HT 566195

Operation Manual
TPL76-C35
ABB Turbo Systems Ltd

CH 5401 Baden
Type TPL76-C35 HT566195

n Mmax 335 t Mmax 650
1/s °C
n Bmax 326 t Bmax 620
04070 kg 35 50 50
Application according to
Year 2016 the Operation Manual
made in Switzerland
Original Operation Manual
HZTL2485 English
ABB Turbocharging

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.
Operation Manual / TPL76-C
Table of contents Page 1
Table of contents
December 2016
1 Preliminary remarks
1.1 Purpose of this manual
1.2 Layout and function
1.3 Intended use
1.4 Deflagration on gas engines
1.5 Storage of new turbochargers and spare parts
1.6 Essential information
1.7 Symbols and definitions
1.8 Turbocharger rating plate
1.9 Contact information
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2 Safety
2.1 Introduction
2.2 CE conformity
2.3 Definition of mandatory signs
2.4 Definition of Safety instructions
2.5 Warning plates on the turbocharger
2.6 Safe operation and maintenance
2.7 Hazards during operation and maintenance
2.8 Periodic checking of the pressure vessel
2.9 Lifting loads
3 Commissioning
3.1 Oil supply
3.2 Inspection work
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3.3 Commissioning after taking out of operation
4 Operation
4.1 Noise emissions
4.2 Servicing work
4.3 Replacement intervals for turbocharger components
4.4 Speed measurement
4.5 Stopping the engine
© Copyright 2016 ABB. All rights reserved.

5 Maintenance
5.1 Foreword to Maintenance
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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 Cleaning components mechanically
6 Troubleshooting
6.1 Malfunctions when starting
6.2 Surging of the turbocharger
6.3 Malfunctions during operation
6.4 Malfunctions when stopping
6.5 Speed measurement system
7 Removal and installation

7.1 Turbocharger weight
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7.2 Removing the turbocharger
7.3 Installing the turbocharger
8 Disassembly and assembly

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

9.1 Possibilities for emergency repair
9.2 Locking the rotor
9.3 Fit cover plate
9.4 Blocking the inlets and outlets
9.5 Bypass the turbocharger
10 Mothballing the turbocharger

10.1 Taking out of operation for up to 12 months

10.2 Taking out of operation for more than 12 months
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11 Disposing of turbocharger components
12 Spare parts
12.1 Ordering spare parts
12.2 View of turbocharger with part numbers
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Preliminary remarks 1
Purpose of this manual 1.1 Page 5
1 Preliminary remarks
December 2016
1.1
1.1 Purpose of this manual
This Operation Manual belongs to the turbocharger with the identical seri-
al number (01), see the cover sheet of the Operation Manual and the tur-
bocharger rating plate.
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Operation Manual
This Operation Manual enables you to familiarize yourself with the turbo-
charger supplied by ABB Turbo Systems and to use it as intended.
It provides important information in order that the turbocharger can be op-

erated safely, correctly and efficiently.
This Operation Manual complements and expands existing national regu-

lations concerning work safety and accident prevention.
Target group
This Operation Manual is intended for engineers and qualified mechanics

who are responsible for operating the engine and the turbocharger in-
stalled on it.
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Availability of operation manual
An operation manual must be available at all times at the place where the
turbocharger is used.
Everyone who operates or works on the turbocharger must have first read
and understood the operation manual.

Layout and function 1.2 Page 6
1.2
1.2 Layout and function
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01 Filter silencer 08 Nozzle ring
02 Radial plain bearing 09 Turbine wheel
03 Thrust bearing 10 Bearing casing
04 Bearing bush 11 Diffuser
05 Radial plain bearing 12 Compressor wheel
06 Gas outlet casing 13 Compressor casing
07 Gas inlet casing
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Layout and function 1.2 Page 7
Mode of operation
The turbocharger is a turbomachine and consists of the following main

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components:
 Turbine
 Compressor
These are both mounted on a common shaft.
The exhaust gases from the diesel engine flow through the gas inlet cas-
ing (07) and nozzle ring (08) to the turbine wheel.
The turbine wheel (09) uses the energy contained in the exhaust gas to
drive the compressor wheel (12). The compressor then draws in fresh air,
compresses it and then forces it into the cylinders.
The exhaust gases escape to free air through an exhaust gas pipe which
is connected to the gas outlet casing (06).
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The air which is necessary for operation of the diesel engine and is com-
pressed in the turbocharger is drawn through the suction branch or the fil-
ter silencer (01) into the compressor wheel (12). This air then passes
through the diffuser (11) and leaves the turbocharger through the com-
pressor casing (13).
The rotor runs in two radial plain bearings (02/05). One plain bearing is in
the bearing bush (04), and the second one is in the axial thrust bearing
(03) at the compressor end.
The plain bearings are connected to a central lubricating oil duct which is
fed with oil from the engine's lubricating oil circuit. The oil outlet is always
at the lowest point of the bearing casing (10).
Turbocharger version with compressor wheel cooling system
Depending on its range of use, the turbocharger is provid-

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ed with a compressor wheel cooling system. Compressor

wheel cooling means that, after the charge air cooler at the
engine end, cooled compressor air is delivered to the tur-
bocharger to cool the compressor wheel.
Depending on the respective operating conditions, it is ab-
solutely essential that the compressor wheel is cooled in
order to guarantee its reliability and the replacement inter-
vals. In the case of the turbocharger version with compres-
sor wheel cooling, the cooling air is supplied through the
side connection (15) in the bearing casing.

Intended use 1.3 Page 8
1.3
1.3 Intended use
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Use on internal combustion engines in general
ABB turbochargers are intended for turbocharging internal combustion

engines.
To ensure compliance with the machinery directive 2006/42/EC when us-

ing on gas engines, the turbocharger must be operated in an engine room
classified as "not at risk of explosion". This is in accordance with the posi-
tion paper [2] relating to ATEX issued by EUROMOT [1].
The turbocharger supplies the engine with the air volume or air/gas mix-
ture and the associated charging pressure required for operation.
The turbocharger is solely intended to be operated with a clockwise direc-

tion of rotation as viewed from the turbine end.
The specific operating limits of the turbocharger were determined on the

basis of information from the enginebuilder about the intended use. These
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data are given on the rating plate.
ABB Turbo Systems accepts no liability and rejects all warranty claims for
any non-intended uses.
[1] Euromot = The European Association of Internal Combustion Engine Man-

ufacturers
[2] Directive 94/9/EC concerning equipment and protective systems intended
for use in potentially explosive atmospheres (ATEX) The Euromot Position
as of November 2003, ATEX Euromot Position 191103
Unapproved operation
Any operation of the turbocharger outside of its operating limits can be
hazardous to personnel.
WARNING
 Only operate the turbocharger within the operating limits.
 Only trained personnel must operate the turbocharger.
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The intended use of the turbocharger includes compliance with all regula-
tions and conditions.
In particular, the following must be observed:
 Operation Manual
 Instructions of the enginebuilder

1.4 Page 9
State of the art
The turbocharger is designed and built according to the state of the art
December 2016
and is safe to operate.
Flawless condition
The turbocharger must only be used when it is in a technically flawless

condition and operated in compliance with its intended use.
ABB Turbo Systems excludes any liability for damage resulting from un-
authorized modifications to the turbocharger or improper operation.
1.4
1.4 Deflagration on gas engines
ABB turbochargers can tolerate a deflagration with a transient pressure
increase of 12 bar.
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ABB Turbo Systems recommends subjecting the turbocharger to a visual

inspection after a deflagration event. As part of the inspection, the position
of the turbine casing and the position of the compressor casing to the
bearing casing must be checked, and the bearing casing must be exam-
ined to see if it has shifted in relation to the bracket. A crack inspection of
the casings and the bellows is also recommended. The nearest ABB Tur-
bocharging Service Station should be instructed to carry out this inspec-
tion and assessment.
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Storage of new turbochargers and 1.5 Page 10

spare parts
1.5 Storage of new turbochargers and spare

parts
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1.5
Storage of new turbochargers and spare parts up to 6 months
New turbochargers and spare parts from ABB Turbo Systems can be stored
in sealed packaging without additional mothballing measures for up to 6
months from the date of delivery (marked by the VCI label on the package).
Volatile Corrosion Inhibitor (VCI)
Only dry rooms in which the relative humidity is between 40…70 % and
no condensation can form are suitable for storage.
Storage of new turbochargers and spare parts for more than 6 months (VCI)
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Protection of health when handling VCIs
VCI products are not hazardous in the sense of the Hazardous Sub-
stances Ordinance. Nevertheless, the following points are to be ob-
WARNING
served when handling VCIs:
 Ensure good room ventilation.
 Do not eat, drink or keep food at the workplace while working with
VCIs.
 Wear safety gloves.
 Clean hands and face after working with VCIs.
 For further information refer to www.branopac.com.
Wear safety gloves to protect against chemical hazards.
The following mothballing measures are required every 6 months:

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 Open the package.

 Remove the VCI corrosion protection emitter from the package and
replace it with a new, identical VCI corrosion protection emitter. New
VCI corrosion protection emitters can be obtained at
www.branopac.com.
 Dispose of the old VCI corrosion protection emitter in an environmen-
tally compatible manner, professionally and in accordance with local
regulations.
 Seal the package. The better the external seal is designed, the more
permanent the protection.

Storage of new turbochargers and 1.5 Page 11

spare parts
Long-term storage of replacement turbochargers or spare parts
Per order, turbochargers or cartridge groups will be prepared by ABB Tur-

December 2016
bo Systems for prolonged storage. The package is equipped with a

hygrometer (see illustration).
The following measures are required every 6 months:
 Check the hygrometer (02) in the sight-glass. There is an opening (01)

in the wooden crate which allows this check to be carried out. When
the display field has changed colour at the 70% level, the maximum
permissible humidity has been exceeded. In this case the turbocharger
or rotor must be inspected by an ABB Turbocharging Service Station
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and repacked.
 Inspect the package for damage. If the package is damaged, the tur-
bocharger or cartridge group must be inspected by an ABB Turbo-
charging Service Station and repacked.
After every 3 years the following work steps must be performed by an

ABB Turbocharging Service Station:
 Inspect the components

 Exchange the desiccant agent
 Repackage the components.
Replacement components ready for operation

If the 70% display field of the hygrometer (02) has not changed colour
and the package is undamaged, the replacement turbocharger or re-
NOTICE
placement cartridge group can be placed into operation without any pri-
or testing by an ABB Turbocharging Service Station.
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Unpacking replacement turbochargers or spare parts
The corrosion protection effect ends after the material is unpacked from
the VCI package.
To avoid the formation of condensation, the surroundings and the content

of the package must have the same temperature during unpacking.

Essential information 1.6 Page 12
1.6
1.6 Essential information
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Organisational measures
In addition to this manual, the general, statutory regulations applicable in

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

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

with the turbocharger must be checked regularly with reference to this
manual.
NOTICE
 The turbocharger must be shut down immediately by stopping the en-
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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.
NOTICE
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Original parts and safety
Original parts and accessories are specially designed for the turbocharger
December 2016
supplied by ABB Turbo Systems.
Use original parts

Operation of the turbocharger with non-original parts can impair the
safety of the turbocharger and can cause serious damage to property
WARNING
and injury to personnel.
 Only use original parts from ABB Turbo Systems.
ABB Turbo Systems accepts no liability for any damage resulting from the
use of non-original parts and corresponding accessories.
Competence of personnel
The turbocharger must only be operated and serviced by trained and au-
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thorised personnel. Basic mechanical training is a prerequisite.

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Design variants
This document is valid for different design variants of turbochargers.
December 2016
There may be sections and descriptions of components that are not rele-
vant for a specific turbocharger variant.
ABB Turbocharging Service Stations will be happy to provide information

on questions regarding a design variant (see Contact information at
www.abb.com/turbocharging).
Accuracy of illustrations
The illustrations in this document are general in nature and intended for
ease of understanding. Differences in detail are therefore possible.
Storage of new turbochargers
New turbochargers supplied by ABB Turbo Systems can be stored without

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

charger free from rust.
NOTICE Revision D

Symbols and definitions 1.7 Page 15
1.7
1.7 Symbols and definitions
December 2016
The following symbols are used in the documents:
 Prerequisite
 Step of a procedure
 List, first level
- List, second level
[➙ ] Refers to a page number
Definition of notes
Note
A note provides suggestions which facilitate the work on the product.
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NOTICE
Definition of mandatory signs
Mandatory signs show the protective equipment to be worn for a task. The
mandatory signs are described in chapter Safety and must be complied
with.
Definition of caution / warning
The caution and warning signs are described in the chapter Safety.
ABB Turbo Systems
In this document, ABB Turbo Systems Ltd is abbreviated to ABB Turbo

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Systems.
Official ABB Turbo Systems Service Stations
In this document, official service stations are referred to as ABB Turbo-

charging Service Stations. They are inspected and certified regularly by
ABB Turbo Systems. See also chapter Contact information [➙ 18].

Turbocharger rating plate 1.8 Page 16
1.8
1.8 Turbocharger rating plate
December 2016
Operating limits
01 Turbocharger operating limits at engine overload (110 %).
Only when operating in the test rig unless otherwise agreed with the
enginebuilder.
02 Turbocharger operating limits during operation
Recommended replace-
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03 Replacement interval for plain bearings in 1000 h
ment intervals for turbo-
charger components 04 Replacement interval for compressor in 1000 h
05 Replacement interval for turbine in 1000 h
Further information
06 Customer part number
07 Designation of the special design
08 Turbocharger weight in kg
09 Turbocharger type
10 Serial number
11 Year of construction of turbocharger
12 Manufacturing plant
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Turbocharger rating plate 1.8 Page 17
1.8.1 Explanation of the rating plate

December 2016
The recommended replacement intervals and the corresponding opera-

tional limits are jointly defined with the engine manufacturer. This
information is specific to the system.
Operation above the indicated values nBmax, tBmax can considerably shorten the
recommended replacement intervals. In such cases, we recommend that you
contact the nearest official ABB Turbocharging service station.
nMmaxand tMmax normally apply only when running at overload (110%) during tri-
als on the engine test bed. These limits can also be permitted during operation
for special applications. Operation above nMmax and tMmax is not permitted.
Non-observance of the recommended replacement intervals can increase the
risk of unpredictable component failures.
1.8.2 Positions of the rating plates
A rating plate is attached to the turbocharger foot, one on the left and one
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on the right. In the case of turbochargers with insulation supplied by ABB

Turbo Systems, at least one additional rating plate is attached to the insu-
lation of the gas outlet casing.
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Contact information 1.9 Page 18
1.9
1.9 Contact information
December 2016
Contact information
Contact information for the official service stations of ABB Turbo Systems
is available online.
 Scan the QR code to access our website.
ABB Turbo Systems Ltd

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
www.abb.com/turbocharging
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Safety 2
Introduction 2.1 Page 19
2 Safety
December 2016
2.1
2.1 Introduction
Turbochargers manufactured by ABB Turbo Systems are state of the art
and comply with the pertinent safety and health-protection requirements
that applied when the turbocharger was manufactured. Consequently, the
turbocharger is safe to operate. Nevertheless, during turbocharger opera-
tion and when working on the turbocharger, residual risks can exist which:
 originate from the turbocharger itself and its accessories

 originate from the operating and auxiliary materials used
 are the consequence of insufficient observance of the safety instruc-
tions
 are the consequence of unsatisfactory and improper execution of
maintenance and inspection work
The operator is responsible for access to the turbocharger as well as the

organisational measures which regulate the safe handling of the turbo-
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charger by his personnel.
All instructions in this chapter must be observed to ensure safe and trou-
ble-free turbocharger operation and during work on the turbocharger.
In the same vein, all other specially marked safety instructions in every
chapter of this manual must be observed (see the section entitled Defini-
tion of safety instructions).
2.2
2.2 CE conformity
Information
ABB turbochargers fulfil Directive 2006/42/EC on machinery and are con-

sidered partly completed machinery in the sense of Article 2 g.
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Safety 2
Definition of mandatory signs 2.3 Page 20
2.3
2.3 Definition of mandatory signs
To be worn at all times
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Protective clothing Safety footwear against
mechanical hazards
To be worn according to the specific work

Safety glasses Safety goggles
Safety gloves against Respiratory mask against

- mechanical hazards - dust
- chemical hazards - gases
- heat hazards
Safety helmet Ear protection
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2.4
2.4 Definition of Safety instructions
The following symbols and terms used in this manual concern safety or
refer to possible hazards:
Definition of warning
Serious personal injuries and even accidents with fatal consequences
may occur if work and operating instructions marked with this symbol and
WARNING
the word WARNING are either not followed or not followed precisely.
 Warning signs must be observed at all times.
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Definition of caution
Serious machine or property damage may occur if work and operating
instructions marked with this symbol and the word CAUTION are either
CAUTION
not followed or not followed precisely.
 Caution signs must be observed at all times.

Safety 2
Warning plates on the turbocharger 2.5 Page 21
2.5
2.5 Warning plates on the turbocharger
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Warnings that have been attached to turbochargers by ABB Turbo Sys-

tems must not be removed. Illegible warnings must be replaced with new
ones. Further information is available from ABB Turbocharging service
stations.
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Part number Size [mm] Product

81080 105 x 74 TPL / TPR
When uninsulated turbochargers are delivered to the engine builder, the

warning plates must be subsequently attached to the insulation. This is
the responsibility of the engine builder.
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Safety 2
Safe operation and maintenance 2.6 Page 22
2.6
2.6 Safe operation and maintenance
December 2016
The instructions specified in this section are for the safety of personnel.
Together with the instructions in the Hazards during operation and
maintenance section, they allow the user to safely use the turbocharger.
Work safety and work area safety
Risk of falling
There is the risk that someone can fall when working on the turbo-
charger.
WARNING
 Do not climb on the turbocharger or on parts attached to it or use
these as climbing aids.
 When working at levels above the head, use climbing aids and work
platforms suitable for this purpose.
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 Observe all general regulations for the prevention of accidents.
 Do not work on the turbocharger if you are under physical or mental
stress.
 Work only with suitable tools as well as equipment and working mate-
rials that are in perfect condition.
 Electric tools must be solidly earthed, and connecting cables may not
be damaged.
 Keep the workplace clean, clear away loose objects and remove ob-
stacles on the floor.
 Keep the floor, equipment and the turbocharger clean.
 Have oil binding materials ready at hand and keep oil catch pans
ready or in position
 Eliminate leaks.
 Keep fire-protection materials and fire-extinguishing equipment ready.
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Welding work
 If welding work is being carried out above the turbocharger, make sure
to cover the filter silencer so that the filter mat is not damaged.
 Remove combustible objects and substances out of the range of flying
sparks.
 Cover all connections on the turbocharger so that no foreign objects
can get into the turbocharger.

Safety 2
Safety during start-up / commissioning and operation
 Before starting work, carry out visual inspection of working area.

December 2016
 Remove any obstacles and objects lying around.

 Before start-up / commissioning, check all pipes from and to turbo-
charger for damage and leaks.
 Don't work in any way that could impair safety when working on turbo-
charger.
 After about every 12 hours of operation or at least once a day, inspect
turbocharger for visible damage and defects.
 Immediately report any damage or changes in operational perfor-
mance to person responsible.
 If damage is discovered, immediately shut down turbocharger and se-
cure it against inadvertent or unauthorized use.
 When switching on auxiliary power sources (hydraulics, pneumatics,
electricity, water), keep an eye open for any hazards resulting from
supplying these power sources.
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Safety during cleaning
It is possible that detergents or solvents will be used for cleaning. In this

case, the safety instructions of the Hazard due to operating materials and
supplies section in this chapter must always be observed.
 Protect the floor against unintentional penetration of detergents or sol-

vents before starting cleaning operations.
 Wear appropriate protective clothing.
 Inspect the electric cables for abrasion and damaged areas before and
after your cleaning work.
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Safety 2
Safety during disassembly, assembly, maintenance and troubleshooting
 Always perform the specified adjustments, servicing as well as inspec-
December 2016
tion work and observe inspection intervals.
 Inform operating personnel about all service and repair work before
beginning.
 Before opening a cover or removing a protective device on a turbo-
charger, the engine must be switched off and the turbocharger must
have come to a standstill.
 Ensure that the supply of oil is interrupted, especially with an external
oil supply.
 Put the engine into operation only after all parts have been refitted
properly.
Mechanical work on the turbocharger

Possible damage to or destruction of components on the turbocharger.
CAUTION  Perform only those tasks that are described in this manual.
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 Perform work only for which training has been carried out.
Safety when taking out of operation or mothballing
 Secure the rotor so it cannot turn. The rotor can turn on its own from
the force of the stack draught.
 Clean the turbocharger before mothballing it.
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Safety 2
Hazards during operation and 2.7 Page 25

maintenance
2.7
2.7 Hazards during operation and maintenance
December 2016
Mechanical hazards during operation
During normal operation, no mechanical hazards emanate from the turbo-

charger if it has been installed properly.
Risk of injury
Contact with rotating parts can lead to serious injuries. The turbo-
charger must never be operated without a filter silencer or an air suction
WARNING
branch. When the engine is at a standstill, the rotor can turn on its own
because of stack draught.
 Operate the turbocharger in accordance with instructions.
 During maintenance work, secure the rotor against unintentional ro-
tation.
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Mechanical hazards when working on the turbocharger
During maintenance work, various risks can occur through the improper
handling of components, through the non-observance of work instructions,
due to inadequate care or as a consequence of insufficient training.
Mechanical hazards
Severe injuries to personnel or fatal accidents can be caused by me-
chanical influences as a consequence of hazardous and inadequate
WARNING
operational procedures.
 Observe the general rules for occupational safety and prevention of
accidents.
 Ensure workplace safety.
 Only perform operations that are described in this chapter.
 Only perform operations for which you have previously received in-
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struction or training.

Safety 2

maintenance
Hazards due to noise
The development of noise during operation is influenced by the installation
December 2016
and operating conditions. Noise with a sound pressure level exceeding
85 dB(A) is harmful.

Noise can cause impaired hearing, damage to health, mental disturb-
ances, diminished attention and irritation.
WARNING
 Always wear ear protection when the engine is running.
 When the sound pressure level is above 85 dB(A), always wear ear
protection.
Wear ear protection.
Hazards due to hot surfaces and substances
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During operation, turbocharger surfaces and attached parts as well as op-
erating materials (lubricating oil) become hot. The surface temperature is
dependent on the effectiveness of the insulation being used. The tem-
perature can become high enough so that it falls into ranges where burns
are possible.
Risk of burning
Touching hot surfaces or contact with hot operating materials can lead
to serious burns.
WARNING
 Do not touch hot surfaces and heed the warning plate on the turbo-
charger.
 Wear heat-resistant safety gloves and protective clothing.
 Allow the turbocharger to cool down before carrying out any work.
Wear safety gloves to protect against thermal hazards.

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Hot surfaces on uninsulated turbochargers

Uninsulated turbochargers can cause serious personal injuries (burns).
WARNING The turbocharger is supplied by ABB Turbo Systems without insulation
depending on the order from the engine builder. In this case, the engine
builder is responsible for insulating the turbocharger properly or for
providing protection against hot surfaces being touched.
 The engine builder's instructions and specifications about protection
against hot turbocharger surfaces must be observed in every case.

Safety 2

maintenance
December 2016
Hazards due to operating and auxiliary materials
Operating and auxiliary materials are substances used for operation or the
execution of maintenance work. Oils, greases, coolants, cleaning agents
and solvents, acids, etc. can be regarded as hazardous materials. Operat-
ing and auxiliary materials can be combustible and easily ignited.
Handling operating and auxiliary materials

Ingestion or inhalation of vapours of operating and auxiliary materials or
contact with such can cause damage to health.
WARNING
 Avoid inhalation and contact with the skin.
 Ensure good ventilation.
 Observe details in the safety data sheets of the operating and auxil-
iary materials.
 Observe local laws.
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Wear safety goggles.
Wear a respiratory mask to protect against gases.
Risk of fire, explosion

Combustible or easily ignited operating and auxiliary materials can
burst into flame, or vapours from them can cause explosions.
WARNING
 Observe specifications in the safety data sheets of the operating and
auxiliary materials.
 Observe local legislation.
 Do not allow any exposed flame during cleaning work.
 Perform cleaning outdoors or ensure for adequate aeration and ven-
Revision D
tilation.
Risk of environmental damage

The escape of operating and auxiliary materials into the atmosphere or
contamination of the ground and water due to improper disposal can
CAUTION
lead to environmental damage.
 Handle operating and auxiliary materials carefully.

Safety 2

maintenance
 Heed the instructions for use, safety data sheets and hazard notices
on the containers of the operating and auxiliary materials.
December 2016
 Avoid inhalation and contact with the skin.
 Ensure that the work space is adequately ventilated.
 Seal containers tightly immediately after use and put them away.
 Collect used working and auxiliary materials safely, store them sepa-
rately in suitable containers and dispose of them properly and in an
environmentally compatible manner in accordance with statutory regu-
lations.
 In the event of leaks or after spilling, immediately spread a suitable
binding agent and dispose of it properly and in an environmentally
compatible manner in accordance with statutory regulations.
Hazards when handling insulating materials
HZTL2485_EN
Hazards due to insulating materials
Dust and fibres from insulating materials can cause damage to health
or irritations. Unsuitable, combustible insulating materials signify a fire
WARNING
hazard.
 Use only suitable, non-combustible insulating materials.
 Ensure that the work area is well ventilated.
 Avoid stirring up dust.
 Use tools and processes which keep dust to a minimum.
 Remove packing materials only in the work area.
 Take particular care when removing old insulating materials.
 Dispose of insulating materials properly and in an environmentally
compatible way in accordance with applicable local regulations.
Wear a respiratory mask to protect against dusts.

Revision D
 Use only suitable, non-combustible insulating materials.

 Ensure that the work area is well ventilated.
 Wear suitable work clothing (safety glasses, respiratory mask).
 Avoid stirring up dust.
 Use tools and processes which keep dust to a minimum.

Safety 2

maintenance
 Remove packing materials only in the work area.

 Take particular care when removing old insulating materials.
December 2016
 Dispose of insulating materials properly and in an environmentally

compatible way in accordance with applicable local regulations.
Hazards due to electrical components
Hazards due to electrical components

Electrical components operate with voltages which can present hazards
to humans.
WARNING
 All work on or with electrical components may only be performed by
trained specialists.
 Heed any country-specific regulations.
HZTL2485_EN
Revision D

Safety 2
Periodic checking of the pressure 2.8 Page 30

vessel
2.8
2.8 Periodic checking of the pressure vessel
December 2016
The pressure vessels used by ABB Turbo Systems, such as those for wet
or dry cleaning, are so-called "simple pressure vessels".
 The local, statutory regulations covering periodic checks of pressure

vessels must be observed.
 The operator is responsible for the safe operation of the pressure ves-
sel.
Hazards from pressure vessels

The operator must keep the pressure vessel in a proper condition and
monitor it. Necessary repair or maintenance work must be carried out
WARNING
without delay and the required safety precautions must be taken.
 Pressure equipment must not be operated if it has defects.
HZTL2485_EN
Revision D

Safety 2
Lifting loads 2.9 Page 31
2.9
2.9 Lifting loads
December 2016
Suspended loads
Loads not suspended in compliance with regulations may lead to per-
sonal injury or accidents with fatal consequences.
WARNING
 Loads must always be fastened to technically perfect lifting gear with
sufficient loading capacity.
 Make sure the load is suspended properly on the crane hook.
 Do not let anyone stand beneath a suspended load.
Wear safety gloves to protect against mechanical hazards.
Wear safety helmet.

HZTL2485_EN
In the case of two or more suspension points, the slinging angle must not
exceed 45°. This avoids excessive loading due to inclined tensile loading.
 Fasten turbocharger assemblies / components as described in respec-

tive handling steps.
Revision D
 Before attaching slings, allow turbocharger components to cool down

(maximum 80°C).
 Use suitable protection at sharp edges.
 Completely screw in assembly / fitting devices without fail so that they
cannot work loose during use.
 Use assembly / fitting devices only for applications described.
 Make sure removed turbocharger components stand safely and se-
curely.

Commissioning 3
Oil supply 3.1 Page 33
3 Commissioning
December 2016
3.1
3.1 Oil supply
A carefully designed and installed oil supply, which functions in all possi-
ble operational conditions, is an important prerequisite for trouble-free tur-
bocharger operation.
The turbocharger is normally lubricated with oil from the engine oil circuit.
With regard to the oil supply, please observe the engine builder's speci-
fications for lubricating oil selection, oil change intervals, oil filtration, oil
pressure and oil temperature.
NOTICE
Oil filtration
HZTL2485_EN
A lubrication oil filter system with a mesh size ≤0.050 mm is adequate for
TPL76-C turbochargers.
This filter system can also be achieved by using an additional self-

cleaning fine filter.
NOTICE
Revision D

Commissioning 3
Oil pressure
The oil pressure in front of the turbocharger must be maintained precisely
December 2016
to ensure trouble-free operation.
The permissible oil pressure ranges at measuring point M (blind connec-

tion) on the turbocharger are listed below.
Status for operation Oil pressure at measuring point M

poil,in [bar]
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Permissible, for normal operation 1.3 … 2.5
Permissible, during engine warm-up 1.3 … 5.0
Temporarily admissible ( < 1 h ) -> alarm 1.1 … 1.3
Not permissible -> emergency stop 0.0 … 1.1
Permissible, during pre- and post-lubrication 0.2 … 2.5
(engine stopped)
Oil orifice
A metering orifice is installed in the oil inlet of the turbocharger to en-
sure these oil pressures. The orifice is installed by the enginebuilder
NOTICE
and it is fixed in place with a locking ring. Revision D

Commissioning 3
Lubricating oil temperature at inlet

December 2016
Machine damage
If the oil temperature at the oil inlet exceeds the admissible range, this
may lead to engine damage.
CAUTION
 Observe oil temperature at the oil inlet according to the following ta-
ble.
Oil temperature at inlet

Status for operation Toil,inlet [°C]
Permissible 30 … 80
Temporarily permissible (< 1h) -> alarm > 80
Not permissible -> stop engine > 85
Not permissible -> Do not start engine (before < 30
starting: preheat oil)
HZTL2485_EN
Lubricating oil temperature at outlet
The oil temperature at the outlet is mainly dependant on:
 Lubricating oil temperature and pressure at the oil inlet

 Engine load and turbocharger speed
 Exhaust gas temperature
The maximum admissible oil temperature at the outlet is listed in the fol-
lowing table. The specified oil outlet temperature is to be considered as
alarm value for the turbocharger operation and must be monitored accord-
ing to the current regulations.
Oil temperature at outlet

Status for operation Toil,outlet [°C]
Revision D
Permissible ≤ 130
Temporarily permissible -> alarm > 130
Not permissible -> stop engine > 150
If the turbocharger was operated for a longer period of time outside of the
admissible range, ABB Turbo Systems recommends to have the turbo-
charger inspected by an ABB Turbocharging Service Station.

Commissioning 3
Inspection work 3.2 Page 36
3.2
3.2 Inspection work
December 2016
Inspection work includes preventive visual controls plus monitoring and
measuring work before and during commissioning. Inspections help detect
changes to the turbocharger. Machine damage can be avoided.
3.2.1 Inspection before commissioning
Monitoring devices  Check for correct functioning.
Air filter mat  Inspect for damage.
HZTL2485_EN
Lubricating system  Check oil filter for cleanliness before commissioning.
Contaminated oil
Particles of dirt and solid matter in the oil can cause serious damage to
the machine or property.
CAUTION
 During initial commissioning and after all service work, the complete
lubricating system must be flushed thoroughly with warm oil.
 When running in the engine and after all service work on the lubricat-
ing system, special running-in filters must be used.
 Check oil pressure in oil supply lines.

Revision D
Warning plates on  Check whether the warning plates are present and legible.
turbocharger
 Check whether the protective sheets have been removed.

Commissioning 3
Inspection work 3.2 Page 37
3.2.2 Check after start-up (engine at idling speed)

December 2016
Lubricating system
 Check oil pressure in oil supply lines.

 Check oil inlet temperature.
The permissible values are listed in the section Oil supply.
Gas, air and oil lines
 Check all gas, air and oil lines for leaks after starting the engine.
3.2.3 Check when running up engine

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 Measure speed, oil pressure and charging pressure at various engine

performance levels.
 Measure exhaust gas temperature in front of and behind turbine.
 Measure air temperature in front of and behind compressor.
The measured values must be compared with the values in the ac-
ceptance test report, while taking different operating conditions into ac-
count.
Lubricants and pastes used during assembly of the turbocharger liquefy

or vaporise and might escape as an oily liquid in the first few hours after
commissioning. If oily liquid continues to escape after this period, an oil
leak must be suspected. The first step is to check for leakage of the oil
NOTICE
supply to the turbocharger. If this is leaky, contact an official ABB Tur-
bocharging service station.
Revision D
3.2.4 Inspection after 100 service hours
Clean or replace lubricating oil filters after the first 100 service hours.

Commissioning 3
Commissioning after taking out of 3.3 Page 38

operation
3.3
3.3 Commissioning after taking out of operation
December 2016
If provided  Remove cover plates (blind flanges) between compressor casing out-
let and charge air duct, before gas inlet and after gas outlet.
 Inspect exhaust gas duct / line in front of and after turbine for any
combustion deposits, foreign matter or residual water. Clean and re-
move.
 Inspect air supply line or filter silencer for any foreign matter. Clean
and remove.
 Start up turbocharger oil circulation system at engine end.
 Prepare turbocharger for operation as instructed in section "Inspection
work before start-up / commissioning" of chapter headed "Start-up /
commissioning".
 Start up turbocharger.
HZTL2485_EN
Revision D

Operation 4
Noise emissions 4.1 Page 39
4 Operation
December 2016
4.1
4.1 Noise emissions

Noise can cause impaired hearing, damage to health, mental disturb-
ances, diminished attention and irritation.
WARNING
 Always wear ear protection when the engine is running.
 When the sound pressure level is above 85 dB(A), always wear ear
protection.
Wear ear protection.
The sound pressure level (A-weighted) of emissions is measured at a dis-

tance of 1 metre from the turbocharger.
HZTL2485_EN
The highest sound pressure level of emissions1) reaches a maximum of

105 dB(A) near the filter silencer and over the entire speed range.
The following prerequisites must be fulfilled on the turbocharger in order

to observe this limit value:
 Fitted air-inlet system

 All standard, noise-reducing measures have been taken2).
 The bellows at the air outlet have been perfectly insulated acoustically
by the engine builder. He is also responsible for insulating the charge
air / scavenging air line and the charge air cooler.
Revision D
1) Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 :

A-weighted emission sound pressure level
2) In the event of divergent insulation designs, the engine builder must en-
sure that equivalent acoustic insulating measures are taken.

Operation 4
Noise emissions 4.1 Page 40
Suggestion for noise insulation of the bellows
December 2016
01 Compressor casing 04 Insulation pads
HZTL2485_EN
02 Bellows 05 Insulation mat (at least 15 mm)
03 Charge air duct / scavenging 06 Sheet metal cover
air line
Revision D

Operation 4
Servicing work 4.2 Page 41
4.2
4.2 Servicing work
December 2016
Service work to be carried out during operation involves visual checks,

monitoring, measuring, inspection work and functional checks. It is then
possible for changes to the turbocharger to be identified and rectified. In
this way, it can be ensured that the turbocharger remains in full working
order.
Service intervals
Service work on the turbocharger that is neglected or carried out too
late can lead to excessive contamination and wear as well as operating
CAUTION
failures.
 Carry out service work at specified time intervals.
Shortened service intervals

Despite observance of the service intervals, unusual loads, such as
HZTL2485_EN
several start-stops a day, harsh environmental factors, poor fuel quality

CAUTION
or heavy installation vibration can lead to premature machine damage.
 A shortened service interval must be arranged with ABB Turbo Sys-
tems.
Service inspection after 5 years

To prevent age- and stoppage-related machine damage, an inspection
by an ABB Turbocharging Service Station is recommended at the latest
NOTICE
5 years after the last service.
4.2.1 Service work every 25 … 50 hours
 Visual inspection for air, exhaust gas, water and oil leaks.
 Record operating data and enter it in the engine logbook.
Revision D
 Clarify the cause of any variances.
Unknown changes during operation

The consequences can range from an impairment to a breakdown.
CAUTION  Have unknown causes clarified by an ABB Turbocharging service
station.

Operation 4
December 2016
4.2.2 Entries in engine logbook
By monitoring the engine, conclusions can be drawn about the turbo-

charger performance.
The following operating data and measured values must be entered regu-
larly in the engine manufacturer's engine logbook:
 Engine performance and speed

 Air intake temperature
 Exhaust gas temperature in front of and behind the turbine
 Pressure of charge air
 Pressure drop in charge air cooler
 Lubricating oil pressure and lubricating oil temperature
If provided  Air temperature behind compressor and charge air cooler
HZTL2485_EN
 Turbocharger speed
 Pressure loss in air filter
4.2.3 Servicing work according to the engine manufacturer's instructions
Oil filter  Clean or replace oil filter in supply line to turbocharger when engine is
not running.
Revision D

Operation 4

December 2016
The inspection and assessment of the rotor and the bearing parts must be
carried out by an official ABB Turbocharging service station.
 Disassemble turbocharger.
 Measure clearances.
 Clean the turbine and compressor wheels and inspect for damage.
 Clean the turbine and compressor casings and inspect for any cracks
and erosion or corrosion.
 Clean bearing casing and blow air through oil ports.
 Clean nozzle ring and check for cracks and erosion.
 Inspect and assess bearing parts and rotor.

HZTL2485_EN
The replacement of bearing parts as well as the inspection and assess-

ment of the rotor must be carried out by an ABB Turbocharging Service
Station.
 Disassemble turbocharger.
 Measure clearances.
 Clean the turbine and compressor wheels and inspect for damage.
 Clean the turbine and compressor casings and inspect for any cracks
and erosion or corrosion.
 Clean bearing casing and blow air through oil ports.
 Clean nozzle ring and check for cracks and erosion.
 Inspection and assessment of the rotor
 Replace plain bearings with original parts from ABB Turbo Systems.
Revision D

Operation 4
Replacement intervals for turbocharger 4.3 Page 44

components
4.3 Replacement intervals for turbocharger com-

ponents
December 2016
4.3
Rotating components The recommended replacement intervals for the compressor and turbine
wheels due to stress caused by centrifugal forces and load cycles are cal-
culated under consideration of the operating conditions while applying the
safety concept for rotating components. They can be found on the turbo-
charger rating plate. Incalculable influencing parameters can shorten the
recommended replacement intervals for the rotor, see Influencing pa-
rameters.
Non-rotating components The expected replacement intervals for non-rotating components and
bearing parts are extremely dependent upon system-specific operating
conditions, see Influencing parameters.
When the specified, periodic inspections are carried out, the individual
components are inspected for wear and tear and replaced if necessary. In
this way, trouble-free operation is ensured.
HZTL2485_EN
Influencing parameters The following parameters influence the replacement intervals for turbo-
charger components:
Parameters influencing bearing parts
 Poor quality of the lubricating oil (lubrication oil filter system, condition
of lubricating oil)
 Unusual loads (vibration, start/stop frequency)
 Non-permissible state of rotor unbalance
Parameters influencing non-rotating components exposed to exhaust gas
 Fuel quality (gas, MDO, HFO)

 Load profile (thermal load changes, number of starts/stops)
 Temperature level of exhaust gas
Revision D
 Turbine cleaning frequency

 Procedure for turbine cleaning

Operation 4
Replacement intervals for turbocharger 4.3 Page 45

components
Parameters influencing rotating components exposed to exhaust gas
 Fuel quality (gas, MDO, HFO)

December 2016
 Turbine cleaning frequency

 Procedure for turbine cleaning
 Load profile
Expected replacement
Component GAS / MDO HFO
intervals [h]
Gas inlet casing 50000 … 100000 25000 … 50000
Gas outlet casing 50000 … 100000 35000 … 100000
Nozzle ring 35000 … 50000 25000 … 50000
Turbine diffuser / cover ring 35000 … 50000 25000 … 50000
Other casings 100000 100000
Axial bearing components 24000 … 36000 24000 … 36000
Radial bearing components 24000 … 36000 24000 … 36000
Turbine blades - ≥ 12000
(due to wear)
HZTL2485_EN
Recommended
Rotor components See the data on the rating plate
replacement intervals [h]
GAS = Gas Engine

MDO = Marine Diesel Oil
HFO = Heavy Fuel Oil
The specified values are guides and not guaranteed. (See Influencing
parameters.)
NOTICE
Revision D

Operation 4
Speed measurement 4.4 Page 46
4.4
4.4 Speed measurement
December 2016
A speed measuring system permits continuous monitoring of the turbo-
charger speed.
Do not use cables as a climbing aid

If you pull the speed measurement cables too hard, contacts can be
pulled out.
CAUTION
 Do not tension the speed measurement cables.
HZTL2485_EN
Part number Description

42047 Screw plug
86505 Speed sensor
Revision D
86515 Cable connector for 86505

86526 F/I converter
86528 Tachometer

Operation 4
4.4.1 Speed differences with multiple turbochargers per engine
The speeds of all turbochargers on one engine differ only slightly from
December 2016
each other in normal operation.
The difference between the highest and the lowest turbocharger speed
must not be more than 3 % relative to the speed limit nBmax.
If this permissible range of difference is exceeded, the following steps

must be carried out:
 Reduce engine performance immediately until the highest turbo-

charger speed no longer exceeds 70% of nBmax.
 If the engine cannot be stopped, continue to run at this reduced engine
performance or turbocharger speed.
 If the turbocharger surges continuously, engine performance must be
reduced further.
 Measure the temperatures in the air and gas lines to and from the tur-
bochargers and compare them with standard values.
HZTL2485_EN
If the engine can be stopped for a short time:
 Inspect the air and gas lines as well as the turbocharger and eliminate
any problems.
 In any event, it is recommended that you contact the nearest ABB
Turbocharging Service Station.
4.4.2 Assembly
If the speed sensor is not fitted on the turbocharger, the following proce-
dure must be adopted to fit it:
 Engine and turbocharger are not running.

 The turbocharger lubricating system is switched off.
Revision D
 Remove screw plug (42047) from bearing casing.
Part position
The position of the screw plug for measuring the speed is marked "n"
on the bearing casing.
NOTICE

Operation 4
 Screw in speed sensor (86505) as far as it will go and tighten to torque

specified in table. (See chapter Table of tightening torques.)
 Connect speed sensor using cable connector (86515).
December 2016
4.4.3 Replacing the speed sensor
Hot cable connector and hot speed sensor

Risk of burning. During operation, the cable connector and the speed
sensor can reach temperatures exceeding 100 °C.
WARNING
 Wear safety gloves when removing the cable connector and speed
sensor.
 Reduce engine performance to the idling speed, then stop the engine.
 Switch off the lubricating oil supply to the turbocharger.
HZTL2485_EN
 Disconnect the cable connector from the speed sensor.
 Screw out defective speed sensor.
 Screw in a new speed sensor up to the limit block.

 Observe the tightening torque (see the table of tightening torques in
the chapter entitled Disassembly and assembly).
Sealing of the speed sensor

The speed sensor is designed with a sealing lip and does not require
any additional gasket for assembly.
NOTICE
 Connect cable connector to speed sensor.

Revision D
 Switch on lubricating oil supply to turbocharger.
4.4.4 Failure of speed measuring system
Possible reasons for failure of the speed measuring system are described
in the chapter Troubleshooting.

Operation 4
Stopping the engine 4.5 Page 49
4.5
4.5 Stopping the engine
December 2016
Stopping the engine

Heat in the turbocharger must be dissipated by the further circulating
lubricating oil.
CAUTION
 Allow the engine to continue running at idling speed for a further
10 minutes before stopping.
HZTL2485_EN
Revision D

Maintenance 5
Foreword to Maintenance 5.1 Page 51
5 Maintenance
December 2016
5.1
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.
The cleaning points described in the following are:

HZTL2485_EN
 Filter silencer
 Compressor
 Turbine and nozzle ring
Revision D

Maintenance 5
Cleaning the filter silencer 5.2 Page 52
5.2
5.2 Cleaning the filter silencer
December 2016
5.2.1 Filter silencer and connecting rod
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81265 Filter ring (if provided) 81136 Absorption segment
81269 Connecting rods 81137 Sheet-metal covering
81266 Cover grid 81135 Filter silencer body
81272 Screwdriver 81273 Lock nut
E Insert unit = absorption segment + sheetmetal covering
Revision D

Maintenance 5
Removing and cleaning filter silencer

December 2016
If provided  Remove filter strip (81265).

 Rinse filter strip (81265) using water with detergent additive or, if very
dirty, soak it and squeeze out carefully. Rinse it in cold water. Avoid
rough treatment (not a jet of water).
How dirty the filter strip (81265) is, depends on how clean the drawn-in
air is. Clean filter strip every 500 hours of service or more frequently if
necessary.
NOTICE
 Unscrew and remove lock nuts (81273).

 Unscrew and remove screws (81272) for connecting rods (81269).
 Remove connecting rods (81269).
 Carefully remove cover grids (81266).
HZTL2485_EN
 Pull out insert units (E), bend open sheet metal coverings (81137) and
then remove absorption segments (81136).
 Clean the absorption segments (81136).
During cleaning, ensure that the absorption segments (81136) are only
cleaned with a mild jet of compressed air, soft brush or a damp cloth.
Otherwise there is a risk of damage or deformation.
Replace heavily contaminated or damaged parts with original parts from

ABB Turbo Systems.
NOTICE
Revision D

Maintenance 5
Fitting filter silencer
 Assemble insert units (E) by putting fleece segments (81136) into
December 2016
sheet-metal cover (81137).
 Bend back sheet-metal cover (81137) to original shape.
 Put insert units (E) into slot guides in filter silencer body (81135).
If a cleaning container is fitted to the filter silencer (optional depending

on turbocharger type), the water injection line must now be refitted.
(See also following section Fitting cleaning pipe.)
NOTICE
 Put cover grids (81266) uniformly into correct position.

 Push connecting rods (81269) through clips on cover grids (81266).
If the connecting rods (81269) are not located correctly in their recesses
on the filter silencer body (81135), the cover grids (81266) can twist and
HZTL2485_EN
shift. There is then a risk of foreign matter and dirt getting into the com-
pressor.
CAUTION
Revision D
 Join connecting rods (81269) using screws (81272). When tightening

the screws (81272), ensure that connecting rods (81269) are located
correctly in recesses in filter silencer body (81135). Now tighten
screws (81272) alternately until the following maximum torque is
reached:

Maintenance 5
Screw Tightening torque [Nm]

81272 20
December 2016
 Screw lock nuts (81273) onto screw (81272) and tighten to following
torque:
Lock nut Tightening torque [Nm]
81273 40
HZTL2485_EN
Revision D

Maintenance 5
Cleaning the compressor during 5.3 Page 56

operation
5.3
5.3 Cleaning the compressor during operation
December 2016
Approval by enginebuilder These instructions for wet cleaning only apply when cleaning is carried out
with clean water and under the precondition that the enginebuilder ap-
proves the process.
General The degree of contamination of the compressor stage (compressor wheel,

wall insert and diffuser) depends on how clean the drawn-in air is.
Deposits can build up in the flow channels if salt, oil mist or dust are in the
intake air.
Consequences of contamination:
 Impaired compressor efficiency

 Higher exhaust gas temperatures
 Increased fuel consumption
 Increased rotor unbalance
HZTL2485_EN
Periodic cleaning of the compressor during operation prevents or delays a
severe increase of the contamination. It does not, however, replace the
regular service work, during which the turbocharger is completely disman-
tled and the compressor is cleaned mechanically.
Cleaning interval The interval between periodic cleaning is very dependent on the operating
conditions. In general, cleaning should be carried out every 25 ... 100 op-
erating hours.
Should the specified cleaning intervals prove incompatible with engine

operation, please contact ABB Turbo Systems.
Revision D

Maintenance 5

operation
Cleaning method
Cleaning of the compressor during operation is carried out using the

December 2016
cleaning method described in the following:
 Wet cleaning
This cleaning method has been tested and approved by ABB Turbo Sys-
tems.
Principle of wet cleaning To clean the compressor stage during operation, water is injected in front
of the compressor wheel.
The water does not act as a solvent, but the contamination deposit is re-
moved by the mechanical impact of the droplets. This is a very suitable
process, provided that the degree of contamination is not too high.
Corrosion and deposits when cleaning

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Damage and impairment of turbocharger parts due to salt water and

cooling water additives
CAUTION
 Don't use salt water for cleaning, but only clean fresh water.
Uncontrolled volumes of water

Uncontrolled volumes of water can damage the turbocharger and the
engine.
CAUTION
 Never connect the water line without the orifice specified for the tur-
bocharger.
Formation of ice at low temperatures

Damage to turbocharger due to the formation of ice during wet cleaning
if the intake air temperatures are too low.
CAUTION
 Never carry out wet cleaning if intake air temperatures are under
Revision D
5 °C.
V-engines In the case of V-engines with several turbochargers on each engine, we

recommend parallel cleaning of the compressors. This cleaning process is
faster and the risk of turbocharger surging is reduced.

Maintenance 5

operation
5.3.1 Wet cleaning with orifice plate on filter silencer (XC2)
December 2016
Operating state prerequisites for wet cleaning XC2
Increased stress on material

During cleaning of the compressor at an engine load of 85 to 100 %,
the stress on the material of the compressor-end turbocharger parts
WARNING
can be increased.
 No personnel is allowed to be present in the vicinity of the turbo-
charger during compressor cleaning.
 Compressor cleaning must be activated from the engine control panel.
Wet cleaning procedure for compressor with XC2
 Trigger water injection according to the specifications of the en-
HZTL2485_EN
ginebuilder.
 The specified water pressure upstream of the connection to the turbo-
charger must be maintained.
 Operate engine for at least five additional minutes after cleaning.
Not more than three cleaning cycles should be conducted consecutively.
Cleaning parameters per turbocharger compressor
Product Engine load Water Water Water Ø orifice

pressure injection time temperature [mm]
[bar] [sec] [°C]
TPL76-C 50 … 100% 3 10 5 … 50 2.9
Revision D

Maintenance 5

operation
Surging of the compressor stage
Should repeated surging of the compressor stage occur during compres-

December 2016
sor cleaning, first the cleaning parameters as well as the engine-side sys-
tem must be checked with regard to deviations (e.g. an increased pres-
sure loss in the charge air cooler) and corrected if necessary.
If, despite correct settings, surging of the compressor stage occurs while
cleaning the compressor, as a remedial measure the engine load can be
reduced further while cleaning the compressor. The reduction of the en-
gine load can lead to a reduction in the effectiveness of the compressor
cleaning.
 To avoid a decreased engine availability, the compressor stage can be

cleaned at reduced engine load during the drying time after wet clean-
ing of the turbine has been completed. (see section Wet cleaning tur-
bine and nozzle ring during operation). In this case, the water injection
time for cleaning the compressor can be increased from ten to forty
seconds.
HZTL2485_EN
Revision D

Maintenance 5

operation
5.3.2 Wet cleaning using external water-pressure vessel (XC3)
December 2016
Operating state prerequisites for compressor cleaning with XC3
In order to carry out a successful cleaning procedure that has been

tested and is recommended by ABB Turbo Systems, the following pre-
requisite must be met:
NOTICE  Engine load 50 – 85%
 Start cleaning cycle according to following description Wet cleaning
operation with XC3.
Operating procedure for compressor wet cleaning with XC3
HZTL2485_EN
Revision D
Operating the water  The operating state prerequisites for compressor cleaning with XC3
pressure vessel must be fulfilled.
 Remove sealing plug (X).
 Fill vessel with required volume of clean water (see table Cleaning pa-
rameters).

Maintenance 5

operation
 Screw in sealing plug (X).

 Push the valve activator (Y) against the spring and hold it for 10 ... 15
seconds until the entire volume of water has been injected.
December 2016
 After cleaning, wait at least 5 minutes to allow turbocharger to dry.
The cleaning process can be repeated up to two times.
If the cleaning is still unsuccessful after three cleaning processes and the
engine values are unsatisfactory, it is recommended to have the turbo-
charger checked and cleaned by an ABB Turbocharging Service Station.
Cleaning parameters per turbocharger compressor
Product Engine load Water temperature Contents of water

[°C] vessel
[dm3]
TPL76-C 50 ... 85% 5 … 50 1
HZTL2485_EN
Surging of the compressor stage
Should repeated surging of the compressor stage occur during compres-

sor cleaning, first the cleaning parameters as well as the engine-side sys-
tem must be checked with regard to deviations (e.g. an increased pres-
sure loss in the charge air cooler) and corrected if necessary.
If, despite correct settings, surging of the compressor stage occurs while
cleaning the compressor, as a remedial measure the engine load can be
reduced further while cleaning the compressor. The reduction of the en-
gine load can lead to a reduction in the effectiveness of the compressor
cleaning.
 To avoid a decreased engine availability, the compressor stage can be

cleaned at reduced engine load during the drying time after wet clean-
ing of the turbine has been completed. (see section Wet cleaning tur-
bine and nozzle ring during operation). In this case, the water injection
time for cleaning the compressor can be increased from ten to forty
seconds.
Revision D

Maintenance 5
Cleaning turbine blades and nozzle ring 5.4 Page 62

in operation
5.4 Cleaning turbine blades and nozzle ring in

operation
December 2016
5.4
The combustion of heavy fuel oil in diesel engines contaminates the tur-
bine blades and nozzle rings of turbochargers. The deposits on the tur-
bine components originate from the following combustion products:
 Soot
 Molten ash
 Cinder
 Incompletely burned fuel
 Sodium vanadyl vanadate
It is advisable to use fuels with a low ash, sulphur, sodium and vanadium
content. The fuel must also be correctly stored, prepared and handled.
We recommend using fuels with a vanadium-to-sodium mass ratio of less

than 3:1 so that the melting temperature of the sodium vanadyl vanadate
HZTL2485_EN
is as high as possible.
The amount of contamination increases over time, which is why regular

and correctly performed cleaning is important in order to remove the de-
posits that have formed.
Contaminated turbine components can cause a slight increase in charging

pressure because of narrowing of the turbine cross-section. The contami-
nation causes a drop in turbine efficiency, and the engine temperatures
downstream of the cylinder can increase. The engine performance must
therefore be reduced if necessary.
The contamination of the turbine also causes rotor unbalance. Extremely

heavy contamination can lead to non-permissibly high unbalance of the
rotor.
Operating experience has shown that, in spite of regular cleaning during

operation, it is essential to carry out the overhauls during which the tur-
bine and the nozzle ring are cleaned mechanically. However, if cleaning is
carried out properly and the cleaning system is properly dimensioned, the
Revision D
intervals between overhauls can be increased.
Wet cleaning interval The interval between periodic cleaning is very dependent on the operating
conditions. As a rule, cleaning should be carried out every 50 to 200 op-
erating hours.

Maintenance 5

in operation
Cleaning method When cleaning the turbine components during operation, use wet clean-
ing. This cleaning method has been tested and approved by ABB Turbo
December 2016
Systems.
Prerequisites for wet cleaning are that the engine builder approves the
process and his instructions are followed.
Principle of wet cleaning Wet cleaning makes use of various effects. Depending on the composition
of the contamination, the individual effects with their different levels of in-
tensity have a varying influence on the cleaning result:
 Erosion
The dirt is removed by the mechanical action of the impacting water
droplets.
 Solubility
Water solubility of the contamination deposits in water.
 Thermal shock
Spalling of contamination due to temperature difference.
HZTL2485_EN
Corrosion and deposits when cleaning

Damage and impairment of turbocharger parts due to salt water and
cooling water additives
CAUTION
 Don't use salt water for cleaning, but only clean fresh water.
Components at the turbine end are not cleaned until the engine has been
started or the engine load reduced. The exhaust gas temperature must
not exceed the value specified in the respective cleaning instructions (see
section Prerequisites [➙ 64]).
Reduced service life of the components

Failure to comply with the minimum stabilisation time before cleaning,
the prescribed turbine inlet temperatures and the drying time after
CAUTION
cleaning significantly reduces the expected service life of the compo-
Revision D
nents.
 Comply with the cleaning parameters given in the tables.
V-engines In the case of V-engines with several turbochargers on each engine, we

recommend parallel cleaning of both turbochargers. This cleaning process
is faster and the risk of turbocharger surging is reduced. We recommend
finding the most suitable method by performing trials.

Maintenance 5

in operation
5.4.1 Wet cleaning turbine and nozzle ring during operation
December 2016
Prerequisites for wet cleaning of turbine
The following operating state and prerequisites have been tested and ap-
proved by ABB Turbo Systems for the cleaning process:
HZTL2485_EN
 The engine has just been started or the engine load has been reduced
as far as possible (best cleaning is achieved at a load level of roughly
10 ... 15%).
 As soon as the turbine inlet temperature is stable and below 430 °C,
wait at least another 10 minutes for the charger parts to cool down.
 Start cleaning cycle according to following description Wet cleaning
procedure.
Revision D

Maintenance 5

in operation
Layout of cleaning pipes

December 2016
Wet cleaning procedure for turbine during operation
 Meet prerequisites and operating state requirements without fail before

cleaning!
HZTL2485_EN
 Make sure water supply (01) is connected, turned on and guaranteed.

 Open drain pipe (08, 09), if provided.
 Switch over 3-way valve (04) from scavenging air mode to water sup-
ply.
 Set the required volume of water on the flowmeter as shown in the ta-
ble (see table Cleaning parameters).
 Shut off the water supply again by switching the 3-way valve (04) to
scavenging air mode after injecting the required volume of water.
 The injection process has been completed.
 Close drain hole (if provided) above drain pipe (08, 09).
 After cleaning, wait with engine running for at least 10 minutes without
changing load to allow turbocharger to dry.
Revision D

Maintenance 5

in operation
Recommendation for It is necessary to have the corresponding water pipe pressure in order to
water pressure achieve the correct water flow rate (see table Cleaning parameters). If the
December 2016
water pressure is too low, the water flow rate specified in the table will not
be obtained. In this case, the cleaning effect will be decreased.
Repeating cleaning cycles immediately after each other must be avoided

as this can lead to high mechanical loading and consequently to a reduc-
tion in the service life of the components.
If cleaning is unsatisfactory, the length of the process can be extended. If

the injection time is extended, it must be ensured that no unacceptable
volume of water collects in the gas outlet casing. To avoid this, a drainage
system for the gas outlet casing should be installed and open during the
cleaning process. If a drainage system is not provided, the injected vol-
ume of water can be controlled by a flowmeter in the water supply. The
maximum volume of water allowed in individual cases must be determined
together with an ABB Turbocharging Service Station. The influence of the
cleaning water on peripheral equipment, such as a boiler, must be clari-
fied by the operator.
HZTL2485_EN
Points to remember when The following points must be observed with regard to draining the gas out-
cleaning let casing:
 The exhaust gas temperature behind the turbocharger drops signifi-

cantly when cleaning (typical turbocharger outlet temperatures during
cleaning: 60 ... 180 °C).
 Depending on the engine load, water might run out of the drain pipe.
This outflow might not start for two or three minutes, or it might not oc-
cur at all.
 If the drainage of the gas outlet casing is omitted, the turbocharger
speed and/or the gas inlet temperature must be monitored during the
cleaning process. If the load is too low, water can collect in the gas
outlet casing. Indicators for this are a sudden severe drop in the turbo-
charger speed or a very large increase in the gas inlet temperature. In
such cases, the cleaning operations must be stopped and the cleaning
cycle restarted with reduced water pressure or higher engine load.
Revision D
Wet cleaning parameters for turbine and nozzle ring
Product Maximum temperature at Injection time Water flow rate per turbo-
start of cleaning process t i [min] charger at pWater = 3 bar
TTI [°C] MW [l/min]
TPL76-C 430 10 37

Maintenance 5
Cleaning components mechanically 5.5 Page 67
5.5
5.5 Cleaning components mechanically
December 2016
5.5.1 Introduction
Compressor wheels can be heavily contaminated by badly filtered intake

air, as can turbines by heavy fuel oil operation or coked oil. Such contam-
ination may possibly no longer be removed through cleaning during op-
eration and must be cleaned mechanically during the standard service in-
tervals (see chapter entitled Service work).
Professional overhauling of the components by an ABB Turbocharging

Service Station is required, preferably using the cleaning method de-
scribed in the following.
Choosing cleaning tools

Turbocharger components are sensitive to mechanical damage. The
use of needle guns or other impact tools, for example, damages the
CAUTION
components. Depending on the specification, nozzle rings have protec-
HZTL2485_EN
tive coatings, which can also be damaged.

 Only use soft tools such as scouring cloths, brushes or wire brushes.
 In the event of heavy contamination, the cleaning methods described
in this chapter such as soaking can be repeated until a satisfactory
result has been achieved.
Disassembly and assembly

Disassembly and assembly of the parts is described in the chapter enti-
tled Fitting and dismantling.
NOTICE
 Dispose of contaminated water and cleaning agents in an environmen-

tally compatible manner, professionally and in accordance with valid
local regulations.
Revision D

Maintenance 5
5.5.2 Turbine-end, non-rotating parts
December 2016
Handling operating materials and supplies
Swallowing or inhaling vapours of operating materials and supplies or
contact with them may be harmful to health.
WARNING
 Do not breathe in these substances and avoid contact with the skin.
 Ensure proper ventilation.
 Observe the information in the material safety data sheet for the op-
erating materials and supplies.
 Wear personal protective equipment (PPE) according to the material
safety data sheet.
 Comply with local legislation.
HZTL2485_EN
Wear a respiratory mask to protect against gases.
Baked-on layers of contamination, for example from heavy fuel oil or

coked oil, occur at the turbine end. The following performance-relevant
parts can be cleaned according to the following description.
56001 Nozzle ring

Revision D
63000 Turbine diffuser
 Place contaminated parts in hot water or in a liquid such as carbon

remover, so that the contamination softens.
 Brush off the contamination or remove it with a steam cleaner.
 Repeat the soaking and brushing if necessary.
 Completely remove any solvents from the parts in clean water.
 Dry components completely.

Maintenance 5
 Spray cleaned surfaces with penetrating oil. Do not spray the outer
surfaces of the turbocharger.
 Dispose of contaminated water and cleaning agent in accordance with
December 2016
the specifications in the safety data sheet.
5.5.3 Cartridge group – General
Corrosion
If the cartridge group is not put into operation again immediately after
cleaning, parts may corrode.
CAUTION
 Re-install and use the cartridge group immediately after cleaning.
 Remove turbocharger from the engine (see chapter Removal and in-
stallation).
 Remove cartridge group (see chapter Disassembly and assembly).
HZTL2485_EN
First clean the compressor end and then the turbine end in accordance
with the following description.
5.5.4 Cleaning the cartridge group on the compressor end
Selection of the cleaning agent

Cleaning agents which contain chlorine attack metals.
CAUTION  Use only pH-neutral cleaning agents which do not attack metals.
 Observe safety data sheet.
Revision D
Water and contamination in the cartridge group

If water or contamination penetrates the cartridge group, this can impair
the function of the turbocharger and damage parts inside the cartridge
CAUTION
group.
 Make sure that no water or contamination can enter into the cartridge
group.

Maintenance 5
 Clean compressor wheel with a scouring cloth or soft brush soaked in

water with household cleaning agent. Do not use any wire brushes!
 Dry the compressor wheel and the gap between the compressor and
December 2016
the bearing casing with a weak jet of compressed air.
 Lightly spray the gap between the compressor and the bearing casing
with penetrating oil.
the safety data sheet.
5.5.5 Cleaning the cartridge group on the turbine end
Soaking the contamination
Baked layers of contamination from fuel residue or coked oil may occur at
the turbine end. The contamination can be removed by soaking and
brushing. The procedure for soaking the layers of contamination as well
as for cleaning the turbine are described in the following.
HZTL2485_EN
To soften the layers of contamination on the turbine, the cartridge group
can be submerged vertically in a tank with liquid.
The cartridge group must be rotated to do this.
 Two cranes (or chain blocks) must be used for the rotating operation.
Suspending the chain block directly from the crane and rotating the car-
tridge group is not permitted because of the risk of damage to the com-
pressor wheel.
Cartridge group with a central suspension point
Damage to compressor wheel

The lifting gear must not touch the compressor wheel at any time during
rotation.
Revision D
CAUTION
 Choose appropriate lifting gear length.

Maintenance 5

December 2016
1. Suspend cartridge group from normal suspension point and suspend

from first crane.
2. Secure two lifting loops with swivel lifting eyes in the lower push-off
threads and suspend from a second crane.
3. Rotate cartridge group horizontally by lifting the second crane.
HZTL2485_EN
4. When the cartridge group is horizontal, secure one chain block from
one of the upper push-off threads using a swivel lifting eye and sus-
pend from the second crane.
Revision D
5. Tighten chain block until entire cartridge group is suspended from

second crane.
6. Remove loop from first crane.

Maintenance 5
Cartridge group with two side suspension points
Or use two swivel lifting eyes at top.
December 2016
Damage to compressor wheel
The lifting gear must not touch the compressor wheel at any time during
rotation.
CAUTION
 Choose appropriate lifting gear length.
HZTL2485_EN
1. Suspend cartridge group from the two side suspension points on the
crane using two lifting loops.
or
Attach two swivel lifting eyes to the side and suspend the cartridge
group from the crane using two lifting loops.
2. Attach third lifting loop with swivel lifting eye to thread of oil outlet
flange.
3. Rotate the cartridge group into a horizontal position by lifting.
Revision D

Maintenance 5

December 2016
4. When the cartridge group is suspended horizontally, attach a chain

block to the swivel lifting eye and attach to the first crane.
5. Tighten chain block until entire cartridge group is suspended from first
crane.
6. Remove loop from second crane.
HZTL2485_EN
Selection of the cleaning agent

Cleaning agents which contain chlorine attack metals.
CAUTION  Use only pH-neutral cleaning agents which do not attack metals.
 Observe safety data sheet.
 Fill the tank with soaking liquid.

Revision D
 Only immerse the cartridge group until all blades are covered with
cleaning agent.

Maintenance 5
Heating the liquid

To shorten the soaking time the liquid can be heated to maximum
December 2016
60 ºC.
NOTICE
Heating up of cleaning agents and operating fluids

When cleaning agents or operating fluids are heated up, explosive va-
pours can be produced which are hazardous to health.
WARNING
 Observe the information in the material safety data sheet.
Wear a respiratory mask according to material safety data sheet.

If water or contamination gets into the cartridge group, the turbocharger
function may be impaired and parts in the cartridge group may be dam-
CAUTION
aged.
HZTL2485_EN
 Place cartridge group on suitable wooden or metal supports.
 Allow the layers of contamination on the turbine to soak for at least

four hours.
Removing contamination
Health hazard due to soot particles

If soot particles enter the eyes or respiratory tract, this can be harmful
to health.
WARNING
 Avoid the formation of dust.
 Vacuum up dust with a suitable vacuum cleaner.
 Wear a respiratory mask to protect against particles (P1 or P2 mask).
 Wear safety goggles.
Revision D
 Raise the cartridge group and align horizontally.

Maintenance 5
 Remove contamination manually with a soft brush or wire brush.

December 2016

If water or contamination gets into the cartridge group, the turbocharger
function may be impaired and parts in the cartridge group may be dam-
CAUTION
aged.
 Make sure that water or contamination does not get into the gap be-
tween the sealing cover and turbine.
Non-permissible rotor unbalance after cleaning

Invisible and unevenly distributed residual contamination deposits lead
to rotor unbalance. This can result in bearing or turbocharger damage.
CAUTION
 Remove all traces of contamination from the turbine.
HZTL2485_EN
 After brushing off the contamination, fill the tank with clean water, not
salt water.
 Submerge the turbine of the cartridge group in clean water, so that
loose particles of contamination detach completely.
 Lift the cartridge group.
 Dry turbine and gap between turbine and sealing cover with a weak jet
of compressed air.
 Lightly spray turbine and gap between turbine and sealing cover with
penetrating oil.
 Rotate cartridge group back to horizontal position (described proce-
dure in reverse order, see Cleaning the cartridge group on the turbine
end [➙ 70]).
the specifications in the safety data sheet.
Revision D

Troubleshooting 6
Malfunctions when starting 6.1 Page 77
6 Troubleshooting
December 2016
6.1
6.1 Malfunctions when starting
Sluggish start-up
Possible causes Elimination

Turbo- Turbocharger contaminated Clean it
charger Damaged bearing Contact an ABB Turbocharging
Rubbing rotor Service Station
Foreign object in turbocharger
Vibrations

HZTL2485_EN
Turb- Rotor unbalance Contact an ABB Turbocharging

ocharger Damaged turbine or compressor Service Station
Damaged bearing
Rubbing of rotating parts
Normal behaviour, no malfunction

Turbo- Minor uniform wear around the periphery of rotor components,
charger caused by slight local rubbing of adjacent components, is permis-
sible. The compressor blades and turbine blades are then short-
ened somewhat. Certain tolerances must be observed to avoid a
significant loss of efficiency.
 If there is any doubt about the extent of rubbing, then an ABB
Turbocharging Service Station must be contacted.
 Have a dimension check carried out by an ABB Turbocharging
Service Station.
Revision D

Troubleshooting 6
Surging of the turbocharger 6.2 Page 78
6.2
6.2 Surging of the turbocharger
December 2016
Turbocharger surging

Engine Guard in front of the turbo- Clean / replace it
charger is contaminated or
damaged
Turbocharger Filter silencer or diffuser con- Clean it
taminated
Heavy deposits of dirt in the
turbine or nozzle ring
Charge air Cooler contaminated Clean it
cooler Charge air duct blocked
Prolonged or periodic surging
HZTL2485_EN
Possible damage to components, such as the compressor wheel, tur-
bine blades, bearings and filter silencer
CAUTION
 Have the cause clarified immediately by an ABB Turbocharging ser-
vice station and rectified.
 Have components inspected for damage and, if necessary, replaced
by an ABB Turbocharging service station.
Sporadic surge blows
Surging of the turbocharger can occur during certain operating conditions

such as when reducing the engine performance quickly when manoeu-
vring. At the same time, the flow direction in the compressor is momentari-
ly reversed. Such sporadic surge blows do not impair the safe operation of
the turbocharger.
 A surge blow is accompanied by a loud bang and escape of hot air

from the filter silencer.
Revision D

Troubleshooting 6
Malfunctions during operation 6.3 Page 79
6.3
6.3 Malfunctions during operation
December 2016
Lubricating oil pressure too low

Engine Oil filter heavily contaminated Clean it
Defective oil pump in lubricating Check / replace it
system
Manometer display wrong Replace the manometer
Turbo- Rotor axial clearance too large Contact an ABB Turbocharging
charger Service Station
Reduction in speed

Engine Defects of connected cylinders Contact the enginebuilder
HZTL2485_EN
when pulse charging

Turbo- Heavy contamination of the tur- Clean it
charger bine
Damaged rotor components or Contact an ABB Turbocharging
bearing Service Station
Pipes Defects such as leaks in the Make repairs
exhaust gas pipes or charge air
ducts
Increase in speed

Turbo- Heavily contaminated nozzle Contact an ABB Turbocharging
charger ring (with 4-stroke application) Service Station
Revision D

Troubleshooting 6
Exhaust gas temperature too high
Engine performance and engine speed unchanged
December 2016
Engine Malfunctioning injection Repair it or contact the manufac-
system turer
Turbocharger Air starvation, for example Clean it
filter silencer clogged with
dirt
Compressor / turbine
contaminated
Exhaust counterpressure too Clean or repair the boiler or ex-
high haust silencer
Damaged or eroded turbine Contact an ABB Turbocharging
Service Station
Charge air Cooler contaminated Clean it
cooler Cooling water volume too Top up the water
low
HZTL2485_EN
Entry temperature of cooling Inspect / clean the cooling sys-
water too high tem
Inadequate ventilation Improve the ventilation
Revision D

Troubleshooting 6
Charge air pressure too low
Engine performance and engine speed unchanged, air intake condition

December 2016
normal

Engine Air receiver leaking Make repairs
Gas piping between the engine
and the turbine leaking
Poorly adjusted injection system Correct it
Poorly adjusted valve control
Turbo- Manometer display wrong Replace the manometer
charger Line to manometer leaking Repair the leak
Contaminated filter silencer Clean it
causing excessive loss of pres-
sure
Compressor / turbine
contaminated
HZTL2485_EN
Damaged compressor / turbine Contact an ABB Turbocharging

Service Station
Exhaust counterpressure too Clean or repair the boiler or ex-
high haust silencer
Charge air pressure too high
Engine performance and engine speed unchanged, air intake condition

normal

Engine Malfunctioning injection system Repair it or contact the manufac-
turer
Poorly adjusted injection system Correct it
Engine performance higher than Check engine performance
expected
Revision D
Turbo- Manometer display wrong Replace the manometer

charger

Troubleshooting 6
Malfunctions when stopping 6.4 Page 82
6.4
6.4 Malfunctions when stopping
December 2016
Noises during run-down

Run-down time too short

HZTL2485_EN
Revision D

Troubleshooting 6
Speed measurement system 6.5 Page 83
6.5
6.5 Speed measurement system
December 2016

Signal Fitting error The screw plug for the sensor is fitted with a
amplitude non gasket.
existent or When fitting the speed sensor, this gasket
poor must be removed. If it is fitted by mistake,
the distance from the sensor tip to the sig-
nal-generating sealing disc increases. As a
result, the voltage amplitude of the speed
signal decreases, which can cause problems
for the evaluation electronics.
This problem is eliminated by removing the
gasket.
Defective sensor Contact ABB Turbocharging service station.
Measured Dirty sensor tip The sensor tip is magnetic and can thus at-
speeds too tract metal particles. As a result, the dis-
high tance to the auxiliary bearing decreases,
HZTL2485_EN
which can lead to amplification of the noise

component and consequently to faulty trig-
gering.
Remove the sensor, clean its tip and refit the
sensor using the specified tightening torque.
Measured -- Contact ABB Turbocharging service station.
speed too low
Other sources -- If none of the above measures eliminates
of errors the problem, we recommend that you have
the speed measuring system inspected by
an official ABB Turbocharging service sta-
tion.
Revision D

Removal and installation 7
Turbocharger weight 7.1 Page 85
7 Removal and installation

December 2016
7.1
7.1 Turbocharger weight
Lifting gear with a sufficient load limit must be used for removing and in-
stalling the turbocharger. The following weight specification is the heaviest
variant possible. This standard value may deviate from the data on the
rating plate depending on the specification.
Weight [kg]
TPL76-C
4070
HZTL2485_EN
Revision D

Removing the turbocharger 7.2 Page 86
7.2
7.2 Removing the turbocharger
December 2016
 A suitable suspension device (as illustrated) must be used when re-
moving and installing the turbocharger. The suspension device is not
supplied by ABB Turbo Systems.
 Disconnect all gas, air and oil lines in accordance with engine builder’s
instructions.
Oil orifice plates

An orifice plate for adjusting the oil pressure is fitted in each of the two
oil inlet channels in the bearing casing. When the cartridge group, the
CAUTION
bearing casing or the turbocharger is fitted to the engine, it must be en-
sured that the orifice plates that are specified for the turbocharger have
been installed in the two oil inlet channels.
 Check correct installation of oil orifice plates.
HZTL2485_EN
Suspension dimension Distance in [mm]

A 860
B 1210
Revision D
C 800
Use the two suspension lugs (L1, L2) on the bearing casing (observe the
marking on the insulation).
The two suspension lugs on the foot at the turbine end (T1, T2) serve to
align the turbocharger horizontally.
 Remove the insulation shell from the bearing casing and turbine-end
foot. Leave the remaining insulation on the turbocharger.

Removing the turbocharger 7.2 Page 87
Version with compressor wheel cooling system
 Dismantle the air supply line (also see the chapter entitled Preliminary
December 2016
remarks / Layout and functioning).
 Inspect the lifting gear.

 Fasten the lifting gear to the suspension lugs on the bearing casing
and on the turbine-end foot.
 Unplug the cable connector on the speed sensor.
 Unscrew the fixing screws on the feet.
 Lift the turbocharger off the engine and set it down to one side.
If support for the turbocharger is not provided or is inadequate, the tur-

bocharger could tip over during installation or removal and cause a se-
rious or even fatal injury.
WARNING
HZTL2485_EN
 Support the turbocharger at a suitable point.

 Cover the oil connection.
Revision D

Installing the turbocharger 7.3 Page 88
7.3
7.3 Installing the turbocharger
December 2016
 Remove the cover from the oil connection.
 Inspect the lifting gear.
 Fasten the lifting gear to the suspension lugs on the bearing casing
and the turbine-end foot.
Oil orifice plates

CAUTION
 Fit the turbocharger to the engine.

 Tighten the fixing screws on the foot.
HZTL2485_EN
The fastening specifications for the foot fixing screws are supplied to
the engine builder by ABB Turbo Systems and given in his manual.
NOTICE
 Fasten the gas, air and oil lines in accordance with the engine build-
er’s instructions.
 Fit the air supply line (also see the chapter entitled Preliminary re-
marks / Layout and functioning).
Revision D
 Plug in the cable connector on the speed sensor.

Disassembly and assembly 8
8 Disassembly and assembly

December 2016
8.1
8.1 Introduction
Further work
Further tasks, which are not described here, may be carried out only by
trained personnel from an ABB Turbocharging service station.
CAUTION
 Only carry out those tasks that are described in this chapter.
Marking casing positions for assembly

ABB Turbo Systems recommends that the casing positions are marked
before disassembling the turbocharger.
NOTICE
HZTL2485_EN
Identifying assembly devices
Not all assembly devices are marked with a part number. They can be
identified using the tool list. This list is enclosed in the toolbox.
Maintaining assembly devices

Assembly devices must be checked for damage before and after use.
WARNING  Visually check for corrosion, cracks, deformation and wear.
 Don't use damaged assembly devices, but replace them.
Customer spare parts set
Before beginning work, ensure that the required customer spare parts
sets are available.
Revision D
 See chapter Spare parts.

Tightening torques for turbocharger components
The specified tightening torques of screw connections for turbocharger
December 2016
components must be observed. (See section Table of tightening torques.)
Tightening torques for assembly devices of ABB Turbo Systems
If nothing else is described, the screws and nuts of the assembly devices
must be tightened down firmly.
Suspended loads
Loads not suspended in compliance with regulations may lead to per-
sonal injury or accidents with fatal consequences.
WARNING
 Attach turbochargers, assemblies or individual components only to
lifting gear which is in technically perfect condition and has sufficient
load capacity.
 Make sure the load is suspended properly on the crane hook.
HZTL2485_EN
 Do not let anyone stand beneath a suspended load.
Wear safety helmet.
Definition of terms
 Suspension point
Defined load carrying point on a component or an assembly (blind hole
thread, eye, lug).
 Assembly device
Devices mounted on the turbocharger to create a suspension point.
Assembly devices are calculated and designed especially for the de-
fined application. They are not commercially available products. Use
assembly / fitting devices only for the applications described.
Revision D
 Lifting gear
Equipment for lifting and transporting loads (ropes, chain hoists,
cranes). Lifting gear is not supplied by ABB Turbo Systems.

Module weights 8.2 Page 91
8.2
8.2 Module weights
December 2016
The specified weights of individual parts or assemblies are guides round-

ed off to the next highest value.
Assemblies
HZTL2485_EN
Weights [kg]
Item Description TPL76-C
1 Filter silencer 280
2 Axial air suction branch 70
3 Radial air suction branch 120
4 Compressor casing internal part 220
5 Wall insert 220
6 Diffuser 45
7 Compressor casing external part 310
8 Cartridge group 900
Revision D
9 Turbine diffuser 80
10 Nozzle ring 23
11 Radial gas inlet casing with segment connection 250
12 Segment 18
13 Radial gas inlet casing with flange connection 190

Module weights 8.2 Page 92
Complete compressor casing internal part
December 2016
Weight [kg]
TPL76-C
490
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.
NOTICE
HZTL2485_EN
Revision D

Removing and fitting filter silencer or air 8.3 Page 93

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

tion branch
December 2016
8.3
 Disconnect all air lines / ducts in accordance with engine builder’s in-
structions.
 Remove the insulation where necessary.
HZTL2485_EN
 Loop the lifting gear around the air suction branch.

 Unscrew the nuts (74027) and remove them together with their wash-
ers (74018).
 Remove the air suction branch and set it down to one side.
Installing the air suction  Install the air suction branch in reverse order.
branch
Revision D

Removing and fitting filter silencer or air 8.3 Page 94

suction branch
Removing filter silencer  Remove insulation where necessary.
December 2016
 Pass lifting gear through rib on filter silencer and through eyelets at
rear.
HZTL2485_EN
 Unscrew nuts (74027) and remove them together with washers
(74018).
 Remove filter silencer and it set down to one side.
Fitting the filter silencer  Fit filter silencer in reverse order.
Revision D

Axial clearance 8.4 Page 95
8.4
8.4 Axial clearance
December 2016
Physical hazards due to sharp edges on compressor wheel

The compressor wheel has sharp edges which can result in injury.
WARNING  Wear safety gloves.

HZTL2485_EN
The axial clearance (A) must be measured before removing and after in-
stalling the cartridge group.
 Measure and note the axial clearance (A).

Clearance A [mm]
TPL76-C
0.43 … 0.69
Clearances outside the tolerance

Revision D
Serious damage to engines or property can be caused by clearances

outside the tolerance and excessively worn parts.
CAUTION
 Have the components assessed and, if necessary, replaced by an
ABB Turbocharging Service Station.

Removing cartridge group 8.5 Page 96
8.5
8.5 Removing cartridge group
December 2016
Locked safety segments (76080) during disassembly
Observe the maximum tightening torque for the nuts (90458) so as not
to shear off the threaded studs of the safety segments (76080).
CAUTION
 Fit four nuts (74027) complete with washers (74018), equally spaced
around circumference, and tighten.
 Remove insulation (from bearing casing).
Removing safety segments / releasing casing
 Take nuts (90458) out of toolbox and screw them onto threaded studs
of safety segments (76080) on internal part of compressor casing
(76000).
HZTL2485_EN
 Tighten nuts (90458) to a maximum torque of 30 Nm.
The internal part of the compressor casing (76000) has now been sepa-
rated from the external part (74000) and can be removed.
Note the control dimension (u).
NOTICE
Revision D
Check dimension (u) [mm]

Dimension TPL76-C
u 21.8

Removing the compressor casing internal part

December 2016
HZTL2485_EN
 Remove two studs (74029 / 74026) at the point where the lifting device
(90190) will be fitted later.
 Using press-off screws (90900), push apart the compressor casing in-
ternal part (76000) until the lifting device (90190/90195) can be at-
tached.
 Slightly lift and then withdraw the compressor casing internal part in-
cluding the wall insert and diffuser.
 Attach the support angle (90025) using screws (90021) and nuts
Revision D
(74027).
 Put down the compressor casing internal part including the wall insert
and diffuser on the support angle and an underlay.
 Remove the O-ring (76040).

Transporting / turning internal part of compressor casing
December 2016
HZTL2485_EN
 Carefully turn internal part of compressor casing complete with wall in-
sert and diffuser about support angle (90025) and put onto underlay.
 Set down casing on flange (F).
 Set down internal part of compressor casing in such a way that lifting
device (90190/90195) can be removed.
Ensure that the shim does not slip.

 Rest the internal part of the compressor casing only on flange (F).
 Check shim and adjust as necessary.
WARNING
Revision D

Removing diffuser and wall insert

December 2016
HZTL2485_EN
 Remove screws (76002).

 Remove diffuser (79000) using swivel lifting eyes (90235).
 Press away wall insert (77000) using press-off screws (90230) and
remove from internal part of compressor casing (76000) using swivel
lifting eyes (90235).
Revision D

Removing external part of compressor casing
December 2016
HZTL2485_EN
 Fasten lifting device (90190/90195) to external part of compressor
casing (74000) using screws and secure to crane.
 Remove screws (42280).
 Uniformly press away external part of compressor casing (74000) us-
ing press-off screws (90900) and remove.
Insulation on external part of compressor casing

The insulation on the external part of the compressor casing does not
need to be taken off when removing or fitting the casing.
NOTICE
 Remove O-ring (42012).

Revision D

Removing the cartridge group

December 2016
HZTL2485_EN
 Unplug cable connector (86515) and unscrew speed sensor (86505)

with O-ring (86506).
 Disconnect oil inlet and oil outlet pipes.
Oil orifice plates

CAUTION
Revision D
 Remove air supply line. (See also chapter entitled Preliminary remarks /
Layout and functionality)

December 2016
HZTL2485_EN
* When pressing off, use diametrically opposite press-off threads. Other-
wise the bearing casing can jam and damage the turbine blades.
 Check lifting gear and attach to bearing casing (42001).

 Loosen nuts (61037) and remove Verbus Ripp® washers (61051).
 Screw guide rod (90490) onto threaded stud (X) to balance cartridge
group.
 Evenly press off cartridge group by screwing press-off screws (90900)
into the designated holes.
If the blades have insufficient or no clearance between the rotor and the
casing, the blades and the casing may be damaged.
 Check that the blades do not rub on the turbine diffuser by rotating
CAUTION the rotor.
Revision D
 Withdraw cartridge group.

 Remove screws (42064) together with flange (42044) and also remove
possible contamination behind the flange.
 Fit supports (90450) using screws (42280) and put down cartridge
group.
 Cover the oil connections.

Dismantling and installing the turbine 8.6 Page 103

diffuser and nozzle ring
8.6 Dismantling and installing the turbine diffuser

and nozzle ring
December 2016
8.6
Removing turbine diffuser

HZTL2485_EN
 Put assembly plate (90020) over strain bolts (61036).

 Insert extension (A) of torque spanner (B) through hole in assembly
plate and loosen screws (61056) one after other.
 Don't remove screws (61056) yet.
Revision D


December 2016
HZTL2485_EN
 Replace two screws (61056) with guide studs (90320).
 Fit assembly plate (90020) over studs (61036).
 Screw nuts (61037) onto start of threads of studs (61036) to secure.
 Remove remaining screws (61056).
 Press away turbine diffuser (63000) using press-off screws (90901)
and withdraw it until assembly plate (90020) touches nuts (61037).
 Loop lifting gear around turbine diffuser (63000) and secure to crane.
 Remove nuts (61037) and assembly plate (90020) from studs.
 Fully withdraw turbine diffuser and remove.
 Remove guide studs (90320).
Revision D


Removing the nozzle ring

December 2016
 Bend up the locking plates (56018), undo screws (56019) and remove.
 Pull out nozzle ring.
HZTL2485_EN
Fastening the nozzle ring

When fitting the nozzle ring, new screws (56019) and locking plates
(56018) from the customer spare part set (97070) must be used.
CAUTION
Clogged partial areas on the nozzle ring

If a nozzle ring is found to be clogged over partial areas or covered by
loose parts, it is recommended that you have a turbine blade inspection
CAUTION
including a crack inspection carried out by an ABB Turbocharging Ser-
vice Station.
Revision D


Fitting nozzle ring
December 2016
CAUTION
HZTL2485_EN
 Push in nozzle ring (56001) as far as it will go up to cover of gas inlet
casing.
 Coat thread of screws (56019) with high-temperature grease and fit
with locking plates (56018).
 Tighten screws (56019) and bend locking plates (56018) over.
Correct assembly
The nozzle ring must be easy to move after assembly.
CAUTION
Revision D


Fitting turbine diffuser

December 2016
Coat all screw threads on and in the gas casings with high-temperature
grease.
NOTICE
HZTL2485_EN
 Fasten turbine diffuser (63000) to lifting gear.

 Align marking "TOP" with position of gas outlet flange and pay atten-
tion to where positioning pin is in gas outlet casing.
 Fit turbine diffuser (63000) to guide studs (90320).
 Put assembly plate (90020) over strain bolts (61036) and guide studs
(90320).
 Remove lifting gear and push in turbine diffuser.
Revision D
 Using three screws (61056), alternately and uniformly screw in turbine

diffuser as far as it will go.
 Insert torque spanner extension through hole in assembly plate and
tighten screws (61056) one after other. (See illustration in section Re-
moving turbine diffuser.)

Installing cartridge group 8.7 Page 108
8.7
8.7 Installing cartridge group
December 2016
Oil orifice plates
CAUTION
HZTL2485_EN
 Remove cover from oil connection.

 Fit flange (42044) with new gasket (42045) and screws (42064).
 Check lifting gear and attach to bearing casing (42001) in such a way
Revision D
that cartridge group is suspended in a straight position.

 Screw guide rod (90490) onto threaded stud (X) to balance cartridge
group.
 Remove supports (90450) and carefully insert cartridge group.
 Fit three oiled nuts (61037) complete with new Verbus Ripp® washers
(61051) around circumference at 120° intervals.

 Tighten the three nuts (61037) evenly and alternately with pre-
tightening torque of (MV) (see chapter Table of tightening torques).
 Each time the three nuts (61037) are gradually tightened, check rotor
December 2016
by turning it. The blades must not touch other parts.
If the blades have insufficient or no clearance between the rotor and the
casing, the blades and the casing may be damaged.
CAUTION
 Fit the remaining oiled nuts (61037) complete with new Verbus Ripp®
washers (61051) and tighten with pre-tightening torque (MV) (see
chapter Table of tightening torques).
 Tighten all nuts (61037) in a star pattern with tightening angle (DW)
(see chapter Table of tightening torques)
 Remove the lifting gear.
 Remove guide rod (90490).
 Screw in the speed sensor (86505) together with the O-ring (86506)
HZTL2485_EN
and plug in the cable connector (86515).

 Reconnect oil and air lines.
 Fit the air supply line. (See also chapter entitled Preliminary remarks /
Layout and functionality)
Revision D

Fitting external part of compressor casing
December 2016
HZTL2485_EN
 Fasten lifting device (90190/90195) to external part (74000) of com-
pressor casing and secure it with crane.
 Fit O-ring (42012).
 Fit external part of compressor casing (74000) and fasten using
screws (42280).
 Remove lifting device (90190/90195).
Revision D

Fitting diffuser and wall insert

December 2016
HZTL2485_EN
 Screw swivel lifting eyes (90235) into holes in wall insert (77000).
 Align mark (A) with notch (B).
 Fit centering screws (90230) in such a way that spigots on centering
screws protrude maximum 5 mm.
 Lower wall insert and align centering screws (90230) with threaded
holes.
 Remove swivel lifting eyes (90235) and centering screws (90230).
 Put the diffuser (79000) in place using the swivel lifting eyes (90235).
 Remove the swivel lifting eyes (90235).
 Fit screws (76002).
Revision D

Turning / transporting internal part of compressor casing
December 2016
HZTL2485_EN
 Fasten lifting device (90190/90195) to front side of flange (F).
 Carefully turn internal part of compressor casing (76000) complete
with wall insert and diffuser about support angle (90025) and lift up
vertically.
Ensure that the shim does not slip.
WARNING
Revision D

Fitting compressor casing internal part

December 2016
HZTL2485_EN
* The two compressor casing parts are centred via the long cylindrical
flange. No guide pieces are needed.
 Check whether the nuts (90458) of the three safety segments have
been tightened (safety segments are in the "not engaged" position).
 Fit O-ring (76040).
 Remove the support angle (90025), screws (90021) and nuts (74027).
 Align the compressor casing internal part (76000) with the compressor
casing external part as shown in the illustration on the next page.
 Carefully insert the compressor casing internal part (76000) including
the wall insert and diffuser into the compressor casing external part
and then remove the lifting device (90190/90195).
Revision D

December 2016
HZTL2485_EN
Align the compressor casing internal part (76000) with the notch (see
the arrow) so that the notch is positioned at the rib of the compressor
casing external part (74000) (see the arrow).
NOTICE
Revision D
 Fully insert the compressor casing internal part (76000).

 Fit the studs (74026/74029).

Engaging safety elements / securing casing

December 2016
Locked safety segments (76080) during assembly

The safety segments (76080) are not in the operating position. Addi-
tional axial securing of the two compressor casings (74000/76000) is
CAUTION
not guaranteed.
 Fit four nuts (74027) complete with washers (74018), equally spaced
around circumference, and tighten.
 Unscrew nuts (90458) on threaded studs of safety segments (76080)

on internal part of compressor casing (76000).
The internal part of the compressor casing (76000) is now secure relative
to the external part (74000).
HZTL2485_EN
Note the control dimension (s). The safety segments (76080) are in the
operating condition again ("engaged").
NOTICE
Revision D
Check dimension (s) [mm]

Dimension TPL76-C
s 16.5
 Put nuts (90458) back into toolbox.

Measuring and checking axial clearance
December 2016
Risk of injury due to sharp edges on the compressor wheel
The compressor wheel has sharp edges which can cause injuries.
WARNING  Wear safety gloves.
HZTL2485_EN
 Measure and note axial clearance A.
Clearance A [mm]
TPL76-C
0.43 … 0.69
If the axial clearance (A) is out of tolerance, an official ABB Turbo Sys-
tems service station must be contacted.
Revision D
CAUTION
 Connect oil lines and all air lines in accordance with engine builder
specifications.
 Fit filter silencer or air suction branch and fasten with nuts (74027) and
washers (74018).
 Refit insulation if it was removed.

Dismantling and fitting nozzle ring at 8.8 Page 117

turbine end
8.8 Dismantling and fitting nozzle ring at turbine

end
December 2016
8.8
If only the nozzle ring has to be removed, this can be done at the tur-
bine end.
NOTICE
Clogged partial areas on the nozzle ring

If a nozzle ring is found to be clogged over partial areas or covered by
loose parts, it is recommended that you have a turbine blade inspection
CAUTION
including a crack inspection carried out by an ABB Turbocharging Ser-
vice Station.
HZTL2485_EN
If provided
 The fitted spiral-wound gasket (61050) may be used only once!
 Make ready a new spiral-wound gasket (61050).
Disassembly
 Remove insulation from gas inlet casing (51001) and disconnect

cleaning pipe (if provided).
 Secure gas inlet casing using lifting gear.
When looping the securing line around the casing, make sure that no
cleaning pipes are squashed or damaged. Do not fasten the lifting gear
Revision D
to cleaning pipes under any circumstances.

CAUTION
Mark positions of gas inlet casing and segments.
NOTICE


turbine end
December 2016
HZTL2485_EN
Segment connection  Remove screws (61044) and segments (51012).
Flange connection  Undo and remove screws (61044).
 Pull gas inlet casing (51001) complete with nozzle ring (56001) away
from gas outlet casing (61001).
Use suitable underlays when putting down gas inlet casing.
CAUTION
Revision D
1) If present  Remove gasket (61050).


turbine end
December 2016
 Bend up the locking plates (56018), undo screws (56019) and remove.
 Remove nozzle ring (56001).
Nozzle ring assembly
 Carefully clean grooves and contact surfaces of the casings and keep
them free of metal chips.
HZTL2485_EN
 Keep grooves and spiral-wound gasket free of oil and grease.

CAUTION
Revision D
 Push in nozzle ring (56001) as far as it will go up to cover of gas inlet

casing.


turbine end
 Coat thread of screws (56019) with high-temperature grease and fit

with locking plates (56018).
 Tighten screws (56019) and bend locking plates (56018) over.
December 2016
1) If present  Fix a new spiral-wound gasket (61050) in groove using a little instant
adhesive (for example "Loctite 454 Gel"), applied at three equally
spaced points.
 Position gas inlet casing complete with nozzle ring on gas outlet cas-
ing (61001).
Tightening of segment connection
Radial gas inlet casing with segment 51012
HZTL2485_EN
In the case of the radial inlet casing with segments, the segments are
positioned by a pin in the slot on the casing. The centering bolt (90177)
NOTICE
is always needed.
Revision D
 First place segment (51012) complete with roll pin on gas inlet casing,
fix it in correct radial position using centering bolt (90177) and then fit it
loosely using screws (61044).


turbine end
In only one of the three segments is there a roll pin as an aid when po-
sitioning the gas inlet casing. This segment fits in only one position in
the gas inlet casing (note the circle in the illustration). Consequently,
December 2016
begin with this segment.

NOTICE
 Put remaining segments (51012) in place on gas inlet casing (51001)

and fit them loosely using screws (61044).
 Replace centering bolts (90177) with screws (61044).
Check
HZTL2485_EN
 Collars (C) of segments (51012) must be in groove (S).

Revision D


turbine end
 Tighten screws (61044) in accordance with following procedure and in

following order:
December 2016
Segment connection
HZTL2485_EN
 Begin with two middle screws of individual segments and then contin-
ue outwards alternately.
Screw tightening sequence

The screw positioning numbers must be marked on the component.
This enables simple and efficient tightening.
NOTICE
Tightening torques for

Tightening TPL76-C
screws (61044) [Nm]
with spiral-wound gasket Step 1 Screw in all screws hand-tight
Step 2 140
Step 3 280
Revision D
Tightening TPL76-C
screws (61044) [Nm]
without spiral-wound gas- Step 1 Screw in all screws hand-tight
ket Step 3 280
Checking the tightening  Beginning with screw 1, tighten all screws in a clockwise direction with
torque tightening torque from step 3.
 Remove lifting gear from gas inlet casing (51001).
 Connect cleaning pipe (if present) and attach insulation to gas inlet
casing (51001).


turbine end
Tightening flange connection

December 2016
 Fit screws (61044).

 Tighten screws (61044) in accordance with following procedure and in
following order:
HZTL2485_EN
Flange connection
Revision D
 Tighten screws crosswise
Screw tightening sequence

The screw positioning numbers must be marked on the component.
This enables simple and efficient tightening.
NOTICE


turbine end

screws (61044) [Nm]
Tightening TPL76-C
with spiral-wound gasket Step 1 Screw in all screws hand-tight
December 2016
Step 2 140
Step 3 280
Tightening TPL76-C
screws (61044) [Nm]
without spiral-wound gas- Step 1 Screw in all screws hand-tight
ket Step 3 280
Checking the tightening  Beginning with screw 1, tighten all screws in a clockwise direction with
torque tightening torque from step 3.
 Remove lifting gear from gas inlet casing (51001).
 Connect cleaning pipe (if present) and attach insulation to gas inlet
casing (51001).
HZTL2485_EN
Revision D


turbine end
December 2016
HZTL2485_EN
Revision D

Table of tightening torques 8.9 Page 126
8.9
8.9 Table of tightening torques
December 2016
HZTL2485_EN
Figure 1
Key to table 1) Place new Verbus Ripp® washers onto strain bolts (7). New Verbus
Ripp® washers must be fitted every time the unit is assembled.
2) a) Tighten three nuts at 120° intervals to pre-tightening torque MV
(lightly oil contact surface of nut).
b) Tighten the remaining nuts with pre-tightening torque MV.
c) Tighten all nuts (in a star pattern) with tightening angle DW.
3) After putting a new Verbus Ripp® washer under each nut (8), tighten
with pre-tightening torque of MV 80 Nm, then mark the 0° point and
tighten (under tightening angle control) to a DW of 90°.
VR Verbus Ripp® Washer
MV Pre-tightening torque
Revision D
DW Tightening angle

Table of tightening torques 8.9 Page 127
Tightening torques [Nm]

Position Part number TPL76-C
1 82005 M16 x 1.5
December 2016
45
3 76002 M6
10
4 74027 M18
With washer 170
5 74026/74029 M18
40
6 42280 M18
280
7 61036 M18
61051 (VR) 1) 40
8 61037 2,3) M18
MV 80 / DW 90°
9 42059 M16
42064 105
HZTL2485_EN
17 61044 M18
280
21 61056 M18
280
22 56019 M8
25
29 86505 M18x1.5
150
Revision D

Taking out of operation at short notice 9
Possibilities for emergency repair 9.1 Page 129
9 Taking out of operation at short notice

December 2016
9.1
9.1 Possibilities for emergency repair
Danger of fire and explosion due to lubricating oil leaks

Leaking oil may ignite on hot surfaces. This can result in serious injuries
to personnel or fatal accidents.
WARNING
 Cordon off danger area.
 Raise the alarm and, depending on the situation, stop the engine.
 Seal the oil leak.
 Soak up oil and dispose of in an environmentally compatible manner.
Directives for taking out of operation

HZTL2485_EN
Serious damage to engine or property can be caused by non-

compliance with the directives for locking/blanking off the turbocharger
CAUTION
on the engine.
 Follow the directives of the enginebuilder.
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

 Fitting the cover plate
 Shutting off inlets and outlets
 Turbocharger bypass
Revision D

Locking the rotor 9.2 Page 130
9.2
9.2 Locking the rotor
December 2016
A locked rotor must be removed and checked for unbalance after the
turbocharger repair.
CAUTION
An exception is a test rig run up to a maximum of 25% of the engine

load in the case of new engines with one or several turbochargers. This
is sometimes requested by customers. As operation with a locked rotor
is only brief and the loads are low in these cases, subsequent removal
NOTICE
of the rotor is not necessary.
During operation of the engine with a blocked turbocharger, the lubricat-

ing oil system must remain connected to this turbocharger also and be
turned on if the gas inlet cannot be blocked. (See section Further
measures and information for operation with a blocked rotor for 4-stroke
CAUTION
engines.) Otherwise components that are still intact can be damaged
HZTL2485_EN
through overheating.
Shut off the oil supply in the event of lubricating oil leaking from the tur-
bocharger.
Revision D

Locking rotor
December 2016
HZTL2485_EN
Table of tightening
Part no. TPL76-C
torques
74027 M18
135 Nm
94006 M8
25 Nm
Carry out work as described in the chapter Disassembly and assembly.

Revision D
NOTICE
 Remove silencer or air suction branch.

 Insert lifting device (90427) into compressor wheel.
 Twist screws (94006) into free threaded holes in compressor wheel
and tighten to values shown in Table of tightening torques.

Don't remove any balancing screws from the compressor wheel. Use
only free threaded holes to fit the lifting device.
December 2016
CAUTION
 Put assembly/disassembly device (90020) over studs (74026) and lift-

ing device (90427).
 Turn compressor wheel until holes in lifting device (90427) align with
holes in assembly/disassembly device (90020).
 Fasten assembly/disassembly device to lifting device (90427) using
screws (94006).
 Secure assembly/disassembly device (90020) to compressor housing
by screwing nuts (74027) onto studs (74026). (See also chapter Table
of tightening torques.)
Fitted assembly plate CV
33, CV 34
HZTL2485_EN
Make sure all components are clean and free from grease.
CAUTION
Revision D

Further measures and information for operation with blocked rotor for
4-stroke engines
December 2016
4-stroke engine with one turbocharger
No further measures are necessary. The engine can be operated as a

naturally-aspirated engine according to the engine builder's instructions.
4-stroke engine with several turbochargers
Separate receivers No further measures are necessary on engines with separate air and ex-
haust gas receivers. The engine can be operated as a naturally-aspirated
engine according to the engine builder's instructions.
Common air receiver If the engine is equipped with a common air receiver and separate ex-
HZTL2485_EN
haust gas receivers, the bellows at the compressor outlet of the damaged
turbocharger must be removed and the air duct on the engine side must
be closed off. If this is not done, the undamaged turbocharger can race
under no load and run at overspeed.
Depending on the engine turbocharging system, more or less powerful

pulses from the exhaust gas system act on the locked rotor. The locking
device is then heavily stressed, particularly in the case of pulse charging
(turbine casing with more than one gas inlet). With this in mind, the follow-
ing operating limits should not be exceeded:
 In systems similar to those with constant pressure (1 gas inlet), the

engine can be operated up to a maximum of 25% engine load. The
pressure in the charge air receiver must not exceed 0.9 bar overpres-
sure.
 In the case of pulse charging (2...4 gas inlets), the engine can be op-
erated up to a maximum of 20% engine load. The pressure in the
charge air receiver must not exceed 0.5 bar overpressure.
Revision D
Attention must always be paid to the speed of the undamaged turbo-

charger. The speed limit nBmax given on the rating plate must not be ex-
ceeded.
CAUTION

Fit cover plate 9.3 Page 134
9.3
9.3 Fit cover plate
December 2016
The cover plate (material: General structural steel, in accordance with
DIN EN 10025-2) must be manufactured in-house according to the
drawing.
NOTICE
HZTL2485_EN
Cover plate dimensions
Product B1 B2 B3 B4 B5 B6 B7 B8
[mm]
TPL76-C 13 470 50 50 9 12 8 82
Product Ø1 Ø2 Ø3 Ø4 Ø5 Ø6
TPL76-C 915 990 950 20 28 20
Product ⍺1 ⍺2 ⍺3
Revision D
TPL76-C 4 x 90° 37.5° 24 x 15°


December 2016
HZTL2485_EN
Carry out the work as described in the chapter Removal and fitting.
NOTICE
 Remove cartridge group.

Revision D

December 2016
HZTL2485_EN
 Close off opening in gas outlet casing using cover plate.
 Fasten cover plate using spacer sleeves and nuts (61037).
Shut off the supply of lubricating oil to the turbocharger.
CAUTION Revision D

Further measures and information for operation with a turbocharger with

cover plate on 4-stroke engines
December 2016
4-stroke engine with one turbocharger
No further measures are necessary. The engine can be operated as a

naturally-aspirated engine according to the engine builder's instructions.
4-stroke engine with several turbochargers
Separate receivers No further measures are necessary on engines with separate air and ex-
haust gas receivers. The engine can be operated as a naturally-aspirated
engine according to the engine builder's instructions.
Common receiver The air line must be closed off at the engine end because the undamaged
turbochargers build up a receiver pressure.
HZTL2485_EN
The engine can be operated according to the engine builder's instruc-

tions. Attention must always be paid to the speed of the undamaged
turbocharger. The speed limit nBmax given on the rating plate must not
be exceeded.
CAUTION
Revision D

Blocking the inlets and outlets 9.4 Page 138
9.4
9.4 Blocking the inlets and outlets
December 2016
Shut off the lubricating oil supply to the turbocharger.
CAUTION
 Shut off compressor casing outlet, gas inlet and gas outlet by fitting
cover plates.
In this respect, refer to the engine manufacturer's instructions.
NOTICE
HZTL2485_EN
9.5
9.5 Bypass the turbocharger
Shut off the lubricating oil supply to the turbocharger.
CAUTION
 This applies to engines with one turbocharger only:

 The connections are ready and pipes for the bypass are available.
 Fit bypass around turbocharger.
In this respect, refer to the engine manufacturer's instructions.

Revision D
NOTICE

Mothballing the turbocharger 10
Taking out of operation for up to 12 10.1 Page 139

months
10 Mothballing the turbocharger

December 2016
10.1
10.1 Taking out of operation for up to 12 months
Condition of engine lubricating oil
The turbocharger normally remains mounted on the engine. Mothballing a

turbocharger depends on the condition of the lubricating oil:
 If the total acid number (TAN) is lower than 2 mg KOH/g, no measures

have to be taken.
 If the engine lubricating oil is replaced by preserving oil before taking
the engine out of operation and this is circulated by the prelubrication
pump, no measures have to be taken. Any remaining old engine oil will
thus be flushed away and the bearing sections largely protected
against corrosion.
Mothballing measures
HZTL2485_EN
If the total acid number (TAN) is greater than 2 mg KOH/g, the following
mothballing measures are necessary after taking an engine out of opera-
tion:
 Remove turbocharger.
 Rotor and bearing parts must be removed by an official ABB Turbo-
charging service station and refitted afterwards.
 Clean all parts.
 Oil machined, bright surfaces of steel and cast parts using anticorro-
sive oil.
 Reassemble complete turbocharger.
Rotor turns in stack draught
If the rotor turns as a result of the stack draught:

Revision D
 Install blind flange between compressor casing outlet flange and

charge air duct.

Mothballing the turbocharger 10
Taking out of operation for more than 10.2 Page 140

12 months
10.2 Taking out of operation for more than

12 months
December 2016
10.2
If the engine is taken out of service, the following can be done with the
turbocharger:
 The turbocharger remains mounted on the engine.

 The turbocharger casing remains mounted on the engine, but the rotor
and the bearing parts are removed and stored separately.
 The turbocharger is removed completely, either as a whole or in indi-
vidual parts.
See the section Taking out of operation for up to 12 months, under Moth-
balling measures, for the measures always necessary when mothballing
turbocharger parts.
HZTL2485_EN
If the turbocharger remains mounted on the engine, refer to the section
Taking out of operation for up to 12 months, under Rotating the rotor in
stack draught.
If the entire turbocharger is removed or if the turbocharger is re-

assembled next to the engine using the individual parts:
 Close all turbocharger openings using wooden covers and paraffin pa-
per.
Suitable storage locations are only dry rooms where the relative humidity
is between 40 to 70 % and no condensation can form.
Condition of the mothballed turbocharger

Revision D
 Check the mothballed turbocharger parts for corrosion every year.

 If there are signs of rust: Clean parts thoroughly and renew protection
against corrosion.

Disposing of turbocharger components 11
Taking out of operation for more than 10.2 Page 141

12 months
11 Disposing of turbocharger components

December 2016
Handling damaged thermal insulation

Damaged thermal insulation can lead to dust exposure. The glass fibres
can cause mechanical irritation of the eyes, skin, and respiratory tracts.
WARNING
 Avoid the formation of dust.
 Vacuum up dust with a suitable vacuum cleaner.
 Wear a respiratory mask to protect against dusts (P1 or P2 mask).
 Wear work gloves made of leather.

HZTL2485_EN
Disposal must be environmentally compatible, professional, and in com-

pliance with locally applicable regulations.
The turbocharger consists largely of metal (cast iron materials, steel,

nickel-steel alloys, aluminium and bearing brass).
Further components are: Non-metallic materials (filter components of felt

and polyethylene), lubricants (engine oil), electronic parts (speed sensor
and associated components), and thermal insulation.
 Dispose of metals as scrap metal for recycling.

 Dispose of non-metallic materials as waste.
 Dispose of residues of lubricants as waste oil.
 Dispose of electronic components as electronic waste.
 Dispose of thermal insulation as hazardous waste.
Revision D

Spare parts 12
Ordering spare parts 12.1 Page 143
12 Spare parts
December 2016
12.1
12.1 Ordering spare parts
When making inquiries or ordering spare parts, the following data must be
specified:
 Turbocharger type
 Serial number (HT……)
 Description and part number
Spare parts can be ordered from an official ABB Turbocharging Service

Station.
 If different design versions have not been taken into consideration in

this document, please contact an ABB Turbocharging Service Station.
Storage of spare parts

HZTL2485_EN
All spare parts ordered with the turbocharger must be kept complete
and ready for use.
CAUTION
 Parts showing signs of rust should be carefully cleaned and greased.
 Dispose of replaced and unusable parts in a professional and envi-

ronmentally compatible way.
Revision D

Spare parts 12
Required customer spare part set (97070)
For the operations described in the Operation Manual, the customer spare
December 2016
part set (97070) is required. These parts are available only as a complete
set.
Quantity Description Part number

1 O-ring 42012
1 Gasket 42041
2 Gasket 42045
2 Hexagon-head screw 42059, 42064
3 Locking plate 56018
3 Hexagon-head screw 56019
3 Stud 56021
3 Hexagon nut 56022
3 Hexagon nut 61037
12 Hexagon-head screw 61044, 61056
17 Verbus Ripp® washer 61051
HZTL2485_EN
3 Socket screw 76002
1 O-ring 76040
1 O-ring 77005
1 O-ring 86506
Revision D

Spare parts 12

December 2016
HZTL2485_EN
Revision D

Spare parts 12
View of turbocharger with part numbers 12.2 Page 146
12.2
12.2 View of turbocharger with part numbers
December 2016
HZTL2485_EN
Revision D

Spare parts 12
View of turbocharger with part numbers 12.2 Page 147
Part number Description

- Cartridge group
December 2016
42012 (in customer spare part set) O-ring

51001 Gas inlet casing
51012 Segment
56001 Nozzle ring
56018 (in customer spare part set) Locking plate
56019 (in customer spare part set) Hexagon-head screw
61001 Gas outlet casing
61037 (in customer spare part set) Hexagon nut
61050 (in customer spare part set) Gasket
61051 (in customer spare part set) Verbus Ripp® Washer
61065 Gasket
61066 Blind flange
HZTL2485_EN
61067 Hexagon-head screw

63000 Turbine diffuser
68001 Foot at compressor end
68002 Foot at turbine end
68006 Cup spring
68007 Bush
61079 Gasket
74000 Compressor casing external part
76000 Compressor casing internal part
76002 (in customer spare part set) Socket screw
76080 Safety segments
77000 Wall insert
Revision D
79000 Diffuser
81000 Filter silencer
82000 Radial air suction branch

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

HT 566195

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Operation Manual

ABB Turbo Systems Ltd

Type TPL76-C35 HT566195

ABB Turbocharging 

Table of contents Page 1

3.3 Commissioning after taking out of operation

© Copyright 2016 ABB. All rights reserved.

Table of contents Page 2

7 Removal and installation

8 Disassembly and assembly

9 Taking out of operation at short notice

10 Mothballing the turbocharger

© Copyright 2016 ABB. All rights reserved.

Table of contents Page 3

10.1 Taking out of operation for up to 12 months

11 Disposing of turbocharger components

© Copyright 2016 ABB. All rights reserved.

Purpose of this manual 1.1 Page 5

It provides important information in order that the turbocharger can be op-

This Operation Manual complements and expands existing national regu-

This Operation Manual is intended for engineers and qualified mechanics

Availability of operation manual

© Copyright 2016 ABB. All rights reserved.

Layout and function 1.2 Page 6

© Copyright 2016 ABB. All rights reserved.

Layout and function 1.2 Page 7

The turbocharger is a turbomachine and consists of the following main

These are both mounted on a common shaft.

Turbocharger version with compressor wheel cooling system

Depending on its range of use, the turbocharger is provid-

ed with a compressor wheel cooling system. Compressor

© Copyright 2016 ABB. All rights reserved.

Intended use 1.3 Page 8

ABB turbochargers are intended for turbocharging internal combustion

To ensure compliance with the machinery directive 2006/42/EC when us-

The turbocharger is solely intended to be operated with a clockwise direc-

The specific operating limits of the turbocharger were determined on the

[1] Euromot = The European Association of Internal Combustion Engine Man-

© Copyright 2016 ABB. All rights reserved.

State of the art

and is safe to operate.

The turbocharger must only be used when it is in a technically flawless

ABB Turbo Systems recommends subjecting the turbocharger to a visual

© Copyright 2016 ABB. All rights reserved.

Storage of new turbochargers and 1.5 Page 10

1.5 Storage of new turbochargers and spare

Storage of new turbochargers and spare parts up to 6 months

Volatile Corrosion Inhibitor (VCI)

Wear safety gloves to protect against chemical hazards.

The following mothballing measures are required every 6 months:

 Open the package.

© Copyright 2016 ABB. All rights reserved.

Storage of new turbochargers and 1.5 Page 11

Long-term storage of replacement turbochargers or spare parts

Per order, turbochargers or cartridge groups will be prepared by ABB Tur-

bo Systems for prolonged storage. The package is equipped with a

The following measures are required every 6 months:

 Check the hygrometer (02) in the sight-glass. There is an opening (01)

After every 3 years the following work steps must be performed by an

ABB Turbocharging