Instruction manual TPL 73 -B 80-B

Turbocharger
Operation Manual
TPL 73 -B.. ÷ 80 -B..
ABB Turbo Systems Ltd

Turbocharger
Type TPL73B-80B HT
n Mmax t Mmax
1/s °C
n Bmax t Bmax
Mod. A
ZTL 2480_EN
Application according to
the Operation Manual
made in Switzerland
ABB Turbo Systems Ltd ABB

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 2002
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
ABB Turbo Systems AG
Bruggerstrasse 71a
CH-5400 Baden
Switzerland
Turbocharger Operation Manual TPL
Table of contents Page 3
Preliminary remarks 0
HZTL 10450_EN
Instructions on safety and hazards 1

HZTL 10451_EN
Putting into operation 2

HZTL 10452_EN
Operation and maintenance 3

HZTL 10453_EN
Troubleshooting 4
HZTL 10454_EN
Disassembly and assembly 5

HZTL 10455_EN
Taking out of operation 6

HZTL 10456_EN
Cartridge group with screwed connection
HZTL 10464_EN
Cartridge group with polygon connection
Guide to service stations 7
ABB Turbo Systems Ltd ZTL 2480_EN

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ABB
0
Turbocharger Operation Manual TPL Chapter 0
Preliminary remarks Page 1
0
Preliminary remarks
Contents Page
1
Foreword ......................................................................................................................................3
2
Mode of operation .......................................................................................................................5
3
Correct application .....................................................................................................................6
4
Organizational measures ...........................................................................................................7
5
Original parts and safety ............................................................................................................7
6
Qualification of personnel ..........................................................................................................8
7
After-sales service ......................................................................................................................8
8
Various models ...........................................................................................................................8
9
Storage of new turbochargers ...................................................................................................9
10
Abbreviations ..............................................................................................................................9
11
Rating plate Turbocharger .......................................................................................................10
Volume: 11 pages
Edition: 06 / 2002
HZTL 10450_EN
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Chapter 0 Turbocharger Operation Manual TPL
Page 2 Prelininary remarks
Notes
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1
Foreword
This operation manual will help you to become familiar with your turbocharger supplied by ABB
Turbo Systems Ltd and to utilize it to full effect in its intended application.
This operation manual provides important instructions as to the safe, correct, and economical
operation of the turbocharger. It contains helpful information on how to recognize hazards at an
early stage and avoid them, how to reduce repair costs and standstill times, and how to
improve the reliability and the service life of the turbocharger.
This operation manual is a complement to, and an extension of, existing national regulations on
accident protection and prevention.
This operation manual must be available at all times at the site of operation of the turbocharger.
It is essential that this operation manual is read before beginning operation by all persons
working with or at the turbocharger.
Even personnel only working occasionally (e.g. installation and maintenance) must have read
and fully understood the manual before working on the turbocharger.
All instructions must be strictly observed.
This applies especially to the general and special safety instructions preceding, and in the
course of, the respective chapters.
In the event of doubt, consult the officer for safety and accident protection responsible for your
area.
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1 2 3 4 5 6 7
10
11
12
13
14
Fig. 0-1
Section of the Turbocharger
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2
Mode of operation
The turbocharger consists of two machines, a turbine and a compressor which are mounted on
a common shaft.
The exhaust gases from the diesel engine flow through the gas inlet casing (9) and nozzle ring
(7) to the turbine wheel.
The turbine (10) uses the energy contained in the exhaust gas to drive the compressor (13),
whereby the compressor draws in fresh air, compresses it before being forced into the cylinders.
The exhaust gases exit the turbocharger via the gas outlet casing (6).
The turbocharger is gastight.
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 silencer (1) into the compressor
wheel (13). It then passes through the diffuser (12) and leaves the turbocharger through the
volute of the air outlet housing (14).
The rotor runs in two radial plain bearings (3/8) which are located in the bearing bush (5)
between the compressor casing and turbine casing. The axial thrust bearing (4) is on the
compressor side.
The plain bearings are connected to a central lubricating oil feed in which the oil is supplied by
the oil system of the engine. The oil outlet is always at the lowest point of the bearing casing
(11).
The turbocharger is provided with an emergency lubricating oil tank (2). In the event of failure
of the lubricating oil system, this emergency lubrication provides a supply of oil to the bearing
positions until rotor standstill.
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3
Correct application
This turbocharger supplied by ABB Turbo Systems has been developed exclusively for use on
diesel engines to generate the volume of air and the pressure necessary for the operation of
the diesel engine.
Any other usage shall be regarded as a special application which must be clarified with ABB
Turbo Systems. The manufacturer accepts no liability for other applications.
This turbocharger was built in accordance with state of the art technology and the recognized
safety regulations and is safe for operation.
Nonetheless, the turbocharger can cause injury or death to the user or a third party, or damage
to the turbocharger itself or to other property if it is not operated by trained personnel, or if it is
used incorrectly, or for purposes other than that for which it was intended.
Correct application of the turbocharger also includes observation of the operating, maintenance
and repair conditions specified by the manufacturer.
The turbocharger should only be operated and used in a technically perfect condition, for its
intended purpose and in compliance with the operation manual.
Defects which could affect safety must be eliminated immediately.
The manufacturer shall not accept liability for damages resulting from unauthorized alterations
to, or interference with, the turbocharger.
The turbocharger has been designed for the diesel engine described including speed and
output. If it is used otherwise ABB Turbo Systems reserves the rigth to reject all guarantee
claims.
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4
Organizational 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 at and with the turbocharger shall
be checked regularly in accordance with the manual.
The turbocharger must be shut down immediately in the event of alterations affecting safety or
of corresponding operating behaviour. The fault should be reported to the person or department
responsible.
Additions to, and alterations and conversions of the turbocharger, which could impair safety,
require the prior approval of ABB Turbo Systems.
5
Original parts and safety
Original parts and accessories are especially designed for the turbocharger supplied by ABB
Turbo Systems Ltd.
We wish to state clearly that parts and accessories not supplied by us have not been tested
and approved by us.
The installation and / or the use of such products can thus have a negative effect on design
features of the turbocharger.
This in turn can be detrimental to the active and / or passive safety of the machine.
ABB Turbo Systems shall not be liable for any damage caused by using non-original parts and
accessories.
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6
Qualification of personnel
The turbocharger may only be operated and maintained by skilled and authorized personnel.
Work on mechanical components, such as bearings or rotors, must only be performed by

qualified fitters from an official service station of ABB Turbo Systems Ltd.!
It must be ensured that only authorized personnel work on the turbocharger.
7
After-sales service
For spare parts orders, technical inquiries and maintenance work there is a list at the end of
this manual (see chap. 7) with an updated, worldwide guide to service stations of ABB Turbo
Systems Ltd.
8
Various models
This instruction manual are valid for various turbocharger models.
Therefore, it can occur that components are listed which are not present in the turbocharger
supplied.
Our agents and service stations (see list in chapter 7) will provide information if special cases
are not covered in the present general instructions.
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9
Storage of new turbochargers
Turbochargers supplied by ABB Turbo Systems can be stored for 6 months as from the date of
delivery without any additional conservation measures in a dry place with an average air
humidity of 40 to 70 %.
After 6 months and every following period of 6 months spray rust -proofing oil on the surfaces
(remove insualtion) and on all accessible areas.
10
Abbreviations
The following abbreviations are being used:
CE Compressor end
chap. Chapter
e.g. For example
fig. Figure
No. Number
sec. Section
Temp. Temperature
TC Turbocharger
TE Turbine end
- Working steps / Enumerations

+ Add. working steps for options
Notes for assembling
Conformité Européenne
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11
Rating plate Turbocharger

ABB Turbocharger
Type HT
n Mmax 1 1 t Mmax 1
HZTL 428 765 P.
s
n Bmax 2 t Bmax 2 °C
6
7 8 kg 3 4 5
Application according to
the Operation Manual
made in Switzerland
Operational limits:
1 n Mmax, t Mmax: Turbocharger - operational limit at engine overload (110%).
For test trials only, if not otherwise agreed with the engine
manufacturer.
2 n Bmax, t Bmax: Turbocharger - operational limits in service.
n = Turbocharger speed
t = Exhaust gas temperature before turbine
Inspection and replacement intervals for turbocharger components:

3 Inspection intervals for the plain bearings in 1000 h
Replacement interval for the compr. wheel in 1000 h

4
Unless otherwise stated: 100'000 h
5 Replacement interval for the bladed shaft in 1000 h

Unless otherwise stated: 100'000 h
Further descriptions:
6 Customer part-number
7 Space for the special design designation
8 Weight of the turbocharger in kg
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Note The conditions agreed with the engine manufacturer apply to the values stated on
the rating plate with regard to operational limits, inspection intervals and replacement
intervals.
Caution ! The turbocharger is to be used only up to the application limits specified on the
rating plate nBmax, tBmax. These are determined with the engine manufacturer for the
specific application.
Unless otherwise agreed operational limits nMmax, tMmax are allowed for test trials
only.
The inspection intervals and replacement intervals for the turbocharger components
specified must be observed without fail!
Turbocharger components whose permissible operating times have expired may
not be used again under any circumstances!
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1
Turbocharger Operation Manual Chapter 1
Instructions on safety and hazards Page 1
1
Instructions on safety and hazards
Contents Page
1
Basic safety instructions ...........................................................................................................3
2
Special safety instructions ........................................................................................................4
2.1
Safety when connecting .......................................................................................................4
2.2
Safety when commissioning and during operation ..............................................................5
2.3
Safety when cleaning ...........................................................................................................5
2.4
Safety during disassembling and assembling ....................................................................6
2.5
Safety when taking out of service ........................................................................................6
3
Hazards and hazard protection .................................................................................................7
3.1
Mechanical influences .........................................................................................................7
3.2
Operation and process materials .........................................................................................8
3.3
Noise ..................................................................................................................................10
Volume: 10 pages
Edition: 06 / 2002
HZTL 10451_EN
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Chapter 1 Turbocharger Operation Manual
Page 2 Instructions on safety and hazards
Notes
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1
Basic safety instructions
The following symbols and terms are used in this operation manual for safety instructions:
Warning ! Serious injury or fatal accident may result if the working and operation instructions
marked with this symbol are not, or only partly, observed.
Warning signs must be strictly observed.
Caution ! 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 signs must be observed to the letter.
Note Work can be carried out more efficiently and simply when work and operation
instructions marked with this symbol are observed.
Notes help to simplify your work.
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2
Special safety instructions
The instructions here are designed to ensure your safety and to promote safe handling of the
turbocharger and its operating materials.
These safety instructions must be observed when working on or operating the turbocharger.
- Work on a turbocharger only in a stable physical and mental condition.
- Wear protective clothing (helmet, ear protection, protective glasses, protective suit, gloves,
protective shoes).
- Attach individual parts and large component modules carefully to suitable lifting devices which
are in technically perfect condition and which possess adequate load-bearing capacity.
- Do not stand under suspended loads.
- For overhead assembly work use the steps and work platforms provided for this purpose.
- Do not use machine parts as steps.
- If welding work is to be carried out above the turbocharger, the air filter must be covered to
prevent damage to the filter mat.
2.1
Safety when connecting
- Work only on those connections for which you are qualified.
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2.2
Safety when commissioning and during operation
- Before starting to work make a visual inspection of the working area.
- Remove obstacles and any other objects lying around from the work area.
- Before commissioning check the turbocharger for damage or leaks.
- Refrain from any activity which could impair safety at the turbocharger.
- Inspect the turbocharger approx. every 12 hours or at least once a day for visible external
damage and defects.
- Report immediately any damage or changes in operation performance to the person/

department responsible .
- In the event of damage, shut down the turbocharger immediately and secure it against
unintended or unauthorized interference.
2.3
Safety when cleaning
- Before cleaning, protect the floor against unintended leaks of oil and operating materials.
- Wear protective clothing (oil- and petrol resistant gloves, protective suit, eye protection,
knee protection, foot protection).
- Handle operation materials and detergents with utmost caution.
- When handling solvents, protective clothing must be worn. Avoid contact with the skin,
inhalation and penetration of clothes.
- After cleaning, check electric cables for signs of wear or damage.
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2.4
Safety during disassembly and assembly
- Perform the prescribed adjustment, maintenance and inspection work at the specified intervals.
- Inform operating personnel about special work and repairs before starting.
- Keep absorbent materials available to clean up any working materials accidentally spilled.
- Ensure safe and environmentally-friendly drainage, collection and disposal of operating and
auxiliary materials.
- Assembly and disassembly work must only be performed by trained personnel.

Work on mechanical components, such as bearings or rotors, must only be performed by
qualified fitters from an official service station of ABB Turbo Systems Ltd.!
2.5
Safety when taking out of service
- Secure the rotor against turning.
- Clean the turbocharger before mothballing.
- Wear protective clothing during mothballing the turbocharger.
- Keep the work area clean and free of oil and operating materials.
- Remove any obstacles laying around on the floor.
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3
Hazards and hazard protection
Hazards may arise during operation of, and work on, the turbocharger:
- from the turbocharger and its accessories
- from the operating materials used
- from failure to observe safety instructions
- from inadequate maintenance and inspection work.
3.1
Mechanical influences
Physical injury
Warning ! Unconsciousness and injury due to:
crushing, shearing, cutting, winding, demolishing
drawing in, knocking, stabbing, rubbing
loss of liquids under high pressure and high temperature
slipping, tripping, falling
Causes
- sharp edges, pointed parts

- crush, shear and winding areas
- fragmentation / ejection of parts
- fracture or rupture of parts due to overload
- elastic elements (e.g. springs), liquids and gases under pressure or in a vacuum
- slippery, oily work area, obstacles on the floor
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Protective measures
- Wear leather protective gloves

- Wear close-fitting protective clothing
- Tie up long hair and beards, wear hair protection
- Wear face and eye protection
- Wear protective shoes
- Keep floor, equipment and the turbocharger clean
- Ensure the availability of oilabsorbing materials and have oil collector basins ready or in
position
- Eliminate leaks
3.2
Operation and process materials
This includes all substances such as oil, grease, coolant, detergents and solvents, acids and
other hazardous substances.
Physical injury and damage to property
Warning ! Allergies, skin disease, unconsciousness, poisoning or nausea after inhalation
Injury by scalding and burning of the skin
Burning by vapours or contact with acids or alkalis
Caution ! Environmental pollution due to leakage of operation and process materials and
penetration into soil and water.
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Causes
- Inhalation of toxic gases, smoke and vapours
- Skin contact with aggressive fluids
- Clothing wet or soaked with hazardous substances
- Spilling and tipping over of vessels with operation materials
- Leakages
- 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
Protection measures
- Utmost caution when handling operation and process materials.
- Protective clothing must be worn (oil-proof, solvent-proof and acid-proof gloves, impermea-
ble protective clothing, respiratory protection).
- Avoid skin contact and inhalation.
- Ensure that the workroom is properly ventilated.
- Observe the hazard indications on the containers for operation and process materials.
- Immediately after use, seal the hazardous substance container tight.
- Used operation materials must be collected safely in accordance with the legal provisions,
stored separately in suitable containers as prescribed, and disposed of as special waste in
an environmentally compatible manner.
- Ensure that containers with new / used operation materials are sealed tight.
- In the event of leaks or spills immediately apply a suitable absorbent material and dispose of
this in an environmentally compatible manner as special waste.
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3.3
Noise
Physical injury
Warning ! Loss of hearing, deafness
Impairments of health such as loss of balance or of consciousness, cardiac and

circulatory disturbances.
Causes
- Machine noise level in excess of 90 dB (A)
Protective measures
- Wear ear protection
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2
Putting into operation Page 1
2
Putting into operation
Contents Page
1
Oil supply .....................................................................................................................................3
1.1
Oil filtration ...........................................................................................................................3
1.2
Oil pressure .........................................................................................................................3
1.3
Oil temperature ....................................................................................................................4
2
Inspection during putting into operation ..................................................................................5
2.1
Outline of inspection work....................................................................................................5
2.2
Inspection before putting into operation ..............................................................................8
2.3
Inspection after putting into operation .................................................................................8
2.4
Inspection after 100 service hours .......................................................................................9
3
Putting into operation after out of service period ...................................................................9
4
Operation without emergency oil supply ...............................................................................11
Volume: 11 pages
Edition: 06 / 2002
HZTL 10452_EN
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Page 2 Putting into operation
Notes
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1
Oil supply
A carefully designed oil supply, which functions under all operating conditions, is an important
precondition for interference-free operation of the turbocharger.
Lubrication of the TPL turbocharger is normally done with oil from the engine oil circuit. It can,
however, also be provided from a separate lubricating oil system.
The lifetime of the bearings can be increased with a separate lubricating system owing to
reduced oil contamination.
Note The engine manaufacturer's recommen-dation regarding oil selection, and oil change
intervals are to be observed.
1.1
Oil filtration
A lubrication oil filter system with a mesh sizes £ 0.050 mm is adequate for the TPL 73 to TPL 85
turbochargers. However, if a finer filter is used (recommendation: filter out particles larger than
0.034 mm), this is likely to extend the life time of the bearings.
This filter system can also be achieved by using an additional self-cleaning filter.
Note Observe the engine manufacturer's recommendations.
1.2
Oil pressure
The oil pressure before the bearings (measuring point in blind connection) must be exactly
maintained to ensure fault-free operation.
Note Observe the engine manufacturer's recommendations.

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The permissible oil pressures are shown in the following table as a function of the lubrication
(engine, separate lubricating system).
(LQJLQHOXEULFDWLRQ 6HSDUDWHOXEULFDWLRQ
Kin. Viscosity Kin. Viscosity
45 - 170 cSt 12 - 170 cSt
Oil pressure Oil pressure
>EDU@ >EDU@
Not permissible oil pressure range → (QJLQH6KXW'RZQ
0.0 - 0.8 0.0 - 1.1
(no time delay)
Permissible short-term oil pressure range (<1h) → $ODUP 0.8 - 1.0 1.1 - 1.3
3HUPLVVLEOHUDQJHRIRLOSUHVVXUHGXULQJQRUPDO
1.0 - 2.5 1.3 - 2.5
RSHUDWLRQ
Permissible range of oil pressure during engine warm-up
1.0 - 4.0 1.3 - 4.0
phase
Long-term lubrication on standby operation

The sealing system of the TPL turbocharger is designed so that optimum sealing is ensured in
operation. If the turbocharger is run for prolonged periods (over 12 hours approx.) on standby
operation with the lubrication pump switched on the oil pressure before the bearings must not
exceed 4 bar.
1.3
Oil temperature
Oil inlet temperature: 30 °C - 70 °C.

The oil outlet temperature must not exceed the following values:
0D[RLORXWOHWWHPSHUDWXUH
>&@
Shut-down
Alarm
(60 sec. delay)
Oil inlet temperature 70° 130 140
Oil inlet temperature 90° 150 160
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2
Inspection during putting into operation
Inspection work includes preventive visual controls, as well as monitoring and measurement to
ensure the correct functioning of the turbocharger. These serve as an aid for the recognition of
deviations before and during putting into operation in order to prevent damage to the machine.
- Control and measurement checks must be carried out at the listed inspection points at the
intervals quoted below.
- Before and during inspection work, the safety instructions cited in chap. 1 must be observed.
2.1
Outline of inspection work
Inspection symbols and intervals
Inspection location
Inspection point
(visible in the outline)
Inspection point
(not visible in the outline)
Inspection
Recording of measurement values
Abbreviations for the inspection times
Before before putting into operation
After after putting into operation

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Before
After
Fig. 2-1
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,QWHUYDO ,QVSHFWLRQPHDVXUHPHQWDQG
,WHP ,QVSHFWLRQSRLQW VHH
LQVSHFWLRQWLPH DGMXVWPHQW
Oil pipe pressure gauge - check oil pressure engine manual

EHIRUHSXWWLQJ
LQWRRSHUDWLRQ
Air filter matting - check for damage chap. 3
Gas, air and oil lines - check for leaks sec. 2.3
Oil pipe pressure gauge - check oil pressure sec. 2.3
Charger speed - measure chap. 3

DIWHUSXWWLQJ
LQWRRSHUDWLRQ
Charger pressure - measure chap. 3
- measure before and after turbine

Temperatures and compressor and oil supply chap. 3
at various engine speeds

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2.2
Inspection before putting into operation
Caution ! It is urgently recommended, before putting into operation for the first time and every
time after lubricating system overhaul, that the entire lubrication system be
scavenged thoroughly with warm oil, with a bypass pipe.
It is urgently recommended, before putting into operation of the engine and every
time after lubricating system overhaul, that a starting filter be used.
- Before putting into operation check the oil filters for cleanliness.
- Check the oil pressure of the oil feeding lines.
- Check that the monitoring devices are functioning.
2.3
Inspection after putting into operation
- After the engine has been started up, check all gas, air and oil lines for leaks.
- Measure the speed, oil pressure, charging pressure and temperatures before and after the
turbine and the compressor at various engine speeds.
Note If the oil pressure is too low, i.e. is not reached, it must be checked whether the
dosage diaphragm in the oil inlet has the wrong cross section
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- Compare the measured values with those of the inspection report, taking into account the
different operation conditions.
Caution ! Before stopping the engine let it idle for appr. 3 minutes to allow the heat in the
bearings to dissipate by the circulating oil.
2.4
Inspection after 100 service hours
After the first 100 service hours clean or change the oil filter (see chap. 3).
3
Putting into operation after out of service period
- If applicable, remove the blind flange between the air outlet casing and the charge-air line.
- Start up the engine end oil circulation system.

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42248 42211
42231
42232
42231
B
A
42245
42232
42231
90950
42243
90951
90952
Fig. 2-2
Operation without emergency oil supply
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4
Operation without emergency oil supply
If a leak occurs in the emergency oil system during operation and immediate repair is not
possible, the turbocharger can be operated until repair without emergency oil supply.
The following procedure should be adopted:
- Take turbocharger out of operation and shut off oil system.
- Remove screw plug (42245) and empty the oil tank and pipes. To bleed remove the cap
(42248) and screw plug (42211).
- Release screws (42232) and remove with collars (42231).
- Remove pipe (A) and (B).
- Fit flange (90951) and gasket (90952) with screws (42243).
- Fit screw plug (90950).
Note Components 90950, 90951 and 90952 form part of the complete toolbox 90000
See chap. 5 for screw tightening torques.
Caution! Operation without emergency oil supply is possible without harm, as long as the
lubricating system functions properly during operation of the turbocharger.

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3
Operation and maintenance Page 1
3
Operation and maintenance
Contents Page
1
Inspection ....................................................................................................................................3
1.1
Outline of inspection work....................................................................................................3
1.2
Inspection every
25 to 50 hours ......................................................................................................................6
1.3
Inspection according to data
from engine manufacturer ...................................................................................................6
1.4
Inspection every
14'000 - 18'000 hours ..........................................................................................................6
1.5
Entries in the machine logbook ...........................................................................................7
2
Monitoring ...................................................................................................................................9
2.1
Speed measurement ...........................................................................................................9
2.2
U-tube manometer .............................................................................................................10
2.3
Surging of turbocharger .....................................................................................................11
2.4
Contact of rotating parts ....................................................................................................11
Volume: 29 pages
Edition: 06 / 2002

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Page 2 Operation and maintenance
Contents Page
3
Cleaning work ...........................................................................................................................12
3.1
Safety instructions ............................................................................................................. 12
3.2
Outline of cleaning work ....................................................................................................13
3.3
Cleaning the silencer TPL 73 ¸ 85 ..................................................................................... 17
3.4
Cleaning the compressor in operation ...............................................................................20
3.5
Cleaning turbine blades and nozzle ring in operation ........................................................ 26
4
Maintenance work .....................................................................................................................28
4.1
Outline of maintenance work .............................................................................................28
4.2
Intervals for inspectiig the bearings ...................................................................................29
4.3
Intervals for replacing the compressor wheel .......................................................................29
4.4
Intervals for replacing the bladad shaft .............................................................................. 29
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1
Inspection
Inspection work during operation includes visual checks, as well as monitoring and measuring
in order to ensure correct functioning of the turbocharger. This serves as an aid for the
recognition of deviations during operation in order to prevent damage to the machine.
- Control and measurement checks must be carried out on the listed inspection points at the
intervals quoted below.
- The safety instructions cited in the corresponding chapters must be observed in the course
of all inspection work.
1.1
Inspection symbols and intervals
Inspection location
Inspection point
Inspection point
(not visible in the outline)
Inspection
Recording of measurement values
Abbreviations for inspection intervals
25 - 50 [h] every 25-50 service hours
see eng. see engine

manuf. manufacturer
r. plate or see rating plate or every

14'000 - 18'000 [h] 14'000 - 18'000 service hours

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Inspection work
25 - 50 [h]
see eng. manuf.
r. plate or
14'000 - 18'000 [h]
Fig. 3-1
ABB 10453_EN
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,QVSHFWLRQLQWHUYDOVDFF ,QVSHFWLRQ
,WHP ,QVSHFWLRQPHDVXUHPHQWDGMXVWPHQW VHH
WRVHUYLFHKRXUV SRLQWV
- check sec. 1.2
(YHU\WR>K@ Operation data - enter in the log book
- establish the cause of deviations chap. 4

- clean or replace oil filter with engine at a
6HHHQJLQHPDQXIDFWXUHU Oil filter sec. 1.3
standstill
- dismount and clean the turbocharger chap. 5
- check tolerances
- clean turbine and compressor casing and sec. 1.4
check for any cracks and erosion / corrosion
6HHUDWLQJSODWHRUHYHU\ - clean nozzle ring and check for any cracks
Turbocharger
>K@ and erosion
- Inspection and evaluation of the shaft and sec. 1.4
bearing parts must be performed by an chap.7
official service station of ABB Turbo Systems

10453_EN
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1.2
Inspection every
25 to 50 hours
- The operating data of the exhaust gas turbocharger must be recorded regularly every 25 to
50 hours and entered in the machine logbook (see sec. 1.5).
- If the operation data deviates significantly from the data in the inspection report the causes
must be established in accordance with chap. 4.
- Call an authorized ABB service station (see chap. 7) if the reasons for the deviation cannot
be established.
1.3
Inspection according to data
from engine manufacturer
- With the engine at standstill clean or replace the oil filter insert.
1.4
Inspection every
14'000 - 18'000 hours
- Check the turbine and compressor wheels for any damages.

- Check turbine- and compressor casing for any cracks and for erosion / corrosion.
- Check the nozzle ring for erosion.
The operation life of the plain bearings depends on the quality of the oil filtration.
Caution ! The first inspection and assessement of the bearing parts has to be carried out acc.
to the rating plate or between 14'000 and 18'000 service hours.
- These inspections must be performed by an official service station of ABB Turbo Systems.
ABB 10453_EN
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1.5
Entries in the machine logbook
Monitoring of the machine plant provides information about the performance of the turbocharger.
The following operation data and measurement values must be entered regularly in the machine
logbook of the engine manufacturer:
- Output and speed of the diesel engine

- Speed of the turbocharger
- Air intake temperature
- Exaust gas temperature before the turbine
- Pressure of the charge-air
- Pressure drop in the cooler
- Lub oil pressure, lube oiltemperature
If provided:
- Air temperature after compressor and after the charge-air cooler
- Pressure loss in the air filter
In the event of measurement values which deviate significantly from the norm (see the specifications
of the engine manufacturer and chap. 4), establish the cause.

10453_EN
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Bearing casing
Axial bearing
Guide in axial bearing
Screw plug
Connecting cable
Alternative fitting
Speed transmitter
Line amplifier (option)
Fig. 3-2
Fitting of speed measurement
ABB 10453_EN
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2
Monitoring
2.1
Speed measurement
TPL turbochargers are fitted as standard with a speed transmitter system for measuring the
turbocharger speed. This speed transmitter system, in conjunction with the corresponding
measuring units or monitoring systems (not part of the delivery), permits continuous remote
monitoring of the turbocharger speed. With continuous monitoring of the engine installation, the
turbocharger speed can be used as a suitable control parameter.
The line amplifier can be procured as an additional option to the described of the speed
measuring system.
A reduction in speed of a charger can signify:

- Damaged turbine or bearing
- Severe contamination of turbine
Possible reasons for the breakdown of the speed indicator:

- Defect in speed transmitter, connecting cable and plug to measuring unit, measuring unit or
in power supply.
- Turbocharger damage.
Note If the speed indication fails, it is recommended that the engine output be reduced to
idling speed and the engine stopped. The cause of the failure should then be
determined.

10453_EN
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2.2
U-tube manometer
The U-tube manometer measures the vacuum in the silencer and thus provides an indication of
the degree of contamination of the filter material.
Vibration of the U-tube manometer is reduced by the installation of felt discs.
All parts required for assembly are supplied in a separate package.
Caution ! The U-tube manometer must not be exposed to shock or vibration.
For best redability lightly coloured water should befilled into the U-tube.
Under new conditions the pressure loss is £ 120 mmH2O at full load.
The filter should be cleaned at the latest when the pressure loss has reached 200 mmH2O.
ABB 10453_EN
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2.3
Surging of turbocharger
Surging of the turbocharger can occur with certain engine operating states, such as rapid load
removal or while manoeuvering, particularly with high engine loads. The general direction of
flow in the compressor is then temporarily reversed. Although surging leads to increased load
of individual turbocharger components, sporadic pulses do not generally affect safe operation
of the turbocharger.
Caution ! The following components can be damaged by continuous or periodically recurring

surging:
- compressor wheel (vibration fractures, etc.)
- turbine blades (cracks)
- bearings (overheating)
- filter silencer
Note Action to be taken:

The operating safety of the turbocharger is no longer ensured with continuous or
periodically recurring surging. The operator, together with the next ABB service
station (see chap. 7), must take immediate action to eliminate the surging.
The above mentioned components should be examined for damage and replaced in
case of doubt.
2.4
Contact of rotating parts
Mild, uniform wear around the circumference of rotor components, caused by slight local
grazing against adjacent components, is non-hazardous and permissible. This slightly reduces
the length of the blades in the compressor or turbine. Certain tolerances must be observed to
avoid a significant loss in efficiency.
Note The check on dimensions must be carried out by an official Service Station of ABB
Turbo Systems Ltd.

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3
Cleaning work
Cleaning work includes regular visual checks and washing to ensure the correct functioning of
the turbocharger and its auxiliary appliances.
- The external condition and the degree of contamination of the cleaning points listed below
must be established by visual checks at the intervals quoted.
- During all cleaning work the safety instructions in the respective chapters must be observed.
3.1
Safety instructions
When handling detergents, solvents, acids and alkalis be sure to observe the respective safety
directions on the manufacturers label and in the operation manual. Observe also the instructions
for the environmentally compatible collection, storage and disposal of these substances (see
chap. 1).
Warning ! Cleaning work should be carried out outdoors due to explosion hazards. If this is
not possible, ensure that there is adequate ventilation.
Before beginning cleaning work in confined spaces, extinguish naked flame (including
cigarettes!) due to the danger of explosion.
Always wear protective clothing (solvent and acid resistant gloves, body protection
and eye protection). When using chemical cleaning agents the instructions and
warnings of the manufacture must be observed.
ABB 10453_EN
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3.2
Outline of cleaning work
Cleaning symbols
Cleaning location
Cleaning point
Cleaning point
(hidden in the outline)
Visual check
Cleaning
Abbreviations for cleaning intervals
as reqd. as required
see eng. see engine

manuf. manufacturer

10453_EN
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see eng. manuf.
as reqd.
Fig. 3-3
Outline of cleaning work
ABB 10453_EN
-C-
&OHDQLQJ
LQWHUYDOV
&OHDQLQJ &OHDQLQJ
,WHP 3UHOLPLQDULHV &OHDQLQJDJHQW VHH
SRLQW PHDVXUHV VHH
DV
HQJLQH
UHTXLUHG
PDQXI
- Dismantle silencer
- Silencer - cleaning [ - dry clean sec. 3.3
- Insulating material
- engine at normal
operation
- Compressor - wet cleaning [ - pure water sec. 3.4
- high compressor
speed
- no reduction in speed
- wet cleaning
[ - Gas inlet temperature - pure water
(thermalshock)
befor turbine 430-
- Turbine 500°C (703-773 K) sec. 3.5
- Natural core-
- Gas inlet temperature
granulat
- dry cleaning [ befor turbine < 590°C
- Activated char-
(< 863 K)
coalparticles

10453_EN
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81136
81137
81266
81271
81266
81270
Option
81265
Fig. 3-4
Silencer
ABB 10453_EN
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3.3
Cleaning the silencer
If provided:
+ Cleaning the filter ring (81265):
The filter ring can be replaced or cleaned by washing.
Caution ! The dirt in the filter ring depends on the cleanness of the air drawn in. Wash or
replace the filter ring if required or every 500 operating hours.
+ Washing the filter ring:
Rinse with water using washing powder or, if very dirty, soak it. Squeeze it out carefully.
Rinse in cold water. Avoid high mechanical stress (water jet).
For cleaning, dismantle the silencer:

- Loosen the tension bands (81270) and remove the cover grid (81266) (see fig. 3-4).
- Withdraw the cover sheet-metals (81137), bend them and remove the felt segments (81136).
Caution ! During cleaning take care that the felt segments does not become wet.
- Remove dirt with a soft brush or dry compressed air.
- Heavily soiled felt segments should be replaced by one of our Service Stations (see chap. 7).

10453_EN
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1
2
3
Fig. 3-5
Guide tube cleaning device
ABB 10453_EN
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Before removing the slide-in module where the guide tube for compressor washing hose
(3) is inserted, remove this tube as folllows:
- Release pipe (2) by injection pipe (1) and remove screw coupling from hose (see fig. 3-5/1).
- Withdraw hose from guide tube (3).
- Punch guide tube with a bolt (dia. 16 mm) from the caulking and withdraw (see fig. 3-5/2).
Note: After fitting the slide-in modules, re-fit the guide tube and caulk (see fig. 3-5/2).
Fit pipe and screw to injection pipe (see fig. 3-5/3).
Caution ! Damaged tension bands must be replaced by new ones (see chap. 5 sec. 5).

10453_EN
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3.4
Cleaning the compressor in operation
Introduction
The dirt in the compressor stage (compressor wheel and diffuser) depends on the cleanness of
the air drawn in and the operating point.
A deposit of dirt in the flow ducts occurs particularly when oil or saline mist, solid combustion
residues and dusts of various kinds are drawn in.
Soiling of the compressor stage has a negative influence on the compressor efficiency and
turbo-charger pressure, particularly for smaller turbochargers.
This results in higher exhaust gas temperatures and increased fuel consumption by the motor.
Contamination of the compressor also increases the rotor unbalance.
Periodic cleaning of the compressor in operation prevents or delays severe increase of soiling,
but this in no way replaces normal overhauls, during which the turbocharger is completely
dismantled.
Principle of cleaning during operation
Water is fed or injected before the compressor wheel via injection pipes fitted in the filter
silencer and suction branch in order to clean the compressor stage in operation.
The water does not act as a solvent in the process, but the coating is removed by the
mechanical impact of the falling drops. The process is ideal, provided the soiling is not too
advanced.
Cleaning is most effective when the engine is fully loaded.
The cleaning installation can be provided in principle in two different ways:
a. Cleaning with the cleaning device on the turbocharger. (only with filter silencer)
b. Cleaning with externally attached water vessel .
ABB 10453_EN
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General instructions
If the coating is very thick and hard, the compressor can only be cleaned when dismantled.
Therfore, periodical cleaning of the compressor after commissioning is recommended.
Caution ! Due to the danger of corrosion, only fresh water must be used and on no account
salt water. The water should not contain any cooling additives which could form
deposits in the flow ducts.
The injection pipe must on no account be connected directly via a cock to a water pipe, a larger
dosing or water vessel than available from ABB Turbo Systems. This prevents uncontrolled
volumes of water entering the turbocharger and engine, which can lead to major damage.
The interval between periodic cleanings largely depends on the operating conditions. Cleaning
should normally be performed every 24 operating hours.

10453_EN
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Procedure for cleaning
Cleaning of the compressor stage must be performed with the engine warm from running and
as fully loaded as possible, i.e. at high turbocharger speed.
The success of the cleaning can be seen from the charger or flushing pressure or from the
exhaust gas temperatures.
If cleaning is unsuccessful, it can be repeated up to 2 times. If the cleaning is still unsuccessful
after three attempts, and if the engine operating values are unsatisfactory, it is recommended
to have the turbocharger checked and cleaned by an authorised ABB Turbo Systems service
department.
After cleaning the compressor stage, the engine must be run on load for at least another 5
minutes.
Note These guidelines apply exclusively to turbocharger cleaning with water, assuming
that the engine manufacturer permits the procedure.
If the cleaning container is used, the detailed cleaning instructions provided on the
plate fitted on the silencer should be followed.
ABB 10453_EN
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Fitting the cleaning container on the filter silencer
All parts required for assembly are supplied in a separate package.
- Fix cleaning container (27010) to the silencer with the screws supplied.
- Bend pipe (1) for fitting by injection pipe (2), place through silencer and screw to injection
pipe.
- Bend pipe accordingly and screw to cleaning container.
- Affix cleaning instruction (3).
2
1 27010
5
TPL 73/77 = 2 litre
TPL 80/85 = 3 litre
Use of cleaning container
1. Open the filling cap (4) and fill the water container with clean freshwater.
2. Close the filling cap (4) and open the valve (5) for approx. 3 minutes.
3. Close the valve (5) and check, that all water has been sucked out.
4. With TPL 77 or TPL 85 repeat steps 1-3.
Note In dirty operating conditions the cleaning procedure can be repeat once more.
In total, up to 2 cleaning cycles are allowed with TPL 73/80 and 3 cleaning cycles
with TPL 77/85.

10453_EN
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Operating the pressure water vessel
1. Remove the screw plug (A).

2. Fill the vessel with pure water.
3. After filling tighten the screw plug (A).
4. Actuate the valve lever (B) towards the spring and hold it for about 10 seconds until all the
water has been injected.
9ROXPHRIZDWHUYHVVHO :DWHULQMHFWLRQWLPH
7XUERFKDUJHUW\SH 7XUERFKDUJHUVSHHG
>GP @ W>V@
73/ 1,0
73/ As nearly as possible 1,0
4 ... 10
73/ nBmax 2,0
73/ 2,0
ABB 10453_EN
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3.5
Cleaning the turbine blades and nozzle ring in operation
Introduction
Combustion of heavy oil in diesel engines causes contamination of the turbine blades and
nozzle rings of the turbochargers.
Contamination increases with time, so that regular and properly performed cleaning is important
to remove the deposits produced.
The frequency of cleaning depends on the degree of contamination of the turbine during a
specific period of operation.
An abnormally high consumption of lubricating oil can similarly increase the volume of ash and
slag.
The exhaust gas temperature after the cylinder can rise and the charging pressure at the air
receiver fall owing to contaminated turbine components. Contamination of the turbine also
results in rotor unbalance. Severe contamination can lead to impermissibly high rotor unbalance.
Experience in operation has shown that despite periodic cleaning during operation it is impossible
to dispense with overhauls in which the turbine and nozzle ring are mechanically cleaned. If
cleaning is performed correctly and the cleaning system is properly dimensioned, however, the
intervals between overhauls can be extended.
Principle of cleaning during operation
Two different processes are used for cleaning the turbine components during operation:
Wet cleaning of turbine and nozzle ring (section 3.5.1)
Dry cleaning of turbine and nozzle ring (section 3.5.2)
Note From experience in operation we recommend the use of wet cleaning.

10453_EN
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3.5.1
Wet cleaning
The following general instructions must be observed together with the Operating instructions
for the diesel engine:
The maximum exhaust gas temperature before the turbine must not exceed 430°C before
cleaning. The turbine inlet temperature may rise to 500°C during cleaning.
Caution The prescribed water injection pressure and the duration of water injection must be
observed without fail.
Smaller volumes of water can lead to an inadequate cleaning effect. Larger volumes
of water result in impermissible thermal stresses and possible turbine touching.
Clean fresh water free from cleaning agents and solvents must be used.
Note Pay attention to the specifications of the engine manufacturer.
ABB 10453_EN
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3.5.2
Dry cleaning
Dry solid matter in granular form is blown by compressed air into the exhaust pipes before the
gas inlet casing. The solid matter has a mechanical cleaning effect and removes deposits on
the turbine and nozzle ring. This method of cleaning should be performed every 24-48 operating
hours on full load. The interval between cleaning operations depends on the degree of
contamination and on the increase of exhaust gas temperature following the turbine. Cleaning
must be repeated if the gas temperature following the turbine rises to 20°C above the mean
temperature on full load. In engines with several turbochargers the turbochargers should be
cleaned in turn.
To prevent excessive combustion of the dry cleaning agent before the turbine, the gas inlet
temperature before the turbine must not exceed < 590 °C).
Since it is not possible to remove thick coatings with relatively small amounts of solid matter,
this method must be used more frequently.
Injection of the granulated dry cleaning agent in the turbine is best performed at high turbocharger
speed to ensure efficient mechanical cleaning.
General instructions
The gas inlet temperature before the turbine must not exceed < 590 °C (< 863 K).
The drain openings in the gas outlet casing must remain closed during dry cleaning.
Care should be taken, since incompletely burnt soot particles can be emitted with the
exhaust gas fumes.
Note Pay attention to the specifications of the engine manufacturer.

10453_EN
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4
Maintenance work
Maintenance work includes inspection and function checks of wearing parts with or without
changing process materials, parts or modules. It must be carried out in accordance with the
intervals as set out in the Outline of Maintenance work.
Warning ! Failure to carry out the maintenance work within the prescribed intervals can lead to
damage and inoperation of the turbocharger.
The safety instructions in the respective chapters must be observed for all mainte-
nance work.
Keep lubrication and process materials ready.
4.1
Outline of maintenance work
VHHUDWLQJSODWHDQGRU
0DLQWHQDQFHSRLQW 0DLQWHQDQFHPHDVXUH VHH
VHUYLFHVWDWLRQ
Bearings - replace complete [ sec. 4.2
Compressor wheel - replace [ sec. 4.3
Turbine - replace [ sec. 4.4
ABB 10453_EN
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4.2
Intervals for inspecting the bearings
The bearings must be inspected if damaged or at the latest according to the data on the rating
plate and/or the service station (see chap. 0).
The service life of the bearings depends on the fineness of the lubricating oil filter and the
operating conditions.
The bearings are changed by an official service station of ABB Turbo Systems.
4.3
Intervals for replacing the compressor wheel
The compressor should be changed if damaged or at least according to the data on the rating
The compressor wheel is changed by an official service station of ABB Turbo Systems.
4.4
Intervals for replacing the bladed shaft
The turbine should be changed if damaged or at the latest according to the data on the rating
The turbine is changed by an official service station of ABB Turbo Systems.

10453_EN
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4
Troubleshooting Page 1
4
Troubleshooting
Contents Page
1
Troubles causes, remedies ........................................................................................................3
Volume: 4 pages
Edition: 06 / 2002
HZTL 10454_EN
-.- ABB
Page 2 Troubleshooting
ABB 10454_EN
-.-
Troubleshooting Page 3
1
Troubles, causes, remedies
7URXEOH /RFDWLRQ &DXVH 5HPHG\ VHH

- repair or consult
(QJLQH - faults in injection system
engine manufacturer
- lack of air, e.g. filter blocked by dirt by - clean chap. 3
dirt
- compressor / turbine contaminated - clean chap. 3
7XUERFKDUJHU - Exhaust gas back pressure too high - clean or repair boiler
([KDXVWJDV
or exhaust gas
WHPSHUDWXUHWRR
silencer
KLJKHQJLQH
SHUIRUPDQFH
- turbine damaged or eroded - call service station chap. 7
DQGVSHHG
XQDOWHUHG
- dirt in the cooler - clean
- insufficient cooling water - top up

&KDUJHDLU
FRROHU - cooling water inlet temperature to high - check / clean
cooling system
- insufficient ventilation - improve ventilation

- leak in the air receiver - repair
- leak in the gas duct between engine - repair

(QJLQH
and turbine
- injection incorrectly adjusted - adjust correctly

&KDUJHDLV - manometer indication defective - replace manometer
SUHVVXUHWRR
ORZHQJLQH - leaks in the line to the manometer - repair leak
SHUIRUPDQFH
DQGVSHHG - dirt in the air filter causing, excessive - clean chap. 3
XQDOWHUHGDLU pressure loss
LQWDNHQRUPDO 7XUERFKDUJHU
- dirt in the compressor / turbine - clean chap. 3
- turbine / compressor damaged - call service station chap. 7
- exhaust gas back pressure too high - clean boiler or

exhaust gas silencer

10454_EN
-.- ABB
Page 4 Troubleshooting
7URXEOH /RFDWLRQ &DXVH 5HPHG\ VHH
- faults in the injection system - adjust correctly

&KDUJHDLU
- engine performance higher than - check engine
SUHVVXUHWRR (QJLQH
assumed performance
KLJKHQJLQH
- injection system incorrectly adjusted - adjust correctly
SHUIRUPDQFHDQG
VSHHGXQDOWHUHG
7XUERFKDUJHU - manometer indication incorrect - replace manometer
- rotor unbalance due to heavy - call service station chap. 7

contamination of compressor / turbine
9LEUDWLRQV 7XUERFKDUJHU
- turbine or compressor damaged - call service station chap. 7
- bearing defect - call service station chap. 7
1RLVHVRQ - bearing damaged - call service station chap. 7

UXQQLQJGRZQ - rotor rubbing - call service station chap. 7
7XUERFKDUJHU
WLPHWRRVKRUW - dirt in turbocharger - clean chap. 3
UHOXFWDQWVWDUWLQJ - foreign bodies in the turbocharger - call service station chap. 7
- oil filter choked with dirt - clean

3UHVVXUHRI
- damaged pump for oil circulation - check
OXEULFDWLRQRLOWRR 7XUERFKDUJHU
- axial play of the rotor to large - call service station chap. 7
ORZ
- manometer indication incorrect - replace manometer
- Take the
(PHUJHQF\
/HDNDJH - leaky emergency oil tank chap. 2
RLOWDQN
out or operation
&RQVWDQWVXUJLQJ
RIWKH - increased flow resistance due to:
WXUERFKDUJHU - dirt in the charge air cooler or silencer - clean chap. 3
7XUERFKDUJHU
- heavy deposits of dirt in the - clean chap. 3
compressor / turbine
- exhaust gas pressure increased after - clean

the turbine, because the boiler or the
(QJLQH
exhaust gas silencer are dirty
- grid dirty - clean
&DOOWKHVHUYLFHVWDWLRQLIWKHFDXVHRIWKHVXUJLQJFDQQRWEHGHWHFWHG
1) TPL 73-B.. ÷ 85-B.. only
ABB 10454_EN
-.-
5
Disassembly and assembly Page 1
5
Disassembly and assembly
Contents Page
1
Weights ....................................................................................................................................... 3
2
Removing and installing the turbocharger .............................................................................. 5
3
Disassembling and assembling the turbocharger.................................................................. 7
3.1
Axial clearance.....................................................................................................................7
3.2
Removing the cartridge group .............................................................................................9
3.3
Dismantling the diffuser and nozzle ring ............................................................................13
3.4
Installing the cartridge group .............................................................................................15
3.5
Turbine-end removal / fitting of nozzle ring .......................................................................17
4
Inspection and assesment of valve block ..............................................................................19
5
Table of tightening torques ......................................................................................................21
6
Spare-parts ................................................................................................................................24
7
Tools ...........................................................................................................................................27
7.1
Rotor with screwed connection ..........................................................................................27
7.2
Rotor with polygon connection ...........................................................................................29
8
Directory of part numbers ........................................................................................................33
Volume: 33 pages
Edition: 03 / 2003

HZTL 10455_EN
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Page 2 Disassembly and assembly
4 5
9
8
Fig. 5-1
Weights of assemblies
ABB 10455_EN
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1
Weights
Warning ! Attach individual parts and large component modules carefully to suitable lifting
devices which are in technically perfect condition and which possess adequate
loading-bearing capacity.
Do not stand under suspended loads (see chap. 1).
Turbocharger
7XUERFKDUJHUFRPSOHWH
73/ (without silencer / air suction branch)
>NJ@
2.310
3.524
5.510
9.300
Assemblies
Weight
3RV 'HVLJQDWLRQ [kg]
73/ 73/ 73/ 73/
Air suction branch radial 140 155 242 290
Silencer 244 404 576 955
Compressor casing internal part 148 260 355 550
Diffuser 57 80 125 225
Compressor casing external part 290 475 680 1149
Cartridge group 560 941 1443 2588
Turbine diffuser 72 150 250 460
Nozzle ring 25 44 63 95
Gas inlet casing radial 147 250 340 550

10455_EN
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Fig. 5-2
Removing and installing the turbocharger
ABB 10455_EN
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2
Removing and installing
the turbocharger
- Disconnect all gas air and oil lines in accordance with the manufacturers instructions.
- Remove the insulating dish of the bearing casing.
- Check the lifting equipment.
- Fix lifting equipment to suspension lugs of bearing casing (see fig. 5-2).
Caution ! Take into account the weight of turbo-charger when selecting rope
Suspend the complete turbocharger on bearing casing, using the two ribs provided
for this purpose. In no event should the rope be looped round the emergency oil
tank to suspend the turbocharger.
The turbocharger must be transported as horizontally as possible.
Ensure that the transport ropes do not touch the emergency oil tank!
If the silencer is provided with a post (A), this must not be used when lifting the
complete turbocharger.
- Release fixing screws on foot.
- Lift the turbocharger from the engine and put it by side.
Caution ! Beware of tilting.

Support turbocharger at suitable place.
- Cover oil connectors.
To install the turbocharger follow these instructions in the reverse order.
- Putting into operation as in chap. 2.

10455_EN
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90231
Fig. 5-3
Transport silencer
Û
A
74027 74028
Fig. 5-4
Axial clearances
Clearance $ [mm] Clearance $ [mm]

Screwed connection Polygon connection
TPL73 TPL 77 TPL 80 TPL 85 TPL 80
0.35 ... 0.51 0.39 ... 0.54 0.40 ... 0.57 0.44 ... 0.64 0.46 ... 0.68
ABB 10455_EN
-G-
Caution ! Further disassembly and assembly as described in this chapter must only be
performed by a trained ABB Turbo Systems fitter from an official service station of
ABB Turbo Systems Ltd.
3
Disassembling and assembling turbocharger
Caution ! Take account of the weight of the turbocharger parts when selecting a suitable
rope.
Check lifting equipment and secure properly.
- Disconnect all air lines in accordance with the motor manufacturers instructions.
- Remove the insulating dishes.
- Release nuts (74027) with verbus-discs (74028) and remove air suction branch (see fig. 5-
4).
- Fit lifting eye bolt (90231) on silencer. Sling lifting gear through the loops at the rear and fix
in the lifting eye bolt with a shackle (see fig. 5-3).
- Release nuts (74027) with verbus-discs (74028) and remove the silencer (see fig. 5-4).
3.1
Axial clearance
Measure and note axial clearance (see fig. 5-4).
Caution! If the clearance is outside the tolerance, an official service station of ABB Turbo
Systems must be contacted.

10455_EN
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90320
42245
1
76040
76000
74027
90190 / 90195
3
90025
90900 74026
76002
90235
TPL 77 - 85
2
90190
79000
76000
Fig. 5-5
Removing the cartridge group
ABB 10455_EN
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3.2
Removing the cartridge group
- Open oil drain screw (42245) on emergency lubrication oil tank pipe and collect any residual
oil in a bucket.
- Disconnect oil pipelines according to details from engine manufacturer.
- Remove six studs (74026) in upper section and fit four guide bolts (90320) (see fig. 5-5/1).
Note Leave two holes free for the lifting device (90190).
- Press off internal part of compressor casing (76000) with puller screws (90900) until the
lifting device (90190/90195) can be fitted.
- Raise internal part of compressor casing slightly with wall insert and diffuser, remove guide
studs (90320) and then withdraw the components.
- Fit angle support (90025).
- Place internal part of compressor casing with wall insert and diffuser on angle support and
base.
- Suspend lifting device on rear of flange (see fig. 5-5/2).
- Turn internal part of compressor casing with wall insert and diffuser carefully over the angle
support (90025) and place on base.
Caution! Ensure that the bases do not slide away.
- Remove O-ring gasket (76040).
TPL 73
+ Remove screws (76002) and diffuser (79000) (see fig. 5-5/3).
TPL 77-85
+ Remove screws (76002) (see fig. 5-5/3).
+ Remove diffuser (79000) with lifting eye bolts (90235).

10455_EN
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42212
74000
42213
42246
A 1
42214 90190 / 90195 42221
42217 42233
42232 42222
42216
42223
42215
42243
42244 61037
61037
42231
42232
42001
90900
61035
90450 3
86525
86505 / 86506
86515 42045
42052
TPL85
90450
42230
Fig. 5-6
Removing the cartridge group 42241
ABB 10455_EN
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- Secure lifting device (90190/90195) to external part of compressor casing (74000) and fix to
crane (see fig. 5-6/1).
- Loosen nuts (61037), press off external part of compressor casing evenly with the three
press-off nuts (61037) and remove.
- Withdraw cable (86515) and unscrew speed measuring transmitter (86505) with O-ring
(86506) (see fig. 5-6/2).
If provided:
+ Disconect cable to line amplifier (86525).
- Remove three screws (61035), check lifting gear and secure to bearing casing (42001).
Caution ! Take account of weight of cartridge group when selecting the rope.
Note To correct the slight inclination of the cartridge group suspended from the rope, a piece
of squared timber must be jammed between the rope and the emergency oil tank fixing.
Use only squared timber and not an iron bar, otherwise there is a danger of slipping!
- Press cartridge group down evenly with jack screws (90900) into the holes provided.
Caution ! By turning the rotor, check that the blades does not touch the turbine diffuser.
- Extract cartridge group.

- Release hex.-headed screws (42241) and remove valve block (42230) (see fig. 5-6/3).
Check valve block according to section 4.
- Fit supports (90450).
- Cover oil connectors.

10455_EN
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1
61032
90921
61036
2 A
90320
3
90178
90921
63000 90325
90901 56001
Fig. 5-7
Removing the turbine diffusor & nozzle ring
ABB 10455_EN
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3.3
Removing diffuser and nozzle ring
- Remove cartridge block according to section 3.2.
- Place clamp (90921) over stud (61036) until it lies against the inner radius of the gas outlet
casing. Insert extension (A) of torque spanner (B) through clamp hole and release the
torque of screws (61032) in succession. Do not yet remove screws (61032) (see fig. 5-7/1).
- In upper section of turbine diffuser (63000) replace two screws (61032) with two guide studs
(90320). The guide studs are taken through the hole of clamps (90921) at the front. To
secure fit hexagon nuts (90178) (see fig. 5-7/3).
- Before dismantling the turbine diffuser, the nozzle ring should be secured against falling if
possible, with clamping set and wooden block (see fig. 5-7/2).
- Release remaining screws (61032), push back the turbine diffuser (63000) with press-off
screws (90901) and withdraw turbine diffuser as far until the clamp (90921) will hit the hex-
headed nut (90178).
- Fix diffusor (63000) at lifting gear and remove.
Caution ! If nozzle ring not secured:

The nozzle ring (56001) hangs loosely from the positioning pins and can drop
down.

10455_EN
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90490
56001
Fig. 5-7
Removing the turbine diffusor & nozzle ring
ABB 10455_EN
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- Fix holder (90490) on gas outlet casing (see fig. 5-7/4).
- Draw nozzle ring (56001) forward, fix nozzle ring at lifting gear and remove (see fig. 5-7/5).
3.4
Fitting the cartridge group
Assembly takes place in the opposite sequence to that described in section 3.2 for removing
the cartridge group.
The following instructions must also be noted:
Assembling the nozzle ring
Note Align positioning pins in nozzle ring with the holes in the gas inlet casing.
Smear all screws in and on the gas outlet casing with Anti Scuff Paste 868 from
SPANJAARD.
Fitting cartridge group
Caution! Fix bearing casing straight on crane and insert carefully.

Tighten screws (61035) evenly and turn the shaft to ensure that the blades do not
touch the turbine diffuser (see fig. 5-6/2).
Fitting emergency oil system
Caution! To prevent scale, the pipes of the emergency oil system must not be heated with
the welding torch.
Fitting external part of compressor casing
Note Before fitting the external part of the compressor casing, screw three press-off nuts
(61037) up to the end of the thread on the studs provided for this purpose (see fig.
5-5/1).

10455_EN
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61009 90195 90178
90175
51001
56001
90177
61001
Fig. 5-8
Turbine-end removal of nozzle ring
ABB 10455_EN
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3.5
Turbine-end removal / fitting of nozzle ring
If only the nozzle ring has to be removed, it is possible to dismantle/fit this at the turbine end.
- Remove insulation on gas inlet casing (51001).
- Secure gas inlet casing with shackle (90195) and suspension rope (see fig. 5-8).
- Remove two hexagon-headed screws (61009) from the lower section and replace with two
studs (90177).
Lock the studs with hexagon nuts (90178).
- Release and remove the remaining flange screwed coupling.
- Withdraw gas inlet casing with nozzle ring from gas outlet casing until holder (90175) with
screw (61009) can be fitted from outside.
- Release the hexagon nuts (90178) from the studs and fully withdraw gas inlet casing and
remove.
- Release holder (90175) and remove nozzle ring.
Assembly is performed in the reverse sequence.

10455_EN
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Valve flap
O - ring gasket (42234)
Valve seating
Fig. 5-9
Inspection of valve block
ABB 10455_EN
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4
Inspection and assessment of valve block
When the valve block is removed, check the following (see fig. 5-9):
- Smooth motion of valve flap
- Check valve seat with finger
- If necessary, the O-ring gasket (42234) should be exchanged.
If scratches are found on the valve seat or the valve flap jams, the valve block should be
exchanged.
An authorised service station of ABB Turbo Systems Ltd. should be contacted if there is any
uncertainty.
Notes

10455_EN
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1 2 3 4 5 6 7
11 10 9 8
Fig. 5-10
Summary of tightening torques
ABB 10455_EN
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5
Table of tightening torques
For the screws in the table below the following tightening torques have to be applied:
7LJKWHQLQJWRUTXHV
3RV 3DUWQR >1P@
73/ 73/ 73/ 73/
M16x1,5 M16x1,5 M16x1,5 M16x1,5
82005

76002 M14 1) M16 1) M18 1) M20 1)
M18 2) M20 2) M22 2) M24 2)
61037

M18 M20 M22 M24
61036

M18 M20 M22 M24
61035

M18 M20 M22 M24
61032

M18 M20 M22 M24
61009

M18 M20 M20 M20
42042

M18 M20 M22 M24
74026

M18 M20 M22 M24
74027

M18x1,5 M18x1,5 M22x1,5 M22x1,5
86505

1) Tighten screw (76002) up to the stop and then release by a ¼ turn. The screw must be loose
and the diffuser freely movable.
2) With verbus ripp washer
Table of tightening torques of emergency oil tank, see next pages.

10455_EN
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7
1
8
2 6
9
3 10
11
4
TPL 85
12
Fig. 5-11
Summary of tightening torques emergency oil tank
ABB 10455_EN
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Table of tightening torques of emergency oil tank

For the screws in the table below the following tightening torques have to be applied:
7LJKWHQLQJWRUTXHVHPHUJHQF\RLOWDQN
3RV 3DUWQR >1P@
73/ 73/ 73/ 73/
M8 M8 M8 M8

M12 M12 M12 M12

M10 M10 M12 M12

38 38
G1/4 G1/4 G1/4 G1/4

M16 M20 M20 M24

M8 M8 M8 M8

M38 M38 M45 M45

M33 M33 M42 M42

M33 M33 M42 M42

M33 M33 M42 M42

M33 M33 M42 M42

M16 M20 M20 M24


10455_EN
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6
Spare-parts
When making inquiries or ordering spare parts, the following data should be specified:
- Type TPL
- HT number
- Designation and part number
Our agents and service stations (see list of service stations in chapter 7) accept orders for
spare-parts. They also provide information if special cases are not covered in the present
general instructions.
Note The spare-parts set 97070 is required for the work described in this manual.
The parts included in the spare-parts set are only available as complete set.
$PRXQW 'HVLJQDWLRQ 3DUWQR

6HUYLFHNLW
15 1) Hex. -headed screw 42042 / 42046 /
61009 / 61032 /
61035
2 2) Hex. -headed screw 42042 / 42046
15 2) Hex. -headed screw 61009 / 61032 /

61035
3 Hex. -headed nut 61037
1 Gasket 42041
1 Gasket 42045
2 O-ring gasket 42012 / 76040
1 3) O-ring gasket 42052
2 O-ring gasket 77005 / 77006
1 O-ring gasket 86506
1)
TPL 77 / 85
2)
TPL 73 / 80
3)
TPL 85
ABB 10455_EN
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The spare-parts ordered with the turbocharger should be kept complete and serviceable.
Therefore:
- any parts exchanged or missing must be replaced immediately.
- rusty parts should be carefully cleaned and greased.
Note Parts exchanged and no longer usable must be disposed of correctly according to
the environmental regulations.

10455_EN
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90020 90025
90170
90174
90178 90195
90175
90177
90190
90230 90231 90235 90240

(TPL 77 - 85)
90450
90300 90305
90380
90320
90325
90470
90460
90480 90490
90600
90920
90500
90901 90950 90951 90952

90921
90900
ABB 10455_EN
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7
Tools
7.1
Rotor with screwed connection
Part no. Designation
90000 Tools complete

90010 Box
90010
90020 Assembly-disassembly device

90025 Support angle
90170 Guide plate
90174 Extension piece
90175 Holder
90177 Stud
90178 Hex.-headed nut
90190 Lifting device
90195 Shackle
90230 Ring bolt
90231 Ring bolt
90235 Ring bolt (TPL 77 - 85)
90240 C-spanner
90300 Guide tube
90305 Radial bearing pin
90320 Guide bolt
90325 Pin
90380 Pressing-on bush
90450 Support
90460 Torque multiplier
(Not for the polygon connection)
90470 Box spanner
90480 Lock
90490 Holder
90500 Locking device
90600 Lifting tool
90900 Puller screw
90901 Puller screw
90920 Press-off tool
90921 Clamp
90950 Screw plug
90951 Flange
90952 Gasket

10455_EN
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90020 90025
90170
90178 90195
90175
90177
90190
90230 90231 90235

(TPL 77 - 85)
90450
90300 90305
90320
90325
90490 90600
90901
90900
90920
90921 90950 90951 90952
ABB 10455_EN
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7.2
Rotor with polygon connection
90000 Tools complete

90010 Box
90010
90020 Assembly-disassembly device

90025 Support angle
90170 Guide plate
90175 Holder
90177 Stud
90178 Hex.-headed nut
90190 Lifting device
90195 Shackle
90230 Ring bolt
90231 Ring bolt
90235 Ring bolt (TPL 77 - 85)
90300 Guide tube
90305 Radial bearing pin
90320 Guide bolt
90325 Pin
90450 Support
90490 Holder
90600 Lifting tool
90900 Puller screw
90901 Puller screw
90920 Press-off tool
90921 Clamp
90950 Screw plug
90951 Flange
90952 Gasket

10455_EN
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90024
90421
90023
90027
90426
90422 90424
90423
90439
90427
90431
90434
90195
90441
90443 90447
90442 90444
90440
90445 90484
90471
90483
90700
90486 90487
ABB 10455_EN
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90010 Box
90010
90023 Hydraulic pump

90024 High-pressure hose
90027 Assembly tool
90421 Centering tube
90424 Pipe piece
90426 Lifting eye nut
90427 Lifting lug
90195 Shackle
90431 Threaded rod
90434 Venting screw
90439 Suspension device
90440 Protective sleeve
90441 Locking clamp
90442 Hex.-headed screw
90443 C-spanner
90444 C-spanner
90445 Protection pipe
90447 C-spanner
90471 Split-pin driver
90483 Spacer ring
90484 Spacer ring
90486 Extractor ring
90487 Extractor nut
90700 Oil can

10455_EN
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81000
82000
74000
61009
76000
77005
79000
76040
61037
56001 51001
61032
77006
61001
42000
63000
61035
42012 86506
42052
TPL85
42045 42046
42041
42042
ABB 10455_EN
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8
Directory of part numbers
In ALL correspondence or for all orders use the following part numbers and designations:
Part nr. Designation
42000 Cartridge group

42012 O-ring gasket
42041 Gasket
42042 Hexagon headed screw
42045 Gasket
42052 O-ring gasket
51001 Gas inlet casing
56001 Nozzle ring
61001 Gas oulet casing
61037 Hex. headed nut
63000 Turbine diffusor
74000 Compressor casing, external part
76000 Compressor casing, internal part
76040 O-ring gasket
77005 O-ring gasket
77006 O-ring gasket
79000 Diffuser
81000 Silencer
82000 Air suction branch, radial
86506 O-ring gasket
Note = Available within the service kit only (see page 24)

10455_EN
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6
Taking out of operation Page 1
6
Taking out of operation
Cartridge group with screwed connection
Contents Page
1
Shutting down the turbocharger at short notice .....................................................................3
1.1
Blocking rotor TPL 69 ÷ 85 ..................................................................................................5
1.2
Fitting the cover plate ..........................................................................................................9
2
Mothballing the turbocharger ..................................................................................................11
2.1
for up to 12 months ............................................................................................................11
2.2
for over 12 months .............................................................................................................11
Volume: 11 pages
Edition: 06 / 2002
HZTL 10456_EN
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Page 2 Taking out of operation
ABB 10456_EN
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1
Shutting down the turbocharger at short notice
If it must be possible to return the diesel engine to service as quickly as possible in the event of
damage to the turbocharger (emergency repair), the turbocharger rotor can be locked as
described in section 1.1. If more time is available, it is recommended to remove the cartridge
group and to fit a cover plate according to section 1.2.
Caution ! In both cases the instructions of the engine manufacturer for operation of the
engine with locked/inactivated turbocharger must be followed exactly.

10456_EN
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25005
90020
90480
Fig. 6-1
Blocking rotor
ABB 10456_EN
-B-
1.1
Blocking rotor
TPL 69 ÷ 85
In emergencies with a damaged turbocharger it can occur that the engine must continue to
operate without or, in applications with several turbochargers, with reduced charging. If the
engine must be returned to service as quickly as possible, the rotor of the damaged turbocharger
can be locked.
If more time is available, it is recommended to dismantle the cartridge group and to fit a cover
plate according to section 1.2.
Caution ! Be careful to observe the manufacturer’s instructions!
The following procedure should be adopted for locking the rotor (refer also to fig. 6-1):
- Remove silencer or air suction branche and internal part of compressor casing with wall
insert (see chap. 5).
- Remove screw plug (25005) (see fig. 6-1).
- Fit assembly-disassembly device (90020).
- Block the rotor with the lock (90480).
Note Cut a thread (M12 or 1/2") in the existing hole to secure the lock with a screw (A).
Caution ! A locked rotor must be dismantled in all cases.
During the operation of the engine with a locked turbocharger rotor, the lubri-cation
system must remain attached and turned on if the gas inlet can not be blocked (see
next section). Otherwise intact components can be damaged by overheating.

10456_EN
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Further measures and information for operation with a locked turbo-

charger:
Various cases must be distinguished:

1. 2-stroke engine with one turbocharger:
No further measures are necessary.
The engine can be operated according to the instructions of the manufacturer.
2. 2-stroke engine with several turbochargers:

- The compensator at the compressor outlet must be dismantled and the air duct blocked at
the engine end (undamaged turbochargers develop a receiver pressure!).
- The operating limit of the engine can be raised by additionally blocking the gas inlet. The
loading and temperature of the locked rotor are also reduced.
- If the gas inlet cannot be blocked, the following operating limits apply:
1. The pressure in the charge-air receiver must not exceed 1 bar.
2. Max. permissible engine load: 50%.
- Attention must be paid to the speed of the undamaged turbocharger in all cases. The speed
limit nBmax according to the turbocharger rating plate must not be exceeded.

No further measures are necessary. The engine can be operated as suction engine according
to the instructions of the manufacturer.
4. 4-stroke engine with two turbochargers:

a) Separate receivers:
No further measures are necessary on engines with separate air and exhaust-gas receivers.
The engine can be operated as a normally aspirated engine according to the instructions of
the manufacturer.
ABB 10456_EN
-B-
b) Common receiver:
- If the engine is provided with a common air receiver and separate exhaust-gas receivers,
the compensator at the compressor outlet of the damaged turbocharger must be dismantled
without fail and the air duct blocked at the engine end. Otherwise the undamaged turbocharger
can spin under no load and reach overspeed.
- More or less powerful pulses from the exhaust-gas system are applied to the locked rotor,
depending on the engine turbocharging system. Particularly with pulse supercharging (turbine
casing with more than one gas inlet) the locking device is then subjected to heavy loading.
The following operating limits should therefore not be exceeded:
1. In systems similar to those with constant pressure (1 gas inlet) the engine can be
operated at up to max. 25% engine load. The pressure in the charge-air receiver must
not exceed 0.9 bar overpressure.
2. With pulse supercharging (2-4 gas inlets) the engine can be operated at up to max. 20%
engine load. The pressure in the charge-air receiver must not exceed 0.5 bar overpressure.
The engine can be operated according to the instructions of the engine manufacturer. However,
attention must, without fail, be paid to the speed of the undamaged turbocharger. The speed

10456_EN
-B- ABB
1 2
B5
3
B3
Æ2
B7
3
4
Æ
Æ
B2
Æ1
a1
a3
a2
B1
B4 B6
B8
Æ5
Æ4
Fig. 6-2
Steel pipe Cover plate
ABB 10456_EN
-B-
1.2
Fitting cover plate
- Dismantle cartridge block as described in chapter 5.
- Close opening in gas outlet casing with cover plate (see fig. 6-2)
- Secure cover plate with spacer sleeves and nuts (61037).
Caution ! Seal oil pipes!
Note The cover plate (material: ST37) must be manufactured according to the drawing.
Type B1 B2 B3 B4 B5 B6 B7 B8 Æ1 Æ2 Æ3 Æ4 Æ5 min a1 a2 a3
TPL 61 278 6 8 61 529 596 567 14 21
TPL 65 325 30 30 8 10 6 70 616 694 660 16 22
TPL 69 385 8 10 84 726 818 779 18 25
TPL 73 13 450 9 12 94 844 948 905 20 28 4x90° 37,5° 24x15°
TPL 77 535 9 12 107 1003 1124 1075 22 30
50 50 8
TPL 80 623 11 15 136 1164 1300 1248 24 32
TPL 85 774 14 18 167 1425 1586 1528 26 36
All measurements in mm

10456_EN
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Further measures and information for operation with a turbocharger

with cover plate:

The engine can be operated according to the instructions of the engine manufacturer.

- The compensator at the compressor outlet must be dismantled and the air duct blocked
at the engine end (undamaged turbochargers develop a receiver pressure!).
- The operating limit of the engine can be raised considerably by additionally blocking the
gas inlet.
The engine can basically be operated according to the instructions of the manufacturer.
However, attention must be paid, without fail, to the speed of the undamaged turbocharger.
The speed limit nBmax according to the turbocharger rating plate must not be exceeded.

No further measures are necessary. The engine can be operated as a normally aspirated
engine according to the instructions of the manufacturer.

The engine can be operated as normally aspirated engine according to the instructions of
the manufacturer.
b) Common receiver:
- If the engine is provided with a common air receiver, the compensator at the compressor
outlet of the damaged turbocharger must be dismantled without fail and the air duct blocked
at the engine end. Otherwise the undamaged turbocharger can spin under no load and
reach overspeed.
The engine can basically be operated according to the instructions of the manufacturer. However,
attention must be paid, without fail, to the speed of the undamaged turbocharger. The speed
ABB 10456_EN
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2
Mothballing the turbocharger
2.1
for up to 12 months
If a turbocharger has to be laid up for up to 12 months, the decision whether the turbocharger
needs special protection or not depends mainly on the condition of the lubricating oil before
laying up.
If the Total Acid Number (TAN) is lower than 2 mg KOH/g no special measures need to be
taken. However, if the factor is higher the turbocharger must be dismantled after laying up,
cleaned and protective oil has to be applied on the bright parts.
If the turbocharger is left on the engine, and the engine oil replaced by a protective oil which is
circulated with a prelubrication pump prior to laying up, no mesures need to be taken in respect
of the turbocharger. The remains of the old engine oil will be washed away and the sensitive
bearing parts extensively protected against corrosion.
If the rotor turns due to a draught from the flue, fit a blind flange between the compressor
casing and the charge-air receiver.
2.2
for over 12 months
If a charger has to be removed from the engine and stored for any length of time, the
disassembling and mothballing of the turbocharger must be prepaired by an official service
station of ABB Turbo Systems.
Ensure that the room in which the turbocharger is going to be stored is dry and free of
condensation.
Note Check mothballed turbochargers yearly for corrosion.

In the event of rust, clean and renew the corrosion protection.

10456_EN
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6
6
Cartridge group with polygon connection
Contents Page
1
Shutting down the turbocharger
at short notice .............................................................................................................................3
1.1
Blocking rotor .......................................................................................................................3
1.2
Fitting the cover plate ..........................................................................................................9
2
Mothballing the turbocharger ..................................................................................................11
2.1
for up to 12 months ............................................................................................................11
2.2
for over 12 months .............................................................................................................11
3
Locking device ..........................................................................................................................13
Volume: 13 pages
Edition: 11 / 2002

HZTL 10464_EN
-.- ABB
94005
94004 90442
(TPL85)
94031
(TPL85)
94032
(TPL85)
90020
94002
94001
94006
94007/94008
94003
Fig. 6-1
Blocking rotor
ABB 10464_EN
-.-
1
Shutting down the turbocharger
at short notice
If the diesel engine must be put into operation again as soon as possible in the event of
damage to the turbocharger (emergency repair), the following possibilities are available:
1. The turbocharger rotor can be locked as described in section 1.1.
2. On engines with several turbochargers it is possible (and often simpler) to isolate the
damaged turbocharger according to data from the manufacturer by fitting cover plates in the
compressor outlet, turbine inlet and turbine outlet. In this case it is recommended to shut off
the supply of lubricating oil to the damaged turbocharger.
3. For engines with one turbocharger, a bypass can be fitted around the turbocharger (according
to data of the engine manufacturer) if the relevant connections and pipes are available. In this
case it is recommended to shut off the supply of lubricating oil to the damaged turbocharger.
4. If more time is available, it is recommended to dismantle the cartridge group and fit a cover
plate as described in section 1.2.
Caution! The instructions of the engine manufacturer for operation of the engine with locked
/ shutdown turbocharger must be followed exactly in all cases!
1.1
Locking the rotor
In emergencies with a damaged turbocharger it can occur that the engine must continue to
operate without or, in applications with several turbochargers, with reduced charging. If the
engine must be returned to service as quickly as possible, the rotor of the damaged turbocharger
can be locked.
Caution ! The instructions of the engine manufacturer must be observed!
The following procedure should be adopted for locking the rotor (refer also to fig. 6-1 and 6-2):
- Remove silencer or air suction branch and internal part of compressor casing with wall insert
and diffuser (see chapter 5).
- Fit partition wall clamp (94005) with screws (90442).
- For engines with three or four turbochargers, the balancing screws should be removed from
the compressor wheel concerned, so that the adjustment ring (94004) can be fitted with
maximum compressive force.
For engines with one or two turbochargers, eight screws are sufficient for secure fixing of
the adjustment ring.

10464_EN
-.-
ABB
Case 1 TPL 85 Case 2 TPL 85

(CV 11) (CV 12)
Designation "CV"
94002 94001 94001 & 94002
94031 94004 94031 94004
Case 1 TPL 80 Case 2 TPL 80

(CV 11) (CV 12)
94002 94001
94001 & 94002
Fig. 6-2
Blocking rotor
ABB 10464_EN
-.-
TPL 85
+ Fit correct adjustment ring (94004) together with intermediate ring (94031) and locking
flange (94003) on the compressor ring.
Note Various adjustment rings (94004) are provided with the locking device for different
compressor wheels. The designation CV must be noted.
The thread depth is not the same on all compressor wheels. It is recommended to
use screws as long as possible for fixing the adjustment ring 94004. Two different
screw lengths are therefore supplied with the locking device (94007 / 94008).
The space between the lock (94003) and the assembly-disassembly device (90020) must be
compensated by the intermediate rings (94001 and/or 94002) depending on the version of
compressor wheel (see fig. 6-2).
Caution! It must be ensured that all components are clean and free from grease.
- Place the correct intermediate rings (94001 and/or 94002) on the locking flange (94003) and
fit the assembly-disassembly device (90020).
- Insert the remaining intermediate rings (94001 and/or 94002) and fix the locking flange
(94003) with the screws (94006).
Caution! A locked rotor should be disassembled following repair and given an unbalance
check. Balancing screws screwed out must not be screwed in again.
The only exceptions are test rig runs up to max. 25% engine load on new engines
with one or two turbochargers, which are requested in part by customers. Since in
these cases, operation with a locked rotor is brief and the loads are small, subse-
quent disassembly of the rotor is unnecessary.
Caution! During the operation of the engine with a locked turbocharger rotor, the lubrication
system must remain attached and turned on if the gas inlet can not be blocked (see
next section). Otherwise intact components can be damaged by overheating.

10464_EN
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ABB
Further measures and information for operation with a locked turbo-

charger:

No further measures are necessary. The engine can be operated as suction engine
according to the instructions of the manufacturer.

- The operating limit of the engine can be raised by additionally blocking the gas inlet. The
loading and temperature of the locked rotor are also reduced.
- If the gas inlet cannot be blocked, the following operating limits must be observed:
1. The pressure in the charge-air receiver must not exceed 1 bar.
2. Max. permissible engine load: 50%.
- Attention must be paid to the speed of the undamaged turbocharger in all cases. The
speed limit nBmax according to the turbocharger rating plate must not be exceeded.

No further measures are necessary. The engine can be operated as suction engine
according to the instructions of the manufacturer.
ABB 10464_EN
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The engine can be operated as a normally aspirated engine according to the instructions of
the manufacturer.
b) Common receiver:
- If the engine is provided with a common air receiver and separate exhaust-gas receivers,
the compensator at the compressor outlet of the damaged turbocharger must be dismantled
without fail and the air duct blocked at the engine end. Otherwise the undamaged turbocharger
can spin under no load and reach overspeed.
- More or less powerful pulses from the exhaust-gas system are applied to the locked rotor,
depending on the engine turbocharging system. Particularly with pulse supercharging (turbine
casing with more than one gas inlet) the locking device is then subjected to heavy loading.
The following operating limits should therefore not be exceeded:
1. In systems similar to those with constant pressure (1 gas inlet) the engine can be
operated at up to max. 25% engine load. The pressure in the charge-air receiver must
not exceed 0.9 bar overpressure.
2. With pulse supercharging (2-4 gas inlets) the engine can be operated at up to max. 20%
engine load. The pressure in the charge-air receiver must not exceed 0.5 bar overpressure.
The engine can be operated according to the instructions of the engine manufacturer. However,
attention must, without fail, be paid to the speed of the undamaged turbocharger. The speed

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ABB
Fig. 6-3
Steel tube Cover plate
ABB 10464_EN
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1.2
Fitting cover plate
- Dismantle cartridge block as described in chapter 5.
- Close opening in gas outlet casing with cover plate (see fig. 6-3)
- Secure cover plate with spacer sleeves and nuts (61037).
Caution ! Seal oil pipes!
Note The cover plate (material: ST37) must be manufactured according to the drawing.
Type B1 B2 B3 B4 B5 B6 B7 B8 ∅ 1 ∅ 2 ∅ 3 ∅ 4 ∅ 5 min α1 α2 α3
TPL 61 278 6 8 61 529 596 567 14 21
TPL 65 325 30 30 8 10 6 70 616 694 660 16 22
TPL 69 385 8 10 84 726 818 779 18 25
TPL 73 13 450 9 12 94 844 948 905 20 28 4x90° 37,5° 24x15°
TPL 77 535 9 12 107 1003 1124 1075 22 30
50 50 8
TPL 80 623 11 15 136 1164 1300 1248 24 32
TPL 85 774 14 18 167 1425 1586 1528 26 36
All measurements in mm

10464_EN
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ABB
Further measures and information for operation with a turbocharger

with cover plate:

The engine can be operated according to the instructions of the engine manufacturer.

- The operating limit of the engine can be raised considerably by additionally blocking the
gas inlet.
The engine can basically be operated according to the instructions of the manufacturer.
However, attention must be paid, without fail, to the speed of the undamaged turbocharger.
The speed limit nBmax according to the turbocharger rating plate must not be exceeded.

No further measures are necessary. The engine can be operated as a normally aspirated
engine according to the instructions of the manufacturer.

The engine can be operated as normally aspirated engine according to the instructions of
the manufacturer.
b) Common receiver:
If the engine is provided with a common air receiver, the compensator at the compressor
outlet of the damaged turbocharger must be dismantled without fail and the air duct blocked
at the engine end. Otherwise the undamaged turbocharger can spin under no load and
reach overspeed.
The engine can basically be operated according to the instructions of the manufacturer. However,
attention must be paid, without fail, to the speed of the undamaged turbocharger. The speed
ABB 10464_EN
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2
Mothballing the turbocharger
2.1
for up to 12 months
If a turbocharger has to be laid up for up to 12 months, the decision whether the turbocharger
needs special protection or not depends mainly on the condition of the lubricating oil before
laying up.
If the Total Acid Number (TAN) is lower than 2 mg KOH/g no special measures need to be
taken. However, if the factor is higher the turbocharger must be dismantled after laying up,
cleaned and protective oil has to be applied on the bright parts.
If the turbocharger is left on the engine, and the engine oil replaced by a protective oil which is
circulated with a prelubrication pump prior to laying up, no mesures need to be taken in respect
of the turbocharger. The remains of the old engine oil will be washed away and the sensitive
bearing parts extensively protected against corrosion.
If the rotor turns due to a draught from the flue, fit a blind flange between the compressor
casing and the charge-air receiver.
2.2
for over 12 months
If a charger has to be removed from the engine and stored for any length of time, the
disassembling and mothballing of the turbocharger must be prepaired by an official service
station of ABB Turbo Systems.
Ensure that the room in which the turbocharger is going to be stored is dry and free of
condensation.
Note Check mothballed turbochargers yearly for corrosion.

In the event of rust, clean and renew the corrosion protection.

10464_EN
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Notes
ABB 10464_EN
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3
Locking device
94000
90442
90010
94005
94032 (TPL85)
94004 (TPL 85)
94031 (TPL85)
94003 94008
94007
94002
94001
94006
94000 Locking device complete

90010 Box
94001 Intermediate ring
94002 Intermediate ring
94003 Locking flange
94004 Adjustement ring (TPL 85)
94005 Clamp
94031 Intermediate ring (TPL 85)
94032 Washers (TPL 85)

10464_EN
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ABB
7
ABB
ABB Turbo Systems AG
Bruggerstrasse 71a
CH-5400 Baden
Switzerland

Instruction manual TPL 73 -B 80-B

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Instruction manual TPL 73 -B 80-B

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Turbocharger

ABB Turbo Systems Ltd

ABB Turbo Systems Ltd ABB

 Copyright by ABB TURBO SYSTEMS Ltd 2002

Design and specifications are subject to change without notice.

Instructions on safety and hazards 1

Putting into operation 2

Operation and maintenance 3

Disassembly and assembly 5

Taking out of operation 6

Guide to service stations 7

ABB Turbo Systems Ltd ZTL 2480_EN

All instructions must be strictly observed.

Defects which could affect safety must be eliminated immediately.

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

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

This instruction manual are valid for various turbocharger models.

The following abbreviations are being used:

e.g. For example

- Working steps / Enumerations

Notes for assembling

ABB Turbo Systems Ltd

2 n Bmax, t Bmax: Turbocharger - operational limits in service.

Inspection and replacement intervals for turbocharger components:

Replacement interval for the compr. wheel in 1000 h

5 Replacement interval for the bladed shaft in 1000 h

7 Space for the special design designation

8 Weight of the turbocharger in kg

Warning signs must be strictly observed.

Caution signs must be observed to the letter.

Notes help to simplify your work.

- Work on a turbocharger only in a stable physical and mental condition.

- Do not stand under suspended loads.

- Do not use machine parts as steps.

- Work only on those connections for which you are qualified.

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

- Before commissioning check the turbocharger for damage or leaks.

- Report immediately any damage or changes in operation performance to the person/

- Handle operation materials and detergents with utmost caution.

- After cleaning, check electric cables for signs of wear or damage.

- Assembly and disassembly work must only be performed by trained personnel.

- Secure the rotor against turning.

- Clean the turbocharger before mothballing.

- Wear protective clothing during mothballing the turbocharger.

- Remove any obstacles laying around on the floor.

- from the turbocharger and its accessories

- from the operating materials used

- from failure to observe safety instructions

- from inadequate maintenance and inspection work.

Warning ! Unconsciousness and injury due to:

crushing, shearing, cutting, winding, demolishing

drawing in, knocking, stabbing, rubbing

loss of liquids under high pressure and high temperature

slipping, tripping, falling

- sharp edges, pointed parts

- Wear leather protective gloves

Physical injury and damage to property

Warning ! Allergies, skin disease, unconsciousness, poisoning or nausea after inhalation

Injury by scalding and burning of the skin

Burning by vapours or contact with acids or alkalis

- Inhalation of toxic gases, smoke and vapours

- Skin contact with aggressive fluids

- Clothing wet or soaked with hazardous substances

- Spilling and tipping over of vessels with operation materials

(YHU\WR>K@ Operation data - enter in the log book