ABB Turbocharger Operations Manual PDF

Operation Manual
List of contents Page 1
List of contents
January 2007
1 Preliminary remarks
1.1 Purpose of the manual
1.2 Layout and function
1.3 Correct use of the turbocharger
1.4 Essential information
1.5 Abbreviations and symbols
1.6 Turbocharger rating plate
2 Safety
HZTL2491_EN (TPL85-B14/-B15/-B16)
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
3 Commissioning
3.1 Oil supply
3.2 Inspection work
3.3 Putting into operation after laying up
4 Operation
4.1 Servicing work
4.2 Monitoring
4.3 Surging of turbocharger
4.4 Contact with rotating parts
4.5 Shutting the engine down
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5 Maintenance
5.1 Foreword to Maintenance
5.2 Cleaning the filter silencer
5.3 Cleaning the compressor during operation
5.4 Cleaning turbine blades and nozzle ring in operation
5.5 Suppliers of materials for dry cleaning
ABB Turbo Systems Ltd

Operation Manual
List of contents Page 2
6 Troubleshooting
January 2007
6.1 Possible remedies for failures
7 Removal and installation

7.1 Turbocharger weights
7.2 Remove the turbocharger
7.3 Installing the turbocharger
8 Disassembly and assembly

8.1 Module weights
8.2 Removing and fitting the filter silencer or air suction branch
8.3 Axial clearance
8.4 Dismantling the internal part of the compressor casing
HZTL2491_EN (TPL85-B14/-B15/-B16)
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
9 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 Reserve and spare parts

11.1 Ordering spare parts
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11.2 Directory of part numbers

11.3 General view of turbocharger
11.4 General view of cartridge group

Operation Manual
Preliminary remarks 1
Purpose of the manual 1.1 Page 1
1 Preliminary remarks
1.1 Purpose of the manual
January 2007
Operation manual This operation manual will help you to become familiar with your ABB
Turbo Systems Ltd turbocharger and to use it to full effect in its intended
application. You will find important instructions as to the safe, correct, and
economical operation of the turbocharger.
Target group The content of this operation manual is intended for persons such as en-
gineers, marine mechanics and service technicians who are responsible
for the running of the engine and the turbocharger installed thereon.
Content of operation ma- This operation manual includes helpful information on the following topics:
nual
Information on the operation of the turbocharger and ways to prolong
the turbocharger's service life.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Early awareness and avoidance of hazards.

Minimising repair costs and failure times.
This operation manual is a complement to, and an extension of, existing

national regulations on accident protection and prevention.
An operation manual must be available at all times at the site where the
turbocharger is used. It is essential that this operation manual is read
before beginning work by all persons working with or on the turbo-
NOTE charger. Personnel who only work occasionally on the machine (e.g.
during installation and maintenance) must also have read and fully un-
derstood the operating manual before beginning work.
The instructions included in this operation manual must be followed under

all circumstances.
This applies especially to the general and special safety instructions

preceding and in the respective chapters. Ignoring hazards and the sa-
fety instructions can lead to serious personal injury and damage to e-
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WARNING quipment.
In the event of doubt, consult the officer for safety and accident protection
responsible for your area.

Operation Manual
Layout and function 1.2 Page 2
1.2 Layout and function
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
1.2.
1 Filter silencer 7 Nozzle ring

2 Radial plain bearing 8 Turbine wheel
3 Thrust bearing 9 Bearing casing
4 Radial plain bearing 10 Diffuser
5 Gas outlet casing 11 Compressor wheel
6 Gas inlet casing 12 Air outlet casing
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Operation Manual
Layout and function 1.2 Page 3
Mode of operation
January 2007
The turbocharger is a turbo-machine and consists of the following main

components:
Turbine
Compressor
These are both are mounted on a common shaft.
The exhaust gases from the diesel engine flow through the gas inlet cas-
ing (6) and nozzle ring (7) to the turbine wheel (8).
The turbine wheel (8) uses the energy contained in the exhaust gas to
drive the compressor wheel (11), whereby the compressor draws in fresh
HZTL2491_EN (TPL85-B14/-B15/-B16)
air, and the compressed air is forced into the cylinders.
The exhaust gases escape through the exhaust pipe which is connected
to the gas outlet casing (5).
The air which is necessary for the operation of the diesel engine and
which is compressed in the turbocharger is drawn through the suction
branch or the filter silencer (1) into the compressor wheel (11). It then
passes through the diffuser (10) and leaves the turbocharger through the
compressor outlet on the air outlet 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).
The turbocharger is equipped with an emergency lubrication oil tank,

which is integrated in the bearing casing. With a failure of the lubrication
oil system, the bearings are supplied with oil with this emergency lubrica-
tion until the rotor comes to a standstill.
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Operation Manual
Correct use of the turbocharger 1.3 Page 4
1.3 Correct use of the turbocharger
January 2007
This turbocharger supplied by ABB Turbo Systems has been developed
for use on diesel engines to generate the volume of air and the charg-
ing pressure required to operate the engine.
NOTE The engine manufacturer has provided ABB Turbo Systems with infor-
mation regarding the intended purpose of the engine, from which the
operating parameters specific to the turbocharger (such as rotating
speeds, temperatures, replacement periods / exchange intervals) have
been derived and are indicated on the rating plate.
Any other usage shall be regarded as a special application which must
be discussed with ABB Turbo Systems. The manufacturer accepts no
liability for other applications. If it is used otherwise, ABB Turbo Sys-
tems reserves the right to reject all claims under the warranty.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Latest technology This turbocharger was built according to state-of-the-art technology and is
operationally safe according to prevailing safety regulations.
Improper operation and maintenance of the turbocharger can result in

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

bly, disassembly, operating, maintenance and repair conditions specified
by the manufacturer. Regulations set out by local authorities must be ob-
served when disposing of the turbine.
Perfect condition The turbocharger must only be installed in a technically perfect condition,
corresponding to its intended purpose and following the instructions in the
Engine Manufacturers' Manual, and must be operated and used in com-
pliance with the Operation Manual.
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X Defects which could affect safety must be eliminated immediately.
The manufacturer shall not accept liability for damages resulting from un-
authorised alterations to the turbocharger.

Operation Manual
Essential information 1.4 Page 5
1.4 Essential information

January 2007
Organisational measures
In addition to this manual, the general, statutory regulations applicable in

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

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

with the turbocharger must be checked regularly with reference to this
manual.
NOTE
HZTL2491_EN (TPL85-B14/-B15/-B16)
X The turbocharger must be shut down immediately in the event of al-

terations affecting safety or of corresponding operating behaviour. The
fault should be reported to the person or department responsible.
Additions and alterations to, and conversions of the turbocharger that

could compromise safety require the prior approval of ABB Turbo Sys-
tems.
NOTE
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Operation Manual
Original parts and safety
January 2007
Original parts and accessories are especially designed for the turbo-
charger supplied by ABB Turbo Systems Ltd.
We herewith expressly state that parts and accessories not supplied by

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

Turbo Systems are used, this may have a negative effect on the techni-
cal design specifications of the turbocharger.
HZTL2491_EN (TPL85-B14/-B15/-B16)
WARNING Moreover, the active and/or passive safety of the turbocharger may be
compromised by the use of non-original parts. Note that such improper
use may endanger personnel and the machine.
ABB Turbo Systems shall not be liable for any damage caused by using
non-original parts and accessories.
Qualification of personnel
The turbocharger must only be operated and maintained by trained and

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

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

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charger.

Operation Manual
After-sales service
January 2007
The Contact Information brochure contains an overview of official ABB

Turbo Systems Ltd. service stations worldwide.
Design variants
This operating manual is valid for various turbocharger design variants.
This means that some sections and component descriptions in this oper-
ating manual do not apply to your turbocharger.
Our service stations and agencies will gladly answer your questions relat-
ing specifically to your model.
HZTL2491_EN (TPL85-B14/-B15/-B16)
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 instruc-
tions. Differences may exist in certain details.
Storage of new turbochargers
New turbochargers supplied by ABB Turbo Systems Ltd. can be stored

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

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

months.
NOTE

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

The following abbreviations are used in this document:
January 2007
Z Prerequisite
X Work step
D Result
9 Positive checkpoint (activity that must be carried out without fail)

U Negative checkpoint (activity that must not be carried out under any
circumstances)
Basic Instructions
HZTL2491_EN (TPL85-B14/-B15/-B16)
The following symbol is used for notes in this manual:
This note provides suggestions and tips to make work on the turbo-
charger easier.
The note provides further essential information.
NOTE
ABB Turbo Systems
The term ABB Turbo Systems used in this manual signifies ABB Turbo
Systems Ltd.
Official ABB Turbo Systems service station

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

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

January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00012
Operational limits 1 Turbocharger operational limits at engine overload (110 %).

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

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ment periods / exchange

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

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

7 Field for special design designation
8 Weight of the turbocharger in kg
January 2007
9 CE = Conformité Européenne
10 Turbocharger type
11 Series number
12 Year of construction of the turbocharger
Explanations of the rating plate
The recommended exchange intervals and the corresponding operation

limits are defined together with the engine builder. These specifications
are system-specific.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Continuous running above the indicated nBmax, tBmax values may consid-
erably reduce the recommended exchange intervals. In such cases, we
recommend you contact the nearest official service station of ABB
CAUTION Turbo Systems Ltd.
nMmax , tMmax normally apply only when running at overload (110 %) dur-
ing trials on the engine test bed. These limits may also be permitted in
service for special applications. The operation over nMmax , tMmax is not
permitted.
Non-compliance with the recommended exchange intervals may in-
crease the risk of unpredictable component failure.
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Operation Manual
Safety 2
Basic safety instructions 2.1 Page 1
2 Safety
2.1 Basic safety instructions
January 2007
The following symbols and terms are used for the safety instructions in
this manual:
Failure to follow work steps and operating instructions marked with this
symbol completely and rigorously may result in serious personal injury
or even fatal accidents.
WARNING Warning signs must be strictly observed at all times.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Serious damage to the machine or to other property may result if the

working and operation instructions marked with this symbol are not, or
only partly, observed.
CAUTION Caution signs must be strictly observed at all times.
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Operation Manual
Safety 2
General safety instructions 2.2 Page 2
2.2 General safety instructions

The instructions listed here are designed to ensure your safety and to
January 2007
promote safe handling of the turbocharger and its associated operating
materials.
The following safety instructions must be followed when operating and

when working on the turbocharger.
WARNING
Do not work on the turbocharger if you are under physical or mental

stress.
Wear protective clothing at all times.
Helmet
Ear protection
HZTL2491_EN (TPL85-B14/-B15/-B16)
Protective glasses
Protective suit
Oil and petrol resistant gloves
Protective shoes
Attach individual parts and larger component modules carefully to suit-
able hoists/lifting devices which are in technically perfect condition and
which have adequate load-bearing capacity.
Do not stand under suspended loads.
If welding work is to be carried out above the turbocharger, the air filter
must be covered to prevent damage to the filter mat.
When working on the turbocharger, be aware of the risk of it falling.
For overhead assembly work, use the steps and platforms provided for
this purpose.
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Operation Manual
Safety 2
Special safety instructions 2.3 Page 3
2.3 Special safety instructions

January 2007
Safety when connecting
Work only on those connections for which you are qualified.
Safety when commissioning and during operation
Before starting work, make a visual inspection of the working area.

Remove obstacles and any objects lying around from the work area.
Before commissioning check the turbocharger for damage and leaks.
Refrain from any activity which could compromise safety while working
with the turbocharger.
Inspect the turbocharger after about 12 hours of operation or at least
HZTL2491_EN (TPL85-B14/-B15/-B16)
once a day for visible damage and defects.

Report any damage or changes in operational performance to the per-
son/department responsible immediately.
In the event of damage, shut down the turbocharger immediately and
secure it against inadvertent or unauthorized use.
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, sto-

rage and disposal of these liquids.
Explosion hazard
Cleaning work should be carried out outdoors due to explosion hazard.
If this is not possible, ensure that there is adequate ventilation and air
WARNING circulation. Before beginning cleaning work in confined spaces, extin-
guish naked flames (including cigarettes!) due to the risk of explosion.
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Operation Manual
Safety 2
Before cleaning, protect the floor against unintended leaks of oil and
operation materials.
January 2007
You must wear protective clothing (see section General safety instruc-
tions).
Handle operation materials and detergents with utmost caution.
When handling solvents, wear protective clothing and observe the fol-
lowing rules:
Avoid skin contact with solvents.
Avoid inhaling vapours under all circumstances.
Do not allow solvents to soak protective clothing.
After cleaning, check electric cables for signs of wear or damage.
Safety during disassembly, assembly, maintenance and troubleshooting
HZTL2491_EN (TPL85-B14/-B15/-B16)
Follow the prescribed maintenance and inspection schedules for all ad-
justment, maintenance and inspection work.
Inform operating personnel about special work and repairs before start-
ing.
Ensure that absorbent materials are available to clean up any opera-
tion materials that escape accidentally.
Ensure safe and environmentally-friendly drainage, collection and dis-
posal of operating and auxiliary materials.
Before opening a cover or removing a protective component on the
turbocharger, the engine must have been switched off and must not be
started up again until all parts have been properly re-assembled.
Assembly and disassembly work must only be performed by trained

personnel. Work on mechanical components, such as bearings or ro-
tors, must only be performed by qualified fitters from an official service
CAUTION station of ABB Turbo Systems. Version 4

Operation Manual
Safety 2
Safety when taking out of operation or putting into storage

January 2007
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.
HZTL2491_EN (TPL85-B14/-B15/-B16)
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Operation Manual
Safety 2
Safety instructions and hazard 2.4 Page 6

protection
2.4 Safety instructions and hazard protection

Associated hazards may arise during operation of and work on the turbo-
January 2007
charger:
from the turbocharger and its accessories.

from the operating materials used.
due to failure to comply with the safety instructions.
from inadequate performance of maintenance and inspection work.
Mechanical influences
Mechanical influences can cause serious injury or even fatal injury.
HZTL2491_EN (TPL85-B14/-B15/-B16)
WARNING
Personal injury Unconsciousness and injury due to:
crushing
shearing
cutting
winding
smashing
drawing in
knocking
stabbing
rubbing
Escape of liquids under high pressure and / or at high temperature
slipping
tripping
falling
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Operation Manual
Safety 2

protection
Causes sharp edges, pointed parts

crush, shear and winding areas
fragmentation / ejection of parts
January 2007
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 Wear leather protective gloves

9 Wear close-fitting protective clothing
9 Tie up long hair and beards (wear hair protection)
9 Wear face and eye protection
9 Wear protective shoes
9 Keep floor, equipment and the turbocharger clean
9 Ensure the availability of oil absorbing materials and have oil collector
basins ready or in position
9 Eliminate leaks
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation and process materials
Operation and process materials refer to chemical and hazardous sub-

stances:
Oils
Grease
Coolants
Detergents and solvents
Acids
Note that operation and process materials are harmful to the environ-
ment if they penetrate soil or water.
CAUTION
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Operation Manual
Safety 2

protection
Personal injury The following injuries can be caused by operation and process materials:
Allergies
January 2007
Skin disease
Loss of consciousness
Poisoning or nausea after inhalation
Causes 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
HZTL2491_EN (TPL85-B14/-B15/-B16)
Protective measures 9 Utmost caution when handling process and operation materials
9 Protective clothing must be worn
9 Avoid skin contact and inhalation under all circumstances
9 Ensure that the workroom is properly ventilated
9 Observe the hazard indications on the containers for operation and
process materials
9 Immediately after use, seal the hazardous substance container tight
9 Used operation materials must be collected safely in accordance with
the legal provisions, stored separately in suitable containers as pre-
scribed, and disposed of as special waste in a technically and envi-
ronmentally compatible manner
9 Ensure that containers for new / used operation materials are sealed
tight
9 In the event of leaks or spills immediately apply a suitable absorbent
material and dispose of this in a technically and environmentally com-
patible manner as special waste
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Operation Manual
Safety 2

protection
Handling insulating materials

January 2007
9 Ensure that the work area is well ventilated

9 Keep the work area clean
9 Avoid disturbing dust
9 Dust-suppressing tools and processing steps
9 Remove from packaging only in the work area
9 Exercise particular care when removing old insulating materials
9 Dispose of insulating materials in a technically and environmentally
compatible manner
9 If large quantities of dust are created, wear protective glasses
9 Use half or quarter masks
9 Wear suitable work clothing and gloves
9 For sensitive skin, apply moisturising, protective barrier cream
Noise
HZTL2491_EN (TPL85-B14/-B15/-B16)
The effects of noise above a legally permitted level can cause personal in-
jury.
Personal injury Loss of hearing

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

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Causes Missing or incorrectly fitted insulation.
Protective measures 9 Wear leather protective gloves.

Operation Manual
Safety 2
Warnings on the turbocharger 2.5 Page 10
2.5 Warnings on the turbocharger
January 2007
Warnings that have been applied to turbochargers by ABB Turbo Systems
must not be removed, painted over or obscured with other stickers. Miss-
ing or illegible warnings must be replaced by new warnings.
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00227
Apply warnings so that they are clearly visible in the positions intended
for that purpose. Please contact an official ABB Turbo Systems service
station for further information.
NOTE
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Operation Manual
Commissioning 3
Oil supply 3.1 Page 1
3 Commissioning
3.1 Oil supply
January 2007
A carefully designed oil supply, which functions under all operating condi-
tions, is an important precondition for trouble-free operation of the turbo-
charger.
Lubrication of the turbocharger is normally carried out with oil from the
engine oil circuit.
Regarding the oil supply, follow the engine manufacturer's instructions

concerning selection of lubricating oil, oil change intervals, oil filtration,
and oil pressure and temperature.
NOTE
HZTL2491_EN (TPL85-B14/-B15/-B16)
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 before the bearings must be maintained precisely to en-
sure fault-free operation.
The permissible oil pressures are specified in the following tables de-
pendent on the lubrication (engine lubrication or separate lubricating sys-
tem).
Engine lubrication Kinetic viscosity 45 - 170 cST Oil pressure [bar]

Impermissible oil-pressure range -> 0.0 - 0.6
Engine Shut Down (without delay)
Short-term (<1h) permissible oil-pressure range -> 0.6 - 0.8
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Alarm
Permissible oil-pressure range for normal operation 0.8 - 2.5
Permissible oil-pressure range during engine warm- 0.8 - 4.0
up phase

Operation Manual
Commissioning 3
Oil supply 3.1 Page 2
Separate lubrication sys- Kinetic viscosity 12 - 170 cST Oil pressure [bar]
tem
Impermissible oil-pressure range -> 0.0 - 0.9
Engine Shut Down (without delay)
January 2007
Short-term (<1h) permissible oil-pressure range -> 0.9 - 1.1
Alarm
Permissible oil-pressure range for normal operation 1.1 - 2.5
Permissible oil-pressure range during engine warm- 1.1 - 4.0
up phase
Oil temperature during normal operation
Engine lubrication Oil inlet Engine load Oil inlet pressure Oil outlet
HZTL2491_EN (TPL85-B14/-B15/-B16)
temperature [%] [ bar ] temperature
[ °C ] [ °C ]
45 100 1.5 - 2 70 - 90
70 100 1.5 - 2 90 - 110
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Operation Manual
Commissioning 3
Inspection work 3.2 Page 3
3.2 Inspection work

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

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

HZTL2491_EN (TPL85-B14/-B15/-B16)
Air filter mat X Inspect for damage.
Lubricating system X Check oil filter for cleanliness before commissioning.
It is urgently recommended that the entire lubrication system be flushed

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

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Operation Manual
Commissioning 3
Inspection work 3.2 Page 4
3.2.2 Inspection after commissioning
January 2007
Lubricating system X Check oil pressure in oil supply lines.
Charger speed X Measuring
Charger pressure X Measuring
Temperatures X Measure upstream/downstream from turbine, compressor and oil feed

for various engine speeds
HZTL2491_EN (TPL85-B14/-B15/-B16)
Gas, air, and oil lines X After the engine has been started up, check all gas, air and oil lines for
leaks.
Further must be observed:
Lubricants and pastes are liquefied or vaporised during assembly of the

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

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

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

If provided X Remove the cover plates (blind flanges) between the compressor cas-
January 2007
ing outlet and charge-air receiver, upstream of the gas inlet, down-
stream of the gas outlet.
X Inspect the exhaust pipe before and after the turbine for any combus-
tion residue, clean / remove foreign bodies or residual water.
X Inspect air supply line or filter silencer for any foreign bodies, clean /
remove.
X Start up the turbocharger's engine end oil circulation system.
X Prepare the turbocharger for operation as instructed in the section In-
spection work before commissioning in the chapter entitled Commis-
sioning.
X Start up the turbocharger.
HZTL2491_EN (TPL85-B14/-B15/-B16)
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Operation Manual
Operation 4
Servicing work 4.1 Page 1
4 Operation
4.1 Servicing work
January 2007
Servicing work during operation includes visual checks, monitoring and

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

work.
WARNING
HZTL2491_EN (TPL85-B14/-B15/-B16)
Servicing work must be carried out at the prescribed intervals in order

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

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

official ABB Turbo Systems service station.
CAUTION
Version 4

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

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

Air intake temperature
Exhaust temperature before and after the turbine
Pressure of the charge-air
Pressure drop in the charge-air cooler
Lubricating oil pressure, lubricating oil temperature
HZTL2491_EN (TPL85-B14/-B15/-B16)
If provided Air temperature after compressor and after the charge-air cooler
Speed of the turbocharger
Pressure loss in the air filter
4.1.3 Servicing work according to the engine manufacturer's instructions
Oil filters X With the engine at standstill clean or replace oil filters
Version 4

Operation Manual
Operation 4
4.1.4 Inspection work every 18,000 hours

January 2007
X Remove filter silencer or air suction branch

X Clean filter silencer as far as accessible, and inspect for damage
X Remove the internal part of the compressor casing
X Check clearance A (axial bearing clearance)
X Clean accessible parts (compressor wheel, diffuser, wall insert), and
inspect for damage
X Visual inspection of the turbine parts (nozzle ring, turbine diffuser/cover
ring, turbine blades) without dismantling, using the endoscope, for pos-
sible soiling and damage. As an option, this inspection can also be per-
formed after the disassembly of the gas inlet casing.
X Refit the internal part of the compressor casing
X Re-install the filter silencer or air suction branch.
HZTL2491_EN (TPL85-B14/-B15/-B16)
This inspection work and the checks are to be carried out by an official
service station of ABB Turbo Systems Ltd.
NOTE
Version 4

Operation Manual
Operation 4
4.1.5 Servicing work every 36,000 hours
January 2007
X Remove filter silencer or air suction branch
X Clean filter silencer as far as accessible, and inspect for damage
X Remove the internal part of the compressor casing
X Check clearance A (axial bearing clearance)
X Clean accessible parts (diffuser, wall insert), and inspect for damage
X Remove gas inlet casing, and dismantle nozzle ring
X Clean nozzle ring, and check for damage/wear
X Clean turbine diffuser/cover ring, and check for damage/wear
X Replacement of the radial bearing and axial bearing with original parts
from ABB Turbo Systems Ltd.
X Inspection and assessment of the rotor
HZTL2491_EN (TPL85-B14/-B15/-B16)
The replacement of the bearing parts as well as the inspection and as-
sessment of the rotor must be carried out by an official ABB Turbo Sys-
tems service station.
NOTE
Version 4

Operation Manual
Operation 4
Monitoring 4.2 Page 5
4.2 Monitoring
January 2007
4.2.1 Speed measurement

HZTL2491_EN (TPL85-B14/-B15/-B16)
86505_001
1 Bearing casing 6 Connecting cable

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

speed also permits, in conjunction with the corresponding measuring in-
struments and/or monitoring systems (not included in the scope of deliv-
ery), a constant remote monitoring of the turbocharger speed. With con-
tinuous monitoring of the machine installation, the turbocharger speed can
be used as a suitable control parameter. The line amplifier can be pur-
chased as an optional addition to the described speed measuring system.

Operation Manual
Operation 4
Possible reasons for failure of the speed indicator:
Defects in the speed transmitter, the connecting cable and plug to the
measuring unit, in the measuring unit itself or the power supply.
January 2007
Turbocharger damage.
Failure of the speed indicator

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

transmitter system should be carried out only by an official ABB Turbo
Systems service station.
HZTL2491_EN (TPL85-B14/-B15/-B16)
NOTE
A reduction in speed of a charger can signify:
Damaged turbine or bearing

Severe soiling of the turbine
Version 4

Operation Manual
Operation 4
4.2.2 Underpressure measurement on filter silencer

January 2007
A U-tube manometer can be ordered from ABB Turbo Systems Ltd. for
measuring the underpressure at the filter silencer.
The measurement can be used for the following purposes:
To measure the correction factor for calculating the efficiency of the

turbocharger when accepting the engine
The use of a filter mat on the filter silencer can cause a loss of pres-
sure. More significant pressure loss is an indication of increased soiling
of the filter material.
U-tube manometer
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
L_00003
L_00004
1 Felt discs
A [mm H2O] Pressure differential / pressure loss

Operation Manual
Operation 4
All parts required for assembly are supplied in a separate package.
Mechanical vibration of the U-tube manometer is reduced by the installa-

tion of additional felt discs (1).
January 2007
The U-tube manometer must be exposed to minimum possible me-
chanical shock or vibration.
NOTE
X Fit the U-tube manometer to the filter silencer as shown in the preced-
ing description.
X For best readability, the U-tube manometer can be filled with slightly
coloured water.
Under as-new conditions (new or clean filter silencer and filter mat), the
maximum pressure loss (A) is 120 mm H2O under full loading.
HZTL2491_EN (TPL85-B14/-B15/-B16)
X Clean the filter as soon as the loss of pressure (A) reaches a value of
200 mm H2O if not before.
For better readability of the pressure differential (A) on the U-tube ma-
nometer, the measuring rod can be withdrawn to the level of the lower
water level indicators.
NOTE
Version 4

Operation Manual
Operation 4
Surging of turbocharger 4.3 Page 9
4.3 Surging of turbocharger

Surging of the turbocharger can occur with certain engine operating sta-
January 2007
tes, such as rapid load removal or while manoeuvring. The direction of

flow in the compressor is then briefly reversed. However, sporadic surging
of this kind does not generally affect the safe operation of the turbo-
charger.
Prolonged or periodic surging

If surging is prolonged or occurs periodically, the following components
may be damaged:
CAUTION - Compressor wheel (vibration fractures, ...)
- Turbine blades (cracks)
- Bearing (overheating)
- Filter silencer
HZTL2491_EN (TPL85-B14/-B15/-B16)
Action to be taken:
The operating safety of the turbocharger is no longer ensured with con-

tinuous or periodically recurring surging. The operator must take immedi-
ate 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.
Version 4

Operation Manual
Operation 4
Contact with rotating parts 4.4 Page 10
4.4 Contact with rotating parts

Mild, uniform wear around the circumference of rotor components, caused
January 2007
by slight local grazing against adjacent components, is non-hazardous
and permissible. This slightly reduces the length of the blades in the com-
pressor and/or the turbine. Certain tolerances must be observed to avoid
significant loss of efficiency.
X A check on dimensions must be carried out by an official ABB Turbo

Systems service station.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4

Operation Manual
Operation 4
Shutting the engine down 4.5 Page 11
4.5 Shutting the engine down

January 2007
Before shutting the engine down, it must be allowed to idle for about 3
minutes longer so that the circulating lubricating oil can dissipate the
heat in the turbocharger bearings.
CAUTION
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4

Operation Manual
Maintenance 5
Foreword to Maintenance 5.1 Page 1
5 Maintenance
5.1 Foreword to Maintenance
January 2007
Cleaning work includes regular visual checks and washing to ensure the
correct functioning of the turbocharger and its auxiliary appliances.
The external condition and the degree of contamination of the cleaning

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

HZTL2491_EN (TPL85-B14/-B15/-B16)
Filter silencer
Compressor
Turbine and nozzle ring
Version 4

Operation Manual
Maintenance 5
Cleaning the filter silencer 5.2 Page 2
5.2 Cleaning the filter silencer
January 2007
5.2.1 Filter silencer with tension band
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00210
Version 4
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
E Slide-in module = fleece segment + cover panel installed

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

January 2007
X Rinse filter ring (81265) with water using detergent or, if very dirty, so-
ak it. Squeeze out carefully. Rinse in cold water. Avoid high mechani-
cal stress (water jet).
The dirt in the filter ring (81265) depends on the cleanness of the air
drawn in. Wash or replace the filter ring as necessary or every 500 ser-
vice hours.
NOTE
X Loosen tension bands (81270) on trap covers (81271) and carefully

remove cover grid (81266) from connecting strips (81268).
HZTL2491_EN (TPL85-B14/-B15/-B16)
In the case of a slide-in module (E), with a cleaning container attached

to the filter silencer (available as option depending on turbocharger ty-
pe) the water injection line must first be removed (see also following
NOTE section Disassembling the cleaning line).
X Pull the slide-in modules (E) out, bend the cover panels (81137) open,
and then take out the fleece segments (81136).
X Clean fleece segments (81136).
When cleaning, ensure that the fleece segments (81136) are cleaned
only with a mild jet of compressed air, a soft brush or damp cloth. Oth-
erwise the segments may be damaged or lose their shape.
Heavily soiled fleece segments and filter ring as well as damaged con-
necting strips should be replaced with original parts from ABB Turbo
Systems.
Version 4
NOTE

Operation Manual
Maintenance 5
Assembling the filter silencer
January 2007
X Assemble the slide-in modules (E) by inserting fleece segments
(81136) in the cover panels (81137).
X Bend the cover panels back to their original shape.
X Insert slide-in modules (E) in the grooves in the filter silencer body
(81135).
With a cleaning container fitted to the filter silencer (available as option

depending on turbocharger type) the water injection line must now be
re-installed (see also following section Assembling the cleaning line).
NOTE
HZTL2491_EN (TPL85-B14/-B15/-B16)
X When fitting, insert the cover grid (81266) into the connecting strips
(81268).
X Fit the tension bands (81270) and tighten on the trap covers (81271).
If provided X Fit filter ring (81265).
Version 4

Operation Manual
Maintenance 5
5.2.2 Removing / installing the cleaning line

January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00192
1 Injection pipe 2 Pipe

3 Guide tube
Version 4

Operation Manual
Maintenance 5
Removing the cleaning line
January 2007
X Disconnect the line (2) at the injection pipe (1) and remove the screw
coupling from the pipe.
X Withdraw the pipe (2) from the guide tube (3).
Punch out the guide tube
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00193
X Punch the guide tube (3) out of the caulking with a bolt (diameter = 16
mm) and withdraw it.
Heavily soiled components of the cleaning line must be replaced with

original parts from ABB Turbo Systems.
Version 4
NOTE

Operation Manual
Maintenance 5
Installing the cleaning line

January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00194
X After fitting the slide-in modules (E), re-fit the guide tube (3) and re-
caulk it.
X Fit the pipe (2) and screw to the injection pipe (1).
Version 4

Operation Manual
Maintenance 5
Cleaning the compressor during 5.3 Page 8

operation
5.3 Cleaning the compressor during operation
January 2007
These guidelines for wet cleaning apply exclusively for cleaning with
clean water and are subject to permission for the procedure being ob-
tained from the engine manufacturer.
NOTE
The dirt in the compressor stage (compressor wheel and diffuser) de-
pends on the cleanness of the air drawn in and the operating point.
A deposit of dirt in the flow ducts will be formed if the following substances
are present in the intake air:
Oil or saline mist
HZTL2491_EN (TPL85-B14/-B15/-B16)
Solid combustion residues
Dust of various kinds
Soiling of the compressor stage has a negative effect on compressor effi-

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

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

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

Version 4
operation of the ship, please contact ABB Turbo Systems.
NOTE

Operation Manual
Maintenance 5

operation
Cleaning method
The compressor is cleaned while operating using the cleaning method de-
January 2007
scribed in the following. This method has been tested and is approved by
ABB Turbo Systems:
Wet cleaning
Principle of wet cleaning Water is injected before the compressor wheel via an injection pipe fitted
in the filter silencer or the suction branch in order to clean the compressor
stage in operation.
The water does not act as a solvent in the process, but the deposit is re-
moved by the mechanical impact of the drops. The process is ideal, pro-
vided the soiling is not too advanced.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Due to the danger of corrosion, only clean water may be used, and on
no account salt water. The water should also contain no cooling addi-
tives, which could form deposits in the flow ducts.
CAUTION
Cleaning more than one If several turbochargers are installed on one engine, we recommend clea-
turbocharger compressor ning the turbocharger compressors one after the other.
Version 4

Operation Manual
Maintenance 5

operation
5.3.1 Wet cleaning the compressor with external pressurised water con-
January 2007
tainer (XC3)
The water feed with the externally mounted dosing vessel is only suit-
able for applications with underpressure upstream of the compressor
wheel (cannot be used for: Blower connected upstream of the com-
NOTE pressor or high-pressure compressor stage in the case of two-stage
charging).
Operating state preconditions for cleaning compressors with XC3
HZTL2491_EN (TPL85-B14/-B15/-B16)
In order to carry out a successful cleaning procedure that has been
tested and is recommended by ABB Turbo Systems, the following pre-
conditions must be met:
NOTE
Z Engine warm from running (engine under full loading as far as possi-
ble)
Z High turbocharger speed
X Cleaning cycle started according to the following description in Pro-
cedure for wet cleaning with XC3.
Version 4

Operation Manual
Maintenance 5

operation
Procedure for compressor wet cleaning with XC3

January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00198
X Screw plug
Y Valve lever
Operating the pressure X The Operating state preconditions for cleaning compressors with XC3
water vessel must be met before cleaning can begin.
X Remove the screw plug (X).
X Fill the vessel with pure water.
Version 4
X Tighten screw plug (X).

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

Operation Manual
Maintenance 5

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

mes.
January 2007
If cleaning is still unsuccessful after three attempts and the engine op-
NOTE erating values are unsatisfactory, we recommend that the turbocharger
be checked and cleaned by an official ABB Turbo Systems service sta-
tion.
Cleaning parameters for each turbocharger compressor
Turbocharger type Turbocharger Contents of the Water injection

speed dosing vessel time
[dm3] t1 [s]
TPL 69BA Possible 0.4 4 ... 15
HZTL2491_EN (TPL85-B14/-B15/-B16)
TPL 73-B nBmax 1
TPL 77-B
TPL 80-B 2
TPL 85-B
TPL 91-B
Version 4

Operation Manual
Maintenance 5

operation
5.3.2 Wet cleaning compressors with water vessel (XC4)

January 2007
Operating state preconditions for cleaning compressors with XC4

NOTE
Z Engine warm from running (engine under full loading as far as possi-
ble)
Z High turbocharger speed
cedure for wet cleaning with XC4.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Procedure for compressor wet cleaning with XC4

Version 4
L_00197
1 Cleaning container 2 Pipe

3 Injection pipe 4 Cleaning instructions
5 Cover 6 Valve

Operation Manual
Maintenance 5

operation
If the cleaning container on the filter silencer is used, the detailed clean-
ing instructions provided on the plate (4) fitted to the filter silencer
January 2007
should be followed.
NOTE
Use of cleaning container X The Operating state preconditions for cleaning compressors with XC4
must be met before cleaning can begin.
X Open filling cap (5) on cleaning container (1).
X Fill with clean water.
X Screw filling cap (5) back into place.
X Open valve (6) for about 3 minutes.
X Close valve (6) and check that all the water has been sucked out.
X After cleaning, a waiting time of at least 5 minutes with the engine run-
HZTL2491_EN (TPL85-B14/-B15/-B16)
ning must be allowed so that the turbocharger can dry.

mes.
tion.
Cleaning parameters for each turbocharger compressor
Turbocharger type Turbocharger Contents of the Water injection

speed dosing vessel time
[dm3] t1 [s]
TPL 69BA Possible 2 4 ... 15
TPL 73-B nBmax
TPL 77-B
Version 4
TPL 80-B 3
TPL 85-B
TPL 91-B

Operation Manual
Maintenance 5
Cleaning turbine blades and nozzle ring 5.4 Page 15

in operation
5.4 Cleaning turbine blades and nozzle ring in

operation
January 2007
Combustion of heavy fuel oil in diesel engines causes soiling of the tur-
bine blades and nozzle rings of the turbochargers.
Soiling increases with time, so that regular and properly performed clean-
ing 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 be-
come soiled.
A soiled turbine also results in rotor unbalance. Severe soiling can lead to
impermissibly high rotor imbalance.
Experience in operation has shown that despite periodic cleaning during

HZTL2491_EN (TPL85-B14/-B15/-B16)
operation, it is impossible to dispense with overhauls during which the tur-

bine and nozzle ring are mechanically cleaned. However, if cleaning is
performed correctly and the cleaning system is properly dimensioned, the
intervals between overhauls can be extended.
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
Interval for dry cleaning The interval between periodic cleaning depends in large measure on the
operating conditions. In general, cleaning should be carried out every 20
Version 4

Operation Manual
Maintenance 5

in operation
Cleaning methods
January 2007
Several methods are possible for cleaning the turbine and nozzle ring dur-
ing operation. The cleaning methods described in the following have been
tested and are recommended by ABB Turbo Systems:
Wet cleaning
Dry cleaning
Principle of wet cleaning During wet cleaning using droplets of water, the water does not act as a
solvent. Instead, the deposit is removed by the mechanical impact of the
drops.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Due to the danger of corrosion, only clean water may be used, and on
no account salt water. The water should also contain no cooling addi-
tives, which could form deposits in the flow ducts.
CAUTION
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.
Wet and dry cleaning are equally effective. However, it may be useful to
apply both methods together.
NOTE
Version 4

Operation Manual
Maintenance 5

in operation
January 2007
Stabilising and drying time
Cleaning of the turbine-side components begins after engine start or

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

turbine, and to allow the minimum stabilising time before and between
cleaning procedures and the drying time after cleaning in accordance
HZTL2491_EN (TPL85-B14/-B15/-B16)
CAUTION with the pertinent cleaning instructions will shorten the expected service
life of the components significantly.
Cleaning more than one If several turbochargers are installed on one engine, we recommend clea-
turbocharger turbine ning the turbocharger turbines with nozzle rings one after the other.
Version 4

Operation Manual
Maintenance 5

in operation
5.4.1 Wet cleaning the turbine and nozzle ring during operation at partial
January 2007
power
The maximum exhaust gas temperature specified by the engine manufac-

turer and the TMmax temperature as shown on the turbocharger rating plate
must not be exceeded under any circumstances. During wet cleaning, the
turbine is braked and the turbocharger operates at reduced speed. As a
result, less air is supplied to the engine and the temperature after the en-
gine cylinder and exhaust valve rises.
Operating state precondition for wet cleaning
HZTL2491_EN (TPL85-B14/-B15/-B16)
NOTE
Z After the engine has been started or during operation, the engine
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 tempera-
ture at the turbine inlet is stable and below 430°C, the auxiliary
blower must also be operating.
cedure for wet cleaning.
Version 4

Operation Manual
Maintenance 5

in operation
Procedure for wet cleaning

January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00394
1 Water supply (fresh water 8 Drainage line

only) at least 6.0 bar
2 Regulating valve 9 Drain cock
3 Manometer 10 Outflow
4 Air supply with 3-way-valve 11 Orifice (integrated in turbo-
charger)
5 Stainless steel piping 21 Air duct from compressor cas-
ing
6 Other turbochargers A Position 1
7 Injection pipe B Position 2
Version 4
Operating the wet clea- Z The Operating state preconditions for wet cleaning must be satisfied
ning system 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.
X Firstly, slowly open the 3-way-valve (4) (if fitted), then the regulating
valve (2) until the manometer (3) shows a pressure of 1 ∓ 0.2 bar.

Operation Manual
Maintenance 5

in operation
X Inject water for 5 minutes at constant engine output.

X Check whether the exhaust-gas temperature after the turbine drops.
X Close the regulating valve (2) and the 3-way-valve (4).
January 2007
X Set drain cock (9) of the drain pipe (8) on the gas outlet casing to Posi-
tion 2, in order to keep the drain pipe clean with air from the compres-
sor casing (21).
X The water supply connection (1) to the regulating valve (2) must be
disconnected.
X After cleaning, a waiting time of at least 10 minutes with the engine
running must be allowed so that the turbocharger can dry.

mes.
HZTL2491_EN (TPL85-B14/-B15/-B16)
tion.
Points to remember when The gas outlet casing must be drained of water via the drain pipe (8)
cleaning when cleaning.
The exhaust-gas temperature after the turbocharger falls significantly
during cleaning (by 50 to 150°C).
Outflow can (but need not) take place through the drain-pipe, depend-
ing on the engine load. This outflow might not start for 2 - 3 minutes, or
it may not occur at all.
If draining is not carried out, the turbocharger speed and / or gas inlet
temperature must be monitored closely during the washing operation. If
the load is too low, water can collect in the gas outlet casing. Signs of
this are a sudden fall in the turbocharger speed or very rapid increase
in the gas inlet temperature. In either of these cases, the washing op-
eration must be terminated and the washing cycle begun again with a
lower water pressure or higher engine loading.
Version 4

Operation Manual
Maintenance 5

in operation
5.4.2 Integrated dry cleaning of the turbine and nozzle ring during opera-
January 2007
tion
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 state preconditions for integrated dry cleaning device

HZTL2491_EN (TPL85-B14/-B15/-B16)

NOTE
Z High engine output (50 to 100%) and high turbocharger speed.
Z Gas inlet temperature upstream of the turbine must be below 590°C.
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.
Version 4

Operation Manual
Maintenance 5

in operation
Operation of integrated dry cleaning device
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00094
1 Container for granulated mate- 5 ON/OFF valve

rial
Version 4
2 Trap-cover 6 Safety valve

3 Compressed air supply [4 to 10 7 Combined air valve/pressure
bar] relief valve
4 Pipe made from stainless steel 8 Cleaning instructions
The air system must be protected against overpressure (> 10 bar).
CAUTION

Operation Manual
Maintenance 5

in operation
Operation of the dry Z The Operating state preconditions for integrated dry cleaning must be
satisfied before cleaning is begun.
January 2007
cleaning device
X Ensure that the ON/OFF valve (5) is closed.
X Check that the combined air valve/pressure relief valve (7) is in the
pressure relief position.
X Open the trap-cover (2) carefully.
X Fill the container (1) with the prescribed amount of granulate.
X Close and seal the trap-cover (2).
X Open the air valve (7).
X Open the safety valve (6).
X Whilst cleaning the turbine, open the ON/OFF valve (5) and leave it
open for approx. 1 minute.
X Close the ON/OFF valve (5).
X Close the safety valve (6).
HZTL2491_EN (TPL85-B14/-B15/-B16)
X Set the combined air valve/pressure relief valve (7) to the pressure re-
lief position.
X Check whether the exhaust gas temperature has dropped downstream
of the turbine.
In order to obtain the best possible cleaning effect, it is essential that

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

mes.
Version 4

tion.

Operation Manual
Maintenance 5

in operation
Cleaning parameters for integrated dry cleaning device
January 2007
Selection of materials The following materials are suitable for use in dry cleaning:
Hard, granulated materials (such as natural core granulates)

Softblast media
Activated carbon particles
The average grain size of the cleaning granulate must be between 1.2
and 2.0 mm.
HZTL2491_EN (TPL85-B14/-B15/-B16)
The specific weight of the cleaning granulate must not exceed 1.2 kg/dm3.
Granulate quantity per TPL 69BA TPL 73-B TPL 77-B TPL 80-B TPL 85-B TPL 91-B
turbocharger [litres]
1.0 1.0 1.5 2.0 3.0 3.5
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 sup-
NOTE pliers of dry cleaning agents.
Version 4

Operation Manual
Maintenance 5

in operation
5.4.3 Non-integrated dry cleaning device for the turbine and nozzle ring
January 2007
during opration
As an alternative to the built-in dry cleaning system, a non-integrated dry

cleaning device can be installed upstream of the gas inlet casing by the
engine manufacturer.
Operating state preconditions for non-integrated dry cleaning device

HZTL2491_EN (TPL85-B14/-B15/-B16)
NOTE
Z High engine output (50 to 100%) and high turbocharger speed.
Z Gas inlet temperature upstream of the turbine must be below 590°C.
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.
Version 4

Operation Manual
Maintenance 5

in operation
Operation of non-integrated dry cleaning device
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
L_00208

Operation Manual
Maintenance 5

in operation
1 Trap-cover G2“ 6 Strap for securing the container

2 Poss. copper gasket 7 Safety valve with ventilation
3 Double nipple G2“ 8 Compressed air shut-off valve
January 2007
4 Copper gasket 9 Compressed air pipe

(internal diameter 8mm)
5 Friction cock or slide controller 10 Compressed air max. 6 bar
G1''
The air system must be protected against overpressure (> 6 bar).
CAUTION
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation of the dry Z The Operating state preconditions for non-integrated dry cleaning de-
cleaning device vice must be satisfied before cleaning is begun.
Z Friction cock or slide controller (5) closed and safety valve with ventila-
tion (7) open.
X Close the safety valve with ventilation (7).
X Tighten the trap-cover (1).
X Open the compressed air shut-off valve (8) so that deposits and any
condensation are blown off.
X Close the compressed air shut-off valve (8) again after about 3 min-
utes.
X Close the friction cock / slide controller (5).
X Open the safety valve with ventilation (7) to blow out the exhaust ga-
ses.
X Open the trap-cover (1) on the granulate container carefully.
X Fill the granulate container with the prescribed quantity of granulate.
X Close and seal the trap-cover (1).
X Close the safety valve with ventilation (7).
X Open the compressed air shut-off valve (8).
X Open the friction cock or slide controller (5) for approx. 1 minute.
X Close the friction cock or slide controller (5).
Version 4
X Close the compressed air shut-off valve (8).

X Open the safety valve with ventilation (7).
X Check whether the exhaust gas temperature has dropped downstream
of the turbine.

Operation Manual
Maintenance 5

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

the prescribed quantity of granulate is blown in.
January 2007
The drain openings in the gas outlet casing must remain closed while
NOTE the turbine is being cleaned. Careless handling can cause incompletely
combusted soot particles to escape.

mes.
tion.
HZTL2491_EN (TPL85-B14/-B15/-B16)
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.
NOTE
Granulate quantity per Turbocharger type Amount of granulate Container size

turbocharger [dm3]
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
Version 4
TPL 91-B 3.5 III

Operation Manual
Maintenance 5
Suppliers of materials for dry cleaning 5.5 Page 29
5.5 Suppliers of materials for dry cleaning

Manufacturer Country Address Number for contact
January 2007
ABB Service Australia 20 Queen Street Tel. +61 2 9795310

Revesby Sydney Fax. +61 2 9773 8855
NSW 2212
Paul Auer GmbH Germany Bad Kreuznacher Str. 81 Tel. +49,621,727 69 -0
68309 Mannheim-Käfertal Fax. +49 621 717 6988
Email: vertrieb@auer-strahltechnik.de
BRIGANTINE Hong Kong 48 Wang Lok Street Tel. +852 24737900
Service Ltd. Yuen Long Industrial Estate Fax. +852 24786657
N.T. Hong Kong Email: a-
sibrgcorp@brigantinegroup.com
LEERING HENGE- Netherlands Barnsteenstraat 1 Tel. +31 74 255 8282
LO B.V. NL-7554 TC Hengelo Fax. +31 74 242 2373
HZTL2491_EN (TPL85-B14/-B15/-B16)
The Netherlands Email: info@leering.nl

GUYSON UK Snaygill Industrial Estate Tel. +44 1756 799911
International Ltd. Keighley Rd. Fax. +44 1756 790213
Skipton, N Yorks BD 23 Email: info@guyson.co.uk
2QR
United Kingdom
DASIC UK Winchester Hill Tel. +44 1794 5124198
International Ltd. Romsey SO51 7YD Fax. +44 1794 522346
United Kingdom Email: info@dasicinter.co.uk
PAN Singapore Pioneer Sector 2 Tel. +65 6861 6988
Abrasives (Pte) Ltd. Jurong Fax. +65 6861 0919
628382 Singapore Email: pagroup@pan-abrasives.com
CARLANDER & Co. Sweden Valtersang 9 Tel. +46 30 363075
S-442 49 Kungalv Fax. +46 30 363077
Sweden Email: lars@carlander.com
BOSUNG Enginee- Korea 1189-1, Choryang-3 Dong, Tel. +82 51 466 0881-5
ring Co., Ltd. Dong-Ku, Busan, 601-013 Fax. +82 51 466 0886-9
Email: master@bosung.com
Version 4

Operation Manual
Troubleshooting 6
Possible remedies for failures 6.1 Page 1
6 Troubleshooting
6.1 Possible remedies for failures
January 2007
Exhaust temperature too high
Engine output and speed unchanged
Engine Z Malfunction in the injection system

X Repair, or contact the manufacturer.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Turbocharger Z Air starvation, e.g. air filter clogged with dirt

X Clean
Z Compressor / turbine soiled

X Clean
Z Exhaust counterpressure too high

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

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

X Clean
Z Insufficient coolant water quantity

X Replenish
Z Coolant water inlet temperature too hot

Version 4
X Clean/inspect cooling system
Z Ventilation inadequate
X Improve ventilation

Operation Manual
Troubleshooting 6
Charge-air pressure too low
January 2007
Intake condition normal
Engine Z Air receiver leaking

X Repair
Z Gas line between engine and turbine leaking

X Repair
Z Injection misadjusted
X Correct adjustment
HZTL2491_EN (TPL85-B14/-B15/-B16)
Z Valve control misadjusted
Turbocharger Z Manometer display faulty

X Replace manometer
Z Leak in line to the manometer

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

X Clean
Z Compressor / turbine soiled

X Clean
Z Compressor / turbine damaged

Z Excessive exhaust counterpressure

Version 4
X Clean boiler or exhaust silencer

Operation Manual
Troubleshooting 6
Charge-air pressure too high

January 2007
Intake condition normal
Engine Z Malfunction in the injection system

Z Engine output higher than expected

X Check engine output
Z Injection misadjusted
HZTL2491_EN (TPL85-B14/-B15/-B16)
Turbocharger Z Manometer display faulty

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

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

X Clean
Z Bearing damaged
Version 4
Z Rotor grazing
Z Foreign bodies in the turbocharger

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

X Clean
HZTL2491_EN (TPL85-B14/-B15/-B16)
Z Bearing damaged
Z Rotor grazing
Lubricating oil pressure too low
Engine Z Oil filter heavily soiled

X Clean
Z Oil pump in the lubricating system defective

X Inspect
Z Manometer provides false reading

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

Version 4

Operation Manual
Troubleshooting 6
Constant surging of the turbocharger

January 2007
Engine Z Exhaust pressure after the turbine elevated because boiler or exhaust
silencer is dirty
Z Trap dirty
X Clean
Turbocharger Z Charge-air cooler or silencer dirty

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

official ABB Turbo Systems service station.
HZTL2491_EN (TPL85-B14/-B15/-B16)
NOTE
Version 4

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

7.1 Turbocharger weights
January 2007

WARNING
Loads that are not suspended in accordance with the regulations during
disassembly and assembly may fall and can cause serious or even fatal
injury.
X Select a suitable rope taking into account the weight of the load.
X Hang rope crossed over on the crane hook
X Do not stand under suspended loads.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
L_00082

Operation Manual
Turbocharger weights 7.1 Page 2
Turbocharger complete unit without filter silencer/air suction branch
Weight [kg] TPL 85-B
January 2007
9745
Turbocharger complete unit with filter silencer

10700
Turbocharger complete unit with air suction branch
HZTL2491_EN (TPL85-B14/-B15/-B16)
10035
Version 4

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

X Disconnect all gas, air, and oil lines in accordance with the engine ma-
January 2007
nufacturer’s instructions.
The two oil supply channels in the bearing casing are fitted with one ori-
fice each. In order to obtain the required oil pressure, the ∅ of this ori-
fice has been individually adjusted by the engine builder. Whenever
NOTE these orifices are removed, or if the bearing casing or the complete tur-
bocharger is replaced, it is essential to ensure that the orifice with the
correct ∅ is fitted into the oil supplying oil-inlet channel.
X Check the lifting equipment.

X Secure lifting equipment to the suspension lugs on the bearing casing.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
7.2

Operation Manual
Remove the turbocharger 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.
January 2007
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 bear-
ing casing provided for this purpose.
X The turbocharger must be transported as horizontally as possible.
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
HZTL2491_EN (TPL85-B14/-B15/-B16)
aside, the turbocharger may tip over and can cause serious or even fa-
tal injury.
WARNING
X Support turbocharger in a suitable location.

X Cover oil connector.
Version 4

Operation Manual
Installing the turbocharger 7.3 Page 5
7.3 Installing the turbocharger

January 2007
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 bear-
ing casing provided for this purpose.
X The turbocharger must be transported as horizontally as possible.
X Remove cover from the oil connector.

X Check the lifting equipment.
Secure lifting equipment to the suspension lugs on the bearing casing.
HZTL2491_EN (TPL85-B14/-B15/-B16)
X
X Mate turbocharger with the engine.
X 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 manu-
facturer’s instructions.
Version 4

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

8.1 Module weights
January 2007

WARNING
Loads that are not suspended in accordance with the regulations during
disassembly and assembly may fall and can cause serious or even fatal
injury.
X Select a suitable rope taking into account the weight of the load.
X Hang rope crossed over on the crane hook
X Do not stand under suspended loads.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
L_00082

Operation Manual
Modules
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
8.1
Version 4

Operation Manual
Weights [kg] Description TPL 85-B

1 Air suction branch, radial 290
2 Filter silencer 955
January 2007
3 Compressor casing, internal 550

part
4 Wall insert 850
5 Diffuser 225
6 Compressor casing external 1200
part
7 Cartridge group 3000
8 Cover ring 145
9 Nozzle ring 95
10 Gas inlet casing radial 495
HZTL2491_EN (TPL85-B14/-B15/-B16)
Compressor casing, internal part, complete

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.
NOTE
Version 4

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

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

suction branch
January 2007
Not all tools are identified with a part number. The identification of the
tools is ensured with the tools list (included in the toolbox).
NOTE
X Remove insulation where necessary.

X Disconnect all air ducts in accordance with the engine manufacturer’s
instructions.
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00011
Version 4
X Fit safety ring bolt (90231) in the bearing plate (P) on the filter silencer.

Operation Manual
Removing and fitting the filter silencer or 8.2 Page 5

air suction branch
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00226
X Mount shackle (90195) on the fin on the filter silencer.
Remove filter silencer X Sling lifting gear through the loops at the rear and secure to the
shackle (90195) or to the safety ring bolt (90231) with a shackle.
X Release nuts (74027) with Verbus washers (74028) and remove the fil-
ter silencer or air suction branch.
Install the filter silencer X The filter silencer or air suction branch is installed in the reverse se-
quence.
During removal and assembly, turbocharger components that have not

been suspended in compliance with regulations may fall, and can cause
Version 4
serious or even fatal injury.

WARNING X Do not stand under suspended loads.

Operation Manual
Axial clearance 8.3 Page 6
8.3 Axial clearance
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
8.3
X Before disassembly and after assembly of the internal part of the com-
pressor casing, as well as of the gas inlet casing (if dismantled), the
axial clearance (A) must be measured.
X Measure and note the axial clearance A.
If the axial clearance A is out of tolerance, an official ABB Turbo Sys-

tems service station must be contacted.
CAUTION
Version 4
Clearance A [mm] TPL 85-B

0.54 – 0.79

Operation Manual
Dismantling the internal part of the 8.4 Page 7

compressor casing
8.4 Dismantling the internal part of the compres-

sor casing
January 2007
Not all tools are identified with a part number. The identification of the
tools is ensured with the tools list (included in the toolbox).
NOTE
Position of the safety X Take nuts (90458) from the toolbox and fit them on the threaded pins
segments before disas- of the three safety segments (Y) in the internal part of the compressor
sembly casing (76000).
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00269
X Tighten nuts (90458) with a maximum torque of 30 Nm.
D The internal part of the compressor casing (76000) is now detached

from the external part of the compressor casing (74000) and can be
removed.
Note control dimension (u).

Version 4
NOTE
Control dimension (u) Dimension TPL 85-B

[mm]
u 27.6

Operation Manual

compressor casing
X Remove 4 studs (74026) in the upper area.

X Hoist the lifting device (90190) using the shackle (90195) and lifting
gear.
January 2007
Dismantling the internal
part of the compressor
casing
HZTL2491_EN (TPL85-B14/-B15/-B16)
8.4.2
X Press off the internal part of the compressor casing (76000) with press-
off screws (90900) so far, until the lifting device (90190/90195) can be
fitted.
Version 4
X Fit the lifting device to the internal part of the compressor casing
(76000).
X Remove internal part of the compressor casing (76000) with wall insert
and diffuser.
X Fit support angle (90025).
X Set down internal part of compressor casing (76000) in a horizontal
position.

Operation Manual

compressor casing
If necessary X Attach two shackles (90195) to the support angle (90025) and fasten a
second lifting gear to the two shackles (90195).
X With lifting device (90190) slightly raise internal part of compressor
January 2007
casing (76000) with wall insert and diffuser.

X By actuating the second lifting gear bring the internal part of the com-
pressor casing (76000) carefully to the vertical position.
X Rest the casing on shim with flange (F).
Ensure that the shim does not slip.
X Rest the internal part of the compressor casing only on flange (F).
WARNING X Check shim and adjust as necessary.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4

Operation Manual

compressor casing
Remove diffuser
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
8.4
X Remove screws (76002).

Version 4
X Remove diffuser (79000).

X Press off wall insert (77000) with press-off screws (90900) and remove
using ring bolts (90235).
X Remove O-ring gaskets (77005, 77006).
Work that exceeds the scope of the description in this chapter must on-
ly be performed by a trained fitter from an official ABB Turbo Systems
service station.
CAUTION

Operation Manual
Dismantling gas inlet casing 8.5 Page 11
8.5 Dismantling gas inlet casing

X Remove the insulation on the gas inlet casing (51001).
January 2007
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.
WARNING
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00022
X Loosen the screws (61044) and remove gas inlet casing (51001) with
nozzle ring (56001).
X Remove screws (56014), bushings (56013) and nozzle ring (56001).
X Loosen and remove screws (57005).
Version 4
X Fit two guide studs (90320).

X Press off the cover ring (51085) with press-off screws (90320) and re-
move over the guide bolts (90907).
Work that exceeds the scope of the description in this chapter must on-
ly be performed by a trained fitter from an official ABB Turbo Systems
service station.
CAUTION

Operation Manual
Fitting gas inlet casing 8.6 Page 12
8.6 Fitting gas inlet casing

If removed: X Fit cover ring (51085) with the help of the two guide bolts (90320) and
January 2007
fasten tight with screws (57005).
X Remove guide bolts (90320).
X Mount nozzle ring (56001) on the gas inlet casing (51001) with screws
(56014) and bushings (56013).
Smear all screws in and on the gas casings with Anti Scuff Paste 868
from SPANJAARD.
NOTE
HZTL2491_EN (TPL85-B14/-B15/-B16)
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).
X Fit the insulation on the gas inlet casing (51001).
Version 4

Operation Manual
Fitting the internal part of the 8.7 Page 13

compressor casing
8.7 Fitting the internal part of the compressor

casing
January 2007
Fitting the diffuser

HZTL2491_EN (TPL85-B14/-B15/-B16)
8.4
Version 4
X Seat O-ring gaskets (77005, 77006) on the wall insert (77000).

X Mount wall insert (77000) and diffuser (79000) in the internal part of the
compressor casing (76000).
X Tighten the screws (76002), then loosen again by ¼-turn.
X Secure the lifting gear to the lifting device (90190) and to the shackles
(90195) of the support bracket (90025).
X Lift internal part of compressor casing (76000) with wall insert and dif-
fuser using two hoists.

Operation Manual

compressor casing
X Carefully slacken the lifting gear on the support bracket (90025) and
through this bring the internal part of the compressor casing (76000) to
a horizontal position.
January 2007
X Remove support bracket (90025) with shackle (90195).
Fitting the internal part of

the compressor casing
HZTL2491_EN (TPL85-B14/-B15/-B16)
8.4.2
X Seat O-ring gasket (76040) to the internal part of the compressor cas-
ing (76000).
X Fit guide bolts (90320).
X Carefully insert internal part of the compressor casing (76000) with wall
Version 4
insert and diffuser over the guide bolts (90320) into the external part of
the compressor casing (74000).
X Remove the lifting device (90190/90195).
X Insert the internal part of the compressor casing as far as it will go.
X Remove guide bolts (90320) and fit studs (74026).

Operation Manual

compressor casing
X Release the nuts (90458) on the threaded pins of the three safety
segments (Y) on the internal part of the compressor casing (76000).
D The internal part of the compressor casing (76000) is now secured a-

January 2007
gainst the external part of the compressor casing (74000).
Position of the safety

segments after assembly
L_00276
HZTL2491_EN (TPL85-B14/-B15/-B16)
Note control dimension (s). Safety segments (Y) are in an operating

state again.
NOTE
Control dimension (s) Dimension TPL 85-B

[mm]
s 18.5
X Replace the nuts (90458) back in the toolbox.
X Measure and note the axial clearance A.
If the axial clearance A is out of tolerance, an official ABB Turbo Sys-

tems service station must be contacted.
Version 4
CAUTION
Clearance A [mm] TPL 85-B

0.54 – 0.79

Operation Manual

compressor casing
Install the filter silencer X Fit the filter silencer or air suction branch and secure with nuts (76027)
and Verbus washers (76028) (see section Removing and installing the
filter silencer or air suction branch).
January 2007
X Connect all air lines in accordance with the engine manufacturer’s in-
structions.
X Install all insulation that has been removed.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4

Operation Manual
Table of tightening torques 8.8 Page 17
8.8 Table of tightening torques

January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00059
The following tightening torques must be maintained for the specified

screwed connections:
Version 4

Operation Manual
Table of tightening torques 8.8 Page 18
Tightening torque [Nm] Part number TPL 85-B

42059, 42064 M12
110
January 2007
56014 M16
160
57005 M16
160
61044 M24
480
74026 M24
80
74027 M24
300
76002 M20
- 1)
HZTL2491_EN (TPL85-B14/-B15/-B16)
82005 M16 x 1.5
50
86505 M22 x 1.5
220
90458 M12
30
1) Tighten so that the diffuser can still be moved.
86505
Version 4
L_00228

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

9.1 Possibilities for emergency repair
January 2007
Lubricating oil leaks are a fire hazard.
WARNING
The instructions of the engine manufacturer for operation of the engine

with locked / isolated turbocharger must be followed precisely in all ca-
ses!
CAUTION
HZTL2491_EN (TPL85-B14/-B15/-B16)
If the diesel engine must be capable of operation again as soon as possi-

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

Blocking the inlets and outlets
Bypass the turbocharger
Those emergency repairs that can be performed fastest are to be per-

formed first.
NOTE
Version 4

Operation Manual
Locking the rotor 9.2 Page 2
9.2 Locking the rotor
January 2007
A locked rotor must be disassembled following turbocharger repair and
given an imbalance check.
CAUTION
The only exceptions are test rig runs up to a maximum of 25% engine
load on new engines with one or a number of turbochargers, which are
requested by some customers. Since in these cases operation with a
NOTE locked rotor is brief and the loads are small, subsequent disassembly of
the rotor is unnecessary.
U Once unscrewed, balancing screws must not be screwed in again.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Various intermediate rings are provided with the locking device for dif-
ferent compressor wheels. The compressor wheel type ”CV” (for the
balancing screw holes) must be noted. The space between the locking
NOTE flange (94003) and the assembly-disassembly device (90020) must be
compensated by the intermediate rings (94001 and/or 94002) depend-
ing on the version of compressor wheel.
During operation of the engine with a locked turbocharger, the lubrica-

tion oil system must also remain connected to this turbocharger and tur-
ned on if the gas inlet cannot be blocked (see section Further measures
CAUTION and information for operation with a locked rotor for 2-stroke engines).
Otherwise components that are still intact can be damaged by over-
heating.
The supply of lubricating oil to the turbocharger must be shut off in the
event of a lubricating oil leak on the turbocharger.
Version 4

Operation Manual
Locking rotor with polygon connection

January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
L_00261
Version 4

Operation Manual
These operations must be carried out as described in the chapter Dis-

assembly and assembly.
January 2007
NOTE
X Remove the filter silencer or air suction branch and the compressor
casing 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).
CAUTION
HZTL2491_EN (TPL85-B14/-B15/-B16)
Table of tightening tor- Part number TPL85-B
ques [Nm]
94006 M12
75
94007 / 94008 M12
60
X Fit the locking flange (94003) with screws (94007 or 94008, using the
longest possible screws) as well as the adjustment ring (94004) and in-
termediate ring (94031).
Version 4

Operation Manual
Compressor type CV11

January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
94000_15
It must be ensured that all components are clean and free from grease.
CAUTION
Version 4
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).

Operation Manual
Compressor type CV12, CV13
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
94000_012
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).
Version 4
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).

Operation Manual
Further measures and information for operation with a locked rotor for 2-
stroke engines
January 2007
2-stroke engine with one No further measures are necessary. The engine can be operated with the
turbocharger: auxiliary blower according to the instructions of the manufacturer.
9 The lubrication oil system must remain connected and turned on.
2-stroke engine with seve- X The compensator at the compressor outlet must be dismantled and the
ral turbochargers: air duct blocked at the engine end, as undamaged turbochargers de-
velop 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. The loading and temperature of the locked rotor are also
reduced.
HZTL2491_EN (TPL85-B14/-B15/-B16)
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 rotating speed limit nBmax according to the turbocharger
rating plate must not be exceeded.
CAUTION
Version 4

Operation Manual
Blocking the inlets and outlets 9.3 Page 8
9.3 Blocking the inlets and outlets
January 2007
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 instruc-

tions.
NOTE
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4

Operation Manual
Bypass the turbocharger 9.4 Page 9
9.4 Bypass the turbocharger

January 2007
Shut off the supply of lubricating oil to the turbocharger.
CAUTION
Z For engines with one turbocharger only:

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

tions.
HZTL2491_EN (TPL85-B14/-B15/-B16)
NOTE
Version 4

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

months
10 Mothballing the turbocharger

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

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

measures need to be taken. However, if the neutralisation factor is higher
the turbocharger must be dismantled after laying up, cleaned and protec-
tive oil must be applied to the naked parts.
If the turbocharger is left mounted on the engine, and the engine oil is re-
placed by a protective oil which is circulated with a pre-lubrication pump
prior to laying up, no measures need to be taken in respect of the turbo-
charger. The remains of the old engine oil will be washed away and the
HZTL2491_EN (TPL85-B14/-B15/-B16)
sensitive bearing parts will be largely protected against corrosion.
If the rotor turns due to a draught from the flue, fit a blind flange between
the compressor casing and the charge-air duct.
Version 4

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

months
10.2 Taking out of operation for more than 12

months
January 2007
If the turbocharger has to be removed from the engine and stored for a
prolonged period of time, disassembly and mothballing of the turbo-
charger must be done by an official ABB Turbo Systems service station.
Ensure that the storage area is dry with humidity of 40-70% and free of
condensation.
Check mothballed turbochargers yearly for corrosion.

In the event of rust, clean and renew the corrosion protection.
NOTE
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4

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

11.1 Ordering spare parts
January 2007
When making inquiries or ordering spare parts, the following data should
be specified:
Turbocharger type
HT number
Description and part number
Our service stations and agents accept orders for spare parts.
X If special variants/cases are not addressed in these general instruc-

tions, contact an official ABB Turbo Systems Ltd. service station or an
ABB agent.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4

Operation Manual
Ordering spare parts 11.1 Page 2
Spare-parts set
January 2007
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.
NOTE
Spare parts set (97070) Quantity Description Part number

2 O-ring gasket 42012, 76040
2 Gasket 42041, 42069
12 Hexagon head screw 42059, 42064
1 Gasket 42045
6 Hexagon head screw 56014, 57005
HZTL2491_EN (TPL85-B14/-B15/-B16)
4 Hexagon nut 61037
1 Gasket 61041
2 O-ring gasket 77005, 77006
1 O-ring gasket 86506
All spare parts that were ordered with the turbocharger should be kept
as a complete set and ready for use.
X Parts showing signs of rust should be carefully cleaned and greased.
CAUTION
X Dispose of parts, which have been replaced and are no longer usable,
in a proper and environmentally compatible manner. Version 4

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

The following part numbers and descriptions must be used in ALL corre-
January 2007
spondence 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
HZTL2491_EN (TPL85-B14/-B15/-B16)
74000 Compressor casing external part

76000 Compressor casing, internal part
76040 (in spare parts set) O-ring gasket
76080 Safety segment
77000 Wall insert
79000 Diffuser
81000 Filter silencer
82000 Air suction branch, radial
Version 4

Operation Manual
Directory of part numbers 11.2 Page 4
Cartridge group - polygon Part number Description

connection
21000 Shaft
25000 Compressor wheel
January 2007
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
HZTL2491_EN (TPL85-B14/-B15/-B16)
42015 Sealing cover
42041 (in spare parts set) Gasket
42045 (in spare parts set) Gasket
42059 (in spare parts set) Hexagon head screw
42064 (in spare parts set) Hexagon head screw
42295 Non-return valve
43001 Partition wall
43005 O-ring gasket
86505 Speed sensor
Version 4

Operation Manual
General view of turbocharger 11.3 Page 5
11.3 General view of turbocharger

January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
Version 4
11.3_page1

L_00906
42015
32102
42011

21000
42045 25008
32105
32001
32106
Reserve and spare parts
42002
32101
General view of cartridge group
42001
42295
32104
11
42064
11.4
42012
86506
42041
11.4 General view of cartridge group
43001
42059 86505
25009 25000 43005

Page 6
Operation Manual
Version 4 HZTL2491_EN (TPL85-B14/-B15/-B16) January 2007

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Operation Manual

List of contents Page 1

2.1 Basic safety instructions

ABB Turbo Systems Ltd

List of contents Page 2

7 Removal and installation

8 Disassembly and assembly

9 Taking out of operation temporarily

10 Mothballing the turbocharger

11 Reserve and spare parts

11.2 Directory of part numbers

ABB Turbo Systems Ltd

Purpose of the manual 1.1 Page 1

 Early awareness and avoidance of hazards.

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

The instructions included in this operation manual must be followed under

This applies especially to the general and special safety instructions

ABB Turbo Systems Ltd

Layout and function 1.2 Page 2

1.2 Layout and function

1 Filter silencer 7 Nozzle ring

ABB Turbo Systems Ltd

Layout and function 1.2 Page 3

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

These are both are mounted on a common shaft.

air, and the compressed air is forced into the cylinders.

The turbocharger is equipped with an emergency lubrication oil tank,

ABB Turbo Systems Ltd

Correct use of the turbocharger 1.3 Page 4

1.3 Correct use of the turbocharger

Improper operation and maintenance of the turbocharger can result in

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

X Defects which could affect safety must be eliminated immediately.

ABB Turbo Systems Ltd

Essential information 1.4 Page 5

1.4 Essential information

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

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

The safety and risk consciousness of the personnel working on and

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

Additions and alterations to, and conversions of the turbocharger that

ABB Turbo Systems Ltd

Essential information 1.4 Page 6

Original parts and safety

We herewith expressly state that parts and accessories not supplied by

If components and assemblies not manufactured and tested by ABB

The turbocharger must only be operated and maintained by trained and

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

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

ABB Turbo Systems Ltd

Essential information 1.4 Page 7

The Contact Information brochure contains an overview of official ABB

This operating manual is valid for various turbocharger design variants.

Storage of new turbochargers

New turbochargers supplied by ABB Turbo Systems Ltd. can be stored

X After 6 months, rust-proofing oil should be sprayed on exposed sur-

Repeat the steps described for rust-proofing your turbocharger every 6

ABB Turbo Systems Ltd

Abbreviations and symbols 1.5 Page 8

1.5 Abbreviations and symbols

9 Positive checkpoint (activity that must be carried out without fail)

ABB Turbo Systems

Official ABB Turbo Systems service station

Early awareness and avoidance of hazards.

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

Work only on those connections for which you are qualified.

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

Secure the rotor against turning.

from the turbocharger and its accessories.

Causes sharp edges, pointed parts

fracture or rupture of parts due to overload

Causes Inhalation of toxic gases, smoke and vapours

Personal injury Loss of hearing

Causes Machine noise level above 85 dB (A)

Personal injury Burns

Causes Missing or incorrectly fitted insulation.