engine
Malfunction in the injection system Correct adjustment Engine output higher than expected Check engine output Injection misadjusted Correct adjustment
HZTL2481_EN (TPL73-A.. - 80-A..)
Turbocharger
Manometer display faulty Replace manometer
Vibrations
Turbocharger

Rotor imbalance due to heavy fouling of compressor/turbine Turbine or compressor damaged Bearing defective Contact an official ABB Turbo Systems service station.
Noises during run-out

Turbocharger
Turbocharger dirty Clean
Version 2.0
Bearing damaged Rotor grazing Foreign bodies in the turbocharger Contact an official ABB Turbo Systems service station.
ABB
Run-out time too short

Turbocharger
May 2006
Sluggish start-up
Turbocharger

Lubricating oil pressure too low

Engine
Oil filter heavily soiled Clean Oil pump in the lubricating system defective Inspect Manometer provides false reading Replace manometer
ABB
Version 2.0
Turbocharger
Axial clearance of the rotor too big Contact an official ABB Turbo Systems service station.
HZTL2481_EN (TPL73-A.. - 80-A..)
Constant surging of the turbocharger

May 2006
Engine
Exhaust pressure after the turbine elevated because boiler or exhaust
silencer is dirty
Trap dirty Clean
Turbocharger
Charge-air cooler or silencer dirty Heavy deposits of contamination in the turbine Clean
HZTL2481_EN (TPL73-A.. - 80-A..)
If it is not possible to determine the reason for the surging, contact an official ABB Turbo Systems service station.
NOTE
Version 2.0
ABB
Operation Manual Removal and installation Turbocharger weights 7 7.1 Page 1
7 Removal and installation

May 2006
7.1 Turbocharger weights

Attach individual parts and larger component modules carefully to suitable hoists/lifting devices which are in technically perfect condition and which have adequate load-bearing capacity.
WARNING
Turbocharger parts that are not suspended in accordance with the regulations during disassembly and assembly may fall and can cause serious or even fatal injury.
Select a suitable rope taking into account the weight of the turbo-
charger parts.
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
Cross and loop the rope over the crane hook Do not stand under suspended loads.
L_00082
For the safety of loads on the crane hook, the ropes must be suspended crossed over each other. See also previous illustration.
WARNING
ABB
Operation Manual Removal and installation Turbocharger weights 7 7.1 Page 2
Turbocharger complete unit without silencer/air suction branch

May 2006
Weights [kg]
TPL 73 2080
TPL 77 3200
TPL 80 4920
Turbocharger complete unit with silencer

Weights [kg]
TPL 73 2324
TPL 77 3604
TPL 80 5496
Turbocharger complete unit with air suction branch

Weights [kg]
TPL 73 2220
TPL 77 3355
TPL 80 5162
ABB
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
Operation Manual Removal and installation Remove the turbocharger 7 7.2 Page 3
7.2 Remove the turbocharger

May 2006
Disconnect all gas, air, and oil lines in accordance with the engine ma-
nufacturers instructions.
NOTE
The two oil supply channels in the bearing casing are fitted with one orifice each. In order to obtain the required oil pressure, the of this orifice has been individually adjusted by the engine builder. Whenever these orifices are removed, or if the bearing casing or the complete turbocharger is replaced, it is essential to ensure that the orifice with the correct is fitted into the oil-conducting oil-inlet channel.
Remove the insulating shell from the bearing casing. Check the lifting equipment. Secure lifting equipment to the suspension lugs on the bearing casing.
HZTL2481_EN (TPL73-A.. - 80-A..)
Observe weight of the turbocharger.

CAUTION
Version 2.0
ABB
Turbocharger without reinforced suspension lug

May 2006
L_00052
During removal, a turbocharger that is not lifted in compliance with regulations may fall, and can cause serious or even fatal injury.
WARNING
(lugs are flush with external diameter of the flange), the complete charger must be secured by the air outlet casing and gas inlet casing. See following illustration. Select a suitable rope taking into account the weight of the turbocharger.
ABB
Version 2.0
If the bearing casing is not provided with a reinforced suspension lug
HZTL2481_EN (TPL73-A.. - 80-A..)
Turbocharger with reinforced suspension lug

May 2006 HZTL2481_EN (TPL73-A.. - 80-A..)
L_00051
Release the fixing screws on the foot. Lift the turbocharger from the engine and place it aside.
If the support for the turbocharger is missing or defective, the turbocharger may tip over during installation and removal and can cause serious or even fatal injury.
WARNING
Version 2.0
Support turbocharger in a suitable location. Cover oil connector.
ABB
Operation Manual Removal and installation Installing the turbocharger 7 7.3 Page 6
7.3 Installing the turbocharger

During installation, a turbocharger that is not lifted in compliance with regulations may fall, and can cause serious or even fatal injury.
WARNING
If the bearing casing is not provided with a reinforced suspension
lug, the complete charger must be secured by the air outlet casing and gas inlet casing. Select a suitable rope taking into account the weight of the turbocharger. Suspend the complete turbocharger using the two ribs provided for this purpose.
Remove cover from the oil connector. Check the lifting equipment. Secure lifting equipment to the suspension lugs on the bearing casing.
If provided
Secure the lifting equipment to the suspension lugs on the gas inlet ca-
sing (see illustration under Removing the turbocharger).
Observe weight of the turbocharger.

CAUTION
Mate turbocharger with the engine. Tighten the fixing screws on the foot, in accordance with the engine
manufacturer's instructions. Mate the insulating shell with the bearing casing and secure. Secure all gas, air, and oil lines in accordance with the engine manufacturers instructions.
ABB
Operation Manual Disassembly and assembly Module weights 8 8.1 Page 1
8 Disassembly and assembly

May 2006
8.1 Module weights

Attach individual parts and larger component modules carefully to suitable hoists/lifting devices which are in technically perfect condition and which have adequate load-bearing capacity.
WARNING
Turbocharger parts that are not suspended in accordance with the regulations during disassembly and assembly may fall and can cause serious or even fatal injury.
Select a suitable rope taking into account the weight of the turbo-
charger parts.
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
Cross and loop the rope over the crane hook Do not stand under suspended loads.
L_00082
For the safety of loads on the crane hook, the ropes must be suspended crossed over each other. See also previous illustration.
WARNING
ABB
Modules
May 2006
L_00048
Weights [kg]
Description 1 2 3 4 5 6 7 8 9 10 Air suction branch, radial Air suction branch, axial Filter silencer Compressor casing, internal part Wall insert Diffuser Compressor casing external part Cartridge group Turbine diffuser Nozzle ring
TPL 73 140 244 148 134 57 290 546 72 25
TPL 77 155 404 260 276 80 475 950 150 44
TPL 80 242 576 355 125 680 1356 250 63

Version 2.0
431
ABB
HZTL2481_EN (TPL73-A.. - 80-A..)
Compressor casing, internal part, complete

Weights [kg]
May 2006
TPL 73 339
TPL 77 616
TPL 80 911
The total weight of the complete internal part of the compressor casing includes the internal part of the compressor casing, the diffuser and the wall insert.
NOTE
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
ABB
Operation Manual Disassembly and assembly 8 Page 4
Removing and fitting the filter silencer or 8.2 air suction branch
8.2 Removing and fitting the filter silencer or air suction branch
Not all tools are identified with a part number. The identification of the tools is ensured with the tools list (included in the toolbox).
NOTE
Remove insulation where necessary. Disconnect all air ducts in accordance with the engine manufacturers
instructions.
TPL 69 - 73
81000_003
Fit safety ring bolt (90231) on the filter silencer.
ABB
TPL 77 - 85
HZTL2481_EN (TPL73-A.. - 80-A..)
May 2006
L_00011
Fit safety ring bolt (90231) in the bearing plate (P) on the filter silencer.
TPL 77 85
Version 2.0
L_00226
Mount shackle (90195) on the fin on the filter silencer.
ABB
Remove filter silencer
Sling lifting gear through the loops at the rear and secure to the
Install the filter silencer
The filter silencer or air suction branch is installed in the reverse se-
quence.
ABB
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
May 2006
shackle (90195) or to the safety ring bolt (90231) with a shackle. Release nuts (74027) with Verbus washers (74028) and remove the filter silencer or air suction branch.
Operation Manual Disassembly and assembly Removing cartridge group 8 8.3 Page 7
8.3 Removing cartridge group

May 2006
Not all tools are identified with a part number. The identification of the tools is ensured with the tools list (included in the toolbox).
NOTE
Remove insulation Disconnect the oil lines in accordance with the engine manufacturer's
instructions.
If provided:
HZTL2481_EN (TPL73-A.. - 80-A..)
Position of the safety segments before disassembly
Take nuts (90458) out of the toolbox and fit them on the threaded pins
of the safety segments (Y) on the internal part of the compressor casing (76000).
L_00269
Version 2.0
Tighten nuts (90458) to a maximum torque of 30 Nm. The internal part of the compressor casing is now detached from the
external part of the compressor casing (74000) and can be removed.
Note control dimension (u).

NOTE
ABB
Control dimension u [mm]
Dimension u
TPL73-A 18.6
TPL77-A 19.0
TPL80-A 19.6
May 2006
L_00266
Release and remove nuts (74027) and discs (74028). Remove six studs (74026) in the upper section and and fit four guide
bolts (90320).
Leave 2 holes free for fitting the lifting device (90190). Push back internal part of compressor casing (76000) with extraction

screws (90900) until the lifting device (90190) can be attached with shackle (90195) and secured to the crane. Raise internal part of compressor casing slightly with wall insert and diffuser, remove guide bolts (90320) and then withdraw. Fit support angle (90025). Place internal part of compressor casing with wall insert and diffuser on support bracket and shim. Remove O-ring gasket (76040).
ABB
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
Compressor casing, internal part

May 2006 HZTL2481_EN (TPL73-A.. - 80-A..)
L_00047
Refit the lifting device on the other side of the flange (F). Turn the internal part of the compressor casing with wall insert and dif-
fuser carefully over the support bracket (90025) and set down with the front side of the flange (F) on the shim.
Version 2.0
Ensure that the shim does not slip.

Check shim and adjust as necessary.
CAUTION
ABB
Diffuser
L_00053
NOTE
Loosen and remove screws (76002).

If provided:
Fit safety ring bolts (90230) on diffuser (79000).
Remove diffuser (79000).
ABB
Version 2.0
For the turbocharger sizes up to and including TPL 73-A, the diffuser is positioned by hand and therefore has no threaded holes in the diffuser for the safety ring bolt 90230.
HZTL2481_EN (TPL73-A.. - 80-A..)
May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)
May 2006
Compressor casing external part
74000_002
Secure lifting device (90190) with shackle (90195) to external part of
compressor casing (74000) and attach securely to the crane. Loosen nuts (61037), press off external part of compressor casing evenly with the three press-off nuts (61037) and remove.
Version 2.0
ABB
Cartridge group
L_00054
Withdraw cable (86515) and unscrew speed measuring transmitter
(86505) with O-ring gasket (86506).
If provided:
Disconnect cable to line amplifier (86525).
Remove the three screws (61059) and Verbus washers (61058). Check lifting equipment and secure to bearing casing (42001).
ABB
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
May 2006
During removal, a cartridge group that is not lifted in compliance with regulations may fall, and can cause serious or even fatal injury.
May 2006
CAUTION
Select a suitable rope taking into account the weight of the cartridge
group.
Press cartridge group down evenly with jack screws (90900) into the
holes provided.
If the turbine blades on the rotor have too little or no clearance, this may damage the blades and the casing.
CAUTION
By turning the rotor, check that the turbine blades do not touch the
turbine diffuser.
HZTL2481_EN (TPL73-A.. - 80-A..)
Extract the cartridge group and fit supports (90450). Cover oil connections.
Work that exceeds the scope of the description in this chapter must only be performed by a trained fitter from an official ABB Turbo Systems service station.
CAUTION
Version 2.0
ABB
Operation Manual Disassembly and assembly Axial clearance 8 8.4 Page 14
8.4 Axial clearance

May 2006
01000_001
Axial clearance A must be measured after the cartridge group is re-
moved and before it is fitted. Measure and note the axial clearance A.
Clearance A [mm]
TPL 73 0.36 - 0.53
TPL 77 0.39 - 0.57
TPL 80 0.42 - 0.65
If the axial clearance (A) is out of tolerance, an official service station of ABB Turbo Systems must be contacted.
CAUTION
ABB
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
Operation Manual Disassembly and assembly Dismantling and installing the turbine diffuser and nozzle ring 8 8.5 Page 15
8.5 Dismantling and installing the turbine diffuser and nozzle ring
May 2006 HZTL2481_EN (TPL73-A.. - 80-A..)
L_00055
Place clamp (90921) over stud (61036) until it lies flush with the inner
radius of the gas outlet casing. Insert extension (A) of torque spanner (B) through the clamp hole and release the torque of screws (61056) and Verbus washers (61057) in succession. Do not yet remove the screws (61056) and Verbus washers (61057).
Version 2.0
ABB
Operation Manual Disassembly and assembly Dismantling and installing the turbine diffuser and nozzle ring
Removing the turbine diffuser
May 2006
8 8.5 Page 16
56001_001
In the upper section of the turbine diffuser (63000), replace the two
screws (61056) and Verbus washers (61057) with two guide bolts (90320). Pass the guide bolts through the holes in clamps (90921). To secure, fit hexagon nuts (90178).
ABB
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
Secure diffuser
May 2006 HZTL2481_EN (TPL73-A.. - 80-A..)
61000_002
Before dismantling the turbine diffuser, if possible the nozzle ring
should be secured against falling with a clamping set and a wooden block. Loosen the remaining screws (61056) and Verbus washers (61057). Push back the turbine diffuser (63000) with extraction screws (90901) and withdraw the turbine diffuser until clamp (90921) contacts the hexheaded nut (90178). If the nozzle ring is not secured when the turbine diffuser is withdrawn, it may fall. Note that the nozzle ring (56001) hangs loosely from the positioning pins.
CAUTION
Version 2.0
Fix turbine diffuser (63000) to the lifting gear and remove.
ABB
Operation Manual Disassembly and assembly Dismantling and installing the turbine diffuser and nozzle ring
Remove diffuser
8 8.5 Page 18
56001_002
Fix the holder (90490) on gas outlet casing.
ABB
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)
May 2006
56001_003
Draw the nozzle ring (56001) forward, fix the nozzle ring to the lifting
gear and remove.
Version 2.0
ABB
Fitting the turbine diffuser and nozzle ring

Fitting
for removal.
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 the gas casings with Anti Scuff Paste 868 from SPANJAARD.
NOTE
CAUTION
ABB
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
May 2006
Fit the nozzle ring and the turbine diffuser by reversing the sequence
Operation Manual Disassembly and assembly Installing the cartridge group 8 8.6 Page 21
8.6 Installing the cartridge group

May 2006 HZTL2481_EN (TPL73-A.. - 80-A..)
L_00054
Remove cover from the oil connector. Check the lifting equipment and secure it to the bearing casing (42001)
Version 2.0
so that the cartridge group is hanging straight. Remove supports (90450) and carefully insert cartridge group. Tighten screws (61059) and the Verbus washers (61058) evenly.
ABB
If the blades on the rotor have too little or no clearance, this may damage the blades and the casing.
CAUTION
By turning the rotor, check that the turbine blades do not touch the
turbine diffuser.
Remove lifting equipment.

If provided:
Connect cable to line amplifier (86525).
Screw in the speed measuring transmitter (86505) with O-ring gasket
(86506) and connect cable (86515).
74000_002
Secure lifting device (90190) and shackle (90195) to external part of
compressor casing (74000) and attach securely to the crane. Assemble the external part of the compressor casing (74000) and secure with nuts (61037). Before fitting the external part of the compressor casing, screw three press-off nuts (61037) to the end of the thread on the studs provided for this purpose.
NOTE
ABB
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)
May 2006
L_00053
Version 2.0
For the turbocharger sizes up to and including TPL 73-A, the diffuser is positioned by hand and therefore has no threaded holes in the diffuser for the safety ring bolt 90230.
NOTE If provided
Transport diffuser (79000) with the fitted safety ring bolts (90230). Mount diffuser (79000) and align. Remove safety ring bolts. Fit the diffuser with the screws (76002).
ABB
L_00047
Attach the lifting device (90190) and shackle (90195) securely to the
back side of flange (F). Turn the internal part of compressor casing with wall insert and diffuser carefully over the support bracket (90025) to the vertical position and set down on the shim and support bracket.
Version 2.0
ABB
HZTL2481_EN (TPL73-A.. - 80-A..)
May 2006
HZTL2481_EN (TPL73-A.. - 80-A..)
May 2006
L_00266
Check that the nuts (90348) on the three safety segments are all tight-
ened.
Attach the lifting device (90190) and shackle (90195) securely to the
front side of flange (F). Fit O-ring gasket (76040). Remove the support angle. (90025) Fit four guide bolts (90320). Carefully place the internal part of the compressor casing together with the wall insert and the diffuser over the guide bolts.
Version 2.0
If provided:
Position of the safety segments after assembly
Loosen nuts (90458) on the threaded pins of the safety segments (Y)
on the internal part of the compressor casing (76000) and push the threaded pins together with safety segment (Y) as far as they will go against the external part of the compressor casing (74000).
The internal part of the compressor casing (76000) is now secured a-
gainst the external part of the compressor casing (74000).
ABB
L_00276
Note control dimension (s). Safety segments (Y) are in an operating state again.
NOTE Control dimension s [mm]
Dimension s
TPL73-A 12.1
TPL77-A 12.9
TPL80-A 11.9
Replace the nuts (90458) that were taken from the toolbox.
Measure and note the axial clearance

Clearance A [mm]
TPL 73 0.36 - 0.53
TPL 77 0.39 - 0.60
TPL 80 0.42 - 0.65
If the axial clearance A is out of tolerance, an official service station of ABB Turbo Systems Ltd. must be contacted.
CAUTION
manufacturers instructions.
Mount filter silencer or air suction branch and secure with nuts (72027)
and Verbus washers (74028). Fit insulation again.
CAUTION
ABB
Version 2.0
Connect the oil lines and all air lines in accordance with the engine
HZTL2481_EN (TPL73-A.. - 80-A..)
May 2006
Operation Manual Disassembly and assembly Turbine-end removal / fitting of the nozzle ring 8 8.7 Page 27
8.7 Turbine-end removal / fitting of the nozzle ring

May 2006
If only the nozzle ring has to be removed, it is possible to dismantle it at the turbine end.
NOTE
HZTL2481_EN (TPL73-A.. - 80-A..)
L_00290
Disassembly of the nozzle ring

Version 2.0
Remove the insulation on the gas inlet casing (51001). Secure the gas inlet casing with shackle (90195) and a suspension ro

pe. Remove the two hexagon head screws (61044) and Verbus washers (61043) from the lower section and replace them with two studs (90177). To secure, fit hexagon nuts (90178) onto the studs (90177). Loosen and remove the remaining screws (61044) and Verbus washers (61043) on the gas inlet casing flange (61001). Withdraw the gas inlet casing with the nozzle ring from the gas outlet casing until holder (90175) can be fitted from outside with screws (61044) and Verbus washers (61043). Release the hexagon nuts (90178) from the studs.
ABB
Operation Manual Disassembly and assembly Turbine-end removal / fitting of the nozzle ring 8 8.7 Page 28
Withdraw gas inlet casing fully and remove.
CAUTION
Release holder (90175) and remove the nozzle ring with gasket
(61050).
Assembly of the nozzle ring
Fit nozzle ring and place the holder (90175) over the nozzle ring. Tighten holder (90175) with screw (61044) and Verbus washer
(61043). Insert gasket (61050) in the groove in the gas inlet casing (61001). Align the gas inlet casing and secure by fitting hexagon nuts (90178) on the studs (90177). Remove holder (90175) and screw (61044) and Verbus washers (61043). Fit and tighten the gas inlet casing flange to the gas outlet casing with screws (61044) and Verbus washers (61043). Remove hexagon nuts (90178) from studs (90177). Replace the studs (91077) with hexagon head screws (61044) and Verbus washers (61043). Remove shackle (90195) and suspension rope from gas inlet casing (51001). Secure the insulation on the gas inlet casing (51001).
CAUTION
Version 2.0
ABB
HZTL2481_EN (TPL73-A.. - 80-A..)
May 2006
When positioning the gas inlet casing, use suitable shims and take care to avoid damaging the brackets for the insulation.
Operation Manual Disassembly and assembly Table of tightening torques 8 8.8 Page 29
8.8 Table of tightening torques

May 2006 HZTL2481_EN (TPL73-A.. - 80-A..)
L_00044
The following tightening torques must be maintained for the specified screwed connections:
Version 2.0
ABB
Operation Manual Disassembly and assembly Table of tightening torques 8 8.8 Page 30
Tightening torques [Nm]
Part no. 42059 61036 61037 61044 61056 61059 74026 74027 76002 82005 86505 90458
TPL 73 M16 105 M18 80 M18 160 M18 370 M18 370 M18 370 M18 80 M18 135 M14 1) M16 x 1.5 50 M18 x 1.5 150 M10 30
1)
Tighten so that the diffuser can still be moved.
L_00228
ABB
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
May 2006
Operation Manual Taking out of operation temporarily Possibilities for emergency repair 9 9.1 Page 1
9 Taking out of operation temporarily

May 2006
9.1 Possibilities for emergency repair

Lubricating oil leaks are a fire hazard.
WARNING
The instructions of the engine manufacturer for operation of the engine with locked / isolated turbocharger must be followed precisely in all cases!
CAUTION
HZTL2481_EN (TPL73-A.. - 80-A..)
If the diesel engine must be capable of operation again as soon as possible after damage to the turbocharger (emergency repair), the following possibilities are available:

Lock the turbocharger rotor Fitting the cover plate Blocking the inlets and outlets Bypass the turbocharger
Version 2.0
ABB
Operation Manual Taking out of operation temporarily Locking the rotor 9 9.2 Page 2
9.2 Locking the rotor

A locked rotor must be disassembled following turbocharger repair and given an imbalance check.
CAUTION
NOTE
The only exceptions are test rig runs up to a maximum of 25% engine load on new engines with one or a number of turbochargers, which are requested by some customers. Since in these cases operation with a locked rotor is brief and the loads are small, subsequent disassembly of the rotor is unnecessary. Once unscrewed, balancing screws must not be screwed in again. Various intermediate rings are provided with the locking device for different compressor wheels. The compressor wheel type CV (for the balancing screw holes) must be noted. The space between the locking flange (94003) and the assembly-disassembly device (90020) must be compensated by the intermediate rings (94001 and/or 94002) depending on the version of compressor wheel.
NOTE
CAUTION
During operation of the engine with a locked turbocharger, the lubrication oil system must also remain connected to this turbocharger and turned on if the gas inlet cannot be blocked (see section Further measures and information for operation with a locked rotor for 4-stroke engines). Otherwise components that are still intact can be damaged by overheating. The supply of lubricating oil to the turbocharger must be shut off in the event of a lubricating oil leak on the turbocharger.
ABB
Locking rotor with screwed connection

May 2006 HZTL2481_EN (TPL73-A.. - 80-A..)
L_00225
Table of tightening torques [Nm]
Part no. 74027 94006 94007
TPL73-A M18 135 M8 25 M8 15
TPL77-A M20 175 M8 25 M8 15
TPL80-A M22 235 M10 45 M10 35
Version 2.0
These operations must be carried out as described in the chapter Disassembly and assembly.
NOTE
Remove the silencer or air suction branch and the compressor casing
internal part together with the wall insert and the diffuser.
ABB
Remove screw plug (25005). Fit studs (74026) as needed for the locking device on the compressor
casing.
(74027) to the torques indicated in theTable of tightening torques. Block the rotor with lock (90480). Cut a thread (M12 or 1/2") in the existing hole and secure the lock with a screw (A).
ABB
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
May 2006
Mount the assembly-disassembly device (90020) and tighten nuts
Locking rotor with polygon connection

May 2006 HZTL2481_EN (TPL73-A.. - 80-A..)
L_00046
Table of tightening torques [Nm]
Part no. 74027 94006 94007
TPL73-A M18 135 M8 25 M8 15
TPL77-A M20 175 M8 25 M8 15
TPL80-A M22 235 M10 45 M10 35
Version 2.0
NOTE
ABB
Remove the silencer or air suction branch and the compressor casing
internal part together with the wall insert and the diffuser. Fit partition wall clamp (94005) with screws (90442). Fit locking flange (94003) with the nuts (74027) and then with the screws (94007 / 94006) according to the Table of tightening torques.
For engines with three or four turbochargers, the balancing screws
should be removed from the compressor wheel concerned. for secure fixing of the locking flange.
For engines with one or two turbochargers, eight screws are sufficient
Locking rotor with polygon connection

HZTL2481_EN (TPL73-A.. - 80-A..)
Compressor type CV10
94000_002
ABB
Version 2.0
May 2006
Compressor type CV 20
HZTL2481_EN (TPL73-A.. - 80-A..)
May 2006
94000_003
It must be ensured that all components are clean and free from grease.
CAUTION
Push the intermediate rings (94001 and/or 94002) and assembly-
disassembly device (90020) onto the locking flange (94003) in the correct sequence. Now push on the other remaining intermediate rings (94001 and/or 94002). Tighten intermediate rings, assembly-disassembly device (90020) and locking flange (94003) with the screws (94006) according to the values shown in the preceding Table of tightening torques. Now tighten the assembly-/disassembly device (74027) to the compressor casing with the nuts (74027) and the studs to the values shown in the preceding Tightening torques table.
Version 2.0
ABB
Further measures and information for operation with a locked rotor for 4May 2006
stroke engines
4-stroke engine with one turbocharger No further measures are necessary. The engine can be operated as naturally aspirated engine according to the instructions of the manufacturer.
4-stroke engine with several turbochargers

Separate receivers
Common air receiver
If the engine is equipped with a common air receiver and separate exhaust-gas receivers, the compensator at the compressor outlet of the damaged turbocharger must be dismantled and the air line on the engine side must be isolated. Otherwise the undamaged turbocharger can spin "unloaded" and overspeed. More or less powerful pulses from the exhaust-gas system are applied to the locked rotor, depending on the engine turbocharging system. Particularly with pulse supercharging (turbine casing with more than one gas inlet) the locking device is then subjected to heavy loading. The following operating limits should therefore not be exceeded:
In systems similar to those with constant pressure (1 gas inlet) the en-
gine can be operated up to a maximum of 25% engine load. The pressure in the charge-air receiver must not exceed 0.9 bar overpressure. With pulse supercharging (2...4 gas inlets) the engine can be operated up to a maximum of 20% engine load. The pressure in the charge-air receiver must not exceed 0.5 bar overpressure. Attention must be paid to the speed of the undamaged turbocharger in all cases. Rotating speed limit nBmax as indicated on the rating plate must not be exceeded.
CAUTION
Version 2.0
ABB
HZTL2481_EN (TPL73-A.. - 80-A..)
No further measures are necessary on engines with separate air and exhaust receivers. The engine can be operated as naturally aspirated engine according to the instructions of the manufacturer.
Operation Manual Taking out of operation temporarily Fitting the cover plate 9 9.3 Page 9
9.3 Fitting the cover plate

May 2006
The cover plate (material: General structural steel, in accordance with DIN EN 10025-2) must be produced in-house according to the drawing.
NOTE
HZTL2481_EN (TPL73-A.. - 80-A..)
90000_001
Cover plate dimensions [mm]
Version 2.0
Type TPL 73 TPL 77 TPL 80
B1
B2
B3 50
B4 50
B5 9 9 11
B6 12 12 15
B7 8
B8 94 107 136
ABB
Type TPL 73 TPL 77 TPL 80
1 844 1003 1164
2 948 1124 1300
3 905 1075 1248
4 20 22 24
5 28 30 32
6 20
May 2006
Type TPL 73 - 80
1 4 x 90
2 37.5
3 24 x 15
20000_003
Version 2.0
NOTE
Removing cartridge group
ABB
HZTL2481_EN (TPL73-A.. - 80-A..)
HZTL2481_EN (TPL73-A.. - 80-A..)
May 2006
61000_003
Block the opening in the gas outlet casing with the cover plate. Secure cover plate with spacer sleeves and nuts (61037).
Shut off the supply of lubricating oil to the turbocharger.

CAUTION
Version 2.0
ABB
Further measures and information for operation with a turbocharger with cover plate in 4-stroke engines
May 2006
4-stroke engine with one turbocharger No further measures are necessary. The engine can be operated as naturally 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 exhaust receivers. The engine can be operated as naturally aspirated engine according to the instructions of the manufacturer. The air line must be blocked on the engine side, since the undamaged turbochargers develop a receiver pressure. The engine can be operated according to the instructions of the engine manufacturer. Attention must be paid to the speed of the undamaged turbocharger in all cases. Rotating speed limit nBmax as indicated on the rating plate must not be exceeded.
Common receiver
CAUTION
ABB
Operation Manual Taking out of operation temporarily Blocking the inlets and outlets 9 9.4 Page 13
9.4 Blocking the inlets and outlets

May 2006

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

NOTE
ABB
Operation Manual Taking out of operation temporarily Bypass the turbocharger 9 9.5 Page 14
9.5 Bypass the turbocharger

CAUTION
May 2006
For engines with one turbocharger only: The connections are ready and pipes for the bypass are to hand. Fit the bypass around the turbocharger.
For information about how to do this, see the manufacturer's instructions.

HZTL2481_EN (TPL73-A.. - 80-A..)
NOTE
ABB
Version 2.0
Operation Manual Mothballing the turbocharger Taking out of operation for up to 12 months 10 10.1 Page 1
10 Mothballing the turbocharger

May 2006
10.1 Taking out of operation for up to 12 months

If a turbocharger has to be laid up for up to 12 months, the decision whether the turbocharger needs special protection or not depends mainly on the condition of the lubricating oil before laying up. If the Total Acid Number (TAN) is lower than 2 mg KOH/g no special measures need to be taken. However, if the neutralisation factor is higher the turbocharger must be dismantled after laying up, cleaned and protective oil must be applied to the naked parts. If the turbocharger is left mounted on the engine, and the engine oil is replaced by a protective oil which is circulated with a pre-lubrication pump prior to laying up, no measures need to be taken in respect of the turbocharger. The remains of the old engine oil will be washed away and the sensitive bearing parts will be largely protected against corrosion. If the rotor turns due to a draught from the flue, fit a blind flange between the compressor casing and the charge-air duct.
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
ABB
Operation Manual Mothballing the turbocharger 10 Page 2
Taking out of operation for more than 12 10.2 months
10.2 Taking out of operation for more than 12 months

If the turbocharger has to be removed from the engine and stored for a prolonged period of time, disassembly and mothballing of the turbocharger must be done by an official ABB Turbo Systems service station. Ensure that the storage area is dry with humidity of 40-70% and free of condensation. Check mothballed turbochargers yearly for corrosion. In the event of rust, clean and renew the corrosion protection.
NOTE
HZTL2481_EN (TPL73-A.. - 80-A..) May 2006 Version 2.0
ABB
Operation Manual Reserve and spare parts Ordering spare parts 11 11.1 Page 1
11 Reserve and spare parts

May 2006
11.1 Ordering spare parts

When making inquiries or ordering spare parts, the following data should be specified:
Turbocharger type HT number Description and part number
Our service stations and agents accept orders for spare parts.
If special variants/cases are not addressed in these general instruc-
tions, contact an official ABB Turbo Systems Ltd. service station or an ABB agent.
HZTL2481_EN (TPL73-A.. - 80-A..)
Spare-parts set Spare-parts set (97070) is required for the work described in this manual. The parts included in the spare-parts set are only available as part of the complete set.
NOTE
TPL73-A
Quantity 2 2 15 15
Description Hexagon head screw Verbus washer Hexagon head screw Verbus washer Hexagon nut Gasket Gasket O-ring gasket O-ring gasket O-ring gasket O-ring gasket
Part number 42059 / 42064 42058 / 42063 61044 / 61056 / 61059 61043 / 61057 / 61058 61037 42041 42045 42012 / 76040 77005 / 77006 86506 25011
Version 2.0
3 1 1 2 2 1 1
ABB
Operation Manual Reserve and spare parts Ordering spare parts 11 11.1 Page 2
TPL77-A
Quantity 15 15 3 1 1 2 2 1 1
Description Hexagon head screw Verbus washer Hexagon nut Gasket Gasket O-ring gasket O-ring gasket O-ring gasket O-ring gasket
Part number 42059 / 42064 / 61044 / 61056 / 61059 42058 / 42063 / 61043 / 61057 / 61058 61037 42041 42045 42012 / 76040 77005 / 77006 86506 25011
TPL80-A
Quantity 2 2 15 15 3 1 1 2 2 1 1
Description Hexagon head screw Verbus washer Hexagon head screw Verbus washer Hexagon nut Gasket Gasket O-ring gasket O-ring gasket O-ring gasket O-ring gasket
Part number 42059 / 42064 42058 / 42063 61044 / 61056 / 61059 61043 / 61057 / 61058 61037 42041 42045 42012 / 76040 77005 / 77006 86506 25011
All spare parts that have been ordered with the turbocharger should be kept complete and serviceable.
CAUTION
Rusty parts should be carefully cleaned and greased. Dispose of parts that have been exchanged and are no longer usable
in a technically and environmentally compatible manner.
ABB
Operation Manual Reserve and spare parts Directory of part numbers 11 11.2 Page 3
11.2 Directory of part numbers

May 2006
The following part numbers and descriptions must be used in ALL correspondence or orders:
Turbocharger
Part number 51001 56001 61001 61043 (in spare parts set) 61044 (in spare parts set) 61050 61056 (in spare parts set)
Description Cartridge group Gas inlet casing Nozzle ring Gas outlet casing Verbus washer Hexagon headed screw Gasket Hexagon headed screw Verbus washer Verbus washer Hexagon headed screw Hex.-headed nut Turbine diffuser Foot Hex.-headed nut Compressor casing external part Compressor casing, internal part O-ring gasket Safety segment Wall insert O-ring gasket O-ring gasket Diffuser Silencer Air suction branch, radial Air suction branch, axial
HZTL2481_EN (TPL73-A.. - 80-A..)
61057 (in spare parts set) 61058 (in spare parts set) 61059 (in spare parts set) 61037 (in spare parts set) 63000 68000 74027 74000 76000 76040 (in spare parts set) 76080 77000 77005 (in spare parts set) 77006 (in spare parts set) 79000 81000 82000 82000
Version 2.0
ABB
Cartridge group screwed connection
Part number 21000 25000 25005 32001 32101 32102 32104 32105 32106 32107 42001 42002 42011 42012 (in spare parts set) 42015 42041 (in spare parts set) 42045 (in spare parts set) 42058 (in spare parts set) 42059 (in spare parts set) 42063 (in spare parts set) 42064 (in spare parts set) 43001 43005 86505 86506 (in spare parts set)
Description Shaft Screw plug Cam bearing Radial bearing, compressor side Radial bearing, turbine side Auxiliary bearing Float disc Axial bearing Bearing bush Bearing casing Cowling O-ring gasket Gasket cover Gasket Gasket Verbus washer Hexagon headed screw Verbus washer Hexagon headed screw Partition wall O-ring gasket Speed sensor O-ring gasket
HZTL2481_EN (TPL73-A.. - 80-A..) May 2006
Compressor wheel
O-ring gasket
ABB
Version 2.0
Cartridge group - polygon connection

May 2006
Part number 21000 25000 25008 25009 32001 32101 32102 32104 32105 32106 32107 42001 42002 42011 42012 (in spare parts set) 42015 42041 (in spare parts set) 42045 (in spare parts set) 42058 (in spare parts set) 42059 (in spare parts set) 42063 (in spare parts set) 42064 (in spare parts set) 43001 43005 86505 86506 (in spare parts set)
Description Shaft Compressor wheel Threaded pin Ring nut Cam bearing Radial bearing, compressor side Radial bearing, turbine side Auxiliary bearing Float disc Axial bearing Bearing bush Bearing casing Cowling O-ring gasket O-ring gasket Gasket cover Gasket Gasket Verbus washer Hexagon headed screw Verbus washer Hexagon headed screw Partition wall O-ring gasket Speed sensor O-ring gasket
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
ABB
Operation Manual Reserve and spare parts General view of turbocharger 11 11.3 Page 6
11.3 General view of turbocharger

May 2006
L_00291
ABB
Version 2.0
HZTL2481_EN (TPL73-A.. - 80-A..)
Operation Manual Reserve and spare parts General view of cartridge group 11 11.4 Page 7
11.4 General view of cartridge group

L_00039
ABB

ABB

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Operation Manual

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

4.5 5 5.1 5.2 5.3 5.4

ABB Turbo Systems Ltd

Dismantling and installing the turbine diffuser and nozzle ring

Ordering spare parts

ABB Turbo Systems Ltd

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

1.1 Purpose of the manual

Content of operation manual

ABB Turbo Systems Ltd

Operation Manual Preliminary remarks Layout and function 1 1.2 Page 2

1.2 Layout and function

ABB Turbo Systems Ltd

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

Operation Manual Preliminary remarks Layout and function 1 1.2 Page 3

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

These are both mounted on a common shaft.

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

ABB Turbo Systems Ltd

1.3 Correct use of the turbocharger

ABB Turbo Systems Ltd

Operation Manual Preliminary remarks Essential information 1 1.4 Page 5

1.4 Essential information

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

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

ABB Turbo Systems Ltd

Operation Manual Preliminary remarks Essential information 1 1.4 Page 6

It must be ensured that only authorised personnel work on the turbocharger.

ABB Turbo Systems Ltd

Operation Manual Preliminary remarks Essential information 1 1.4 Page 7

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

ABB Turbo Systems Ltd

Operation Manual Preliminary remarks Abbreviations and symbols 1 1.5 Page 8

1.5 Abbreviations and symbols

The following abbreviations are used in this document:

The note provides further essential information.

ABB Turbo Systems Ltd

Operation Manual Preliminary remarks Turbocharger rating plate 1 1.6 Page 9

1.6 Turbocharger rating plate

Recommended replacement periods / exchange intervals for turbocharger components

ABB Turbo Systems Ltd

Operation Manual Preliminary remarks Turbocharger rating plate 1 1.6 Page 10

ABB Turbo Systems Ltd

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

Operation Manual Safety Basic safety instructions 2 2.1 Page 1

2.1 Basic safety instructions

Warning signs must be strictly observed at all times.

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

Caution signs must be strictly observed at all times.

ABB Turbo Systems Ltd

Operation Manual Safety General safety instructions 2 2.2 Page 2

2.2 General safety instructions

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

Wear protective clothing at all times.

ABB Turbo Systems Ltd

Operation Manual Safety Special safety instructions 2 2.3 Page 3

2.3 Special safety instructions

Safety when connecting

ABB Turbo Systems Ltd

Operation Manual Safety Special safety instructions 2 2.3 Page 4

Safety when cleaning

ABB Turbo Systems Ltd

Operation Manual Safety Special safety instructions 2 2.3 Page 5