Operation Manual: TPL85-B15

Turbocharging
Operation Manual
TPL85-B15
ABB Turbo Systems Ltd
CH 5401 Baden
Type
TPL85-B15
HT489493
n Mmax 200
Mmax
550
Bmax
520
1/s
n Bmax 190
10620kg
Year
C
t
36
100
100
Application according to
the Operation Manual
2008
HZTL2491 English
made in Switzerland

Operating condition and replacement intervals

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

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

ABB Turbo Systems AG

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Operation Manual / TPL85-B14/-B15/-B16
Version 5
HZTL2491_EN
January 2008
List of contents
Page 1
List of contents
1
Preliminary remarks
1.1
Purpose of manual
1.2
Layout and function
1.3
Correct use of the turbocharger
1.4
Essential information
1.5
Abbreviations and symbols
1.6
Turbocharger rating plate
Safety
2.1
Basic safety instructions
2.2
General safety instructions
2.3
Special safety instructions
2.4
Safety instructions and hazard protection
2.5
Warnings on the turbocharger
Commissioning
3.1
Oil supply
3.2
Inspection work
3.3
Putting into operation after laying up
Operation
4.1
Servicing work
4.2
Expected exchange intervals
4.3
Monitoring
4.4
Surging of turbocharger
4.5
Contact with rotating parts
4.6
Shutting the engine down
Maintenance
5.1
Foreword to Maintenance
5.2
Cleaning the filter silencer
5.3
Cleaning the compressor during operation
5.4
Cleaning turbine blades and nozzle ring in operation
5.5
Suppliers of materials for dry cleaning
ABB
6.1
Possible remedies for failures
Removal and installation
7.1
Turbocharger weights
7.2
Remove the turbocharger
7.3
Installing the turbocharger
Disassembly and assembly
8.1
Module weights
8.2
Removing and fitting filter silencer or air suction branch
8.3
Axial clearance
8.4
Dismantling the internal part of the compressor casing
8.5
Dismantling gas inlet casing
8.6
Fitting gas inlet casing
8.7
Fitting the internal part of the compressor casing
8.8
Table of tightening torques
Taking out of operation temporarily
9.1
Possibilities for emergency repair
9.2
Locking the rotor
9.3
Blocking the inlets and outlets
9.4
Bypass the turbocharger
10
Mothballing the turbocharger
10.1
Taking out of operation for up to 12 months
10.2
Taking out of operation for more than 12 months
11
Disposal
11.1
Environmentally compatible disposal of turbocharger

components
12
Reserve and spare parts
12.1
Ordering spare parts
12.2
Directory of part numbers
12.3
General view of turbocharger
12.4
General view of cartridge group
January 2008
Troubleshooting
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Page 2
Version 5
List of contents
ABB

Preliminary remarks
Purpose of manual
1.1
Page 1
January 2008
1 Preliminary remarks
1.1 Purpose of manual
Operating manual
This operation manual will help you to become familiar with your ABB
Turbo Systems turbocharger and to use it to full effect in its intended application. You will find important instructions as to the safe, correct, and
economical operation of the turbocharger.
Target group
The content of this operation manual is intended for persons such as engineers, marine mechanics and service technicians who are responsible
for the running of the engine and the turbocharger installed thereon.
Content of operating manual
This operation manual includes helpful information on the following topics:

Information on the operation of the turbocharger and ways to prolong
HZTL2491_EN
the turbocharger's service life.

Early identification and avoidance of hazards.
Minimizing repair costs and downtime.
This operating manual complements and extends existing national regulations on protection against accidents and accident prevention.
NOTE
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. Anyone who works only occasionally on the machine, e.g. during installation and maintenance, must also read and fully understand
the operating manual before beginning work.
Version 5
The instructions included in this operating manual must be followed without fail.
WARNING
This applies especially to the general and special safety instructions

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

Preliminary remarks
Layout and function
1.2
Page 2
HZTL2491_EN
January 2008
1.2 Layout and function
1.2.
Filter silencer
Nozzle ring
Radial plain bearing
Turbine wheel
Thrust bearing
Bearing casing
Radial plain bearing
10
Diffuser
Gas outlet casing
11
Compressor wheel
Gas inlet casing
12
Compressor casing
Version 5
ABB

Preliminary remarks
Layout and function
1.2
Page 3
January 2008
Working principle
The turbocharger is a turbo-machine and consists of the following main
components:
Turbine
Compressor
These are both mounted on a common shaft.
Exhaust gases from the diesel engine flow through the gas inlet casing (6)
and the nozzle ring (7) to impinge on the turbine wheel (8).
The turbine wheel (8) uses the energy contained in the exhaust gas to
drive the compressor wheel (11). The compressor draws in fresh air,
compresses it and then forces it into the engine cylinders.
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The exhaust gas escapes to free air through the exhaust manifold which
is connected to the gas outlet casing (5).
The air, which is necessary for the operation of the diesel engine and
compressed in the turbocharger, is drawn through the suction branch or
the filter silencer (1) into the compressor wheel (11). This air then passes
through the diffuser (10) and leaves the turbocharger through the compressor casing (12).
The rotor runs in two radial plain bearings (2/4), which are located in the
bearing casing (9) between the compressor and the turbine. The axial
thrust bearing (3) is on the compressor side.
The plain bearings are connected to a central lubricating oil feed which is
normally supplied by the oil lubrication circuit of the engine. The oil outlet
is always at the lowest point of the bearing casing (9).
Version 5
The turbocharger is equipped with an emergency lubrication oil tank,

which is integrated in the bearing casing. During an emergency stop caused by a failure of the lubrication oil system, this emergency lubrication
unit supplies oil to the bearings until the rotor comes to a standstill.
ABB

Preliminary remarks
Correct use of the turbocharger
1.3
Page 4
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
January 2008
1.3 Correct use of the turbocharger
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.
Latest technology
WARNING
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.
HZTL2491_EN
Any other use will be regarded as a special application which must first
be discussed with ABB Turbo Systems. The manufacturer accepts no
liability for other applications. If it is used otherwise, ABB Turbo Systems reserves the right to reject all claims under the warranty.
Correct use of the turbocharger also includes observation of the assembly, disassembly, operating, maintenance and repair conditions specified
by the manufacturer. Disposal regulations set down by local authorities
must be observed.
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.
X Malfunctions / defects which could affect safety must be eliminated
immediately.
The manufacturer shall not accept liability for damages resulting from unauthorised alterations to the turbocharger.
ABB
Version 5
Perfect condition

Preliminary remarks
1.4
Page 5
January 2008
1.4 Essential information

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.
NOTE
X The turbocharger must be shut down immediately by stopping the enHZTL2491_EN
gine in the event of alterations affecting safety or of corresponding operating behaviour. The fault must 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.
Version 5
NOTE
ABB

Preliminary remarks
1.4
Page 6
January 2008
Original parts and safety

Original parts and accessories are especially designed for the turbocharger supplied by ABB Turbo Systems.
We herewith expressly state that parts and accessories not supplied by
us have also not been tested and approved by us.
NOTE
If components and assemblies not manufactured and tested by ABB

Turbo Systems are used, this may have a negative effect on the technical design specifications of the turbocharger.
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.
HZTL2491_EN
WARNING
Qualification of personnel
The turbocharger must only be operated and maintained by trained and
authorised personnel.
Work on mechanical components, such as bearings or rotors, may only
be performed by qualified fitters from an official service station of ABB
Turbo Systems.
CAUTION
Version 5
It must be ensured that only authorised personnel work on the turbocharger.
ABB

Preliminary remarks
1.4
Page 7
January 2008
After-sales service
The Contact Information brochure contains an overview of official ABB
Turbo Systems. service stations worldwide.
Design variants
This operating manual is valid for various turbocharger design variants.
This means that some sections and component descriptions in this operating manual do not apply to your turbocharger.
Our service stations and agencies will gladly answer your questions relating specifically to your model.
HZTL2491_EN
Accuracy of illustrations
The graphics and images shown in this manual are of a general nature
and are intended to assist understanding of the work steps and instructions. Differences may exist in certain details.
Storage of new turbochargers
New turbochargers supplied by ABB Turbo Systems can be stored without
additional safeguarding measures for a period of 6 months after the delivery date.
Suitable storage locations are dry rooms where the relative humidity is between 40-70% and no condensation can form.
X After expiry of the 6 months, all surfaces and accessible areas of the
Version 5
turbocharger should be sprayed with anticorrosive agent.

X To do this, the insulating materials must be removed.
Repeat the described measures every 6 months to keep your turbocharger free from rust.
NOTE
ABB

Preliminary remarks
Abbreviations and symbols
1.5
Page 8
January 2008
1.5 Abbreviations and symbols

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

U Negative checkpoint (activity that must not be carried out under any
circumstances)
Basic Instructions
HZTL2491_EN
The following symbol is used for notes in this manual:

This note provides suggestions and tips to make work on the turbocharger easier.
NOTE
The note provides further essential information.
Reference to safety instructions

The warnings and cautions are described in the chapter Safety .
CAUTION
ABB Turbo Systems Ltd is specified in this manual as ABB Turbo Systems.
Official ABB Turbo Systems service station
The term Official ABB Turbo Systems service station used in this manual
signifies ABB turbocharger service stations, that have been tested and
certified by ABB Turbo Systems.
ABB
Version 5
ABB Turbo Systems

Preliminary remarks
1.6
Page 9
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January 2008
1.6 Turbocharger rating plate
L_00012
Operational limits
Version 5
Recommended replacement periods / exchange

intervals for turbocharger
components
3
4
5
Turbocharger operational limits at engine overload (110 %).

In test rig operation only, unless otherwise agreed with the
engine manufacturer.
Turbocharger operational limits in service.
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)
ABB

1
1.6
6
7
8
9
10
11
12
Page 10
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
January 2008
Additional specifications:
Preliminary remarks
Explanations of the rating plate
CAUTION
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.
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.
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The recommended exchange intervals and the corresponding operation

limits are defined together with the engine builder. These specifications
are system-specific.
Version 5
Non-compliance with the recommended exchange intervals may increase the risk of unpredictable component failure.
ABB

Safety
Basic safety instructions
2.1
Page 1
2 Safety
January 2008
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.
CAUTION
Caution signs must be strictly observed at all times.
Version 5
HZTL2491_EN
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.
ABB

Safety
General safety instructions
2.2
Page 2
The instructions listed here are designed to ensure your safety and to
promote safe handling of the turbocharger and its associated operating
materials.
January 2008
2.2 General safety instructions
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.
Version 5
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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Wear protective clothing at all times.
ABB

Safety
2.3
Page 3
January 2008
2.3 Special safety instructions

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
Version 5
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.
ABB

Safety
2.3
Page 4
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.
January 2008
Before cleaning, protect the floor against unintended leaks of oil and
Safety during disassembly, assembly, maintenance and troubleshooting
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.
Version 5
CAUTION
justment, maintenance and inspection work.

Inform operating personnel about special work and repairs before starting.
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.
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Follow the prescribed maintenance and inspection schedules for all ad-
ABB

Safety
2.3
Page 5
January 2008
Safety when taking out of operation or putting into storage

Secure the rotor against turning.
Clean the turbocharger before mothballing.
Wear protective clothing when mothballing the turbocharger.
Keep the work area clean and free of oil and operating materials.
Remove any obstacles lying around on the floor.
Version 5
HZTL2491_EN
ABB

Safety
Safety instructions and hazard

protection
2.4
Page 6
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.
January 2008
2.4 Safety instructions and hazard protection
Mechanical influences
Mechanical influences can cause serious injury or even fatal 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
ABB
Version 5
Personal injury
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WARNING

Safety

protection
2.4
Page 7
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
Protective measures
9
9
9
9
9
9
9
January 2008
Causes
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
9 Eliminate leaks
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Operation and process materials

Operation and process materials refer to chemical and hazardous substances:
Oils
Grease
Coolants
Detergents and solvents
Acids
Note that operation and process materials are harmful to the environment if they penetrate soil or water.
Version 5
CAUTION
ABB

2

protection
2.4
Page 8
The following injuries can be caused by operation and process materials:

Allergies
Skin disease
Loss of consciousness
Poisoning or nausea after inhalation
January 2008
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
Causes
Protective measures
9
9
9
9
9
9
9
Version 5
Utmost caution when handling process and operation materials

Protective clothing must be worn
Avoid skin contact and inhalation
Ensure that the workroom is properly ventilated
Observe the hazard indications on the containers for operation and
process materials
Seal the hazardous substance container tight immediately after use
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 an environmentally compatible manner
Ensure that containers with 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
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Personal injury
Safety
ABB

Safety

protection
2.4
Page 9
January 2008
Handling insulating materials

9
9
9
9
9
9
9
9
9
9
9
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
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Noise
The effects of noise above a legally permitted level can cause personal injury.
Loss of hearing
Deafness
Impaired hearing
Health disorders such as loss of balance or of consciousness
Cardiac and circulatory disturbances
Personal injury
Causes
Machine noise level above 85 dB (A)
Protective measures
9 Wear ear protection

Heat hazard
Version 5
When the turbocharger is operated, surfaces become very hot.

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

Safety
Warnings on the turbocharger
2.5
Page 10
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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.
January 2008
2.5 Warnings on the turbocharger
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.
Version 5
NOTE
ABB

Commissioning
Oil supply
3.1
Page 1
3 Commissioning
January 2008
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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Oil filtration
A lubrication oil filter system with a mesh size 0.050 mm is adequate for
TPL ..-B turbochargers.
Oil pressure
The oil pressure in front of the bearings must be maintained precisely to
ensure trouble-free operation.
Version 5
The permissible oil pressures are specified in the following tables dependent on the lubrication (engine lubrication or separate lubricating system).
ABB
Separate lubricating system
NOTE
Oil supply
3.1
Page 2
Oil pressure [bar]
Inadmissible oil pressure range ->

Emergency shutdown (without time lag)
0.0 - 0.6
Oil pressure range permissible in short term (<1h) ->

Alarm
0.6 - 0.8
Permissible oil pressure range for normal operation
0.8 - 2.5
Permissible oil pressure range during engine warmup phase
0.8 - 4.0
Kinetic viscosity 12 - 170 cST
January 2008
Kinetic viscosity 45 - 170 cST
Oil pressure [bar]
Inadmissible oil pressure range ->

Emergency shutdown (without time lag)
0.0 - 0.9
Oil pressure range permissible in short term (<1h) ->

Alarm
0.9 - 1.1
Permissible oil pressure range for normal operation
1.1 - 2.5
Permissible oil pressure range during engine warmup phase
1.1 - 4.0
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Engine lubrication
Commissioning
If a separate lubricating system has been designed for operation in the

viscosity range of the engine lubrication system, i.e. 45 170 cSt, the
oil pressure limits according to the engine lubrication information may
be used for this system.
Engine lubrication
Oil entry
temperature
[ C ]
Engine load
[%]
Oil entry pressure

[bar]
Oil exit
temperature
[ C ]
45
100
1.5 - 2
70 - 90
70
100
1.5 - 2
90 - 110
ABB
Version 5
Oil temperature during normal operation

Commissioning
Inspection work
3.2
Page 3
3.2 Inspection work

January 2008
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 inspec-
tion work.
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3.2.1
Inspection before commissioning
Monitoring equipment
X Check for correct functioning.
Air filter mat
X Inspect for damage.
Lubrication system
X Check that the oil filter is clean before commissioning.
It is urgently recommended that the entire lubrication system be flushed

thoroughly with warm oil using a bypass pipe before commissioning and
after every servicing operation on the lubrication system.
CAUTION
We strongly recommend the use of a starting filter when running the

engine in and after every servicing operation on the lubrication system.
Version 5
X Check oil pressure in oil supply lines.
ABB

3
Inspection work
3.2
Page 4
January 2008
Inspection after commissioning
Lubrication system
X Check oil pressure in oil supply lines.
Charger speed
X Measure
Charger pressure
X Measuring
Measure temperatures
X upstream/downstream from turbine, compressor and oil feed for vari-
Gas, air, and oil lines
X Check all gas, air, and oil lines for leaks after the engine has been star-
ous engine speeds
ted up.
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3.2.2
Commissioning
Further must be observed:
Lubricants and pastes are liquefied or vaporised during assembly of the

turbocharger and may escape as an oily liquid in the first few hours after commissioning. If further oily liquid continues to appear after this period, an oil leak must be suspected. Then, the first step is to check for
leakage of the oil supply to the turbocharger. If something wrong is detected, contact an official ABB Turbo Systems service station.
NOTE
before and after the turbine and the compressor at various engine
speeds.
X 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.
ABB
Version 5
X Measure the speed, oil pressure, charging pressure and temperatures

Commissioning
Putting into operation after laying up
3.3
Page 5
January 2008
3.3 Putting into operation after laying up

If they are present
X Remove the cover plates (blind flanges) between the compressor cas-
ing outlet and the charge-air receiver, upstream of the gas inlet, downstream of the gas outlet.
X Inspect the exhaust-gas duct before and after the turbine for any comX
X
X
Version 5
HZTL2491_EN
bustion 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.
Commission the turbocharger.
ABB

Operation
Servicing work
4.1
Page 1
4 Operation
January 2008
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.
HZTL2491_EN
WARNING
Servicing work must be carried out at the prescribed intervals in order

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

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

official ABB Turbo Systems service station.
Version 5
CAUTION
ABB

4
Servicing work
4.1
Page 2
Entries in the machine logbook

Monitoring of the machine plant provides information about the performance of the turbocharger.
January 2008
4.1.2
Operation
The following operation data and measurement values must be entered

regularly in the engine manufacturer's machine log book:
Output and speed of the engine
Air intake temperature
Exhaust temperature before and after the turbine
Pressure of the charge-air
Pressure drop in the charge-air cooler
Lubricating oil pressure, lubricating oil temperature
Air temperature after compressor and after the charge-air cooler

Speed of the turbocharger
Pressure loss in the air filter
If provided
4.1.3
X With the engine at standstill clean or replace oil filters
Version 5
Oil filters
Servicing work according to the engine manufacturer's instructions
HZTL2491_EN
ABB

4
Servicing work
4.1
Page 3
Inspection work every 18,000 hours

Remove filter silencer or air suction branch
Clean filter silencer as far as accessible, and inspect for damage
Remove internal part of compressor casing
Check clearance A (axial bearing play).
Clean accessible parts (compressor wheel, diffusor, wall insert), and
inspect for damage
X Without removing turbine parts and using an endoscope, carry out a
visual check for possible soiling and damage (nozzle ring, turbine diffusor/cover ring, turbine blades). As an option, this inspection can be carried out after removal of gas inlet casing.
X Refit internal part of compressor casing
X Re-install filter silencer or air suction branch.
X
X
X
X
X
This inspection work and checks must be carried out by an official service station of ABB Turbo Systems.
NOTE
Version 5
HZTL2491_EN
January 2008
4.1.4
Operation
ABB
Servicing work
4.1
Page 4
Servicing work every 36,000 hours

Remove filter silencer or air suction branch
Clean filter silencer as far as accessible, and inspect for damage
Remove internal part of compressor casing
Check clearance A (axial bearing play).
Clean accessible parts (diffusor, wall insert), and inspect for damage.
Take apart gas inlet casing and remove nozzle ring.
Clean nozzle ring and check for damage or wear.
Clean turbine diffusor / cover ring and check for damage or wear.
Replace radial bearing and thrust bearing with original parts from ABB
Turbo Systems.
X Inspect and assess rotor.
X
X
X
X
X
X
X
X
X
Replacement of the bearing parts as well as inspection and assessment

of the rotor must be carried out by an official ABB Turbo Systems service station.
Version 5
NOTE
January 2008
HZTL2491_EN
4.1.5
Operation
ABB

Operation
Expected exchange intervals
4.2
Page 5
January 2008
4.2 Expected exchange intervals

Expected replacement
intervals [h]
Turbocharger part
HFO
Gas inlet casing
50'000 100000
Gas outlet casing
50'000 100000
Nozzle ring
35'000 50000
Turbine diffusor / cover ring
25'000 50000
Other housings
100000
Rotor components
See rating plate for information
Bearings
See rating plate for information
HZTL2491_EN
HFO
The values indicated are for guidance only and are not guaranteed values. These values may vary significantly for example due to inadequate
servicing, frequent emergency stoppages as well as through the use of
fuel or lubricating oil of inferior quality.
Version 5
NOTE
= Heavy Fuel Oil
ABB

Operation
Monitoring
4.3
Page 6
4.3.1
January 2008
4.3 Monitoring
Measuring speed
1
9
2
11
3
10
HZTL2491_EN
6
7
8
L_01246
Bearing casing
Line amplifier (optional)
Thrust bearing
Speed transmitter
Guide in axial bearing
Auxiliary bearing
10
Alternative for fitting speed

transmitter
Screw plug
11
Tachometer (option)
Connecting cable (with

voltage limiting module)
The speed transmitter system for measuring the turbocharger speed also
permits continuous remote monitoring of the turbocharger speed when it
is used in conjunction with the corresponding measuring instruments and /
or monitoring systems (not included in the scope of delivery). If the machine installation is monitored continuously, the turbocharger speed can
be used as a suitable control parameter. The line amplifier (7) can be purchased as an option to the described speed measuring system.
ABB
Version 5

Operation
Monitoring
4.3
Page 7
Possible reasons for failure of speed transmitter system:

Defects of the speed transmitter (8), connecting cable (6) and connect-
January 2008
ing plug for the measuring unit or on the measuring unit or power supply.
Turbocharger breakdown.
Failure of speed indicator
CAUTION
If the speed indicator fails, it is recommended that the engine output be

reduced to idling and the engine then stopped.
X Investigate cause of failure and eliminate problem.
Fitting speed transmitter system
HZTL2491_EN
NOTE
It is recommended that fitting or replacing a speed transmitter system

on an in-place turbocharger be carried out only by an official ABB Turbo
Systems service station.
A reduction in turbocharger speed can signify:
Version 5
Damaged turbine or bearing

Severe soiling of the turbine
ABB

4
Monitoring
4.3
Page 8
Underpressure measurement on filter silencer

A U-tube manometer can be ordered from ABB Turbo Systems for measuring the negative pressure at the filter silencer.
January 2008
4.3.2
Operation
This measuring can be used for the following purposes:

Measuring the correction factor for calculating the turbocharger effi-
ciency during engine acceptance

The use of a filter mat on the filter silencer can cause a loss of pressure. More significant pressure loss is an indication of increased soiling
of the filter material.
Version 5
HZTL2491_EN
U-tube manometer
L_00003
L_00004
Felt discs
A [mm H2O]
Pressure differential / pressure loss
ABB

Operation
Monitoring
4.3
Page 9
January 2008
All parts required for assembly are supplied in a separate package.

Mechanical vibration of the U-tube manometer is reduced by the installation of additional felt discs (1).
The U-tube manometer must be exposed to minimum possible mechanical shock or vibration.
NOTE
X Fit U-tube manometer to filter silencer as shown in preceding illustra-
tion.
X Fill U-tube manometer with slightly coloured water to obtain best legibil-
ity.
HZTL2491_EN
Under as-new conditions (new or clean filter silencer and filter mat), the
maximum pressure loss (A) is 120 mm H2O under full loading.
X Clean filter at latest as soon as loss of pressure (A) reaches a value of
200 mm H2O.
For better legibility of the pressure differential (A) on the U-tube manometer, the measuring rod can be withdrawn to the level of the bottom
water level.
Version 5
NOTE
ABB

Operation
Surging of turbocharger
4.4
Page 10
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.
January 2008
4.4 Surging of turbocharger
Prolonged or periodic surging
Action to be taken:
Version 5
NOTE
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.
HZTL2491_EN
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
ABB

Operation
Contact with rotating parts
4.5
Page 11
4.5 Contact with rotating parts

January 2008
Slight, uniform wear around the periphery of rotor components, caused by

their just touching adjacent components locally, is not 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 a
significant loss of efficiency.
X A check on dimensions must be carried out by an official ABB Turbo
Version 5
HZTL2491_EN
Systems service station.
ABB

Operation
Shutting the engine down
4.6
Page 12
Before shutting down the engine, it must be allowed to idle for about 3
minutes longer so that the circulating lubricating oil can take away heat
from the turbocharger bearings.
January 2008
4.6 Shutting the engine down
Version 5
HZTL2491_EN
CAUTION
ABB

Maintenance
Foreword to Maintenance
5.1
Page 1
January 2008
5 Maintenance
5.1 Foreword to Maintenance
Maintenance and servicing work involves regular visual checks and cleaning to ensure that the turbocharger and its attached units function troublefree.
The external condition and how dirty the cleaning points specified in
this chapter are, must be established by visual checks at the specified

intervals.
The safety precautions must be observed during all maintenance and
servicing work.
HZTL2491_EN
The cleaning points described in the following are:
Version 5
Filter silencer
Compressor
Turbine and nozzle ring
ABB

Maintenance
5.2
Page 2
5.2.1
January 2008
5.2 Cleaning the filter silencer

Filter silencer with tension band
81137
81136
81266
81268
81271
L
HZTL2491_EN
81270
81135
81266
81268
81270
Version 5
81265
L_01158
81265
Filter ring (if provided)
81266
Cover grids
81270
Tension ring
81136
Fleece segment
38271
Trap cover
81137
Cover panel
81268
Connecting strip
81135
Filter silencer body
Slide-in module = fleece segment + cover plate installed
ABB
January 2008

Maintenance
5.2
Page 3
Disassembling and cleaning filter silencer

X Remove filter ring (81265).
X Rinse filter ring (81265) with water using detergent or, if very dirty, soak
If provided
it. Squeeze out carefully. Rinse in cold water. Avoid high mechanical
stress (water jet).
The dirt in the filter ring (81265) depends on how clean the drawn-in air
is. Wash or replace the filter ring as necessary or every 500 service
hours.
NOTE
X Loosen clamping straps (81270) at tightening point (81271) and re-
HZTL2491_EN
move together with mesh covers (81266) and connecting bars (81268).
NOTE
In the case of a slide-in module (E) when a cleaning container is 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 cleaning line).
X Withdraw slide-in modules (E), bend open cover plates (81137) and
then take out fleece segments (81136).
X Clean fleece segments (81136).
Version 5
When cleaning, ensure that fleece segments (81136) are cleaned only
with a weak jet of compressed air, 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 bars should be replaced with original parts from ABB Turbo
Systems.
NOTE
ABB

Maintenance
5.2
Page 4
X Assemble slide-in modules (E) by inserting fleece segments (81136) in
cover plates (81137).
X Bend cover plates back to their original shape.

X Insert slide-in modules (E) in grooves in filter silencer body (81135).
January 2008
Mounting filter silencer
When the cleaning container is fitted to the filter silencer (available as

option depending on turbocharger type), the water injection line must be
re-installed (see also following section Assembling cleaning line).
NOTE
lencer body (81135).

X Pass clamping straps (81270) through eyelets in connecting bars (see
detail L in illustration L_01158).
X Tension all clamping straps at tightening points (81271).
X Fit filter ring (81265).
Version 5
If provided
HZTL2491_EN
X Fit mesh covers (81266) and connecting bars (81268) onto filter si-
ABB
5.2.2
Maintenance
5.2
Page 5
Removing / installing the cleaning line
HZTL2491_EN
January 2008
L_00192
Injection pipe
Guide tube
Pipe
Version 5
ABB

Maintenance
5.2
Page 6
X Disconnect the line (2) at the injection pipe (1) and remove the screw
coupling from the pipe.
X Pull line (2) out of the guide tube(3).
January 2008
Disassembling the cleaning line
HZTL2491_EN
Punching out the guide

tube
L_00193
X Punch the guide tube (3) out of the caulking with a bolt (diameter = 16
mm) and pull it out.
Version 5
Heavily soiled components of the cleaning line must be replaced with

original parts from ABB Turbo Systems.
NOTE
ABB

Maintenance
5.2
Page 7
HZTL2491_EN
January 2008
Installing the cleaning line
L_00194
X After fitting the slide-in modules (E), re-fit the guide tube (3) and re-
Version 5
caulk it.
X Fit line (2) and screw it to the injection pipe (1).
ABB

Maintenance
Cleaning the compressor during

operation
5.3
Page 8
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.
January 2008
5.3 Cleaning the compressor during operation
NOTE
The contamination of the compressor stage (compressor wheel and diffuser) depends on the cleanness of the air drawn in.
A deposit of dirt in the flow ducts will be formed if the following substances
are present in the intake air:
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.
HZTL2491_EN
Oil or saline mist

Solid combustion residues
Dust of various kinds
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.
The interval between periodic cleaning depends considerably 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 engine, please contact ABB Turbo Systems.
NOTE
ABB
Version 5
Interval between cleanings

Maintenance

operation
5.3
Page 9
January 2008
Cleaning method
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.
HZTL2491_EN
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.
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
If several turbochargers are installed on one engine, we recommend cleaning the turbocharger compressors one after the other.
Version 5
Cleaning more than one

turbocharger compressor
ABB
NOTE

operation
5.3
Page 10
Wet cleaning the compressor with external pressurised water container (XC3)
The supply of water with the externally fitted dosing vessel is only suitable for applications with underpressure before the compressor wheel
(not applicable for: Blower connected upstream of the compressor or
high-pressure compressor stage in the case of two-stage charging).
January 2008
5.3.1
Maintenance
Operating state preconditions for cleaning compressors with XC3
NOTE
Z Engine loading as full as possible

Z High turbocharger speed
X Cleaning cycle started according to the following description in Pro-
Version 5
cedure for wet cleaning with XC3.
HZTL2491_EN
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:
ABB

Maintenance

operation
5.3
Page 11
HZTL2491_EN
January 2008
Procedure for compressor wet cleaning with XC3
L_00198
Operating the pressurised

water container
Version 5
Screw plug
Valve activator
X The Operating state preconditions for cleaning the compressor with

X
X
X
X
X
XC3 must be met before cleaning can begin.

Remove screw plug (X).
Fill container with clean water.
Screw screw plug (X) back in.
Actuate valve lever (Y) against the spring and hold for 10 to 15 seconds, until all the water has been injected.
After cleaning, the turbocharger must be allowed to dry for at least 5
minutes before any further activity.
ABB

5

operation
5.3
Page 12
If the cleaning operation was not successful, it can be repeated up to 2

times.
NOTE
If cleaning is still not successfulafter three attempts and the engine operating values are unsatisfactory, we recommend that you have the turbocharger checked and cleaned by an official ABB Turbo Systems service station.
January 2008
Maintenance
Cleaning parameters for each turbocharger compressor

Turbocharger type
Turbocharger
speed
Contents of the
dosing vessel
[dm3]
Water injection
time
t1 [s]
TPL 69BA
Possible
nBmax
0.4
4 ... 15
TPL 73-B
TPL 77-B
2
HZTL2491_EN
TPL 80-B
TPL 85-B
Version 5
TPL 91-B
ABB
January 2008
5.3.2
Maintenance

operation
5.3
Page 13
Wet cleaning compressors using water vessel (XC4)

Operating state preconditions for cleaning compressors with XC4

NOTE
Z Engine loading as full as possible

Z High turbocharger speed
X Cleaning cycle started according to the following description in Pro-
cedure for wet cleaning with XC4.
Version 5
HZTL2491_EN
Procedure for compressor wet cleaning with XC34
L_00197
Cleaning container
2 Pipe
Injection pipe
4 Cleaning instructions
Cover
6 Valve
ABB

5

operation
5.3
Page 14
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
X The Operating state preconditions for cleaning compressors with XC4

X
X
X
X
X
X
must be met before cleaning can begin.

Open lid (5) of the cleaning container (1).
Fill with clean water.
Screw lid (5) closed.
Open valve (6) for about 3 minutes.
Close valve (6) and check that all the water has been sucked out.
After cleaning, the turbocharger must be allowed to dry for at least 5
minutes with the engine running before any further activity.

times.
NOTE
HZTL2491_EN
Operation of the cleaning

container
January 2008
Maintenance
Cleaning parameters for each turbocharger compressor

Turbocharger type
Turbocharger
speed
Contents of the
dosing vessel
[dm3]
Water injection
time
t1 [s]
TPL 69BA
Possible
nBmax
4 ... 15
TPL 73-B
TPL 80-B
Version 5
TPL 77-B
3
TPL 85-B
TPL 91-B
ABB
January 2008

Maintenance
Cleaning turbine blades and nozzle ring

in operation
5.4
Page 15
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.
Soiling increases with time, so that regular and properly performed cleaning is important to remove the accumulated deposits.
The exhaust gas temperature downstream of the cylinders can rise and
the charging pressure at the air receiver can fall if turbine components become soiled.
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.
Wet cleaning interval
The interval between periodic cleaning depends in large measure on the

operating conditions. In general, cleaning should be carried out every 50
to 500 operating hours.
Interval for dry cleaning
The interval between periodic cleaning depends considerably on the operating conditions. In general, cleaning should be carried out every 20 to
50 operating hours.
Version 5
HZTL2491_EN
A soiled turbine also results in rotor unbalance. Severe soiling can lead to
impermissibly high rotor imbalance.
ABB

Maintenance

in operation
5.4
Page 16
Several methods are possible for cleaning the turbine and nozzle ring during operation. The cleaning methods described in the following have been
tested and are recommended by ABB Turbo Systems:
January 2008
Cleaning methods
Wet cleaning
Dry 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 risk of corrosion, only clean water may be used and on no
account salt water. Furthermore, the water should contain no cooling
additives, which could form deposits in the flow ducts.
CAUTION
Principle of dry cleaning
During dry cleaning using dry solid particles in granulate form, the deposit
is removed by the mechanical impact of the grains hitting the surface.
HZTL2491_EN
Principle of wet cleaning
Wet and dry cleaning are equally effective. However, it may be useful to
apply both methods together.
Version 5
NOTE
ABB
January 2008
NOTE
Cleaning more than one

turbocharger turbine

in operation
5.4
Page 17
Components at the turbine end are not cleaned until the engine has
been started or the engine load reduced. The exhaust temperature
must not exceed the value specified in the pertaining cleaning instructions (see respective section Operating state prerequisites).
Failure to maintain the specified exhaust temperature in front of the turbine, the minimum stabilising time before as well as between cleaning
operations and the drying time after cleaning in accordance with the
pertaining cleaning instructions will drastically shorten the expected
service life of the components.
If several turbochargers are installed on one engine, we recommend cleaning the turbocharger turbines with nozzle rings one after the other.
Version 5
HZTL2491_EN
CAUTION
Maintenance
ABB

5

in operation
5.4
Page 18
Wet cleaning turbine and nozzle ring during operation

The maximum exhaust gas temperature specified by the engine manufacturer and the TMmax temperature shown on the turbocharger rating plate
must not be exceeded under any circumstances. During wet cleaning the
turbine delivers less power to the shaft and the turbocharger speed sinks.
As a result, less air is supplied to the engine and the temperature after the
engine cylinder and exhaust valve rises.
January 2008
5.4.1
Maintenance
Operating state precondition for wet cleaning
NOTE
Z After the engine has been started or during operation, the engine
Version 5
output must be adjusted until the scavenging air pressure pscav is

within the range of 0.3 0.6 bar (gauge pressure).
Z Wait 10 to 15 minutes (stabilising time), until the exhaust temperature at the turbine inlet is stable and below 430C, the auxiliary
blower must also be operating.
X Cleaning cycle started according to the following description in Procedure for wet cleaning.
HZTL2491_EN

ABB

Maintenance

in operation
5.4
Page 19
Version 5
HZTL2491_EN
January 2008
Procedure for wet cleaning
L_00394
Operating the wet cleaning system
Water supply (fresh water

only) at least 6.0 bar
Drain pipe
Regulating valve
Drain cock
Manometer
10
Outflow
Air supply with 3-way-valve
11
Orifice (integrated in turbocharger)
Stainless-steel pipe
21
Air duct from compressor casing
Other turbochargers
Position 1
Injection nozzle
Position 2
Z The Operating state preconditions for wet cleaning must be satisfied
before cleaning is begun.
X Check that the water supply (1) is open and ensured, and also con-
nected to the regulating value (2) in front of the turbocharger.

X Set the shut-off valve (9) of the drain pipe (8) on the gas outlet casing
to Position 1 and check whether exhaust gas escapes.
ABB

Maintenance

in operation
5.4
Page 20
X
X
X
X
X
X
valve (2) until the manometer (3) shows a pressure of 1 0.2 bar.
Inject water for 5 minutes at constant engine output.
Check whether the exhaust-gas temperature after the turbine drops.
Close the regulating valve (2) and the 3-way-valve (4).
Set drain cock (9) of the drain pipe (8) on the gas outlet casing to Position 2, in order to keep the drain pipe clean with air from the compressor casing (21).
The water supply connection (1) to the regulating valve (2) must be
disconnected.
After cleaning, wait at least 10 minutes with engine running to allow
turbocharger to dry.
January 2008
X Firstly, slowly open the 3-way-valve (4) (if fitted), then the regulating
Points to remember when

cleaning
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 cases, the wet cleaning
operation must be terminated and the wet cleaning cycle begun again
with a lower water pressure or higher engine loading.
ABB
Version 5
NOTE
HZTL2491_EN

times.
January 2008
5.4.2
Maintenance

in operation
5.4
Page 21
Integrated dry cleaning of turbine and nozzle ring during operation

This cleaning method is not suitable for removing thick dirt deposits and
must therefore be carried out more often (see chapter Cleaning turbine
blades and nozzle ring in operation).
NOTE
Operating mode prerequisites for integrated dry cleaning device

tested and is recommended by ABB Turbo Systems, the following prerequisites must be met:
HZTL2491_EN
NOTE
Z High engine output (50 to 100%) and high turbocharger speed.

Z Gas inlet temperature upstream of the turbine must be below 590C.
Version 5
Otherwise, there is considerable danger that the dry cleaning agent

will be burnt off.
X Start the cleaning cycle with reference to the following description
Operating procedure for integrated dry cleaning device.
ABB

Maintenance

in operation
5.4
Page 22
HZTL2491_EN
January 2008
Operation of integrated dry cleaning device
Container for granulated material
ON/OFF valve
Trap-cover
Safety valve
Compressed air supply [4 to 10

bar]
Combined air valve/pressure

relief valve
Pipe made from stainless steel
Cleaning instructions
The air system must be protected against overpressure (> 10 bar).

CAUTION
ABB
Version 5
L_00094
January 2008
Operation of the dry

cleaning device
Maintenance

in operation
5.4
Z The Operating mode prerequisites for integrated dry cleaning must be

X
X
X
X
X
X
X
X
X
X
X
HZTL2491_EN
Page 23
satisfied before cleaning begins.

Ensure that the ON/OFF valve (5) is closed.
Check that combined air valve/pressure relief valve (7) is in pressure
relief position.
Carefully open trap cover (2).
Fill container (1) with specified amount of granulate.
Close and seal trap cover (2).
Open air valve (7).
Open safety valve (6).
Open ON/OFF valve (5) and leave it open for approx. 1 minute to clean
turbine.
Close ON/OFF valve (5).
Close safety valve (6).
Set the combined air valve/pressure relief valve (7) to the pressure relief position.
Check whether exhaust gas temperature after turbine has dropped.
In order to obtain the best possible cleaning effect, it is essential that

the prescribed quantity of granulate is blown in.
NOTE
The drain openings in the gas outlet casing must remain closed while
the turbine is being cleaned. Careless handling can cause incompletely
combusted soot particles to escape.
Version 5

times.
NOTE
ABB

Maintenance

in operation
5.4
Page 24
Selection of materials
January 2008
Cleaning parameters for integrated dry cleaning device
The following materials are suitable for use when dry cleaning:
Hard, granulated materials, such as natural core granulates
Softblast media
Activated carbon particles
The mean grain size of the cleaning granulate must be between 1.2 and
2.0 mm.
Amount of granulate per

turbocharger [litres]
HZTL2491_EN
The specific weight of the cleaning granulate must not exceed 1.2 kg/dm3.
TPL 85-B
3.0
The cleaning granulate must be stored in a dry, clean place in order to

avoid clogging the pipes during cleaning.
The table in chapter Suppliers of dry cleaning agents lists possible suppliers of dry cleaning agents.
Version 5
NOTE
ABB
January 2008
5.4.3
Maintenance

in operation
5.4
Page 25
Non-integrated dry cleaning device for turbine and nozzle ring during operation
As an alternative to the built-in dry cleaning system, a non-integrated dry
cleaning device can be installed in front of the gas inlet casing by the engine manufacturer.
Operating mode prerequisites for non-integrated dry cleaning device

tested and is recommended by ABB Turbo Systems, the following prerequisites must be met:
NOTE
Z High engine output (50 to 100%) and high turbocharger speed.

Z Gas inlet temperature in front of the turbine must be below 590C.
Version 5
HZTL2491_EN
Otherwise, there is considerable danger that the dry cleaning agent

will be burnt off.
X Start the cleaning cycle with reference to the following description
Operating procedure for non-integrated dry cleaning device.
ABB

Maintenance

in operation
5.4
Page 26
Version 5
HZTL2491_EN
January 2008
Operation of non-integrated dry cleaning device
L_00208
ABB
January 2008

Maintenance

in operation
5.4
Page 27
Trap cover G2
Strap for securing the container
Poss. copper gasket
Safety valve with ventilation
Double nipple G2
Compressed air shut-off valve
Copper gasket
Compressed air pipe

(internal diameter 8mm)
Friction cock or slide controller

G1''
10
Compressed air max. 6 bar
The air system must be protected against overpressure (> 6 bar).

CAUTION
Operation of the dry

cleaning device
Z The Operating mode prerequisites for non-integrated dry cleaning de-
HZTL2491_EN
Z
X
X
X
Version 5
X
X
X
X
X
X
X
X
X
X
X
X
X
vice must be satisfied before cleaning begins.

Friction cock or slide controller (5) closed and safety valve with ventilation (7) open.
Close safety valve with ventilation (7).
Tighten trap cover (1).
Open compressed air shut-off valve (8) so that deposits and any condensation are blown off.
Close compressed air shut-off valve (8) again after about 3 minutes.
Close friction cock / slide controller (5).
Open safety valve with ventilation (7) to blow out exhaust gases.
Carefully open trap cover (1) on granulate container.
Fill granulate container with specified quantity of granulate.
Close and seal trap cover (1).
Close safety valve with ventilation (7).
Open compressed air shut-off valve (8).
Open friction cock or slide controller (5) for approx. 1 minute.
Close friction cock or slide controller (5).
Close compressed air shut-off valve (8).
Open safety valve with ventilation (7).
Check whether exhaust gas temperature has dropped after turbine.
ABB

5

in operation
5.4
Page 28
In order to obtain the best possible cleaning effect, it is essential that

the spcified quantity of granulate is blown in.
NOTE
The drain openings in the gas outlet casing must remain closed while
the turbine is being cleaned. Careless handling can cause incompletely
combusted soot particles to escape.
January 2008
Maintenance

times.
HZTL2491_EN
NOTE
Cleaning parameters for the non-integrated dry cleaning device
The choice of material takes place according to chapter Integrated dry

cleaning of the turbine and nozzle ring during operation.
Granulate quantity per

turbocharger
Turbocharger type
Amount of granulate
[dm3]
Container size
TPL 69BA
1.0
II
TPL 73-B
1.0
II
TPL 77-B
1.5
II
TPL 80-B
2.0
II
TPL 85-B
3.0
III
TPL 91-B
3.5
III
Version 5
NOTE
ABB

Maintenance
Suppliers of materials for dry cleaning
5.5
Page 29
Manufacturer
Country
Address
Number for contact
ABB Australia Pty.

Limited
Australia
Dock 7W Bapaume Road

2170 Moorebank- N.S.W.
Tel.: +61 2 9821 0940

Fax: +61 2 9821 0941
Email: turbo@au.abb.com
Paul AUER GmbH
Germany
Bad Kreuznacherstr. 18
D-68309 MannheimKaefertal
Tel.: +49 621 72 769 - 0

Fax: +49 621 72 769 - 88
Email: vertrieb@auer-strahltechnik.de
BRIGANTINE
Service Ltd.
Hong Kong
48 Wang Lok Street

Yuen Long Industrial Estate
N.T. Hong Kong
Tel.: +852 2473 7933

Fax: +852 2237 4731
Email:
gcabrgpropur@brigantinegroup.com
LEERING HENGELO B.V.
Netherlands
Barnsteenstraat 1
NL-7554 TC Hengelo
The Netherlands
Tel.: +31 74 255 82 82

Fax: +31 74 242 23 73
Email: info@leering.nl
GUYSON
International Ltd
United
Kingdom
Snaygill Industrial Estate

Keighley Road, Skipton,
North Yorkshire BD23 2QR
United Kingdom
Tel.: +44 1756 799911

Fax: +44 1756 790213
Email: info@guyson.co.uk
DASIC
International Ltd.
United
Kingdom
Winchester Hill, Romsey,

Hampshire SO51 7YD
United Kingdom
Tel.: +44 1794 512 419

Fax: +44 1794 522 346
Email: info@dasicinter.com
PAN
Abrasives (Pte) Ltd.
Singapore
24 Pioneer Sector 2
Jurong
628381 Singapore
Tel.: +65 6861 6988

Fax: +65 6861 0919
Email: pagroup@pan-abrasives.com
CARLANDER & Co.
Sweden
Valtersang 9
S-442 49 Kungalv
Sweden
Tel.: +46 303 630 75

Fax: +46 303 630 77
Email: lars@carlander.com
BOSUNG Engineering Co., Ltd.
Korea
1189-1, Choryang-3 Dong,

Dong-Ku, Busan, 601-013
Tel.: +82 51 466 0881-5

Fax: +82 51 466 0886-9
Email: master@bosung.com
POLITEK Ltd.
Turkey
Barajyolu Cad. No: 22/6

Y. Camlica Mahallesi
Yukari Dudullu
34779 Umraniye
Istanbul / Turkey
Tel.: +90 216 455 77 66

Fax: +90 216 455 77 25
Email: politekltd@politekltd.com
UNISERVICE S.A.
Italy
Via Al Santuario di N.S.

della Guardia 58 / A
16162 Genova
Tel.: +39 010 711 395

Fax: +39 010 713 120
Email: info@uniservicemarine.com
Version 5
HZTL2491_EN
January 2008
5.5 Suppliers of materials for dry cleaning
ABB

Troubleshooting
6.1
Page 1
6 Troubleshooting
January 2008
6.1 Possible remedies for failures

Exhaust temperature too high
Engine output and speed unchanged
Z Malfunction in the injection system

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

X Clean
HZTL2491_EN
Engine
Z Compressor / turbine soiled

X Clean
Z Exhaust counterpressure too high
X Clean or repair boiler or exhaust silencer
Z Turbine damaged or worn
X Contact an official ABB Turbo Systems service station.
Charge-air cooler
Z Cooler soiled
X Clean
Z Insufficient coolant water quantity
X Replenish
Version 5
Z Coolant water inlet temperature too hot

X Clean/inspect cooling system
Z Ventilation inadequate
X Improve ventilation
ABB

Troubleshooting
6.1
Page 2
January 2008
Charge-air pressure too low

Intake condition normal
Engine
Z Air receiver leaking

X Repair
Z Gas line between engine and turbine leaking
X Repair
Z Injection misadjusted
X Correct adjustment
Turbocharger
HZTL2491_EN
Z Valve control misadjusted

Z Manometer display faulty

X Replace manometer
Z Leak in line to the manometer
X Repair leak
Z Air filter dirty, causing excessive loss of pressure
X Clean
Z Compressor / turbine soiled
X Clean
Z Compressor / turbine damaged
Version 5
Z Excessive exhaust counterpressure

X Clean boiler or exhaust silencer
ABB

Troubleshooting
6.1
Page 3
January 2008
Charge-air pressure too high

Intake condition normal
Engine
Z Malfunction in the injection system

Z Engine output higher than expected
X Check engine output
HZTL2491_EN
Z Injection misadjusted
Turbocharger
Z Manometer display faulty

X Replace manometer
Vibrations
Turbocharger
Z
Z
Z
X
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
Z Turbocharger dirty
X Clean
Version 5
Z
Z
Z
X
Bearing damaged
Rotor grazing
Foreign bodies in the turbocharger
ABB

Troubleshooting
6.1
Page 4
Turbocharger
January 2008
Run-out time too short

X Clean
Z
Z
Z
X
Bearing damaged
Rotor grazing
Sluggish start-up
X Clean
Z
Z
Z
X
Bearing damaged
Rotor grazing
HZTL2491_EN
Turbocharger
Lubricating oil pressure too low

Engine
Z Oil filter heavily soiled

X Clean
Z Oil pump in the lubricating system defective
X Inspect
Z Manometer provides false reading
X Replace manometer
Z Axial clearance of the rotor too big

Version 5
Turbocharger
ABB

Troubleshooting
6.1
Page 5
January 2008
Constant surging of the turbocharger

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

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

official ABB Turbo Systems service station.
Version 5
HZTL2491_EN
NOTE
ABB

7.1
Page 1
January 2008
7 Removal and installation

7.1 Turbocharger weights
WARNING
Loads that are not suspended in accordance with the regulations during
disassembly and assembly may fall and can cause serious or even fatal
injury.
Version 5
HZTL2491_EN
X Select a suitable rope taking into account the weight of the load
X Hang rope crossed over on the crane hook
X Do not stand under suspended loads
L_00082
ABB

7.1
Page 2
Weight [kg]
January 2008
Turbocharger complete unit without filter silencer/air suction branch

TPL 85-B
9745
Turbocharger complete unit with filter silencer

Weight [kg]
TPL 85-B
10700
Turbocharger complete unit with air suction branch

Weight [kg]
TPL 85-B
Version 5
HZTL2491_EN
10035
ABB

7.2
Page 3
7.2 Remove the turbocharger

January 2008
X 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 supplying oil-inlet channel.
Version 5
HZTL2491_EN
X Check the lifting equipment.

X Secure lifting equipment to the suspension lugs on the bearing casing.
7.2
ABB

7
7.2
Page 4
During removal, a turbocharger that is not lifted in compliance with

regulations may fall, and can cause serious or even fatal injury.
WARNING
X Select a suitable rope taking into account the weight of the turbo-
charger.
X Suspend the complete turbocharger using the two ribs on the bearing casing provided for this purpose.
X The turbocharger must be transported as horizontally as possible.
January 2008
X Release the fixing screws on the foot.

X Lift the turbocharger from the engine and place it aside.
If the support for the turbocharger is missing or defective when setting

aside, the turbocharger may tip over and can cause serious or even fatal injury.
HZTL2491_EN
WARNING
Version 5
X Support turbocharger in a suitable location.

X Cover oil connector.
ABB

Installing the turbocharger
7.3
Page 5
January 2008
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
X Select a suitable rope taking into account the weight of the turbo-
charger.
X Suspend the complete turbocharger using the two ribs on the bearing casing provided for this purpose.
X The turbocharger must be transported as horizontally as possible.
Remove cover from oil connector.
Check the lifting equipment.
Secure lifting equipment to the suspension lugs on the bearing casing.
Mate turbocharger to engine.
Tighten the fixing screws on the foot, in accordance with the engine
manufacturer's instructions.
X Secure all gas, air, and oil lines in accordance with the engine manufacturers instructions.
Version 5
HZTL2491_EN
X
X
X
X
X
ABB

Module weights
8.1
Page 1
January 2008
8 Disassembly and assembly

8.1 Module weights
WARNING
Loads that are not suspended in accordance with the regulations during
disassembly and assembly may fall and can cause serious or even fatal
injury.
Version 5
HZTL2491_EN
X Select a suitable rope taking into account the weight of the load
X Hang rope crossed over on the crane hook
X Do not stand under suspended loads
L_00082
ABB

Module weights
8.1
Page 2
HZTL2491_EN
January 2008
Modules
Version 5
8.1
ABB

Module weights
8.1
January 2008
Weights [kg]
Page 3
Description
TPL 85-B
Air suction branch, radial
290
Filter silencer
955
Compressor casing, internal

part
550
Wall insert
850
Diffuser
225
Compressor casing external

part
1200
Cartridge group
3000
Cover ring
145
Nozzle ring
95
10
Gas inlet casing radial
495
HZTL2491_EN
Compressor casing, internal part, complete

Weight [kg]
TPL 85-B
1625
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.
Version 5
NOTE
ABB

8
Removing and fitting filter silencer or air

suction branch
8.2
Page 4
8.2 Removing and fitting 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).
January 2008
NOTE
X Remove insulation where necessary.

X Disconnect all air ducts in accordance with the engine manufacturers
HZTL2491_EN
instructions.
74027
74018
90195
Version 5
L_01214
X Secure shackle (90195) to rib / fin on filter silencer.
ABB
Removing and fitting filter silencer or air

suction branch
8.2
Page 5
During removal and assembly, turbocharger components that have not

been suspended in compliance with regulations may fall, and can cause
serious or even fatal injury.
WARNING
X Do not stand under suspended loads.
Remove filter silencer
X Pass lifting gear through lugs on rear side and secure to shackle
Mounting the filter silencer
X Mount filter silencer or air suction branch in reverse order.
(90195).
X Unscrew nuts (74027) with washers (74018) and remove filter silencer
or air suction branch.
Version 5
HZTL2491_EN
January 2008
ABB

Axial clearance
8.3
Page 6
January 2008
8.3 Axial clearance

74018
74027
L_01250
Z Before removing as well as after fitting the internal part of the compres-
HZTL2491_EN
sor casing and the gas inlet casing (if removed), the axial clearance (A)
must be measured.
X Screw on at least four nuts (74027) with washers (74018) equally
spaced around circumference and tighten to secure partition wall axially.
X Measure and note axial clearance A.
If the axial clearance A is out of tolerance, an official ABB Turbo Systems service station must be contacted.
Clearance A [mm]
Version 5
CAUTION
TPL 85-B
0.54 0.79
ABB

Dismantling the internal part of the

compressor casing
8.4
Page 7
January 2008
8.4 Dismantling the internal part of the compressor casing

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
Blocked safety segments (Y) during disassembly

CAUTION
Observe the maximal tightening torque for the nuts (90458) so as not to
shear off the threaded studs of the safety segments (Y).
X Screw on and tighten four nuts (74027) with washers (74018/74028)
HZTL2491_EN
equally spaced around circumference.
X Take nuts (90458) out of toolbox and screw onto threaded studs of
three safety segments (Y) in internal part of compressor casing

(76000).
Position of safety segments during disassembly
76000
74000
Version 5
90458
90458
L_00269
X Tighten nuts (90458) to a maximal torque of 30 Nm.

D The internal part of the compressor casing (76000) is now separated
from the external part of the compressor casing (74000) and can be
removed.
ABB


compressor casing
8.4
Page 8
January 2008
Note check dimension (u).

NOTE
Check dimension (u) [mm]
Dimension
TPL 85-B
27.6
X Remove nuts (74027) with washers (74018).

X Remove 4 studs (74026/74029) from upper area.
X Hoist up lifting device (90190) using shackle (90195) and lifting gear.
90320
HZTL2491_EN
Removing internal part of

compressor casing
74026 / 74029
90195
90190
90900
74018
74027
76040
76000
F
74000
Version 5
90195
90025
90458
L_01215
X Press off internal part of compressor casing (76000) using press-off
screws (90900), until lifting device (90190/90195) can be fitted.
ABB


compressor casing
8.4
Page 9
X Fit lifting device to internal part of compressor casing (76000).

X Withdraw internal part of compressor casing (76000) complete with
January 2008
wall insert and diffuser.
X Fit support angle (90025).

X Set down internal part of compressor casing (76000) in a horizontal
position.
If necessary
X Attach two shackles (90195) to support angle (90025) and fasten a se-
cond set of lifting gear to both shackles (90195).

X Slightly raise internal part of compressor casing (76000) complete with
wall insert and diffuser using lifting device (90190).
X Use second set of lifting gear to carefully move internal part of compressor casing (76000) into vertical position.
X Set down casing on flange (F) on an underlay.
WARNING
X Rest internal part of compressor casing only on flange (F).

X Check underlay and adjust if necessary.
Version 5
HZTL2491_EN
Ensure that the underlay does not slip.
ABB


compressor casing
8.4
Page 10
Remove diffuser
January 2008
76002
90235
79000
90230
90900
77000
77005
HZTL2491_EN
77006
76000
90025
X Remove screws (76002).

X Remove diffuser (79000) using ring bolts (90235).
X Ease off wall insert (77000) using press-off screws (90900) and re-
move using ring bolts (90230).

X Remove O-rings (77005, 77006).
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
ABB
Version 5
L_01251

Dismantling gas inlet casing
8.5
Page 11
8.5 Dismantling gas inlet casing

January 2008
X Remove the insulation on the gas inlet casing (51001).

X Fix lifting gear to the eyes on the gas inlet casing with shackle (90195).
Do not stand under or near the suspended gas inlet casing.
HZTL2491_EN
WARNING
L_00022
X Loosen the screws (61044) and remove gas inlet casing (51001) with
Version 5
X
X
X
X
nozzle ring (56001).

Remove screws (56014), bushings (56013) and nozzle ring (56001).
Loosen and remove screws (57005).
Fit two guide studs (90320).
Press off the cover ring (51085) with press-off screws (90320) and remove over the guide bolts (90907).
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
ABB

Fitting gas inlet casing
8.6
Page 12
8.6 Fitting gas inlet casing

January 2008
X Fit cover ring (51085) using two guide bolts (90320) as a help.
If removed:
Positioning cover ring

CAUTION
The marking "TOP" on the cover ring (51085) must be as far up as possible.
X Pay attention to installing cover ring in correct position.
X Screw in and tighten screws (57005).
X Remove guide bolts (90320).
X Mount nozzle ring (56001) on gas inlet casing (51001) using screws
Smear all screws in and on the gas casings with Anti Scuff Paste 868
from SPANJAARD.
HZTL2491_EN
(56014) and sleeves (56013).
NOTE
X Fit gas inlet casing (51001) with nozzle ring onto the gas outlet casing
(61044) with screws (61009).

X Remove lifting gear with shackle (90195).
Version 5
X Fit the insulation on the gas inlet casing (51001).
ABB
January 2008

Fitting the internal part of the

compressor casing
8.7
Page 13
8.7 Fitting the internal part of the compressor

casing
Fitting the diffuser
76002
90235
79000
90230
90900
HZTL2491_EN
77000
77005
77006
76000
Version 5
90025
L_01251
X Put O-rings (77005, 77006) on wall insert (77000).

X Fit wall insert (77000) and diffuser (79000) in internal part of compres-
sor casing (76000).

X Tighten screws (76002), then loosen again by a turn.
X Secure lifting gear to lifting device (90190) and shackles (90195) in
support bracket (90025).
X Lift internal part of compressor casing (76000) complete with wall insert
and diffuser using two sets of lifting gear.
ABB


compressor casing
8.7
Page 14
as a result, bring internal part of compressor casing (76000) into a horizontal position.
X Remove support bracket (90025) complete with shackle (90195).
Fitting internal part of

compressor casing
90320
January 2008
X Carefully slacken lifting gear attached to support bracket (90025) and,
74026 / 74029
90195
90190
74018
74027
76040
76000
F
HZTL2491_EN
90900
74000
90195
90025
90458
L_01215
X
X
X
X
with wall insert and diffuser over guide bolts (90320) into external part
of compressor casing (74000).
Remove lifting device (90190/90195).
Insert internal part of compressor casing as far as it will go.
Remove guide bolts (90320) and screw in studs (74026/74029).
Use studs [10x 74029, 2x 74026 (each screwed in at top and bottom)].
74026
74029
L_01124
ABB
Version 5
X Put O-ring (76040) onto internal part of compressor casing (76000).

X Fit guide bolts (90320).
X Carefully insert internal part of compressor casing (76000)complete


compressor casing
8.7
Page 15
X Screw on at least four nuts (74027) with washers (74018) equally

January 2008
spaced around circumference and tighten to secure partition wall axially.
Blocked safety segments (Y) during assembly

CAUTION
The safety segments (Y) are not in the operating position. There is no
guarantee of additional axial securing of the two compressor casings
(74000/76000).
X Screw on and tighten four nuts (74027) with washers (74018/74028)
equally spaced around circumference.
X Unscrew nuts (90458) on threaded studs of three safety segments (Y)
on internal part of compressor casing (76000).
relative to the external part of the compressor casing (74000).
Position of safety segments after assembly
76000
74000
Y
HZTL2491_EN
D The internal part of the compressor casing (76000) is now secured
90458
90458
Version 5
L_00276
ABB

8

compressor casing
8.7
Page 16
Note check dimension (s). The safety segments (Y) are back in the operating position.
NOTE
Check dimension (s) [mm]
Dimension
January 2008
TPL 85-B
18.5
X Put nuts (90458) back into toolbox.
If the axial clearance A is out of tolerance, an official ABB Turbo Systems service station must be contacted.
CAUTION
Clearance A [mm]
HZTL2491_EN
X Measure and note axial clearance A.
TPL 85-B
0.54 0.79
X Remove nuts (74027) with washers (74018).
X Mount filter silencer or air suction branch and secure with nuts (74027)
and washers (74018) (see section Removing and mounting filter silencer or air suction branch).
X Connect all air lines / ducts in accordance with engine manufacturers
instructions.
X Fit all insulation that was removed.
ABB
Version 5
Mounting the filter silencer

8

compressor casing
8.7
Page 17
Version 5
HZTL2491_EN
January 2008
ABB

8.8
Page 18
74026
74029
90458
74027
76002 42059
42064
57005
61044
HZTL2491_EN
82002
January 2008
8.8 Table of tightening torques
56014
L_01216
L_00228
The following tightening torques must be kept to for the specified threaded
connections:
ABB
Version 5
86505

8.8
HZTL2491_EN
January 2008
Tightening torques [Nm]
Part number
TPL 85-B
42059, 42064
M12
110
56014
M16
160
57005
M16
160
61044
M24
480
74026 / 74029
M24
80
74027
(with larger washer)
M24
400
76002
M20
- 1)
82005
M16 x 1.5
50
86505
M22 x 1.5
220
90458
M12
30
Tighten only so much that the diffuser can still be moved.
Version 5
1)
Page 19
ABB

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

January 2008
9.1 Possibilities for emergency repair

Lubricating oil leakage is a fire hazard.
WARNING
The instructions of the engine manufacturer for operation of the engine

with locked / isolated turbocharger must be followed precisely in all cases!
CAUTION
HZTL2491_EN
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
Emergency repairs that can be carried out quickest have been described first.
Version 5
NOTE
ABB

Locking the rotor
9.2
Page 2
January 2008
9.2 Locking the rotor

A blocked/ jammed rotor must be disassembled following the turbocharger repair and given an imbalance check.
CAUTION
NOTE
The only exception is a test rig run up to maximum 25% of the engine
load with new engines with one or a number of turbochargers, which
are requested by some customers. Since in these cases operation with
a blocked rotor is brief and the loads are low, subsequent disassembly
of the rotor is unnecessary.
NOTE
CAUTION
Various intermediate rings are provided with the blocking device for different compressor wheels. The compressor wheel type CV (for the balancing screw holes) must be noted. The space between the blocking
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.
HZTL2491_EN
U Once unscrewed, balancing screws must not be screwed in again.
During operation of the engine with a blocked 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 blocked rotor for 2-stroke engines). Otherwise components that are still intact can be damaged by
overheating.
Version 5
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 the rotor
9.2
Page 3
HZTL2491_EN
January 2008
Locking rotor with polygon connection
Version 5
L_00261
ABB

9
Locking the rotor
9.2
Page 4
These operations must be carried out as described in the chapter Disassembly and assembly.
NOTE
X Remove the filter silencer or air suction branch and the compressor ca-
January 2008
sing internal part together with the wall insert and the diffuser.
X Fix partition wall with press-off tools (90920).
Fit locking flange (94003) to the compressor wheel with at least 9

screws (94007 or 94008) (refer to Table of tightening torques).
Table of tightening torques [Nm]
Part number
TPL85-B
94006
M12
75
94007 / 94008
M12
60
HZTL2491_EN
CAUTION
X Fit the locking flange (94003) with screws (94007 or 94008, using the
Version 5
longest possible screws) as well as the adjustment ring (94004) and intermediate ring (94031).
ABB

Locking the rotor
9.2
Page 5
HZTL2491_EN
January 2008
Compressor type CV11
94000_15
Version 5
It must be ensured that all components are clean and free from grease.
CAUTION
X Push correct intermediate rings (94001 and/or 94002) on to the locking
flange (94003).
X Fit assembly-disassembly device (90020) in each case with 2 washers
(94032).
X Insert the remaining intermediate rings (94001 and/or 94002) and
mount the locking flange (94003) with screws (94006).
ABB

Locking the rotor
9.2
Page 6
HZTL2491_EN
January 2008
Compressor type CV12, CV13
94000_012
It must be ensured that all components are clean and free from grease.
CAUTION
flange (94003).
X Fit assembly-disassembly device (90020) in each case with 2 washers
(94032).
X Insert the remaining intermediate rings (94001 and/or 94002) and
mount the locking flange (94003) with screws (94006).
ABB
Version 5
X Push correct intermediate rings (94001 and/or 94002) on to the locking

Locking the rotor
9.2
Page 7
January 2008
Further measures and information for operation with blocked rotor for 2stroke engines
2-stroke engine with one
turbocharger:
No further measures are necessary. The engine can be operated with the
auxiliary blower according to the manufacturer's instructions.
9 The lubrication oil system must remain connected and turned on.
HZTL2491_EN
2-stroke engine with several turbochargers:
X The compensator at the compressor outlet must be dismantled and the
air duct blocked at the engine end, as undamaged turbochargers develop a receiver pressure.
X The operating limit of the engine can be raised by additionally blocking
the gas inlet, as the exhaust gas is then used to drive the undamaged
turbocharger. In addition, the loading and temperature of the blocked
rotor is reduced.
If the gas inlet cannot be blocked, the following operating limits must be
observed:
The pressure in the charge-air receiver must not exceed 1 bar over-
pressure.
Max. permissible engine load: 50%.
Attention must be paid to the speed of the undamaged turbochargers in

all cases. The speed limit nBmax according to the turbocharger rating plate must not be exceeded.
Version 5
CAUTION
ABB

9.3
Page 8
January 2008
9.3 Blocking the inlets and outlets

Shut off the supply of lubricating oil to the turbocharger.
CAUTION
X Block the compressor casing outlet, gas inlet and gas outlet by fitting
cover plates.
For information about how to do this, see the manufacturer's instructions.
Version 5
HZTL2491_EN
NOTE
ABB

9.4
Page 9
January 2008
9.4 Bypass the turbocharger

Shut off the supply of lubricating oil to the turbocharger.
CAUTION
Z Only applies for engines with one turbocharger.

Z The connections are ready and pipes for the bypass are to hand.
X Fit the bypass around the turbocharger.
For information about how to do this, see the manufacturer's instructions.
Version 5
HZTL2491_EN
NOTE
ABB

10
Taking out of operation for up to 12

months
10.1
Page 1
January 2008
10 Mothballing the turbocharger

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.
Version 5
HZTL2491_EN
If the rotor turns due to a draught from the flue, fit a blind flange between
the compressor casing and the charge-air duct.
ABB

10
Taking out of operation for more than 12 10.2

months
Page 2
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.
January 2008
Suitable storage locations are dry rooms where the relative humidity is between 40-70% and no condensation can form.
Check mothballed turbochargers yearly for corrosion.
Version 5
HZTL2491_EN
NOTE
If there are signs of rust, clean parts and renew means for protection
against corrosion.
ABB

Disposal
11
Environmentally compatible disposal of

turbocharger components
11.1
Page 1
January 2008
11 Disposal
11.1 Environmentally compatible disposal of turbocharger components
Environmentally compatible disposal of turbocharger components
HZTL2491_EN
NOTE
Component disposal must be environmentally compatible, professionaland in accordance with locally regulations.
The turbocharger mainly consists of metal (cast-iron materials, steel,
nickel-steel alloys, aluminium, bearing brass).
Other components are: non-metallic materials (filter components made
of felt and polyethylene), lubricants (engine oil), electronic components
(speed sensor and associated components), thermal insulation.
X
X
X
X
Dispose of metals by melting down and recycling.

Dispose of non-metallic materials as waste.
Dispose of lubricant left-overs and residues as used oil.
Dispose of electronic components as electrical / electronic scrap.
Handling damaged thermal insulation

WARNING
Damaged thermal insulation can burden the air with dust. The glass fibres can cause mechanical irritation of the eyes, skin and respiratory
tracts.
Version 5
X Prevent dust from being produced.

X Remove dust with a suitable vacuum cleaner.
X Wear respiratory mask as protection against particles (P1 or P2
mask).
X Wear leather protective gloves.
X Wear close-fitting safety goggles.
X Dispose of thermal insulation as special waste.
ABB

12
12.1
Page 1
January 2008
12 Reserve and spare parts

12.1 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 will take orders for spare parts.
X If special variants/cases are not addressed in these general instruc-
Version 5
HZTL2491_EN
tions, then contact an official ABB Turbo Systems service station or an

ABB agent.
ABB

12
12.1
Page 2
To carry out the work described in this manual, you need a set of spare
parts (97070). These spare parts in this set are available only as a
complete set.
Spare parts set (97070)
Quantity
Description
Part number
O-ring gasket
42012, 76040
Gasket
42041, 42069
12
Hexagon head screw
42059, 42064
Gasket
42045
Hexagon head screw
56014, 57005
Hexagon nut
61037
Gasket
61041
O-ring gasket
77005, 77006
O-ring gasket
86506
HZTL2491_EN
NOTE
January 2008
Spare-parts set
All spare parts that were ordered with the turbocharger should be kept
as a complete set and ready for use.
CAUTION
X Parts showing signs of rust should be carefully cleaned and grea-
sed.
X Dispose of parts, which have been replaced and are no longer usable,
Version 5
in a proper and environmentally compatible manner.
ABB

12
12.2
Page 3
The following part numbers and descriptions must be used in ALL correspondence or orders:
Turbocharger
Part number
Description
Cartridge group
51001
Gas inlet casing
51085
Cover ring
56001
Nozzle ring
61001
Gas outlet casing
61035
Hexagon head screw
61037 (in spare parts set)
Hexagon nut
68000
Foot
74000
Compressor casing external part
76000
Compressor casing, internal part
O-ring gasket
76080
Safety segment
77000
Wall insert
O-ring gasket
O-ring gasket
79000
Diffuser
81000
Filter silencer
82000
Air suction branch, radial
Version 5
HZTL2491_EN
January 2008
12.2 Directory of part numbers
ABB
12.2
Part number
Description
21000
Shaft
25000
Compressor wheel
25008
Threaded pin
25009
Ring nut
32001
Thrust bearing
32101
Radial bearing, compressor end
32102
Radial bearing, turbine end
32104
Auxiliary bearing
32105
Floating disc
32106
Axial bearing
42001
Bearing casing
42002
Hood
42011
O-ring gasket
O-ring gasket
42015
Sealing cover
Gasket
Gasket
Hexagon head screw
Hexagon head screw
42295
Non-return valve
43001
Partition wall
43005
O-ring gasket
86505
Speed sensor
O-ring gasket
Page 4
January 2008
HZTL2491_EN
12
Version 5
Cartridge group - polygon

connection
ABB

12
General view of turbocharger
12.3
Page 5
61001
68000
61035
61037
76000
77005 77006
76040
76080
82000
81000
Version 5
77000
79000
74000
56001
51085
51001
HZTL2491_EN
January 2008
12.3 General view of turbocharger
L_01217
ABB

12
General view of cartridge group
12.4
Page 6
86505
Version 5
25009
32104
32101
32106
25000
32105
43005
32001
43001
42045
42012
42041
HZTL2491_EN
42059
42001
86506
42064
42295
42002
25008
32102
42011
21000
42015
January 2008
12.4 General view of cartridge group
L_00906
ABB
ABB
ABB Turbo Systems AG

Bruggerstrasse 71a
CH-5400 Baden
Switzerland

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Turbocharging

ABB Turbo Systems Ltd

Operating condition and replacement intervals

Copyright by ABB TURBO SYSTEMS Ltd 2004

ABB Turbo Systems AG

Operation Manual / TPL85-B14/-B15/-B16

Layout and function

Correct use of the turbocharger

Abbreviations and symbols

Turbocharger rating plate

Basic safety instructions

General safety instructions

Special safety instructions

Safety instructions and hazard protection

Warnings on the turbocharger

Putting into operation after laying up

Expected exchange intervals

Contact with rotating parts

Shutting the engine down

Cleaning the filter silencer

Cleaning the compressor during operation

Cleaning turbine blades and nozzle ring in operation

Suppliers of materials for dry cleaning

ABB Turbo Systems Ltd

Operation Manual / TPL85-B14/-B15/-B16

Possible remedies for failures

Removal and installation

Remove the turbocharger

Installing the turbocharger

Disassembly and assembly

Removing and fitting filter silencer or air suction branch

Dismantling the internal part of the compressor casing

Dismantling gas inlet casing

Fitting gas inlet casing

Fitting the internal part of the compressor casing

Table of tightening torques

Taking out of operation temporarily

Possibilities for emergency repair

Locking the rotor

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

Environmentally compatible disposal of turbocharger

Reserve and spare parts

Ordering spare parts

Directory of part numbers

General view of turbocharger

General view of cartridge group

ABB Turbo Systems Ltd

Operation Manual / TPL85-B14/-B15/-B16

Content of operating manual

This operation manual includes helpful information on the following topics:

the turbocharger's service life.

This applies especially to the general and special safety instructions

ABB Turbo Systems Ltd

Operation Manual / TPL85-B14/-B15/-B16

Layout and function

1.2 Layout and function

Radial plain bearing

Radial plain bearing

Gas outlet casing