TPL 80

Turbocharging
Operation Manual
TPL80-B12
ABB Turbo Systems Ltd

CH 5401 Baden
Type TPL80-B12 HT492717

n Mmax 245 t Mmax 550
1/s °C
n Bmax 233 t Bmax 520
5775 kg 36 100 100

Application according to
Year 2008 the Operation Manual
made in Switzerland
HZTL2480 English

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

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

ABB Turbo Systems AG
Bruggerstrasse 71a
CH-5401 Baden
Switzerland
Operation Manual
Table of contents Page 1
Table of contents
November 2007
1 Preliminary remarks
1.1 Purpose of manual
1.2 Layout and function
1.3 Correct use of the turbocharger
1.4 Essential information
1.5 Abbreviations and symbols
1.6 Turbocharger rating plate
2 Safety
2.1 Basic safety instructions
HZTL2480_EN (TPL73-B.. - 85-B..)
2.2 General safety instructions

2.3 Special safety instructions
2.4 Safety instructions and hazard protection
2.5 Warnings on the turbocharger
3 Commissioning
3.1 Oil supply
3.2 Inspection work
3.3 Putting into operation after laying up
4 Operation
4.1 Servicing work
4.2 Expected exchange intervals
4.3 Monitoring
4.4 Operation without emergency oil supply
4.5 Surging of turbocharger
4.6 Contact with rotating parts
Version 5.1
4.7 Shutting the engine down
5 Maintenance
5.1 Foreword to Maintenance
5.2 Cleaning the filter silencer
5.3 Cleaning the compressor during operation
5.4 Cleaning turbine blades and nozzle ring in operation
5.5 Suppliers of materials for dry cleaning
ABB Turbo Systems Ltd ABB

Operation Manual
Table of contents Page 2
6 Troubleshooting
6.1 Possible remedies for failures
November 2007
7 Removal and installation
7.1 Turbocharger weights
7.2 Remove the turbocharger
7.3 Installing the turbocharger
8 Disassembly and assembly

8.1 Module weights
8.2 Removing and fitting filter silencer or air suction branch
8.3 Axial clearance
8.4 Removing cartridge group
8.5 Inspection and assessment of valve block
8.6 Dismantling and installing the turbine diffuser and nozzle ring
HZTL2480_EN (TPL73-B.. - 85-B..)

8.7 Installing cartridge group
8.8 Turbine-end removal / fitting of the nozzle ring
8.9 Table of tightening torques
9 Shut-down at short notice

9.1 Possibilities for emergency repair
9.2 Locking the rotor
9.3 Blocking the inlets and outlets
9.4 Bypass the turbocharger
9.5 Fit cover plate
10 Preserving turbocharger
10.1 Taking out of operation for up to 12 months
10.2 Taking out of operation for more than 12 months
11 Disposal
11.1 Environmentally compatible disposal of turbocharger
components
Version 5.1
12 Reserve and spare parts

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

Operation Manual
Preliminary remarks 1
Purpose of manual 1.1 Page 1
1 Preliminary remarks
November 2007
1.1 Purpose of manual

Operating manual This operation manual will help you to become familiar with your ABB
Turbo Systems turbocharger and to use it to full effect in its intended ap-
plication. You will find important instructions as to the safe, correct, and
economical operation of the turbocharger.
Target group The content of this operation manual is intended for persons such as en-
gineers, marine mechanics and service technicians who are responsible
for the running of the engine and the turbocharger installed thereon.
Content of operating ma- This operation manual includes helpful information on the following topics:
nual
Information on the operation of the turbocharger and ways to prolong
the turbocharger's service life.
HZTL2480_EN (TPL73-B.. - 85-B..)
Early identification and avoidance of hazards.

Minimizing repair costs and downtime.
This operating manual complements and extends existing national regula-

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

out fail.
This applies especially to the general and special safety instructions

preceding the respective chapters and in them. Ignoring hazards and
Version 5.1
the safety instructions can lead to serious personal injury and damage
WARNING to equipment.
If in doubt, consult the safety officer responsible and the person account-
able for protection against accidents in your domain.

Operation Manual
Layout and function 1.2 Page 2
1.2 Layout and function
November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
L_01079
1 Filter silencer 8 Nozzle ring

2 Radial plain bearing 9 Turbine wheel
3 Thrust bearing 10 Bearing casing
4 Bearing bush 11 Air diffuser
5 Radial plain bearing 12 Compressor wheel
Version 5.1
6 Gas outlet casing 13 Compressor casing

7 Gas inlet casing 14 Emergency lubrication oil
tank

Operation Manual
Layout and function 1.2 Page 3
Working principle
November 2007
The turbocharger is a turbo-machine and consists of the following main

components:
Turbine
Compressor
These are both mounted on a common shaft.
The exhaust gases from the diesel engine flow through the gas inlet cas-
ing (7) and nozzle ring (8) to the turbine wheel.
The turbine wheel (9) uses the energy contained in the exhaust gas to
drive the compressor wheel (12). The compressor draws in fresh air,
HZTL2480_EN (TPL73-B.. - 85-B..)
compresses it and then forces it into the engine cylinders.
The exhaust gas escapes to free air through the exhaust manifold which
is connected to the gas outlet casing (6).
The air which is necessary for the operation of the diesel engine and
which is compressed in the turbocharger is drawn through the suction
branch or the filter silencer (1) into the compressor wheel (12). This air
then passes through the diffuser (11) and leaves the turbocharger through
the compressor casing (13).
The rotor runs in two radial plain bearings (2/5). One plain bearing is in
the bearing bush (4) and one plain bearing is in the axial thrust bearing (3)
at the compressor end.
The plain bearings are connected to a central lubricating oil channel which
is fed with oil from the engine lubrication circuit. The oil outlet is always at
the lowest point of the bearing casing (10).
The turbocharger is equipped with an emergency lubrication oil tank (14).

Version 5.1
If the main oil lubrication system fails, this emergency lubrication unit sup-
plies oil to the bearings until the rotor comes to a standstill.

Operation Manual
Correct use of the turbocharger 1.3 Page 4
1.3 Correct use of the turbocharger
November 2007
This turbocharger supplied by ABB Turbo Systems has been developed
for use on diesel engines to generate the volume of air and the charg-
ing pressure required to operate the engine.
NOTE The engine manufacturer has provided ABB Turbo Systems with infor-
mation regarding the intended purpose of the engine, from which the
operating parameters specific to the turbocharger (such as rotating
speeds, temperatures, replacement periods / exchange intervals) have
been derived and are indicated on the rating plate.
Any other use will be regarded as a special application which must first
be discussed with ABB Turbo Systems. The manufacturer accepts no
liability for other applications. If it is used otherwise, ABB Turbo Sys-
tems reserves the right to reject all claims under the warranty.
HZTL2480_EN (TPL73-B.. - 85-B..)

Latest technology This turbocharger was built according to state-of-the-art technology and is
operationally safe according to prevailing safety regulations.
Improper operation and maintenance of the turbocharger can result in

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

bly, disassembly, operating, maintenance and repair conditions specified
by the manufacturer. Disposal regulations set down by local authorities
must be observed.
Perfect condition The turbocharger must only be installed in a technically perfect condition,
corresponding to its intended purpose and following the instructions in the
Engine Manufacturers' Manual, and must be operated and used in com-
pliance with the Operation Manual.
Version 5.1
X Malfunctions / defects which could affect safety must be eliminated

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

Operation Manual
Essential information 1.4 Page 5
1.4 Essential information

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

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

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

with the turbocharger must be checked regularly with reference to this
manual.
NOTE
HZTL2480_EN (TPL73-B.. - 85-B..)
X The turbocharger must be shut down immediately by stopping the en-

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

could compromise safety require the prior approval of ABB Turbo Sys-
tems.
NOTE
Version 5.1

Operation Manual
Original parts and safety
November 2007
Original parts and accessories are especially designed for the turbo-
charger supplied by ABB Turbo Systems.
We herewith expressly state that parts and accessories not supplied by

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

Turbo Systems are used, this may have a negative effect on the techni-
cal design specifications of the turbocharger.
WARNING Moreover, the active and/or passive safety of the turbocharger may be
HZTL2480_EN (TPL73-B.. - 85-B..)

compromised by the use of non-original parts. Note that such improper
use may endanger personnel and the machine.
ABB Turbo Systems shall not be liable for any damage caused by using
non-original parts and accessories.
Qualification of personnel
The turbocharger must only be operated and maintained by trained and

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

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

Version 5.1
charger.

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

Turbo Systems. service stations worldwide.
Design variants
This operating manual is valid for various turbocharger design variants.
This means that some sections and component descriptions in this oper-
ating manual do not apply to your turbocharger.
Our service stations and agencies will gladly answer your questions relat-
ing specifically to your model.
HZTL2480_EN (TPL73-B.. - 85-B..)
Accuracy of illustrations
The graphics and images shown in this manual are of a general nature
and are intended to assist understanding of the work steps and instruc-
tions. Differences may exist in certain details.
Version 5.1

Operation Manual
Storage of new turbochargers
November 2007
New turbochargers supplied by ABB Turbo Systems can be stored without
additional safeguarding measures for a period of 6 months after the deliv-
ery date.
Suitable storage locations are dry rooms where the relative humidity is be-
tween 40-70% and no condensation can form.
X After expiry of the 6 months, all surfaces and accessible areas of the
turbocharger should be sprayed with anticorrosive agent.
X To do this, the insulating materials must be removed.
Repeat the described measures every 6 months to keep your turbo-

charger free from rust.
HZTL2480_EN (TPL73-B.. - 85-B..)

NOTE
Version 5.1

Operation Manual
Abbreviations and symbols 1.5 Page 9
1.5 Abbreviations and symbols

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

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

HZTL2480_EN (TPL73-B.. - 85-B..)
This note provides suggestions and tips to make work on the turbo-
charger easier.
The note provides further essential information.
NOTE
Reference to safety instructions

The warnings and cautions are described in the chapter Safety .
CAUTION
ABB Turbo Systems
ABB Turbo Systems Ltd is specified in this manual as ABB Turbo Sys-
tems.
Version 5.1
Official ABB Turbo Systems service station
The term Official ABB Turbo Systems service station used in this manual
signifies ABB turbocharger service stations, that have been tested and
certified by ABB Turbo Systems.

Operation Manual
Turbocharger rating plate 1.6 Page 10
1.6 Turbocharger rating plate
November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
L_00012
Operational limits 1 Turbocharger operational limits at engine overload (110 %).

In test rig operation only, unless otherwise agreed with the
engine manufacturer.
2 Turbocharger operational limits in service.
Version 5.1
Recommended replace- 3 Replacement interval for the plain bearings in 1000 h

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

Operation Manual
Turbocharger rating plate 1.6 Page 11
Additional specifications: 6 Customer part number

7 Field for special design designation
November 2007
8 Weight of the turbocharger in kg

9 CE = Conformité Européenne
10 Turbocharger type
11 Series number
12 Year of construction of the turbocharger
Explanations of the rating plate
The recommended exchange intervals and the corresponding operation

limits are defined together with the engine builder. These specifications
are system-specific.
HZTL2480_EN (TPL73-B.. - 85-B..)
Continuous running above the indicated nBmax, tBmax values may consid-
erably reduce the recommended exchange intervals. In such cases, we
recommend you contact the nearest official service station of ABB
CAUTION Turbo Systems.
nMmax , tMmax normally apply only when running at overload (110 %) dur-
ing trials on the engine test bed. These limits may also be permitted in
service for special applications. The operation over nMmax , tMmax is not
permitted.
Non-compliance with the recommended exchange intervals may in-
crease the risk of unpredictable component failure.
Version 5.1

BLANK
Operation Manual
Safety 2
Basic safety instructions 2.1 Page 1
2 Safety
November 2007
2.1 Basic safety instructions

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

HZTL2480_EN (TPL73-B.. - 85-B..)
working and operation instructions marked with this symbol are not, or
only partly, observed.
CAUTION Caution signs must be strictly observed at all times.
Version 5.1

Operation Manual
Safety 2
General safety instructions 2.2 Page 2
2.2 General safety instructions

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

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

stress.
Wear protective clothing at all times.
Helmet
Ear protection
HZTL2480_EN (TPL73-B.. - 85-B..)

Protective glasses
Protective suit
Oil and petrol resistant gloves
Protective shoes
Attach individual parts and larger component modules carefully to suit-
able hoists/lifting devices which are in technically perfect condition and
which have adequate load-bearing capacity.
Do not stand under suspended loads.
If welding work is to be carried out above the turbocharger, the air filter
must be covered to prevent damage to the filter mat.
When working on the turbocharger, be aware of the risk of it falling.
For overhead assembly work, use the steps and platforms provided for
this purpose.
Version 5.1

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

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

Remove obstacles and any objects lying around from the work area.
Before commissioning check the turbocharger for damage and leaks.
Refrain from any activity which could compromise safety while working
with the turbocharger.
Inspect the turbocharger after about 12 hours of operation or at least
HZTL2480_EN (TPL73-B.. - 85-B..)
once a day for visible damage and defects.

Report any damage or changes in operational performance to the per-
son/department responsible immediately.
In the event of damage, shut down the turbocharger immediately and
secure it against inadvertent or unauthorized use.
Safety when cleaning
When handling detergents, solvents, acids and alkalis be sure to observe

the respective safety directions on the manufacturers' labels.
Follow directions regarding the environmentally compatible collection, sto-

rage and disposal of these liquids.
Explosion hazard
Cleaning work should be carried out outdoors due to explosion hazard.
If this is not possible, ensure that there is adequate ventilation and air
WARNING circulation. Before beginning cleaning work in confined spaces, extin-
guish naked flames (including cigarettes!) due to the risk of explosion.
Version 5.1

Operation Manual
Safety 2
Before cleaning, protect the floor against unintended leaks of oil and
operation materials.
November 2007
You must wear protective clothing (see section General safety instruc-
tions).
Handle operation materials and detergents with utmost caution.
When handling solvents, wear protective clothing and observe the fol-
lowing rules:
Avoid skin contact with solvents.
Avoid inhaling vapours under all circumstances.
Do not allow solvents to soak protective clothing.
After cleaning, check electric cables for signs of wear or damage.
Safety during disassembly, assembly, maintenance and troubleshooting
Follow the prescribed maintenance and inspection schedules for all ad-
HZTL2480_EN (TPL73-B.. - 85-B..)

justment, maintenance and inspection work.
Inform operating personnel about special work and repairs before start-
ing.
Ensure that absorbent materials are available to clean up any opera-
tion materials that escape accidentally.
Ensure safe and environmentally-friendly drainage, collection and dis-
posal of operating and auxiliary materials.
Before opening a cover or removing a protective component on the
turbocharger, the engine must have been switched off and must not be
started up again until all parts have been properly re-assembled.
Assembly and disassembly work must only be performed by trained

personnel. Work on mechanical components, such as bearings or ro-
tors, must only be performed by qualified fitters from an official service
CAUTION station of ABB Turbo Systems. Version 5.1

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

November 2007
Secure the rotor against turning.

Clean the turbocharger before mothballing.
Wear protective clothing when mothballing the turbocharger.
Keep the work area clean and free of oil and operating materials.
Remove any obstacles lying around on the floor.
HZTL2480_EN (TPL73-B.. - 85-B..)
Version 5.1

Operation Manual
Safety 2
Safety instructions and hazard 2.4 Page 6

protection
2.4 Safety instructions and hazard protection

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

from the operating materials used.
due to failure to comply with the safety instructions.
from inadequate performance of maintenance and inspection work.
Mechanical influences
Mechanical influences can cause serious injury or even fatal injury.
HZTL2480_EN (TPL73-B.. - 85-B..)

WARNING
Personal injury Unconsciousness and injury due to:
crushing
shearing
cutting
winding
smashing
drawing in
knocking
stabbing
rubbing
Escape of liquids under high pressure and / or at high temperature
slipping
tripping
falling
Version 5.1

Operation Manual
Safety 2

protection
Causes sharp edges, pointed parts

crush, shear and winding areas
fragmentation / ejection of parts
November 2007
fracture or rupture of parts due to overload

Elastic elements (springs), liquids and / or gases under pressure/in a
vacuum
slippery, oily work area, obstacles on the floor
Protective measures 9 Wear leather protective gloves

9 Wear close-fitting protective clothing
9 Tie up long hair and beards (wear hair protection)
9 Wear face and eye protection
9 Wear protective shoes
9 Keep floor, equipment and the turbocharger clean
9 Ensure the availability of oil absorbing materials and have oil collector
basins ready or in position
9 Eliminate leaks
HZTL2480_EN (TPL73-B.. - 85-B..)
Operation and process materials
Operation and process materials refer to chemical and hazardous sub-

stances:
Oils
Grease
Coolants
Detergents and solvents
Acids
Note that operation and process materials are harmful to the environ-
ment if they penetrate soil or water.
CAUTION
Version 5.1

Operation Manual
Safety 2

protection
Personal injury The following injuries can be caused by operation and process materials:
Allergies
November 2007
Skin disease
Loss of consciousness
Poisoning or nausea after inhalation
Causes Inhalation of toxic gases, smoke and vapours

Skin contact with aggressive fluids
Clothing wet or soaked with hazardous substances
Spilling and tipping over of vessels containing substances used during
operation
Escape due to leakage
Tanks and collectors which are not gas-tight and which do not comply
with the regulations on hazardous substances
Burning cigarettes or open flame in the proximity of operation materials
HZTL2480_EN (TPL73-B.. - 85-B..)

Protective measures 9 Utmost caution when handling process and operation materials
9 Protective clothing must be worn
9 Avoid skin contact and inhalation
9 Ensure that the workroom is properly ventilated
9 Observe the hazard indications on the containers for operation and
process materials
9 Seal the hazardous substance container tight immediately after use
9 Used operation materials must be collected safely in accordance with
the legal provisions, stored separately in suitable containers as pre-
scribed, and disposed of as special waste in an environmentally com-
patible manner
9 Ensure that containers with new / used operation materials are sealed
tight
9 In the event of leaks or spills, immediately apply a suitable absorbent
material and dispose of this in a technically and environmentally com-
patible manner as special waste
Version 5.1

Operation Manual
Safety 2

protection
Handling insulating materials

November 2007
9 Ensure that the work area is well ventilated

9 Keep the work area clean
9 Avoid disturbing dust
9 Dust-suppressing tools and processing steps
9 Remove from packaging only in the work area
9 Exercise particular care when removing old insulating materials
9 Dispose of insulating materials in a technically and environmentally
compatible manner
9 If large quantities of dust are created, wear protective glasses
9 Use half or quarter masks
9 Wear suitable work clothing and gloves
9 For sensitive skin, apply moisturising, protective barrier cream
Noise
HZTL2480_EN (TPL73-B.. - 85-B..)
The effects of noise above a legally permitted level can cause personal in-
jury.
Personal injury Loss of hearing

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

Version 5.1
Causes Missing or incorrectly fitted insulation.
Protective measures 9 Wear leather protective gloves.

Operation Manual
Safety 2
Warnings on the turbocharger 2.5 Page 10
2.5 Warnings on the turbocharger
November 2007
Warnings that have been applied to turbochargers by ABB Turbo Systems
must not be removed, painted over or obscured with other stickers. Miss-
ing or illegible warnings must be replaced by new warnings.
HZTL2480_EN (TPL73-B.. - 85-B..)

L_00227
Apply warnings so that they are clearly visible in the positions intended
for that purpose. Please contact an official ABB Turbo Systems service
station for further information.
NOTE
Version 5.1

Operation Manual
Commissioning 3
Oil supply 3.1 Page 1
3 Commissioning
November 2007
3.1 Oil supply

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

concerning selection of lubricating oil, oil change intervals, oil filtration,
and oil pressure and temperature.
NOTE
HZTL2480_EN (TPL73-B.. - 85-B..)
Oil filtration
A lubrication oil filter system with a mesh size ≤ 0.050 mm is adequate for
TPL ..-B turbochargers.
Oil pressure
The oil pressure in front of the bearings must be maintained precisely to

ensure trouble-free operation.
The permissible oil pressures are specified in the following tables de-
pendent on the lubrication (engine lubrication or separate lubricating sys-
tem).
Engine lubrication Kinetic viscosity 45 - 170 cST Oil pressure [bar]

Inadmissible oil pressure range -> 0.0 - 0.6
Emergency shutdown (without time lag)
Oil pressure range permissible in short term (<1h) -> 0.6 - 0.8
Version 5.1
Alarm
Permissible oil pressure range for normal operation 0.8 - 2.5
Permissible oil pressure range during engine warm- 0.8 - 4.0
up phase

Operation Manual
Commissioning 3
Oil supply 3.1 Page 2
Separate lubricating sys- Kinetic viscosity 12 - 170 cST Oil pressure [bar]
tem
Inadmissible oil pressure range -> 0.0 - 0.9
November 2007
Emergency shutdown (without time lag)
Oil pressure range permissible in short term (<1h) -> 0.9 - 1.1
Alarm
Permissible oil pressure range for normal operation 1.1 - 2.5
Permissible oil pressure range during engine warm- 1.1 - 4.0
up phase
If a separate lubricating system has been designed for operation in the

viscosity range of the engine lubrication system, i.e. 45 – 170 cSt, the
oil pressure limits according to the engine lubrication information may
NOTE be used for this system.
HZTL2480_EN (TPL73-B.. - 85-B..)

Oil temperature during normal operation
Engine lubrication Oil entry Engine load Oil entry pressure Oil exit
temperature [%] [bar] temperature
[ °C ] [ °C ]
45 100 1.5 - 2 70 - 90
70 100 1.5 - 2 90 - 110
Version 5.1

Operation Manual
Commissioning 3
Inspection work 3.2 Page 3
3.2 Inspection work

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

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

HZTL2480_EN (TPL73-B.. - 85-B..)
Air filter mat X Inspect for damage.
Lubrication system X Check that the oil filter is clean before commissioning.
It is urgently recommended that the entire lubrication system be flushed

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

Version 5.1

Operation Manual
Commissioning 3
Inspection work 3.2 Page 4
3.2.2 Inspection after commissioning
November 2007
Lubrication system X Check oil pressure in oil supply lines.
Charger speed X Measure
Charger pressure X Measuring
Measure temperatures X upstream/downstream from turbine, compressor and oil feed for vari-
ous engine speeds
HZTL2480_EN (TPL73-B.. - 85-B..)

Gas, air, and oil lines X Check all gas, air, and oil lines for leaks after the engine has been star-
ted up.
Further must be observed:
Lubricants and pastes are liquefied or vaporised during assembly of the

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

before and after the turbine and the compressor at various engine
Version 5.1
speeds.
X Compare the measured values with those of the inspection report, tak-
ing into account the different operating conditions.
3.2.3 Inspection after 100 service hours
Clean or replace lubricating oil filters after the first 100 service hours.

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

X Remove the cover plates (blind flanges) between the compressor cas-
November 2007
If they are present

ing outlet and the charge-air receiver, upstream of the gas inlet, down-
stream of the gas outlet.
X Inspect the exhaust-gas duct before and after the turbine for any com-
bustion residue, clean / remove foreign bodies or residual water.
X Inspect air supply line or filter silencer for any foreign bodies, clean /
remove.
X Start up the turbocharger's engine end oil circulation system.
X Prepare the turbocharger for operation as instructed in the section In-
spection work before commissioning in the chapter entitled Commis-
sioning.
X Commission the turbocharger.
HZTL2480_EN (TPL73-B.. - 85-B..)
Version 5.1

BLANK
Operation Manual
Operation 4
Servicing work 4.1 Page 1
4 Operation
November 2007
4.1 Servicing work

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

work.
WARNING
HZTL2480_EN (TPL73-B.. - 85-B..)
Servicing work must be carried out at the prescribed intervals in order

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

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

official ABB Turbo Systems service station.
CAUTION
Version 5.1

Operation Manual
Operation 4
November 2007
4.1.2 Entries in the machine logbook
Monitoring of the machine plant provides information about the perform-

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

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

Air intake temperature
Exhaust temperature before and after the turbine
Pressure of the charge-air
Pressure drop in the charge-air cooler
Lubricating oil pressure, lubricating oil temperature
HZTL2480_EN (TPL73-B.. - 85-B..)

If provided Air temperature after compressor and after the charge-air cooler
Speed of the turbocharger
Pressure loss in the air filter
4.1.3 Servicing work according to the engine manufacturer's instructions
Oil filters X With the engine at standstill clean or replace oil filters
Version 5.1

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

November 2007
X Remove filter silencer or air suction branch

X Clean filter silencer as far as accessible, and inspect for damage
X Remove internal part of compressor casing
X Check clearance A (axial bearing play).
X Clean accessible parts (compressor wheel, diffusor, wall insert), and
inspect for damage
X Without removing turbine parts and using an endoscope, carry out a
visual check for possible soiling and damage (nozzle ring, turbine diffu-
sor/cover ring, turbine blades). As an option, this inspection can be car-
ried out after removal of gas inlet casing.
X Refit internal part of compressor casing
X Re-install filter silencer or air suction branch.
HZTL2480_EN (TPL73-B.. - 85-B..)
This inspection work and checks must be carried out by an official ser-
vice station of ABB Turbo Systems.
NOTE
Version 5.1

Operation Manual
Operation 4
November 2007
4.1.5 Servicing work every 36,000 hours
X Remove filter silencer or air suction branch

X Clean filter silencer as far as accessible, and inspect for damage
X Remove internal part of compressor casing
X Check clearance A (axial bearing play).
X Clean accessible parts (diffusor, wall insert), and inspect for damage.
X Take apart gas inlet casing and remove nozzle ring.
X Clean nozzle ring and check for damage or wear.
X Clean turbine diffusor / cover ring and check for damage or wear.
X Replace radial bearing and thrust bearing with original parts from ABB
Turbo Systems.
X Inspect and assess rotor.
HZTL2480_EN (TPL73-B.. - 85-B..)

Replacement of the bearing parts as well as inspection and assessment
of the rotor must be carried out by an official ABB Turbo Systems ser-
vice station.
NOTE
Version 5.1

Operation Manual
Operation 4
Expected exchange intervals 4.2 Page 5
4.2 Expected exchange intervals

November 2007
Expected replacement Turbocharger part HFO

intervals [h]
Gas inlet casing 50'000 … 100’000
Gas outlet casing 50'000 … 100’000
Nozzle ring 35'000 … 50’000
Turbine diffusor / cover ring 25'000 … 50’000
Other housings 100’000
Rotor components See rating plate for information
Bearings See rating plate for information
HZTL2480_EN (TPL73-B.. - 85-B..)
HFO = Heavy Fuel Oil
The values indicated are for guidance only and are not guaranteed val-
ues. These values may vary significantly for example due to inadequate
servicing, frequent emergency stoppages as well as through the use of
NOTE fuel or lubricating oil of inferior quality.
Version 5.1

Operation Manual
Operation 4
Monitoring 4.3 Page 6
4.3 Monitoring
November 2007
4.3.1 Measuring speed
HZTL2480_EN (TPL73-B.. - 85-B..)

86505_001
1 Bearing casing 6 Connecting cable

2 Thrust bearing 7 Line amplifier (optional)
3 Guidance in axial bearing 8 Speed sensor
4 Gasket ring 9 Alternative for fitting speed
sensor
5 Screw plug
Version 5.1
The speed transmitter system for the measurement of the turbocharger

speed also permits, in conjunction with the corresponding measuring in-
struments and/or monitoring systems (not included in the scope of deliv-
ery), a constant remote monitoring of the turbocharger speed. If the ma-
chine installation is monitored continuously, the turbocharger speed can
be used as a suitable control parameter. The line amplifier can be pur-
chased as an option to the described speed measuring system.

Operation Manual
Operation 4
Possible reasons for failure of the transmitter system are:
Defects in the speed transmitter, the connecting cable and plug to the
November 2007
measuring unit, in the measuring unit itself or the power supply.

Turbocharger damage.
Failure of speed indicator

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

transmitter system should be carried out only by an official ABB Turbo
Systems service station.
HZTL2480_EN (TPL73-B.. - 85-B..)
NOTE
A reduction in turbocharger speed can signify:
Damaged turbine or bearing

Severe soiling of the turbine
Version 5.1

Operation Manual
Operation 4
4.3.2 Underpressure measurement on filter silencer
November 2007
A U-tube manometer can be ordered from ABB Turbo Systems for meas-
uring the negative pressure at the filter silencer.
This measuring can be used for the following purposes:
Measuring the correction factor for calculating the turbocharger effi-

ciency during engine acceptance
The use of a filter mat on the filter silencer can cause a loss of pres-
sure. More significant pressure loss is an indication of increased soiling
of the filter material.
U-tube manometer
HZTL2480_EN (TPL73-B.. - 85-B..)

Version 5.1
L_00003 L_00004
1 Felt discs
A [mm H2O] Pressure differential / pressure loss

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

November 2007
tion of additional felt discs (1).
The U-tube manometer must be exposed to minimum possible me-

chanical shock or vibration.
NOTE
X Fit U-tube manometer to filter silencer as shown in preceding illustra-

tion.
X Fill U-tube manometer with slightly coloured water to obtain best legibil-
ity.
Under as-new conditions (new or clean filter silencer and filter mat), the
maximum pressure loss (A) is 120 mm H2O under full loading.
HZTL2480_EN (TPL73-B.. - 85-B..)
X Clean filter at latest as soon as loss of pressure (A) reaches a value of

200 mm H2O.
For better legibility of the pressure differential (A) on the U-tube ma-
nometer, the measuring rod can be withdrawn to the level of the bottom
water level.
NOTE
Version 5.1

Operation Manual
Operation 4
Operation without emergency oil supply 4.4 Page 10
4.4 Operation without emergency oil supply
November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
00000_028
If a leak occurs in the emergency oil system during operation and imme-
diate repair is not possible, the turbocharger can be operated until repair
without emergency oil supply.
X Dismantle pipe leading from valve unit or branch piece to tank.

X Fit a blind flange to valve unit or branch piece.
X Close opening on tank to prevent oil from escaping.
Operation without an emergency oil supply is possible without harm, as

long as the lubricating system functions properly when the turbocharger
is running.
Version 5.1
CAUTION

Operation Manual
Operation 4
Surging of turbocharger 4.5 Page 11
4.5 Surging of turbocharger

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

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

If surging is prolonged or occurs periodically, the following components
may be damaged:
CAUTION - Compressor wheel (vibration fractures, ...)
- Turbine blades (cracks)
- Bearing (overheating)
- Filter silencer
HZTL2480_EN (TPL73-B.. - 85-B..)
Action to be taken:
The operating safety of the turbocharger is no longer ensured with con-
tinuous or periodically recurring surging. The operator must take imme-
NOTE diate steps to correct the surging together with the closest official ABB
Turbo Systems service station.
The components listed above must be inspected for damage by an offi-
cial ABB Turbo Systems service station, and replaced in cases of
doubt.
Version 5.1

Operation Manual
Operation 4
Contact with rotating parts 4.6 Page 12
4.6 Contact with rotating parts

Slight, uniform wear around the periphery of rotor components, caused by
November 2007
their just touching adjacent components locally, is not hazardous and
permissible. This slightly reduces the length of the blades in the compres-
sor and/or the turbine. Certain tolerances must be observed to avoid a
significant loss of efficiency.
X A check on dimensions must be carried out by an official ABB Turbo

Systems service station.
HZTL2480_EN (TPL73-B.. - 85-B..)

Version 5.1

Operation Manual
Operation 4
Shutting the engine down 4.7 Page 13
4.7 Shutting the engine down

November 2007
Before shutting down the engine, it must be allowed to idle for about 3
minutes longer so that the circulating lubricating oil can take away heat
from the turbocharger bearings.
CAUTION
HZTL2480_EN (TPL73-B.. - 85-B..)
Version 5.1

BLANK
Operation Manual
Maintenance 5
Foreword to Maintenance 5.1 Page 1
5 Maintenance
November 2007
5.1 Foreword to Maintenance

Maintenance and servicing work involves regular visual checks and clean-
ing to ensure that the turbocharger and its attached units function trouble-
free.
The external condition and how dirty the cleaning points specified in
this chapter are, must be established by visual checks at the specified
intervals.
The safety precautions must be observed during all maintenance and
servicing work.
HZTL2480_EN (TPL73-B.. - 85-B..)
The cleaning points described in the following are:
Filter silencer
Compressor
Turbine and nozzle ring
Version 5.1

Operation Manual
Maintenance 5
Cleaning the filter silencer 5.2 Page 2
5.2 Cleaning the filter silencer
November 2007
5.2.1 Filter silencer with tension band
81137 81136
81266
81268
81271
L
HZTL2480_EN (TPL73-B.. - 85-B..)

81270
81266
81135
81268
81270
81265
Version 5.1
L_01158
81265 Filter ring (if provided) 81266 Cover grids

81270 Tension ring 81136 Fleece segment
38271 Trap cover 81137 Cover panel
81268 Connecting strip 81135 Filter silencer body
E Slide-in module = fleece segment + cover plate installed

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

November 2007
X Rinse filter ring (81265) with water using detergent or, if very dirty, soak
it. Squeeze out carefully. Rinse in cold water. Avoid high mechanical
stress (water jet).
The dirt in the filter ring (81265) depends on how clean the drawn-in air
is. Wash or replace the filter ring as necessary or every 500 service
hours.
NOTE
X Loosen clamping straps (81270) at tightening point (81271) and re-

move together with mesh covers (81266) and connecting bars (81268).
HZTL2480_EN (TPL73-B.. - 85-B..)
In the case of a slide-in module (E) when a cleaning container is at-

tached to the filter silencer (available as option depending on turbo-
charger type), the water injection line must first be removed (see also
NOTE following section Disassembling cleaning line).
X Withdraw slide-in modules (E), bend open cover plates (81137) and
then take out fleece segments (81136).
X Clean fleece segments (81136).
When cleaning, ensure that fleece segments (81136) are cleaned only
with a weak jet of compressed air, a soft brush or damp cloth. Other-
wise the segments may be damaged or lose their shape.
Heavily soiled fleece segments and filter ring as well as damaged con-
necting bars should be replaced with original parts from ABB Turbo
Systems.
Version 5.1
NOTE

Operation Manual
Maintenance 5
Mounting filter silencer
November 2007
X Assemble slide-in modules (E) by inserting fleece segments (81136) in
cover plates (81137).
X Bend cover plates back to their original shape.
X Insert slide-in modules (E) in grooves in filter silencer body (81135).
When the cleaning container is fitted to the filter silencer (available as

option depending on turbocharger type), the water injection line must be
re-installed (see also following section Assembling cleaning line).
NOTE
X Fit mesh covers (81266) and connecting bars (81268) onto filter si-
HZTL2480_EN (TPL73-B.. - 85-B..)

lencer body (81135).
X Pass clamping straps (81270) through eyelets in connecting bars (see
detail L in illustration L_01158).
X Tension all clamping straps at tightening points (81271).
If provided X Fit filter ring (81265).
Version 5.1

Operation Manual
Maintenance 5
5.2.2 Filter silencer and connecting rod

November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
L_00185
81265 Filter ring (if provided) 81136 Fleece segment

81269 Connecting rods 81137 Cover panel
81266 Cover grids 81135 Filter silencer body
Version 5.1
81272 Screw 81273 Locknut

E Slide-in module = fleece segment + cover panel

Operation Manual
Maintenance 5
Disassembling and cleaning filter silencer
November 2007
If provided X Remove filter ring (81265).
Rinse filter ring (81265) with water using detergent or, if very dirty, so-
ak it. Squeeze out carefully. Rinse in cold water. Avoid high mechani-
cal stress (water jet).
The dirt in the filter ring (81265) depends on how clean the drawn-in air
is. Wash or replace the filter ring as necessary or every 500 service
hours.
NOTE
X Loosen and remove locknuts (81273).

Loosen and remove screws (81272) to the connecting rods (81269).
HZTL2480_EN (TPL73-B.. - 85-B..)

X
X Remove connecting rods (81269).
X Carefully remove the cover grid (81266).
In the case of a slide-in module (E) when a cleaning container is at-

tached to the filter silencer (available as option depending on turbo-
charger type), the water injection line must first be removed (see also
NOTE following section Disassembling cleaning line).
X Withdraw slide-in modules (E), bend open cover panels (81137) and
then take out fleece segments (81136).
X Clean fleece segment (81136).
When cleaning, ensure that the fleece segments (81136) are cleaned
only with a mild jet of compressed air and a soft brush or damp cloth.
Otherwise the segments may be damaged or lose their shape.
Replace heavily contaminated fleece segments and filter ring as well as

damaged connecting rods with original parts from ABB Turbo Systems.
Version 5.1
NOTE

Operation Manual
Maintenance 5
Mounting filter silencer

November 2007
X Assemble slide-in modules (E) by inserting fleece segments (81136) in

cover plates (81137).
X Bend cover panels (81137) back to their original shape.
X Insert slide-in modules (E) in the grooves in the filter silencer body
(81135).
When the cleaning container is fitted to the filter silencer (available as

option depending on turbocharger type), the water injection line must be
re-installed (see also following section Assembling cleaning line).
NOTE
HZTL2480_EN (TPL73-B.. - 85-B..)
X Place cover grids (81266) evenly in the correct position.

X Push the connecting rods (81269) through the clips on the cover grids
(81266).
If the connecting rods (81269) are not located correctly in their recesses
on the filter silencer body (81135), the cover grid (81266) can twist and
shift. This can allow foreign bodies and dirt to get into the compressor.
CAUTION
Version 5.1
L_00232

Operation Manual
Maintenance 5
November 2007
L_00234
HZTL2480_EN (TPL73-B.. - 85-B..)

X Connect the connecting rods (81269) with the screws (81272). While
tightening the screws (81272), ensure that the connecting rods (81269)
are located correctly in the recesses in the filter silencer body (81135).
Now tighten the screws (81272) alternately to the following max. tight-
ening torque:
Screw Tightening torque

81272 20 Nm
X Fit locknuts (81273) onto screw (81272) and tighten to the following
torque:
Locknut Tightening torque

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

Version 5.1

Operation Manual
Maintenance 5
5.2.3 Removing / installing the cleaning line

November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
L_00192
1 Injection pipe 2 Pipe

3 Guide tube
Version 5.1

Operation Manual
Maintenance 5
Disassembling the cleaning line
November 2007
X Disconnect the line (2) at the injection pipe (1) and remove the screw
coupling from the pipe.
X Pull line (2) out of the guide tube(3).
Punching out the guide

tube
HZTL2480_EN (TPL73-B.. - 85-B..)

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

original parts from ABB Turbo Systems.
Version 5.1
NOTE

Operation Manual
Maintenance 5
Installing the cleaning line

November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
L_00194
X After fitting the slide-in modules (E), re-fit the guide tube (3) and re-
caulk it.
X Fit line (2) and screw it to the injection pipe (1).
Version 5.1

Operation Manual
Maintenance 5
Cleaning the compressor during 5.3 Page 12

operation
5.3 Cleaning the compressor during operation
November 2007
These guidelines for wet cleaning apply exclusively for cleaning with
clean water and are subject to permission for the procedure being ob-
tained from the engine manufacturer.
NOTE
The contamination of the compressor stage (compressor wheel and dif-

fuser) depends on the cleanness of the air drawn in.
A deposit of dirt in the flow ducts will be formed if the following substances
are present in the intake air:
Oil or saline mist
HZTL2480_EN (TPL73-B.. - 85-B..)

Solid combustion residues
Dust of various kinds
Soiling of the compressor stage has a negative effect on compressor effi-

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

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

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

Version 5.1
operation of the engine, please contact ABB Turbo Systems.
NOTE

Operation Manual
Maintenance 5

operation
Cleaning method
The compressor is cleaned while operating using the cleaning method de-
November 2007
scribed in the following. This method has been tested and is approved by
ABB Turbo Systems:
Wet cleaning
Principle of wet cleaning Water is injected before the compressor wheel via an injection pipe fitted
in the filter silencer or the suction branch in order to clean the compressor
stage in operation.
The water does not act as a solvent in the process, but the deposit is re-
moved by the mechanical impact of the drops. The process is ideal, pro-
vided the soiling is not too advanced.
HZTL2480_EN (TPL73-B.. - 85-B..)
Due to the danger of corrosion, only clean water may be used, and on
no account salt water. The water should also contain no cooling addi-
tives, which could form deposits in the flow ducts.
CAUTION
Cleaning more than one If several turbochargers are installed on one engine, we recommend clea-
turbocharger compressor ning the turbocharger compressors one after the other.
Version 5.1

Operation Manual
Maintenance 5

operation
5.3.1 Wet cleaning the compressor with external pressurised water con-
November 2007
tainer (XC3)
The supply of water with the externally fitted dosing vessel is only suit-
able for applications with underpressure before the compressor wheel
(not applicable for: Blower connected upstream of the compressor or
NOTE high-pressure compressor stage in the case of two-stage charging).
Operating state preconditions for cleaning compressors with XC3
In order to carry out a successful cleaning procedure that has been
HZTL2480_EN (TPL73-B.. - 85-B..)

tested and is recommended by ABB Turbo Systems, the following pre-
conditions must be met:
NOTE
Z Engine loading as full as possible
Z High turbocharger speed
X Cleaning cycle started according to the following description in Pro-
cedure for wet cleaning with XC3.
Version 5.1

Operation Manual
Maintenance 5

operation
Procedure for compressor wet cleaning with XC3

November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
L_00198
X Screw plug
Y Valve activator
Operating the pressurised X The Operating state preconditions for cleaning the compressor with
water container XC3 must be met before cleaning can begin.
X Remove screw plug (X).
X Fill container with clean water.
Version 5.1
X Screw screw plug (X) back in.

X Actuate valve lever (Y) against the spring and hold for 10 to 15 sec-
onds, until all the water has been injected.
X After cleaning, the turbocharger must be allowed to dry for at least 5
minutes before any further activity.

Operation Manual
Maintenance 5

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

times.
November 2007
If cleaning is still not successfulafter three attempts and the engine op-
NOTE erating values are unsatisfactory, we recommend that you have the tur-
bocharger checked and cleaned by an official ABB Turbo Systems ser-
vice station.
Cleaning parameters per turbocharger compressor
Turbocharger type Turbocharger Content dosing Water injection

speed vessel [dm3] time
t1 [s]
TPL 73-B As far as possible 1 4 … 15
TPL 77-B nBmax
HZTL2480_EN (TPL73-B.. - 85-B..)

TPL 80-B 2
TPL 85-B
Version 5.1

Operation Manual
Maintenance 5

operation
5.3.2 Wet cleaning compressors using water vessel (XC4)

November 2007
Operating state preconditions for cleaning compressors with XC4

NOTE
Z Engine loading as full as possible
Z High turbocharger speed
cedure for wet cleaning with XC4.
HZTL2480_EN (TPL73-B.. - 85-B..)
Procedure for compressor wet cleaning with XC34

Version 5.1
L_00197
1 Cleaning container 2 Pipe

3 Injection pipe 4 Cleaning instructions
5 Cover 6 Valve

Operation Manual
Maintenance 5

operation
If the cleaning container on the filter silencer is used, the detailed clean-
ing instructions provided on the plate (4) fitted to the filter silencer
November 2007
should be followed.
NOTE
Operation of the cleaning X The Operating state preconditions for cleaning compressors with XC4
container must be met before cleaning can begin.
X Open lid (5) of the cleaning container (1).
X Fill with clean water.
X Screw lid (5) closed.
X Open valve (6) for about 3 minutes.
X Close valve (6) and check that all the water has been sucked out.
X After cleaning, the turbocharger must be allowed to dry for at least 5
minutes with the engine running before any further activity.
HZTL2480_EN (TPL73-B.. - 85-B..)

times.
vice station.
Cleaning parameters per turbocharger compressor
Turbocharger type Turbocharger Content dosing Water injection

speed vessel [dm3] time
t1 [s]
TPL 73-B As far as possible 2 4 … 15
TPL 77-B nBmax
TPL 80-B 3
Version 5.1
TPL 85-B

Operation Manual
Maintenance 5
Cleaning turbine blades and nozzle ring 5.4 Page 19

in operation
5.4 Cleaning turbine blades and nozzle ring in

operation
November 2007
Combustion of heavy fuel oil in diesel engines causes soiling of the tur-
bine blades and nozzle rings of the turbochargers.
Soiling increases with time, so that regular and properly performed clean-
ing is important to remove the accumulated deposits.
The exhaust gas temperature downstream of the cylinders can rise and
the charging pressure at the air receiver can fall if turbine components be-
come soiled.
A soiled turbine also results in rotor unbalance. Severe soiling can lead to
impermissibly high rotor imbalance.
Experience in operation has shown that despite periodic cleaning during

operation, it is impossible to dispense with overhauls during which the tur-
HZTL2480_EN (TPL73-B.. - 85-B..)
bine and nozzle ring are mechanically cleaned. However, if cleaning is

performed correctly and the cleaning system is properly dimensioned, the
intervals between overhauls can be extended.
Wet cleaning interval The interval between periodic cleaning depends in large measure on the
operating conditions. In general, cleaning should be carried out every 50
to 500 operating hours.
Interval for dry cleaning The interval between periodic cleaning depends considerably on the op-
erating conditions. In general, cleaning should be carried out every 20 to
50 operating hours.
Version 5.1

Operation Manual
Maintenance 5

in operation
Cleaning methods
November 2007
Several methods are possible for cleaning the turbine and nozzle ring dur-
ing operation. The cleaning methods described in the following have been
tested and are recommended by ABB Turbo Systems:
Wet cleaning
Dry cleaning
Principle of wet cleaning During wet cleaning using droplets of water, the water does not act as a
solvent. Instead, the deposit is removed by the mechanical impact of the
drops.
HZTL2480_EN (TPL73-B.. - 85-B..)

Due to the danger of corrosion, only clean water may be used, and on
no account salt water. The water should also contain no cooling addi-
tives, which could form deposits in the flow ducts.
CAUTION
Principle of dry cleaning During dry cleaning using dry solid particles in granulate form, the deposit
is removed by the mechanical impact of the grains hitting the surface.
Wet and dry cleaning are equally effective. However, it may be useful to
apply both methods together.
NOTE
Version 5.1

Operation Manual
Maintenance 5

in operation
Stabilising and drying time

November 2007
Cleaning of the turbine-side components begins after engine start or

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

turbine, and to allow the minimum stabilising time before and between
cleaning procedures and the drying time after cleaning in accordance
CAUTION with the pertinent cleaning instructions will shorten the expected service
life of the components significantly.
HZTL2480_EN (TPL73-B.. - 85-B..)
Cleaning more than one If several turbochargers are installed on one engine, we recommend clea-
turbocharger turbine ning the turbocharger turbines with nozzle rings one after the other.
Version 5.1

Operation Manual
Maintenance 5

in operation
5.4.1 Wet cleaning turbine and nozzle ring during operation
November 2007
The maximum exhaust gas temperature specified by the engine manufac-
turer and the TMmax temperature shown on the turbocharger rating plate
must not be exceeded under any circumstances. During wet cleaning the
turbine delivers less power to the shaft and the turbocharger speed sinks.
As a result, less air is supplied to the engine and the temperature after the
engine cylinder and exhaust valve rises.
Operating state precondition for wet cleaning
HZTL2480_EN (TPL73-B.. - 85-B..)

NOTE
Z After the engine has been started or during operation, the engine
output must be adjusted until the scavenging air pressure pscav is
within the range of 0.3 – 0.6 bar (gauge pressure).
Z Wait 10 to 15 minutes (stabilising time), until the exhaust tempera-
ture at the turbine inlet is stable and below 430°C, the auxiliary
blower must also be operating.
cedure for wet cleaning.
Version 5.1

Operation Manual
Maintenance 5

in operation
Procedure for wet cleaning

November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
L_00394
1 Water supply (fresh water 8 Drain pipe

only) at least 6.0 bar
2 Regulating valve 9 Drain cock
3 Manometer 10 Outflow
4 Air supply with 3-way-valve 11 Orifice (integrated in turbo-
charger)
5 Stainless-steel pipe 21 Air duct from compressor cas-
ing
6 Other turbochargers A Position 1
7 Injection nozzle B Position 2
Version 5.1
Operating the wet clea- Z The Operating state preconditions for wet cleaning must be satisfied
ning system before cleaning is begun.
X Check that the water supply (1) is open and ensured, and also con-
nected to the regulating value (2) in front of the turbocharger.
X Set the shut-off valve (9) of the drain pipe (8) on the gas outlet casing
to Position 1 and check whether exhaust gas escapes.

Operation Manual
Maintenance 5

in operation
X Firstly, slowly open the 3-way-valve (4) (if fitted), then the regulating
valve (2) until the manometer (3) shows a pressure of 1 ± 0.2 bar.
X Inject water for 5 minutes at constant engine output.
November 2007
X Check whether the exhaust-gas temperature after the turbine drops.
X Close the regulating valve (2) and the 3-way-valve (4).
X Set drain cock (9) of the drain pipe (8) on the gas outlet casing to Posi-
tion 2, in order to keep the drain pipe clean with air from the compres-
sor casing (21).
X The water supply connection (1) to the regulating valve (2) must be
disconnected.
X After cleaning, wait at least 10 minutes with engine running to allow
turbocharger to dry.

times.
HZTL2480_EN (TPL73-B.. - 85-B..)

vice station.
Points to remember when The gas outlet casing must be drained of water via the drain pipe (8)
cleaning when cleaning.
The exhaust-gas temperature after the turbocharger falls significantly
during cleaning (by 50 to 150°C).
Outflow can (but need not) take place through the drain-pipe, depend-
ing on the engine load. This outflow might not start for 2 - 3 minutes, or
it may not occur at all.
If draining is not carried out, the turbocharger speed and / or gas inlet
temperature must be monitored closely during the washing operation. If
the load is too low, water can collect in the gas outlet casing. Signs of
this are a sudden fall in the turbocharger speed or very rapid increase
in the gas inlet temperature. In either of these cases, the wet cleaning
operation must be terminated and the wet cleaning cycle begun again
with a lower water pressure or higher engine loading.
Version 5.1

Operation Manual
Maintenance 5

in operation
5.4.2 Integrated dry cleaning of turbine and nozzle ring during operation
November 2007
This cleaning method is not suitable for removing thick dirt deposits and
must therefore be carried out more often (see chapter Cleaning turbine
blades and nozzle ring in operation).
NOTE
Operating mode prerequisites for integrated dry cleaning device

requisites must be met:
HZTL2480_EN (TPL73-B.. - 85-B..)
NOTE
Z High engine output (50 to 100%) and high turbocharger speed.
Z Gas inlet temperature upstream of the turbine must be below 590°C.
Otherwise, there is considerable danger that the dry cleaning agent
will be burnt off.
X Start the cleaning cycle with reference to the following description
Operating procedure for integrated dry cleaning device.
Version 5.1

Operation Manual
Maintenance 5

in operation
Operation of integrated dry cleaning device
November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
L_00094
1 Container for granulated mate- 5 ON/OFF valve

rial
Version 5.1
2 Trap-cover 6 Safety valve

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

Operation Manual
Maintenance 5

in operation
Operation of the dry Z The Operating mode prerequisites for integrated dry cleaning must be
November 2007
cleaning device satisfied before cleaning begins.

X Ensure that the ON/OFF valve (5) is closed.
X Check that combined air valve/pressure relief valve (7) is in pressure
relief position.
X Carefully open trap cover (2).
X Fill container (1) with specified amount of granulate.
X Close and seal trap cover (2).
X Open air valve (7).
X Open safety valve (6).
X Open ON/OFF valve (5) and leave it open for approx. 1 minute to clean
turbine.
X Close ON/OFF valve (5).
X Close safety valve (6).
HZTL2480_EN (TPL73-B.. - 85-B..)
X Set the combined air valve/pressure relief valve (7) to the pressure re-
lief position.
X Check whether exhaust gas temperature after turbine has dropped.
In order to obtain the best possible cleaning effect, it is essential that

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

times.
Version 5.1

vice station.

Operation Manual
Maintenance 5

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

Softblast media
Activated carbon particles
The average grain size of the cleaning granulate must be between 1.2
and 2.0 mm.
The specific weight of the cleaning granulate must not exceed 1.2 kg/dm3.
HZTL2480_EN (TPL73-B.. - 85-B..)

Granulate quantity per TPL 73-B TPL 77-B TPL 80-B TPL 85-B
turbocharger [litres]
1.0 1.5 2.0 3.0
The cleaning granulate must be stored in a dry, clean place in order to

avoid clogging the pipes during cleaning.
The table in chapter Suppliers of dry cleaning agents lists possible sup-
NOTE pliers of dry cleaning agents.
Version 5.1

Operation Manual
Maintenance 5

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

cleaning device can be installed in front of the gas inlet casing by the en-
gine manufacturer.
Operating mode prerequisites for non-integrated dry cleaning device

requisites must be met:
NOTE
HZTL2480_EN (TPL73-B.. - 85-B..)
Z High engine output (50 to 100%) and high turbocharger speed.

Z Gas inlet temperature in front of the turbine must be below 590°C.
Otherwise, there is considerable danger that the dry cleaning agent
will be burnt off.
X Start the cleaning cycle with reference to the following description
Operating procedure for non-integrated dry cleaning device.
Version 5.1

Operation Manual
Maintenance 5

in operation
Operation of non-integrated dry cleaning device
November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
Version 5.1
L_00208

Operation Manual
Maintenance 5

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

2 Poss. copper gasket 7 Safety valve with ventilation
November 2007
3 Double nipple G2“ 8 Compressed air shut-off valve

4 Copper gasket 9 Compressed air pipe
(internal diameter 8mm)
5 Friction cock or slide controller 10 Compressed air max. 6 bar
G1''
The air system must be protected against overpressure (> 6 bar).
CAUTION
Operation of the dry Z The Operating mode prerequisites for non-integrated dry cleaning de-
HZTL2480_EN (TPL73-B.. - 85-B..)
cleaning device vice must be satisfied before cleaning begins.

Z Friction cock or slide controller (5) closed and safety valve with ventila-
tion (7) open.
X Close safety valve with ventilation (7).
X Tighten trap cover (1).
X Open compressed air shut-off valve (8) so that deposits and any con-
densation are blown off.
X Close compressed air shut-off valve (8) again after about 3 minutes.
X Close friction cock / slide controller (5).
X Open safety valve with ventilation (7) to blow out exhaust gases.
X Carefully open trap cover (1) on granulate container.
X Fill granulate container with specified quantity of granulate.
X Close and seal trap cover (1).
X Close safety valve with ventilation (7).
X Open compressed air shut-off valve (8).
X Open friction cock or slide controller (5) for approx. 1 minute.
X Close friction cock or slide controller (5).
X Close compressed air shut-off valve (8).
Version 5.1
X Open safety valve with ventilation (7).

X Check whether exhaust gas temperature has dropped after turbine.

Operation Manual
Maintenance 5

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

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

times.
vice station.
HZTL2480_EN (TPL73-B.. - 85-B..)

Cleaning parameters for non-integrated dry cleaning device
The choice of material takes place according to chapter Integrated dry

cleaning of turbine and nozzle ring during operation.
NOTE
Granulate quantity per Turbocharger type Amount of granulate Container size

turbocharger [dm3]
TPL 73-B 1.0 II
TPL 77-B 1.5 II
TPL 80-B 2.0 II
TPL 85-B 3.0 III
Version 5.1

Operation Manual
Maintenance 5
Suppliers of materials for dry cleaning 5.5 Page 33
5.5 Suppliers of materials for dry cleaning

November 2007
Manufacturer Country Address Number for contact

ABB Australia Pty. Australia Dock 7W Bapaume Road Tel.: +61 2 9821 0940
Limited 2170 Moorebank- N.S.W. Fax: +61 2 9821 0941
Email: turbo@au.abb.com
Paul AUER GmbH Germany Bad Kreuznacherstr. 18 Tel.: +49 621 72 769 - 0
D-68309 Mannheim- Fax: +49 621 72 769 - 88
Kaefertal Email: vertrieb@auer-strahltechnik.de
BRIGANTINE Hong Kong 48 Wang Lok Street Tel.: +852 2473 7933
Service Ltd. Yuen Long Industrial Estate Fax: +852 2237 4731
N.T. Hong Kong Email:
gcabrgpropur@brigantinegroup.com
LEERING HENGE- Netherlands Barnsteenstraat 1 Tel.: +31 74 255 82 82
LO B.V. NL-7554 TC Hengelo Fax: +31 74 242 23 73
HZTL2480_EN (TPL73-B.. - 85-B..)
The Netherlands Email: info@leering.nl

GUYSON United Snaygill Industrial Estate Tel.: +44 1756 799911
International Ltd Kingdom Keighley Road, Skipton, Fax: +44 1756 790213
North Yorkshire BD23 2QR Email: info@guyson.co.uk
United Kingdom
DASIC United Winchester Hill, Romsey, Tel.: +44 1794 512 419
International Ltd. Kingdom Hampshire SO51 7YD Fax: +44 1794 522 346
United Kingdom Email: info@dasicinter.com
PAN Singapore 24 Pioneer Sector 2 Tel.: +65 6861 6988
Abrasives (Pte) Ltd. Jurong Fax: +65 6861 0919
628381 Singapore Email: pagroup@pan-abrasives.com
CARLANDER & Co. Sweden Valtersang 9 Tel.: +46 303 630 75
S-442 49 Kungalv Fax: +46 303 630 77
Sweden Email: lars@carlander.com
BOSUNG Enginee- Korea 1189-1, Choryang-3 Dong, Tel.: +82 51 466 0881-5
ring Co., Ltd. Dong-Ku, Busan, 601-013 Fax: +82 51 466 0886-9
Email: master@bosung.com
POLITEK Ltd. Turkey Barajyolu Cad. No: 22/6 Tel.: +90 216 455 77 66
Version 5.1
Y. Camlica Mahallesi Fax: +90 216 455 77 25

Yukari Dudullu Email: politekltd@politekltd.com
34779 Umraniye
Istanbul / Turkey
UNISERVICE S.A. Italy Via Al Santuario di N.S. Tel.: +39 010 711 395
della Guardia 58 / A Fax: +39 010 713 120
16162 Genova Email: info@uniservicemarine.com

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

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

HZTL2480_EN (TPL73-B.. - 85-B..)
Turbocharger
X Clean
Z Compressor / turbine soiled

X Clean
Z Exhaust counterpressure too high

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

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

X Clean
Z Insufficient coolant water quantity

X Replenish
Z Coolant water inlet temperature too hot

Version 5.1
X Clean/inspect cooling system
Z Ventilation inadequate
X Improve ventilation

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

X Repair
Z Gas line between engine and turbine leaking

X Repair
Z Injection misadjusted
X Correct adjustment
HZTL2480_EN (TPL73-B.. - 85-B..)

Z Valve control misadjusted
Turbocharger Z Manometer display faulty

X Replace manometer
Z Leak in line to the manometer

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

X Clean
Z Compressor / turbine soiled

X Clean
Z Compressor / turbine damaged

Version 5.1
Z Excessive exhaust counterpressure

X Clean boiler or exhaust silencer

Operation Manual
Troubleshooting 6
Charge-air pressure too high

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

Z Engine output higher than expected

X Check engine output
Z Injection misadjusted
HZTL2480_EN (TPL73-B.. - 85-B..)
Turbocharger Z Manometer display faulty

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

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

X Clean
Version 5.1
Z Bearing damaged
Z Rotor grazing
Z Foreign bodies in the turbocharger

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

X Clean
HZTL2480_EN (TPL73-B.. - 85-B..)

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

X Clean
Z Oil pump in the lubricating system defective

X Inspect
Z Manometer provides false reading

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

Version 5.1

Operation Manual
Troubleshooting 6
Constant surging of the turbocharger

November 2007
Engine Z Exhaust pressure to the turbine elevated because boiler or exhaust si-
lencer is dirty
Z Trap dirty
X Clean
Turbocharger Z Charge-air filter or silencer dirty

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

official ABB Turbo Systems service station.
HZTL2480_EN (TPL73-B.. - 85-B..)
NOTE
Version 5.1

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

November 2007
7.1 Turbocharger weights

WARNING
Loads that are not suspended in accordance with the regulations during
disassembly and assembly may fall and can cause serious or even fatal
injury.
X Select a suitable rope taking into account the weight of the load
X Hang rope crossed over on the crane hook
X Do not stand under suspended loads
HZTL2480_EN (TPL73-B.. - 85-B..)
Version 5.1
L_00082

Operation Manual
Turbocharger weights 7.1 Page 2
Complete turbocharger without filter silencer/air suction branch
November 2007
Weights [kg] TPL 73-B TPL 77-B TPL 80-B TPL 85-B
2310 3524 5510 9300
Complete turbocharger unit with filter silencer
2554 3928 6086 10255
Complete turbocharger unit with air suction branch
HZTL2480_EN (TPL73-B.. - 85-B..)

2450 3679 5752 9590
Version 5.1

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

X Disconnect all gas, air, and oil lines in accordance with engine manu-
November 2007
facturer’s instructions.
An orifice plate is fitted in each of the two oil inlet channels in the bear-
ing casing. In order to obtain the required oil pressure, the diameter of
the orifice plate holes in the oil-supplying oil inlet channel has been ad-
NOTE justed individually by the manufacturer. Whenever these orifices plates
are removed, or if the bearing casing or the complete turbocharger is
replaced, it is essential to ensure that the orifice plate with the correct
orifice diameter is fitted into the oil supplying oil-inlet channel.
X Remove the insulating shell from bearing casing.

X Check the lifting equipment.
X Secure lifting equipment to the suspension lugs on the bearing casing.
HZTL2480_EN (TPL73-B.. - 85-B..)
Version 5.1
L_00233

Operation Manual
Remove the turbocharger 7.2 Page 4
During removal, a turbocharger that is not lifted in compliance with

regulations may fall, and can cause serious or even fatal injury.
November 2007
WARNING Z Under no circumstances loop a rope around the emergency oil tank
and suspend the turbocharger from it.
X Select a suitable rope taking into account the weight of the turbo-
charger.
X Suspend the complete turbocharger using the two ribs on the bear-
ing casing provided for this purpose.
X The turbocharger must be transported as horizontally as possible.
Ensure that transport ropes do not touch emergency oil tank.
X Release the fixing screws on the foot.

X Lift the turbocharger from the engine and place it aside.
HZTL2480_EN (TPL73-B.. - 85-B..)

If the support for the turbocharger is missing or defective, the turbo-
charger might tip over during installation and removal and can cause
serious or even fatal injury.
WARNING
X Support turbocharger in a suitable location.

X Cover oil connector.
Version 5.1

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

November 2007
During installation work, a turbocharger that is not lifted in compliance

with regulations could fall and cause serious personal injuries or even
fatal accidents.
WARNING
Z Suspend the complete turbocharger using the two ribs provided for
this purpose. In no event should the rope be looped round the emer-
gency oil tank to suspend the turbocharger.
X Select a suitable rope taking into account the weight of the turbo-
charger.
X The turbocharger must be transported as horizontally as possible.
Ensure that transport ropes do not touch emergency oil tank.
X Remove cover from oil connector.

HZTL2480_EN (TPL73-B.. - 85-B..)
X Check the lifting equipment.

X Secure lifting equipment to the suspension lugs on the bearing casing.
X Mate turbocharger to engine.
X Tighten the fixing screws on the foot, in accordance with the engine
manufacturer's instructions.
X Secure all gas, air, and oil lines in accordance with the engine manu-
facturer’s instructions.
X Adapt insulating shell to suit bearing casing and secure it.

Version 5.1

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

November 2007
8.1 Module weights

WARNING
Loads that are not suspended in accordance with the regulations during
disassembly and assembly may fall and can cause serious or even fatal
injury.
X Select a suitable rope taking into account the weight of the load
X Hang rope crossed over on the crane hook
X Do not stand under suspended loads
HZTL2480_EN (TPL73-B.. - 85-B..)
Version 5.1
L_00082

Operation Manual
Assembly units
L_00404 November 2007

HZTL2480_EN (TPL73-B.. - 85-B..)
Version 5.1

Operation Manual
Weights [kg] Description TPL 73- TPL 77- TPL 80- TPL 85-
B B B B
1 Air suction branch, radial 140 155 242 290
November 2007
2 Filter silencer 244 404 576 955

3 Compressor casing, internal 148 260 355 550
part
4 Wall insert 134 276 431 850
5 Diffusor 57 80 125 225
6 Compressor casing, external 290 475 680 1149
part
7 Cartridge group 560 941 1443 2588
8 Turbine diffusor 72 150 250 460
9 Nozzle ring 25 44 63 95
10 Gas inlet casing radial 147 250 340 550
HZTL2480_EN (TPL73-B.. - 85-B..)
Compressor casing, internal part, complete
339 616 911 1625
The total weight of the complete internal part of the compressor casing
includes the internal part of the compressor casing, the diffuser and the
wall insert.
NOTE
Version 5.1

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

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

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

X Disconnect all air lines in accordance with engine manufacturer’s in-
structions.
HZTL2480_EN (TPL73-B.. - 85-B..)

TPL 73
81000_003
X Fit safety ring bolt (90231) on filter silencer.

Version 5.1

Operation Manual

suction branch
TPL 77 – 85
November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
L_00011
X Fit safety ring bolt (90231) in bearing plate (P) on filter silencer.
TPL 77 – 85
Version 5.1
L_00226
X Mount shackle (90195) on rib/fin on filter silencer.

Operation Manual

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

been suspended in compliance with regulations may fall, and can cause
November 2007
serious or even fatal injury.
WARNING X Do not stand under suspended loads.
Remove filter silencer X Pass lifting gear through rear rings and secure to shackle (90195) or
safety lifting eye bolt (90231) using a shackle.
X Unscrew nuts (74027) with Verbusripp washers (74028) or washers
(74018) and remove filter silencer or air suction branch.
Install the filter silencer X Install filter silencer or air suction branch in reverse order.
HZTL2480_EN (TPL73-B.. - 85-B..)

Version 5.1

Operation Manual
Axial clearance 8.3 Page 7
8.3 Axial clearance

November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
L_00405
Z The axial clearance (A) must be measured before the cartridge group
is removed and after it has been fitted.
Z Screw on at least four nuts (74027) with washers (74028/74018) equal-
ly spaced around circumference and tighten them to secure partition
wall axially.
X Measure and note axial clearance (A).
If the axial clearance (A) is out of tolerance, an official ABB Turbo Sys-
tems service station must be contacted.
Version 5.1
CAUTION
Axial clearance A [mm] TPL 73-B TPL 77-B TPL 80-B TPL 85-B
0.40 – 0.58 0.43 – 0.64 0.46 – 0.69 0.54 – 0.79

Operation Manual
Removing cartridge group 8.4 Page 8
8.4 Removing cartridge group
November 2007
Not all tools are identified with a part number. The identification of the
tools is ensured with the tools list (included in the toolbox).
NOTE
If provided:
Position of the safety X Take nuts (90458) out of the toolbox and screw them onto threaded
segments before disas- pins of three safety segments (Y) on internal part of compressor casing
sembly (76000).
76000 74000
HZTL2480_EN (TPL73-B.. - 85-B..)

Y
90458 90458
u
L_00269
X Tighten nuts (90458) to maximum 30 Nm.
D The internal part of the compressor casing is now detached from the
external part of the compressor casing (74000) and can be removed.
Version 5.1
Note check dimension (u).
NOTE
Check dimension u [mm] Dimension TPL 73-B TPL 77-B TPL 80-B TPL 85-B
u 18.6 19.0 19.6 27.6

Operation Manual
X Remove insulation if necessary.

X Disconnect oil lines in accordance with engine manufacturer's instruc-
tions.
November 2007
X Open oil drain screw (42245) in pipe to emergency lubricating oil tank
and collect any residual oil in a bucket.
X Fit oil drain screw (42245).
X Unscrew and remove nuts (74027) and washers (74028/74018).

X Remove six studs (74026/74029) in upper section and fit four guide
bolts (90320), if necessary.
X Leave 2 holes free for attaching lifting device (90190).
Remove internal part of 90320

compressor casing 42245
HZTL2480_EN (TPL73-B.. - 85-B..)
90190 / 90195
74018 /
74028
74027
74026 / 74029
76040
76000
90900
90458 90025
Version 5.1
L_01186
X Ease back internal part of compressor casing (76000) using puller

screws (90900) until lifting device (90190/90195) can be attached.
X Remove internal part (76000) of compressor casing.

Operation Manual
Internal part of compres-

sor casing
November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
72000_009
X Fit support angle (90025).

X Put internal part (76000) of compressor casing with the wall insert
(77000) and diffuser (79000) on support angle and underlay.
X Remove O-ring seal (76040).
X Hang lifting device (90190/90195) around back of flange (F).
X Carefully turn internal part of compressor casing with wall insert and
diffuser over support angle and put on unterlay.
X Set down casing on flange (F).
Version 5.1

Operation Manual
Ensure that the underlay does not slip.

November 2007
X Rest internal part of compressor casing only on flange F.

WARNING X Check underlay and adjust if necessary.
Remove diffuser
HZTL2480_EN (TPL73-B.. - 85-B..)
Version 5.1
79000_001

Operation Manual
TPL 73 X Remove screws (76002) and diffuser (79000).
November 2007
TPL 77 - 85 X Remove screws (76002).
X Remove diffuser (79000) by means of ring bolts (90235).
Remove external part of

compressor casing
HZTL2480_EN (TPL73-B.. - 85-B..)

74000_001
X Secure lifting device (90190/90195) to external part of compressor cas-

ing (74000) and attach securely to crane.
X Unscrew nuts (61037), uniformly ease back external part of compres-
sor casing using extraction nuts (61037) and remove. Version 5.1

Operation Manual
Removing cartridge group

November 2007
42001
90900
61059
61058
63000
86505 / 86506
HZTL2480_EN (TPL73-B.. - 85-B..)
86515
42012 86525
L_00924
X Unplug cable (86515) and screw out speed sensor (86505) with O-ring
seal (86506).
If provided: X Disconnect cable of line amplifier (86525).
X Remove O-ring seal (42012).

X Remove three screws (61059) and washers (61058).
X Check lifting equipment and secure to bearing casing (42001).
Version 5.1
During removal, a cartridge group that is not lifted in compliance with

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

Operation Manual
To correct the slight tilt of the cartridge group suspended from the rope,
a piece of square timber must be jammed between the rope and the
November 2007
emergency oil tank fixing.
NOTE Use only a square timber and not an iron bar otherwise there is a dan-
ger of slipping.
X Uniformly press off cartridge group (42001) using puller screws (90900)
in holes provided.
If the turbine blades on the rotor have insufficient or no clearance, this

can lead to damage of the blades and the casing.
X Turn rotor to check that turbine blades do not touch turbine diffuser
CAUTION
(63000).
HZTL2480_EN (TPL73-B.. - 85-B..)

X Extract cartridge group.
X Cover oil connections.
Version 5.1

Operation Manual
Fitting supports for cartridge group
TPL 73 – 85
November 2007
42052
(nur/only
TPL85-B11/12)
HZTL2480_EN (TPL73-B.. - 85-B..)
L_01077
X Unscrew hexagon-head screws (42241) and remove valve block

(42230).
X Attach supports (90450) and set down cartridge group.
Version 5.1

Operation Manual
TPL 73 – 85
November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
42001
90450
L_00925
X Attach supports (90450) and set down cartridge group (42001).
Work that exceeds the scope of the description in this chapter must on-
ly be performed by a trained fitter from an official ABB Turbo Systems
service station.
CAUTION Version 5.1

Operation Manual
Inspection and assessment of valve 8.5 Page 17

block
8.5 Inspection and assessment of valve block

November 2007
TPL 73 - 80
HZTL2480_EN (TPL73-B.. - 85-B..)
20000_005
1 Valve flap
2 O-ring seal (42234)
3 Valve seat
On the removed valve block (42230):
X Check the smooth movement of the valve flap (1)

X Check valve seat (3) with finger
X If necessary, the O-ring seal (2) should be replaced.
If scratches are found on the valve seat or the valve flap jams, the valve
block should be exchanged.
Version 5.1
In case of doubt, contact an authorized service station of ABB Turbo

NOTE Systems.

Operation Manual
Dismantling and installing the turbine 8.6 Page 18

diffuser and nozzle ring
8.6 Dismantling and installing the turbine diffuser

and nozzle ring
November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
61000_001
X Place clamp (90921) over stud (61036) until it lies flat against inner ra-
dius of gas outlet casing.
X Insert extension (A) of torque wrench (B) through hole in clamp and
loosen screws (61056) one after other.
X Do not remove screws (61056) and washers (61057) yet.
Version 5.1

Operation Manual

Turbine diffusor
November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
56001_001
X Replace two screws (61056) with two guide bolts (90320) in upper sec-
tion of turbine diffusor (63000). Pass guide bolts through holes in
clamps (90921) and fit using tommy bar (90325).
X Screw on hexagon nuts (90178) to secure.
The nozzle ring (56001) must be secured against falling before turbine
diffusor (63000) is withdrawn. The nozzle ring hangs only loosely on the
positioning pins.
CAUTION
Version 5.1

Operation Manual

Securing nozzle ring
November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
61000_002
X Before dismantling turbine diffusor (63000), secure nozzle ring (56001)

against falling using a clamping set and a wooden block.
X Unsscrew remaining screws (61056) and remove with Verbusripp was-
hers (61057).
X Ease back turbine diffusor using puller screws (90901) and withdraw
turbine diffusor until clamp (90921) is up against hexagon nut (90178).
X Fix hoisting gear to turbine diffusor (63000) and remove it. Version 5.1

Operation Manual

Nozzle ring
November 2007
56001_002
X Fix holder (90490) on gas outlet casing.

HZTL2480_EN (TPL73-B.. - 85-B..)
56001_003
X Pull forward nozzle ring (56001), fix to hoisting gear and remove it.
Version 5.1
Fitting X Fit nozzle ring and turbine diffusor in reverse order to removing them.
X Align positioning pins in nozzle ring with holes in gas inlet casing.
Smear all screws in and on gas outlet casing with Anti Scuff Paste 868
from SPANJAARD.
NOTE

Operation Manual
Installing cartridge group 8.7 Page 22
8.7 Installing cartridge group

X Fit the nozzle ring and turbine diffuser.
November 2007
If removed:
These operations must be carried out as described in the chapter Re-

moving and fitting turbine diffuser and nozzle ring.
NOTE
Removing supports for cartridge group
HZTL2480_EN (TPL73-B.. - 85-B..)

42052
(nur/only
TPL85-B11/12)
L_01077
X Remove cover from oil connector.

Version 5.1
X Check lifting equipment and secure it to bearing casing (42001) so that

cartridge group hangs straight.
X Remove supports (90450).
TPL 73 - 85 X Mount valve block (42230) with gasket (42045) [and O-ring seal
(42052)] and hexagon-head screws (42241).

Operation Manual
Installing cartridge group

November 2007
42001
90900
61059
61058
63000
86505 / 86506
HZTL2480_EN (TPL73-B.. - 85-B..)
86515
42012 86525
L_00924
X Carefully insert cartridge group (42001).
If the turbine blades on the rotor have insufficient or no clearance, this

can lead to damage of the blades and the casing.
X Turn rotor to check that turbine blades do not touch turbine diffuser
CAUTION
(63000).
X Uniformly tighten screws (61059) with Verbusripp washers (61058).

X Remove lifting equipment.
X Fit O-ring seal (42012).
Version 5.1
If provided: X Connect cable to line amplifier (86525).

X Screw in speed sensor (86505) fitted with O-ring (86506) and connect
cable (86515).

Operation Manual
Fitting external part of

compressor casing
November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
74000_001
X Secure lifting device (90190/90195) to external part of compressor cas-

ing (74000) and attach securely to crane.
Before fitting external part of compressor casing, screw all press-off

nuts (61037) up to end of thread of studs provided for this purpose.
NOTE
X Mount external part of compressor casing (74000) and secure with nuts
(61037).
X Remove lifting device (90190/90195).
Version 5.1

Operation Manual
Fitting the diffuser

November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
79000_001
TPL 73 X Fit diffuser (79000) and screws (76002).

Version 5.1
TPL 77 - 85 X Mount diffuser (79000) by means of ring bolts (90235).

X Fit screws (76002).
X Tighten screws (76002), then loosen again by a ¼ turn.

Operation Manual
Internal part of compres-

sor casing
November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
72000_009
X Attach lifting device (90190/90195) securely to back of flange (F).

X Carefully turn internal part of compressor casing (76000) with wall in-
sert (77000) and diffuser (79000) over support angle (90025) and put
down on underlay.
Version 5.1

Operation Manual
Fitting internal part of 90320

compressor casing 42245
November 2007
90190 / 90195
74018 /
74028
74027
74026 / 74029
76040
HZTL2480_EN (TPL73-B.. - 85-B..)
76000
90900
90458 90025
L_01186
If removed X Fit oil drain screw (42245).

X Securely attach lifting device (90190/90195) to front of flange on inter-
nal part of compressor casing (76000).
X Fit O-ring seal (76040).
X Remove support angle (90025).
X Fit four guide bolts (90320).
X Carefully position internal part of compressor casing (76000) with wall
insert and diffuser the guide bolts and insert it, then remove lifting de-
vice (90190/90195).
X Insert internal part of compressor casing as far as it will go.
X Remove guide bolts (90320) and fit studs (74026/74029).
Version 5.1
If provided X Use studs [10x 74029, 2x 74026 (fitted at top and bottom)].
74026 74029
L_01124

Operation Manual
If provided:
Position of safety seg- X Unscrew nuts (90458) on threaded pins of three safety segments (Y)
November 2007
ments after assembly on internal part of compressor casing (76000) and push threaded pins
together with safety segment (Y) as far as they will go up against ex-
ternal part of compressor casing (74000).
D The internal part of the compressor casing (76000) is now secured re-
lative to the external part of the compressor casing (74000).
76000 74000
Y
s
HZTL2480_EN (TPL73-B.. - 85-B..)

90458 90458
L_00276
Note check dimension (s). Safety segments (Y) are in position again for
operating mode.
NOTE
Check dimension s [mm] Dimension TPL 73-B TPL 77-B TPL 80-B TPL 85-B
s 12.1 12.9 11.9 18.5
X Put nuts (90458) back into toolbox.

Version 5.1

Operation Manual
X Measure and note axial clearance A.

November 2007
If the axial clearance A is out of tolerance, an official ABB Turbo Sys-

tems service station must be contacted.
CAUTION
Axial clearance A [mm] TPL 73-B TPL 77-B TPL 80-B TPL 85-B
0.40 – 0.58 0.43 – 0.64 0.46 – 0.69 0.54 – 0.79
Install the filter silencer X Fit filter silencer or air suction branch and secure using nuts (74027)
HZTL2480_EN (TPL73-B.. - 85-B..)
and Verbusripp washers (74028) or washers (74018) (see section Re-

moving and installing filter silencer or air suction branch).
X Connect oil lines and all air ducts in accordance with engine manufac-
turer’s instructions.
X Fit all insulation that has been removed.
Version 5.1

Operation Manual
Turbine-end removal / fitting of the 8.8 Page 30

nozzle ring
8.8 Turbine-end removal / fitting of the nozzle

ring
November 2007
If only the nozzle ring has to be removed, this is possible at the turbine
end.
NOTE
Disassembly X Remove insulation on gas inlet casing (51001).

X Fix lifting gear to eyelet nuts on gas inlet casing using shackle (90195).
HZTL2480_EN (TPL73-B.. - 85-B..)

Version 5.1
56001_001
X Remove two hexagon-head screws (61044) and Verbusripp washers

(61043) from lower section and replace them with two studs (90177).
X Screw hexagon nuts (90178) onto studs to secure.
X Loosen and screw out remaining flange screws.

Operation Manual
Turbine-end removal / fitting of the 8.8 Page 31

nozzle ring
X Withdraw gas inlet casing (51001) together with nozzle ring (56001)
from gas outlet casing (61001) until holder (90175) and screw (61044)
can be fitted from outside.
November 2007
X Unscrew hexagon nuts (90178) from studs.

X Fully withdraw gas inlet casing and remove.
When setting down gas inlet casing to one side, use suitable underlay
and take care not to damage insulation angles.
CAUTION
X Loosen holder (90175) and remove nozzle ring (56001) using suitable
lifting gear.
Assembly X Fit nozzle ring (56001) and tighten holder (90175) using screw (61044).
X Fit gas inlet casing (51001) and secure by screwing hexagon nuts
HZTL2480_EN (TPL73-B.. - 85-B..)
(90178) onto studs (90177).

X Remove holder (90175) and screw (61044).
X Mount gas inlet casing together with nozzle ring on gas outlet casing
(61001).
X Screw in and tighten hexagon-head screws (61044) with Verbusripp
washers (61043).
X Remove hexagon nuts (90178) from studs (90177).
X Replace studs with hexagon-head screws (61044) and Verbusripp
washers (61043) and tighten.
X Remove shackle (90195) and suspension rope from gas inlet casing.
X Secure insulation to gas inlet casing (51001).
Version 5.1

Operation Manual
Table of tightening torques 8.9 Page 32
8.9 Table of tightening torques
November 2007
82005 90458 76002 61037 61036 61059
61056
61044
HZTL2480_EN (TPL73-B.. - 85-B..)

74027 74026 / 42059, 42064
74029
L_00406
86505 Version 5.1
L_00228
The following tightening torques must be kept to for the specified threaded
connections:

Operation Manual
Table of tightening torques 8.9 Page 33
Tightening torques [Nm] Part number TP 73-B TPL 77-B TPL 80-B TPL 85-B
42059, M16 M20 M20 M24
November 2007
42064 105 240 240 240

61044 M18 M20 M22 M24
370 480 480 480
61056 M18 M20 M22 M24
370 480 480 480
61059 M18 M20 M22 M24
370 480 480 480
61036 M18 M20 M22 M24
80 80 80 80
61037 M18 M20 M22 M24
160 210 280 360
74026 / M18 M20 M22 M24
74029 80 80 80 80
HZTL2480_EN (TPL73-B.. - 85-B..)
74027 M18 M20 M22 M24

(with Verbus- 135 175 235 300
ripp washer)
74027 M18 M20 M22 M24
(with larger 170 220 300 400
washer)
76002 M14 M16 M18 M20
– 1) – 1) – 1) – 1)
82005 M16x1.5 M16x1.5 M16x1.5 M16x1.5
50 50 50 50
86505 M18x1.5 M18x1.5 M22x1.5 M22x1.5
150 150 220 220
90458 M10 M10 M10 M12
30 30 30 30
1) Tighten only so much that the diffuser can still be moved.

Version 5.1

BLANK
Operation Manual
Shut-down at short notice 9
Possibilities for emergency repair 9.1 Page 1
9 Shut-down at short notice

November 2007
9.1 Possibilities for emergency repair
Lubricating oil leakage is a fire hazard.
WARNING
The instructions of the engine manufacturer for operation of the engine

with locked / isolated turbocharger must be followed precisely in all ca-
ses!
CAUTION
HZTL2480_EN (TPL73-B.. - 85-B..)
If the diesel engine must be capable of operation again as soon as possi-

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

Blocking inlets and outlets
Bypass around turbocharger
Fit cover plate
Emergency repairs that can be carried out quickest have been de-
scribed first.
NOTE
Version 5.1

Operation Manual
Locking the rotor 9.2 Page 2
9.2 Locking the rotor
November 2007
A blocked/ jammed rotor must be disassembled following the turbo-
charger repair and given an imbalance check.
CAUTION
The only exception is a test rig run up to maximum 25% of the engine
load with new engines with one or a number of turbochargers, which
are requested by some customers. Since in these cases operation with
NOTE a blocked rotor is brief and the loads are low, subsequent disassembly
of the rotor is unnecessary.
U Once unscrewed, balancing screws must not be screwed in again.
HZTL2480_EN (TPL73-B.. - 85-B..)

Various intermediate rings are provided with the blocking device for dif-
ferent compressor wheels. The compressor wheel type ”CV” (for the ba-
lancing screw holes) must be noted. The space between the blocking
NOTE flange (94003) and the assembly-disassembly device (90020) must be
compensated by the intermediate rings (94001 and/or 94002) depend-
ing on the version of compressor wheel.
During operation of the engine with a blocked turbocharger, the lubrica-

tion oil system must also remain connected to this turbocharger and
turned on if the gas inlet cannot be blocked (see section Further meas-
CAUTION ures and information for operation with a blocked rotor for 2-stroke en-
gines). Otherwise components that are still intact can be damaged by
overheating.
The supply of lubricating oil to the turbocharger must be shut off in the
event of a lubricating oil leak on the turbocharger.
Version 5.1

Operation Manual
Blocking rotor with polygon connection

November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
94000_001
These operations must be carried out as described in the chapter Dis-

assembly and assembly.
NOTE
Version 5.1

Operation Manual
November 2007
X Remove silencer or air suction branch and internal part of compressor
casing in together with wall insert and diffusor.
X Fix partition wall with clamp (94005) and screws (90442).
Fit blocking flange (94003) to compressor wheel using at least 9 screws

(94007 or 94008) (refer to Table of tightening torques).
CAUTION
Table of tightening tor- Part number TPL 73-B TPL 77-B TPL 80-B TPL 85-B
HZTL2480_EN (TPL73-B.. - 85-B..)

ques [Nm]
94006 M8 M8 M10 M12
25 25 45 75
94007 / 94008 M8 M8 M10 M12
15 15 35 60
TPL 73 - 80 X Attach blocking flange (94003) using screws (94007).
TPL 85 X Fit blocking flange (94003) using screws (94007 or 94008, if at all pos-
sible use longest screws) and adjustment ring (94004) and intermedi-
ate ring (94031).
Version 5.1

Operation Manual
Compressor type CV11
TPL 73 – 80
November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
94000_13
Make sure all components are clean and free from grease.
CAUTION
X Push correct intermediate rings (94001 and/or 94002) onto blocking

flange (94003) and fit assembly-disassembly device (90020).
X Push on remaining intermediate rings (94001 and/or 94002) and mount
locking flange (94003) using screws (94006).
Version 5.1

Operation Manual
Compressor type CV12, CV13
TPL 73 – 80
November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
94000_014
CAUTION
X Place correct intermediate rings (94001 and/or 94002) on blocking

flange (94003) and fit assembly-disassembly device (90020).
blocking flange (94003) using screws (94006).
Version 5.1

Operation Manual
Compressor type CV11
TPL 85
November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
94000_15
Version 5.1
CAUTION

flange (94003).
X Fit assembly-disassembly device (90020) in each case with 2 washers
(94032).
locking flange (94003) using screws (94006).

Operation Manual
Compressor type CV12, CV13
TPL 85
November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
94000_012
CAUTION

flange (94003).
Version 5.1
X Fit assembly-disassembly device (90020) in each case with 2 washers

(94032).
blocking flange (94003) with screws (94006).

Operation Manual
Further measures and information for operation with blocked rotor for 2-
stroke engines
November 2007
2-stroke engine with one No further measures are necessary. The engine can be operated with the
turbocharger: auxiliary blower according to the manufacturer's instructions.
9 The lubrication oil system must remain connected and turned on.
2-stroke engine with seve- X The compensator at the compressor outlet must be dismantled and the
ral turbochargers: air duct blocked at the engine end, as undamaged turbochargers de-
velop a receiver pressure.
X The operating limit of the engine can be raised by additionally blocking
the gas inlet, as the exhaust gas is then used to drive the undamaged
turbocharger. In addition, the loading and temperature of the blocked
rotor is reduced.
HZTL2480_EN (TPL73-B.. - 85-B..)
If the gas inlet cannot be blocked, the following operating limits must be
observed:
The pressure in the charge-air receiver must not exceed 1 bar over-
pressure.
Max. permissible engine load: 50%.
Attention must be paid to the speed of the undamaged turbochargers in

all cases. The speed limit nBmax according to the turbocharger rating pla-
te must not be exceeded.
CAUTION
Version 5.1

Operation Manual
Blocking the inlets and outlets 9.3 Page 10
9.3 Blocking the inlets and outlets
November 2007
Shut off the supply of lubricating oil to the turbocharger.
CAUTION
X Block the compressor casing outlet, gas inlet and gas outlet by fitting
cover plates.
For information about how to do this, see the manufacturer's instruc-

tions.
NOTE
HZTL2480_EN (TPL73-B.. - 85-B..)

Version 5.1

Operation Manual
Bypass the turbocharger 9.4 Page 11
9.4 Bypass the turbocharger

November 2007
CAUTION
Z Only applies for engines with one turbocharger.

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

tions.
NOTE
HZTL2480_EN (TPL73-B.. - 85-B..)
Version 5.1

Operation Manual
Fit cover plate 9.5 Page 12
9.5 Fit cover plate
November 2007
The cover plate (material: General structural steel, in accordance with
DIN EN 10025-2) must be manufactured in-house according to the
drawing.
NOTE
HZTL2480_EN (TPL73-B.. - 85-B..)

Version 5.1
L_00917

Operation Manual

November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
L_00926
These operations must be carried out as described in the chapter Dis-

assembly and assembly.
NOTE
X Remove the cartridge group
Version 5.1

Operation Manual
November 2007
HZTL2480_EN (TPL73-B.. - 85-B..)
61000_003
X Block the opening in the gas outlet casing with the cover plate.
X Secure the cover plate with spacer sleeves and nuts (61037).
CAUTION
Version 5.1

Operation Manual
Further measures and information for operation with a turbocharger with

November 2007
cover plate in 2-stroke engines
2-stroke engine with one turbocharger:
No further measures are necessary. The engine can be operated with the
auxiliary blower according to the manufacturer's instructions.
2-stroke engine with several turbochargers:
X Block air line on engine side as undamaged turbochargers develop a

receiver pressure.
HZTL2480_EN (TPL73-B.. - 85-B..)
X Significantly raise operating limit of engine by blocking the gas inlet

additionally as exhaust gas is then used to drive undamaged turbo-
charger.
Attention must be paid to the speed of the undamaged turbochargers in

all cases. The speed limit nBmax according to the turbocharger rating pla-
te must not be exceeded.
CAUTION
Basically, the engine can be operated according to the engine manufac-

turer's instructions.
NOTE
Version 5.1

BLANK
Operation Manual
Preserving turbocharger 10
Taking out of operation for up to 12 10.1 Page 1

months
10 Preserving turbocharger
November 2007
10.1 Taking out of operation for up to 12 months

If a turbocharger has to be laid up for up to 12 months, the decision
whether the turbocharger needs special protection or not depends mainly
on the condition of the lubricating oil before laying up.
If the Total Acid Number (TAN) is lower than 2 mg KOH/g no special

measures need to be taken. However, if the neutralisation factor is higher
the turbocharger must be dismantled after laying up, cleaned and protec-
tive oil must be applied to the naked parts.
If the turbocharger is left mounted on the engine, and the engine oil is re-
placed by a protective oil which is circulated with a pre-lubrication pump
prior to laying up, no measures need to be taken in respect of the turbo-
charger. The remains of the old engine oil will be washed away and the
HZTL2480_EN (TPL73-B.. - 85-B..)
sensitive bearing parts will be largely protected against corrosion.
If the rotor turns due to a draught from the flue, fit a blind flange between
the compressor casing and the charge-air duct.
Version 5.1

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

months
10.2 Taking out of operation for more than 12

months
November 2007
If the turbocharger has to be removed from the engine and stored for a
prolonged period of time, disassembly and mothballing of the turbo-
charger must be done by an official ABB Turbo Systems service station.
Suitable storage locations are dry rooms where the relative humidity is be-
tween 40-70% and no condensation can form.
Check mothballed turbochargers yearly for corrosion.

If there are signs of rust, clean parts and renew means for protection
against corrosion.
NOTE
HZTL2480_EN (TPL73-B.. - 85-B..)

Version 5.1

Operation Manual
Disposal 11
Environmentally compatible disposal of 11.1 Page 1

turbocharger components
11 Disposal
November 2007
11.1 Environmentally compatible disposal of tur-

bocharger components
Environmentally compatible disposal of turbocharger components

Component disposal must be environmentally compatible, profes-
sionaland in accordance with locally regulations.
NOTE
The turbocharger mainly consists of metal (cast-iron materials, steel,
nickel-steel alloys, aluminium, bearing brass).
Other components are: non-metallic materials (filter components made
of felt and polyethylene), lubricants (engine oil), electronic components
(speed sensor and associated components), thermal insulation.
HZTL2480_EN (TPL73-B.. - 85-B..)
X Dispose of metals by melting down and recycling.

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

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

X Remove dust with a suitable vacuum cleaner.
X Wear respiratory mask as protection against particles (P1 or P2
Version 5.1
mask).
X Wear leather protective gloves.
X Wear close-fitting safety goggles.
X Dispose of thermal insulation as special waste.

BLANK
Operation Manual
Reserve and spare parts 12
Ordering spare parts 12.1 Page 1
12 Reserve and spare parts

November 2007
12.1 Ordering spare parts

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

tions, then contact an official ABB Turbo Systems service station or an
HZTL2480_EN (TPL73-B.. - 85-B..)
ABB agent.
Version 5.1

Operation Manual
Spare parts set
November 2007
The spare-parts set (97070) is required for the work described in this
manual. The parts included in the spare parts set are available only as
part of the complete set.
NOTE
Spare parts set (97070)
TPL73-B Quantity Description Part number

2 Hexagon-head screw 42059 / 42064
2 Verbusripp washer 42058 / 42063
15 Hexagon-head screw 61044 / 61056 / 61059
15 Verbusripp washer 61043 / 61057 / 61058
HZTL2480_EN (TPL73-B.. - 85-B..)

3 Hexagon nut 61037
1 Gasket 42041
1 Gasket 42045
2 O-ring seal 42012 / 76040
2 O-ring seal 77005 / 77006
1 O-ring seal 86506

15 Hexagon-head screw 42059 / 42064 / 61044 / 61056 / 61059
15 Verbusripp washer 42058 / 42063 / 61043 / 61057 / 61058
3 Hexagon nut 61037
1 Gasket 42041
1 Gasket 42045
2 O-ring seal 42012 / 76040
2 O-ring seal 77005 / 77006
Version 5.1
1 O-ring seal 86506

Operation Manual

2 Hexagon-head screw 42059 / 42064
November 2007
2 Verbusripp washer 42058 / 42063

15 Hexagon-head screw 61044 / 61056 / 61059
15 Verbusripp washer 61043 / 61057 / 61058
3 Hexagon nut 61037
1 Gasket 42041
1 Gasket 42045
2 O-ring seal 42012 / 76040
2 O-ring seal 77005 / 77006
1 O-ring seal 86506

HZTL2480_EN (TPL73-B.. - 85-B..)
15 Hexagon-head screw 42059 / 42064 / 61044 / 61056 / 61059

15 Verbusripp washer 42058 / 42063 / 61043 / 61057 / 61058
3 Hexagon nut 61037
1 Gasket 42041
1 Gasket 42045
2 O-ring seal 42012 / 76040
1 O-ring seal 42052
2 O-ring seal 77005 / 77006
1 O-ring seal 86506
All spare parts that have been ordered with the turbocharger should be
kept complete and serviceable.
X Rusty parts should be carefully cleaned and greased.
CAUTION
Version 5.1
X Dispose of replaced parts that are no longer usable in a technically and

environmentally compatible manner.

Operation Manual
Directory of part numbers 12.2 Page 4
12.2 Directory of part numbers

The following part numbers and descriptions must be used in ALL corre-
November 2007
spondence or orders:
turbochargers Part number Description

- Cartridge group
42052 (in spare parts set) O-ring seal
51001 Gas inlet casing
56001 Nozzle ring
61001 Gas outlet casing
61037 (in spare parts set) Hexagon nut
61044 & 61043 (in spare parts set) Hexagon-head screw & Verbusripp
washer
HZTL2480_EN (TPL73-B.. - 85-B..)

washer
washer
63000 Turbine diffusor
68000 Foot
74000 External part of compressor casing
76000 Internal part of compressor casing
76040 O-ring seal
76080 Safety segment
77000 Wall insert
79000 Diffusor
81000 Filter silencer
82000 Radial air suction branch
Version 5.1

Operation Manual
Directory of part numbers 12.2 Page 5
Cartridge group - polygon Part number Description

connection
21000 Shaft
November 2007
25000 Compressor wheel

25008 Threaded pin
25009 Ring nut
32001 Thrust bearing
32101 Radial bearing, compressor end
32102 Radial bearing, turbine end
32104 Auxiliary bearing
32105 Floating disc
32106 Thrust bearing
32107 Bearing bush
42001 Bearing casing
42002 Hood
HZTL2480_EN (TPL73-B.. - 85-B..)
42011 O-ring seal

42015 Sealing cover
42041 (in spare parts set) Gasket
42045 (in spare parts set) Gasket
washer
washer
43001 Partition wall
43005 O-ring seal
86505 Speed sensor
Version 5.1

L_00927
74000
79000
82000

77006
76040
77000
77005
Reserve and spare parts
76080
61044 61043
76000
General view of turbocharger
51001
61037
81000
61058 61059
12
12.3
12.3 General view of turbocharger
61001
63000
56001 68000
61056 61057
Page 6
Operation Manual
ABB
Version 5.1 HZTL2480_EN (TPL73-B.. - 85-B..) November 2007
Version 5.1 HZTL2480_EN (TPL73-B.. - 85-B..) November 2007
L_00928
21000

42011 25008
32102
32107
42015
32001
32106
42012
Reserve and spare parts
32105 42002
42001
General view of cartridge group
32101
43001 86506
32104
43005
86505
12
12.4
25009
12.4 General view of cartridge group
25000 42041 42058 42063 42045

42059 42064
Page 7
Operation Manual
ABB
ABB
ABB Turbo Systems AG
Bruggerstrasse 71a
CH-5400 Baden
Switzerland

TPL 80

Uploaded by

Copyright:

Available Formats

TPL 80

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

TPL 80

Uploaded by

Copyright:

Available Formats

Turbocharging

ABB Turbo Systems Ltd

Type TPL80-B12 HT492717

5775 kg 36 100 100

ABB Turbo Systems Ltd 

© Copyright by ABB TURBO SYSTEMS Ltd 2004

Table of contents Page 1

2.2 General safety instructions

4.7 Shutting the engine down

ABB Turbo Systems Ltd ABB

Table of contents Page 2

8 Disassembly and assembly

HZTL2480_EN (TPL73-B.. - 85-B..)

9 Shut-down at short notice

12 Reserve and spare parts

ABB Turbo Systems Ltd ABB

Purpose of manual 1.1 Page 1

1.1 Purpose of manual

 Early identification and avoidance of hazards.

This operating manual complements and extends existing national regula-

The instructions included in this operating manual must be followed with-

This applies especially to the general and special safety instructions

ABB Turbo Systems Ltd ABB

Layout and function 1.2 Page 2

1.2 Layout and function

1 Filter silencer 8 Nozzle ring

6 Gas outlet casing 13 Compressor casing

ABB Turbo Systems Ltd ABB

Layout and function 1.2 Page 3

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

These are both mounted on a common shaft.

compresses it and then forces it into the engine cylinders.

The turbocharger is equipped with an emergency lubrication oil tank (14).

ABB Turbo Systems Ltd ABB

Correct use of the turbocharger 1.3 Page 4

1.3 Correct use of the turbocharger

HZTL2480_EN (TPL73-B.. - 85-B..)

Improper operation and maintenance of the turbocharger can result in

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

X Malfunctions / defects which could affect safety must be eliminated

ABB Turbo Systems Ltd ABB

Essential information 1.4 Page 5

1.4 Essential information

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

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

The safety and risk consciousness of the personnel working on and

X The turbocharger must be shut down immediately by stopping the en-

Additions and alterations to, and conversions of the turbocharger that

ABB Turbo Systems Ltd ABB

Essential information 1.4 Page 6

Original parts and safety

We herewith expressly state that parts and accessories not supplied by

If components and assemblies not manufactured and tested by ABB

HZTL2480_EN (TPL73-B.. - 85-B..)

The turbocharger must only be operated and maintained by trained and

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

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

ABB Turbo Systems Ltd ABB

Essential information 1.4 Page 7

ABB Turbo Systems Ltd

Early identification and avoidance of hazards.

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

Work only on those connections for which you are qualified.

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

Secure the rotor against turning.

from the turbocharger and its accessories.

Causes sharp edges, pointed parts

fracture or rupture of parts due to overload