Operation Manual: TPL67-C34

Turbocharging
Operation Manual
TPL67-C34
ABB Turbo Systems Ltd

CH 5401 Baden
Type TPL67-C34 HT503638

n Mmax 478 t Mmax 650
1/s °C
n Bmax 460 t Bmax 620
1260 kg 35 50 50
Application according to
Year 2009 the Operation Manual
made in Switzerland
HZTL2488 English

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

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

ABB Turbo Systems AG
Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Turbocharging
Operation Manual
TPL67-C34

CH 5401 Baden

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


recycled cardboard.

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Operation Manual / TPL 67-C + 71-C
Table of contents Page 1
Table of contents
November 2008
1 Preliminary remarks
1.1 Purpose of manual
1.2 Layout and function
1.3 Correct use of the turbocharger
1.4 Essential information
1.5 Abbreviations and symbols
1.6 Turbocharger rating plate
2 Safety
2.1 Basic safety instructions
2.2 General safety instructions
HZTL2488_EN
2.3 Special safety instructions

2.4 Safety instructions and hazard protection
2.5 Warnings on the turbocharger
3 Commissioning
3.1 Oil supply
3.2 Inspection work
3.3 Putting into operation after laying up
4 Operation
4.1 Servicing work
4.2 Replacement intervals for turbocharger components
4.3 Measuring speed
4.4 Surging of turbocharger
Version 2.8
4.5 Contact with rotating parts

4.6 Shutting the engine down
5 Maintenance
5.1 Foreword to Maintenance
5.2 Cleaning the filter silencer
5.3 Cleaning the compressor during operation
5.4 Cleaning turbine blades and nozzle ring in operation
© 2008 ABB Turbo Systems Ltd ABB

Table of contents Page 2
6 Troubleshooting
November 2008
6.1 Possible remedies for failures
7 Removal and installation

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

8.1 Module weights
8.2 Removing and fitting filter silencer or air suction branch
8.3 Axial clearance
8.4 Removing cartridge group
8.5 Dismantling and installing the turbine diffuser and nozzle ring
8.6 Installing cartridge group
HZTL2488_EN
8.7 Table of tightening torques
9 Taking out of operation at short notice

9.1 Possibilities for emergency repair
9.2 Locking the rotor
9.3 Fit cover plate
9.4 Blocking the inlets and outlets
9.5 Bypass the turbocharger
10 Mothballing turbocharger
10.1 Taking out of operation for up to 12 months
10.2 Taking out of operation for more than 12 months
11 Disposal
11.1 Environmentally compatible disposal of turbocharger
Version 2.8
components
12 Reserve and spare parts

12.1 Ordering spare parts
12.2 Directory of part numbers
12.3 General view of turbocharger
12.4 General view of cartridge group

Preliminary remarks 1
Purpose of manual 1.1 Page 1
1 Preliminary remarks
November 2008
1.1 Purpose of manual

Operating manual This operation manual will help you to become familiar with your ABB
Turbo Systems turbocharger and to use it to full effect in its intended app-
lication. You will find important instructions as to the safe, correct, and
economical operation of the turbocharger.
Target group The content of this operation manual is intended for persons such as en-
gineers, marine mechanics and service technicians who are responsible
for the running of the engine and the turbocharger installed thereon.
Content of operating ma- This operation manual includes helpful information on the following topics:
nual
Information on the operation of the turbocharger and ways to prolong
the turbocharger's service life.
Early identification and avoidance of hazards.
Minimizing repair costs and downtime.
HZTL2488_EN
This operating manual complements and extends existing national regula-

tions on protection against accidents and accident prevention.
An operation manual must be available at all times at the site where the
turbocharger is used. It is essential that this operation manual is read
before beginning work by all persons working with or on the turbochar-
NOTE ger. Anyone who works only occasionally on the machine, e.g. during
installation and maintenance, must also read and fully understand the
operating manual before beginning work.
The instructions included in this operating manual must be followed

without fail.
This applies especially to the general and special safety instructions

preceding the respective chapters and in them. Ignoring hazards and
Version 2.8
the safety instructions can lead to serious personal injury and damage
WARNING to equipment.
If in doubt, consult the safety officer responsible and the person accoun-
table for protection against accidents in your domain.

Layout and function 1.2 Page 2
1.2 Layout and function
November 2008
TPL 67/71-C
1 2 3 4 5 6
8
9
10
HZTL2488_EN
11
12
13
1 Filter silencer 8 Nozzle ring

2 Radial plain bearing 9 Turbine wheel
3 Thrust bearing 10 Bearing casing
4 Bearing bush 11 Diffusor
5 Radial plain bearing 12 Compressor wheel
6 Gas outlet casing 13 Compressor casing
7 Gas inlet casing
Version 2.8

Layout and function 1.2 Page 3
Working principle
November 2008
The turbocharger is a turbo-machine and consists of the following main

components:
Turbine
Compressor
These are both mounted on a common shaft.
The exhaust gases from the diesel engine flow through the gas inlet ca-
sing (7) and nozzle ring (8) to the turbine wheel.
The turbine wheel (9) uses the energy contained in the exhaust gas to
drive the compressor wheel (12), whereby the compressor draws in fresh
air, and the compressed air is forced into the cylinders.
The exhaust gases escape to free air through the exhaust manifold which
HZTL2488_EN
is connected to the gas outlet casing (6).
The air which is necessary for the operation of the diesel engine and
which is compressed in the turbocharger is drawn through the suction
branch or the filter silencer (1) into the compressor wheel (12). It then
passes through the diffusor (11) and leaves the turbocharger through the
compressor casing (13).
The rotor runs in two radial plain bearings (2/5). One plain bearing is si-
tuated in the bearing bush (4) and one plain bearing is situated in the axial
thrust bearing (3) at the compressor side.
The plain bearings are connected to a central lubricating oil channel which
is fed with oil from the engine lubrication circuit. The oil outlet is always at
the lowest point of the bearing casing (10).
Version 2.8

Correct use of the turbocharger 1.3 Page 4
1.3 Correct use of the turbocharger
November 2008
This turbocharger supplied by ABB Turbo Systems has been developed
for use on diesel engines to generate the volume of air and the char-
ging pressure required to operate the engine.
NOTE The engine manufacturer has provided ABB Turbo Systems with infor-
mation regarding the intended use of the engine, from which the opera-
ting parameters specific to the turbocharger shown on the rating plate,
such as operation speeds, temperatures, replacement periods / ex-
change intervals, have been derived.
Any other use will be regarded as a special application which must first
be discussed with ABB Turbo Systems. The manufacturer accepts no
liability for other applications. If it is used otherwise, ABB Turbo Sy-
stems reserves the right to reject all claims under the warranty.
Latest technology This turbocharger was built according to state-of-the-art technology and is
HZTL2488_EN
operationally safe according to prevailing safety regulations.
Improper operation and maintenance of the turbocharger can result in

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

bly, disassembly, operating, maintenance and repair conditions specified
by the manufacturer. Disposal regulations set down by local authorities
must be observed.
Perfect condition The turbocharger must only be installed in a technically perfect condition,
corresponding to its intended purpose and following the instructions in the
Engine Manufacturers' Manual, and must be operated and used in com-
pliance with the Operation Manual.
Version 2.8
X Malfunctions / defects which could affect safety must be eliminated

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

Essential information 1.4 Page 5
1.4 Essential information

November 2008
Organisational measures
In addition to this manual, the general, statutory regulations applicable in

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

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

with the turbocharger must be checked regularly with reference to this
manual.
NOTE
X The turbocharger must be shut down immediately by stopping the en-

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

could compromise safety require the prior approval of ABB Turbo Sy-
stems.
NOTE
Version 2.8

Original parts and safety
November 2008
Original parts and accessories are especially designed for the turbochar-
ger supplied by ABB Turbo Systems.
We herewith expressly state that parts and accessories not supplied by

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

Turbo Systems are used, this may have a negative effect on the techni-
cal design specifications of the turbocharger.
WARNING Moreover, the active and/or passive safety of the turbocharger may be
compromised by the use of non-original parts. Note that such improper
use may endanger personnel and the machine.
HZTL2488_EN
ABB Turbo Systems shall not be liable for any damage caused by using
non-original parts and accessories.
Qualification of personnel
The turbocharger may be operated and maintained only by trained and

authorized personnel.
Work on mechanical components, such as bearings or rotors, may be

performed only by trained / qualified fitters from an official service stati-
on of ABB Turbo Systems.
CAUTION
Version 2.8

After-sales service
November 2008
The Contact Information brochure contains an overview of official ABB

Turbo Systems. service stations worldwide.
Design variants
This operating manual is valid for various turbocharger design variants.
This means that some sections and component descriptions in this opera-
ting manual do not apply to your turbocharger.
Our service stations and agencies will gladly answer your questions rela-
ting specifically to your model.
Accuracy of illustrations
HZTL2488_EN
The graphics and images shown in this manual are of a general nature
and are intended to assist understanding of the work steps and instructi-
ons. Differences may exist in certain details.
Storage of new turbochargers
New turbochargers supplied by ABB Turbo Systems can be stored without

additional safeguarding measures for a period of 6 months after the deli-
very date.
Suitable storage locations are dry rooms where the relative humidity is
between 40-70% and no condensation can form.
X After expiry of the 6 months, all surfaces and accessible areas of the
turbocharger should be sprayed with anticorrosive agent.
X To do this, the insulating materials must be removed.
Version 2.8
Repeat the described measures every 6 months to keep your turbo-

charger free from rust.
NOTE

Abbreviations and symbols 1.5 Page 8
1.5 Abbreviations and symbols
November 2008
The following abbreviations are used in this document:
Z Prerequisite
X Work step
D Result
9 Positive checkpoint (activity that must be carried out without fail)

U Negative checkpoint (activity that must not be carried out under any
circumstances)
Basic Instructions
The following symbol is used for notes in this manual:
HZTL2488_EN
This note provides suggestions and tips to make work on the turbo-
charger easier.
The note provides further essential information.
NOTE
Reference to safety instructions

The warnings and cautions are described in the chapter Safety .
CAUTION
ABB Turbo Systems
ABB Turbo Systems Ltd is specified in this manual as ABB Turbo Sy-
Version 2.8
stems.
Official ABB Turbo Systems service station
The term official ABB Turbo Systems service station used in this manual
signifies ABB turbocharger service stations that have been checked and
certified by ABB Turbo Systems.

Turbocharger rating plate 1.6 Page 9
1.6 Turbocharger rating plate

November 2008
HZTL2488_EN
Operational limits 1 Turbocharger operational limits at engine overload (110 %).

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

ment intervals / change
4 Replacement interval for the compressor in 1000 h
periods for turbocharger
components 5 Replacement interval for the turbine in 1000 h
Additional specifications: 6 Customer part number

Version 2.8
7 Description of the special design

8 Weight of turbocharger in kg
9 CE identification
10 Turbocharger type
11 Serial number
12 Year of turbocharger construction

Turbocharger rating plate 1.6 Page 10
1.6.1 Explanation of the rating plate
The recommended replacement intervals and the corresponding operatio-
November 2008
nal limits are jointly defined with the engine manufacturer. This information
is specific to the system.
Operation above the indicated values nBmax, tBmax can considerably shorten the
recommended replacement intervals. In such a case, we recommend that you
contact the nearest official service station of ABB Turbo Systems.
nMmax, tMmax normally apply only when running at overload (110%) during trials
on the engine test bed. These limits can also be permitted during operation for
special applications. Operation above nMmax and tMmax is not permitted.
Non-observance of the recommended replacement intervals can increase the
risk of unpredictable component failures.
HZTL2488_EN
Version 2.8

Safety 2
Basic safety instructions 2.1 Page 1
2 Safety
November 2008
2.1 Basic safety instructions

The following symbols and terms are used for the safety instructions in
this manual:
Failure to follow work steps and operating instructions marked with this
symbol completely and rigorously may result in serious personal injury
or even fatal accidents.
WARNING Warning signs must be strictly observed at all times.
Serious damage to the machine or to other property may result if the

working and operation instructions marked with this symbol are not, or
only partly, observed.
CAUTION Caution signs must be strictly observed at all times.
HZTL2488_EN
Version 2.8

Safety 2
General safety instructions 2.2 Page 2
2.2 General safety instructions

The instructions listed here are designed to ensure your safety and to
November 2008
promote safe handling of the turbocharger and its associated operating
materials.
The following safety instructions must be followed when operating and

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

stress.
Wear protective clothing at all times.
Helmet
Ear protection
Protective glasses
Protective suit
Oil and petrol resistant gloves
HZTL2488_EN
Protective shoes
Attach individual parts and larger component modules carefully to sui-
table hoists/lifting devices which are in technically perfect condition and
which have adequate load-bearing capacity.
Do not stand under suspended loads.
If welding work is to be carried out above the turbocharger, the air filter
must be covered to prevent damage to the filter mat.
When working on the turbocharger, be aware of the risk of it falling.
For overhead assembly work, use the steps and platforms provided for
this purpose.
Version 2.8

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

November 2008
Safety when connecting
Work only on those connections for which you are qualified.
Safety when commissioning and during operation
Before starting work, make a visual inspection of the working area.

Remove obstacles and any objects lying around from the work area.
Before commissioning check the turbocharger for damage and leaks.
Refrain from any activity which could compromise safety while working
with the turbocharger.
Inspect the turbocharger after about 12 hours of operation or at least
once a day for visible damage and defects.
Report any damage or changes in operational performance to the per-
son/department responsible immediately.
HZTL2488_EN
In the event of damage, shut down the turbocharger immediately and

secure it against inadvertent or unauthorized use.
Version 2.8

Safety 2
Safety when cleaning
November 2008
When handling detergents, solvents, acids and alkalis be sure to observe
the respective safety directions on the manufacturers' labels.
Follow directions regarding the environmentally compatible collection, sto-

rage and disposal of these liquids.
Explosion hazard
Cleaning work should be carried out outdoors due to explosion hazard.
If this is not possible, ensure that there is adequate ventilation and air
WARNING circulation. Before beginning cleaning work in confined spaces, extingu-
ish naked flames (including cigarettes!) due to the risk of explosion.
Before cleaning, protect the floor against unintended leaks of oil and
operation materials.
You must wear protective clothing (see section General safety instruc-
HZTL2488_EN
tions).
Handle operation materials and detergents with utmost caution.
When handling solvents, wear protective clothing and observe the fol-
lowing rules:
Avoid skin contact with solvents.
Avoid inhaling vapours under all circumstances.
Do not allow solvents to soak protective clothing.
After cleaning, check electric cables for signs of wear or damage.
Version 2.8

Safety 2
Safety during disassembly, assembly, maintenance and troubleshooting

November 2008
Follow the prescribed maintenance and inspection schedules for all ad-
justment, maintenance and inspection work.
Inform operating personnel about special work and repairs before star-
ting.
Ensure that absorbent materials are available to clean up any operati-
on materials that escape accidentally.
Ensure safe and environmentally-friendly drainage, collection and
disposal of operating and auxiliary materials.
Before opening a cover or removing a protective component on the
turbocharger, the engine must have been switched off and must not be
started up again until all parts have been properly re-assembled.
Assembly and disassembly work must only be performed by trained

personnel. Work on mechanical components, such as bearings or ro-
tors, must only be performed by qualified fitters from an official service
CAUTION station of ABB Turbo Systems.
HZTL2488_EN
Safety when taking out of operation or putting into storage
Secure the rotor against turning.

Clean the turbocharger before mothballing.
Wear protective clothing when mothballing the turbocharger.
Keep the work area clean and free of oil and operating materials.
Remove any obstacles lying around on the floor.
Version 2.8

Safety 2
Safety instructions and hazard 2.4 Page 6

protection
2.4 Safety instructions and hazard protection

Associated hazards may arise during operation of and work on the turbo-
November 2008
charger:
from the turbocharger and its accessories.

from the operating materials used.
due to failure to comply with the safety instructions.
from inadequate performance of maintenance and inspection work.
Mechanical influences
Mechanical influences can cause serious injury or even fatal injury.
WARNING
HZTL2488_EN
Personal injury Unconsciousness and injury due to:
crushing
shearing
cutting
winding
smashing
drawing in
knocking
stabbing
rubbing
Escape of liquids under high pressure and / or at high temperature
slipping
tripping
falling
Version 2.8
Causes sharp edges, pointed parts

crush, shear and winding areas
fragmentation / ejection of parts
fracture or rupture of parts due to overload
Elastic elements (springs), liquids and / or gases under pressure/in a
vacuum
slippery, oily work area, obstacles on the floor

Safety 2

protection
Protective measures 9 Wear leather protective gloves

9 Wear close-fitting protective clothing
9 Tie up long hair and beards (wear hair protection)
November 2008
9 Wear face and eye protection

9 Wear protective shoes
9 Keep floor, equipment and the turbocharger clean
9 Ensure the availability of oil absorbing materials and have oil collector
basins ready or in position
9 Eliminate leaks
Operation and process materials
Operation and process materials refer to chemical and hazardous sub-

stances:
Oils
Grease
Coolants
Detergents and solvents
Acids
HZTL2488_EN
Note that operation and process materials are harmful to the environ-
ment if they penetrate soil or water.
CAUTION
Personal injury The following injuries can be caused by operation and process materials:
Allergies
Skin disease
Loss of consciousness
Poisoning or nausea after inhalation
Causes Inhalation of toxic gases, smoke and vapours

Version 2.8
Skin contact with aggressive fluids

Clothing wet or soaked with hazardous substances
Spilling and tipping over of vessels containing substances used during
operation
Escape due to leakage
Tanks and collectors which are not gas-tight and which do not comply
with the regulations on hazardous substances
Burning cigarettes or open flame in the proximity of operation materials

Safety 2

protection
Protective measures 9 Utmost caution when handling process and operation materials
9 Protective clothing must be worn
9 Avoid skin contact and inhalation
November 2008
9 Ensure that the workroom is properly ventilated
9 Observe the hazard indications on the containers for operation and
process materials
9 Seal the hazardous substance container tight immediately after use
9 Used operation materials must be collected safely in accordance with
the legal provisions, stored separately in suitable containers as pres-
cribed, and disposed of as special waste in an environmentally compa-
tible manner
9 Ensure that containers with new / used operation materials are sealed
tight
9 In the event of leaks or spills, immediately apply a suitable absorbent
material and dispose of this in a technically and environmentally com-
patible manner as special waste
Handling insulating materials
9 Ensure that the work area is well ventilated

Keep the work area clean
HZTL2488_EN
9
9 Avoid disturbing dust
9 Dust-suppressing tools and processing steps
9 Remove from packaging only in the work area
9 Exercise particular care when removing old insulating materials
9 Dispose of insulating materials in a technically and environmentally
compatible manner
9 If large quantities of dust are created, wear protective glasses
9 Use half or quarter masks
9 Wear suitable work clothing and gloves
9 For sensitive skin, apply moisturising, protective barrier cream
Version 2.8

Safety 2

protection
Noise
November 2008
The effects of noise above a legally permitted level can cause personal in-
jury.
Personal injury Loss of hearing

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

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

Version 2.8

Safety 2
Warnings on the turbocharger 2.5 Page 10
2.5 Warnings on the turbocharger
November 2008
Warnings that have been applied to turbochargers by ABB Turbo Systems
must not be removed, painted over or obscured with other stickers. Mis-
sing or illegible warnings must be replaced by new ones.
HZTL2488_EN
Attach warnings so that they are clearly visible in the positions intended
for the purpose. Please contact an official ABB Turbo Systems service
station for further information.
NOTE
Version 2.8

Commissioning 3
Oil supply 3.1 Page 1
3 Commissioning
November 2008
3.1 Oil supply

A carefully designed oil supply, which functions under all operating condi-
tions, is an important precondition for trouble-free operation of the turbo-
charger.
Lubrication of the turbocharger is normally carried out with oil from the
engine oil circuit.
Regarding the oil supply, follow the engine manufacturer's instructions

concerning selection of lubricating oil, oil change intervals, oil filtration,
and oil pressure and temperature.
NOTE
Oil filtration
HZTL2488_EN
Filtration of the lubricating oil using a filter mesh size ≤ 0.034 mm is ade-
quate for TPL67-C turbochargers and a mesh size ≤0.050 mm for TPL71-
C turbochargers.
This filtration can also be carried out using an additional self-cleaning

fine filter.
NOTE
Version 2.8

Commissioning 3
Oil supply 3.1 Page 2
Oil pressure
November 2008
The oil pressure in front of the bearings must be maintained precisely to
ensure trouble-free operation.
The measuring point M in the blind connection on the turbocharger must

show the following permissible oil pressure range:
HZTL2488_EN
Oil pressure range Oil pressure [bar]
Permissible oil pressure range for 1.3 - 2.5
normal operation
To ensure this oil pressure, a regulating orifice is fitted in the oil inlet of
the turbocharger.
NOTE Version 2.8

Commissioning 3
Inspection work 3.2 Page 3
3.2 Inspection work

This inspection work includes preventive visual controls, as well as moni-
November 2008
toring and measurement to ensure the correct functioning of the turbo-

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

HZTL2488_EN
Lubrication system X Check that the oil filter is clean before commissioning.
It is urgently recommended that the entire lubrication system be flushed

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

Version 2.8

Commissioning 3
Inspection work 3.2 Page 4
3.2.2 Inspection after commissioning
November 2008
Lubrication system X Check oil pressure in oil supply lines.
Charger speed X Measure
Charger pressure X Measuring
Measure temperatures X upstream/downstream from turbine, compressor and oil feed for vari-
ous engine speeds
Gas, air, and oil lines X Check all gas, air, and oil lines for leaks after the engine has been star-
HZTL2488_EN
ted up.
Further must be observed:
Lubricants and pastes are liquefied or vaporised during assembly of the

turbocharger and may escape as an oily liquid in the first few hours af-
ter commissioning. If further oily liquid continues to appear after this pe-
NOTE riod, an oil leak must be suspected. Then, the first step is to check for
leakage of the oil supply to the turbocharger. If something wrong is de-
tected, contact an official ABB Turbo Systems service station.
X Measure the speed, oil pressure, charging pressure and temperatures

before and after the turbine and the compressor at various engine
speeds.
Version 2.8
X Compare the measured values with those of the inspection report, ta-
king into account the different operating conditions.
3.2.3 Inspection after 100 service hours
Clean or replace lubricating oil filters after the first 100 service hours.

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

X Remove the cover plates (blind flanges) between the compressor ca-
November 2008
If they are present

sing outlet and the charge-air receiver, upstream of the gas inlet,
downstream of the gas outlet.
X Inspect the exhaust-gas duct before and after the turbine for any com-
bustion residue, clean / remove foreign bodies or residual water.
X Inspect air supply line or filter silencer for any foreign bodies, clean /
remove.
X Start up the turbocharger's engine end oil circulation system.
X Prepare the turbocharger for operation as instructed in the section In-
spection work before commissioning in the chapter entitled Commis-
sioning.
X Commission the turbocharger.
HZTL2488_EN
Version 2.8

Operation 4
Servicing work 4.1 Page 1
4 Operation
November 2008
4.1 Servicing work

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

work.
WARNING
Servicing work must be carried out at the prescribed intervals in order

to avoid damage to and malfunctioning of the turbocharger.
HZTL2488_EN
CAUTION
4.1.1 Servicing work every 25 to 50 hours
Operating data X Recording and entering in the machine logbook

X Establish cause of major anomalies in parameters.
If you are unable to establish the cause of the anomalies, contact an

official ABB Turbo Systems service station.
CAUTION
Version 2.8

Operation 4
November 2008
4.1.2 Entries in the machine logbook
Monitoring of the machine plant provides information about the perfor-

mance of the turbocharger.
The following operation data and measurement values must be entered

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

Air intake temperature
Exhaust temperature before and after the turbine
Pressure of the charge-air
Pressure drop in the charge-air cooler
Lubricating oil pressure, lubricating oil temperature
If provided Air temperature after compressor and after the charge-air cooler
Speed of the turbocharger
HZTL2488_EN
Pressure loss in the air filter
4.1.3 Servicing work according to the engine manufacturer's instructions
Oil filters X With the engine at standstill clean or replace oil filters
4.1.4 Servicing work every 8,000 - 12,000 hours
X Dismantle the turbocharger

X Clearance measurement
X Clean turbine and compressor casings and check for any cracks and
erosion / corrosion
X Clean bearing casing, blow through oil ports
X Clean nozzle ring and inspect for cracks and erosion
Version 2.8
X Inspect and assess rotor and bearing parts
The inspection and assessment of the rotor and bearing parts must be
performed by an official ABB Turbo Systems service station.
NOTE

Operation 4
4.1.5 Servicing work every 36,000 hours
X Dismantle the turbocharger

November 2008
X Clearance measurement
X Clean turbine and compressor casings and check for any cracks and
erosion / corrosion
X Clean bearing casing, blow through oil ports
X Clean nozzle ring and inspect for cracks and erosion
X Inspect and assess rotor
X Replace the plain bearings with original parts from ABB Turbo Systems
Replacement of the bearing parts as well as inspection and assessment

of the rotor must be carried out by an official ABB Turbo Systems ser-
vice station.
NOTE
HZTL2488_EN
Version 2.8

Operation 4
Replacement intervals for turbocharger 4.2 Page 4

components
4.2 Replacement intervals for turbocharger com-

ponents
November 2008
Rotating components The recommended replacement intervals for the compressor and turbine
wheels due to stressing caused by centrifugal forces and load cycles are
calculated under consideration of the operating conditions while applying
the safety concept for rotating components. They can be found on the tur-
bocharger rating plate. Non-calculable influencing parameters can shorten
recommended rotor replacement intervals, see Influencing parameters.
Non-rotating components The expected replacement intervals for non-rotating components and bea-
ring parts greatly depend on system-specific operating conditions, see In-
fluencing 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 periods for turbo-
charger components:
HZTL2488_EN
Parameters influencing bearing parts:
Poor lubricating oil quality (lubrication oil filter system, condition of lu-
bricating oil)
Unusual loads (vibration, start / stop frequency)
Impermissible state of rotor unbalance
Parameters influencing non-rotating components exposed to exhaust gas
Fuel quality (Gas, MDO, HFO)

Loading profile (thermal load changes, number of starts/stops)
Temperature level of exhaust gas
Turbine cleaning frequency
Procedure for turbine cleaning
Version 2.8
Parameters influencing rotating components exposed to exhaust gas
Fuel quality (Gas, MDO, HFO)

Turbine cleaning frequency
Procedure for turbine cleaning
Loading profile

Operation 4
Replacement intervals for turbocharger 4.2 Page 5

components
Expected replacement Component GAS / MDO HFO

intervals [h]
Gas inlet casing 50'000…100’000 25'000…50’000
November 2008
Gas outlet casing 50'000…100’000 35'000…100’000

Nozzle ring 35'000…50’000 25'000…50’000
Turbine diffuser / cover 35'000…50’000 25'000…50’000
ring
Other casings 100’000 100’000
Axial bearing compo- 36’000 36’000
nents
Radial bearing compo- 24'000…36’000 24'000…36’000
nents
Turbine blades - ≥ 12’000
(due to wear)
Recommended replace- Rotor components See data on rating plate.

ment intervals [h]
HZTL2488_EN
GAS = Gas engine

MDO = Marine Diesel Oil
HFO = Heavy Fuel Oil
The values indicated are for guidance only and are not guaranteed va-
lues, see Influencing parameters.
NOTE
Version 2.8

Operation 4
Measuring speed 4.3 Page 6
4.3 Measuring speed
November 2008
42047
86505
HZTL2488_EN
86526 86528 86515
Part number Description

42047 Screw plug
86505 Speed sensor
86515 Cable connector for 86505
86526 F/I converter
86528 Tachometer
Version 2.8
Turbochargers can be equipped with a speed measuring system.
The system permits continuous monitoring of the turbocharger speed,

which can also be used as a suitable control parameter for continuous
monitoring of the engine.

Operation 4
4.3.1 Assembly
If the speed sensor is not fitted on the turbocharger, the following proce-
November 2008
dure must be adopted to fit it:
Z Engine and turbocharger are not running.

Z The turbocharger lubricating system is switched off.
X Remove screw plug (42047) from bearing casing.
Position
The position of the screw plug for speed measurement is marked "n" on
the bearing casing.
NOTE
X Screw in speed sensor (86505) as far as it will go and tighten to torque

specified in table. (See chapter Table of tightening torques.)
X Connect speed sensor to cable connector (86515) or power amplifier
(86525).
HZTL2488_EN
4.3.2 Replacement
If the speed sensor has to be replaced, proceed as follows:
Z Engine and turbocharger are not running.

Z The supply of lubricating oil to the turbocharger is switched off.
X Disconnect cable connector (86515) or power amplifier (86525) from
speed sensor (86505).
X Screw out defective speed sensor.
X Screw in new speed sensor as far as it will go and tighten to specified
torque. (See chapter Table of tightening torques.)
X Connect new speed sensor to cable connector or power amplifier.
Replacement / fitting speed sensor

Version 2.8
It is recommend that you have work on the speed sensor carried out by
an official ABB Turbo Systems service station.
NOTE
For work on the speed measuring system, the engine manufacturer's
instructions must be followed.

Operation 4
4.3.3 Sources of error
November 2008
A drop in turbocharger speed can signify:
Damaged rotor components or bearings.

Defective cylinders connected during pulse operation.
Defective or leaking exhaust manifolds or charge-air ducts.
An increase in turbocharger speed can signify:
A very dirty turbine
Possible reasons for failure of speed measuring system:
Defective speed measuring system.

Turbocharger damage.
HZTL2488_EN
Possible reasons for measuring errors of speed measuring system:
Fitting error.
Dirty sensor tip.
Defective speed measuring system.
Problems with speed measuring system

If problems arise with the speed measuring system, it is recommended
that the engine output be reduced to idling speed and the engine stop-
NOTE ped. The cause of the failure should then be determined.
If the cause of the failure or the measuring errors cannot be found,
please contact an official ABB Turbo Systems service station.
Version 2.8

Operation 4
Surging of turbocharger 4.4 Page 9
4.4 Surging of turbocharger

Turbocharger surging can occur during certain engine operating states,
November 2008
such as rapid load removal or when manoeuvring. The direction of flow in

the compressor is then briefly reversed. Sporadic surging of this kind, ho-
wever, does not generally impair safe operation of the turbocharger.
Prolonged or periodic surging

If surging is prolonged or occurs periodically, the following components
may be damaged:
CAUTION - Compressor wheel (vibration fractures, ...)
- Turbine blades (cracks)
- Bearing (overheating)
- Filter silencer
HZTL2488_EN
Action to be taken
The operating safety of the turbocharger is no longer ensured with con-
tinuous or periodically recurring surging. The operator must take imme-
NOTE diate steps to correct the surging together with the closest official ABB
Turbo Systems service station.
The components listed above must be inspected for damage by an offi-
cial ABB Turbo Systems service station, and replaced in cases of
doubt.
Version 2.8

Operation 4
Contact with rotating parts 4.5 Page 10
4.5 Contact with rotating parts

Slight, uniform wear around the periphery of rotor components, caused by
November 2008
their just touching adjacent components locally, is not hazardous and
permissible. This slightly reduces the length of the blades in the compres-
sor and/or the turbine. Certain tolerances must be observed to avoid a si-
gnificant loss of efficiency.
X A check on dimensions must be carried out by an official ABB Turbo

Systems service station.
HZTL2488_EN
Version 2.8

Operation 4
Shutting the engine down 4.6 Page 11
4.6 Shutting the engine down

November 2008
Before shutting the engine down, it must be allowed to idle for 5 to 10

minutes longer so that the circulating lubricating oil can dissipate the
heat in the turbocharger bearings.
CAUTION
HZTL2488_EN
Version 2.8

Maintenance 5
Foreword to Maintenance 5.1 Page 1
5 Maintenance
November 2008
5.1 Foreword to Maintenance

Maintenance and servicing work involves regular visual checks and clea-
ning to ensure that the turbocharger and its attached units function trou-
ble-free.
The external condition and how dirty the cleaning points specified in
this chapter are, must be established by visual checks at the specified
intervals.
The safety precautions must be observed during all maintenance and
servicing work.
The cleaning points described in the following are:

HZTL2488_EN
Filter silencer
Compressor
Turbine and nozzle ring
Version 2.8

Maintenance 5
Cleaning the filter silencer 5.2 Page 2
5.2 Cleaning the filter silencer
November 2008
5.2.1 Filter silencer and connecting rod
81266
81136 81137
81135 E
81265
81272
HZTL2488_EN
81269
81273 81266
81265 Filter strip (if provided) 81136 Fleece segment (Insert unit)
81269 Connecting rods 81137 Cover plate
81266 Mesh cover 81135 Filter silencer body
81272 Screw 81273 Lock nut
E Insert unit = fleece segment + cover plate
Version 2.8

Maintenance 5
Removing and cleaning filter silencer

November 2008
If provided X Remove filter strip (81265).

X Rinse filter strip (81265) using water with detergent additive or, if very
dirty, soak it and squeeze out carefully. Rinse in cold water. Avoid
rough treatment (jet of water).
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.
NOTE
X Unscrew and remove lock nuts (81273).

X Unscrew and remove screws (81272) for connecting rods (81269).
X Remove connecting rods (81269).
X Carefully remove mesh cover (81266).
HZTL2488_EN
In the case of an insert unit (E), the water injection line must first be re-
moved when a cleaning water vessel is fitted to the filter silencer (optio-
nal depending on turbocharger type). (See also following section Re-
NOTE moving cleaning pipe.)
X Take out insert units (E), bend open cover plates (81137) and then
take out fleece segments (81136).
X Clean fleece segments (81136).
When cleaning, ensure that fleece segments (81136) are cleaned only
using a mild jet of compressed air and a soft brush or damp cloth.
Otherwise there is a risk of damage or change of shape.
Replace very dirty fleece segments and filter strip as well as damaged
connecting rods with original parts from ABB Turbo Systems.
Version 2.8
NOTE

Maintenance 5
Mounting filter silencer
November 2008
X Assemble insert units (E) by putting fleece segments (81136) into co-
ver plates (81137).
X Bend back cover panels (81137) to their original shape.
X Put insert units (E) into slot guides in filter silencer body (81135).
If a cleaning water vessel is fitted to the filter silencer (optional depen-

ding on turbocharger type), the water injection line must now be refitted.
(See also following section Fitting cleaning pipe.)
NOTE
X Put mesh covers (81266) uniformly into correct position.

X Push connecting rods (81269) through clips on mesh covers (81266).
HZTL2488_EN
If the connecting rods (81269) are not located correctly in their recesses
on the filter silencer body (81135), the mesh cover (81266) can twist
and shift. There is then a risk of foreign matter and dirt getting into the
CAUTION compressor.
Version 2.8
81266 81269

Maintenance 5

November 2008
X Join connecting rods (81269) using screws (81272). When tensioning

screws (81272), ensure that connecting rods (81269) are located cor-
rectly in recesses in filter silencer body (81135). Now alternately tigh-
ten screws (81272) to following maximum torque:
HZTL2488_EN
Screw Tightening torque

81272 20 Nm
X Screw lock nuts (81273) onto screw (81272) and tighten to following
torque:
Lock nut Tightening torque

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

Version 2.8

Maintenance 5
Cleaning the compressor during 5.3 Page 6

operation
5.3 Cleaning the compressor during operation
November 2008
These guidelines for wet cleaning apply exclusively for cleaning with
clean water and are subject to permission for the procedure being ob-
tained from the engine manufacturer.
NOTE
How dirty the compressor stage (compressor wheel and diffuser) beco-
mes depends on how clean the drawn-in air is.
Deposits of dirt can build up in the flow ducts if the following substances
are in the intake air:
Oily or salty mist

Solid combustion residues
Various kinds of dust
HZTL2488_EN
Dirty deposits on the compressor stage have a negative influence on the
compressor efficiency and on the charging pressure.
This results in higher exhaust temperatures and higher fuel consumption

by the engine. Dirty deposits on the compressor can also increase rotor
unbalance.
Periodic cleaning of the compressor during operation prevents or delays a

severe increase in dirty deposits. In no way, however, does it replace the
regular service work during which the turbocharger is completely dismant-
led and the compressor cleaned mechanically.
Interval between clea- The interval between periodic cleaning depends considerably on the ope-
nings rating conditions. In general, cleaning should be carried out every 25 to
100 operating hours.
Version 2.8
Should the prescribed cleaning intervals prove incompatible with the

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

Maintenance 5

operation
Cleaning method
Cleaning of the compressor during operation is carried out using the clea-
November 2008
ning method described in the following:
Wet cleaning
This cleaning method has been tested and approved by ABB Turbo Sy-
stems.
Principle of wet cleaning To clean the compressor stage while in operation, water is injected in front
of the compressor wheel from an injection pipe that is built in the filter si-
lencer or suction branch.
The water does not act as a solvent in the process, but the deposit is re-
moved by the mechanical impact of the drops. This is a very suitable pro-
cess, provided that the build-up of deposits is not too advanced.
Corrosion and deposits during cleaning

Damage and impairment of turbocharger parts through salt water and
HZTL2488_EN
cooling water additives.

CAUTION
X Always use clean water only for cleaning.
V-engines For 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.
Version 2.8

Maintenance 5

operation
5.3.1 Wet cleaning with orifice plate on filter silencer (XC2)
November 2008
Operating-state preconditions for cleaning compressors with XC2
In order to carry out a successful cleaning procedure that has been te-
sted and is recommended by ABB Turbo Systems, the following prere-
quisites must be met:
NOTE
Z Engine loading as full as possible
Z High turbocharger speed
X Start of the cleaning cycle according to the following description in
Procedure for wet cleaning with XC2.
Procedure for compressor wet cleaning with XC2
HZTL2488_EN
X The water pressure before the connection to the turbocharger (during
the water injection time) must be maintained according to the table
Cleaning parameters.
X After cleaning, a waiting time of at least 5 minutes is necessary to allow
the turbocharger to dry.
If the cleaning operation was not successful, it can be repeated up to 2

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

Version 2.8
Turbocharger Turbocharger Water Orifice plate

type speed injection time hole diameter
[sec] [mm]
TPL67-C As far as possi- 10 2.1
TPL71-C ble 2.5
nBmax
TPL76-C 2.9
TPL 79-C 3.4

Maintenance 5

operation
5.3.2 Wet cleaning using external water-pressure vessel (XC3)

November 2008
Operating-state preconditions for cleaning compressors with XC3
In order to carry out a successful cleaning procedure that has been te-
sted and is recommended by ABB Turbo Systems, the following prere-
quisites must be met:
NOTE
Z Engine loading as full as possible
Z High turbocharger speed
X Start of the cleaning cycle according to the following description in
Procedure for wet cleaning with XC3.
Procedure for compressor wet cleaning with XC3

HZTL2488_EN
Version 2.8
X Y

Maintenance 5

operation
Operating the water pres- X The Operating state prerequisites for cleaning compressors with XC3
sure vessel must be met before cleaning can begin.
X Screw out screw plug (X).
November 2008
X Fill container with clean water.
X Screw in screw plug (X).
X Push back valve activator (Y) against spring pressure and hold it for 10
to 15 seconds until full volume of water has been injected.
X After cleaning, a waiting time of at least 5 minutes is necessary to allow
the turbocharger to dry.
If the cleaning operation is not successful, it can be repeated up to 2

times.
If cleaning is still not successful after three attempts and the engine
NOTE operating values are unsatisfactory, we recommend that you have the
turbocharger checked and cleaned by an official ABB Turbo Systems
service station.
HZTL2488_EN
Cleaning parameters per turbocharger compressor
Turbocharger type Turbocharger Contents of do- Water

speed sing vessel injection time
[dm3] t1 [s]
TPL 67/71-C As far as possible 0.4 4 ... 15
nBmax
Version 2.8

Maintenance 5
Cleaning turbine blades and nozzle ring 5.4 Page 11

in operation
5.4 Cleaning turbine blades and nozzle ring in

operation
November 2008
The combustion of heavy fuel oil in diesel engines leaves dirty deposits on
the turbocharger turbine blades and nozzle rings. These deposits on the
turbine components are caused by the following products of combustion:
Soot
Molten ash
Cinders
Incompletely burned fuel
Sodium vanadyl vanadate
It is therefore an advantage if fuels are used which have a low content of

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

um less than 3:1, so that the melting point of the sodium vanadyl vana-
date is as high as possible.
NOTE
The dirty deposits increase with time so that regular and proper cleaning
is important to remove what has accumulated.
The charging pressure can rise somewhat if the turbine cross-section is

reduced by dirty turbine components. The dirty deposits cause a drop in
turbine efficiency and a rise in engine temperatures after the cylinders.
This may mean that the engine output has to be reduced.
In addition, a dirty turbine results in rotor unbalance. Heavy deposits of

dirt can lead to unacceptably high rotor imbalance.
Experience with turbocharger operation shows that, despite periodic clea-

ning while the installation is running, overhauls during which turbine and
Version 2.8
nozzle ring are cleaned mechanically cannot be dispensed with. If clea-

ning is carried out correctly and the cleaning system is properly sized,
however, the intervals between overhauls can be extended.

Maintenance 5

in operation
Wet cleaning interval The interval between periodic cleaning depends considerably on the ope-
rating conditions. In general, cleaning should be carried out every 50 to
200 operating hours.
November 2008
Cleaning method
The turbine and nozzle ring are cleaned while operating using the clea-
ning method described in the following. This method has been tested and
is approved by ABB Turbo Systems:
Wet cleaning
Principle of wet cleaning During wet cleaning using droplets of water, the water does not act as a
solvent. Instead, the deposit is removed by the mechanical impact of the
drops.
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CAUTION
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 instructi-
NOTE ons. (See respective section Operating state prerequisites.)
Non-observance of the specified exhaust gas temperature in front of the

turbine, the minimum stabilising time before as well as between clea-
Version 2.8
ning operations and the drying time after cleaning in accordance with
CAUTION the pertaining cleaning instructions drastically shortens the expected
service life of components.
V-engines
For V-engines with several turbochargers on each engine, we recommend
parallel cleaning of both turbochargers. This cleaning process is faster
and the risk of turbocharger surging is reduced. We recommend conduc-
ting tests to find the most suitable method.

Maintenance 5

in operation
5.4.1 Wet cleaning turbine and nozzle ring during operation

November 2008
Prerequisites for turbine wet cleaning

CAUTION
Recommended operating state for turbine wet cleaning
The following operating state and prerequisites have been tested and ap-
proved by ABB Turbo Systems for the cleaning process:
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X Start engine or reduce engine load to as low a level as possible (best

cleaning is achieved at a load level of roughly 15 to 20%).
X As soon as turbine inlet temperature is stable and below 430°C, wait a
further 10 minutes for charger parts to cool down.
X Start cleaning cycle according to following description in Wet cleaning
procedure
Version 2.8

Maintenance 5

in operation
Layout of cleaning pipes
November 2008
G
1 6 2 11 3 4 5 7
8
9
10
1 Water supply (freshwater 6 Other engine

only)
2 Regulating valve 7 Injection nozzle
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3 Manometer 8 Drain pipe
4 Air supply with 3-way valve 9 Drain cock
5 Water pipe (stainless steel) 10 Drain
G Pipes on gas inlet casing 11 Flowmeter
Wet cleaning procedure for turbine and nozzle ring during operation
X Meet operating-state requirements and prerequisites without fail before

cleaning!
X Make sure water supply (1) is connected and turned on and water
flows constantly.
X Open drain pipe (8,9) if provided.
X Switch over 3-way valve (4) from scavenging air mode to water supply.
Version 2.8
Set the required volume of water on the flow meter in accordance with
the table in the following chapter Cleaning parameters.
NOTE

Maintenance 5

in operation
X After injecting required volume of water, shut off the water supply again
by switching over the 3-way valve (4) to scavenging air mode.
November 2008
X This completes the injection procedure.

X Close drain hole (if provided) above drain pipe (8,9).
X After cleaning, wait at least 10 minutes with engine running to allow
turbocharger to dry.
Recommendation for To obtain the water flow rates specified in the table of cleaning parame-
water pressure ters, a water pipe pressure of 5 bar is necessary. If a lower water pressu-
re is available, the water flow rate specified in the table will not be obtai-
ned. In this case, cleaning will not be so good. An improvement can be
achieved by reducing the load to below 10%.
Repeating cleaning cycles immediately after each other must be avoi-

ded as this can lead to high mechanical loading and consequently to a
reduction in the service life of the components.
NOTE If the cleaning process is unsuccessful, the length of the process can
be extended. If the injection time is extended, it must be ensured that
no unacceptable quantity of water collects in the gas outlet casing. To
HZTL2488_EN
this end, a drainage system for the gas outlet casing must be installed
and open during the cleaning process. If no drainage system is provi-
ded, the injected volume of water can be controlled by a flow meter in
the water supply. The maximum volume of water allowed in individual
cases must be determined together with an official ABB Turbo Systems
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 The following must be observed where drainage of the gas outlet casing is
cleaning concerned:
The exhaust-gas temperature after the turbocharger drops significantly

during cleaning (by 50 to 150°C).
Water might (but not necessarily) flow out of the drain pipe, depending
on the engine load. This outflow might not start for 2 - 3 minutes, or it
may not occur at all.
Version 2.8
If drainage of the gas outlet casing is dispensed with, 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 out-
let casing. Signs of this are a sudden drop in turbocharger speed or ve-
ry strong increase in the gas inlet temperature. In such cases, cleaning
must be stopped immediately and the cleaning cycle repeated from the
beginning with lower water pressure or higher engine load.

Maintenance 5

in operation
Wet cleaning parameters for turbine and nozzle ring
Table of cleaning parame-
November 2008
TPL type Max. tempera- Injection time Water flow rate per turbochar-
ters ture at start of t i [min] ger at pWater = 5bar
cleaning MW [l/min]
TTI [°C]
TPL67-C 430 10 18
TPL71-C 24
HZTL2488_EN
Version 2.8

Troubleshooting 6
Possible remedies for failures 6.1 Page 1
6 Troubleshooting
November 2008
6.1 Possible remedies for failures
Exhaust temperature too high
Engine output and speed unchanged
Engine Z Malfunction in the injection system

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

X Clean
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Z Compressor / turbine soiled

X Clean
Z Exhaust counterpressure too high

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

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

X Clean
Z Insufficient coolant water quantity

X Replenish
Z Coolant water inlet temperature too hot

Version 2.8
X Clean/inspect cooling system
Z Ventilation inadequate
X Improve ventilation

Troubleshooting 6
Charge-air pressure too low
November 2008
Intake condition normal
Engine Z Air receiver leaking

X Repair
Z Gas line between engine and turbine leaking

X Repair
Z Injection misadjusted
X Correct adjustment
Z Valve control misadjusted

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Turbocharger Z Manometer display faulty
X Replace manometer
Z Leak in line to the manometer

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

X Clean
Z Compressor / turbine soiled

X Clean
Z Compressor / turbine damaged

Version 2.8
Z Excessive exhaust counterpressure

X Clean boiler or exhaust silencer

Troubleshooting 6
Charge-air pressure too high

November 2008
Intake condition normal
Engine Z Malfunction in the injection system

Z Engine output higher than expected

X Check engine output
Z Injection misadjusted
Turbocharger Z Manometer display faulty

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

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

X Clean
Version 2.8
Z Bearing damaged
Z Rotor grazing
Z Foreign bodies in the turbocharger

Troubleshooting 6
Run-out time too short
November 2008
X Clean
Z Bearing damaged
Z Rotor grazing
Sluggish start-up

X Clean
Z Bearing damaged
Z Rotor grazing
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Lubricating oil pressure too low
Engine Z Oil filter heavily soiled

X Clean
Z Oil pump in the lubricating system defective

X Inspect
Z Manometer provides false reading

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

Version 2.8

Troubleshooting 6
Constant surging of the turbocharger

November 2008
Engine Z Exhaust pressure to the turbine elevated because boiler or exhaust si-
lencer is dirty
Z Trap dirty
X Clean
Turbocharger Z Charge-air filter or silencer dirty

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

official ABB Turbo Systems service station.
NOTE
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Version 2.8

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

November 2008
7.1 Turbocharger weights

Carefully fasten individual parts and large assemblies / modules to sui-
table hoists / lifting devices which are in a technically perfect condition
and have an adequate load-bearing capacity.
WARNING
Loads that are not suspended in accordance with regulations during di-
sassembly and assembly might fall and cause a serious or even fatal
injury.
X Select a suitable rope taking into account weight of load.

X Hang rope crossed over on crane hook
X Don't stand under suspended loads.
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Complete turbocharger without filter silencer/air suction branch
Weights [kg] TPL 67-C TPL 71-C

1081 1771
Complete turbocharger unit with filter silencer

Version 2.8

1194 1957
Complete turbocharger unit with radial air suction branch

1128 1840

Remove the turbocharger 7.2 Page 2
7.2 Remove the turbocharger

X Disconnect all gas, air and oil lines in accordance with engine manu-
November 2008
facturer’s instructions.
Oil orifice plate

An orifice plate is fitted in each of the two oil inlet channels in the bea-
ring casing. In order to obtain the required oil pressure, the diameter
NOTE (∅) of this orifice plate was individually adjusted by the engine builder.
Whenever these orifice plates are removed, or if the bearing casing, the
cartridge group or the complete turbocharger is replaced, make absolu-
tely sure that the orifice plate with the correct diameter (∅) is fitted into
the oil inlet channel in which the oil flows.
X Re-use existing orifice plate.
Suspending the turbo-

charger
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Version 2.8

Remove the turbocharger 7.2 Page 3
At least the two suspension lugs on the bearing casing and the two sus-
pension lugs on the gas inlet casing must be used (observe marking on
the insulation). The two suspension lugs on the gas inlet casing are
November 2008
helpful for aligning the turbocharger horizontally.
X Remove insulation jacket (S) from bearing casing and insulation from
gas inlet casing. Leave rest of insulation on turbocharger, if desired.
X Check lifting equipment.
X Attach lifting equipment to suspension lugs on bearing casing and gas
inlet casing.
Take weight of turbocharger into consideration.
CAUTION
During removal work, a turbocharger that is not lifted in compliance with

regulations could fall and cause serious or even fatal injury.
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WARNING Z The filter silencer must not be used for lifting the complete turbo-
charger.
X Select a suitable rope taking into account weight of turbocharger.
X Suspend complete turbocharger from fastening points provided for
this purpose.
X Unscrew fixing screws in foot.

X Lift turbocharger off engine and put it down to one side.
If the support for the turbocharger is missing or defective, the turbo-

charger could tip over during installation and removal and cause seri-
ous or even fatal injury.
WARNING
X Support turbocharger at a suitable point.

Version 2.8
X Cover oil connection.

Installing the turbocharger 7.3 Page 4
7.3 Installing the turbocharger
November 2008
During installation work, a turbocharger that is not lifted in compliance
with regulations could fall and cause serious personal injuries or even
fatal accidents.
WARNING
Z The filter silencer must not be used to lift the turbocharger!
X Select a suitable rope taking into account the weight of the turbo-
charger.
X Suspend the complete turbocharger using the attachment points
provided for this purpose and transport horizontally.
X Remove cover from oil connection.

X Inspect lifting gear.
X Fasten lifting gear to suspension lugs on bearing casing.
Take the turbocharger weight into account when selecting the lifting
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gear.
CAUTION
Oil orifice plate

X Adapt turbocharger to suit engine.

Version 2.8
X Tighten fixing screws in foot in accordance with engine manufacturer's

instructions.
X Fasten gas, air and oil lines in accordance with the engine manufactu-
rer’s instructions.
X Adapt insulating shell to suit bearing casing and fasten it.
X Plug in cable connector on speed sensor.

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

November 2008
8.1 Module weights
Carefully fasten individual parts and large assemblies / modules to sui-

table hoists / lifting devices which are in a technically perfect condition
and have an adequate load-bearing capacity.
WARNING
Loads that are not suspended in accordance with regulations during di-
sassembly and assembly might fall and cause a serious or even fatal
injury.
X Select a suitable rope taking into account weight of load.

X Hang rope crossed over on crane hook
X Don't stand under suspended loads.
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Version 2.8

Assemblies
November 2008
HZTL2488_EN
Version 2.8

Weights [kg] Description TPL 67-C TPL 71-C

1 Filter silencer 113 186
November 2008
2 Radial air suction 44 73

branch
3 Compressor casing 172 282
(one-piece)
4 Wall insert 48 79
5 Diffuser 17 27
6 Cartridge group 282 463
7 Turbine diffuser 31 51
8 Nozzle ring 8 13
9 Gasket 0.07 0.07
10 Gas inlet casing 90 138
11 Segment 7 11.5
Complete compressor casing

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

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

the combined weights of the compressor casing, the diffuser, and the
wall insert.
NOTE
Version 2.8

Removing and fitting filter silencer or air 8.2 Page 4

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

tion branch
November 2008
Not all tools are marked with a part number. Tools are identified using
the tool list (provided in the toolbox).
NOTE
X Remove insulation where necessary.

X Disconnect all air ducts in accordance with engine manufacturer’s in-
structions.
72027
(72028)
72018
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90231
X Fit safety lifting eye bolt (90231) to filter silencer.
During removal and assembly, turbocharger components that have not

been suspended in compliance with regulations may fall, and can cause
serious or even fatal injury.
WARNING X Do not stand under suspended loads.
Remove filter silencer

X Sling lifting gear through the loops at rear and secure to shackle
(90195) or safety ring bolt (90231) using a shackle.
Version 2.8
X Unscrew nuts (72027) with washers (72018) or verbusripp washers

(72028) and remove filter silencer or air suction branch.
Mounting the filter silencer X Mount filter silencer or air suction branch in reverse order.

Axial clearance 8.3 Page 5
8.3 Axial clearance

November 2008
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Z The axial clearance (A) must be measured before removal and after in-
stallation of the cartridge group.
X Measure and note axial clearance (A).
Clearance A [mm] TPL 67-C TPL 71-C

Version 2.8
0.31 – 0.49 0.33 – 0.50
If the axial clearance (A) is out of tolerance, an official service station of

ABB Turbo Systems must be contacted.
CAUTION

Removing cartridge group 8.4 Page 6
8.4 Removing cartridge group
November 2008
Spare parts sets
Ensure that the spare parts sets required are available.
NOTE X See chapter entitled Reserve and spare parts.
Not all tools are marked with a part number. Tools are identified using
the tool list (provided in the toolbox).
NOTE
X Remove insulation.
X Disconnect oil lines in accordance with engine manufacturer's instructi-
ons.
HZTL2488_EN
Oil orifice plate
Version 2.8

Remove complete com-

pressor casing
November 2008
90195 (TPL71-C)
90213 (TPL67-C)
90195
42012
HZTL2488_EN
61037
72000
90190
X Attach compressor casing clamp (90190) and secure compressor ca-

sing (72000) to crane using a shackle (90195).
X Unscrew nuts (61037).
X Uniformly press off compressor casing (72000) using three press-off
nuts (61037) fitted at bearing casing side.
X Slightly lift compressor casing (72000) and withdraw a little.
X Attach second shackle (90195) for TPL-71-C or (90213) for TPL-67-C
to flange of compressor casing (72000).
X Withdraw compressor casing (72000) completely.
X Remove O-ring seal (42012).
Place down compressor casing (72000) with wall insert and diffuser
Version 2.8
X
with flange (F) on underlay.
Ensure that the underlay does not slip.
X Maximum working load for shackle (90213) is 300kg.

WARNING X Allow compressor casing to rest only on flange (F).
X Check underlay and adjust if necessary.

Completely disassemble
November 2008
compressor casing.
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X Remove three screws (72002).

Remove diffuser (79000) using lifting eye bolts (90235).
Version 2.8
X
X Remove wall insert (77000) using lifting eye bolts (90230).
X Remove O-Ring seal (77005) from wall insert.

Remove cartridge group.

November 2008
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X Unplug cable connector (86515) and screw out speed sensor (86505)
with O-ring seal (86506).
X Check lifting equipment and fasten to bearing casing (42001).
X Unscrew three screws (61059) and remove together with Verbusripp
washers (61058).
During removal work, a cartridge group that is not lifted in compliance

with regulations could fall and cause serious or even fatal injury.
Version 2.8
X Select a rope suitable for weight of cartridge group.

WARNING
X Uniformly press off cartridge group using puller screws (90900) in holes
provided.

If the blades have insufficient or no clearance between the rotor and
November 2008
casing, this can lead to damage to the blades and the casing.
Turn rotor to check that turbine blades do not touch turbine diffuser.
CAUTION
X Extract cartridge group.

X Fit supports (90450) using screws and set down cartridge group to one
side.
X Cover oil connections.
Work that exceeds the scope of the description in this chapter must on-
ly be performed by a trained fitter from an official ABB Turbo Systems
service station.
CAUTION
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Version 2.8

Dismantling and installing the turbine 8.5 Page 11

diffuser and nozzle ring
8.5 Dismantling and installing the turbine diffuser

and nozzle ring
November 2008
Release turbine diffuser.

HZTL2488_EN
X Plut clamp (90921) over threaded stud (61036).

X Insert extension (A) of torque spanner (B) through hole in clamp
(90921) and release torque on screws (61056) one after the other.
X Don't remove screws (61056) complete with Verbusripp washers
Version 2.8
(61057) yet.


Remove turbine diffuser.
November 2008
HZTL2488_EN
X Replace two screws (61056) and Verbusripp washers (61057) with
guide bolts (90320).
X Remove remaining screws (61056) and Verbusripp washers (61057).
X Press off turbine diffuser (63000) using press-off screws (90901) and
withdraw a little.
X Fasten turbine diffuser (63000) to lifting gear and remove as a comple-
te unit.
Version 2.8


Remove nozzle ring.

November 2008
HZTL2488_EN
After removal of the turbine diffuser, the nozzle ring (56001) is clamped
only weakly to the gas outlet casing. By pulling it forward, the nozzle
ring (56001) is released and could fall down.
CAUTION
X Pull nozzle ring (56001) forward and remove.

Version 2.8


Fitting turbine diffuser and nozzle ring
November 2008
Fitting X Fit nozzle ring and turbine diffuser in reverse order to removing them.
X Align nozzle ring with holes or cams in gas inlet casing and fit it using
screws, nuts and sleeves.
Smear all screws in and on gas casings with Anti Scuff Paste 868 from
SPANJAARD.
NOTE
service station.
CAUTION
HZTL2488_EN
Version 2.8

Installing cartridge group 8.6 Page 15
8.6 Installing cartridge group

November 2008
Oil orifice plate

X Remove cover from oil connection.

X Check lifting equipment and fasten it to bearing casing (42001) so that
cartridge group hangs straight.
HZTL2488_EN
When it is being fitted, a cartridge group that is not suspended in com-

pliance with regulations could fall and cause serious or even fatal injury.
X Select a rope suitable for weight of cartridge group.
WARNING
Version 2.8

November 2008
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X Remove supports (90450) and carefully insert cartridge group.
If the blades on the rotor have insufficient or no clearance, the blades

and the casing could be damaged.
X Turn rotor to check that turbine blades do not touch turbine diffuser.
CAUTION
X Uniformly tighten three screws (61059) complete with Verbusripp was-

Version 2.8
hers (61058).
X Remove lifting equipment.
X Screw in speed sensor (86505) complete with O-ring seal (86506) and
plug in cable connector (86515).
X Fit all oil lines in accordance with engine manufacturer's instructions.

Fit complate compressor

casing
November 2008
HZTL2488_EN
X Fit O-Ring seal (77005) to wall insert (77000).

X Screw lifting eye bolts (90230) into holes in wall insert (77000).
X Align wall insert (77000) so that lugs on lifting eye bolts (90230) centre
Version 2.8
wall insert (77000) in three threaded holes.

X Lower wall insert (77000).
X Release lifting eye bolts (90230).
X Mount diffuser (79000) using lifting eye bolts (90235).
X Remove lifting eye bolts (90235).
X Fit screws (72002).

Install complate compres-

sor casing
November 2008
90195 (TPL71-C)
90213 (TPL67-C)
90195
42012
HZTL2488_EN
61037
72000
90190
X Fit O-ring seal (42012).

X Attach compressor casing clamp (90190) and secure compressor ca-
sing (72000) to crane using a shackle (90195).
X Attach second shackle (90195) for TPL-71-C or (90213) for TPL-67-C
to flange of compressor casing (72000).
When lifting the compressor, ensure that the underlay does not slip.
X Maximum working load for shackle (90213) is 300kg.

WARNING X Allow compressor casing to rest only on flange (F).
Version 2.8
X Check underlay and adjust if necessary.
X Fit three press-off nuts (61037), distributed evenly around circumference.
X Push compressor casing (72000) onto studs in cartridge group and re-
move only one shackle (90195) on flange.
X Push compressor casing (72000) further to fitt snugly on cartridge
group and secure using nuts (61037).

X Measure and note axial clearance (A).

November 2008
Clearance A [mm] TPL 67 TPL 71

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

ABB Turbo Systems must be contacted.
CAUTION
X Connect oil lines and all air ducts in accordance with engine manufac-
turer’s instructions.
X Mount filter silencer or air suction branch and secure using nuts
(72027) and Verbusripp washers (72028).
X Fit insulation.
HZTL2488_EN
service station.
CAUTION
Version 2.8

Table of tightening torques 8.7 Page 20
8.7 Table of tightening torques
November 2008
1 6 7 8
28
HZTL2488_EN
4 5 3 9 21 17
29
9
Version 2.8

Table of tightening torques 8.7 Page 21
Tightening torques [Nm] Item Part no. TPL 67-C TPL 71-C
No.
1 82005 M16x1.5 M16x1.5
November 2008
45 45
3 72002 M10 M12
50 80
4 72027 M14 M16
with verbus- 75 105
ripp washer
4a 72027 M14 M16
with washer 95 125
5 72026 M14 M16
with verbus- 30 30
ripp washer
5a 72029 M14 M16
with washer 30 30
6 61037 M16 M18
110 160
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7 61036 M16 M18

30 40
8 61059 M16 (VR) M18 (VR)
200 280
9 42059 M12 (VR) M16 (VR)
80 180
17 61044 M12-T M14-T
80 130
21 61056 M12-T (VR) M14-T (VR)
105 130
28 51300 M12-T (VR) M14-T (VR)
130 200
29 86505 M18x1.5 M18x1.5
150 150
Version 2.8

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

November 2008
9.1 Possibilities for emergency repair
Lubricating oil leakage is a fire hazard.
WARNING
The instructions of the engine manufacturer for operation of the engine

with locked / isolated turbocharger must be followed precisely in all ca-
ses!
CAUTION
If the diesel engine must be capable of operation again as soon as possi-

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

Blocking the inlets and outlets
Bypass the turbocharger
Fit cover plate
Version 2.8

Locking the rotor 9.2 Page 2
9.2 Locking the rotor
November 2008
A blocked rotor must be removed after the turbocharger repair and gi-
ven an imbalance check.
CAUTION
An exception is a test rig run up to maximum 25% engine load on new

engines with one or several turbochargers, which are sometimes re-
quested by customers. As operation with a blocked rotor is only brief in
NOTE these cases and the loads are low, subsequent removal of the rotor is
not necessary.
U Removed balancing screws must not be screwed in again.
During operation of the engine with a blocked turbocharger, the lubrica-

tion oil system must remain connected to this turbocharger too and tur-
HZTL2488_EN
ned on if the gas inlet cannot be blocked. (See section Further measu-
CAUTION res and information for operation with a blocked rotor for 4-stroke engi-
nes.) Otherwise components that are still intact can be damaged
through overheating.
The lubricating oil supply to the turbocharger must be shut off in the
event of a lubricating oil leak on the turbocharger.
Version 2.8


November 2008
HZTL2488_EN
Tightening torques table Part no. TPL67-C TPL71-C

72027 M14 M16
75 Nm 105 Nm
94007 M8 M8
25 Nm 25 Nm
X Remove silencer or air suction branch.
Carry out this work as described in the chapter Removal and fitting.
Version 2.8
NOTE
X Insert locking flange (94003) into compressor wheel.

X Put screws (94007) into unoccupied threaded holes in compressor
wheel and tighten to values shown in Tightening torques table.
Don't remove any balancing screws from the compressor wheel. Use
only free threaded holes to fit the lifting device.
CAUTION

X Position assembly / disassembly device (90020) over studs (72026)

and locking flange (94003).
X Turn compressor wheel so that locking flange hexagon aligns with the
November 2008
hexagon in assembly / disassembly device (90020).
X Secure assembly / disassembly device (90020) on compressor housing
using nuts (72027) on studs (72026) tightened to values shown in pre-
ceding Tightening torques table.
HZTL2488_EN
Make sure all components are clean and free from grease.
Version 2.8
CAUTION

Further measures and information for operation with blocked rotor for 4-
November 2008
stroke engines
4-stroke engine with one turbocharger
No further measures are necessary. The engine can be operated as natu-

rally aspirated engine according to the instructions of the manufacturer.
4-stroke engine with several turbochargers
Separate receivers No further measures are necessary on engines with separate air and ex-
haust receivers. The engine can be operated as naturally aspirated engi-
ne according to the instructions of the manufacturer.
Common air receiver If the engine is equipped with a common air receiver and separate ex-
HZTL2488_EN
haust-gas receivers, the compensator at the compressor outlet of the da-

maged turbocharger must be dismantled and the air duct on the engine
side must be isolated. Otherwise the undamaged turbocharger can spin
"unloaded" and run at overspeed.
More or less powerful pulses from the exhaust-gas system are applied to
the locked rotor, depending on the engine turbocharging system. Particu-
larly with pulse supercharging (turbine casing with more than one gas in-
let) the locking device is then subjected to heavy loading. The following
operating limits should therefore not be exceeded:
In systems similar to those with constant pressure (1 gas inlet) the en-
gine can be operated up to a maximum of 25% engine load. The pres-
sure in the charge-air receiver must not exceed 0.9 bar overpressure.
With pulse supercharging (2...4 gas inlets) the engine can be operated
up to a maximum of 20% engine load. The pressure in the charge-air
receiver must not exceed 0.5 bar overpressure.
Version 2.8
Attention must be paid to the speed of the undamaged turbocharger in

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

Fit cover plate 9.3 Page 6
9.3 Fit cover plate
November 2008
The cover plate (material: General structural steel, in accordance with
DIN EN 10025-2) must be manufactured in-house according to the
drawing.
NOTE
Cover plate dimensions Type B1 B2 B3 B4 B5 B6 B7 B8 HZTL2488_EN

[mm]
TPL 67-C 13 325 30 30 8 10 6 70
TPL 71-C 13 385 30 30 8 10 6 84
Type Ø1 Ø2 Ø3 Ø4 Ø 5 min. Ø 6 min.
Version 2.8
TPL 67-C 616 694 660 16 22 15

TPL 71-C 726 818 779 18 25 15
Type ⍺1 ⍺2 ⍺3
TPL 67-C 4 x 90° 37.5° 24 x 15°
TPL 71-C 4 x 90° 37.5° 24 x 15°


November 2008
HZTL2488_EN
Carry out this work as described in the chapter Removal and fitting.
NOTE
X Remove cartridge group.
Version 2.8

November 2008
HZTL2488_EN
X Close off opening in gas outlet casing using cover plate.
X Fasten cover plate using spacer sleeves and nuts (61037).
Shut off the lubricating oil supply to the turbocharger.
CAUTION
Version 2.8

Further measures and information for operation with a turbocharger with

November 2008
cover plate in 4-stroke engines
4-stroke engine with one turbocharger
No further measures are necessary. The engine can be operated as natu-

rally aspirated engine according to the instructions of the manufacturer.
4-stroke engine with several turbochargers
Separate receivers No further measures are necessary on engines with separate air and ex-
haust receivers. The engine can be operated as naturally aspirated engi-
ne according to the instructions of the manufacturer.
Common receiver The air line must be blocked on the engine side, since the undamaged
turbochargers develop a receiver pressure.
HZTL2488_EN
The engine can be operated according to the instructions of the engine

manufacturer. Attention must be paid to the speed of the undamaged
turbocharger in all cases. Rotating speed limit nBmax as indicated on the
CAUTION rating plate must not be exceeded.
Version 2.8

Blocking the inlets and outlets 9.4 Page 10
9.4 Blocking the inlets and outlets
November 2008
Shut off the supply of lubricating oil to the turbocharger.
CAUTION
X Block the compressor casing outlet, gas inlet and gas outlet by fitting
cover plates.
For information about how to do this, see the manufacturer's instructi-

ons.
NOTE
HZTL2488_EN
Version 2.8

Bypass the turbocharger 9.5 Page 11
9.5 Bypass the turbocharger

November 2008
Shut off the supply of lubricating oil to the turbocharger.
CAUTION
Z Only applies for engines with one turbocharger.

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

ons.
NOTE
HZTL2488_EN
Version 2.8

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

months
10 Mothballing turbocharger
November 2008
10.1 Taking out of operation for up to 12 months

If a turbocharger put out of use for up to 12 months, any possible special
turbocharger storage measures depend primarily on the condition of the
lubricating oil before the shut-down.
If the Total Acid Number (TAN) is lower than 2 mg KOH/g no special

measures need to be taken. If, however, the Total Acid Number is greater,
the turbocharger must be dismantled after its shut-down, cleaned and
bright parts oiled with protective oil.
If the turbocharger is left mounted on the engine and the engine oil is re-
placed by protective oil which is circulated by the pre-lubrication pump
prior to the shut-down, no measures need to be taken with the turbochar-
ger. The remains of the old engine oil will be washed away and the sensi-
tive bearing parts will be largely protected against corrosion.
If the rotor turns due to a draught from the flue, fit a blind flange between
HZTL2488_EN
the compressor casing and the charge-air duct.

Version 2.8

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

months
10.2 Taking out of operation for more than 12

months
November 2008
If the turbocharger is removed from the engine and stored for a prolonged
period of time, its disassembly and the special storage measures must be
carried out by an official ABB Turbo Systems service station.
Suitable storage locations are dry rooms where the relative humidity is
between 40% and 70% and no condensation can form.
Inspect stored turbochargers yearly for corrosion.

If there are signs of rust, clean parts and renew protection against cor-
rosion.
NOTE
HZTL2488_EN
Version 2.8

Disposal 11
Environmentally compatible disposal of 11.1 Page 1

turbocharger components
11 Disposal
November 2008
11.1 Environmentally compatible disposal of tur-

bocharger components
Environmentally compatible disposal of turbocharger components

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

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

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

X Remove dust with a suitable vacuum cleaner.
Version 2.8
X Wear respiratory mask as protection against particles (P1 or P2

mask).
X Wear leather protective gloves.
X Wear close-fitting safety goggles.
X Dispose of thermal insulation as special waste.

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

November 2008
12.1 Ordering spare parts

When making inquiries or ordering spare parts, the following data should
be specified:
Turbocharger type
HT number
Description and part number.
Our service stations and agents take orders for spare parts.
X Contact an official ABB Turbo Systems service station or an ABB agent

if special versions / cases are not addressed in these general instructi-
ons.
HZTL2488_EN
Spare parts
The parts included in the spare parts set are available only as a whole
set.
NOTE
Storaging spare parts

All spare parts, ordered with the turbocharger, should be kept complete
and ready for use.
CAUTION
X Parts showing signs of rust should be carefully cleaned and grea-
sed.
Version 2.8
X Dispose of replaced, unusable parts in a technically and environmen-

tally compatible way.

Ordering spare parts 12.1 Page 2
Spare parts set (97070) for servicing work every 36,000 h
November 2008
Quantity Description Part number
1 O-ring seal 42012
1 Gasket 42041
2 Gasket 42045
2 Verbusripp washer 42058
2 Hexagon-head screw 42059
3 Hexagon nut 61037
1 Gasket 77005
1 O-ring seal (speed sen- 86506
sor)
HZTL2488_EN
Version 2.8

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

The following part numbers and descriptions must be used in ALL cor-
November 2008
respondence or orders:
Turbocharger Part number Description

42012 (in spare parts set) O-ring seal
51001 Gas inlet casing
51012 Segment
56001 Nozzle ring
61001 Gas outlet casing
61037 (in spare parts set) Hexagon nut
61044 Hexagon-head screw
61050 Gasket
61056 (in spare parts set) Hexagon-head screw
61057 (in spare parts set) Verbusripp washer
HZTL2488_EN

63000 Turbine diffuser
68001 Foot at compressor end
68002 Foot at turbine end
68003 Slide plate
68006 Cup spring
68007 Bushing
72000 Compressor casing
77000 Wall insert
79000 Diffuser
81000 Filter silencer
82000 Radial air suction branch
Version 2.8

Directory of part numbers 12.2 Page 4
Cartridge group – screw Part number Description

connection
21000 Shaft
November 2008
25000 Compressor wheel
32001 (in spare parts set) Thrust bearing
32101 (in spare parts set) Radial bearing, compressor end
32102 (in spare parts set) Radial bearing, turbine end
32104 (in spare parts set) Auxiliary bearing
32105 (in spare parts set) Floating disc
32106 (in spare parts set) Thrust bearing
32107 Bearing bush
42001 Bearing casing
42002 Hood
42015 Sealing cover
42041 (in spare parts set) Gasket
42045 (in spare parts set) Gasket
HZTL2488_EN
42063 Verbusripp washer
42064 Hexagon-head screw
43001 Partition wall
86505 Speed sensor
Version 2.8

General view of turbocharger 12.3 Page 5
12.3 General view of turbocharger

November 2008
61044
HZTL2488_EN
51012
51001
42012
68003
79000
61050
68002
68006
68007
77000
61001
77005
72000
68001
Version 2.8
61059
61058
61037
56001
81000
63000
82000
61056
61057

General view of cartridge group 12.4 Page 6
12.4 General view of cartridge group
November 2008
21000
42015
42011
42002
86505
HZTL2488_EN
86506
42064 42045
32102
42001
42063 42058
42041 42059
43006
32107
43005
43007
32001
32105
43001
Version 2.8
32106
32101
25000
32104

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Type TPL67-C34 HT503640

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Type TPL67-C34 HT503641

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Type TPL67-C34 HT503643

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Type TPL67-C34 HT503644

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Type TPL67-C34 HT503645

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Type TPL67-C34 HT503751

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Type TPL67-C34 HT503752

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Type TPL67-C34 HT503753

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Type TPL67-C34 HT503754

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Type TPL67-C34 HT503755

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Type TPL67-C34 HT503756

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Type TPL67-C34 HT504301

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Type TPL67-C34 HT504302

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Type TPL67-C34 HT504303

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