Operation Manual
TPL76-C32
ABB Turbo Systems Ltd
CH 5401 Baden
Type TPL76-C32
nMmax 352
HT586989
t
t
650
650
Mmax
Bmax
1/s
°C
nBmax 337
04070 kg 35
50
50
Application according to
the Operation Manual
Year 2019
made in Switzerland
ABB Turbocharging
ꢀꢁꢁ
Operation Manual / TPL76-C
Table of contents
Operation Manual
1
Preliminary remarks................................................................................................. 3
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
Purpose of this manual.................................................................................................. 3
Layout and function........................................................................................................ 4
Intended use..................................................................................................................... 6
Deflagration on gas engines......................................................................................... 7
Storage of new turbochargers and spare parts ....................................................... 8
Essential information................................................................................................... 10
Symbols and definitions.............................................................................................. 12
Turbocharger rating plate........................................................................................... 13
Contact information..................................................................................................... 14
2
Safety....................................................................................................................... 15
Introduction ................................................................................................................... 15
CE conformity ................................................................................................................ 15
Definition of mandatory signs ................................................................................... 16
Definition of Safety instructions ............................................................................... 16
Warning plates on the turbocharger......................................................................... 17
Safe operation and maintenance............................................................................... 18
Hazards during operation and maintenance........................................................... 21
Periodic checking of the pressure vessel................................................................. 26
Lifting loads ................................................................................................................... 26
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3
Commissioning...................................................................................................... 28
Oil supply ........................................................................................................................ 28
Inspection work............................................................................................................. 31
Commissioning after taking out of operation........................................................ 33
3.1
3.2
3.3
4
Operation ............................................................................................................... 34
Noise emissions ............................................................................................................ 34
Servicing work ............................................................................................................... 36
Replacement intervals for turbocharger components.......................................... 39
Speed measurement .................................................................................................... 41
Stopping the engine.................................................................................................... 44
4.1
4.2
4.3
4.4
4.5
5
Maintenance .......................................................................................................... 45
Foreword to Maintenance .......................................................................................... 45
Cleaning the filter silencer.......................................................................................... 46
Cleaning the compressor during operation ........................................................... 49
Cleaning turbine blades and nozzle ring in operation........................................... 55
Cleaning components mechanically......................................................................... 60
5.1
5.2
5.3
5.4
5.5
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Operation Manual / TPL76-C
Table of contents
6
Troubleshooting.................................................................................................... 69
6.1
6.2
6.3
6.4
6.5
Malfunctions when starting....................................................................................... 69
Surging of the turbocharger....................................................................................... 70
Malfunctions during operation .................................................................................. 71
Malfunctions when stopping...................................................................................... 74
Speed measurement system ...................................................................................... 75
7
Removal and installation...................................................................................... 76
Turbocharger weight.................................................................................................... 76
Removing the turbocharger........................................................................................ 77
Installing the turbocharger ......................................................................................... 79
7.1
7.2
7.3
8
Disassembly and assembly.................................................................................. 80
Introduction .................................................................................................................. 80
Module weights ............................................................................................................. 82
Removing and fitting filter silencer or air suction branch................................... 84
Axial clearance .............................................................................................................. 86
Removing cartridge group .......................................................................................... 87
Dismantling and installing the turbine diffuser and nozzle ring........................ 94
Installing cartridge group........................................................................................... 98
Dismantling and fitting nozzle ring at turbine end............................................. 108
Table of tightening torques...................................................................................... 116
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
9
Taking out of operation at short notice ........................................................... 118
Possibilities for emergency repair........................................................................... 118
Locking the rotor......................................................................................................... 119
Fit cover plate .............................................................................................................. 123
Blocking the inlets and outlets................................................................................. 127
Bypass the turbocharger........................................................................................... 127
9.1
9.2
9.3
9.4
9.5
10
10.1
10.2
Mothballing the turbocharger........................................................................... 128
Taking out of operation for up to 12 months........................................................ 128
Taking out of operation for more than 12 months............................................... 129
11
Disposing of turbocharger components.......................................................... 130
12
12.1
12.2
Spare parts............................................................................................................ 131
Ordering spare parts.................................................................................................. 131
View of turbocharger with part numbers .............................................................. 132
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Operation Manual / TPL76-C
1 Preliminary remarks / 1.1 Purpose of this manual
1 Preliminary remarks
1.1 Purpose of this manual
This Operation Manual belongs to the turbocharger with the identical
serial number (01), see the cover sheet of the Operation Manual and the
turbocharger rating plate.
Operation Manual
This Operation Manual enables you to familiarize yourself with the tur-
bocharger supplied by ABB Turbo Systems and to use it as intended.
It provides important information in order that the turbocharger can be
operated safely, correctly and efficiently.
This Operation Manual complements and expands existing national reg-
ulations concerning work safety and accident prevention.
Target group
This Operation Manual is intended for engineers and qualified mechan-
ics who are responsible for operating the engine and the turbocharger
installed on it.
Availability of operation manual
An operation manual must be available at all times at the place where
the turbocharger is used.
Everyone who operates or works on the turbocharger must have first
read and understood the operation manual.
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1 Preliminary remarks / 1.2 Layout and function
1.2 Layout and function
01Filter silencer
08Nozzle ring
02Radial plain bearing
03Thrust bearing
04Bearing bush
09Turbine wheel
10Bearing casing
11Diffuser
05Radial plain bearing
06Gas outlet casing
07Gas inlet casing
12Compressor wheel
13Compressor casing
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Operation Manual / TPL76-C
1 Preliminary remarks / 1.2 Layout and function
Mode of operation
The turbocharger is a turbomachine and consists of the following main
components:
¡
¡
Turbine
Compressor
These are both mounted on a common shaft.
The exhaust gases from the diesel engine flow through the gas inlet cas-
ing (07) and nozzle ring (08) to the turbine wheel.
The turbine wheel (09) uses the energy contained in the exhaust gas to
drive the compressor wheel (12). The compressor then draws in fresh air,
compresses it and then forces it into the cylinders.
The exhaust gases escape to free air through an exhaust gas pipe which
is connected to the gas outlet casing (06).
The air which is necessary for operation of the diesel engine and is com-
pressed in the turbocharger is drawn through the suction branch or the
filter silencer (01) into the compressor wheel (12). This air then passes
through the diffuser (11) and leaves the turbocharger through the com-
pressor casing (13).
The rotor runs in two radial plain bearings (02/05). One plain bearing is
in the bearing bush (04), and the second one is in the axial thrust bearing
(03) at the compressor end.
The plain bearings are connected to a central lubricating oil duct which is
fed with oil from the engine's lubricating oil circuit. The oil outlet is al-
ways at the lowest point of the bearing casing (10).
Turbocharger version with compressor wheel cooling system
Depending on its range of use, the turbocharger is
provided with a compressor wheel cooling system. Com-
pressor wheel cooling means that, after the charge air
cooler at the engine end, cooled compressor air is de-
livered to the turbocharger to cool the compressor
wheel.
Depending on the respective operating conditions, it is
absolutely essential that the compressor wheel is cooled
in order to guarantee its reliability and the replacement
intervals. In the case of the turbocharger version with
compressor wheel cooling, the cooling air is supplied
through the side connection (15) in the bearing casing.
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Operation Manual / TPL76-C
1 Preliminary remarks / 1.3 Intended use
1.3 Intended use
Use on internal combustion engines in general
ABB turbochargers are intended for turbocharging internal combustion
engines.
To ensure compliance with the machinery directive 2006/42/EC when
using on gas engines, the turbocharger must be operated in an engine
room classified as "not at risk of explosion". This is in accordance with
the position paper [2] relating to ATEX issued by EUROMOT [1].
The turbocharger supplies the engine with the air volume or air/gas mix-
ture and the associated charging pressure required for operation.
The turbocharger is solely intended to be operated with a clockwise dir-
ection of rotation as viewed from the turbine end.
The specific operating limits of the turbocharger were determined on
the basis of information from the enginebuilder about the intended use.
These data are given on the rating plate.
ABB Turbo Systems accepts no liability and rejects all warranty claims
for any non-intended uses.
[1]Euromot = The European Association of Internal Combustion Engine
Manufacturers
[2]Directive 94/9/EC concerning equipment and protective systems in-
tended for use in potentially explosive atmospheres (ATEX) The Eur-
omot Position as of November 2003, ATEX Euromot Position 191103
WARNING
Unapproved operation
Any operation of the turbocharger outside of its operating limits can be
hazardous to personnel.
u Only operate the turbocharger within the operating limits.
u Only trained personnel must operate the turbocharger.
The intended use of the turbocharger includes compliance with all regu-
lations and conditions.
In particular, the following must be observed:
¡
¡
Operation Manual
Instructions of the enginebuilder
State of the art
The turbocharger is designed and built according to the state of the art
and is safe to operate.
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1 Preliminary remarks / 1.4 Deflagration on gas engines
Flawless condition
The turbocharger must only be used when it is in a technically flawless
condition and operated in compliance with its intended use.
ABB Turbo Systems excludes any liability for damage resulting from un-
authorized modifications to the turbocharger or improper operation.
1.4 Deflagration on gas engines
ABB turbochargers can tolerate a deflagration with a transient pressure
increase of 12 bar.
ABB Turbo Systems recommends subjecting the turbocharger to a visual
inspection after a deflagration event. As part of the inspection, the posi-
tion of the turbine casing and the position of the compressor casing to
the bearing casing must be checked, and the bearing casing must be ex-
amined to see if it has shifted in relation to the bracket. A crack inspec-
tion of the casings and the bellows is also recommended. The nearest
ABB Turbocharging Service Station should be instructed to carry out this
inspection and assessment.
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Operation Manual / TPL76-C
1 Preliminary remarks / 1.5 Storage of new turbochargers and spare
parts
1.5 Storage of new turbochargers and spare parts
Storage of new turbochargers and spare parts up to 6 months
New turbochargers and spare parts from ABB Turbo Systems can be
stored in sealed packaging without additional mothballing measures for
up to 6 months from the date of delivery (marked by the VCI label on the
package).
Volatile Corrosion Inhibitor (VCI)
Only dry rooms in which the relative humidity is between 40…70 % and
no condensation can form are suitable for storage.
Storage of new turbochargers and spare parts for more than 6
months (VCI)
WARNING
Protection of health when handling VCIs
VCI products are not hazardous in the sense of the Hazardous Sub-
stances Ordinance. Nevertheless, the following points are to be ob-
served when handling VCIs:
u Ensure good room ventilation.
u Do not eat, drink or keep food at the workplace while working with
VCIs.
u Wear safety gloves.
u Clean hands and face after working with VCIs.
Wear safety gloves to protect against chemical hazards.
The following mothballing measures are required every 6 months:
u Open the package.
u Remove the VCI corrosion protection emitter from the package and
replace it with a new, identical VCI corrosion protection emitter. New
VCI corrosion protection emitters can be obtained at www.brano-
u Dispose of the old VCI corrosion protection emitter in an environ-
mentally compatible manner, professionally and in accordance with
local regulations.
u Seal the package. The better the external seal is designed, the more
permanent the protection.
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Operation Manual / TPL76-C
1 Preliminary remarks / 1.5 Storage of new turbochargers and spare
parts
Long-term storage of replacement turbochargers or spare parts
Per order, turbochargers or cartridge groups will be prepared by ABB
Turbo Systems for prolonged storage. The package is equipped with a
hygrometer (see illustration).
The following measures are required every 6 months:
u Check the hygrometer (02) in the sight-glass. There is an opening (01)
in the wooden crate which allows this check to be carried out. When
the display field has changed colour at the 70% level, the maximum
permissible humidity has been exceeded. In this case the turbochar-
ger or rotor must be inspected by an ABB Turbocharging Service Sta-
tion and repacked.
u Inspect the package for damage. If the package is damaged, the tur-
bocharger or cartridge group must be inspected by an ABB Tur-
bocharging Service Station and repacked.
After every 3 years the following work steps must be performed by an
ABB Turbocharging Service Station:
¡
¡
¡
Inspect the components
Exchange the desiccant agent
Repackage the components.
NOTICE
Replacement components ready for operation
If the 70% display field of the hygrometer (02) has not changed colour
and the package is undamaged, the replacement turbocharger or re-
placement cartridge group can be placed into operation without any
prior testing by an ABB Turbocharging Service Station.
Unpacking replacement turbochargers or spare parts
The corrosion protection effect ends after the material is unpacked from
the VCI package.
To avoid the formation of condensation, the surroundings and the con-
tent of the package must have the same temperature during unpacking.
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Operation Manual / TPL76-C
1 Preliminary remarks / 1.6 Essential information
1.6 Essential information
Organisational measures
In addition to the Operation Manual, the general statutory regulations
for the prevention of accidents and for environmental protection in the
country of use must also be observed.
This also applies to the provision and wearing of personal protective
equipment.
NOTICE
The manner in which personnel work on and with the turbocharger with
regard to safety and risks is to be checked on a regular basis in accord-
ance with the Operation Manual.
u The turbocharger must be shut down immediately in the event of
modifications affecting safety or of corresponding operating beha-
viour by stopping the engine. The fault should be reported to the per-
son or department responsible.
NOTICE
Any modifications, additions or conversions made to the turbocharger,
which could impair safety, require the prior approval of ABB Turbo Sys-
tems.
Original parts and safety
Original parts and accessories are specially designed for the turbochar-
ger supplied by ABB.
WARNING
Use original parts
Operation of the turbocharger with non-original parts can impair the
safety of the turbocharger and can cause serious damage to property
and injury to personnel.
u Only use original parts from ABB.
ABB accepts no liability for any damage resulting from the use of non-
original parts and corresponding accessories.
Competence of personnel
The turbocharger must only be operated and serviced by trained and au-
thorised personnel. Basic mechanical training is a prerequisite.
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1 Preliminary remarks / 1.6 Essential information
Design variants
This document is valid for different design variants of turbochargers.
There may be sections and descriptions of components that are not rel-
evant for a specific turbocharger variant.
ABB Turbocharging Service Stations will be happy to provide information
on questions regarding a design variant (see Contact information at
Accuracy of illustrations
The illustrations in this document are general in nature and intended for
ease of understanding. Differences in detail are therefore possible.
Storage of new turbochargers
New turbochargers supplied by ABB Turbo Systems can be stored
without additional safeguarding measures for a period of 6 months
after the delivery date.
Suitable storage locations are dry rooms where the relative humidity is
between 40-70% and no condensation can form.
u After expiry of the 6 months, all surfaces and accessible areas of the
turbocharger should be sprayed with anticorrosive agent.
u To do this, the insulating materials must be removed.
NOTICE
Repeat the described measures every 6 months to keep your turbochar-
ger free from rust.
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Operation Manual / TPL76-C
1 Preliminary remarks / 1.7 Symbols and definitions
1.7 Symbols and definitions
The following symbols are used in the documents:
w Prerequisite
u Work step
¡
Enumeration, first level
- Enumeration, second level
→ Refers to a page number
Definition of notes
NOTICE
Note
A note provides suggestions which facilitate the work on the product.
Definition of mandatory signs
Mandatory signs show the protective equipment to be worn for a task.
The mandatory signs are described in chapter Safety and must be com-
plied with.
Definition of caution / warning
The caution and warning signs are described in the chapter Safety.
ABB Turbo Systems
In this document, ABB Turbo Systems Ltd is abbreviated to ABB Turbo
Systems.
Official ABB Turbo Systems Service Stations
In this document, official service stations are referred to as ABB Tur-
bocharging Service Stations. They are inspected and certified regularly
by ABB Turbo Systems. See also chapter Contact information →14.
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Operation Manual / TPL76-C
1 Preliminary remarks / 1.8 Turbocharger rating plate
1.8 Turbocharger rating plate
Operating limits
01 Turbocharger operating limits at engine overload (110 %).
Only when operating in the test rig unless otherwise agreed with the
enginebuilder.
02 Turbocharger operating limits during operation
Recommended replace-
ment intervals for tur-
bocharger components
03 Replacement interval for plain bearings in 1000 h
04 Replacement interval for compressor in 1000 h
05 Replacement interval for turbine in 1000 h
Further information
06 Part number for customer
07 Designation of special design
08 Turbocharger weight in kg
09 Turbocharger type
10 Serial number
11 Year of turbocharger construction
12 Manufacturing plant
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Operation Manual / TPL76-C
1 Preliminary remarks / 1.9 Contact information
1.8.1 Explanation of the rating plate
The recommended replacement intervals and the corresponding opera-
tional limits are jointly defined with the engine manufacturer. This in-
formation is specific to the system.
Operation above the indicated values nBmax, tBmax can considerably shorten
the recommended replacement intervals. In such cases, we recommend that
you contact the nearest official ABB Turbocharging service station.
nMmaxand tMmax normally apply only when running at overload (110%) during
trials on the engine test bed. These limits can also be permitted during op-
eration for special applications. Operation above nMmax and tMmax is not per-
mitted.
Non-observance of the recommended replacement intervals can increase
the risk of unpredictable component failures.
1.8.2 Positions of the rating plates
A rating plate is attached to the turbocharger foot, one on the left and
one on the right. On turbochargers with insulation from ABB, at least one
additional rating plate is attached to the insulation of the gas outlet cas-
ing.
1.9 Contact information
Contact information for the official service stations of ABB Turbo Sys-
tems is available online.
u Scan the QR code to access our website.
ABB Turbo Systems Ltd
Bruggerstrasse 71a
CH-5401 Baden
Switzerland
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Operation Manual / TPL76-C
2 Safety / 2.1 Introduction
2 Safety
2.1 Introduction
Turbochargers manufactured by ABB are state of the art and comply
with the pertinent safety and health-protection requirements that ap-
plied when the turbocharger was manufactured. Consequently, the tur-
bocharger is safe to operate. Nevertheless, during turbocharger opera-
tion and when working on the turbocharger, residual risks can exist
which:
¡
¡
¡
originate from the turbocharger itself and its accessories
originate from the operating and auxiliary materials used
are the consequence of insufficient observance of the safety instruc-
tions
¡
are the consequence of unsatisfactory and improper execution of
maintenance and inspection work.
The operating company is responsible for access to the turbocharger as
well as the organisational measures that regulate the safe handling of
the turbocharger by its personnel.
All instructions contained in this chapter must be observed for safe and
trouble-free operation of the turbocharger and during all work on the
turbocharger.
All further safety instructions contained and specifically identified in
every chapter of this manual (see section Definition of Safety Instruc-
tions) must also be observed.
2.2 CE conformity
Information
ABB turbochargers fulfil Directive 2006/42/EC on machinery and are
considered partly completed machinery in the sense of Article 2 g.
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Operation Manual / TPL76-C
2 Safety / 2.3 Definition of mandatory signs
2.3 Definition of mandatory signs
To be worn at all times
Protective clothing
Safety footwear to pro-
tect against mechanical
hazard and risk of fall-
ing
To be worn according to the specific work
Safety glasses
Safety goggles
Safety gloves against
- Mechanical hazard
- Chemical hazard
- Thermal hazard
Respiratory mask
against
- Dusts
- Gases
Safety helmet
Ear protection
2.4 Definition of Safety instructions
The following symbols and terms used in this manual concern safety or
refer to possible hazards:
WARNING
Definition of warning
Serious personal injuries and even accidents with fatal consequences
may occur if work and operating instructions marked with this symbol
and the word WARNING are either not followed or not followed pre-
cisely.
u Warning signs must be observed at all times.
CAUTION
Definition of caution
Serious machine or property damage may occur if work and operating
instructions marked with this symbol and the word CAUTION are either
not followed or not followed precisely.
u Caution signs must be observed at all times.
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2 Safety / 2.5 Warning plates on the turbocharger
2.5 Warning plates on the turbocharger
Warning plates that must be observed are attached to the turbocharger.
The warning plates must always be present in the intended locations
and must be legible.
Part number
Size [mm]
Product
81080
105 x 74
TPL / TPR
When uninsulated turbochargers are delivered to the engine builder, the
warning plates must be subsequently attached to the insulation. This is
the responsibility of the engine builder.
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Operation Manual / TPL76-C
2 Safety / 2.6 Safe operation and maintenance
2.6 Safe operation and maintenance
The instructions specified in this section are for the safety of personnel.
Together with the instructions in the Hazards during operation and
maintenance section, they allow the user to safely use the turbocharger.
Work safety and work area safety
WARNING
Risk of falling
There is the risk that someone can fall when working on the turbochar-
ger.
u Do not climb on the turbocharger or on parts attached to it or use
these as climbing aids.
u When working at levels above the head, use climbing aids and work
platforms suitable for this purpose.
u Observe all general regulations for the prevention of accidents.
u Do not work on the turbocharger if you are under physical or mental
stress.
u Work only with suitable tools as well as equipment and working ma-
terials that are in perfect condition.
u Electric tools must be solidly earthed, and connecting cables may not
be damaged.
u Keep the workplace clean, clear away loose objects and remove
obstacles on the floor.
u Keep the floor, equipment and the turbocharger clean.
u Have oil binding materials ready at hand and keep oil catch pans
ready or in position
u Eliminate leaks.
u Keep fire-protection materials and fire-extinguishing equipment
ready.
Welding work in the vicinity of the turbocharger
u When performing welding work in the vicinity of the turbocharger, al-
ways cover the filter silencer to prevent the filter mat from being
damaged.
u Keep flammable objects and substances out of the range of flying
sparks.
u Cover all connections on the turbocharger so that no foreign objects
can enter the turbocharger.
u Wear personal protective equipment (PPE) for welding operations.
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Operation Manual / TPL76-C
2 Safety / 2.6 Safe operation and maintenance
Safety during start-up / commissioning and operation
u Before starting work, carry out visual inspection of working area.
u Remove any obstacles and objects lying around.
u Before start-up / commissioning, check all pipes from and to tur-
bocharger for damage and leaks.
u Don't work in any way that could impair safety when working on tur-
bocharger.
u After about every 12 hours of operation or at least once a day, inspect
turbocharger for visible damage and defects.
u Immediately report any damage or changes in operational perform-
ance to person responsible.
u If damage is discovered, immediately shut down turbocharger and se-
cure it against inadvertent or unauthorized use.
u When switching on auxiliary power sources (hydraulics, pneumatics,
electricity, water), keep an eye open for any hazards resulting from
supplying these power sources.
Safety during cleaning
If cleaning agents or solvents are used for cleaning, the corresponding
material safety data sheet and the safety instructions in section "Haz-
ards due to operating and auxiliary materials" must be observed.
u Observe the material safety data sheet for the cleaning agent or
solvent.
u Wear personal protective equipment (PPE) according to the material
safety data sheet.
u Inspect the electric cables for abrasion and damage before and after
your cleaning work.
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Operation Manual / TPL76-C
2 Safety / 2.6 Safe operation and maintenance
Safety during disassembly, assembly, maintenance and
troubleshooting
u Always perform the specified adjustments, servicing as well as in-
spection work and observe inspection intervals.
u Inform operating personnel about all service and repair work before
beginning.
u Before opening a cover or removing a protective device on a tur-
bocharger, the engine must be switched off and the turbocharger
must have come to a standstill.
u Ensure that the supply of oil is interrupted, especially with an external
oil supply.
u Put the engine into operation only after all parts have been refitted
properly.
CAUTION
Mechanical work on the turbocharger
Possible damage to or destruction of components on the turbocharger.
u Perform only those tasks that are described in this manual.
u Perform work only for which training has been carried out.
Safety when taking out of operation or preparing for mothballing
u Secure the rotor so it cannot turn. The rotor can turn on its own from
the force of the stack draught.
u Clean the turbocharger before mothballing it.
u Observe the material safety data sheet for the cleaning and moth-
balling agents.
u Wear personal protective equipment (PPE) according to the material
safety data sheet.
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Operation Manual / TPL76-C
2 Safety / 2.7 Hazards during operation and maintenance
2.7 Hazards during operation and maintenance
Mechanical hazards during operation
During normal operation, no mechanical hazards emanate from the tur-
bocharger if it has been installed properly.
WARNING
Risk of injury
Contact with rotating parts can lead to serious injuries. The turbochar-
ger must never be operated without a filter silencer or an air suction
branch. When the engine is at a standstill, the rotor can turn on its own
because of stack draught.
u Operate the turbocharger in accordance with instructions.
u During maintenance work, secure the rotor against unintentional ro-
tation.
Mechanical hazards when working on the turbocharger
During maintenance work, various risks can occur through the improper
handling of components, through the non-observance of work instruc-
tions, due to inadequate care or as a consequence of insufficient train-
ing.
WARNING
Mechanical hazard
Severe injuries to personnel or fatal accidents can be caused by mech-
anical influences as a consequence of hazardous and inadequate opera-
tional procedures.
u Observe the general rules for occupational safety and prevention of
accidents.
u Ensure workplace safety.
u Only perform operations that are described in this chapter.
u Only perform operations for which you have previously received in-
struction or training.
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Operation Manual / TPL76-C
2 Safety / 2.7 Hazards during operation and maintenance
Hazards due to noise
The development of noise during operation is influenced by the installa-
tion and operating conditions. Noise with a sound pressure level exceed-
ing 85 dB(A) is harmful.
WARNING
Hazards due to noise
Noise can cause impaired hearing, damage to health, mental disturb-
ances, diminished attention and irritation.
u Always wear ear protection when the engine is running.
u When the sound pressure level is above 85 dB(A), always wear ear
protection.
Wear ear protection.
Hazards due to hot surfaces and substances
During operation, turbocharger surfaces and attached parts as well as
operating materials (lubricating oil) become hot. The surface temperat-
ure is dependent on the effectiveness of the insulation being used. The
temperature can become high enough so that it falls into ranges where
burns are possible.
WARNING
Risk of burning
Touching hot surfaces or contact with hot operating materials can lead
to serious burns.
u Do not touch hot surfaces and heed the warning plate on the tur-
bocharger.
u Wear heat-resistant safety gloves and protective clothing.
u Allow the turbocharger to cool down before carrying out any work.
Wear safety gloves to protect against thermal hazards.
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Operation Manual / TPL76-C
2 Safety / 2.7 Hazards during operation and maintenance
WARNING
Hot surfaces on uninsulated turbochargers
Uninsulated turbochargers can cause serious personal injuries (burns).
The turbocharger is supplied with or without insulation in accordance
with the purchase order received from the enginebuilder. If supply is
without insulation, the enginebuilder is responsible for providing the
turbocharger with proper insulation and for providing protection
against contact with hot surfaces.
u Compliance with the instructions and specifications given by the en-
ginebuilder to protect against hot turbocharger surfaces is compuls-
ory.
Wear safety gloves to protect against thermal hazards.
Hazards due to operating and auxiliary materials
Operating and auxiliary materials are substances used for operation or
the execution of maintenance work. Oils, greases, coolants, cleaning
agents and solvents, acids, etc. can be regarded as hazardous materials.
Operating and auxiliary materials can be combustible and easily ignited.
WARNING
Handling operating and auxiliary materials
Ingestion or inhalation of vapours of operating and auxiliary materials
or contact with such can cause damage to health.
u Avoid inhalation and contact with the skin.
u Ensure good ventilation.
u Observe details in the safety data sheets of the operating and auxili-
ary materials.
u Observe local laws.
Wear safety goggles.
Wear safety gloves to protect against chemical hazards.
Wear a respiratory mask to protect against gases.
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2 Safety / 2.7 Hazards during operation and maintenance
WARNING
Risk of fire, explosion
Flammable and combustible operating materials and supplies can
catch fire or resulting vapours can lead to an explosion.
u Observe the details in the material safety data sheets of the operat-
ing and auxiliary materials.
u Comply with local legislation.
u Do not allow any exposed flame or ignition source during cleaning
work.
u Carry out cleaning in the open or provide sufficient aeration and
ventilation.
CAUTION
Risk of environmental damage
The escape of operating and auxiliary materials into the atmosphere or
contamination of the ground and water due to improper disposal can
lead to environmental damage.
u Handle operating and auxiliary materials carefully.
u Heed the instructions for use, safety data sheets and hazard notices
on the containers of the operating and auxiliary materials.
u Wear appropriate protective clothing.
u Avoid inhalation and contact with the skin.
u Ensure that the work space is adequately ventilated.
u Seal containers tightly immediately after use and put them away.
u Collect used working and auxiliary materials safely, store them separ-
ately in suitable containers and dispose of them properly and in an
environmentally compatible manner in accordance with statutory reg-
ulations.
u In the event of leaks or after spilling, immediately spread a suitable
binding agent and dispose of it properly and in an environmentally
compatible manner in accordance with statutory regulations.
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2 Safety / 2.7 Hazards during operation and maintenance
Hazards when handling insulating materials
WARNING
Hazards due to insulating materials
Dust and fibres from insulating materials can cause damage to health
or irritations. Unsuitable, combustible insulating materials signify a fire
hazard.
u Use only suitable, non-combustible insulating materials.
u Ensure that the work area is well ventilated.
u Avoid stirring up dust.
u Use tools and processes which keep dust to a minimum.
u Remove packing materials only in the work area.
u Take particular care when removing old insulating materials.
u Dispose of insulating materials properly and in an environmentally
compatible way in accordance with applicable local regulations.
Wear safety goggles.
Wear a respiratory mask to protect against dusts.
Wear safety gloves to protect against chemical hazards.
u Use only suitable, non-combustible insulating materials.
u Ensure that the work area is well ventilated.
u Wear suitable work clothing (safety glasses, respiratory mask).
u Avoid stirring up dust.
u Use tools and processes which keep dust to a minimum.
u Remove packing materials only in the work area.
u Take particular care when removing old insulating materials.
u Dispose of insulating materials properly and in an environmentally
compatible way in accordance with applicable local regulations.
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Operation Manual / TPL76-C
2 Safety / 2.8 Periodic checking of the pressure vessel
Hazards due to electrical components
WARNING
Hazards due to electrical components
Electrical components operate with voltages which can present hazards
to humans.
u All work on or with electrical components may only be performed by
trained specialists.
u Heed any country-specific regulations.
2.8 Periodic checking of the pressure vessel
The pressure vessels used by ABB, such as those for wet or dry cleaning,
are so-called "simple pressure vessels".
¡
The locally applicable legal regulations regarding periodic checks of
the pressure vessels must be observed.
¡
The operating company is responsible for the safe operation of the
pressure vessel.
WARNING
Danger due to pressure vessels
The operating company must make sure the pressure vessels are in
proper working condition and monitor them. Necessary repair or main-
tenance work must be carried out without delay and the required safety
precautions must be taken.
u Pressure equipment must not be operated if it has defects.
2.9 Lifting loads
WARNING
Suspended loads
Loads not suspended in compliance with regulations may lead to per-
sonal injury or accidents with fatal consequences.
u Loads must always be fastened to technically perfect lifting gear
with sufficient loading capacity.
u Make sure the load is suspended properly on the crane hook.
u Do not let anyone stand beneath a suspended load.
Wear safety gloves to protect against mechanical hazards.
Wear safety helmet.
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2 Safety / 2.9 Lifting loads
In the case of two or more suspension points, the slinging angle must
not exceed 45°. This avoids excessive loading due to inclined tensile
loading.
u Fasten turbocharger assemblies / components as described in re-
spective handling steps.
u Before attaching slings, allow turbocharger components to cool down
(maximum 80°C).
u Use suitable protection at sharp edges.
u Completely screw in assembly / fitting devices without fail so that
they cannot work loose during use.
u Use assembly / fitting devices only for applications described.
u Make sure removed turbocharger components stand safely and se-
curely.
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3 Commissioning / 3.1 Oil supply
3 Commissioning
3.1 Oil supply
A carefully designed and installed oil supply, which functions in all pos-
sible operational conditions, is an important prerequisite for trouble-
free turbocharger operation.
The turbocharger is normally lubricated with oil from the engine oil cir-
cuit.
NOTICE
With regard to the oil supply, please observe the engine builder's spe-
cifications for lubricating oil selection, oil change intervals, oil filtration,
oil pressure and oil temperature.
Oil filtration
A lubrication oil filter system with a mesh size ≤0.050 mm is adequate
for TPL76-C turbochargers.
NOTICE
This filter system can also be achieved by using an additional self-clean-
ing fine filter.
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3 Commissioning / 3.1 Oil supply
Oil pressure
The oil pressure in front of the turbocharger must be maintained pre-
cisely to ensure trouble-free operation.
The permissible oil pressure ranges at measuring point M (blind connec-
tion) on the turbocharger are listed below.
Status for operation
Oil pressure at measuring
point M
poil,in [bar]
Permissible, for normal operation
Permissible, during engine warm-up
Temporarily admissible ( < 1 h ) -> alarm
Not permissible -> emergency stop
1.3 … 2.5
1.3 … 5.0
1.1 … 1.3
0.0 … 1.1
0.2 … 2.5
Permissible, during pre- and post-lubrication
(engine stopped)
Oil orifice
A metering orifice is installed in the oil inlet of the turbocharger to en-
sure these oil pressures. The orifice is installed by the enginebuilder and
it is fixed in place with a locking ring.
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3 Commissioning / 3.1 Oil supply
Lubricating oil temperature at the inlet
CAUTION
Machine damage
If the oil temperature at the oil inlet exceeds the admissible range, this
may lead to engine damage.
u Observe oil temperature at the oil inlet according to the following
table.
Oil temperature at the in-
let
Toil,inlet [°C]
30 … 80
> 80
Status for operation
Admissible
Temporarily admissible (< 1 h) -> alarm
Not admissible -> stop engine
> 85
Not admissible -> do not start engine
< 30
(before start: preheat oil)
Lubricating oil temperature at outlet
The oil temperature at the outlet is mainly dependant on:
¡
¡
¡
Lubricating oil temperature and pressure at the oil inlet
Engine load and turbocharger speed
Exhaust gas temperature
The maximum admissible oil temperature at the outlet is listed in the fol-
lowing table. The specified oil outlet temperature is to be considered as
alarm value for the turbocharger operation and must be monitored ac-
cording to the current regulations.
Oil temperature at outlet
Status for operation
Toil,outlet [°C]
Permissible
≤ 130
Temporarily permissible -> alarm
Not permissible -> stop engine
> 130
> 150
If the turbocharger was operated for a longer period of time outside of
the admissible range, ABB Turbo Systems recommends to have the tur-
bocharger inspected by an ABB Turbocharging Service Station.
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3 Commissioning / 3.2 Inspection work
3.2 Inspection work
Inspection work includes preventive visual controls plus monitoring and
measuring work before and during commissioning. Inspections help de-
tect changes to the turbocharger. Machine damage can be avoided.
3.2.1 Inspection before commissioning
Monitoring devices
u Check for correct functioning.
Filter mat
u Inspect for damage.
Lubricating system
u Check oil filter for cleanliness before commissioning.
CAUTION
Contaminated oil
Particles of dirt and solid matter in the oil can cause serious damage to
the machine or property.
u During initial commissioning and after all service work, the complete
lubricating system must be flushed thoroughly with warm oil.
u When running in the engine and after all service work on the lubricat-
ing system, special running-in filters must be used.
u Check oil pressure in oil supply lines.
CAUTION
Prelubrication
Serious machine or property damage might result if the turbocharger is
not supplied with oil when the engine is starting.
u Activate prelubrication device before starting engine.
Warning plates on tur-
bocharger
u Check whether the warning plates are present and legible.
u Check whether the protective sheets have been removed.
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3 Commissioning / 3.2 Inspection work
3.2.2 Check after start-up (engine at idling speed)
Lubricating system
u Check oil pressure in oil supply lines.
u Check oil inlet temperature.
The permissible values are listed in the section Oil supply.
Gas, air and oil lines
u Check all gas, air and oil lines for leaks after starting the engine.
3.2.3 Check when running up engine
u Measure speed, oil pressure and charging pressure at various engine
performance levels.
u Measure exhaust gas temperature in front of and behind turbine.
u Measure air temperature in front of and behind compressor.
The measured values must be compared with the values in the accept-
ance test report, while taking different operating conditions into ac-
count.
NOTICE
Lubricants and pastes used during assembly of the turbocharger li-
quefy or vaporise and might escape as an oily liquid in the first few
hours after commissioning. If oily liquid continues to escape after this
period, an oil leak must be suspected. The first step is to check for leak-
age of the oil supply to the turbocharger. If this is leaky, contact an offi-
cial ABB Turbocharging service station.
3.2.4 Inspection after 100 service hours
Clean or replace lubricating oil filters after the first 100 service hours.
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3 Commissioning / 3.3 Commissioning after taking out of operation
3.3 Commissioning after taking out of operation
If provided
u Remove cover plates (blind flanges) between compressor casing out-
let and charge air duct, before gas inlet and after gas outlet.
u Inspect exhaust gas duct / line in front of and after turbine for any
combustion deposits, foreign matter or residual water. Clean and re-
move.
u Inspect air supply line or filter silencer for any foreign matter. Clean
and remove.
u Start up turbocharger oil circulation system at engine end.
u Prepare turbocharger for operation as instructed in section "Inspec-
tion work before start-up / commissioning" of chapter headed "Start-
up / commissioning".
u Start up turbocharger.
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4 Operation / 4.1 Noise emissions
4 Operation
4.1 Noise emissions
WARNING
Hazards due to noise
Noise can cause impaired hearing, damage to health, mental disturb-
ances, diminished attention and irritation.
u Always wear ear protection when the engine is running.
u When the sound pressure level is above 85 dB(A), always wear ear
protection.
Wear ear protection.
The sound pressure level (A-weighted) of emissions is measured at a dis-
tance of 1 metre from the turbocharger.
The highest sound pressure level of emissions1) reaches a maximum of
105 dB(A) near the filter silencer and over the entire speed range.
The following prerequisites must be fulfilled on the turbocharger in or-
der to observe this limit value:
¡
¡
¡
Fitted air-inlet system
All standard, noise-reducing measures have been taken2).
The bellows at the air outlet have been perfectly insulated acoustic-
ally by the engine builder. He is also responsible for insulating the
charge air / scavenging air line and the charge air cooler.
1)
2)
Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 :
A-weighted emission sound pressure level
In the event of divergent insulation designs, the engine builder must
ensure that equivalent acoustic insulating measures are taken.
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Operation Manual / TPL76-C
4 Operation / 4.1 Noise emissions
Suggestion for noise insulation of the bellows
01 Compressor casing
02 Bellows
04 Insulation pads
05 Insulation mat (at least 15 mm)
03 Charge air duct / scavenging 06 Sheet metal cover
air line
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4 Operation / 4.2 Servicing work
4.2 Servicing work
Service work to be carried out during operation involves visual checks,
monitoring, measuring, inspection work and functional checks. It is then
possible for changes to the turbocharger to be identified and rectified.
In this way, it can be ensured that the turbocharger remains in full work-
ing order.
CAUTION
Service intervals
Service work on the turbocharger that is neglected or carried out too
late can lead to excessive contamination and wear as well as operating
failures.
u Carry out service work at specified time intervals.
CAUTION
Shortened service intervals
Despite observance of the service intervals, unusual loads, such as sev-
eral start-stops a day, harsh environmental factors, poor fuel quality or
heavy installation vibration can lead to premature machine damage.
u A shortened service interval must be arranged with ABB Turbo Sys-
tems.
NOTICE
Service inspection after 5 years
To prevent age- and stoppage-related machine damage, an inspection
by an ABB Turbocharging Service Station is recommended at the latest
5 years after the last service.
4.2.1 Service work every 25 … 50 hours
u Visual inspection for air, exhaust gas, water and oil leaks.
u Record operating data and enter it in the engine logbook.
u Clarify the cause of any variances.
CAUTION
Unknown changes during operation
The consequences can range from an impairment to a breakdown.
u Have unknown causes clarified by an ABB Turbocharging service sta-
tion.
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4 Operation / 4.2 Servicing work
4.2.2 Entries in engine logbook
By monitoring the engine, conclusions can be drawn about the tur-
bocharger performance.
The following operating data and measured values must be entered reg-
ularly in the engine manufacturer's engine logbook:
¡
¡
¡
¡
¡
¡
¡
¡
¡
Engine performance and speed
Air intake temperature
Exhaust gas temperature in front of and behind the turbine
Pressure of charge air
Pressure drop in charge air cooler
Lubricating oil pressure and lubricating oil temperature
Air temperature behind compressor and charge air cooler
Turbocharger speed
If provided
Pressure loss in air filter
4.2.3 Servicing work according to the engine
manufacturer's instructions
Oil filter
u Clean or replace oil filter in supply line to turbocharger when engine is
not running.
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4 Operation / 4.2 Servicing work
4.2.4 Service work every 8000 … 12000 hours
The inspection and assessment of the rotor and the bearing parts must
be carried out by an official ABB Turbocharging service station.
u Disassemble turbocharger.
u Measure clearances.
u Clean the turbine and compressor wheels and inspect for damage.
u Clean the turbine and compressor casings and inspect for any cracks
and erosion or corrosion.
u Clean bearing casing and blow air through oil ports.
u Clean nozzle ring and check for cracks and erosion.
u Inspect and assess bearing parts and rotor.
4.2.5 Service work every 24000 … 36000 hours
The replacement of bearing parts and the inspection and assessment of
the rotor must be carried out by an ABB Turbocharging Service Station.
u Disassemble turbocharger.
u Clearance measurement.
u Clean the turbine and compressor wheels and inspect for damage.
u Clean turbine casing as well as compressor casing and check for any
cracks and erosion or corrosion.
u Clean bearing casing and blow air through oil ports.
u Clean nozzle ring and check for cracks and erosion.
u Dismantle, inspect and balance the rotor.
u Replace plain bearings with original parts from ABB Turbo Systems.
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4 Operation / 4.3 Replacement intervals for turbocharger components
4.3 Replacement intervals for turbocharger
components
Rotating components
The recommended replacement intervals for the compressor and turbine
wheels due to stress caused by centrifugal forces and load cycles are cal-
culated under consideration of the operating conditions while applying
the safety concept for rotating components. They can be found on the
turbocharger rating plate. Incalculable influencing parameters can
shorten the recommended replacement intervals for the rotor, see Influ-
encing parameters.
Non-rotating components
The expected replacement intervals for non-rotating components and
bearing parts are extremely dependent upon system-specific operating
conditions, see Influencing parameters.
When the specified, periodic inspections are carried out, the individual
components are inspected for wear and tear and replaced if necessary.
In this way, trouble-free operation is ensured.
Influencing parameters
The following parameters influence the replacement intervals for tur-
bocharger components:
Parameters influencing bearing parts
¡
Poor quality of the lubricating oil (lubrication oil filter system, condi-
tion of lubricating oil)
¡
¡
Unusual loads (vibration, start/stop frequency)
Non-permissible state of rotor unbalance
Parameters influencing non-rotating components exposed to
exhaust gas
¡
¡
¡
¡
¡
Fuel quality (gas, MDO, HFO)
Load profile (thermal load changes, number of starts/stops)
Temperature level of exhaust gas
Turbine cleaning frequency
Procedure for turbine cleaning
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4 Operation / 4.3 Replacement intervals for turbocharger components
Parameters influencing rotating components exposed to exhaust
gas
¡
¡
¡
¡
Fuel quality (gas, MDO, HFO)
Turbine cleaning frequency
Procedure for turbine cleaning
Load profile
Expected replacement in-
tervals [h]
Component
Gas inlet casing
Gas outlet casing
Nozzle ring
Turbine diffuser / cover ring
Other casings
GAS / MDO
50000 … 100000
50000 … 100000
35000 … 50000
35000 … 50000
100000
HFO
25000 … 50000
35000 … 100000
25000 … 50000
25000 … 50000
100000
Axial bearing components
Radial bearing components
24000 … 36000
24000 … 36000
- -
24000 … 36000
24000 … 36000
≥ 12000
Turbine blades
(due to wear)
Recommended replace-
ment intervals [h]
Rotor components
See rating plate information
GAS
MDO
HFO
= Gas Engine
= Marine Diesel Oil
= Heavy Fuel Oil
NOTICE
The specified values are guides and not guaranteed. (See Influencing
parameters.)
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4 Operation / 4.4 Speed measurement
4.4 Speed measurement
A speed measuring system permits continuous monitoring of the tur-
bocharger speed.
CAUTION
Do not use cables as a climbing aid
If you pull the speed measurement cables too hard, contacts can be
pulled out.
u Do not tension the speed measurement cables.
Part number
42047
Description
Screw plug
86505
86515
86526
Speed sensor
Cable connector for 86505
F/I converter
86528
Tachometer
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4 Operation / 4.4 Speed measurement
4.4.1 Speed differences with multiple turbochargers per
engine
The speeds of all turbochargers on one engine differ only slightly from
each other in normal operation.
The difference between the highest and the lowest turbocharger speed
must not be more than 3 % relative to the speed limit nBmax
.
If this permissible range of difference is exceeded, the following steps
must be carried out:
u Reduce engine performance immediately until the highest turbochar-
ger speed no longer exceeds 70% of nBmax
.
u If the engine cannot be stopped, continue to run at this reduced en-
gine performance or turbocharger speed.
u If the turbocharger surges continuously, engine performance must be
reduced further.
u Measure the temperatures in the air and gas lines to and from the tur-
bochargers and compare them with standard values.
If the engine can be stopped for a short time:
u Inspect the air and gas lines as well as the turbocharger and eliminate
any problems.
u In any event, it is recommended that you contact the nearest ABB Tur-
bocharging Service Station.
4.4.2 Assembly
If the speed sensor is not fitted on the turbocharger, the following pro-
cedure must be adopted to fit it:
w Engine and turbocharger are not running.
w The turbocharger lubricating system is switched off.
u Remove screw plug (42047) from bearing casing.
NOTICE
Part position
The position of the screw plug for measuring the speed is marked "n"
on the bearing casing.
u Screw in speed sensor (86505) as far as it will go and tighten to
torque specified in table. (See chapter Table of tightening torques.)
u Connect speed sensor using cable connector (86515).
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4 Operation / 4.4 Speed measurement
4.4.3 Replacing the speed sensor
WARNING
Hot cable connector and hot speed sensor
Risk of burning. During operation, the cable connector and the speed
sensor can reach temperatures exceeding 100 °C.
u Wear safety gloves when removing the cable connector and speed
sensor.
Wear safety gloves to protect against thermal hazards.
u Reduce engine performance to the idling speed, then stop the engine.
u Switch off the lubricating oil supply to the turbocharger.
u Disconnect the cable connector from the speed sensor.
u Screw out defective speed sensor.
u Screw in a new speed sensor to the stop.
u Observe the tightening torque (see the table of tightening torques in
the chapter entitled Disassembly and assembly).
NOTICE
Sealing of the speed sensor
The speed sensor is designed with a sealing lip and does not require
any additional gasket for assembly.
u Connect cable connector to speed sensor.
u Switch on lubricating oil supply to turbocharger.
4.4.4 Failure of speed measuring system
Possible reasons for failure of the speed measuring system are de-
scribed in the chapter Troubleshooting.
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4 Operation / 4.5 Stopping the engine
4.5 Stopping the engine
CAUTION
Stopping the engine
Heat in the turbocharger must be dissipated by the further circulating
lubricating oil.
u Allow the engine to continue running at idling speed for a further 10
minutes before stopping.
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Operation Manual / TPL76-C
5 Maintenance / 5.1 Foreword to Maintenance
5 Maintenance
5.1 Foreword to Maintenance
Maintenance and servicing work involves regular visual checks and clean-
ing to ensure that the turbocharger and its attached units function
trouble-free.
¡
¡
The external condition and how dirty the cleaning points specified in
this chapter are, must be established by visual checks at the spe-
cified intervals.
The safety precautions must be observed during all maintenance and
servicing work.
The cleaning points described in the following are:
¡
¡
¡
Filter silencer
Compressor
Turbine and nozzle ring
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5 Maintenance / 5.2 Cleaning the filter silencer
5.2 Cleaning the filter silencer
5.2.1 Filter silencer and connecting rod
81265
81269
81266
81272
E
Filter ring (if provided)
Connecting rods
Cover grid
81136 Absorption segment
81137 Sheet-metal covering
81135 Filter silencer body
81273 Lock nut
Screwdriver
Insert unit = absorption segment + sheetmetal covering
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5 Maintenance / 5.2 Cleaning the filter silencer
Removing and cleaning filter silencer
If provided
u Remove filter strip (81265).
u Rinse filter strip (81265) using water with detergent additive or, if very
dirty, soak it and squeeze out carefully. Rinse it in cold water. Avoid
rough treatment (not a jet of water).
NOTICE
How dirty the filter strip (81265) is, depends on how clean the drawn-in
air is. Clean filter strip every 500 hours of service or more frequently if
necessary.
u Unscrew and remove lock nuts (81273).
u Unscrew and remove screws (81272) for connecting rods (81269).
u Remove connecting rods (81269).
u Carefully remove cover grids (81266).
u Pull out insert units (E), bend open sheet metal coverings (81137) and
then remove absorption segments (81136).
u Clean the absorption segments (81136).
During cleaning, ensure that the absorption segments (81136) are
only cleaned with a mild jet of compressed air, soft brush or a damp
cloth. Otherwise there is a risk of damage or deformation.
NOTICE
Replace heavily contaminated or damaged parts with original parts
from ABB Turbo Systems.
Fitting filter silencer
u Assemble insert units (E) by putting fleece segments (81136) into
sheet-metal cover (81137).
u Bend back sheet-metal cover (81137) to original shape.
u Put insert units (E) into slot guides in filter silencer body (81135).
NOTICE
If a cleaning container is fitted to the filter silencer (optional depending
on turbocharger type), the water injection line must now be refitted.
(See also following section Fitting cleaning pipe.)
u Put cover grids (81266) uniformly into correct position.
u Push connecting rods (81269) through clips on cover grids (81266).
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5 Maintenance / 5.2 Cleaning the filter silencer
CAUTION
If the connecting rods (81269) are not located correctly in their recesses
on the filter silencer body (81135), the cover grids (81266) can twist and
shift. There is then a risk of foreign matter and dirt getting into the
compressor.
u Join connecting rods (81269) using screws (81272). When tightening
the screws (81272), ensure that connecting rods (81269) are located
correctly in recesses in filter silencer body (81135). Now tighten
screws (81272) alternately until the following maximum torque is
reached:
Screw
Tightening torque [Nm]
81272
20
u Screw lock nuts (81273) onto screw (81272) and tighten to following
torque:
Lock nut
Tightening torque [Nm]
81273
40
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5 Maintenance / 5.3 Cleaning the compressor during operation
5.3 Cleaning the compressor during operation
Approval by enginebuilder
These instructions for wet cleaning only apply when cleaning is carried
out with clean water and under the precondition that the enginebuilder
approves the process.
General
The contamination of the compressor stage (compressor wheel, wall in-
sert and diffuser) depends on the degree of purity of the air that is
drawn in.
Deposits can form in the flow channels if salt, oil mist, exhaust gas or
dust are sucked in with the air.
Consequences of contamination:
¡
¡
¡
¡
Impaired compressor efficiency
Higher exhaust gas temperatures
Increased fuel consumption
Increased rotor unbalance
Periodic cleaning of the compressor during operation prevents or delays
any major increase in contamination. It does not, however, replace the
regular service work, during which the turbocharger is completely dis-
mantled and the compressor is cleaned mechanically.
Cleaning interval
The interval between periodic cleaning is very dependent on the operat-
ing conditions. In general, cleaning should be carried out every 25 ... 100
operating hours.
Should the specified cleaning intervals prove incompatible with engine
operation, please contact ABB Turbo Systems.
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5 Maintenance / 5.3 Cleaning the compressor during operation
Cleaning method
Cleaning of the compressor during operation is carried out using the
cleaning method described in the following:
¡
Wet cleaning
This cleaning method has been tested and approved by ABB Turbo Sys-
tems.
Principle of wet cleaning
To clean the compressor stage during operation, water is injected in
front of the compressor wheel.
The water does not act as a solvent, but the contamination deposit is re-
moved by the mechanical impact of the droplets. This is a very suitable
process, provided that the degree of contamination is not too high.
CAUTION
Corrosion and deposits when cleaning
Damage and impairment of turbocharger parts due to salt water and
cooling water additives
u Don't use salt water for cleaning, but only clean fresh water.
CAUTION
Uncontrolled volumes of water
Uncontrolled volumes of water can damage the turbocharger and the
engine.
u Never connect the water line without the orifice specified for the tur-
bocharger.
CAUTION
Formation of ice at low temperatures
Damage to turbocharger due to the formation of ice during wet clean-
ing if the intake air temperatures are too low.
u Never carry out wet cleaning if intake air temperatures are under
5 °C.
V-engines
In the case of V-engines with several turbochargers on each engine, we
recommend parallel cleaning of the compressors. This cleaning process
is faster and the risk of turbocharger surging is reduced.
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5 Maintenance / 5.3 Cleaning the compressor during operation
5.3.1 Wet cleaning with orifice plate on filter silencer (XC2)
Operating state prerequisites for wet cleaning XC2
WARNING
Increased stress on material
During cleaning of the compressor at an engine load of 85 to 100 %, the
stress on the material of the compressor-end turbocharger parts can
be increased.
u No personnel is allowed to be present in the vicinity of the tur-
bocharger during compressor cleaning.
u Compressor cleaning must be activated from the engine control
panel.
Wet cleaning procedure for compressor with XC2
u Trigger water injection according to the specifications of the en-
ginebuilder.
u The specified water pressure upstream of the connection to the tur-
bocharger must be maintained.
u Operate engine for at least five additional minutes after cleaning.
Not more than three cleaning cycles should be conducted consecutively.
Cleaning parameters per turbocharger compressor
Product Engine load Water pres-
Water
Water Ø orifice
sure
injection time temper- [mm]
[bar]
[sec]
ature
[°C]
TPL76-C 50 … 100%
3
10
5 … 50
2.9
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5 Maintenance / 5.3 Cleaning the compressor during operation
Surging of the compressor stage
Should repeated surging of the compressor stage occur during com-
pressor cleaning, first the cleaning parameters as well as the engine-side
system must be checked with regard to deviations (e.g. an increased
pressure loss in the charge air cooler) and corrected if necessary.
If, despite correct settings, surging of the compressor stage occurs
while cleaning the compressor, as a remedial measure the engine load
can be reduced further while cleaning the compressor. The reduction of
the engine load can lead to a reduction in the effectiveness of the com-
pressor cleaning.
u To avoid a decreased engine availability, the compressor stage can be
cleaned at reduced engine load during the drying time after wet
cleaning of the turbine has been completed. (see section Wet cleaning
turbine and nozzle ring during operation). In this case, the water injec-
tion time for cleaning the compressor can be increased from ten to
forty seconds.
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5 Maintenance / 5.3 Cleaning the compressor during operation
5.3.2 Wet cleaning using external water-pressure vessel
(XC3)
Operating state prerequisites for compressor cleaning with XC3
In order to carry out a successful cleaning procedure that has been
tested and is recommended by ABB Turbo Systems, the following pre-
requisite must be met:
w Engine load 50 ... 85%
u Start cleaning cycle according to following description Wet cleaning
operation with XC3.
Operating procedure for compressor wet cleaning with XC3
Operating the water pres-
sure vessel
u The operating state prerequisites for compressor cleaning with XC3
must be fulfilled.
u Remove sealing plug (X).
u Fill vessel with required volume of clean water (see table Cleaning
parameters).
u Screw in sealing plug (X).
u Push the valve activator (Y) against the spring and hold it for 10 ... 15
seconds until the entire volume of water has been injected.
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5 Maintenance / 5.3 Cleaning the compressor during operation
u After cleaning, wait at least 5 minutes to allow turbocharger to dry.
The cleaning process can be repeated up to two times.
If the cleaning is still unsuccessful after three cleaning processes and the
engine values are unsatisfactory, it is recommended to have the tur-
bocharger checked and cleaned by an ABB Turbocharging Service Sta-
tion.
Cleaning parameters per turbocharger compressor
Product Engine load
Water temperature
[°C]
Contents of water ves-
sel
[dm3]
TPL76-C
50 ... 85%
5 … 50
1
Surging of the compressor stage
Should repeated surging of the compressor stage occur during com-
pressor cleaning, first the cleaning parameters as well as the engine-side
system must be checked with regard to deviations (e.g. an increased
pressure loss in the charge air cooler) and corrected if necessary.
If, despite correct settings, surging of the compressor stage occurs
while cleaning the compressor, as a remedial measure the engine load
can be reduced further while cleaning the compressor. The reduction of
the engine load can lead to a reduction in the effectiveness of the com-
pressor cleaning.
u To avoid a decreased engine availability, the compressor stage can be
cleaned at reduced engine load during the drying time after wet
cleaning of the turbine has been completed. (see section Wet cleaning
turbine and nozzle ring during operation). In this case, the water injec-
tion time for cleaning the compressor can be increased from ten to
forty seconds.
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5 Maintenance / 5.4 Cleaning turbine blades and nozzle ring in opera-
tion
5.4 Cleaning turbine blades and nozzle ring in
operation
The combustion of heavy fuel oil in diesel engines contaminates the tur-
bine blades and nozzle rings of turbochargers. The deposits on the tur-
bine components originate from the following combustion products:
¡
¡
¡
¡
¡
Soot
Molten ash
Cinder
Incompletely burned fuel
Sodium vanadyl vanadate
It is advisable to use fuels with a low ash, sulphur, sodium and vanadium
content. The fuel must also be correctly stored, prepared and handled.
We recommend using fuels with a vanadium-to-sodium mass ratio of
less than 3:1 so that the melting temperature of the sodium vanadyl
vanadate is as high as possible.
The amount of contamination increases over time, which is why regular
and correctly performed cleaning is important in order to remove the de-
posits that have formed.
Contaminated turbine components can cause a slight increase in char-
ging pressure because of narrowing of the turbine cross-section. The
contamination causes a drop in turbine efficiency, and the engine tem-
peratures downstream of the cylinder can increase. The engine perform-
ance must therefore be reduced if necessary.
The contamination of the turbine also causes rotor unbalance. Extremely
heavy contamination can lead to non-permissibly high unbalance of the
rotor.
Operating experience has shown that, in spite of regular cleaning during
operation, it is essential to carry out the overhauls during which the tur-
bine and the nozzle ring are cleaned mechanically. However, if cleaning is
carried out properly and the cleaning system is properly dimensioned,
the intervals between overhauls can be increased.
Wet cleaning interval
Cleaning method
The interval between periodic cleaning is very dependent on the operat-
ing conditions. As a rule, cleaning should be carried out every 50 to 200
operating hours.
When cleaning the turbine components during operation, use wet clean-
ing. This cleaning method has been tested and approved by ABB Turbo
Systems.
Prerequisites for wet cleaning are that the engine builder approves the
process and his instructions are followed.
Principle of wet cleaning
Wet cleaning makes use of various effects. Depending on the composi-
tion of the contamination, the individual effects with their different
levels of intensity have a varying influence on the cleaning result:
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5 Maintenance / 5.4 Cleaning turbine blades and nozzle ring in opera-
tion
¡
Erosion
The dirt is removed by the mechanical action of the impacting water
droplets.
¡
¡
Solubility
Water solubility of the contamination deposits in water.
Thermal shock
Spalling of contamination due to temperature difference.
CAUTION
Corrosion and deposits when cleaning
Damage and impairment of turbocharger parts due to salt water and
cooling water additives
u Don't use salt water for cleaning, but only clean fresh water.
Components at the turbine end are not cleaned until the engine has been
started or the engine load reduced. The exhaust gas temperature must
not exceed the value specified in the respective cleaning instructions
(see section PrerequisitesTPL-A/-C: Operating state prerequisites for
wet cleaning turbine and nozzle ring →57).
CAUTION
Reduced service life of the components
Failure to comply with the minimum stabilisation time before cleaning,
the prescribed turbine inlet temperatures and the drying time after
cleaning significantly reduces the expected service life of the compon-
ents.
u Comply with the cleaning parameters given in the tables.
V-engines
In the case of V-engines with several turbochargers on each engine, we
recommend parallel cleaning of both turbochargers. This cleaning pro-
cess is faster and the risk of turbocharger surging is reduced. We recom-
mend finding the most suitable method by performing trials.
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5 Maintenance / 5.4 Cleaning turbine blades and nozzle ring in opera-
tion
5.4.1 Wet cleaning turbine and nozzle ring during
operation
Prerequisites for wet cleaning of turbine
The following operating state and prerequisites have been tested and
approved by ABB Turbo Systems for the cleaning process:
u The engine has just been started or the engine load has been reduced
as far as possible (best cleaning is achieved at a load level of roughly
10 ... 15%).
u As soon as the turbine inlet temperature is stable and below 430 °C,
wait at least another 10 minutes for the charger parts to cool down.
u Start cleaning cycle according to following description Wet cleaning
procedure.
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5 Maintenance / 5.4 Cleaning turbine blades and nozzle ring in opera-
tion
Layout of cleaning pipes
Wet cleaning procedure for turbine during operation
u Meet prerequisites and operating state requirements without fail be-
fore cleaning!
u Make sure water supply (01) is connected, turned on and guaranteed.
u Open drain pipe (08, 09), if provided.
u Switch over 3-way valve (04) from scavenging air mode to water sup-
ply.
u Set the required volume of water on the flowmeter as shown in the
table (see table Cleaning parameters).
u Shut off the water supply again by switching the 3-way valve (04) to
scavenging air mode after injecting the required volume of water.
u The injection process has been completed.
u Close drain hole (if provided) above drain pipe (08, 09).
u After cleaning, wait with engine running for at least 10 minutes
without changing load to allow turbocharger to dry.
CAUTION
Corrosion damage to bearing casing
In order to avoid corrosion damage to the bearing casing, it is advisable
to carry out an additional 30 minutes of operation with TTE > 500°C
after the 10 minute drying time.
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5 Maintenance / 5.4 Cleaning turbine blades and nozzle ring in opera-
tion
Recommendation for wa-
ter pressure
It is necessary to have the corresponding water pipe pressure in order to
achieve the correct water flow rate (see table Cleaning parameters). If
the water pressure is too low, the water flow rate specified in the table
will not be obtained. In this case, the cleaning effect will be decreased.
Repeating cleaning cycles immediately after each other must be avoided
as this can lead to high mechanical loading and consequently to a reduc-
tion in the service life of the components.
If cleaning is unsatisfactory, the length of the process can be extended.
If the injection time is extended, it must be ensured that no unaccept-
able volume of water collects in the gas outlet casing. To avoid this, a
drainage system for the gas outlet casing should be installed and open
during the cleaning process. If a drainage system is not provided, the in-
jected volume of water can be controlled by a flowmeter in the water
supply. The maximum volume of water allowed in individual cases must
be determined together with an ABB Turbocharging Service Station. The
influence of the cleaning water on peripheral equipment, such as a
boiler, must be clarified by the operator.
Points to remember when
cleaning
The following points must be observed with regard to draining the gas
outlet casing:
¡
¡
¡
The exhaust gas temperature behind the turbocharger drops signi-
ficantly when cleaning (typical turbocharger outlet temperatures dur-
ing cleaning: 60 ... 180 °C).
Depending on the engine load, water might run out of the drain pipe.
This outflow might not start for two or three minutes, or it might not
occur at all.
If the drainage of the gas outlet casing is omitted, the turbocharger
speed and/or the gas inlet temperature must be monitored during
the cleaning process. If the load is too low, water can collect in the
gas outlet casing. Indicators for this are a sudden severe drop in the
turbocharger speed or a very large increase in the gas inlet temperat-
ure. In such cases, the cleaning operations must be stopped and the
cleaning cycle restarted with reduced water pressure or higher en-
gine load.
Cleaning parameters for wet cleaning of turbine and nozzle ring
Product Max. temperat-
ure when starting
cleaning
Injection time Water flow rate per tur-
bocharger at
pWater = 3 bar
t i [min]
TTI [°C]
MW [l/min]
TPL76-C
430
10
37
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5 Maintenance / 5.5 Cleaning components mechanically
5.5 Cleaning components mechanically
5.5.1 Introduction
Compressor wheels can be heavily contaminated by badly filtered intake
air, as can turbines by heavy fuel oil operation or coked oil. Such contam-
ination may possibly no longer be removed through cleaning during op-
eration and must be cleaned mechanically during the standard service in-
tervals (see chapter entitled Service work).
Professional overhauling of the components by an ABB Turbocharging
Service Station is required, preferably using the cleaning method de-
scribed in the following.
CAUTION
Choosing cleaning tools
Turbocharger components are sensitive to mechanical damage. The
use of needle guns or other impact tools, for example, damages the
components. Depending on the specification, nozzle rings have pro-
tective coatings, which can also be damaged.
u Only use soft tools such as scouring cloths, brushes or wire brushes.
u In the event of heavy contamination, the cleaning methods de-
scribed in this chapter such as soaking can be repeated until a satis-
factory result has been achieved.
The disassembly and assembly of the components is described in
chapter Fitting and dismantling.
u Dispose of contaminated water and cleaning agents in an environ-
mentally compatible manner, professionally and in accordance with
valid local regulations.
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5 Maintenance / 5.5 Cleaning components mechanically
5.5.2 Turbine-end, non-rotating parts
WARNING
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or
contact with them may be harmful to health.
u Do not breathe in these substances and avoid contact with the skin.
u Ensure proper ventilation.
u Observe the information in the material safety data sheet for the op-
erating materials and supplies.
u Wear personal protective equipment (PPE) according to the material
safety data sheet.
u Comply with local legislation.
Wear safety goggles.
Wear safety gloves to protect against chemical hazards.
Wear a respiratory mask to protect against gases.
Baked-on layers of contamination, for example from heavy fuel oil or
coked oil, occur at the turbine end. The following performance-relevant
parts can be cleaned according to the following description.
56001 Nozzle ring
63000 Turbine diffuser
u Place contaminated parts in hot water or in a liquid such as brake
cleaner, so that the contamination softens.
u Brush off the contamination or remove it with a steam cleaner.
u Repeat the soaking and brushing if necessary.
u Completely remove any solvents from the parts in clean water.
u Dry components completely.
u Spray cleaned surfaces with penetrating oil. Do not spray the outer
surfaces of the turbocharger.
u Dispose of contaminated water and cleaning agent in accordance
with the specifications in the safety data sheet.
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5 Maintenance / 5.5 Cleaning components mechanically
5.5.3 Cartridge group – General
CAUTION
Corrosion
If the cartridge group is not put into operation again immediately after
cleaning, parts may corrode.
u Re-install and use the cartridge group immediately after cleaning.
u Remove turbocharger from the engine (see chapter Removal and in-
stallation).
u Remove cartridge group (see chapter Disassembly and assembly).
First clean the compressor end and then the turbine end in accordance
with the following description.
5.5.4 Cleaning the cartridge group on the compressor end
CAUTION
Selection of the cleaning agent
Cleaning agents which contain chlorine attack metals.
u Use only pH-neutral cleaning agents which do not attack metals.
u Observe safety data sheet.
CAUTION
Water and contamination in the cartridge group
If water or contamination penetrates the cartridge group, this can im-
pair the function of the turbocharger and damage parts inside the cart-
ridge group.
u Make sure that no water or contamination can enter into the cart-
ridge group.
u Clean compressor wheel with a scouring cloth or soft brush soaked in
water with household cleaning agent. Do not use any wire brushes!
u Dry the compressor wheel and the gap between the compressor and
the bearing casing with a weak jet of compressed air.
u Lightly spray the gap between the compressor and the bearing casing
with penetrating oil.
u Dispose of contaminated water and cleaning agent in accordance
with the safety data sheet.
5.5.5 Cleaning the cartridge group on the turbine end
Soaking the contamination
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5 Maintenance / 5.5 Cleaning components mechanically
Baked layers of contamination from fuel residue or coked oil may occur
at the turbine end. The contamination can be removed by soaking and
brushing. The procedure for soaking the layers of contamination as well
as for cleaning the turbine are described in the following.
To soak the layers of contamination on the turbine, the cartridge group
can be immersed vertically in a container with fluid.
The cartridge group must be rotated to do this.
u Two cranes (or chain blocks) must be used for the rotating operation.
Suspending the chain block directly from the crane and rotating the cart-
ridge group is not permitted because of the risk of damage to the com-
pressor wheel.
Cartridge group with one central suspension point
CAUTION
Damage to compressor wheel
The lifting gear must not touch the compressor wheel at any time dur-
ing rotation.
u Choose appropriate lifting gear length.
1. Suspend cartridge group from normal suspension point and suspend
from first crane.
2. Secure two lifting loops with swivel lifting eyes in the lower push-off
threads and suspend from a second crane.
3. Rotate cartridge group horizontally by lifting the second crane.
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5 Maintenance / 5.5 Cleaning components mechanically
4. When the cartridge group is horizontal, secure one chain block to one
of the upper push-off threads using a swivel lifting eye and suspend
from the second crane.
5. Tighten chain block until entire cartridge group is suspended from
second crane.
6. Remove loop from first crane.
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5 Maintenance / 5.5 Cleaning components mechanically
Cartridge group with two side suspension points
Or use two swivel lifting eyes at top.
CAUTION
Damage to compressor wheel
The lifting gear must not touch the compressor wheel at any time dur-
ing rotation.
u Choose appropriate lifting gear length.
1. Suspend cartridge group from the two side suspension points on the
crane using two lifting loops.
or
Attach two swivel lifting eyes to the side and suspend the cartridge
group from the crane using two lifting loops.
2. Attach third lifting loop with swivel lifting eye to thread of oil outlet
flange.
3. Rotate the cartridge group into a horizontal position by lifting.
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5 Maintenance / 5.5 Cleaning components mechanically
4. When the cartridge group is suspended horizontally, attach a chain
block to the swivel lifting eye and attach to the first crane.
5. Tighten chain block until entire cartridge group is suspended from
first crane.
6. Remove loop from second crane.
CAUTION
Selection of the cleaning agent
Cleaning agents which contain chlorine attack metals.
u Use only pH-neutral cleaning agents which do not attack metals.
u Observe safety data sheet.
u Fill the tank with soaking liquid.
u Only immerse the cartridge group until all blades are covered with
cleaning agent.
NOTICE
Heating the liquid
To shorten the soaking time the liquid can be heated to maximum
60 ºC.
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5 Maintenance / 5.5 Cleaning components mechanically
WARNING
Heating up of cleaning agents and operating fluids
When cleaning agents or operating fluids are heated up, explosive va-
pours can be produced which are hazardous to health.
u Observe the information in the material safety data sheet.
Wear a respiratory mask according to material safety data sheet.
CAUTION
Water and contamination in the cartridge group
If water or contamination gets into the cartridge group, the turbochar-
ger function may be impaired and parts in the cartridge group may be
damaged.
u Place cartridge group on suitable wooden or metal supports.
u Allow the layers of contamination on the turbine to soak for at least
four hours.
Removing contamination
WARNING
Health hazard due to soot particles
If soot particles enter the eyes or respiratory tract, this can be harmful
to health.
u Avoid the formation of dust.
u Vacuum up dust with a suitable vacuum cleaner.
u Wear a respiratory mask to protect against particles (P1 or P2 mask).
u Wear safety goggles.
Wear safety goggles.
Wear a respiratory mask to protect against dusts.
Wear safety gloves to protect against mechanical hazards.
u Raise the cartridge group and align horizontally.
u Remove contamination manually with a soft brush or wire brush.
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5 Maintenance / 5.5 Cleaning components mechanically
CAUTION
Water and contamination in the cartridge group
If water or contamination gets into the cartridge group, the turbochar-
ger function may be impaired and parts in the cartridge group may be
damaged.
u Make sure that water or contamination does not get into the gap
between the sealing cover and turbine.
CAUTION
Non-permissible rotor unbalance after cleaning
Invisible and unevenly distributed residual contamination deposits lead
to rotor unbalance. This can result in bearing or turbocharger damage.
u Remove all traces of contamination from the turbine.
u After brushing off the contamination, fill the tank with clean water,
not salt water.
u Submerge the turbine of the cartridge group in clean water, so that
loose particles of contamination detach completely.
u Lift the cartridge group.
u Dry turbine and gap between turbine and sealing cover with a weak
jet of compressed air.
u Lightly spray turbine and gap between turbine and sealing cover with
penetrating oil.
u Rotate cartridge group back to horizontal position (described proced-
ure in reverse order, see Cleaning the cartridge group on the turbine
end →62).
u Dispose of contaminated water and cleaning agent in accordance
with the specifications in the safety data sheet.
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Operation Manual / TPL76-C
6 Troubleshooting / 6.1 Malfunctions when starting
6 Troubleshooting
6.1 Malfunctions when starting
Sluggish start-up
Possible causes
Elimination
Turbochar- Turbocharger contaminated
Clean it
ger
Damaged bearing
Rubbing rotor
Contact an ABB Turbocharging
Service Station
Foreign object in turbocharger
Vibrations
Possible causes
Elimination
Turbochar- Rotor unbalance
Contact an ABB Turbocharging
Service Station
ger
Damaged turbine or com-
pressor
Damaged bearing
Rubbing of rotating parts
Normal behaviour, no malfunction
Turbochar- Minor uniform wear around the periphery of rotor components,
ger
caused by slight local rubbing of adjacent components, is per-
missible. The compressor blades and turbine blades are then
shortened somewhat. Certain tolerances must be observed to
avoid a significant loss of efficiency.
¡
If there is any doubt about the extent of rubbing, then an
ABB Turbocharging Service Station must be contacted.
¡
Have a dimension check carried out by an ABB Turbochar-
ging Service Station.
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6 Troubleshooting / 6.2 Surging of the turbocharger
6.2 Surging of the turbocharger
Turbocharger surging
Possible causes
Elimination
Engine
Guard in front of the tur-
Clean / replace it
bocharger is contaminated
or damaged
Turbocharger Filter silencer or diffuser
Clean it
Clean it
contaminated
Heavy deposits of dirt in the
turbine or nozzle ring
Charge air
cooler
Cooler contaminated
Charge air duct blocked
CAUTION
Prolonged or periodic surging
Possible damage to components, such as the compressor wheel, tur-
bine blades, bearings and filter silencer
u Have the cause clarified immediately by an ABB Turbocharging ser-
vice station and rectified.
u Have components inspected for damage and, if necessary, replaced
by an ABB Turbocharging service station.
Sporadic surge blows
Surging of the turbocharger can occur during certain operating condi-
tions such as when reducing the engine performance quickly when man-
oeuvring. At the same time, the flow direction in the compressor is mo-
mentarily reversed. Such sporadic surge blows do not impair the safe
operation of the turbocharger.
¡
A surge blow is accompanied by a loud bang and escape of hot air
from the filter silencer.
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6 Troubleshooting / 6.3 Malfunctions during operation
6.3 Malfunctions during operation
Lubricating oil pressure too low
Possible causes
Elimination
Engine
Oil filter heavily contaminated Clean it
Defective oil pump in lubricat- Check / replace it
ing system
Manometer display wrong
Replace the manometer
Turbochar- Rotor axial clearance too large Contact an ABB Turbocharging
ger
Service Station
Reduction in speed
Possible causes
Elimination
Engine
Defects of connected cylinders Contact the enginebuilder
when pulse charging
Turbochar- Heavy contamination of the
Clean it
ger
turbine
Damaged rotor components or Contact an ABB Turbocharging
bearing Service Station
Pipes
Defects such as leaks in the ex- Make repairs
haust gas pipes or charge air
ducts
Increase in speed
Possible causes
Elimination
Turbochar- Heavily contaminated nozzle Contact an ABB Turbocharging
ger
ring (with 4-stroke application) Service Station
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
6 Troubleshooting / 6.3 Malfunctions during operation
Exhaust gas temperature too high
Engine performance and engine speed unchanged
Possible causes
Engine Malfunctioning injection
system
Elimination
Repair it or contact the manu-
facturer
Turbocharger Air starvation, for example Clean it
filter silencer clogged with
dirt
Compressor / turbine con-
taminated
Exhaust counterpressure
too high
Clean or repair the boiler or ex-
haust silencer
Enlarged flow cross-section Contact an ABB Turbocharging
of the nozzle ring due to de- Service Station
formed blade trailing edges
Damaged or eroded turbine
Charge air
cooler
Cooler contaminated
Clean it
Cooling water volume too Top up the water
low
Entry temperature of cool- Inspect / clean the cooling sys-
ing water too high
tem
Inadequate ventilation
Improve the ventilation
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
6 Troubleshooting / 6.3 Malfunctions during operation
Charge air pressure too low
Engine performance and engine speed unchanged, air intake condition
normal
Possible causes
Elimination
Engine
Air receiver leaking
Make repairs
Gas piping between the engine
and the turbine leaking
Poorly adjusted injection sys- Correct it
tem
Poorly adjusted valve control
Turbochar- Manometer display wrong
Replace the manometer
Repair the leak
Clean it
ger
Line to manometer leaking
Contaminated filter silencer
causing excessive loss of pres-
sure
Compressor / turbine contam-
inated
Damaged compressor / tur-
bine
Contact an ABB Turbocharging
Service Station
Exhaust counterpressure too Clean or repair the boiler or ex-
high
haust silencer
Charge air pressure too high
Engine performance and engine speed unchanged, air intake condition
normal
Possible causes
Engine Malfunctioning injection sys- Repair it or contact the manu-
tem facturer
Elimination
Poorly adjusted injection sys- Correct it
tem
Engine performance higher
than expected
Turbochar- Manometer display wrong
Check engine performance
Replace the manometer
ger
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
6 Troubleshooting / 6.4 Malfunctions when stopping
6.4 Malfunctions when stopping
Noises during run-down
Possible causes
Elimination
Turbochar- Turbocharger contaminated
Clean it
ger
Damaged bearing
Rubbing rotor
Contact an ABB Turbocharging
Service Station
Foreign object in turbocharger
Run-down time too short
Possible causes
Elimination
Turbochar- Turbocharger contaminated
Clean it
ger
Damaged bearing
Rubbing rotor
Contact an ABB Turbocharging
Service Station
Foreign object in turbocharger
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
6 Troubleshooting / 6.5 Speed measurement system
6.5 Speed measurement system
Possible causes
Elimination
Signal amp-
Fitting error
The screw plug for the sensor is fitted with
a gasket.
litude non ex-
istent or poor
When fitting the speed sensor, this gasket
must be removed. If it is fitted by mistake,
the distance from the sensor tip to the sig-
nal-generating sealing disc increases. As a
result, the voltage amplitude of the speed
signal decreases, which can cause prob-
lems for the evaluation electronics.
This problem is eliminated by removing
the gasket.
Defective sensor Contact ABB Turbocharging service sta-
tion.
Measured
speeds too
high
Dirty sensor tip The sensor tip is magnetic and can thus at-
tract metal particles. As a result, the dis-
tance to the auxiliary bearing decreases,
which can lead to amplification of the
noise component and consequently to
faulty triggering.
Remove the sensor, clean its tip and refit
the sensor using the specified tightening
torque.
Measured
- -
Contact ABB Turbocharging service sta-
speed too low
tion.
Other sources - -
If none of the above measures eliminates
the problem, we recommend that you have
the speed measuring system inspected by
an official ABB Turbocharging service sta-
tion.
of errors
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
7 Removal and installation / 7.1 Turbocharger weight
7 Removal and installation
7.1 Turbocharger weight
Lifting gear with a sufficient load limit must be used for removing and
installing the turbocharger. The following weight specification is the
heaviest variant possible. This standard value may deviate from the data
on the rating plate depending on the specification.
Weight [kg]
TPL76-C
4070
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
7 Removal and installation / 7.2 Removing the turbocharger
7.2 Removing the turbocharger
u A suitable suspension device (as illustrated) must be used when re-
moving and installing the turbocharger. The suspension device is not
supplied by ABB Turbo Systems.
u Disconnect all gas, air and oil pipes in accordance with the engineb-
uilder’s instructions.
CAUTION
Oil orifice plates
An orifice plate for adjusting the oil pressure is fitted in each of the two
oil inlet channels in the bearing casing. When the cartridge group, the
bearing casing or the turbocharger is fitted to the engine, it must be
ensured that the orifice plates that are specified for the turbocharger
have been installed in the two oil inlet channels.
u Check correct installation of oil orifice plates.
Suspension dimension
Distance in [mm]
A
B
C
860
1210
800
Use the two suspension eyes on the bearing casing (L1, L2) (observe the
marking on the insulation).
The two suspension eyes on the turbine-end foot (T1, T2) are used for
horizontal alignment of the turbocharger.
u Remove the insulation shell from the bearing casing and turbine-end
foot. Leave the remaining insulation on the turbocharger.
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
7 Removal and installation / 7.2 Removing the turbocharger
Version with compressor wheel cooling system
u Dismantle air supply line. (See also chapter entitled Preliminary re-
marks / Layout and functionality)
u Inspect the lifting gear.
u Secure lifting gear to the suspension eyes of the bearing casing and
the turbine-end foot.
u Unplug the cable connector on the speed sensor.
u Unscrew the fixing screws on the feet.
u Lift the turbocharger off the engine and set it down to one side.
WARNING
If the turbocharger is not sufficiently supported or not supported at all
during removal and installation, it may tip over and cause severe injury
to personnel or accidents resulting in fatalities.
u Support the turbocharger at a suitable point.
u Cover the oil connection.
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
7 Removal and installation / 7.3 Installing the turbocharger
7.3 Installing the turbocharger
u Remove the cover from the oil connection.
u Inspect the lifting gear.
u Fasten the lifting gear to the suspension lugs on the bearing casing
and the turbine-end foot.
CAUTION
Oil orifice plates
An orifice plate for adjusting the oil pressure is fitted in each of the two
oil inlet channels in the bearing casing. When the cartridge group, the
bearing casing or the turbocharger is fitted to the engine, it must be
ensured that the orifice plates that are specified for the turbocharger
have been installed in the two oil inlet channels.
u Check correct installation of oil orifice plates.
u Fit the turbocharger to the engine.
u Tighten the fixing screws on the foot.
NOTICE
The fastening specifications for the foot fixing screws are supplied to
the engine builder by ABB Turbo Systems and given in his manual.
u Fasten the gas, air and oil lines in accordance with the engine
builder’s instructions.
Version with compressor wheel cooling system
u Fit the air supply line (also see the chapter entitled Preliminary re-
marks / Layout and functioning).
u Plug in the cable connector on the speed sensor.
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.1 Introduction
8 Disassembly and assembly
8.1 Introduction
CAUTION
Further work
Further tasks, which are not described here, may be carried out only by
trained personnel from an ABB Turbocharging service station.
u Only carry out those tasks that are described in this chapter.
u Mark the casing position for assembly.
Identifying assembly devices
Not all assembly devices are marked with a part number. They can be
identified using the tool list. This list is enclosed in the toolbox.
WARNING
Maintaining assembly devices
Assembly devices must be checked for damage before and after use.
u Visually check for corrosion, cracks, deformation and wear.
u Don't use damaged assembly devices, but replace them.
Customer spare parts set
Before beginning work, ensure that the required customer spare parts
sets are available.
u See chapter Spare parts.
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.1 Introduction
Tightening torques for turbocharger components
The specified tightening torques of screw connections for turbocharger
components must be observed. (See section Table of tightening
torques.)
Tightening torques for assembly devices of ABB Turbo Systems
If nothing else is described, the screws and nuts of the assembly devices
must be tightened down firmly.
WARNING
Suspended loads
Loads not suspended in compliance with regulations may lead to per-
sonal injury or accidents with fatal consequences.
u Attach turbochargers, assemblies or individual components only to
lifting gear which is in technically perfect condition and has suffi-
cient load capacity.
u Make sure the load is suspended properly on the crane hook.
u Do not let anyone stand beneath a suspended load.
Wear safety gloves to protect against mechanical hazards.
Wear safety helmet.
Definition of terms
¡
Suspension point
Defined load attachment point on a component or an assembly (blind
hole thread, eye, lug).
¡
Assembly device
Devices that are fitted on the turbocharger in order to obtain a sus-
pension point. Assembly devices are specially constructed and de-
signed for the defined use; they are not commercially available
products. Use assembly devices only for the described applications.
¡
Lifting gear
Equipment for lifting and transporting loads (ropes, chain block,
crane). Lifting gear is not supplied by ABB.
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.2 Module weights
8.2 Module weights
The specified weights of individual parts or assemblies are guides roun-
ded off to the next highest value.
Assemblies
Weights [kg]
Item Description
TPL76-C
280
70
1
2
3
4
5
Filter silencer
Axial air suction branch
Radial air suction branch
Compressor casing internal part
Wall insert
120
220
220
45
6
Diffuser
7
8
9
Compressor casing external part
Cartridge group
Turbine diffuser
310
900
80
10
11
12
13
Nozzle ring
23
250
18
Radial gas inlet casing with segment connection
Segment
Radial gas inlet casing with flange connection
190
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.2 Module weights
Complete compressor casing internal part
Weight [kg]
TPL76-C
490
NOTICE
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.
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.3 Removing and fitting filter silencer
or air suction branch
8.3 Removing and fitting filter silencer or air
suction branch
u Disconnect all air lines / ducts in accordance with engine builder’s in-
structions.
u Remove the insulation where necessary.
u Loop the lifting gear around the air suction branch.
u Unscrew the nuts (74027) and remove them together with their wash-
ers (74018).
u Remove the air suction branch and set it down to one side.
Installing the air suction
branch
u Install the air suction branch in reverse order.
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.3 Removing and fitting filter silencer
or air suction branch
Removing filter silencer
u Remove insulation where necessary.
u Pass lifting gear through rib on filter silencer and through eyelets at
rear.
u Unscrew nuts (74027) and remove them together with washers
(74018).
u Remove filter silencer and it set down to one side.
Fitting the filter silencer
u Fit filter silencer in reverse order.
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.4 Axial clearance
8.4 Axial clearance
WARNING
Physical hazards due to sharp edges on compressor wheel
The compressor wheel has sharp edges which can result in injury.
u Wear safety gloves.
Wear safety gloves to protect against mechanical hazards.
The axial clearance (A) must be measured before removing and after in-
stalling the cartridge group.
u Measure and note the axial clearance (A).
Clearance A [mm]
TPL76-C
0.43 … 0.69
CAUTION
Clearances outside the tolerance
Serious damage to engines or property can be caused by clearances
outside the tolerance and excessively worn parts.
u Have the components assessed and, if necessary, replaced by an
ABB Turbocharging Service Station.
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.5 Removing cartridge group
8.5 Removing cartridge group
CAUTION
Locked safety segments (76080) during disassembly
Observe the maximum tightening torque for the nuts (90458) so as not
to shear off the threaded studs of the safety segments (76080).
u Fit four nuts (74027) complete with washers (74018), equally spaced
around circumference, and tighten.
u Remove insulation (from bearing casing).
Removing safety segments / releasing casing
u Take nuts (90458) out of toolbox and screw them onto threaded
studs of safety segments (76080) on internal part of compressor cas-
ing (76000).
u Tighten nuts (90458) to a maximum torque of 30 Nm.
The internal part of the compressor casing (76000) has now been separ-
ated from the external part (74000) and can be removed.
NOTICE
Note the control dimension (u).
Check dimension (u) [mm]
Dimension
u
TPL76-C
21.8
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.5 Removing cartridge group
Removing the compressor casing internal part
u Remove two studs (74029 / 74026) at the point where the lifting
device (90190) will be fitted later.
u Using press-off screws (90900), push apart the compressor casing in-
ternal part (76000) until the lifting device (90190/90195) can be at-
tached.
u Slightly lift and then withdraw the compressor casing internal part in-
cluding the wall insert and diffuser.
u Attach the support angle (90025) using screws (90021) and nuts
(74027).
u Put down the compressor casing internal part including the wall in-
sert and diffuser on the support angle and an underlay.
u Remove the O-ring (76040).
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.5 Removing cartridge group
Transporting / turning internal part of compressor casing
u Carefully turn internal part of compressor casing complete with wall
insert and diffuser about support angle (90025) and put onto under-
lay.
u Set down casing on flange (F).
u Set down internal part of compressor casing in such a way that lifting
device (90190/90195) can be removed.
WARNING
Ensure that the shim does not slip.
u Rest the internal part of the compressor casing only on flange (F).
u Check shim and adjust as necessary.
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.5 Removing cartridge group
Removing diffuser and wall insert
u Remove screws (76002).
u Remove diffuser (79000) using swivel lifting eyes (90235).
u Press away wall insert (77000) using press-off screws (90230) and re-
move from internal part of compressor casing (76000) using swivel
lifting eyes (90235).
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.5 Removing cartridge group
Removing external part of compressor casing
u Fasten lifting device (90190/90195) to external part of compressor
casing (74000) using screws and secure to crane.
u Remove screws (42280).
u Uniformly press away external part of compressor casing (74000) us-
ing press-off screws (90900) and remove.
NOTICE
Insulation on external part of compressor casing
The insulation on the external part of the compressor casing does not
need to be taken off when removing or fitting the casing.
u Remove O-ring (42012).
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.5 Removing cartridge group
Removing the cartridge group
u Unplug cable connector (86515) and unscrew speed sensor (86505)
with O-ring (86506).
u Disconnect oil inlet and oil outlet pipes.
CAUTION
Oil orifice plates
An orifice plate for adjusting the oil pressure is fitted in each of the two
oil inlet channels in the bearing casing. When the cartridge group, the
bearing casing or the turbocharger is fitted to the engine, it must be
ensured that the orifice plates that are specified for the turbocharger
have been installed in the two oil inlet channels.
u Check correct installation of oil orifice plates.
Version with compressor wheel cooling system
u Remove air supply line. (See also chapter entitled Preliminary re-
marks / Layout and functionality)
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.5 Removing cartridge group
* When pressing off, use diametrically opposite press-off threads. Other-
wise the bearing casing can jam and damage the turbine blades.
u Check lifting gear and attach to bearing casing (42001).
u Loosen nuts (61037) and remove Verbus Ripp® washers (61051).
u Screw guide rod (90490) onto threaded stud (X) to balance cartridge
group.
u Evenly press off cartridge group by screwing press-off screws
(90900) into the designated holes.
CAUTION
If the blades have insufficient or no clearance between the rotor and
the casing, the blades and the casing may be damaged.
u Check that the blades do not rub on the turbine diffuser by rotating
the rotor.
u Withdraw cartridge group.
u Remove screws (42064) together with flange (42044) and also remove
possible contamination behind the flange.
u Fit supports (90450) using screws (42280) and put down cartridge
group.
u Cover the oil connections.
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.6 Dismantling and installing the tur-
bine diffuser and nozzle ring
8.6 Dismantling and installing the turbine diffuser
and nozzle ring
Removing turbine diffuser
u Put assembly plate (90020) over strain bolts (61036).
u Insert extension (A) of torque spanner (B) through hole in assembly
plate and loosen screws (61056) one after other.
u Don't remove screws (61056) yet.
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.6 Dismantling and installing the tur-
bine diffuser and nozzle ring
u Replace two screws (61056) with guide studs (90320).
u Fit assembly plate (90020) over studs (61036).
u Screw nuts (61037) onto start of threads of studs (61036) to secure.
u Remove remaining screws (61056).
u Press away turbine diffuser (63000) using press-off screws (90901)
and withdraw it until assembly plate (90020) touches nuts (61037).
u Loop lifting gear around turbine diffuser (63000) and secure to crane.
u Remove nuts (61037) and assembly plate (90020) from studs.
u Fully withdraw turbine diffuser and remove.
u Remove guide studs (90320).
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.6 Dismantling and installing the tur-
bine diffuser and nozzle ring
Removing the nozzle ring
u Bend up the locking plates (56018), undo nuts (56022) and remove.
u Pull out nozzle ring (56001).
u Remove threaded stud (56021).
CAUTION
Fastening the nozzle ring
When fitting the nozzle ring, new threaded studs (56021), nuts (56022)
and locking plates (56018) from the customer spare part set (97070)
must be used.
CAUTION
Clogged areas on the nozzle ring
If a nozzle ring is clogged in some areas or is covered by loose parts, it
is recommended to appoint an ABB Turbocharging Service Station to
inspect the turbine blades and carry out a crack inspection.
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.6 Dismantling and installing the tur-
bine diffuser and nozzle ring
Installing the nozzle ring
CAUTION
Fastening the nozzle ring
When fitting the nozzle ring, new threaded studs (56021), nuts (56022)
and locking plates (56018) from the customer spare part set (97070)
must be used.
u Push in nozzle ring (56001) as far as it will go at the cover of the gas
inlet casing.
u Coat threads of threaded studs (56021) with high-temperature grease
and fit threaded studs. Fit the locking plates (56018) and nuts
(56022).
u Tighten nuts (56022) and bend locking plates (56018) over.
CAUTION
Correct assembly
The nozzle ring must be easily movable after assembly.
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.7 Installing cartridge group
Fitting turbine diffuser
u Coat all screw threads on and in the gas casings with high-temperat-
ure grease.
u Fasten turbine diffuser (63000) to lifting gear.
u Align marking "TOP" with the position of the gas outlet flange and
pay attention to where the positioning pin is in the gas outlet casing.
u Fit turbine diffuser (63000) to guide studs (90320).
u Put assembly plate (90020) over strain bolts (61036) and guide studs
(90320).
u Remove lifting gear and push in turbine diffuser.
u Using three screws (61056), alternately and uniformly screw in turbine
diffuser as far as it will go.
u Insert torque spanner extension through hole in assembly plate and
tighten screws (61056) one after other. (See illustration in section Re-
moving turbine diffuser)
8.7 Installing cartridge group
CAUTION
Oil orifice plates
An orifice plate for adjusting the oil pressure is fitted in each of the two
oil inlet channels in the bearing casing. When the cartridge group, the
bearing casing or the turbocharger is fitted to the engine, it must be
ensured that the orifice plates that are specified for the turbocharger
have been installed in the two oil inlet channels.
u Check correct installation of oil orifice plates.
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.7 Installing cartridge group
u Remove cover from oil connection.
u Fit flange (42044) with new gasket (42045) and screws (42064).
u Check lifting gear and attach to bearing casing (42001) in such a way
that cartridge group is suspended in a straight position.
u Screw guide rod (90490) onto threaded stud (X) to balance cartridge
group.
u Remove supports (90450) and carefully insert cartridge group.
u Fit three oiled nuts (61037) complete with new Verbus Ripp® washers
(61051) around circumference at 120° intervals.
u Tighten the three nuts (61037) evenly and alternately with pre-tight-
ening torque of (MV) (see chapter Table of tightening torques).
u Each time the three nuts (61037) are gradually tightened, check rotor
by turning it. The blades must not touch other parts.
CAUTION
If the blades have insufficient or no clearance between the rotor and
the casing, the blades and the casing may be damaged.
u Fit the remaining oiled nuts (61037) complete with new Verbus Ripp®
washers (61051) and tighten with pre-tightening torque (MV) (see
chapter Table of tightening torques).
u Tighten all nuts (61037) in a star pattern with tightening angle (DW)
(see chapter Table of tightening torques)
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.7 Installing cartridge group
u Remove the lifting gear.
u Remove guide rod (90490).
u Screw in the speed sensor (86505) together with the O-ring (86506)
and plug in the cable connector (86515).
u Reconnect oil and air lines.
Version with compressor wheel cooling system
u Fit the air supply line. (See also chapter entitled Preliminary remarks /
Layout and functionality)
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.7 Installing cartridge group
Fitting external part of compressor casing
u Fasten lifting device (90190/90195) to external part (74000) of com-
pressor casing and secure it with crane.
u Fit O-ring (42012).
u Fit external part of compressor casing (74000) and fasten using
screws (42280).
u Remove lifting device (90190/90195).
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.7 Installing cartridge group
Fitting diffuser and wall insert
u Screw swivel lifting eyes (90235) into holes in wall insert (77000).
u Align mark (A) with notch (B).
u Fit centering screws (90230) in such a way that spigots on centering
screws protrude maximum 5 mm.
u Lower wall insert and align centering screws (90230) with threaded
holes.
u Remove swivel lifting eyes (90235) and centering screws (90230).
u Put the diffuser (79000) in place using the swivel lifting eyes (90235).
u Remove the swivel lifting eyes (90235).
u Fit screws (76002).
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.7 Installing cartridge group
Turning / transporting internal part of compressor casing
u Fasten lifting device (90190/90195) to front side of flange (F).
u Carefully turn internal part of compressor casing (76000) complete
with wall insert and diffuser about support angle (90025) and lift up
vertically.
WARNING
Ensure that the shim does not slip.
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.7 Installing cartridge group
Fitting compressor casing internal part
* The two compressor casing parts are centred via the long cylindrical
flange. No guide pieces are needed.
u Check whether the nuts (90458) of the three safety segments have
been tightened (safety segments are in the "not engaged" position).
u Fit O-ring (76040).
u Remove the support angle (90025), screws (90021) and nuts (74027).
u Align the compressor casing internal part (76000) with the com-
pressor casing external part as shown in the illustration on the next
page.
u Carefully insert the compressor casing internal part (76000) including
the wall insert and diffuser into the compressor casing external part
and then remove the lifting device (90190/90195).
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Operation Manual / TPL76-C
8 Disassembly and assembly / 8.7 Installing cartridge group
NOTICE
Align the compressor casing internal part (76000) with the notch (see
the arrow) so that the notch is positioned at the rib of the compressor
casing external part (74000) (see the arrow).
u Fully insert the compressor casing internal part (76000).
u Fit the studs (74026/74029).
© Copyright 2018 . All rights reserved.
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Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.7 Installing cartridge group
Engaging safety elements / securing casing
CAUTION
Locked safety segments (76080) during assembly
The safety segments (76080) are not in the operating position. Addi-
tional axial securing of the two compressor casings (74000/76000) is
not guaranteed.
u Fit four nuts (74027) complete with washers (74018), equally spaced
around circumference, and tighten.
u Unscrew nuts (90458) on threaded studs of safety segments (76080)
on internal part of compressor casing (76000).
The internal part of the compressor casing (76000) is now secure relat-
ive to the external part (74000).
NOTICE
Note the control dimension (s). The safety segments (76080) are in the
operating condition again ("engaged").
Check dimension (s) [mm]
Dimension
s
TPL76-C
16.5
u Put nuts (90458) back into toolbox.
© Copyright 2018 . All rights reserved.
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Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.7 Installing cartridge group
Measuring and checking axial clearance
WARNING
Risk of injury due to sharp edges on the compressor wheel
The compressor wheel has sharp edges which can cause injuries.
u Wear safety gloves.
Wear safety gloves to protect against mechanical hazards.
u Measure and note axial clearance A.
Clearance A [mm]
TPL76-C
0.43 … 0.69
CAUTION
If the axial clearance (A) is out of tolerance, an official ABB Turbo Sys-
tems service station must be contacted.
u Connect oil lines and all air lines in accordance with engine builder
specifications.
u Fit filter silencer or air suction branch and fasten with nuts (74027)
and washers (74018).
u Refit insulation if it was removed.
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.8 Dismantling and fitting nozzle ring
at turbine end
8.8 Dismantling and fitting nozzle ring at turbine
end
NOTICE
If only the nozzle ring has to be removed, this can be done at the tur-
bine end.
CAUTION
Clogged partial areas on the nozzle ring
If a nozzle ring is found to be clogged over partial areas or covered by
loose parts, it is recommended that you have a turbine blade inspection
including a crack inspection carried out by an ABB Turbocharging Ser-
vice Station.
If provided
w The fitted spiral-wound gasket (61050) may be used only once!
u Make ready a new spiral-wound gasket (61050).
Disassembly
u Remove insulation from gas inlet casing (51001) and disconnect clean-
ing pipe (if provided).
u Secure gas inlet casing using lifting gear.
CAUTION
When looping the securing line around the casing, make sure that no
cleaning pipes are squashed or damaged. Do not fasten the lifting gear
to cleaning pipes under any circumstances.
NOTICE
Mark positions of gas inlet casing and segments.
© Copyright 2018 . All rights reserved.
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Revision F
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Operation Manual / TPL76-C
8 Disassembly and assembly / 8.8 Dismantling and fitting nozzle ring
at turbine end
Segment connection
u Undo screws (61044) and remove segments (51012).
Flange connection
u Undo and remove screws (61044).
u Pull gas inlet casing (51001) complete with nozzle ring (56001) away
from gas outlet casing (61001).
CAUTION
Use suitable underlays when putting down gas inlet casing.
1) If present
u Remove gasket (61050).
© Copyright 2018 . All rights reserved.
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Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.8 Dismantling and fitting nozzle ring
at turbine end
u Bend up the locking plates (56018), undo nuts (56022) and remove.
u Pull out nozzle ring.
u Remove threaded stud (56021).
CAUTION
Fastening the nozzle ring
When fitting the nozzle ring, new threaded studs (56021), nuts (56022)
and locking plates (56018) from the customer spare part set (97070)
must be used.
CAUTION
Clogged areas on the nozzle ring
If a nozzle ring is clogged in some areas or is covered by loose parts, it
is recommended to appoint an ABB Turbocharging Service Station to
inspect the turbine blades and carry out a crack inspection.
Nozzle ring assembly
u Carefully clean slots and contact surfaces of the casings and keep
them free of metal chips.
u Keep slots and spiral-wound gasket free of oil and grease.
CAUTION
Fastening the nozzle ring
When fitting the nozzle ring, new threaded studs (56021), nuts (56022)
and locking plates (56018) from the customer spare part set (97070)
must be used.
© Copyright 2018 . All rights reserved.
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Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.8 Dismantling and fitting nozzle ring
at turbine end
u Push in nozzle ring (56001) as far as it will go at the cover of the gas
inlet casing.
u Coat threads of threaded studs (56021) with high-temperature grease
and fit threaded studs. Fit the locking plates (56018) and nuts
(56022).
u Tighten nuts (56022) and bend locking plates (56018) over.
CAUTION
Correct assembly
The nozzle ring must be easily movable after assembly.
1) If present
u Fix a new spiral-wound gasket (61050) in the slot at three evenly dis-
tributed points with a little superglue (for example "Loctite 454 Gel").
u Position gas inlet casing complete with nozzle ring on gas outlet cas-
ing (61001).
© Copyright 2018 . All rights reserved.
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Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.8 Dismantling and fitting nozzle ring
at turbine end
Tightening of segment connection
NOTICE
Radial gas inlet casing with segment 51012
In the case of the radial inlet casing with segments, the segments are
positioned by a pin in the slot on the casing. The centering bolt (90177)
is always needed.
u First place segment (51012) complete with roll pin on gas inlet casing,
fix it in correct radial position using centering bolt (90177) and then
fit it loosely using screws (61044).
NOTICE
In only one of the three segments is there a roll pin as an aid when posi-
tioning the gas inlet casing. This segment fits in only one position in
the gas inlet casing (note the circles in the illustration). Consequently,
begin with this segment.
u Put remaining segments (51012) in place on gas inlet casing (51001)
and fit them loosely using screws (61044).
u Replace centering bolts (90177) with screws (61044).
Check
u Collar (C) of segments (51012) must be in slot (S).
© Copyright 2018 . All rights reserved.
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Revision F
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Operation Manual / TPL76-C
8 Disassembly and assembly / 8.8 Dismantling and fitting nozzle ring
at turbine end
u Tighten screws (61044) in accordance with following procedure and in
following order:
Segment connection
u Begin with two middle screws of individual segments and then con-
tinue outwards alternately.
NOTICE
Screw tightening sequence
The screw positioning numbers must be marked on the component.
This enables simple and efficient tightening.
Tightening torques for
screws (61044) [Nm]
with spiral-wound gasket
Tightening
Step 1
TPL76-C
Screw in all screws hand-tight
Step 2
Step 3
140
280
Tightening torques for
screws (61044) [Nm]
without spiral-wound
gasket
Tightening
Step 1
Step 3
TPL76-C
Screw in all screws hand-tight
280
Checking the tightening
torque
u Beginning with screw 1, tighten all screws in a clockwise direction
with tightening torque from step 3.
u Remove lifting gear from gas inlet casing (51001).
u Connect cleaning pipe (if present) and attach insulation to gas inlet
casing (51001).
© Copyright 2018 . All rights reserved.
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Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.8 Dismantling and fitting nozzle ring
at turbine end
Tightening flange connection
u Fit screws (61044).
u Tighten screws (61044) in accordance with following procedure and in
following order:
Flange connection
u Tighten screws crosswise
NOTICE
Screw tightening sequence
The screw positioning numbers must be marked on the component.
This enables simple and efficient tightening.
© Copyright 2018 . All rights reserved.
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Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.8 Dismantling and fitting nozzle ring
at turbine end
Tightening torques for
Tightening
TPL76-C
Screw in all screws hand-tight
screws (61044) [Nm]
Step 1
Step 2
Step 3
with spiral-wound gasket
140
280
Tightening torques for
screws (61044) [Nm]
without spiral-wound
gasket
Tightening
Step 1
Step 3
TPL76-C
Screw in all screws hand-tight
280
Checking the tightening
torque
u Beginning with screw 1, tighten all screws in a clockwise direction
with tightening torque from step 3.
u Remove lifting gear from gas inlet casing (51001).
u Connect cleaning pipe (if present) and attach insulation to gas inlet
casing (51001).
© Copyright 2018 . All rights reserved.
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Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.9 Table of tightening torques
8.9 Table of tightening torques
© Copyright 2018 . All rights reserved.
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Revision F
April 2018
Operation Manual / TPL76-C
8 Disassembly and assembly / 8.9 Table of tightening torques
Tightening torques [Nm]
Position
Part number
TPL76-C
1
82005
M16 x 1.5
45
3
76002
M6
10
4
74027
M18
With washer
170
5
74026/74029
42280
M18
40
6
M18
280
7
61036
M18
40
61051 (VR) 1)
8
61037 2,3)
M18
MV 80 / DW 90°
9
42059
42064
M16
105
17
21
22
61044
61056
56021
56022
86505
M18
280
M18
280
M8
20
M8
25
29
M18x1.5
150
1)
Key to table
Place new Verbus Ripp® washers onto strain bolts (7). New Verbus
Ripp® washers must be fitted every time the unit is assembled.
2)
3)
a) Tighten three nuts at 120° intervals to pre-tightening torque MV
(lightly oil contact surface of nut).
b) Tighten the remaining nuts with pre-tightening torque MV.
c) Tighten all nuts (in a star pattern) with tightening angle DW.
After putting a new Verbus Ripp® washer under each nut (8), tighten
with pre-tightening torque of MV 80 Nm, then mark the 0° point and
tighten (under tightening angle control) to a DW of 90°.
VR
MV
DW
Verbus Ripp® Washer
Pre-tightening torque
Tightening angle
© Copyright 2018 . All rights reserved.
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Revision F
April 2018
Operation Manual / TPL76-C
9 Taking out of operation at short notice / 9.1 Possibilities for emer-
gency repair
9 Taking out of operation at short
notice
9.1 Possibilities for emergency repair
WARNING
Danger of fire and explosion due to lubricating oil leaks
Leaking oil may ignite on hot surfaces. This can result in serious injuries
to personnel or fatal accidents.
u Cordon off danger area.
u Raise the alarm and, depending on the situation, stop the engine.
u Seal the oil leak.
u Soak up oil and dispose of in an environmentally compatible manner.
Wear safety gloves to protect against thermal hazards.
CAUTION
Directives for taking out of operation
Serious damage to engine or property can be caused by non-compli-
ance with the directives for locking/blanking off the turbocharger on
the engine.
u Follow the directives of the enginebuilder.
If the diesel engine must be capable of operation again as soon as pos-
sible after damage to the turbocharger (emergency repair), the following
possibilities are available:
¡
¡
¡
¡
Locking turbocharger rotor
Fitting the cover plate
Shutting off inlets and outlets
Turbocharger bypass
© Copyright 2018 . All rights reserved.
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Revision F
April 2018
Operation Manual / TPL76-C
9 Taking out of operation at short notice / 9.2 Locking the rotor
9.2 Locking the rotor
CAUTION
A locked rotor must be removed and checked for unbalance after the
turbocharger repair.
NOTICE
An exception is a test rig run up to a maximum of 25% of the engine
load in the case of new engines with one or several turbochargers. This
is sometimes requested by customers. As operation with a locked rotor
is only brief and the loads are low in these cases, subsequent removal
of the rotor is not necessary.
CAUTION
During operation of the engine with a blocked turbocharger, the lubric-
ating oil system must remain connected to this turbocharger also and
be turned on if the gas inlet cannot be blocked. (See section Further
measures and information for operation with a blocked rotor for 4-
stroke engines.) Otherwise components that are still intact can be
damaged through overheating.
Shut off the oil supply in the event of lubricating oil leaking from the
turbocharger.
© Copyright 2018 . All rights reserved.
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Revision F
April 2018
Operation Manual / TPL76-C
9 Taking out of operation at short notice / 9.2 Locking the rotor
Locking rotor
Table of tightening
torques
Part no.
74027
TPL76-C
M18
135 Nm
94006
M8
25 Nm
NOTICE
Carry out work as described in the chapter Disassembly and assembly.
u Remove silencer or air suction branch.
u Insert lifting device (90427) into compressor wheel.
u Twist screws (94006) into free threaded holes in compressor wheel
and tighten to values shown in Table of tightening torques.
CAUTION
Don't remove any balancing screws from the compressor wheel. Use
only free threaded holes to fit the lifting device.
© Copyright 2018 . All rights reserved.
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Revision F
April 2018
Operation Manual / TPL76-C
9 Taking out of operation at short notice / 9.2 Locking the rotor
u Put assembly/disassembly device (90020) over studs (74026) and lift-
ing device (90427).
u Turn compressor wheel until holes in lifting device (90427) align with
holes in assembly/disassembly device (90020).
u Fasten assembly/disassembly device to lifting device (90427) using
screws (94006).
u Secure assembly/disassembly device (90020) to compressor housing
by screwing nuts (74027) onto studs (74026). (See also chapter Table
of tightening torques.)
Fitted assembly plate CV
33, CV 34
CAUTION
Make sure all components are clean and free from grease.
© Copyright 2018 . All rights reserved.
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Revision F
April 2018
Operation Manual / TPL76-C
9 Taking out of operation at short notice / 9.2 Locking the rotor
Further measures and information for operation with blocked rotor
for 4-stroke engines
4-stroke engine with one turbocharger
No further measures are necessary. The engine can be operated as a nat-
urally-aspirated engine according to the engine builder's instructions.
4-stroke engine with several turbochargers
Separate receivers
No further measures are necessary on engines with separate air and ex-
haust gas receivers. The engine can be operated as a naturally-aspirated
engine according to the engine builder's instructions.
Common air receiver
If the engine is equipped with a common air receiver and separate ex-
haust gas receivers, the bellows at the compressor outlet of the dam-
aged turbocharger must be removed and the air duct on the engine side
must be closed off. If this is not done, the undamaged turbocharger can
race under no load and run at overspeed.
Depending on the engine turbocharging system, more or less powerful
pulses from the exhaust gas system act on the locked rotor. The locking
device is then heavily stressed, particularly in the case of pulse charging
(turbine casing with more than one gas inlet). With this in mind, the fol-
lowing operating limits should not be exceeded:
¡
In systems similar to those with constant pressure (1 gas inlet), the
engine can be operated up to a maximum of 25% engine load. The
pressure in the charge air receiver must not exceed 0.9 bar overpres-
sure.
¡
In the case of pulse charging (2...4 gas inlets), the engine can be oper-
ated up to a maximum of 20% engine load. The pressure in the
charge air receiver must not exceed 0.5 bar overpressure.
CAUTION
Attention must always be paid to the speed of the undamaged tur-
bocharger. The speed limit nBmax given on the rating plate must not be
exceeded.
© Copyright 2018 . All rights reserved.
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Revision F
April 2018
Operation Manual / TPL76-C
9 Taking out of operation at short notice / 9.3 Fit cover plate
9.3 Fit cover plate
NOTICE
The cover plate (material: General structural steel, in accordance with
DIN EN 10025-2) must be manufactured in-house according to the
drawing.
Cover plate dimensions
[mm]
Product
TPL76-C
B1
13
B2
470
B3
50
B4
50
B5
9
B6
12
B7
8
B8
82
Product
TPL76-C
Ø 1
915
Ø 2
990
Ø 3
950
Ø 4
20
Ø 5
28
Ø 6
20
Product
⍺ 1
⍺ 2
⍺ 3
TPL76-C
4 x 90°
37.5°
24 x 15°
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
9 Taking out of operation at short notice / 9.3 Fit cover plate
NOTICE
Carry out the work as described in the chapter Removal and fitting.
u Remove cartridge group.
© Copyright 2018 . All rights reserved.
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Revision F
April 2018
Operation Manual / TPL76-C
9 Taking out of operation at short notice / 9.3 Fit cover plate
u Close off opening in gas outlet casing using cover plate.
u Fasten cover plate using spacer sleeves and nuts (61037).
CAUTION
Shut off the supply of lubricating oil to the turbocharger.
© Copyright 2018 . All rights reserved.
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Revision F
April 2018
Operation Manual / TPL76-C
9 Taking out of operation at short notice / 9.3 Fit cover plate
Further measures and information for operation with a
turbocharger with cover plate on 4-stroke engines
4-stroke engine with one turbocharger
No further measures are necessary. The engine can be operated as a nat-
urally-aspirated engine according to the engine builder's instructions.
4-stroke engine with several turbochargers
Separate receivers
Common receiver
No further measures are necessary on engines with separate air and ex-
haust gas receivers. The engine can be operated as a naturally-aspirated
engine according to the engine builder's instructions.
The air line must be closed off at the engine end because the undam-
aged turbochargers build up a receiver pressure.
CAUTION
The engine can be operated according to the engine builder's instruc-
tions. Attention must always be paid to the speed of the undamaged
turbocharger. The speed limit nBmax given on the rating plate must not
be exceeded.
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
9 Taking out of operation at short notice / 9.4 Blocking the inlets and
outlets
9.4 Blocking the inlets and outlets
CAUTION
Shut off the lubricating oil supply to the turbocharger.
u Shut off compressor casing outlet, gas inlet and gas outlet by fitting
cover plates.
NOTICE
In this respect, refer to the engine manufacturer's instructions.
9.5 Bypass the turbocharger
CAUTION
Shut off the lubricating oil supply to the turbocharger.
w This applies to engines with one turbocharger only:
w The connections are ready and pipes for the bypass are available.
u Fit bypass around turbocharger.
NOTICE
In this respect, refer to the engine manufacturer's instructions.
© Copyright 2018 . All rights reserved.
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Revision F
April 2018
Operation Manual / TPL76-C
10 Mothballing the turbocharger / 10.1 Taking out of operation for up
to 12 months
10 Mothballing the turbocharger
10.1 Taking out of operation for up to 12 months
Condition of engine lubricating oil
The turbocharger normally remains mounted on the engine. Mothballing
a turbocharger depends on the condition of the lubricating oil:
¡
If the total acid number (TAN) is lower than 2 mg KOH/g, no meas-
ures have to be taken.
¡
If the engine lubricating oil is replaced by preserving oil before taking
the engine out of operation and this is circulated by the prelubrica-
tion pump, no measures have to be taken. Any remaining old engine
oil will thus be flushed away and the bearing sections largely protec-
ted against corrosion.
Mothballing measures
If the total acid number (TAN) is greater than 2 mg KOH/g, the following
mothballing measures are necessary after taking an engine out of opera-
tion:
u Remove turbocharger.
u Rotor and bearing parts must be removed by an official ABB Tur-
bocharging service station and refitted afterwards.
u Clean all parts.
u Oil machined, bright surfaces of steel and cast parts using anticorros-
ive oil.
u Reassemble complete turbocharger.
Rotor turns in stack draught
If the rotor turns as a result of the stack draught:
u Install blind flange between compressor casing outlet flange and
charge air duct.
© Copyright 2018 . All rights reserved.
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Revision F
April 2018
Operation Manual / TPL76-C
10 Mothballing the turbocharger / 10.2 Taking out of operation for
more than 12 months
10.2 Taking out of operation for more than 12
months
If the engine is taken out of service, the following can be done with the
turbocharger:
¡
¡
The turbocharger remains mounted on the engine.
The turbocharger casing remains mounted on the engine, but the ro-
tor and the bearing parts are removed and stored separately.
¡
The turbocharger is removed completely, either as a whole or in indi-
vidual parts.
See the section Taking out of operation for up to 12 months, under
Mothballing measures, for the measures always necessary when moth-
balling turbocharger parts.
If the turbocharger remains mounted on the engine, refer to the section
Taking out of operation for up to 12 months, under Rotating the rotor in
stack draught.
If the entire turbocharger is removed or if the turbocharger is re-as-
sembled next to the engine using the individual parts:
u Close all turbocharger openings using wooden covers and paraffin
paper.
Suitable storage locations are only dry rooms where the relative humid-
ity is between 40 to 70 % and no condensation can form.
Condition of the mothballed turbocharger
u Check the mothballed turbocharger parts for corrosion every year.
u If there are signs of rust: Clean parts thoroughly and renew protection
against corrosion.
© Copyright 2018 . All rights reserved.
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Revision F
April 2018
Operation Manual / TPL76-C
11 Disposing of turbocharger components /
11 Disposing of turbocharger
components
WARNING
Handling damaged thermal insulation
Damaged thermal insulation can lead to dust exposure. The glass fibres
can cause mechanical irritation of the eyes, skin, and respiratory tracts.
u Avoid the formation of dust.
u Vacuum up dust with a suitable vacuum cleaner.
u Wear a respiratory mask to protect against dusts (P1 or P2 mask).
u Wear work gloves made of leather.
Wear safety goggles.
Wear a respiratory mask to protect against dusts.
Wear safety gloves to protect against mechanical hazards.
Disposal must be environmentally compatible, professional, and in com-
pliance with locally applicable regulations.
The turbocharger consists largely of metal (cast iron materials, steel,
nickel-steel alloys, aluminium and bearing brass).
Further components are: Non-metallic materials (filter components of
felt and polyethylene), lubricants (engine oil), electronic parts (speed
sensor and associated components), and thermal insulation.
u Dispose of metals as scrap metal for recycling.
u Dispose of non-metallic materials as waste.
u Dispose of residues of lubricants as waste oil.
u Dispose of electronic components as electronic waste.
u Dispose of thermal insulation as hazardous waste.
© Copyright 2018 . All rights reserved.
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Revision F
April 2018
Operation Manual / TPL76-C
12 Spare parts / 12.1 Ordering spare parts
12 Spare parts
12.1 Ordering spare parts
When making inquiries or ordering spare parts, the following data must
be specified:
¡
¡
¡
Turbocharger type
Serial number (HT……)
Designation and part number
Spare parts can be ordered from an official ABB Turbocharging service
station.
u If different design versions have not been taken into consideration in
this document, please contact an ABB Turbocharging service station.
CAUTION
Storage of spare parts
All spare parts ordered with the turbocharger must be kept complete
and ready for use.
u Parts showing signs of rust should be carefully cleaned and greased.
u Dispose of replaced and unusable parts in a professional and environ-
mentally compatible way.
Required customer spare part set (97070)
The customer spare part set (97070) is required for the work described
in this Operation Manual. These parts are available only as a complete
set.
Quantity
Description
O-ring
Part number
42012
1
1
Gasket
42041
2
Gasket
42045
2
Hexagon-head screw
Locking plate
Stud
Hexagon nut
Hexagon nut
Hexagon-head screw
Verbus Ripp® washer
Socket screw
O-ring
42059, 42064
56018
6
6
6
3
12
17
3
56021
56022
61037
61044, 61056
61051
76002
76040
1
1
O-ring
77005
1
O-ring
86506
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
12 Spare parts / 12.2 View of turbocharger with part numbers
12.2 View of turbocharger with part numbers
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
Operation Manual / TPL76-C
12 Spare parts / 12.2 View of turbocharger with part numbers
Part number
Description
01
Cartridge group
O-ring
42012 (in customer spare part set)
51001
51012
Gas inlet casing
Segment
56001
Nozzle ring
56018 (in customer spare part set)
56021 (in customer spare part set)
56022 (in customer spare part set)
Locking plate
Threaded stud
Nut
61001
Gas outlet casing
Hexagon nut
61037 (in customer spare part set)
61044 (in customer spare part set)
61050 (in customer spare part set)
Hexagon-head screw
Gasket
61051 (in customer spare part set)
61056 (in customer spare part set)
61065
Verbus Ripp® washer
Hexagon-head screw
Gasket
61066
Blind flange
61067
63000
68001
68002
Hexagon-head screw
Turbine diffuser
Foot at compressor end
Foot at turbine end
Cup spring
68006
68007
Bush
61079
Gasket
74000
76000
Compressor casing external part
Compressor casing internal part
Socket screw
O-ring
76002 (in customer spare part set)
76040 (in customer spare part set)
76080
77000
Safety segments
Wall insert
77005 (in customer spare part set)
O-ring
79000
81000
82000
Diffuser
Filter silencer
Radial air suction branch
© Copyright 2018 . All rights reserved.
HZTL2485_EN
Revision F
April 2018
ABB
ABB Turbo Systems AG
Bruggerstrasse 71a
CH-5400 Baden
Switzerland
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