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					                                                                        Turbocharging




                   Operation Manual

                           TPL73-B11

                                        ABB Turbo Systems Ltd
                                        CH 5401 Baden

                    Type   TPL73-B11          HT472446
                    n Mmax 340                t   Mmax   550
                                       1/s                              °C
                    n Bmax 323                t   Bmax   520


                                  2275 kg      35         100       100
                                             Application according to
                    Year   2006              the Operation Manual
                                   made in Switzerland
HZTL2480 English




ABB Turbo Systems Ltd
Operating condition and replacement intervals

The operational limits for the turbocharger nBmax, tBmax, nMmax, tMmax, inspection- and replacement intervals for the compon-
ents concerned on the rating plate are valid for the operational mode and compressor inlet condition, which has been agreed upon
between the engine builder and ABB.



Note:        Replacement intervals of components depends on the load profile, turbine inlet temperature, suction air temperature and
             turbocharger speed. In case the operation conditions differs significantly from what is considered to be normal for the cur-
             rent application, it is recommended to contact ABB for a re-calculation of replacement intervals. Frequent load alterations,
             high temperatures and high speed lower the life of components.
             Unless otherwise agreed, the application limits nMmax, tMmax are valid for the test operation for a limited time.




We herewith confirm that this Operation Manual has been drawn up orientated towards the Product Liability Law 1/1/90 as well as to
the „European Machinery Directives“.

We reserve all rights in this document and in the information contained herein.
Reproduction, use or disclosure to third parties without express authority by ABB Turbo Systems Ltd is strictly forbidden.

© Copyright by ABB TURBO SYSTEMS Ltd 2004
Design and specifications are subject to change without notice.


Printed on naturally white paper, bleached free from chlorine and environmentally acceptable.
The CD is made of polycarbonate and contains in addition aluminium, lacquer, dye stuffs and materials of the adhesive label. The CD-cover is made of
recycled cardboard.
These materials may be disposed with the domestic wastes or at a specialised collecting centre.




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




                                                           List of contents                                                  Page 1




                                                  List of contents
January 2006




                                                  1          Preliminary remarks
                                                  1.1        Purpose of the manual
                                                  1.2        Layout and function
                                                  1.3        Correct use of the turbocharger
                                                  1.4        Essential information
                                                  1.5        Abbreviations and symbols
                                                  1.6        Turbocharger rating plate

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




                                                  2.1        Basic safety instructions
                                                  2.2        General safety instructions
                                                  2.3        Special safety instructions
                                                  2.4        Safety instructions and hazard protection
                                                  2.5        Warnings on the turbocharger

                                                  3          Commissioning
                                                  3.1        Oil supply
                                                  3.2        Inspection work
                                                  3.3        Putting into operation after laying up

                                                  4          Operation
                                                  4.1        Servicing work
                                                  4.2        Monitoring
                                                  4.3        Operation without emergency oil supply
                                                  4.4        Surging of turbocharger
                                                  4.5        Contact with rotating parts
Version 2.1




                                                  4.6        Shutting the engine down

                                                  5          Maintenance
                                                  5.1        Foreword to Maintenance
                                                  5.2        Cleaning the filter silencer
                                                  5.3        Cleaning the compressor during operation
                                                  5.4        Cleaning turbine blades and nozzle ring in operation
                                                  5.5        Suppliers of materials for dry cleaning


                                   ABB Turbo Systems Ltd                                                                       ABB
                                                                                   Operation Manual




                        List of contents                                                    Page 2



               6          Troubleshooting
               6.1        Possible remedies for failures




                                                                                                      January 2006
               7          Removal and installation
               7.1        Turbocharger weights
               7.2        Remove the turbocharger
               7.3        Installing the turbocharger

               8          Disassembly and assembly
               8.1        Module weights
               8.2        Removing and fitting the filter silencer or air suction branch
               8.3        Axial clearance
               8.4        Removing cartridge group
               8.5        Inspection and assessment of the valve block




                                                                                                      HZTL2480_EN (TPL73-B.. - 85-B..)
               8.6        Dismantling and installing the turbine diffuser and nozzle ring
               8.7        Installing the cartridge group
               8.8        Turbine-end removal / fitting of the nozzle ring
               8.9        Table of tightening torques

               9          Taking out of operation temporarily
               9.1        Possibilities for emergency repair
               9.2        Locking the rotor
               9.3        Fitting the 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

               11         Reserve and spare parts
                                                                                                      Version 2.1




               11.1       Ordering spare parts
               11.2       Directory of part numbers
               11.3       General view of turbocharger
               11.4       General view of cartridge group




ABB Turbo Systems Ltd                                                                         ABB
                                                                                                                          Operation Manual
                                                               Preliminary remarks                          1


                                                               Purpose of the manual                        1.1                      Page 1




                                                              1 Preliminary remarks
                                                        1.1 Purpose of the manual
January 2006




                                   Operation manual            This operation manual will help you to become familiar with your ABB
                                                               Turbo Systems Ltd turbocharger and to use it to full effect in its intended
                                                               application. You will find important instructions as to the safe, correct, and
                                                               economical operation of the turbocharger.

                                   Target group                The content of this operation manual is intended for persons such as en-
                                                               gineers, marine mechanics and service technicians who are responsible
                                                               for the running of the engine and the turbocharger installed thereon.

                                   Content of operation ma-    This operation manual includes helpful information on the following topics:
                                   nual
                                                                  Information on the operation of the turbocharger and ways to prolong
                                                                  the turbocharger's service life.
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                                  Early awareness and avoidance of hazards.
                                                                  Minimising repair costs and failure times.

                                                               This operation manual is a complement to, and an extension of, existing
                                                               national regulations on accident protection and prevention.


                                                                An operation manual must be available at all times at the site where the
                                                                turbocharger is used. It is essential that this operation manual is read
                                                                before beginning work by all persons working with or on the turbo-
                                              NOTE              charger. Personnel who only work occasionally on the machine (e.g.
                                                                during installation and maintenance) must also have read and fully un-
                                                                derstood the operating manual before beginning work.


                                                               The instructions included in this operation manual must be followed under
                                                               all circumstances.


                                                                This applies especially to the general and special safety instructions
                                                                preceding and in the respective chapters. Ignoring hazards and the sa-
                                                                fety instructions can lead to serious personal injury and damage to e-
Version 2.1




                                            WARNING             quipment.


                                                               In the event of doubt, consult the officer for safety and accident protection
                                                               responsible for your area.




                                   ABB Turbo Systems Ltd                                                                               ABB
                                                                                 Operation Manual
                        Preliminary remarks                     1


                        Layout and function                     1.2                       Page 2



               1.2 Layout and function




                                                                                                    January 2006
                                                                                                    HZTL2480_EN (TPL73-B.. - 85-B..)
                        00000_001


                        1           Filter silencer        8          Nozzle ring
                        2           Radial plain bearing   9          Turbine wheel
                        3           Thrust bearing         10         Bearing casing
                        4           Bearing bush           11         Diffuser
                        5           Radial plain bearing   12         Compressor wheel
                        6           Gas outlet casing      13         Air outlet casing
                                                                                                    Version 2.1




                        7           Gas inlet casing




ABB Turbo Systems Ltd                                                                       ABB
                                                                                                                       Operation Manual
                                                           Preliminary remarks                          1


                                                           Layout and function                          1.2                       Page 3




                                                           Mode of operation
January 2006




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

                                                              Turbine
                                                              Compressor

                                                           These are both mounted on a common shaft.



                                                           The exhaust gases from the diesel engine flow through the gas inlet cas-
                                                           ing (7) and nozzle ring (8) to the turbine wheel.

                                                           The turbine wheel (9) uses the energy contained in the exhaust gas to
                                                           drive the compressor wheel (12), whereby the compressor draws in fresh
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                           air, and the compressed air is forced into the cylinders.

                                                           The exhaust gases escape through the exhaust pipe which is connected
                                                           to the gas outlet casing (6).

                                                           The air which is necessary for the operation of the diesel engine and
                                                           which is compressed in the turbocharger is drawn through the suction
                                                           branch or the filter silencer (1) into the compressor wheel (12). It then
                                                           passes through the diffuser (11) and leaves the turbocharger through the
                                                           compressor outlet on the air outlet casing (13).

                                                           The rotor runs in two radial plain bearings (2/5) which are located in the
                                                           bearing bush (4) between the compressor and the turbine. The axial thrust
                                                           bearing (3) is on the compressor side.

                                                           The plain bearings are connected to a central lubricating oil feed which is
                                                           supplied by the oil lubrication circuit of the engine. The oil outlet is always
                                                           at the lowest point of the bearing casing (10).

                                                           The turbocharger is equipped with an emergency lubrication oil tank. With
                                                           a failure of the lubrication oil system, the bearings are supplied with oil
                                                           with this emergency lubrication until the rotor comes to a standstill.
Version 2.1




                                   ABB Turbo Systems Ltd                                                                             ABB
                                                                                  Operation Manual
                        Preliminary remarks                         1


                        Correct use of the turbocharger             1.3                      Page 4



                    1.3 Correct use of the turbocharger




                                                                                                       January 2006
                         This turbocharger supplied by ABB Turbo Systems has been developed
                         for use on diesel engines to generate the volume of air and the charg-
                         ing pressure required to operate the engine.
            NOTE         The engine manufacturer has provided ABB Turbo Systems with infor-
                         mation regarding the intended purpose of the engine, from which the
                         operating parameters specific to the turbocharger (such as rotating
                         speeds, temperatures, replacement periods / exchange intervals) have
                         been derived and are indicated on the rating plate.
                         Any other usage shall be regarded as a special application which must
                         be discussed with ABB Turbo Systems. The manufacturer accepts no
                         liability for other applications. If it is used otherwise, ABB Turbo Sys-
                         tems reserves the right to reject all claims under the warranty.




                                                                                                       HZTL2480_EN (TPL73-B.. - 85-B..)
Latest technology       This turbocharger was built according to state-of-the-art technology and is
                        operationally safe according to prevailing safety regulations.


                         Improper operation and maintenance of the turbocharger can result in
                         danger to life and limb of the user or third parties. In addition, improper
                         use may cause damage to the machine. The machine may only be ope-
         WARNING         rated by trained personnel.


                        Correct use of the turbocharger also includes observation of the assem-
                        bly, disassembly, operating, maintenance and repair conditions specified
                        by the manufacturer. Regulations set out by local authorities must be ob-
                        served when disposing of the turbine.

Perfect condition       The turbocharger must only be installed in a technically perfect condition,
                        corresponding to its intended purpose and following the instructions in the
                        Engine Manufacturers' Manual, and must be operated and used in com-
                        pliance with the Operation Manual.
                                                                                                       Version 2.1




                          Defects which could affect safety must be eliminated immediately.

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




ABB Turbo Systems Ltd                                                                          ABB
                                                                                                                    Operation Manual
                                                           Preliminary remarks                        1


                                                           Essential information                      1.4                     Page 5



                                                  1.4 Essential information
January 2006




                                                           Organisational measures

                                                           In addition to this manual, the general, statutory regulations applicable in
                                                           the respective country for the prevention of accidents and the protection of
                                                           the environment must be observed.

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


                                                            The safety and risk consciousness of the personnel working on and
                                                            with the turbocharger must be checked regularly with reference to this
                                                            manual.
                                           NOTE
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                             The turbocharger must be shut down immediately in the event of al-
                                                             terations affecting safety or of corresponding operating behaviour. The
                                                             fault should be reported to the person or department responsible.


                                                            Additions and alterations to, and conversions of the turbocharger that
                                                            could compromise safety require the prior approval of ABB Turbo Sys-
                                                            tems.
                                           NOTE
Version 2.1




                                   ABB Turbo Systems Ltd                                                                         ABB
                                                                                 Operation Manual
                        Preliminary remarks                        1


                        Essential information                      1.4                     Page 6




                        Original parts and safety




                                                                                                      January 2006
                        Original parts and accessories are especially designed for the turbo-
                        charger supplied by ABB Turbo Systems Ltd.


                         We herewith expressly state that parts and accessories not supplied by
                         us have also not been tested and approved by us.

        NOTE



                         If components and assemblies not manufactured and tested by ABB
                         Turbo Systems are used, this may have a negative effect on the techni-
                         cal design specifications of the turbocharger.
      WARNING            Moreover, the active and/or passive safety of the turbocharger may be




                                                                                                      HZTL2480_EN (TPL73-B.. - 85-B..)
                         compromised by the use of non-original parts. Note that such improper
                         use may endanger personnel and the machine.


                        ABB Turbo Systems shall not be liable for any damage caused by using
                        non-original parts and accessories.


                        Qualification of personnel

                        The turbocharger must only be operated and maintained by trained and
                        authorised personnel.


                         Work on mechanical components, such as bearings or rotors, must only
                         be performed by qualified fitters from an official service station of ABB
                         Turbo Systems Ltd.!
       CAUTION


                        It must be ensured that only authorised personnel work on the turbo-
                                                                                                      Version 2.1




                        charger.




ABB Turbo Systems Ltd                                                                           ABB
                                                                                                                    Operation Manual
                                                           Preliminary remarks                        1


                                                           Essential information                      1.4                     Page 7




                                                           After-sales service
January 2006




                                                           The Contact Information brochure contains an overview of official ABB
                                                           Turbo Systems Ltd. service stations worldwide.


                                                           Design variants

                                                           This operating manual is valid for various turbocharger design variants.

                                                           This means that some sections and component descriptions in this oper-
                                                           ating manual do not apply to your turbocharger.

                                                           Our service stations and agencies will gladly answer your questions relat-
                                                           ing specifically to your model.
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                           Accuracy of illustrations

                                                           The graphics and images shown in this operation manual are of a general
                                                           nature and are intended to assist understanding of the work steps and in-
                                                           structions. Differences may exist in certain details.
Version 2.1




                                   ABB Turbo Systems Ltd                                                                        ABB
                                                                                Operation Manual
                        Preliminary remarks                       1


                        Essential information                     1.4                     Page 8




                        Storage of new turbochargers




                                                                                                   January 2006
                        New turbochargers supplied by ABB Turbo Systems Ltd. can be stored
                        without additional safeguarding measures for a period of 6 months after
                        the delivery date.

                        Ensure that the storage area is dry with humidity of 40-70% and free of
                        condensation.

                          After 6 months, rust-proofing oil should be sprayed on exposed sur-
                          faces and all accessible areas of the turbocharger.
                          To do this, the insulating materials must be removed.


                         Repeat the steps described for rust-proofing your turbocharger every 6
                         months.




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




                                                                                                   Version 2.1




ABB Turbo Systems Ltd                                                                        ABB
                                                                                                                    Operation Manual
                                                           Preliminary remarks                        1


                                                           Abbreviations and symbols                  1.5                    Page 9



                                                  1.5 Abbreviations and symbols
                                                           The following abbreviations are used in this document:
January 2006




                                                             Prerequisite
                                                             Work step

                                                             Result

                                                             Positive Checkpoint (activity that must be carried out without fail)
                                                             Negative Checkpoint (activity that must not be carried out under any
                                                             circumstances)




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




                                                           The following symbol is used for notes in this manual:


                                                            This note provides suggestions and tips to make work on the turbo-
                                                            charger easier.
                                                            The note provides further essential information.
                                           NOTE




                                                           ABB Turbo Systems

                                                           The term used in this manual ABB Turbo Systems signifies ABB Turbo
                                                           Systems Ltd.


                                                           Official ABB Turbo Systems service station

                                                           The term used in this manual Official ABB Turbo Systems service station
Version 2.1




                                                           signifies ABB Turbocharger service stations, that have been tested and
                                                           certified by ABB Turbo Systems Ltd.




                                   ABB Turbo Systems Ltd                                                                         ABB
                                                                                    Operation Manual
                             Preliminary remarks                      1


                             Turbocharger rating plate                1.6                    Page 10



                      1.6 Turbocharger rating plate




                                                                                                       January 2006
                                                                                                       HZTL2480_EN (TPL73-B.. - 85-B..)
                             L_00012




Operational limits                1    Turbocharger operational limits at engine overload (110 %).
                                       In test rig operation only, unless otherwise agreed with the
                                       engine manufacturer.
                                  2    Turbocharger operational limits in service.



Recommended replace-              3    Replacement interval for the plain bearings in 1000 h
                                                                                                       Version 2.1




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




ABB Turbo Systems Ltd                                                                            ABB
                                                                                                                          Operation Manual
                                                                Preliminary remarks                         1


                                                                Turbocharger rating plate                   1.6                    Page 11



                                   Additional specifications:        6     Customer part number
                                                                     7     Field for special design designation
                                                                     8     Weight of the turbocharger in kg
January 2006




                                                                     9     CE = Conformité Européenne
                                                                     10    Turbocharger type
                                                                     11    Series number
                                                                     12    Year of construction of the turbocharger




                                                                Explanations of the rating plate

                                                                The recommended exchange intervals and the corresponding operation
                                                                limits are defined together with the engine builder. These specifications
                                                                are system-specific.
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                                 Continuous running above the indicated nBmax, tBmax values may consid-
                                                                 erably reduce the recommended exchange intervals. In such cases, we
                                                                 recommend you contact the nearest official service station of ABB
                                             CAUTION             Turbo Systems Ltd.
                                                                 nMmax , tMmax normally apply only when running at overload (110%) dur-
                                                                 ing trials on the engine test bed. These limits may also be permitted in
                                                                 service for special applications. The operation over nMmax , tMmax is not
                                                                 permitted.
                                                                 Non-compliance with the recommended exchange intervals may in-
                                                                 crease the risk of unpredictable component failure.
Version 2.1




                                   ABB Turbo Systems Ltd                                                                               ABB
BLANK
                                                                                                                    Operation Manual
                                                           Safety                                     2


                                                           Basic safety instructions                  2.1                     Page 1




                                                     2 Safety
                                                    2.1 Basic safety instructions
January 2006




                                                           The following symbols and terms are used for the safety instructions in
                                                           this manual:


                                                            Failure to follow work steps and operating instructions marked with this
                                                            symbol completely and rigorously may result in serious personal injury
                                                            or even fatal accidents.
                                         WARNING            Warning signs must be strictly observed at all times.




                                                            Serious damage to the machine or to other property may result if the
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                            working and operation instructions marked with this symbol are not, or
                                                            only partly, observed.
                                          CAUTION           Caution signs must be strictly observed at all times.
Version 2.1




                                   ABB Turbo Systems Ltd                                                                        ABB
                                                                                  Operation Manual
                        Safety                                      2


                        General safety instructions                 2.2                      Page 2



                2.2 General safety instructions
                        The instructions listed here are designed to ensure your safety and to




                                                                                                        January 2006
                        promote safe handling of the turbocharger and its associated operating
                        materials.


                         The following safety instructions must be followed when operating and
                         when working on the turbocharger.

      WARNING

                          Do not work on the turbocharger if you are under physical or mental
                          stress.
                          Wear protective clothing at all times.
                          ­ Helmet
                          ­ Ear protection




                                                                                                        HZTL2480_EN (TPL73-B.. - 85-B..)
                          ­ Protective glasses
                          ­ Protective suit
                          ­ Oil and petrol resistant gloves
                          ­ Protective shoes
                          Attach individual parts and larger component modules carefully to suit-
                          able hoists/lifting devices which are in technically perfect condition and
                          which have adequate load-bearing capacity.
                          Do not stand under suspended loads.
                          If welding work is to be carried out above the turbocharger, the air filter
                          must be covered to prevent damage to the filter mat.
                          When working on the turbocharger, be aware of the risk of it falling.
                          For overhead assembly work, use the steps and platforms provided for
                          this purpose.

                                                                                                        Version 2.1




ABB Turbo Systems Ltd                                                                          ABB
                                                                                                                     Operation Manual
                                                           Safety                                      2


                                                           Special safety instructions                 2.3                      Page 3



                                                   2.3 Special safety instructions
January 2006




                                                           Safety when connecting

                                                              Work only on those connections for which you are qualified.


                                                           Safety when commissioning and during operation

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




                                                              once a day for visible damage and defects.
                                                              Report any damage or changes in operational performance to the per-
                                                              son/department responsible immediately.
                                                              In the event of damage, shut down the turbocharger immediately and
                                                              secure it against inadvertent or unauthorized use.


                                                           Safety when cleaning

                                                           When handling detergents, solvents, acids and alkalis be sure to observe
                                                           the respective safety directions on the manufacturers' labels.

                                                           Follow directions regarding the environmentally compatible collection, sto-
                                                           rage and disposal of these liquids.


                                                            Explosion hazard
                                                            Cleaning work should be carried out outdoors due to explosion hazard.
                                                            If this is not possible, ensure that there is adequate ventilation and air
                                         WARNING            circulation. Before beginning cleaning work in confined spaces, extin-
                                                            guish naked flames (including cigarettes!) due to the risk of explosion.
Version 2.1




                                   ABB Turbo Systems Ltd                                                                          ABB
                                                                                   Operation Manual
                        Safety                                      2


                        Special safety instructions                 2.3                      Page 4




                           Before cleaning, protect the floor against unintended leaks of oil and
                           operation materials.




                                                                                                      January 2006
                           You must wear protective clothing (see section General safety instruc-
                           tions).
                           Handle operation materials and detergents with utmost caution.
                           When handling solvents, wear protective clothing and observe the fol-
                           lowing rules:
                           ­ Avoid skin contact with solvents.
                           ­ Avoid inhaling vapours under all circumstances.
                           ­ Do not allow solvents to soak protective clothing.
                           After cleaning, check electric cables for signs of wear or damage.


                        Safety during disassembly, assembly, maintenance and troubleshooting

                           Follow the prescribed maintenance and inspection schedules for all ad-




                                                                                                      HZTL2480_EN (TPL73-B.. - 85-B..)
                           justment, maintenance and inspection work.
                           Inform operating personnel about special work and repairs before start-
                           ing.
                           Ensure that absorbent materials are available to clean up any opera-
                           tion materials that escape accidentally.
                           Ensure safe and environmentally-friendly drainage, collection and dis-
                           posal of operating and auxiliary materials.
                           Before opening a cover or removing a protective component on the
                           turbocharger, the engine must have been switched off and must not be
                           started up again until all parts have been properly re-assembled.


                         Assembly and disassembly work must only be performed by trained
                         personnel. Work on mechanical components, such as bearings or ro-
                         tors, must only be performed by qualified fitters from an official service
       CAUTION           station of ABB Turbo Systems.                                                Version 2.1




ABB Turbo Systems Ltd                                                                           ABB
                                                                                                                    Operation Manual
                                                           Safety                                     2


                                                           Special safety instructions                2.3                    Page 5




                                                           Safety when taking out of operation or putting into storage
January 2006




                                                              Secure the rotor against turning.
                                                              Clean the turbocharger before mothballing.
                                                              Wear protective clothing when mothballing the turbocharger.
                                                              Keep the work area clean and free of oil and operating materials.
                                                              Remove any obstacles lying around on the floor.
HZTL2480_EN (TPL73-B.. - 85-B..)
Version 2.1




                                   ABB Turbo Systems Ltd                                                                          ABB
                                                                                 Operation Manual
                        Safety                                     2


                        Safety instructions and hazard             2.4                     Page 6
                        protection


                   2.4 Safety instructions and hazard protection
                        Associated hazards may arise during operation of and work on the turbo-




                                                                                                      January 2006
                        charger:

                          from the turbocharger and its accessories.
                          from the operating materials used.
                          due to failure to comply with the safety instructions.
                          from inadequate performance of maintenance and inspection work.


                        Mechanical influences



                         Mechanical influences can cause serious injury or even fatal injury.




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




Personal injury         Unconsciousness and injury due to:

                          crushing
                          shearing
                          cutting
                          winding
                          smashing
                          drawing in
                          knocking
                          stabbing
                          rubbing
                          Escape of liquids under high pressure and / or at high temperature
                          slipping
                          tripping
                          falling
                                                                                                      Version 2.1




ABB Turbo Systems Ltd                                                                           ABB
                                                                                                                    Operation Manual
                                                           Safety                                     2


                                                           Safety instructions and hazard             2.4                      Page 7
                                                           protection


                                   Causes                    sharp edges, pointed parts
                                                             crush, shear and winding areas
                                                             fragmentation / ejection of parts
January 2006




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

                                   Protective measures       Wear leather protective gloves
                                                             Wear close-fitting protective clothing
                                                             Tie up long hair and beards (wear hair protection)
                                                             Wear face and eye protection
                                                             Wear protective shoes
                                                             Keep floor, equipment and the turbocharger clean
                                                             Ensure the availability of oil absorbing materials and have oil collector
                                                             basins ready or in position
                                                             Eliminate leaks
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                           Operation and process materials

                                                           Operation and process materials refer to chemical and hazardous sub-
                                                           stances:

                                                             Oils
                                                             Grease
                                                             Coolants
                                                             Detergents and solvents
                                                             Acids


                                                            Note that operation and process materials are harmful to the environ-
                                                            ment if they penetrate soil or water.

                                            CAUTION
Version 2.1




                                   ABB Turbo Systems Ltd                                                                          ABB
                                                                                Operation Manual
                        Safety                                    2


                        Safety instructions and hazard            2.4                     Page 8
                        protection


Personal injury         The following injuries can be caused by operation and process materials:

                          Allergies




                                                                                                     January 2006
                          Skin disease
                          Loss of consciousness
                          Poisoning or nausea after inhalation

Causes                    Inhalation of toxic gases, smoke and vapours
                          Skin contact with aggressive fluids
                          Clothing wet or soaked with hazardous substances
                          Spilling and tipping over of vessels containing substances used during
                          operation
                          Escape due to leakage
                          Tanks and collectors which are not gas-tight and which do not comply
                          with the regulations on hazardous substances
                          Burning cigarettes or open flame in the proximity of operation materials




                                                                                                     HZTL2480_EN (TPL73-B.. - 85-B..)
Protective measures       Utmost caution when handling operation and process materials
                          Protective clothing must be worn
                          Avoid skin contact and inhalation
                          Ensure that the workroom is properly ventilated
                          Observe the hazard indications on the containers for operation and
                          process materials
                          Immediately after use, seal the hazardous substance container tight
                          Used operation materials must be collected safely in accordance with
                          the legal provisions, stored separately in suitable containers as pre-
                          scribed, and disposed of as special waste in an environmentally com-
                          patible manner
                          Ensure that containers with new / used operation materials are sealed
                          tight
                          In the event of leaks or spills immediately apply a suitable absorbent
                          material and dispose of this in a technically and environmentally com-
                          patible manner as special waste
                                                                                                     Version 2.1




ABB Turbo Systems Ltd                                                                       ABB
                                                                                                                   Operation Manual
                                                           Safety                                        2


                                                           Safety instructions and hazard                2.4                  Page 9
                                                           protection



                                                           Handling insulating materials
January 2006




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


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




                                                           The effects of noise above a legally permitted level can cause personal in-
                                                           jury.

                                   Personal injury           Loss of hearing
                                                             Deafness
                                                             Impaired hearing
                                                             Health disorders such as loss of balance or of consciousness
                                                             Cardiac and circulatory disturbances

                                   Causes                    Machine noise level above 85 dB (A)

                                   Protective measures       Wear ear protection


                                                           Heat hazard

                                                           When the turbocharger is operated, surfaces become very hot.

                                   Personal injury           Burns
Version 2.1




                                   Causes                    Missing or incorrectly fitted insulation.

                                   Protective measures       Wear leather protective gloves.




                                   ABB Turbo Systems Ltd                                                                        ABB
                                                                                 Operation Manual
                        Safety                                     2


                        Warnings on the turbocharger               2.5                    Page 10



               2.5 Warnings on the turbocharger




                                                                                                     January 2006
                        Warnings that have been applied to turbochargers by ABB Turbo Systems
                        must not be removed, painted over or obscured with other stickers. Miss-
                        ing or illegible warnings must be replaced by new warnings.




                                                                                                     HZTL2480_EN (TPL73-B.. - 85-B..)
                        L_00227



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




                                                                                                     Version 2.1




ABB Turbo Systems Ltd                                                                         ABB
                                                                                                                          Operation Manual
                                                            Commissioning                                 3


                                                            Oil supply                                    3.1                           Page 1




                                                         3 Commissioning
                                                        3.1 Oil supply
January 2006




                                                            A carefully designed oil supply, which functions under all operating condi-
                                                            tions, is an important precondition for trouble-free operation of the turbo-
                                                            charger.

                                                            Lubrication of the turbocharger is normally carried out with oil from the
                                                            engine oil circuit.


                                                             Regarding the oil supply, follow the engine manufacturer's instructions
                                                             concerning selection of lubricating oil, oil change intervals, oil filtration,
                                                             and oil pressure and temperature.
                                              NOTE
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                            Oil filtration

                                                            A lubrication oil filter system with a mesh size ≤ 0.050 mm is adequate for
                                                            TPL ..-B turbochargers.


                                                            Oil pressure

                                                            The oil pressure before the bearings must be maintained precisely to en-
                                                            sure fault-free operation.

                                                            The permissible oil pressures are specified in the following tables de-
                                                            pendent on the lubrication (engine lubrication or separate lubricating sys-
                                                            tem).

                                   Engine lubrication       Kinetic viscosity 45 - 170 cST                              Oil pressure [bar]
                                                            Impermissible oil-pressure range ->                             0.0 - 0.6
                                                            Engine Shut Down (without delay)
                                                            Short-term (<1h) permissible oil-pressure range ->              0.6 - 0.8
Version 2.1




                                                            Alarm
                                                            Permissible oil-pressure range for normal operation             0.8 - 2.5
                                                            Permissible oil-pressure range during engine warm-              0.8 - 4.0
                                                            up phase




                                   ABB Turbo Systems Ltd                                                                                 ABB
                                                                                            Operation Manual
                            Commissioning                                3


                            Oil supply                                   3.1                              Page 2



Separate lubrication sys-   Kinetic viscosity 12 - 170 cST                                Oil pressure [bar]
tem
                            Impermissible oil-pressure range ->                               0.0 - 0.9
                            Engine Shut Down (without delay)




                                                                                                                   January 2006
                            Short-term (<1h) permissible oil-pressure range ->                0.9 - 1.1
                            Alarm
                            Permissible oil-pressure range for normal operation               1.1 - 2.5
                            Permissible oil-pressure range during engine warm-                1.1 - 4.0
                            up phase




                            Oil temperature during normal operation

Engine lubrication               Oil inlet          Engine load      Oil inlet pressure          Oil outlet
                               temperature             [%]                  [ bar ]            temperature




                                                                                                                   HZTL2480_EN (TPL73-B.. - 85-B..)
                                  [ °C ]                                                          [ °C ]
                                   45                   100               1.5 - 2                 70 - 90
                                   70                   100               1.5 - 2                90 - 110




                                                                                                                   Version 2.1




ABB Turbo Systems Ltd                                                                                       ABB
                                                                                                                           Operation Manual
                                                               Commissioning                                3


                                                               Inspection work                              3.2                     Page 3



                                                          3.2 Inspection work
                                                               This inspection work includes preventive visual controls, as well as moni-
January 2006




                                                               toring and measurement to ensure the correct functioning of the turbo-
                                                               charger. These serve as an aid to detecting anomalies before and during
                                                               commissioning, thus preventing possible damage to the machine.

                                                                  The safety instructions must be followed before and during all inspec-
                                                                  tion work.



                                                          3.2.1 Inspection before commissioning

                                   Monitoring equipment           To be checked for correct functioning.
HZTL2480_EN (TPL73-B.. - 85-B..)




                                   Air filter mat                 Inspect for damage.



                                   Lubricating system             Check oil filter for cleanliness before commissioning.


                                                                It is urgently recommended that the entire lubrication system be flushed
                                                                thoroughly with warm oil using a bypass pipe before commissioning and
                                                                after every servicing operation on the lubrication system.
                                              CAUTION           We strongly recommend the use of a starting filter when running the
                                                                engine in and after every servicing operation on the lubrication system.

                                                                  Check oil pressure in oil supply lines.
Version 2.1




                                   ABB Turbo Systems Ltd                                                                              ABB
                                                                                             Operation Manual
                                Commissioning                                 3


                                Inspection work                               3.2                       Page 4




                          3.2.2 Inspection after commissioning




                                                                                                                    January 2006
Lubricating system                 Check oil pressure in oil supply lines.



Charger speed                      Measuring



Charger pressure                   Measuring



Temperatures                       Measure upstream/downstream from turbine, compressor and oil feed
                                   for various engine speeds




                                                                                                                    HZTL2480_EN (TPL73-B.. - 85-B..)
Gas, air, and oil lines            After the engine has been started up, check all gas, air and oil lines for
                                   leaks.




                                Further must be observed:



                                 Lubricants and pastes are liquefied or vaporised during assembly of the
                                 turbocharger and may escape as an oily liquid in the first few hours af-
                                 ter commissioning. If oily liquid continues to escape after this period,
             NOTE                the cause must be treated as an oil leak and located. The first step in
                                 this process is to check the oil supply to the turbocharger for leaks. If
                                 this is not in order, contact an official ABB Turbo Systems service sta-
                                 tion.


                                   Measure the speed, oil pressure, charging pressure and temperatures
                                                                                                                    Version 2.1




                                   before and after the turbine and the compressor at various engine
                                   speeds.
                                   Compare the measured values with those of the inspection report, tak-
                                   ing into account the different operating conditions.



                          3.2.3 Inspection after 100 service hours

                                Clean or replace lubricating oil filters after the first 100 service hours.



ABB Turbo Systems Ltd                                                                                         ABB
                                                                                                                       Operation Manual
                                                           Commissioning                                3


                                                           Putting into operation after laying up       3.3                      Page 5



                                                  3.3 Putting into operation after laying up
                                   If provided                Remove the cover plates (blind flanges) between the compressor cas-
January 2006




                                                              ing outlet and charge-air receiver, upstream of the gas inlet, down-
                                                              stream of the gas outlet.



                                                              Inspect the exhaust pipe before and after the turbine for any combus-
                                                              tion residue, clean / remove foreign bodies or residual water.
                                                              Inspect air supply line or filter silencer for any foreign bodies, clean /
                                                              remove.
                                                              Start up the turbocharger's engine end oil circulation system.
                                                              Prepare the turbocharger for operation as instructed in the section In-
                                                              spection work before commissioning in the chapter entitled Commis-
                                                              sioning.
                                                              Start up the turbocharger.
HZTL2480_EN (TPL73-B.. - 85-B..)
Version 2.1




                                   ABB Turbo Systems Ltd                                                                            ABB
BLANK
                                                                                                                     Operation Manual
                                                            Operation                                  4


                                                            Servicing work                             4.1                     Page 1




                                                        4 Operation
                                                      4.1 Servicing work
January 2006




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


                                                             The pertinent safety instructions must be observed during all servicing
                                                             work.

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




                                                             Servicing work must be carried out at the prescribed intervals in order
                                                             to avoid damage to and malfunctioning of the turbocharger.

                                            CAUTION




                                                      4.1.1 Servicing work every 25 to 50 hours

                                   Operation data             must be recorded
                                                              Enter in the machine logbook
                                                              In the event of significant anomalies, establish the cause


                                                             If you are unable to establish the cause of the anomalies, contact an
                                                             official ABB Turbo Systems service station.

                                            CAUTION
Version 2.1




                                   ABB Turbo Systems Ltd                                                                          ABB
                                                                                       Operation Manual
                        Operation                                    4


                        Servicing work                               4.1                        Page 2




               4.1.2 Entries in the machine logbook




                                                                                                          January 2006
                        Monitoring of the machine plant provides information about the perform-
                        ance of the turbocharger.

                        The following operation data and measurement values must be entered
                        regularly in the engine manufacturer's machine log book:

                          Output and speed of the engine
                          Air intake temperature
                          Exhaust temperature before and after the turbine
                          Pressure of the charge-air
                          Pressure drop in the charge-air cooler
                          Lubricating oil pressure, lubricating oil temperature




                                                                                                          HZTL2480_EN (TPL73-B.. - 85-B..)
If provided               Air temperature after compressor and after the charge-air cooler
                          Speed of the turbocharger
                          Pressure loss in the air filter



               4.1.3 Servicing work according to the engine manufacturer's instructions

Oil filters               With the engine at standstill clean or replace oil filters




                                                                                                          Version 2.1




ABB Turbo Systems Ltd                                                                             ABB
                                                                                                                  Operation Manual
                                                           Operation                                 4


                                                           Servicing work                            4.1                     Page 3




                                                  4.1.4 Servicing work every 14,000 - 18,000 hours
January 2006




                                                             Dismantle the turbocharger
                                                             Clearance measurement
                                                             Clean turbine- and compressor casings and check for any cracks and
                                                             erosion / corrosion.
                                                             Clean bearing casing, blow through oil ports
                                                             Clean nozzle ring and check for cracks and erosion
                                                             Inspection and assessment of the rotor and bearing parts


                                                            The inspection and assessment of the rotor and bearing parts must be
                                                            performed by an official ABB Turbo Systems service station.

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




                                                  4.1.5 Servicing work every 35,000 hours

                                                             Dismantle the turbocharger
                                                             Clearance measurement
                                                             Clean turbine- and compressor casings and check for any cracks and
                                                             erosion / corrosion.
                                                             Clean bearing casing, blow through oil ports
                                                             Clean nozzle ring and check for cracks and erosion
                                                             Inspection and assessment of the rotor
                                                             Replacement of the plain bearings with original parts from ABB Turbo
                                                             Systems


                                                            The replacement of the bearing parts as well as the inspection and as-
                                                            sessment of the rotor must be carried out by an official ABB Turbo Sys-
                                                            tems service station.
                                           NOTE
Version 2.1




                                   ABB Turbo Systems Ltd                                                                       ABB
                                                                                     Operation Manual
                        Operation                                     4


                        Monitoring                                    4.2                         Page 4



               4.2 Monitoring




                                                                                                            January 2006
               4.2.1 Speed measurement




                                                                                                            HZTL2480_EN (TPL73-B.. - 85-B..)
                        86505_001


                        1            Bearing casing               6         Connecting cable
                        2            Axial bearing                7         Line amplifier (option)
                        3            Guide in the axial bearing   8         Speed transmitter
                        4            Gasket ring                  9         Installation variant of the
                                                                            speed transmitter
                        5            Screw plug
                                                                                                            Version 2.1




                        The speed transmitter system for the measurement of the turbocharger
                        speed also permits, in conjunction with the corresponding measuring in-
                        struments and/or monitoring systems (not included in the scope of deliv-
                        ery), a constant remote monitoring of the turbocharger speed. With con-
                        tinuous monitoring of the machine installation, the turbocharger speed can
                        be used as a suitable control parameter. The line amplifier can be pur-
                        chased as an optional addition to the described speed measuring system.




ABB Turbo Systems Ltd                                                                                 ABB
                                                                                                                    Operation Manual
                                                           Operation                                   4


                                                           Monitoring                                  4.2                     Page 5



                                                           Possible reasons for failure of the speed indicator:

                                                              Defects in the speed transmitter, the connecting cable and plug to the
                                                              measuring unit, in the measuring unit itself or the power supply.
January 2006




                                                              Turbocharger damage.


                                                            Failure of the speed indicator
                                                            If the speed indication fails, it is recommended that the engine output
                                                            be reduced to idling speed and the engine stopped. The cause of the
                                          CAUTION           failure should then be determined.




                                                            We recommend that subsequent assembly or replacement of the speed
                                                            transmitter system should be carried out only by an official ABB Turbo
                                                            Systems service station.
HZTL2480_EN (TPL73-B.. - 85-B..)




                                           NOTE




                                                           A reduction in speed of a charger can signify:

                                                              Damaged turbine or bearing
                                                              Severe soiling of the turbine
Version 2.1




                                   ABB Turbo Systems Ltd                                                                         ABB
                                                                                  Operation Manual
                         Operation                                  4


                         Monitoring                                 4.2                      Page 6




                   4.2.2 Underpressure measurement on filter silencer




                                                                                                        January 2006
                         A U-tube manometer can be ordered from ABB Turbo Systems Ltd. for
                         measuring the underpressure at the filter silencer.

                         The measurement can be used for the following purposes:

                           To measure the correction factor for calculating the efficiency of the
                           turbocharger when accepting the engine
                           The use of a filter mat on the filter silencer can cause a loss of pres-
                           sure. More significant pressure loss is an indication of increased soiling
                           of the filter material.



U-tube manometer




                                                                                                        HZTL2480_EN (TPL73-B.. - 85-B..)
                                                                                                        Version 2.1




                         L_00003

                                                               L_00004




ABB Turbo Systems Ltd                                                                          ABB
                                                                                                                       Operation Manual
                                                           Operation                                   4


                                                           Monitoring                                  4.2                        Page 7



                                                           1                                      Felt discs
                                                           A [mm H2O]                             Pressure differential / pressure loss
January 2006




                                                           All parts required for assembly are supplied in a separate package.

                                                           Mechanical vibration of the U-tube manometer is reduced by the installa-
                                                           tion of additional felt discs (1).


                                                            The U-tube manometer must be exposed to minimum possible me-
                                                            chanical shock or vibration.

                                           NOTE

                                                               Fit the U-tube manometer to the filter silencer as shown in the preced-
                                                               ing description.
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                               For best readability, the U-tube manometer can be filled with slightly
                                                               coloured water.

                                                           Under as-new conditions (new or clean filter silencer and filter mat), the
                                                           maximum pressure loss (A) is 120 mm H2O under full loading.

                                                               Clean the filter as soon as the loss of pressure (A) reaches a value of
                                                               200 mm H2O if not before.




                                                            For better readability of the pressure differential (A) on the U-tube ma-
                                                            nometer, the measuring rod can be withdrawn to the level of the lower
                                                            water level indicators.
                                           NOTE
Version 2.1




                                   ABB Turbo Systems Ltd                                                                             ABB
                                                                                  Operation Manual
                        Operation                                   4


                        Operation without emergency oil supply      4.3                     Page 8



                 4.3 Operation without emergency oil supply




                                                                                                      January 2006
                                                                                                      HZTL2480_EN (TPL73-B.. - 85-B..)
                        00000_028


                        If a leak occurs in the emergency oil system during operation and imme-
                        diate repair is not possible, the turbocharger can be operated until repair
                        without emergency oil supply.

                           Dismantle the pipe leading from the valve unit or the branch piece to
                           the tank.
                           Fit a blind flange to the valve unit or the branch piece.
                           Close opening on the tank to prevent the escape of oil.


                         Operation without emergency oil supply is possible without harm, as
                         long as the lubricating system functions properly during operation of the
                         turbocharger.
                                                                                                      Version 2.1




       CAUTION




ABB Turbo Systems Ltd                                                                          ABB
                                                                                                                   Operation Manual
                                                           Operation                                  4


                                                           Surging of turbocharger                    4.4                     Page 9



                                                    4.4 Surging of turbocharger
                                                           Surging of the turbocharger can occur with certain engine operating sta-
January 2006




                                                           tes, such as rapid load removal or while manoeuvring. The direction of
                                                           flow in the compressor is then briefly reversed. However, sporadic surging
                                                           of this kind does not generally affect the safe operation of the turbo-
                                                           charger.


                                                            Prolonged or periodic surging
                                                            If surging is prolonged or occurs periodically, the following components
                                                            may be damaged:
                                          CAUTION           - Compressor wheel (vibration fractures, ...)
                                                            - Turbine blades (cracks)
                                                            - Bearing (overheating)
                                                            - Filter silencer
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                           Action to be taken:

                                                           The operating safety of the turbocharger is no longer ensured with con-
                                                           tinuous or periodically recurring surging. The operator must take immedi-
                                                           ate steps to correct the surging together with the closest official ABB
                                                           Turbo Systems service station.
                                                           The components listed above must be inspected for damage by an official
                                                           ABB Turbo Systems service station, and replaced in cases of doubt.
Version 2.1




                                   ABB Turbo Systems Ltd                                                                        ABB
                                                                                 Operation Manual
                        Operation                                  4


                        Contact with rotating parts                4.5                    Page 10



               4.5 Contact with rotating parts
                        Mild, uniform wear around the circumference of rotor components, caused




                                                                                                      January 2006
                        by slight local grazing against adjacent components, is non-hazardous
                        and permissible. This slightly reduces the length of the blades in the com-
                        pressor and/or the turbine. Certain tolerances must be observed to avoid
                        significant loss of efficiency.

                          A check on dimensions must be carried out by an official ABB Turbo
                          Systems service station.




                                                                                                      HZTL2480_EN (TPL73-B.. - 85-B..)
                                                                                                      Version 2.1




ABB Turbo Systems Ltd                                                                        ABB
                                                                                                                    Operation Manual
                                                           Operation                                  4


                                                           Shutting the engine down                   4.6                    Page 11



                                                    4.6 Shutting the engine down
January 2006




                                                            Before shutting the engine down, it must be allowed to idle for about 3
                                                            minutes longer so that the circulating lubricating oil can dissipate the
                                                            heat in the turbocharger bearings.
                                          CAUTION
HZTL2480_EN (TPL73-B.. - 85-B..)
Version 2.1




                                   ABB Turbo Systems Ltd                                                                         ABB
BLANK
                                                                                                                   Operation Manual
                                                           Maintenance                                5


                                                           Foreword to Maintenance                    5.1                    Page 1




                                                     5 Maintenance
                                                  5.1 Foreword to Maintenance
January 2006




                                                           Cleaning work includes regular visual checks and washing to ensure the
                                                           correct functioning of the turbocharger and its auxiliary appliances.



                                                             The external condition and the degree of contamination of the cleaning
                                                             points specified in this chapter must be established by visual checks at
                                                             the intervals indicated.
                                                             The safety instructions must be observed during all cleaning work.



                                                           The cleaning points described in the following are:
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                             Filter silencer
                                                             Compressor
                                                             Turbine and nozzle ring
Version 2.1




                                   ABB Turbo Systems Ltd                                                                        ABB
                                                                                        Operation Manual
                        Maintenance                                   5


                        Cleaning the filter silencer                  5.2                        Page 2



               5.2 Cleaning the filter silencer




                                                                                                           January 2006
               5.2.1 Filter silencer with tension band




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



                        L_00210
                                                                                                           Version 2.1




                        81265     Filter ring (if provided)      81266    Cover grids
                        81270     Tension ring                   81136    Fleece segment
                        38271     Trap cover                     81137    Cover panel
                        81268     Connecting strip               81135    Filter silencer body
                        E         Slide-in module = fleece segment + cover panel installed




ABB Turbo Systems Ltd                                                                              ABB
                                                                                                                       Operation Manual
                                                           Maintenance                                  5


                                                           Cleaning the filter silencer                 5.2                       Page 3



                                                           Disassembling and cleaning the filter silencer

                                   If provided                Remove filter ring (81265).
January 2006




                                                              Rinse filter ring (81265) with water using detergent or, if very dirty, so-
                                                              ak it. Squeeze out carefully. Rinse in cold water. Avoid high mechani-
                                                              cal stress (water jet).


                                                            The dirt in the filter ring (81265) depends on the cleanness of the air
                                                            drawn in. Wash or replace the filter ring as necessary or every 500 ser-
                                                            vice hours.
                                                 NOTE




                                                              Loosen tension bands (81270) on trap covers (81271) and carefully
                                                              remove cover grid (81266) from connecting strips (81268).
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                            In the case of a slide-in module (E), with a cleaning container attached
                                                            to the filter silencer (available as option depending on turbocharger ty-
                                                            pe) the water injection line must first be removed (see also following
                                                 NOTE       section Disassembling the cleaning line).




                                                              Pull the slide-in modules (E) out, bend the cover panels (81137) open,
                                                              and then take out the fleece segments (81136).
                                                              Clean fleece segments (81136).
                                                              When cleaning, ensure that the fleece segments (81136) are cleaned
                                                              only with a mild jet of compressed air, a soft brush or damp cloth. Oth-
                                                              erwise the segments may be damaged or lose their shape.


                                                            Heavily soiled fleece segments and filter ring as well as damaged con-
                                                            necting strips should be replaced with original parts from ABB Turbo
                                                            Systems.
Version 2.1




                                                 NOTE




                                   ABB Turbo Systems Ltd                                                                            ABB
                                                                                    Operation Manual
                        Maintenance                                  5


                        Cleaning the filter silencer                 5.2                       Page 4




                        Assembling the filter silencer




                                                                                                        January 2006
                           Assemble the slide-in modules (E) by inserting fleece segments
                           (81136) in the cover panels (81137).
                           Bend the cover panels back to their original shape.
                           Insert slide-in modules (E) in the grooves in the filter silencer body
                           (81135).


                         With a cleaning container fitted to the filter silencer (available as option
                         depending on turbocharger type) the water injection line must now be
                         re-installed (see also following section Assembling the cleaning line).
              NOTE




                                                                                                        HZTL2480_EN (TPL73-B.. - 85-B..)
                           When fitting, insert the cover grid (81266) into the connecting strips
                           (81268).
                           Fit the tension bands (81270) and tighten on the trap covers (81271).



If provided                Fit filter ring (81265).




                                                                                                        Version 2.1




ABB Turbo Systems Ltd                                                                            ABB
                                                                                                                        Operation Manual
                                                           Maintenance                                  5


                                                           Cleaning the filter silencer                 5.2                        Page 5




                                                  5.2.2 Filter silencer and connecting rod
January 2006
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                           L_00185


                                                           81265     Filter ring (if provided)     81136    Fleece segment
                                                           81269     Connecting rods               81137    Cover panel
                                                           81266     Cover grids                   81135    Filter silencer body
Version 2.1




                                                           B         Screw                         N        Locknut
                                                           E         Slide-in module = fleece segment + cover panel




                                   ABB Turbo Systems Ltd                                                                            ABB
                                                                                    Operation Manual
                        Maintenance                                  5


                        Cleaning the filter silencer                 5.2                       Page 6




                        Disassembling and cleaning the filter silencer




                                                                                                         January 2006
If provided                Remove filter ring (81265).
                           Rinse filter ring (81265) with water using detergent or, if very dirty, so-
                           ak it. Squeeze out carefully. Rinse in cold water. Avoid high mechani-
                           cal stress (water jet).


                         The dirt in the filter ring (81265) depends on the cleanness of the air
                         drawn in. Wash or replace the filter ring as necessary or every 500 ser-
                         vice hours.
              NOTE




                           Loosen and remove locknuts (N).
                           Loosen and remove screws (B) on connecting rods (81269).




                                                                                                         HZTL2480_EN (TPL73-B.. - 85-B..)
                           Remove connecting rods (81269).
                           Carefully remove the cover grid (81266).


                         In the case of a slide-in module (E), with a cleaning container attached
                         to the filter silencer (available as option depending on turbocharger ty-
                         pe) the water injection line must first be removed (see also following
              NOTE       section Disassembling the cleaning line).


                           Withdraw the slide-in modules (E), bend open the cover panels
                           (81137) and then take out the fleece segments (81136).
                           Clean fleece segment (81136).
                           When cleaning, ensure that the fleece segments (81136) are cleaned
                           only with a mild jet of compressed air and a soft brush or damp cloth.
                           Otherwise the segments may be damaged or lose their shape.


                         Heavily soiled fleece segments and filter ring as well as damaged con-
                         necting rods should be replaced with original parts from ABB Turbo
                                                                                                         Version 2.1




                         Systems.
              NOTE




ABB Turbo Systems Ltd                                                                            ABB
                                                                                                                       Operation Manual
                                                           Maintenance                                  5


                                                           Cleaning the filter silencer                 5.2                       Page 7




                                                           Assembling the filter silencer
January 2006




                                                              Assemble the slide-in modules (E) by inserting fleece segments
                                                              (81136) in the cover panels (81137).
                                                              Bend cover panels (81137) back to their original shape.
                                                              Insert slide-in modules (E) in the grooves in the filter silencer body
                                                              (81135).


                                                            With a cleaning container fitted to the filter silencer (available as option
                                                            depending on turbocharger type) the water injection line must now be
                                                            re-installed (see also following section Assembling the cleaning line).
                                           NOTE
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                              Place cover grids (81266) evenly in the correct position.
                                                              Push the connecting rods (81269) through the clips on the cover grids
                                                              (81266).


                                                            If the connecting rods (81269) are not located correctly in their recesses
                                                            on the filter silencer body (81135), the cover grid (81266) can twist and
                                                            shift. This can allow foreign bodies and dirt to get into the compressor.
                                          CAUTION
Version 2.1




                                                           L_00232




                                   ABB Turbo Systems Ltd                                                                            ABB
                                                                                    Operation Manual
                        Maintenance                                  5


                        Cleaning the filter silencer                 5.2                      Page 8




                                                                                                         January 2006
                        L_00234




                                                                                                         HZTL2480_EN (TPL73-B.. - 85-B..)
                            Connect the connecting rods (81269) with screws (B). While tightening
                            the screws (B), ensure that the connecting rods (81269) are located
                            correctly in the recesses in the filter silencer body (81135). Now tighten
                            screws (B) alternately to the following max. tightening torque:

                        Screw                                   Tightening torque
                        B                                       20 Nm




                            Fit locknuts (N) on screw (B) and tighten to the following torque:

                        Locknut                                 Tightening torque
                        N                                       40 Nm




If provided                 Fit filter ring (81265).
                                                                                                         Version 2.1




ABB Turbo Systems Ltd                                                                            ABB
                                                                                                             Operation Manual
                                                           Maintenance                            5


                                                           Cleaning the filter silencer           5.2                 Page 9




                                                  5.2.3 Removing / installing the cleaning line
January 2006
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                           L_00192


                                                           1         Injection pipe        2          Pipe
                                                           3         Guide tube
Version 2.1




                                   ABB Turbo Systems Ltd                                                                ABB
                                                                                    Operation Manual
                           Maintenance                                5


                           Cleaning the filter silencer               5.2                    Page 10




                           Removing the cleaning line




                                                                                                        January 2006
                              Disconnect the line (2) at the injection pipe (1) and remove the screw
                              coupling from the pipe.
                              Withdraw the pipe (2) from the guide tube (3).



Punch out the guide tube




                                                                                                        HZTL2480_EN (TPL73-B.. - 85-B..)
                           L_00193


                              Punch the guide tube (3) out of the caulking with a bolt (diameter = 16
                              mm) and withdraw it.




                            Heavily soiled components of the cleaning line must be replaced with
                            original parts from ABB Turbo Systems.
                                                                                                        Version 2.1




           NOTE




ABB Turbo Systems Ltd                                                                            ABB
                                                                                                                        Operation Manual
                                                           Maintenance                                   5


                                                           Cleaning the filter silencer                  5.2                     Page 11



                                                           Installing the cleaning line
January 2006
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                           L_00194


                                                              After fitting the slide-in modules (E), re-fit the guide tube (3) and re-
                                                              caulk it.
                                                              Fit the pipe (2) and screw to the injection pipe (1).
Version 2.1




                                   ABB Turbo Systems Ltd                                                                             ABB
                                                                                       Operation Manual
                            Maintenance                                 5


                            Cleaning the compressor during              5.3                     Page 12
                            operation


                         5.3 Cleaning the compressor during operation




                                                                                                             January 2006
                             These guidelines for wet cleaning apply exclusively for cleaning with
                             clean water and are subject to permission for the procedure being ob-
                             tained from the engine manufacturer.
           NOTE




                            The dirt in the compressor stage (compressor wheel and diffuser) de-
                            pends on the cleanness of the air drawn in and the operating point.

                            A deposit of dirt in the flow ducts will be formed if the following substances
                            are present in the intake air:

                               Oil or saline mist




                                                                                                             HZTL2480_EN (TPL73-B.. - 85-B..)
                               Solid combustion residues
                               Dust of various kinds

                            Soiling of the compressor stage has a negative effect on compressor effi-
                            ciency and charging pressure, particularly for smaller turbochargers.

                            This results in higher exhaust temperatures and increased fuel consump-
                            tion by the engine. Contamination of the compressor also increases the
                            rotor imbalance.

                            Periodic cleaning of the compressor in operation prevents or retards a se-
                            vere increase in soiling, but in no way replaces the regular servicing work,
                            during which the turbocharger is completely dismantled.



Interval between clea-      The interval between periodic cleaning depends in large measure on the
nings                       operating conditions. In general, cleaning should be carried out every 25
                            to 100 operating hours.


                             Should the prescribed cleaning intervals prove incompatible with the
                                                                                                             Version 2.1




                             operation of the ship, please contact ABB Turbo Systems.

           NOTE




ABB Turbo Systems Ltd                                                                               ABB
                                                                                                                         Operation Manual
                                                               Maintenance                                 5


                                                               Cleaning the compressor during              5.3                     Page 13
                                                               operation


                                                               Cleaning method

                                                               The compressor is cleaned while operating using the cleaning method de-
January 2006




                                                               scribed in the following. This method has been tested and is approved by
                                                               ABB Turbo Systems:

                                                                  Wet cleaning



                                   Principle of wet cleaning   Water is injected before the compressor wheel via an injection pipe fitted
                                                               in the filter silencer or the suction branch in order to clean the compressor
                                                               stage in operation.

                                                               The water does not act as a solvent in the process, but the deposit is re-
                                                               moved by the mechanical impact of the drops. The process is ideal, pro-
                                                               vided the soiling is not too advanced.
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                                Due to the danger of corrosion, only clean water may be used, and on
                                                                no account salt water. The water should also contain no cooling addi-
                                                                tives, which could form deposits in the flow ducts.
                                             CAUTION




                                   Cleaning more than one      If several turbochargers are installed on one engine, we recommend clea-
                                   turbocharger compressor     ning the turbocharger compressors one after the other.
Version 2.1




                                   ABB Turbo Systems Ltd                                                                              ABB
                                                                                Operation Manual
                        Maintenance                               5


                        Cleaning the compressor during            5.3                     Page 14
                        operation




               5.3.1 Wet cleaning the compressor with external pressurised water con-




                                                                                                    January 2006
                     tainer (XC3)


                         The water feed with the externally mounted dosing vessel is only suit-
                         able for applications with underpressure upstream of the compressor
                         wheel (cannot be used for: Blower connected upstream of the com-
        NOTE             pressor or high-pressure compressor stage in the case of two-stage
                         charging).




                        Operating state preconditions for cleaning compressors with XC3




                                                                                                    HZTL2480_EN (TPL73-B.. - 85-B..)
                         In order to carry out a successful cleaning procedure that has been
                         tested and is recommended by ABB Turbo Systems, the following pre-
                         conditions must be met:
        NOTE
                           Engine warm from running (engine under full loading as far as possi-
                           ble)
                           High turbocharger speed
                           Cleaning cycle started according to the following description in Pro-
                           cedure for wet cleaning with XC3.




                                                                                                    Version 2.1




ABB Turbo Systems Ltd                                                                        ABB
                                                                                                                     Operation Manual
                                                            Maintenance                                5


                                                            Cleaning the compressor during             5.3                    Page 15
                                                            operation


                                                            Procedure for compressor wet cleaning with XC3
January 2006
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                            L_00198


                                                               X      Screw plug
                                                               Y      Valve lever




                                   Operating the pressure     The Operating state preconditions for cleaning compressors with XC3
                                   water vessel               must be met before cleaning can begin.
                                                              Remove the screw plug (X).
                                                              Fill the vessel with pure water.
Version 2.1




                                                              Tighten screw plug (X).
                                                              Actuate valve lever (Y) against the spring and hold it for 10 to 15 sec-
                                                              onds until all the water has been injected.
                                                              After cleaning, a waiting time of at least 5 minutes is necessary to allow
                                                              the turbocharger to dry.




                                   ABB Turbo Systems Ltd                                                                          ABB
                                                                                   Operation Manual
                        Maintenance                                 5


                        Cleaning the compressor during              5.3                     Page 16
                        operation



                         If the cleaning operation is unsuccessful, it can be repeated up to 2 ti-
                         mes.




                                                                                                         January 2006
                         If cleaning is still unsuccessful after three attempts and the engine op-
        NOTE             erating values are unsatisfactory, we recommend that the turbocharger
                         be checked and cleaned by an official ABB Turbo Systems service sta-
                         tion.




                        Cleaning parameters for each turbocharger compressor

                        Turbocharger type     Turbocharger       Contents of the    Water injection
                                                 speed            dosing vessel         time
                                                                      [dm3]             t1 [s]
                            TPL 69BA            Possible                0.4             4 ... 15
                                                 nBmax




                                                                                                         HZTL2480_EN (TPL73-B.. - 85-B..)
                            TPL 73-B                                      1
                            TPL 77-B
                            TPL 80-B                                      2
                            TPL 85-B
                            TPL 91-B




                                                                                                         Version 2.1




ABB Turbo Systems Ltd                                                                              ABB
                                                                                                                    Operation Manual
                                                           Maintenance                               5


                                                           Cleaning the compressor during            5.3                        Page 17
                                                           operation




                                                  5.3.2 Wet cleaning compressors with water vessel (XC4)
January 2006




                                                           Operating state preconditions for cleaning compressors with XC4



                                                            In order to carry out a successful cleaning procedure that has been
                                                            tested and is recommended by ABB Turbo Systems, the following pre-
                                                            conditions must be met:
                                           NOTE
                                                               Engine warm from running (engine under full loading as far as possi-
                                                               ble)
                                                               High turbocharger speed
                                                               Cleaning cycle started according to the following description in Pro-
                                                               cedure for wet cleaning with XC4.
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                           Procedure for compressor wet cleaning with XC4
Version 2.1




                                                           L_00197


                                                           1         Cleaning container               2 Pipe
                                                           3         Injection pipe                   4 Cleaning instructions
                                                           5         Cover                            6 Valve




                                   ABB Turbo Systems Ltd                                                                           ABB
                                                                                        Operation Manual
                            Maintenance                                  5


                            Cleaning the compressor during               5.3                     Page 18
                            operation



                             If the cleaning container on the filter silencer is used, the detailed clean-
                             ing instructions provided on the plate (4) fitted to the filter silencer




                                                                                                              January 2006
                             should be followed.
           NOTE




Use of cleaning container     The Operating state preconditions for cleaning compressors with XC4
                              must be met before cleaning can begin.
                              Open filling cap (5) on cleaning container (1).
                              Fill with clean water.
                              Screw filling cap (5) back into place.
                              Open valve (6) for about 3 minutes.
                              Close valve (6) and check that all the water has been sucked out.
                              After cleaning, a waiting time of at least 5 minutes with the engine run-
                              ning must be allowed so that the turbocharger can dry.




                                                                                                              HZTL2480_EN (TPL73-B.. - 85-B..)
                             If the cleaning operation is unsuccessful, it can be repeated up to 2 ti-
                             mes.
                             If cleaning is still unsuccessful after three attempts and the engine op-
           NOTE              erating values are unsatisfactory, we recommend that the turbocharger
                             be checked and cleaned by an official ABB Turbo Systems service sta-
                             tion.




                            Cleaning parameters for each turbocharger compressor

                            Turbocharger type     Turbocharger       Contents of the     Water injection
                                                     speed            dosing vessel          time
                                                                          [dm3]              t1 [s]
                                TPL 69BA             Possible                  2             4 ... 15
                                 TPL 73-B             nBmax

                                 TPL 77-B
                                                                                                              Version 2.1




                                 TPL 80-B                                      3
                                 TPL 85-B
                                 TPL 91-B




ABB Turbo Systems Ltd                                                                                   ABB
                                                                                                                         Operation Manual
                                                               Maintenance                                5


                                                               Cleaning turbine blades and nozzle ring    5.4                     Page 19
                                                               in operation


                                                           5.4 Cleaning turbine blades and nozzle ring in
                                                               operation
January 2006




                                                               Combustion of heavy fuel oil in diesel engines causes soiling of the tur-
                                                               bine blades and nozzle rings of the turbochargers.

                                                               Soiling increases with time, so that regular and properly performed clean-
                                                               ing is important to remove the accumulated deposits.

                                                               The exhaust gas temperature downstream of the cylinders can rise and
                                                               the charging pressure at the air receiver can fall if turbine components be-
                                                               come soiled.

                                                               A soiled turbine also results in rotor unbalance. Severe soiling can lead to
                                                               impermissibly high rotor imbalance.

                                                               Experience in operation has shown that despite periodic cleaning during
                                                               operation, it is impossible to dispense with overhauls during which the tur-
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                               bine and nozzle ring are mechanically cleaned. However, if cleaning is
                                                               performed correctly and the cleaning system is properly dimensioned, the
                                                               intervals between overhauls can be extended.

                                   Wet cleaning interval       The interval between periodic cleaning depends in large measure on the
                                                               operating conditions. In general, cleaning should be carried out every 50
                                                               to 500 operating hours.



                                   Interval for dry cleaning   The interval between periodic cleaning depends in large measure on the
                                                               operating conditions. In general, cleaning should be carried out every 20
                                                               to 50 operating hours.
Version 2.1




                                   ABB Turbo Systems Ltd                                                                              ABB
                                                                                      Operation Manual
                            Maintenance                                5


                            Cleaning turbine blades and nozzle ring    5.4                     Page 20
                            in operation



                            Cleaning methods




                                                                                                           January 2006
                            Several methods are possible for cleaning the turbine and nozzle ring dur-
                            ing operation. The cleaning methods described in the following have been
                            tested and are recommended by ABB Turbo Systems:

                               Wet cleaning
                               Dry cleaning



Principle of wet cleaning   During wet cleaning using droplets of water, the water does not act as a
                            solvent. Instead, the deposit is removed by the mechanical impact of the
                            drops.




                                                                                                           HZTL2480_EN (TPL73-B.. - 85-B..)
                             Due to the danger of corrosion, only clean water may be used, and on
                             no account salt water. The water should also contain no cooling addi-
                             tives, which could form deposits in the flow ducts.
          CAUTION




Principle of dry cleaning   During dry cleaning using dry solid particles in granulate form, the deposit
                            is removed by the mechanical impact of the grains hitting the surface.




                             Wet and dry cleaning are equally effective. However, it may be useful to
                             apply both methods together.

            NOTE
                                                                                                           Version 2.1




ABB Turbo Systems Ltd                                                                              ABB
                                                                                                                          Operation Manual
                                                                 Maintenance                                5


                                                                 Cleaning turbine blades and nozzle ring    5.4                     Page 21
                                                                 in operation


                                   Stabilising and drying time
January 2006




                                                                  Cleaning of the turbine-side components begins after engine start or
                                                                  reduction of engine load. The exhaust temperature must not exceed the
                                                                  value specified in the corresponding cleaning instructions (see the re-
                                               NOTE               spective section Operating state preconditions).




                                                                  Failure to maintain the prescribed exhaust temperature upstream of the
                                                                  turbine, and to allow the minimum stabilising time before and between
                                                                  cleaning procedures and the drying time after cleaning in accordance
                                             CAUTION              with the pertinent cleaning instructions will shorten the expected service
                                                                  life of the components significantly.
HZTL2480_EN (TPL73-B.. - 85-B..)




                                   Cleaning more than one        If several turbochargers are installed on one engine, we recommend clea-
                                   turbocharger turbine          ning the turbocharger turbines with nozzle rings one after the other.
Version 2.1




                                   ABB Turbo Systems Ltd                                                                               ABB
                                                                                 Operation Manual
                        Maintenance                                5


                        Cleaning turbine blades and nozzle ring    5.4                     Page 22
                        in operation




               5.4.1 Wet cleaning the turbine and nozzle ring during operation




                                                                                                       January 2006
                        The maximum exhaust gas temperature specified by the engine manufac-
                        turer and the TMmax temperature as shown on the turbocharger rating plate
                        must not be exceeded under any circumstances. During wet cleaning, the
                        turbine is braked and the turbocharger operates at reduced speed. As a
                        result, less air is supplied to the engine and the temperature after the en-
                        gine cylinder and exhaust valve rises.




                        Operating state precondition for wet cleaning



                         In order to carry out a successful cleaning procedure that has been




                                                                                                       HZTL2480_EN (TPL73-B.. - 85-B..)
                         tested and is recommended by ABB Turbo Systems, the following pre-
                         conditions must be met:
        NOTE
                            After the engine has been started or during operation, the engine
                            output must be adjusted until the scavenging air pressure pscav is
                            within the range of 0.3 – 0.6 bar (gauge pressure).
                            Wait 10 to 15 minutes (stabilising time), until the exhaust tempera-
                            ture at the turbine inlet is stable and below 430°C, the auxiliary
                            blower must also be operating.
                            Cleaning cycle started according to the following description in Pro-
                            cedure for wet cleaning.




                                                                                                       Version 2.1




ABB Turbo Systems Ltd                                                                         ABB
                                                                                                                               Operation Manual
                                                             Maintenance                                      5


                                                             Cleaning turbine blades and nozzle ring          5.4                       Page 23
                                                             in operation


                                                             Procedure for wet cleaning
January 2006
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                             L_00203


                                                             1         Water supply (freshwater only) 6           Other turbochargers
                                                                       at least 6.0 bar
                                                             2         Regulating valve                 7         Injection pipe
                                                             3         Manometer                        8         Drainage line
                                                             4         Air supply with 3-way-valve      9         Drain cock
                                                             5         Stainless steel piping           10        Outflow
                                                             11        Orifice (integrated in turbocharger)




                                   Operating the wet clea-       The Operating state preconditions for wet cleaning must be satisfied
                                   ning system                   before cleaning is begun.
                                                                 Check that the water supply (1) is connected, open and reliable.
Version 2.1




                                                                 Open the shut-off valve (9) on the drain pipe (8) on the gas outlet cas-
                                                                 ing.
                                                                 Connect the water supply (1) to the regulating valve (2) upstream of
                                                                 the turbocharger.




                                   ABB Turbo Systems Ltd                                                                                   ABB
                                                                                     Operation Manual
                          Maintenance                                 5


                          Cleaning turbine blades and nozzle ring     5.4                     Page 24
                          in operation


                            Slowly open first the 3-way-valve (4) (if fitted), then the regulating valve
                            (2) until the manometer (3) shows a pressure of 1 ∓ 0.2 bar.
                            Inject water for 5 minutes.




                                                                                                           January 2006
                            Check whether the exhaust-gas temperature after the turbine drops.
                            Close the regulating valve (2) and the 3-way-valve (4).
                            Close the drain cock (9) on the drain pipe (8) on the gas outlet casing.
                            The water supply connection (1) to the regulating valve (2) must be
                            disconnected.
                            After cleaning, a waiting time of at least 10 minutes with the engine
                            running must be allowed so that the turbocharger can dry.


                           If the cleaning operation is unsuccessful, it can be repeated up to 2 ti-
                           mes.
                           If cleaning is still unsuccessful after three attempts and the engine op-
          NOTE             erating values are unsatisfactory, we recommend that the turbocharger
                           be checked and cleaned by an official ABB Turbo Systems service sta-




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




Points to remember when     The gas outlet casing must be drained of water via the drain pipe (8)
cleaning                    when cleaning.
                            The exhaust-gas temperature after the turbocharger falls significantly
                            during cleaning (by 50 to 150°C).
                            Outflow can (but need not) take place through the drain-pipe, depend-
                            ing on the engine load. This outflow might not start for 2 - 3 minutes, or
                            it may not occur at all.
                            If draining is not carried out, the turbocharger speed and / or gas inlet
                            temperature must be monitored closely during the washing operation. If
                            the load is too low, water can collect in the gas outlet casing. Signs of
                            this are a sudden fall in the turbocharger speed or very rapid increase
                            in the gas inlet temperature. In either of these cases, the washing op-
                            eration must be terminated and the washing cycle begun again with a
                            lower water pressure or higher engine loading.
                                                                                                           Version 2.1




ABB Turbo Systems Ltd                                                                             ABB
                                                                                                                    Operation Manual
                                                           Maintenance                                5


                                                           Cleaning turbine blades and nozzle ring    5.4                     Page 25
                                                           in operation




                                                  5.4.2 Integrated dry cleaning of the turbine and nozzle ring during opera-
January 2006




                                                        tion


                                                            This cleaning method is not suitable for removing thick dirt deposits and
                                                            must therefore be carried out more often (see chapter Cleaning turbine
                                                            blades and nozzle ring in operation).
                                           NOTE



                                                           Operating state preconditions for integrated dry cleaning device



                                                            In order to carry out a successful cleaning procedure that has been
                                                            tested and is recommended by ABB Turbo Systems, the following pre-
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                            conditions must be met:
                                           NOTE
                                                               High engine output (50 to 100%) and high turbocharger speed.
                                                               Gas inlet temperature upstream of the turbine must be below 590°C.
                                                               Otherwise, there is considerable danger that the dry cleaning agent
                                                               will be burnt off.
                                                               Start the cleaning cycle with reference to the following description
                                                               Operating procedure for integrated dry cleaning device.
Version 2.1




                                   ABB Turbo Systems Ltd                                                                         ABB
                                                                                      Operation Manual
                        Maintenance                                5


                        Cleaning turbine blades and nozzle ring    5.4                         Page 26
                        in operation


                        Operation of integrated dry cleaning device




                                                                                                         January 2006
                                                                                                         HZTL2480_EN (TPL73-B.. - 85-B..)
                        L_00094


                        1     Container for granulated mate-   5       ON/OFF valve
                              rial
                        2     Trap-cover                       6       Safety valve
                                                                                                         Version 2.1




                        3     Compressed air supply [4 to 10   7       Combined air valve/pressure
                              bar]                                     relief valve
                        4     Pipe made from stainless steel   8       Cleaning instructions
                        9     Safety valve



                         The air system must be protected against overpressure (> 10 bar).


       CAUTION

ABB Turbo Systems Ltd                                                                             ABB
                                                                                                                       Operation Manual
                                                           Maintenance                                  5


                                                           Cleaning turbine blades and nozzle ring      5.4                      Page 27
                                                           in operation




                                   Operation of the dry      The Operating state preconditions for integrated dry cleaning must be
                                                             satisfied before cleaning is begun.
January 2006




                                   cleaning device
                                                             Ensure that the ON/OFF valve (5) is closed.
                                                             Check that the combined air valve/pressure relief valve (7) is in the
                                                             pressure relief position.
                                                             Open the trap-cover (2) carefully.
                                                             Fill the container (1) with the prescribed amount of granulate.
                                                             Close and seal the trap-cover (2).
                                                             Open the air valve (7).
                                                             Open the safety valve (6).
                                                             Whilst cleaning the turbine, open the ON/OFF valve (5) and leave it
                                                             open for approx. 1 minute.
                                                             Close the ON/OFF valve (5).
                                                             Close the safety valve (6).
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                             Set the combined air valve/pressure relief valve (7) to the pressure re-
                                                             lief position.
                                                             Check whether the exhaust gas temperature has dropped downstream
                                                             of the turbine.




                                                            In order to obtain the best possible cleaning effect, it is essential that
                                                            the prescribed quantity of granulate is blown in.
                                                            The drain openings in the gas outlet casing must remain closed while
                                              NOTE          the turbine is being cleaned. Careless handling can cause incompletely
                                                            combusted soot particles to escape.




                                                            If the cleaning operation is unsuccessful, it can be repeated up to 2 ti-
                                                            mes.
                                                            If cleaning is still unsuccessful after three attempts and the engine op-
Version 2.1




                                              NOTE          erating values are unsatisfactory, we recommend that the turbocharger
                                                            be checked and cleaned by an official ABB Turbo Systems service sta-
                                                            tion.




                                   ABB Turbo Systems Ltd                                                                             ABB
                                                                                   Operation Manual
                         Maintenance                                 5


                         Cleaning turbine blades and nozzle ring     5.4                    Page 28
                         in operation




                         Cleaning parameters for integrated dry cleaning device




                                                                                                      January 2006
Selection of materials   The following materials are suitable for use in dry cleaning:

                            Hard, granulated materials (such as natural core granulates)
                            Softblast media
                            Activated carbon particles



                         The average grain size of the cleaning granulate must be between 1.2
                         and 2.0 mm.

                         The specific weight of the cleaning granulate must not exceed 1.2 kg/dm3.




                                                                                                      HZTL2480_EN (TPL73-B.. - 85-B..)
Granulate quantity per    TPL 69BA     TPL 73-B     TPL 77-B     TPL 80-B     TPL 85-B     TPL 91-B
turbocharger [litres]
                             1.0          1.0          1.5          2.0          3.0         3.5




                          The cleaning granulate must be stored in a dry, clean place in order to
                          avoid clogging the pipes during cleaning.
                          The table in chapter Suppliers of dry cleaning agents lists possible sup-
            NOTE          pliers of dry cleaning agents.


                                                                                                      Version 2.1




ABB Turbo Systems Ltd                                                                          ABB
                                                                                                                     Operation Manual
                                                           Maintenance                                5


                                                           Cleaning turbine blades and nozzle ring    5.4                     Page 29
                                                           in operation




                                                  5.4.3 Non-integrated dry cleaning device for the turbine and nozzle ring
January 2006




                                                        during opration

                                                           As an alternative to the built-in dry cleaning system, a non-integrated dry
                                                           cleaning device can be installed upstream of the gas inlet casing by the
                                                           engine manufacturer.


                                                           Operating state preconditions for non-integrated dry cleaning device



                                                            In order to carry out a successful cleaning procedure that has been
                                                            tested and is recommended by ABB Turbo Systems, the following pre-
                                                            conditions must be met:
                                           NOTE
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                               High engine output (50 to 100%) and high turbocharger speed.
                                                               Gas inlet temperature upstream of the turbine must be below 590°C.
                                                               Otherwise, there is considerable danger that the dry cleaning agent
                                                               will be burnt off.
                                                               Start the cleaning cycle with reference to the following description
                                                               Operating procedure for non-integrated dry cleaning device.
Version 2.1




                                   ABB Turbo Systems Ltd                                                                          ABB
                                                                          Operation Manual
                        Maintenance                               5


                        Cleaning turbine blades and nozzle ring   5.4            Page 30
                        in operation


                        Operation of non-integrated dry cleaning device




                                                                                             January 2006
                                                                                             HZTL2480_EN (TPL73-B.. - 85-B..)
                                                                                             Version 2.1




                        L_00208




ABB Turbo Systems Ltd                                                                ABB
                                                                                                                             Operation Manual
                                                           Maintenance                                      5


                                                           Cleaning turbine blades and nozzle ring          5.4                         Page 31
                                                           in operation


                                                           1       Trap-cover G2“                      6        Strap for securing the container
                                                           2       Poss. copper gasket                 7        Safety valve with ventilation
                                                           3       Double nipple G2“                   8        Compressed air shut-off valve
January 2006




                                                           4       Copper gasket                       9        Compressed air pipe
                                                                                                                (internal diameter 8mm)
                                                           5       Friction cock or slide controller   10       Compressed air max. 6 bar
                                                                   G1''



                                                            The air system must be protected against overpressure (> 6 bar).


                                             CAUTION




                                   Operation of the dry        The Operating state preconditions for non-integrated dry cleaning de-
HZTL2480_EN (TPL73-B.. - 85-B..)




                                   cleaning device             vice must be satisfied before cleaning is begun.
                                                               Friction cock or slide controller (5) closed and safety valve with ventila-
                                                               tion (7) open.
                                                               Close the safety valve with ventilation (7).
                                                               Tighten the trap-cover (1).
                                                               Open the compressed air shut-off valve (8) so that deposits and any
                                                               condensation are blown off.
                                                               Close the compressed air shut-off valve (8) again after about 3 min-
                                                               utes.
                                                               Close the friction cock / slide controller (5).
                                                               Open the safety valve with ventilation (7) to blow out the exhaust ga-
                                                               ses.
                                                               Open the trap-cover (1) on the granulate container carefully.
                                                               Fill the granulate container with the prescribed quantity of granulate.
                                                               Close and seal the trap-cover (1).
                                                               Close the safety valve with ventilation (7).
                                                               Open the compressed air shut-off valve (8).
                                                               Open the friction cock or slide controller (5) for approx. 1 minute.
                                                               Close the friction cock or slide controller (5).
Version 2.1




                                                               Close the compressed air shut-off valve (8).
                                                               Open the safety valve with ventilation (7).
                                                               Check whether the exhaust gas temperature has dropped downstream
                                                               of the turbine.




                                   ABB Turbo Systems Ltd                                                                                    ABB
                                                                                     Operation Manual
                         Maintenance                                  5


                         Cleaning turbine blades and nozzle ring      5.4                       Page 32
                         in operation



                          In order to obtain the best possible cleaning effect, it is essential that
                          the prescribed quantity of granulate is blown in.




                                                                                                           January 2006
                          The drain openings in the gas outlet casing must remain closed while
           NOTE           the turbine is being cleaned. Careless handling can cause incompletely
                          combusted soot particles to escape.




                          If the cleaning operation is unsuccessful, it can be repeated up to 2 ti-
                          mes.
                          If cleaning is still unsuccessful after three attempts and the engine op-
           NOTE           erating values are unsatisfactory, we recommend that the turbocharger
                          be checked and cleaned by an official ABB Turbo Systems service sta-
                          tion.




                                                                                                           HZTL2480_EN (TPL73-B.. - 85-B..)
                         Cleaning parameters for the non-integrated dry cleaning device

Granulate quantity per   Turbocharger type            Amount of granulate           Container size
turbocharger                                                [dm3]
                         TPL 69BA                              1.0                        II
                         TPL 73-B                              1.0                        II
                         TPL 77-B                              1.5                        II
                         TPL 80-B                              2.0                        II
                         TPL 85-B                              3.0                        III
                         TPL 91-B                              3.5                        III
                                                                                                           Version 2.1




ABB Turbo Systems Ltd                                                                                ABB
                                                                                                                             Operation Manual
                                                               Maintenance                                   5


                                                               Suppliers of materials for dry cleaning       5.5                          Page 33



                                                          5.5 Suppliers of materials for dry cleaning
                                       Manufacturer          Country              Address                          Number for contact
January 2006




                                       ABB Service           Australia        20 Queen Street                     Tel. +61 2 9795310
                                                                              Revesby Sydney                     Fax. +61 2 9773 8855
                                                                                 NSW 2212
                                     Paul Auer GmbH         Germany      Bad Kreuznacher Str. 81               Tel. +49 621 727 69-0
                                                                         68309 Mannheim-Käfertal              Fax. +49 621 717 6988
                                                                                                       Email: vertrieb@auer-strahltechnik.de
                                       BRIGANTINE           Hong Kong       48 Wang Lok Street                  Tel. +852 24737900
                                        Service Ltd.                     Yuen Long Industrial Estate            Fax. +852 24786657
                                                                              N.T. Hong Kong                          Email: a-
                                                                                                          sibrgcorp@brigantinegroup.com
                                       LEERING             Netherlands       Barnsteenstraat 1                   Tel. +31 74 255 8282
                                     HENGELO B.V.                           NL-7554 TC Hengelo                   Fax. +31 74 242 2373
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                                              The Netherlands                    Email: info@leering.nl
                                         GUYSON                UK         Snaygill Industrial Estate          Tel. +44 1756 799911
                                     International Ltd.                        Keighley Rd.                   Fax. +44 1756 790213
                                                                          Skipton, N Yorks BD 23             Email: info@guyson.co.uk
                                                                                     2QR
                                                                              United Kingdom
                                          DASIC                UK              Winchester Hill                Tel. +44 1794 5124198
                                     International Ltd.                      Romsey SO51 7YD                  Fax. +44 1794 522346
                                                                              United Kingdom                Email: info@dasicinter.co.uk
                                           PAN              Singapore         Pioneer Sector 2                   Tel. +65 6861 6988
                                    Abrasives (Pte) Ltd.                          Jurong                         Fax. +65 6861 0919
                                                                             628382 Singapore            Email: pagroup@pan-abrasives.com
                                   CARLANDER & Co.           Sweden            Valtersang 9                    Tel. +46 30 363075
                                                                             S-442 49 Kungalv                  Fax. +46 30 363077
                                                                                 Sweden                      Email: lars@carlander.com
                                    BOSUNG Enginee-           Korea      1189-1, Choryang-3 Dong,             Tel. +82 51 466 0881-5
                                      ring Co., Ltd.                     Dong-Ku, Busan, 601-013             Fax. +82 51 466 0886-9
                                                                                                            Email: master@bosung.com
Version 2.1




                                   ABB Turbo Systems Ltd                                                                                     ABB
BLANK
                                                                                                                 Operation Manual
                                                           Troubleshooting                               6


                                                           Possible remedies for failures                6.1              Page 1




                                                        6 Troubleshooting
                                                       6.1 Possible remedies for failures
January 2006




                                                           Exhaust temperature too high

                                                           Engine output and speed unchanged



                                   Engine                    Malfunction in the injection system
                                                             Repair, or contact the manufacturer.



                                                             Air starvation, e.g. air filter clogged with dirt
HZTL2480_EN (TPL73-B.. - 85-B..)




                                   Turbocharger
                                                             Clean

                                                             Compressor / turbine soiled
                                                             Clean

                                                             Exhaust counterpressure too high
                                                             Clean or repair boiler or exhaust silencer

                                                             Turbine damaged or worn
                                                             Contact an official ABB Turbo Systems service station.



                                   Charge-air cooler         Cooler soiled
                                                             Clean

                                                             Insufficient coolant water quantity
                                                             Replenish

                                                             Coolant water inlet temperature too hot
Version 2.1




                                                             Clean/inspect cooling system

                                                             Ventilation inadequate
                                                             Improve ventilation




                                   ABB Turbo Systems Ltd                                                                    ABB
                                                                                 Operation Manual
                        Troubleshooting                             6


                        Possible remedies for failures              6.1                   Page 2




                        Charge-air pressure too low




                                                                                                    January 2006
                        Engine output and speed unchanged

                        Intake condition normal



Engine                    Air receiver leaking
                          Repair

                          Gas line between engine and turbine leaking
                          Repair

                          Injection misadjusted
                          Correct adjustment




                                                                                                    HZTL2480_EN (TPL73-B.. - 85-B..)
                          Valve control misadjusted
                          Correct adjustment



Turbocharger              Manometer display faulty
                          Replace manometer

                          Leak in line to the manometer
                          Repair leak

                          Air filter dirty, causing excessive loss of pressure
                          Clean

                          Compressor / turbine soiled
                          Clean

                          Compressor / turbine damaged
                          Contact an official ABB Turbo Systems service station.

                          Excessive exhaust counterpressure
                                                                                                    Version 2.1




                          Clean boiler or exhaust silencer




ABB Turbo Systems Ltd                                                                       ABB
                                                                                                                 Operation Manual
                                                           Troubleshooting                          6


                                                           Possible remedies for failures           6.1                   Page 3




                                                           Charge-air pressure too high
January 2006




                                                           Engine output and speed unchanged

                                                           Intake condition normal



                                   Engine                    Malfunction in the injection system
                                                             Correct adjustment

                                                             Engine output higher than expected
                                                             Check engine output

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




                                   Turbocharger              Manometer display faulty
                                                             Replace manometer


                                                           Vibrations

                                   Turbocharger              Rotor imbalance due to heavy fouling of compressor/turbine
                                                             Turbine or compressor damaged
                                                             Bearing defective
                                                             Contact an official ABB Turbo Systems service station.


                                                           Noises during run-out

                                   Turbocharger              Turbocharger dirty
                                                             Clean

                                                             Bearing damaged
Version 2.1




                                                             Rotor grazing
                                                             Foreign bodies in the turbocharger
                                                             Contact an official ABB Turbo Systems service station.




                                   ABB Turbo Systems Ltd                                                                    ABB
                                                                              Operation Manual
                        Troubleshooting                          6


                        Possible remedies for failures           6.1                   Page 4




                        Run-out time too short




                                                                                                 January 2006
Turbocharger              Turbocharger dirty
                          Clean

                          Bearing damaged
                          Rotor grazing
                          Foreign bodies in the turbocharger
                          Contact an official ABB Turbo Systems service station.


                        Sluggish start-up

Turbocharger              Turbocharger dirty
                          Clean




                                                                                                 HZTL2480_EN (TPL73-B.. - 85-B..)
                          Bearing damaged
                          Rotor grazing
                          Foreign bodies in the turbocharger
                          Contact an official ABB Turbo Systems service station.


                        Lubricating oil pressure too low

Engine                    Oil filter heavily soiled
                          Clean

                          Oil pump in the lubricating system defective
                          Inspect

                          Manometer provides false reading
                          Replace manometer



Turbocharger              Axial clearance of the rotor too big
                                                                                                 Version 2.1




                          Contact an official ABB Turbo Systems service station.




ABB Turbo Systems Ltd                                                                    ABB
                                                                                                                      Operation Manual
                                                           Troubleshooting                             6


                                                           Possible remedies for failures              6.1                      Page 5




                                                           Constant surging of the turbocharger
January 2006




                                   Engine                    Exhaust pressure after the turbine elevated because boiler or exhaust
                                                             silencer is dirty
                                                             Trap dirty
                                                             Clean



                                   Turbocharger              Charge-air cooler or silencer dirty
                                                             Heavy deposits of contamination in the turbine
                                                             Clean


                                                            If it is not possible to determine the reason for the surging, contact an
                                                            official ABB Turbo Systems service station.
HZTL2480_EN (TPL73-B.. - 85-B..)




                                             NOTE
Version 2.1




                                   ABB Turbo Systems Ltd                                                                           ABB
BLANK
                                                                                                                     Operation Manual
                                                           Removal and installation                    7


                                                           Turbocharger weights                        7.1                      Page 1




                                                     7 Removal and installation
                                                   7.1 Turbocharger weights
January 2006




                                                            Attach individual parts and larger component modules carefully to suit-
                                                            able hoists/lifting devices which are in technically perfect condition and
                                                            which have adequate load-bearing capacity.
                                         WARNING
                                                            Turbocharger parts that are not suspended in accordance with the
                                                            regulations during disassembly and assembly may fall and can cause
                                                            serious or even fatal injury.

                                                               Select a suitable rope taking into account the weight of the turbo-
                                                               charger parts.
                                                               Cross and loop the rope over the crane hook
                                                               Do not stand under suspended loads.
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                           L_00082
Version 2.1




                                                            For the safety of loads on the crane hook, the ropes must be sus-
                                                            pended crossed over each other. See also previous illustration.

                                         WARNING




                                   ABB Turbo Systems Ltd                                                                          ABB
                                                                                     Operation Manual
                        Removal and installation                    7


                        Turbocharger weights                        7.1                       Page 2




                        Turbocharger complete unit without filter silencer/air suction branch




                                                                                                        January 2006
Weights [kg]              TPL 69BA        TPL 73-B       TPL 77-B         TPL 80-B        TPL 85-B
                             1537           2310           3524            5510             9300




                        Turbocharger complete unit with filter silencer

Weights [kg]              TPL 69BA        TPL 73-B       TPL 77-B         TPL 80-B        TPL 85-B
                             1677           2554           3928            6086            10255




                        Turbocharger complete unit with air suction branch




                                                                                                        HZTL2480_EN (TPL73-B.. - 85-B..)
Weights [kg]              TPL 69BA        TPL 73-B       TPL 77-B         TPL 80-B        TPL 85-B
                             1617           2450           3679            5752             9590




                                                                                                        Version 2.1




ABB Turbo Systems Ltd                                                                           ABB
                                                                                                                     Operation Manual
                                                           Removal and installation                    7


                                                           Remove the turbocharger                     7.2                      Page 3



                                                  7.2 Remove the turbocharger
                                                             Disconnect all gas, air, and oil lines in accordance with the engine ma-
January 2006




                                                             nufacturer’s instructions.


                                                            The two oil supply channels in the bearing casing are fitted with one ori-
                                                            fice each. In order to obtain the required oil pressure, the ∅ of this ori-
                                                            fice has been individually adjusted by the engine builder. Whenever
                                           NOTE             these orifices are removed, or if the bearing casing or the complete tur-
                                                            bocharger is replaced, it is essential to ensure that the orifice with the
                                                            correct ∅ is fitted into the oil-conducting oil-inlet channel.


                                                             Remove the insulating shell from the bearing casing.
                                                             Check the lifting equipment.
                                                             Secure lifting equipment to the suspension lugs on the bearing casing.
HZTL2480_EN (TPL73-B.. - 85-B..)
Version 2.1




                                                           L_00233




                                   ABB Turbo Systems Ltd                                                                          ABB
                                                                                 Operation Manual
                        Removal and installation                   7


                        Remove the turbocharger                    7.2                      Page 4




                         During removal, a turbocharger that is not lifted in compliance with
                         regulations may fall, and can cause serious or even fatal injury.




                                                                                                      January 2006
      WARNING               In no event should a rope be looped round the emergency oil tank to
                            suspend the turbocharger.
                            Select a suitable rope taking into account the weight of the turbo-
                            charger.
                            Suspend the complete turbocharger using the two ribs on the bear-
                            ing casing provided for this purpose.
                            The turbocharger must be transported as horizontally as possible.
                            Ensure that the transport ropes do not touch the emergency oil tank.



                          Release the fixing screws on the foot.
                          Lift the turbocharger from the engine and place it aside.




                                                                                                      HZTL2480_EN (TPL73-B.. - 85-B..)
                         If the support for the turbocharger is missing or defective, the turbo-
                         charger may tip over during installation and removal and can cause se-
                         rious or even fatal injury.
      WARNING


                          Support turbocharger in a suitable location.
                          Cover oil connector.




                                                                                                      Version 2.1




ABB Turbo Systems Ltd                                                                           ABB
                                                                                                                      Operation Manual
                                                           Removal and installation                    7


                                                           Installing the turbocharger                 7.3                       Page 5



                                                     7.3 Installing the turbocharger
January 2006




                                                            During installation, a turbocharger that is not lifted in compliance with
                                                            regulations may fall, and can cause serious or even fatal injury.

                                           WARNING             Suspend the complete turbocharger using the two ribs provided for
                                                               this purpose. In no event should the rope be looped round the emer-
                                                               gency oil tank to suspend the turbocharger.
                                                               Select a suitable rope taking into account the weight of the turbo-
                                                               charger.
                                                               The turbocharger must be transported as horizontally as possible.
                                                               Ensure that the transport ropes do not touch the emergency oil tank.



                                                              Remove cover from the oil connector.
HZTL2480_EN (TPL73-B.. - 85-B..)




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



                                   TPL 73-85                  Mate the insulating shell with the bearing casing and secure.
Version 2.1




                                   ABB Turbo Systems Ltd                                                                           ABB
BLANK
                                                                                                                     Operation Manual
                                                           Disassembly and assembly                    8


                                                           Module weights                              8.1                      Page 1




                                                     8 Disassembly and assembly
                                                   8.1 Module weights
January 2006




                                                            Attach individual parts and larger component modules carefully to suit-
                                                            able hoists/lifting devices which are in technically perfect condition and
                                                            which have adequate load-bearing capacity.
                                         WARNING
                                                            Turbocharger parts that are not suspended in accordance with the
                                                            regulations during disassembly and assembly may fall and can cause
                                                            serious or even fatal injury.

                                                               Select a suitable rope taking into account the weight of the turbo-
                                                               charger parts.
                                                               Cross and loop the rope over the crane hook
                                                               Do not stand under suspended loads.
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                           L_00082
Version 2.1




                                                            For the safety of loads on the crane hook, the ropes must be sus-
                                                            pended crossed over each other. See also previous illustration.

                                         WARNING




                                   ABB Turbo Systems Ltd                                                                          ABB
                                                         Operation Manual
                        Disassembly and assembly   8


                        Module weights             8.1            Page 2




                        Modules




                                                                            January 2006
                                                                            HZTL2480_EN (TPL73-B.. - 85-B..)




                        L_00224
                                                                            Version 2.1




ABB Turbo Systems Ltd                                               ABB
                                                                                                                          Operation Manual
                                                           Disassembly and assembly                       8


                                                           Module weights                                 8.1                        Page 3



                                   Weights [kg]                          Description            TPL       TPL      TPL      TPL       TPL
                                                                                               69BA       73-B     77-B     80-B      85-B
                                                             1    Air suction branch, radial    80        140      155      242       290
January 2006




                                                             2          Filter silencer         140       244      404      576       955
                                                             3    Compressor casing inter-      83        282      536      786       1400
                                                                  nal part (with wall insert
                                                                            fitted)
                                                             4             Diffuser             36        57        80      125       225
                                                             5    Compressor casing exter-      180       290      475      680       1149
                                                                         nal part
                                                             6         Cartridge group          436       560      941      1443      2588
                                                             7         Turbine diffuser         46        72       150      250       460
                                                             8           Nozzle ring            17        25        44       63        95
                                                             9     Gas inlet casing radial      139       147      250      340       550
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                           Compressor casing, internal part, complete

                                   Weights [kg]              TPL 69BA         TPL 73-B         TPL 77-B          TPL 80-B         TPL 85-B
                                                                 119             339             616               911             1625




                                                            The total weight of the complete internal part of the compressor casing
                                                            includes the internal part of the compressor casing, the diffuser and the
                                                            wall insert.
                                              NOTE
Version 2.1




                                   ABB Turbo Systems Ltd                                                                               ABB
                                                                                    Operation Manual
                         Disassembly and assembly                     8


                         Removing and fitting the filter silencer or 8.2                       Page 4
                         air suction branch


                     8.2 Removing and fitting the filter silencer or air
                         suction branch




                                                                                                        January 2006
                          Not all tools are identified with a part number. The identification of the
                          tools is ensured with the tools list (included in the toolbox).

              NOTE




                           Remove insulation where necessary.
                           Disconnect all air ducts in accordance with the engine manufacturer’s
                           instructions.




                                                                                                        HZTL2480_EN (TPL73-B.. - 85-B..)
TPL 69 - 73




                         81000_003


                           Fit safety ring bolt (90231) on the filter silencer.
                                                                                                        Version 2.1




ABB Turbo Systems Ltd                                                                             ABB
                                                                                                                       Operation Manual
                                                           Disassembly and assembly                     8


                                                           Removing and fitting the filter silencer or 8.2                        Page 5
                                                           air suction branch


                                   TPL 77 - 85
January 2006
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                           L_00011


                                                             Fit safety ring bolt (90231) in the bearing plate (P) on the filter silencer.



                                   TPL 77 – 85
Version 2.1




                                                           L_00226


                                                             Mount shackle (90195) on the fin on the filter silencer.



                                   ABB Turbo Systems Ltd                                                                            ABB
                                                                                         Operation Manual
                              Disassembly and assembly                    8


                              Removing and fitting the filter silencer or 8.2                       Page 6
                              air suction branch


Remove filter silencer          Sling lifting gear through the loops at the rear and secure to the
                                shackle (90195) or to the safety ring bolt (90231) with a shackle.
                                Release nuts (74027) with Verbus washers (74028) and remove the fil-




                                                                                                             January 2006
                                ter silencer or air suction branch.



Install the filter silencer     The filter silencer or air suction branch is installed in the reverse se-
                                quence.




                               During removal and assembly, turbocharger components that have not
                               been suspended in compliance with regulations may fall, and can cause
                               serious or even fatal injury.
           WARNING                Do not stand under suspended loads.




                                                                                                             HZTL2480_EN (TPL73-B.. - 85-B..)
                                                                                                             Version 2.1




ABB Turbo Systems Ltd                                                                                  ABB
                                                                                                                           Operation Manual
                                                           Disassembly and assembly                       8


                                                           Axial clearance                                8.3                       Page 7



                                                      8.3 Axial clearance
January 2006
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                           01000_001


                                                             Axial clearance A must be measured before the cartridge group is re-
                                                             moved and after it is fitted.
                                                             Fit at least four nuts (74027) and washers (74028) at equal distances
                                                             around the circumference and tighten to secure the partition wall axi-
                                                             ally.
                                                             Measure and note the axial clearance A.


                                                            If the axial clearance A is out of tolerance, an official ABB Turbo Sys-
                                                            tems service station must be contacted.
Version 2.1




                                           CAUTION




                                   Clearance A [mm]          TPL 69BA        TPL 73-B       TPL 77-B            TPL 80-B        TPL 85-B
                                                             0.33 – 0.50     0.36 – 0.56    0.39 – 0.60         0.42 – 0.65    0.46 – 0.73




                                   ABB Turbo Systems Ltd                                                                              ABB
                                                                                        Operation Manual
                             Disassembly and assembly                     8


                             Removing cartridge group                     8.4                      Page 8



                     8.4 Removing cartridge group




                                                                                                            January 2006
                              Not all tools are identified with a part number. The identification of the
                              tools is ensured with the tools list (included in the toolbox).

           NOTE




Removing the internal part
of the compressor casing




                                                                                                            HZTL2480_EN (TPL73-B.. - 85-B..)
                             00000_028


                               Disconnect the oil lines in accordance with the engine manufacturer's
                               instructions.
                                                                                                            Version 2.1




                               Open the oil drain screw (42245) on the pipe to the emergency lubri-
                               cating oil tank and collect any residual oil in a bucket.
                               Fit oil drain screw (42245).
                               Release and remove nuts (74027) and discs (74028).
                               Remove six studs (74026) in the upper section and and fit four guide
                               bolts (90320) as necessary.
                               Leave 2 holes free for fitting the lifting device (90190).




ABB Turbo Systems Ltd                                                                                 ABB
                                                                                                                        Operation Manual
                                                               Disassembly and assembly                   8


                                                               Removing cartridge group                   8.4                     Page 9



                                                                 Push back internal part of compressor casing (76000) with extraction
                                                                 screws (90900) until the lifting device (90190/90195) can be fitted.
                                                                 Remove the internal part (76000) of the compressor casing.
January 2006




                                   Compressor casing, inter-
                                   nal part
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                               72000_009


                                                                 Fit support angle (90025).
                                                                 Place internal part (6000) of the compressor casing with the wall insert
                                                                 (77000) and diffuser (79000 on support angle and shim.
                                                                 Remove O-ring gasket (76040).
                                                                 Re-fit the lifting device (90190/90195) on the back of the flange (F).
Version 2.1




                                                                 Turn the internal part of the compressor casing with wall insert and dif-
                                                                 fuser carefully over the support angle and place on shims.
                                                                 Set the casing down on flange (F).




                                   ABB Turbo Systems Ltd                                                                             ABB
                                                                                Operation Manual
                        Disassembly and assembly                  8


                        Removing cartridge group                  8.4                    Page 10




                         Ensure that the shim does not slip.




                                                                                                      January 2006
                            Rest the internal part of the compressor casing only on flange F.
        WARNING             Check shim and adjust as necessary.




Remove diffuser




                                                                                                      HZTL2480_EN (TPL73-B.. - 85-B..)
                                                                                                      Version 2.1




                        79000_001




ABB Turbo Systems Ltd                                                                           ABB
                                                                                                                    Operation Manual
                                                             Disassembly and assembly                 8


                                                             Removing cartridge group                 8.4                    Page 11



                                   TPL 69 - 73                 Remove screws (76002) and diffuser (79000).
January 2006




                                   TPL 77 - 85                 Remove screws (76002).
                                                               Remove diffuser (79000) by means of ring bolts (90235).

                                   Remove external part of
                                   compressor casing
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                             74000_001


                                                               Secure lifting device (90190/90195) to external part of compressor cas-
                                                               ing (74000) and attach securely to the crane.
                                                               Loosen nuts (61037), press off external part of compressor casing e-
                                                               venly with the extraction nuts (61037) and remove.
Version 2.1




                                   ABB Turbo Systems Ltd                                                                        ABB
                                                                                     Operation Manual
                           Disassembly and assembly                   8


                           Removing cartridge group                   8.4                     Page 12



Removing cartridge group




                                                                                                        January 2006
                                                                                                        HZTL2480_EN (TPL73-B.. - 85-B..)
                           20000_001


                             Withdraw cable (86515) and unscrew speed measuring transmitter
                             (86505) with O-ring gasket (86506).



If provided:                 Disconnect cable to line amplifier (86525).



                             Remove the three screws (61059) and washers (61058).
                             Check lifting equipment and secure to bearing casing (42001).


                            During removal, a cartridge group that is not lifted in compliance with
                                                                                                        Version 2.1




                            regulations may fall, and can cause serious or even fatal injury.
                               Select a suitable rope taking into account the weight of the cartridge
          WARNING
                               group.




ABB Turbo Systems Ltd                                                                             ABB
                                                                                                                     Operation Manual
                                                           Disassembly and assembly                    8


                                                           Removing cartridge group                    8.4                    Page 13




                                                            To correct the slight tilt of the cartridge group suspended from the rope,
                                                            a piece of squared timber must be jammed between the rope and the
January 2006




                                                            emergency oil tank fixing.
                                           NOTE             Use only squared timber and not an iron bar, otherwise there is a dan-
                                                            ger of slipping.

                                                             Press cartridge group down evenly with jack screws (90900) into the
                                                             holes provided.




                                                            If the blades on the rotor have too little or no clearance, this may dam-
                                                            age the blades and the casing.
                                                               By turning the rotor, check that the turbine blades do not touch the
                                          CAUTION
                                                               turbine diffuser.
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                             Extract the cartridge group.
                                                             Cover oil connections.
Version 2.1




                                   ABB Turbo Systems Ltd                                                                          ABB
                                                                             Operation Manual
                        Disassembly and assembly                       8


                        Removing cartridge group                       8.4          Page 14



                        Fitting the supports for the cartridge group

TPL 73 - 80




                                                                                                January 2006
                                                                                                HZTL2480_EN (TPL73-B.. - 85-B..)
                        20000_006


                           Loosen hexagon head screws (42241) and remove valve block
                           (42230).
                           Attach supports (90450) and set down cartridge group.




                                                                                                Version 2.1




ABB Turbo Systems Ltd                                                                   ABB
                                                                                                                   Operation Manual
                                                           Disassembly and assembly                  8


                                                           Removing cartridge group                  8.4                   Page 15



                                   TPL 85
January 2006
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                           20000_008


                                                             Attach supports (90450) and set down cartridge group.




                                                            Work that exceeds the scope of the description in this chapter must on-
                                                            ly be performed by a trained fitter from an official ABB Turbo Systems
                                                            service station.
                                            CAUTION
Version 2.1




                                   ABB Turbo Systems Ltd                                                                       ABB
                                                                                  Operation Manual
                        Disassembly and assembly                    8


                        Inspection and assessment of the valve      8.5                    Page 16
                        block


                     8.5 Inspection and assessment of the valve
                         block




                                                                                                      January 2006
TPL 73 - 80




                                                                                                      HZTL2480_EN (TPL73-B.. - 85-B..)
                        20000_005


                         1    Valve flap
                         2    O-ring gasket (42234)
                         3    Valve seat




                        On the removed valve block (42230):

                             Check the smooth motion of the valve flap (1)
                             Check valve seat (3) with finger
                             If necessary, the O-ring gasket (2) should be replaced.


                         If scratches are found on the valve seat or the valve flap jams, the valve
                                                                                                      Version 2.1




                         block should be exchanged.
                         With uncertainty, an authorized service station of ABB Turbo Systems
              NOTE       is to be contacted.




ABB Turbo Systems Ltd                                                                         ABB
                                                                                                                    Operation Manual
                                                           Disassembly and assembly                   8


                                                           Dismantling and installing the turbine     8.6                    Page 17
                                                           diffuser and nozzle ring


                                                  8.6 Dismantling and installing the turbine diffuser
                                                      and nozzle ring
January 2006
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                           61000_001


                                                             Place clamp (90921) over stud (61036) until it lies flush with the inner
                                                             radius of the gas outlet casing.
                                                             Insert extension (A) of torque spanner (B) through the hole in the
                                                             clamp and loosen screws (61056) one after the other.
                                                             Do not remove screws (61056) and washers (61057) yet.
Version 2.1




                                   ABB Turbo Systems Ltd                                                                         ABB
                                                                               Operation Manual
                        Disassembly and assembly                 8


                        Dismantling and installing the turbine   8.6                    Page 18
                        diffuser and nozzle ring


Turbine diffuser




                                                                                                   January 2006
                                                                                                   HZTL2480_EN (TPL73-B.. - 85-B..)
                        56001_001


                          In the upper section of turbine diffuser (63000), replace two screws
                          (61056) with two guide bolts (90320). Pass the guide bolts through the
                          holes in clamps (90921).
                          To secure, fit hexagon nuts (90178).




                                                                                                   Version 2.1




ABB Turbo Systems Ltd                                                                      ABB
                                                                                                                       Operation Manual
                                                              Disassembly and assembly                   8


                                                              Dismantling and installing the turbine     8.6                    Page 19
                                                              diffuser and nozzle ring


                                   Securing the nozzle ring
January 2006
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                              61000_002


                                                                Before dismantling the turbine diffuser (63000), the nozzle ring (56001)
                                                                must be secured against falling with a clamping set and a wooden
                                                                block.
                                                                Loosen the remaining screws (61056) and remove with Verbus wash-
                                                                ers (61057).
                                                                Push back the turbine diffuser with extraction screws (90901) and
                                                                withdraw the turbine diffuser until the clamp (90921) contacts the he-
                                                                xagon head nut (90178).


                                                               If the nozzle ring (56001) is not secured when the turbine diffuser
                                                               (63000) is withdrawn, it may fall. Note that the nozzle ring hangs loosely
Version 2.1




                                                               from the positioning pins.
                                            CAUTION

                                                                Fix turbine diffuser (63000) to the lifting gear and remove.




                                   ABB Turbo Systems Ltd                                                                            ABB
                                                                                  Operation Manual
                        Disassembly and assembly                    8


                        Dismantling and installing the turbine      8.6                     Page 20
                        diffuser and nozzle ring


Nozzle ring




                                                                                                       January 2006
                        56001_002


                          Fix the holder (90490) on gas outlet casing.




                        56001_003                                                                      HZTL2480_EN (TPL73-B.. - 85-B..)



                          Draw the nozzle ring (56001) forward, fix the nozzle ring to the lifting
                          gear and remove.
                                                                                                       Version 2.1




Fitting                   Fit the nozzle ring and the turbine diffuser by reversing the sequence
                          for removal.
                          Align positioning pins in nozzle ring with the holes in the gas inlet cas-
                          ing.


                         Smear all screws in and on the gas outlet casing with Anti Scuff Paste
                         868 from SPANJAARD.

              NOTE

ABB Turbo Systems Ltd                                                                          ABB
                                                                                                                    Operation Manual
                                                            Disassembly and assembly                       8


                                                            Installing the cartridge group                 8.7               Page 21



                                                        8.7 Installing the cartridge group
                                   If removed:                 Fit the nozzle ring and turbine diffuser.
January 2006




                                                             These operations must be carried out as described in the chapter Re-
                                                             moving and fitting the turbine diffuser and nozzle ring.

                                                 NOTE




                                                            Removing the supports for the cartridge group
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                            20000_006


                                                               Remove cover from the oil connector.
Version 2.1




                                                               Check the lifting equipment and secure it to the bearing casing (42001)
                                                               so that the cartridge group is hanging straight.
                                                               Remove supports (90450).



                                   TPL 73 - 80                 Mount valve block (42230) with gasket (42045) and hexagon head
                                                               screws (42241).




                                   ABB Turbo Systems Ltd                                                                        ABB
                                                                                     Operation Manual
                           Disassembly and assembly                    8


                           Installing the cartridge group              8.7                    Page 22



Installing the cartridge
group




                                                                                                        January 2006
                                                                                                        HZTL2480_EN (TPL73-B.. - 85-B..)
                           20000_001


                              Carefully insert the cartridge group.


                            If the blades on the rotor have too little or no clearance, this may dam-
                            age the blades and the casing.
                               By turning the rotor, check that the turbine blades do not touch the
          CAUTION
                               turbine diffuser.



                              Tighten screws (61059) with Verbus washers (61058) evenly.
                              Remove lifting equipment.
                                                                                                        Version 2.1




If provided:                  Connect cable to line amplifier (86525).
                              Screw in the speed measuring transmitter (86505) with O-ring gasket
                              (86506) and connect cable (86515).




ABB Turbo Systems Ltd                                                                             ABB
                                                                                                                           Operation Manual
                                                                  Disassembly and assembly                   8


                                                                  Installing the cartridge group             8.7                    Page 23



                                   Fitting the external part of
                                   the compressor casing
January 2006
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                                  74000_001


                                                                     Secure lifting device (90190/90195) to external part of compressor cas-
                                                                     ing (74000) and attach securely to the crane.


                                                                   Before fitting the external part of the compressor casing, screw all
                                                                   press-off nuts (61037) to the end of the thread on the studs provided for
                                                                   this purpose.
                                                NOTE


                                                                     Assemble the external part of the compressor casing (74000) and se-
                                                                     cure with nuts (61037).
                                                                     Remove the lifting device (90190/90195).
Version 2.1




                                   ABB Turbo Systems Ltd                                                                               ABB
                                                                               Operation Manual
                        Disassembly and assembly                  8


                        Installing the cartridge group            8.7                 Page 24



Fitting the diffuser




                                                                                                  January 2006
                                                                                                  HZTL2480_EN (TPL73-B.. - 85-B..)
                        79000_001


TPL 69 - 73                Fit diffuser (79000) and screws (76002).
                                                                                                  Version 2.1




TPL 77 - 85                Mount diffuser (79000) by means of ring bolts (90235).
                           Fit screws (76002).



                           Tighten the screws (76002), then loosen again by ¼-turn.




ABB Turbo Systems Ltd                                                                     ABB
                                                                                                                       Operation Manual
                                                               Disassembly and assembly                   8


                                                               Installing the cartridge group             8.7                   Page 25



                                   Compressor casing, inter-
                                   nal part
January 2006
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                               72000_009


                                                                  Attach the lifting device (90190/90195) securely to the back of flange
                                                                  (F).
                                                                  Turn internal part of compressor casing (76000) with wall insert
                                                                  (77000) and diffuser (79000) carefully over the support angle (90025)
                                                                  and place on shims.
Version 2.1




                                   ABB Turbo Systems Ltd                                                                            ABB
                                                                                         Operation Manual
                               Disassembly and assembly                    8


                               Installing the cartridge group              8.7                     Page 26



Fitting the internal part of
the compressor casing




                                                                                                               January 2006
                                                                                                               HZTL2480_EN (TPL73-B.. - 85-B..)
                               00000_028


If removed                        Fit oil drain screw (42245).



                                  Attach the lifting device (90190/90195) securely to the front of the flan-
                                  ge on the internal part of the compressor casing (76000).
                                  Fit O-ring gasket (76040).
                                  Remove support angle (90025).
                                  Fit four guide bolts (90320).
                                  Position internal part of compressor casing (76000) with wall insert and
                                  diffuser carefully over the guide bolts and insert, then remove lifting
                                  device (90190/90195).
                                                                                                               Version 2.1




                                  Insert the internal part of the compressor casing as far as it will go.
                                  Remove guide bolts (90320) and fit studs (74026).




ABB Turbo Systems Ltd                                                                                 ABB
                                                                                                                                 Operation Manual
                                                                 Disassembly and assembly                       8


                                                                 Installing the cartridge group                 8.7                     Page 27



                                                                    Measure and note the axial clearance A.
January 2006




                                                                  If the axial clearance A is out of tolerance, an official ABB Turbo Sys-
                                                                  tems service station must be contacted.

                                              CAUTION




                                   Clearance A [mm]                TPL 69BA        TPL 73-B        TPL 77-B           TPL 80-B        TPL 85-B
                                                                   0.33 – 0.50     0.36 – 0.56    0.39 – 0.60         0.42 – 0.65    0.46 – 0.73




                                   Install the filter silencer      Fit the filter silencer or air suction branch and secure with nuts (74027)
                                                                    and Verbus washers (74028) (see section Removing and installing the
                                                                    filter silencer or air suction branch).
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                                    Connect the oil lines and all air lines in accordance with the engine
                                                                    manufacturer’s instructions.
                                                                    Install all insulation that has been removed.
Version 2.1




                                   ABB Turbo Systems Ltd                                                                                    ABB
                                                                                   Operation Manual
                        Disassembly and assembly                     8


                        Turbine-end removal / fitting of the         8.8                     Page 28
                        nozzle ring


                 8.8 Turbine-end removal / fitting of the nozzle
                     ring




                                                                                                        January 2006
                         If only the nozzle ring has to be removed, it is possible to dismantle it at
                         the turbine end.

          NOTE




Disassembly                Remove the insulation on the gas inlet casing (51001).
                           Fix lifting gear to the eyes on the gas inlet casing with shackle (90195).




                                                                                                        HZTL2480_EN (TPL73-B.. - 85-B..)
                                                                                                        Version 2.1




                        56001_001


                           Remove the two hexagon head screws (61044) and Verbus washers
                           (61043) from the lower section and replace them with two studs
                           (90177).
                           To lock, fit hexagon nuts (90178) to the studs.
                           Release and remove the remaining flange screws.




ABB Turbo Systems Ltd                                                                            ABB
                                                                                                                   Operation Manual
                                                           Disassembly and assembly                  8


                                                           Turbine-end removal / fitting of the      8.8                    Page 29
                                                           nozzle ring


                                                              Withdraw the gas inlet casing (51001) together with the nozzle ring
                                                              (56001) from the gas outlet casing (61001) until the holder (90175) and
                                                              screw (61044) can be fitted from the outside.
January 2006




                                                              Release the hexagon nuts (90178) from the studs.
                                                              Withdraw gas inlet casing fully and remove.


                                                            When positioning the gas inlet casing, use suitable shims and take care
                                                            to avoid damaging the brackets for the insulation.

                                              CAUTION
                                                              Loosen the holder (90175) and remove the nozzle ring (56001) with su-
                                                              itable lifting gear.



                                   Assembly                   Assemble the nozzle ring (56001) and tighten holder (90175) with
                                                              screw (61044).
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                              Assemble the gas inlet casing (51001) and secure by placing hexagon
                                                              nuts (90178) on the studs (90177).
                                                              Remove holder (90175) and screw (61044).
                                                              Assemble the gas inlet casing together with the nozzle ring on gas out-
                                                              let casing (61001).
                                                              Fit and tighten the hexagon head screws (61044) and Verbus washers
                                                              (61043).
                                                              Remove hexagon nuts (90178) from studs (90177).
                                                              Replace the studs with hexagon head screws (61044) and Verbus
                                                              washers (61043) and tighten.
                                                              Remove shackle (90195) and suspension rope from the gas inlet cas-
                                                              ing.
                                                              Secure the insulation on the gas inlet casing (51001).
Version 2.1




                                   ABB Turbo Systems Ltd                                                                        ABB
                                                                                Operation Manual
                        Disassembly and assembly                  8


                        Table of tightening torques               8.9                    Page 30



               8.9 Table of tightening torques




                                                                                                   January 2006
                                                                                                   HZTL2480_EN (TPL73-B.. - 85-B..)
                        00000_034


                        The following tightening torques must be maintained for the specified
                        screwed connections:



                                                                                                   Version 2.1




ABB Turbo Systems Ltd                                                                       ABB
                                                                                                                      Operation Manual
                                                             Disassembly and assembly                   8


                                                             Table of tightening torques                8.9                     Page 31



                                   Tightening torques [Nm]                TPL 69BA         TP 73-B   TPL 77-B    TPL 80-B      TPL 85-B
                                                                  42059      M16            M16        M20         M20           M24
                                                                             105            105        240         240           240
January 2006




                                                                  61044      M16            M18        M20         M22           M24
                                                                             260            370        480         480           480
                                                                  61056      M16            M18        M20         M22           M24
                                                                             260            370        480         480           480
                                                                  61059      M16            M18        M20         M22           M24
                                                                             260            370        480         480           480
                                                                  61036      M16            M18        M20         M22           M24
                                                                             30             80         80          80            80
                                                                  61037      M16            M18        M20         M22           M24
                                                                             105            160        210         280           360
                                                                  74026      M16            M18        M20         M22           M24
                                                                             30             80         80          80            80
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                                  74027      M16            M18        M20         M22           M24
                                                                             105            135        175         235           300
                                                                  76002      M12            M14        M16         M18           M20
                                                                             – 1)           – 1)       – 1)        – 1)          – 1)
                                                                  82005    M16x1.5         M16x1.5   M16x1.5     M16x1.5       M16x1.5
                                                                             50              50        50          50            50
                                                                  86505    M18x1.5         M18x1.5   M18x1.5     M22x1.5       M22x1.5
                                                                            150             150       150         220           220



                                                             1)             Tighten so that the diffuser can still be moved.
Version 2.1




                                                             L_00228




                                   ABB Turbo Systems Ltd                                                                           ABB
BLANK
                                                                                                                    Operation Manual
                                                           Taking out of operation temporarily         9


                                                           Possibilities for emergency repair          9.1                     Page 1




                                                     9 Taking out of operation temporarily
                                                    9.1 Possibilities for emergency repair
January 2006




                                                            Lubricating oil leaks are a fire hazard.


                                         WARNING



                                                            The instructions of the engine manufacturer for operation of the engine
                                                            with locked / isolated turbocharger must be followed precisely in all ca-
                                                            ses!
                                          CAUTION
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                           If the diesel engine must be capable of operation again as soon as possi-
                                                           ble after damage to the turbocharger (emergency repair), the following
                                                           possibilities are available:

                                                             Lock the turbocharger rotor
                                                             Fitting the cover plate
                                                             Blocking the inlets and outlets
                                                             Bypass the turbocharger
Version 2.1




                                   ABB Turbo Systems Ltd                                                                         ABB
                                                                                  Operation Manual
                        Taking out of operation temporarily         9


                        Locking the rotor                           9.2                      Page 2



                 9.2 Locking the rotor




                                                                                                      January 2006
                         A locked rotor must be disassembled following turbocharger repair and
                         given an imbalance check.

       CAUTION



                         The only exceptions are test rig runs up to a maximum of 25% engine
                         load on new engines with one or a number of turbochargers, which are
                         requested by some customers. Since in these cases operation with a
        NOTE             locked rotor is brief and the loads are small, subsequent disassembly of
                         the rotor is unnecessary.

                          Once unscrewed, balancing screws must not be screwed in again.




                                                                                                      HZTL2480_EN (TPL73-B.. - 85-B..)
                         Various intermediate rings are provided with the locking device for dif-
                         ferent compressor wheels. The compressor wheel type ”CV” (for the
                         balancing screw holes) must be noted. The space between the locking
        NOTE             flange (94003) and the assembly-disassembly device (90020) must be
                         compensated by the intermediate rings (94001 and/or 94002) depend-
                         ing on the version of compressor wheel.




                         During operation of the engine with a locked turbocharger, the lubrica-
                         tion oil system must also remain connected to this turbocharger and tur-
                         ned on if the gas inlet cannot be blocked (see section Further measures
       CAUTION           and information for operation with a locked rotor for 2-stroke engines).
                         Otherwise components that are still intact can be damaged by over-
                         heating.
                         The supply of lubricating oil to the turbocharger must be shut off in the
                         event of a lubricating oil leak on the turbocharger.
                                                                                                      Version 2.1




ABB Turbo Systems Ltd                                                                          ABB
                                                                                                                   Operation Manual
                                                           Taking out of operation temporarily       9


                                                           Locking the rotor                         9.2                     Page 3



                                                           Locking rotor with screwed connection
January 2006
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                           L_00225



                                                            These operations must be carried out as described in the chapter Dis-
                                                            assembly and assembly.

                                           NOTE
                                                             Remove the silencer or air suction branch and the compressor casing
                                                             internal part together with the wall insert and the diffuser.
Version 2.1




                                                             Remove screw plug (25005).
                                                             Fit studs (74026) as needed for the locking device on the compressor
                                                             casing.
                                                             Mount the assembly-disassembly device (90020) and tighten nuts
                                                             (74027) to the torques indicated in theTable of tightening torques.
                                                             Block the rotor with lock (90480).
                                                             Cut a thread (M12 or 1/2") in the existing hole and secure the lock with
                                                             a screw (A).




                                   ABB Turbo Systems Ltd                                                                        ABB
                                                                               Operation Manual
                        Taking out of operation temporarily      9


                        Locking the rotor                        9.2                     Page 4



                        Locking rotor with polygon connection




                                                                                                  January 2006
                                                                                                  HZTL2480_EN (TPL73-B.. - 85-B..)
                        94000_001



                         These operations must be carried out as described in the chapter Dis-
                         assembly and assembly.

        NOTE
                                                                                                  Version 2.1




ABB Turbo Systems Ltd                                                                      ABB
                                                                                                                      Operation Manual
                                                              Taking out of operation temporarily        9


                                                              Locking the rotor                          9.2                        Page 5



                                                                Remove the silencer or air suction branch and the compressor casing
                                                                internal part together with the wall insert and the diffuser.
                                                                Fix partition wall with clamp (94005) and screws (90442).
January 2006




                                                               Fit locking flange (94003) to the compressor wheel with at least 9
                                                               screws (94007 or 94008) (refer to Table of tightening torques).

                                             CAUTION




                                   Table of tightening tor-   Part num-    TPL69BA     TPL73-B      TPL77-B     TPL80-B      TPL85-B
                                   ques [Nm]                  ber
                                                              94006        -           M8           M8          M10          M12
                                                                                       25           25          45           75
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                              94007 /      -           M8           M8          M10          M12
                                                              94008                    15           15          35           60




                                   TPL 73 - 80                  Attach locking flange (94003) with screws (94007).



                                   TPL 85                       Fit the locking flange (94003) with screws (94007 or 94008, using the
                                                                longest possible screws) as well as the adjustment ring (94004) and in-
                                                                termediate ring (94031).
Version 2.1




                                   ABB Turbo Systems Ltd                                                                             ABB
                                                                               Operation Manual
                        Taking out of operation temporarily      9


                        Locking the rotor                        9.2                     Page 6



                        Compressor type CV11

TPL 73 – 80




                                                                                                   January 2006
                                                                                                   HZTL2480_EN (TPL73-B.. - 85-B..)
                        94000_13



                         It must be ensured that all components are clean and free from grease.


         CAUTION

                          Place the correct intermediate rings (94001 and/or 94002) on the lock-
                          ing flange (94003) and fit the assembly-disassembly device (90020).
                          Insert the remaining intermediate rings (94001 and/or 94002) and
                          mount the locking flange (94003) with screws (94006).
                                                                                                   Version 2.1




ABB Turbo Systems Ltd                                                                      ABB
                                                                                                                  Operation Manual
                                                           Taking out of operation temporarily      9


                                                           Locking the rotor                        9.2                     Page 7



                                                           Compressor type CV12, CV13

                                   TPL 73 – 80
January 2006
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                           94000_014



                                                            It must be ensured that all components are clean and free from grease.


                                            CAUTION

                                                             Place the correct intermediate rings (94001 and/or 94002) on the lock-
                                                             ing flange (94003) and fit the assembly-disassembly device (90020).
                                                             Insert the remaining intermediate rings (94001 and/or 94002) and
                                                             mount the locking flange (94003) with screws (94006).
Version 2.1




                                   ABB Turbo Systems Ltd                                                                      ABB
                                                                               Operation Manual
                        Taking out of operation temporarily      9


                        Locking the rotor                        9.2                     Page 8



                        Compressor type CV11

TPL 85




                                                                                                   January 2006
                                                                                                   HZTL2480_EN (TPL73-B.. - 85-B..)
                        94000_15



                         It must be ensured that all components are clean and free from grease.
                                                                                                   Version 2.1




         CAUTION

                          Push correct intermediate rings (94001 and/or 94002) on to the locking
                          flange (94003).
                          Fit assembly-disassembly device (90020) in each case with 2 washers
                          (94032).
                          Insert the remaining intermediate rings (94001 and/or 94002) and
                          mount the locking flange (94003) with screws (94006).




ABB Turbo Systems Ltd                                                                      ABB
                                                                                                                  Operation Manual
                                                           Taking out of operation temporarily      9


                                                           Locking the rotor                        9.2                     Page 9



                                                           Compressor type CV12, CV13

                                   TPL 85
January 2006
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                           94000_012



                                                            It must be ensured that all components are clean and free from grease.


                                            CAUTION

                                                             Push correct intermediate rings (94001 and/or 94002) on to the locking
                                                             flange (94003).
Version 2.1




                                                             Fit assembly-disassembly device (90020) in each case with 2 washers
                                                             (94032).
                                                             Insert the remaining intermediate rings (94001 and/or 94002) and
                                                             mount the locking flange (94003) with screws (94006).




                                   ABB Turbo Systems Ltd                                                                      ABB
                                                                                       Operation Manual
                             Taking out of operation temporarily         9


                             Locking the rotor                           9.2                    Page 10



                             Further measures and information for operation with a locked rotor for 2-
                             stroke engines




                                                                                                           January 2006
2-stroke engine with one     No further measures are necessary. The engine can be operated with the
turbocharger:                auxiliary blower according to the instructions of the manufacturer.

                                The lubrication oil system must remain connected and turned on.



2-stroke engine with seve-      The compensator at the compressor outlet must be dismantled and the
ral turbochargers:              air duct blocked at the engine end, as undamaged turbochargers de-
                                velop a receiver pressure.
                                The operating limit of the engine can be raised by additionally blocking
                                the gas inlet, as the exhaust gas is then used to drive the undamaged
                                turbocharger. The loading and temperature of the locked rotor are also
                                reduced.




                                                                                                           HZTL2480_EN (TPL73-B.. - 85-B..)
                             If the gas inlet cannot be blocked, the following operating limits must be
                             observed:

                                The pressure in the charge-air receiver must not exceed 1 bar over-
                                pressure.
                                Max. permissible engine load: 50%.


                              Attention must be paid to the speed of the undamaged turbochargers in
                              all cases. The rotating speed limit nBmax according to the turbocharger
                              rating plate must not be exceeded.
         CAUTION

                                                                                                           Version 2.1




ABB Turbo Systems Ltd                                                                               ABB
                                                                                                                  Operation Manual
                                                           Taking out of operation temporarily       9


                                                           Fitting the cover plate                   9.3                   Page 11



                                                  9.3 Fitting the cover plate
January 2006




                                                            The cover plate (material: general structural steel, in accordance with
                                                            DIN EN 10025-2) must be produced in-house according to the drawing.

                                           NOTE
HZTL2480_EN (TPL73-B.. - 85-B..)
Version 2.1




                                                           90000_001




                                   ABB Turbo Systems Ltd                                                                       ABB
                                                                               Operation Manual
                        Taking out of operation temporarily      9


                        Fitting the cover plate                  9.3                    Page 12




                                                                                                  January 2006
                                                                                                  HZTL2480_EN (TPL73-B.. - 85-B..)
                        20000_007



                         These operations must be carried out as described in the chapter Dis-
                         assembly and assembly.

        NOTE
                           Removing cartridge group


                                                                                                  Version 2.1




ABB Turbo Systems Ltd                                                                      ABB
                                                                                                                      Operation Manual
                                                           Taking out of operation temporarily          9


                                                           Fitting the cover plate                      9.3                  Page 13
January 2006
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                           61000_003


                                                              Block the opening in the gas outlet casing with the cover plate.
                                                              Secure cover plate with spacer sleeves and nuts (61037).


                                                            Shut off the supply of lubricating oil to the turbocharger.


                                          CAUTION
Version 2.1




                                   ABB Turbo Systems Ltd                                                                         ABB
                                                                                  Operation Manual
                        Taking out of operation temporarily         9


                        Fitting the cover plate                     9.3                    Page 14




                        Further measures and information for operation with a turbocharger with




                                                                                                       January 2006
                        cover plate in 2-stroke engines



                        2-stroke engine with one turbocharger:

                        No further measures are necessary. The engine can be operated with the
                        auxiliary blower according to the instructions of the manufacturer.



                        2-stroke engine with several turbochargers:

                           The air line must be blocked on the engine side, since the undamaged
                           turbochargers develop a receiver pressure.




                                                                                                       HZTL2480_EN (TPL73-B.. - 85-B..)
                           The operating limit of the engine can be raised significantly by addi-
                           tionally blocking the gas inlet, as the exhaust gas is then used to drive
                           the undamaged turbocharger.


                         Attention must be paid to the speed of the undamaged turbochargers in
                         all cases. The rotating speed limit nBmax according to the turbocharger
                         rating plate must not be exceeded.
       CAUTION



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

        NOTE
                                                                                                       Version 2.1




ABB Turbo Systems Ltd                                                                          ABB
                                                                                                                      Operation Manual
                                                           Taking out of operation temporarily          9


                                                           Blocking the inlets and outlets              9.4                   Page 15



                                                    9.4 Blocking the inlets and outlets
January 2006




                                                            Shut off the supply of lubricating oil to the turbocharger.


                                          CAUTION
                                                              Block the compressor casing outlet, gas inlet and gas outlet by fitting
                                                              cover plates.


                                                            For information about how to do this, see the manufacturer's instruc-
                                                            tions.

                                           NOTE
HZTL2480_EN (TPL73-B.. - 85-B..)
Version 2.1




                                   ABB Turbo Systems Ltd                                                                          ABB
                                                                                   Operation Manual
                        Taking out of operation temporarily          9


                        Bypass the turbocharger                      9.5                  Page 16



                 9.5 Bypass the turbocharger




                                                                                                      January 2006
                         Shut off the supply of lubricating oil to the turbocharger.


       CAUTION

                          For engines with one turbocharger only:
                          The connections are ready and pipes for the bypass are to hand.
                          Fit the bypass around the turbocharger.


                         For information about how to do this, see the manufacturer's instruc-
                         tions.

        NOTE




                                                                                                      HZTL2480_EN (TPL73-B.. - 85-B..)
                                                                                                      Version 2.1




ABB Turbo Systems Ltd                                                                         ABB
                                                                                                                      Operation Manual
                                                           Mothballing the turbocharger                 10


                                                           Taking out of operation for up to 12         10.1                     Page 1
                                                           months



                                                   10 Mothballing the turbocharger
                                                 10.1 Taking out of operation for up to 12 months
January 2006




                                                           If a turbocharger has to be laid up for up to 12 months, the decision
                                                           whether the turbocharger needs special protection or not depends mainly
                                                           on the condition of the lubricating oil before laying up.

                                                           If the Total Acid Number (TAN) is lower than 2 mg KOH/g no special
                                                           measures need to be taken. However, if the neutralisation factor is higher
                                                           the turbocharger must be dismantled after laying up, cleaned and protec-
                                                           tive oil must be applied to the naked parts.

                                                           If the turbocharger is left mounted on the engine, and the engine oil is re-
                                                           placed by a protective oil which is circulated with a pre-lubrication pump
                                                           prior to laying up, no measures need to be taken in respect of the turbo-
                                                           charger. The remains of the old engine oil will be washed away and the
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                           sensitive bearing parts will be largely protected against corrosion.

                                                           If the rotor turns due to a draught from the flue, fit a blind flange between
                                                           the compressor casing and the charge-air duct.
Version 2.1




                                   ABB Turbo Systems Ltd                                                                            ABB
                                                                                 Operation Manual
                        Mothballing the turbocharger               10


                        Taking out of operation for more than 12 10.2                      Page 2
                        months


               10.2 Taking out of operation for more than 12
                    months




                                                                                                    January 2006
                        If the turbocharger has to be removed from the engine and stored for a
                        prolonged period of time, disassembly and mothballing of the turbo-
                        charger must be done by an official ABB Turbo Systems service station.

                        Ensure that the storage area is dry with humidity of 40-70% and free of
                        condensation.


                         Check mothballed turbochargers yearly for corrosion.
                         In the event of rust, clean and renew the corrosion protection.
        NOTE




                                                                                                    HZTL2480_EN (TPL73-B.. - 85-B..)
                                                                                                    Version 2.1




ABB Turbo Systems Ltd                                                                        ABB
                                                                                                                        Operation Manual
                                                             Reserve and spare parts                    11


                                                             Ordering spare parts                       11.1                     Page 1




                                                         11 Reserve and spare parts
                                                      11.1 Ordering spare parts
January 2006




                                                             When making inquiries or ordering spare parts, the following data should
                                                             be specified:

                                                               Turbocharger type
                                                               HT number
                                                               Description and part number

                                                             Our service stations and agents accept orders for spare parts.

                                                               If special variants/cases are not addressed in these general instruc-
                                                               tions, contact an official ABB Turbo Systems Ltd. service station or an
                                                               ABB agent.
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                             Spare-parts set


                                                              Spare-parts set (97070) is required for the work described in this man-
                                                              ual. The parts included in the spare-parts set are only available as part
                                                              of the complete set.
                                              NOTE




                                   Spare parts set (97070)

                                   TPL73-B                    Quantity          Description                    Part number
                                                                  2      Hexagon head screw                    42059 / 42064
                                                                  2         Verbus washer                      42058 / 42063
                                                                 15      Hexagon head screw              61044 / 61056 / 61059
                                                                 15         Verbus washer                61043 / 61057 / 61058
                                                                  3            Hexagon nut                        61037
Version 2.1




                                                                  1               Gasket                          42041
                                                                  1               Gasket                          42045
                                                                  2            O-ring gasket                   42012 / 76040
                                                                  2            O-ring gasket                   77005 / 77006
                                                                  1            O-ring gasket                      86506




                                   ABB Turbo Systems Ltd                                                                            ABB
                                                                               Operation Manual
                        Reserve and spare parts                11


                        Ordering spare parts                   11.1                     Page 2



TPL77-B                  Quantity       Description                   Part number
                            15      Hexagon head screw   42059 / 42064 / 61044 / 61056 / 61059
                            15        Verbus washer      42058 / 42063 / 61043 / 61057 / 61058




                                                                                                  January 2006
                            3          Hexagon nut                       61037
                            1             Gasket                         42041
                            1             Gasket                         42045
                            2          O-ring gasket                  42012 / 76040
                            2          O-ring gasket                  77005 / 77006
                            1          O-ring gasket                     86506




TPL80-B                  Quantity       Description                   Part number
                            2       Hexagon head screw                42059 / 42064
                            2         Verbus washer                   42058 / 42063




                                                                                                  HZTL2480_EN (TPL73-B.. - 85-B..)
                            15      Hexagon head screw          61044 / 61056 / 61059
                            15        Verbus washer             61043 / 61057 / 61058
                            3          Hexagon nut                       61037
                            1             Gasket                         42041
                            1             Gasket                         42045
                            2          O-ring gasket                  42012 / 76040
                            2          O-ring gasket                  77005 / 77006
                            1          O-ring gasket                     86506




TPL85-B                  Quantity       Description                   Part number
                            15      Hexagon head screw   42059 / 42064 / 61044 / 61056 / 61059
                            15        Verbus washer      42058 / 42063 / 61043 / 61057 / 61058
                            3          Hexagon nut                       61037
                            1             Gasket                         42041
                            1             Gasket                         42045
                                                                                                  Version 2.1




                            2          O-ring gasket                  42012 / 76040
                            1          O-ring gasket                     42052
                            2          O-ring gasket                  77005 / 77006
                            1          O-ring gasket                     86506




ABB Turbo Systems Ltd                                                                      ABB
                                                                                                                  Operation Manual
                                                           Reserve and spare parts                  11


                                                           Ordering spare parts                     11.1                    Page 3




                                                            All spare parts that have been ordered with the turbocharger should be
                                                            kept complete and serviceable.
January 2006




                                                              Rusty parts should be carefully cleaned and greased.
                                          CAUTION


                                                             Dispose of parts that have been exchanged and are no longer usable
                                                             in a technically and environmentally compatible manner.
HZTL2480_EN (TPL73-B.. - 85-B..)
Version 2.1




                                   ABB Turbo Systems Ltd                                                                      ABB
                                                                                  Operation Manual
                        Reserve and spare parts                     11


                        Directory of part numbers                   11.2                   Page 4



               11.2 Directory of part numbers
                        The following part numbers and descriptions must be used in ALL corre-




                                                                                                      January 2006
                        spondence or orders:

Turbocharger            Part number                          Description
                        -                                    Cartridge group
                        42012 (in spare parts set)           O-ring gasket
                        42041 (in spare parts set)           Gasket
                        42045 (in spare parts set)           Gasket
                        42052 (in spare parts set)           O-ring gasket
                        42059 & 42058 (in spare parts set)   Hexagon head screw & Verbus washer
                        42064 & 42063 (in spare parts set)   Hexagon head screw & Verbus washer
                        51001                                Gas inlet casing
                        56001                                Nozzle ring




                                                                                                      HZTL2480_EN (TPL73-B.. - 85-B..)
                        61001                                Gas outlet casing
                        61037 (in spare parts set)           Hexagon nut
                        61044 & 61043 (in spare parts set)   Hexagon head screw & Verbus washer
                        61056 & 61057 (in spare parts set)   Hexagon head screw & Verbus washer
                        61059 & 61058 (in spare parts set)   Hexagon head screw & Verbus washer
                        63000                                Turbine diffuser
                        68000                                Foot
                        74000                                Compressor casing external part
                        76000                                Compressor casing, internal part
                        76040                                O-ring gasket
                        77000                                Wall insert
                        77005 (in spare parts set)           O-ring gasket
                        77006 (in spare parts set)           O-ring gasket
                        79000                                Diffuser
                        81000                                Filter silencer
                        82000                                Air suction branch, radial
                                                                                                      Version 2.1




                        86505                                Speed sensor
                        86506 (in spare parts set)           O-ring gasket




ABB Turbo Systems Ltd                                                                           ABB
                                                                                                                Operation Manual
                                                               Reserve and spare parts           11


                                                               Directory of part numbers         11.2                      Page 5



                                   Cartridge group – screwed   Part number                  Description
                                   connection
                                                               21000                        Shaft
                                                               25000                        Compressor wheel
January 2006




                                                               25005                        Screw plug
                                                               32001                        Cam bearing
                                                               32101                        Radial bearing, compressor side
                                                               32102                        Radial bearing, turbine side
                                                               32104                        Auxiliary bearing
                                                               32105                        Float disc
                                                               32106                        Axial bearing
                                                               32107                        Bearing bush
                                                               42001                        Bearing casing
                                                               42002                        Cowling
                                                               42011                        O-ring gasket
HZTL2480_EN (TPL73-B.. - 85-B..)




                                                               42012 (in spare parts set)   O-ring gasket
                                                               42015                        Gasket cover
                                                               43001                        Partition wall
                                                               43005                        O-ring gasket
Version 2.1




                                   ABB Turbo Systems Ltd                                                                      ABB
                                                                             Operation Manual
                            Reserve and spare parts           11


                            Directory of part numbers         11.2                      Page 6



Cartridge group - polygon   Part number                  Description
connection
                            21000                        Shaft
                            25000                        Compressor wheel




                                                                                                 January 2006
                            25008                        Threaded pin
                            25009                        Ring nut
                            32001                        Cam bearing
                            32101                        Radial bearing, compressor side
                            32102                        Radial bearing, turbine side
                            32104                        Auxiliary bearing
                            32105                        Float disc
                            32106                        Axial bearing
                            32107                        Bearing bush
                            42001                        Bearing casing
                            42002                        Cowling




                                                                                                 HZTL2480_EN (TPL73-B.. - 85-B..)
                            42011                        O-ring gasket
                            42012 (in spare parts set)   O-ring gasket
                            42015                        Gasket cover
                            43001                        Partition wall
                            43005                        O-ring gasket




                                                                                                 Version 2.1




ABB Turbo Systems Ltd                                                                      ABB
                                                                                                 Operation Manual
                                                           Reserve and spare parts        11


                                                           General view of turbocharger   11.3            Page 7



                                                 11.3 General view of turbocharger
January 2006
HZTL2480_EN (TPL73-B.. - 85-B..)
Version 2.1




                                   L_00229




                                   ABB Turbo Systems Ltd                                                    ABB
                                                                 Operation Manual
                        Reserve and spare parts           11


                        General view of cartridge group   11.4            Page 8



              11.4 General view of cartridge group




                                                                                    January 2006
                                                                                    HZTL2480_EN (TPL73-B.. - 85-B..)
                                                                                    Version 2.1




L_00230




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

				
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