Page 1 Operation Manual TPL76-C33 ABB Turbo Systems Ltd CH 5401 Baden Type TPL76-C33 HT578503 Mmax Mmax °C Bmax Bmax 04070 Application according to Year 2017 the Operation Manual made in Switzerland ABB Turbocharging...
Page 2 In case the operation conditions differs signiﬁ cantly 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.
Page 3: Table Of Contents
Operation Manual / TPL76-C Table of contents Operation Manual Preliminary remarks....................3 Purpose of this manual ....................3 Layout and function......................4 Intended use........................6 Deflagration on gas engines..................7 Storage of new turbochargers and spare parts ............8 Essential information....................10 Symbols and definitions ....................
Page 4 Operation Manual / TPL76-C Table of contents Troubleshooting....................69 Malfunctions when starting..................69 Surging of the turbocharger..................70 Malfunctions during operation .................. 71 Malfunctions when stopping ..................74 Speed measurement system ..................75 Removal and installation..................76 Turbocharger weight....................76 Removing the turbocharger..................
Page 5: Operation Manual
Operation Manual This Operation Manual enables you to familiarize yourself with the tur- bocharger supplied by ABB Turbo Systems and to use it as intended. It provides important information in order that the turbocharger can be operated safely, correctly and efficiently.
Page 6: Layout And Function
Operation Manual / TPL76-C 1 Preliminary remarks / 1.2 Layout and function 1.2 Layout and function 01Filter silencer 08Nozzle ring 02Radial plain bearing 09Turbine wheel 03Thrust bearing 10Bearing casing 04Bearing bush 11Diffuser 05Radial plain bearing 12Compressor wheel 06Gas outlet casing 13Compressor casing 07Gas inlet casing ©...
Page 7 Operation Manual / TPL76-C 1 Preliminary remarks / 1.2 Layout and function Mode of operation The turbocharger is a turbomachine 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 (07) and nozzle ring (08) to the turbine wheel.
Page 8: Intended Use
These data are given on the rating plate. ABB Turbo Systems accepts no liability and rejects all warranty claims for any non-intended uses. [1]Euromot = The European Association of Internal Combustion Engine...
Page 9: Deflagration On Gas Engines
The turbocharger must only be used when it is in a technically flawless condition and operated in compliance with its intended use. ABB Turbo Systems excludes any liability for damage resulting from un- authorized modifications to the turbocharger or improper operation.
Page 10: Storage Of New Turbochargers And Spare Parts
1.5 Storage of new turbochargers and spare parts Storage of new turbochargers and spare parts up to 6 months New turbochargers and spare parts from ABB Turbo Systems can be stored in sealed packaging without additional mothballing measures for up to 6 months from the date of delivery (marked by the VCI label on the package).
Page 11 70% level, the maximum permissible humidity has been exceeded. In this case the turbochar- ger or rotor must be inspected by an ABB Turbocharging Service Sta- tion and repacked. Inspect the package for damage. If the package is damaged, the tur- bocharger or cartridge group must be inspected by an ABB Tur- bocharging Service Station and repacked.
Page 12: Essential Information
Only use original parts from ABB. ABB accepts no liability for any damage resulting from the use of non- original parts and corresponding accessories. Competence of personnel The turbocharger must only be operated and serviced by trained and au- thorised personnel.
Page 13 This document is valid for different design variants of turbochargers. There may be sections and descriptions of components that are not rel- evant for a specific turbocharger variant. ABB Turbocharging Service Stations will be happy to provide information on questions regarding a design variant (see Contact information at www.abb.com/turbocharging).
Page 14: Symbols And Definitions
Definition of caution / warning The caution and warning signs are described in the chapter Safety. ABB Turbo Systems In this document, ABB Turbo Systems Ltd is abbreviated to ABB Turbo Systems. Official ABB Turbo Systems Service Stations In this document, official service stations are referred to as ABB Tur- bocharging Service Stations.
Page 15: Turbocharger Rating Plate
Operation Manual / TPL76-C 1 Preliminary remarks / 1.8 Turbocharger rating plate 1.8 Turbocharger rating plate Operating limits 01 Turbocharger operating limits at engine overload (110 %). Only when operating in the test rig unless otherwise agreed with the enginebuilder. 02 Turbocharger operating limits during operation Recommended replace- 03 Replacement interval for plain bearings in 1000 h ment intervals for tur-...
Page 16: Contact Information
A rating plate is attached to the turbocharger foot, one on the left and one on the right. On turbochargers with insulation from ABB, at least one additional rating plate is attached to the insulation of the gas outlet cas- ing.
Page 17: Safety
2 Safety / 2.1 Introduction 2 Safety 2.1 Introduction Turbochargers manufactured by ABB are state of the art and comply with the pertinent safety and health-protection requirements that ap- plied when the turbocharger was manufactured. Consequently, the tur- bocharger is safe to operate. Nevertheless, during turbocharger opera-...
Page 18: Definition Of Mandatory Signs
Operation Manual / TPL76-C 2 Safety / 2.3 Definition of mandatory signs 2.3 Definition of mandatory signs To be worn at all times Protective clothing Safety footwear to pro- tect against mechanical hazard and risk of fall- To be worn according to the specific work Safety glasses Safety goggles Safety gloves against...
Page 19: Warning Plates On The Turbocharger
Operation Manual / TPL76-C 2 Safety / 2.5 Warning plates on the turbocharger 2.5 Warning plates on the turbocharger Warning plates that must be observed are attached to the turbocharger. The warning plates must always be present in the intended locations and must be legible.
Page 20: Safe Operation And Maintenance
Operation Manual / TPL76-C 2 Safety / 2.6 Safe operation and maintenance 2.6 Safe operation and maintenance The instructions specified in this section are for the safety of personnel. Together with the instructions in the Hazards during operation and maintenance section, they allow the user to safely use the turbocharger. Work safety and work area safety WARNING Risk of falling...
Page 21 Operation Manual / TPL76-C 2 Safety / 2.6 Safe operation and maintenance Safety during start-up / commissioning and operation Before starting work, carry out visual inspection of working area. Remove any obstacles and objects lying around. Before start-up / commissioning, check all pipes from and to tur- bocharger for damage and leaks.
Page 22 Operation Manual / TPL76-C 2 Safety / 2.6 Safe operation and maintenance Safety during disassembly, assembly, maintenance and troubleshooting Always perform the specified adjustments, servicing as well as in- spection work and observe inspection intervals. Inform operating personnel about all service and repair work before beginning.
Page 23: Hazards During Operation And Maintenance
Operation Manual / TPL76-C 2 Safety / 2.7 Hazards during operation and maintenance 2.7 Hazards during operation and maintenance Mechanical hazards during operation During normal operation, no mechanical hazards emanate from the tur- bocharger if it has been installed properly. WARNING Risk of injury Contact with rotating parts can lead to serious injuries.
Page 24 Operation Manual / TPL76-C 2 Safety / 2.7 Hazards during operation and maintenance Hazards due to noise The development of noise during operation is influenced by the installa- tion and operating conditions. Noise with a sound pressure level exceed- ing 85 dB(A) is harmful. WARNING Hazards due to noise Noise can cause impaired hearing, damage to health, mental disturb-...
Page 25 Operation Manual / TPL76-C 2 Safety / 2.7 Hazards during operation and maintenance WARNING Hot surfaces on uninsulated turbochargers Uninsulated turbochargers can cause serious personal injuries (burns). The turbocharger is supplied with or without insulation in accordance with the purchase order received from the enginebuilder. If supply is without insulation, the enginebuilder is responsible for providing the turbocharger with proper insulation and for providing protection against contact with hot surfaces.
Page 26 Operation Manual / TPL76-C 2 Safety / 2.7 Hazards during operation and maintenance WARNING Risk of fire, explosion Flammable and combustible operating materials and supplies can catch fire or resulting vapours can lead to an explosion. Observe the details in the material safety data sheets of the operat- ing and auxiliary materials.
Page 27 Operation Manual / TPL76-C 2 Safety / 2.7 Hazards during operation and maintenance Hazards when handling insulating materials WARNING Hazards due to insulating materials Dust and fibres from insulating materials can cause damage to health or irritations. Unsuitable, combustible insulating materials signify a fire hazard.
Page 28: Periodic Checking Of The Pressure Vessel
Heed any country-specific regulations. 2.8 Periodic checking of the pressure vessel The pressure vessels used by ABB, such as those for wet or dry cleaning, are so-called "simple pressure vessels". ¡ The locally applicable legal regulations regarding periodic checks of the pressure vessels must be observed.
Page 29 Operation Manual / TPL76-C 2 Safety / 2.9 Lifting loads In the case of two or more suspension points, the slinging angle must not exceed 45°. This avoids excessive loading due to inclined tensile loading. Fasten turbocharger assemblies / components as described in re- spective handling steps.
Page 30: Commissioning
Operation Manual / TPL76-C 3 Commissioning / 3.1 Oil supply 3 Commissioning 3.1 Oil supply A carefully designed and installed oil supply, which functions in all pos- sible operational conditions, is an important prerequisite for trouble- free turbocharger operation. The turbocharger is normally lubricated with oil from the engine oil cir- cuit.
Page 31 Operation Manual / TPL76-C 3 Commissioning / 3.1 Oil supply Oil pressure The oil pressure in front of the turbocharger must be maintained pre- cisely to ensure trouble-free operation. The permissible oil pressure ranges at measuring point M (blind connec- tion) on the turbocharger are listed below.
Page 32 > 150 If the turbocharger was operated for a longer period of time outside of the admissible range, ABB Turbo Systems recommends to have the tur- bocharger inspected by an ABB Turbocharging Service Station. © Copyright 2018 . All rights reserved.
Page 33: Inspection Work
Operation Manual / TPL76-C 3 Commissioning / 3.2 Inspection work 3.2 Inspection work Inspection work includes preventive visual controls plus monitoring and measuring work before and during commissioning. Inspections help de- tect changes to the turbocharger. Machine damage can be avoided. 3.2.1 Inspection before commissioning Monitoring devices Check for correct functioning.
Page 34 The first step is to check for leak- age of the oil supply to the turbocharger. If this is leaky, contact an offi- cial ABB Turbocharging service station. 3.2.4 Inspection after 100 service hours Clean or replace lubricating oil filters after the first 100 service hours.
Page 35: Commissioning After Taking Out Of Operation
Operation Manual / TPL76-C 3 Commissioning / 3.3 Commissioning after taking out of operation 3.3 Commissioning after taking out of operation If provided Remove cover plates (blind flanges) between compressor casing out- let and charge air duct, before gas inlet and after gas outlet. Inspect exhaust gas duct / line in front of and after turbine for any combustion deposits, foreign matter or residual water.
Page 36: Operation
Operation Manual / TPL76-C 4 Operation / 4.1 Noise emissions 4 Operation 4.1 Noise emissions WARNING Hazards due to noise Noise can cause impaired hearing, damage to health, mental disturb- ances, diminished attention and irritation. Always wear ear protection when the engine is running. When the sound pressure level is above 85 dB(A), always wear ear protection.
Page 37 Operation Manual / TPL76-C 4 Operation / 4.1 Noise emissions Suggestion for noise insulation of the bellows Compressor casing Insulation pads Bellows Insulation mat (at least 15 mm) Charge air duct / scavenging Sheet metal cover air line © Copyright 2018 . All rights reserved. HZTL2485_EN Revision F April 2018...
Page 38: Servicing Work
Despite observance of the service intervals, unusual loads, such as sev- eral start-stops a day, harsh environmental factors, poor fuel quality or heavy installation vibration can lead to premature machine damage. A shortened service interval must be arranged with ABB Turbo Sys- tems. NOTICE...
Page 39 Operation Manual / TPL76-C 4 Operation / 4.2 Servicing work 4.2.2 Entries in engine logbook By monitoring the engine, conclusions can be drawn about the tur- bocharger performance. The following operating data and measured values must be entered reg- ularly in the engine manufacturer's engine logbook: ¡...
Page 40 Inspect and assess bearing parts and rotor. 4.2.5 Service work every 24000 … 36000 hours The replacement of bearing parts and the inspection and assessment of the rotor must be carried out by an ABB Turbocharging Service Station. Disassemble turbocharger. Clearance measurement.
Page 41: Replacement Intervals For Turbocharger Components
Operation Manual / TPL76-C 4 Operation / 4.3 Replacement intervals for turbocharger components 4.3 Replacement intervals for turbocharger components Rotating components The recommended replacement intervals for the compressor and turbine wheels due to stress caused by centrifugal forces and load cycles are cal- culated under consideration of the operating conditions while applying the safety concept for rotating components.
Page 42 Operation Manual / TPL76-C 4 Operation / 4.3 Replacement intervals for turbocharger components Parameters influencing rotating components exposed to exhaust ¡ Fuel quality (gas, MDO, HFO) ¡ Turbine cleaning frequency ¡ Procedure for turbine cleaning ¡ Load profile Expected replacement in- Component GAS / MDO tervals [h]...
Page 43: Speed Measurement
Operation Manual / TPL76-C 4 Operation / 4.4 Speed measurement 4.4 Speed measurement A speed measuring system permits continuous monitoring of the tur- bocharger speed. CAUTION Do not use cables as a climbing aid If you pull the speed measurement cables too hard, contacts can be pulled out.
Page 44 If the engine can be stopped for a short time: Inspect the air and gas lines as well as the turbocharger and eliminate any problems. In any event, it is recommended that you contact the nearest ABB Tur- bocharging Service Station. 4.4.2 Assembly...
Page 45 Operation Manual / TPL76-C 4 Operation / 4.4 Speed measurement 4.4.3 Replacing the speed sensor WARNING Hot cable connector and hot speed sensor Risk of burning. During operation, the cable connector and the speed sensor can reach temperatures exceeding 100 °C. Wear safety gloves when removing the cable connector and speed sensor.
Page 46: Stopping The Engine
Operation Manual / TPL76-C 4 Operation / 4.5 Stopping the engine 4.5 Stopping the engine CAUTION Stopping the engine Heat in the turbocharger must be dissipated by the further circulating lubricating oil. Allow the engine to continue running at idling speed for a further 10 minutes before stopping.
Page 47: Maintenance
Operation Manual / TPL76-C 5 Maintenance / 5.1 Foreword to Maintenance 5 Maintenance 5.1 Foreword to Maintenance Maintenance and servicing work involves regular visual checks and clean- ing to ensure that the turbocharger and its attached units function trouble-free. ¡ The external condition and how dirty the cleaning points specified in this chapter are, must be established by visual checks at the spe- cified intervals.
Page 48: Cleaning The Filter Silencer
Operation Manual / TPL76-C 5 Maintenance / 5.2 Cleaning the filter silencer 5.2 Cleaning the filter silencer 5.2.1 Filter silencer and connecting rod 81265 Filter ring (if provided) 81136 Absorption segment 81269 Connecting rods 81137 Sheet-metal covering 81266 Cover grid 81135 Filter silencer body 81272...
Page 49 Otherwise there is a risk of damage or deformation. NOTICE Replace heavily contaminated or damaged parts with original parts from ABB Turbo Systems. Fitting filter silencer Assemble insert units (E) by putting fleece segments (81136) into sheet-metal cover (81137).
Page 50 Operation Manual / TPL76-C 5 Maintenance / 5.2 Cleaning the filter silencer CAUTION If the connecting rods (81269) are not located correctly in their recesses on the filter silencer body (81135), the cover grids (81266) can twist and shift. There is then a risk of foreign matter and dirt getting into the compressor.
Page 51: Cleaning The Compressor During Operation
The interval between periodic cleaning is very dependent on the operat- ing conditions. In general, cleaning should be carried out every 25 ... 100 operating hours. Should the specified cleaning intervals prove incompatible with engine operation, please contact ABB Turbo Systems. © Copyright 2018 . All rights reserved. HZTL2485_EN Revision F...
Page 52 Cleaning of the compressor during operation is carried out using the cleaning method described in the following: ¡ Wet cleaning This cleaning method has been tested and approved by ABB Turbo Sys- tems. Principle of wet cleaning To clean the compressor stage during operation, water is injected in front of the compressor wheel.
Page 53 Operation Manual / TPL76-C 5 Maintenance / 5.3 Cleaning the compressor during operation 5.3.1 Wet cleaning with orifice plate on filter silencer (XC2) Operating state prerequisites for wet cleaning XC2 WARNING Increased stress on material During cleaning of the compressor at an engine load of 85 to 100 %, the stress on the material of the compressor-end turbocharger parts can be increased.
Page 54 Operation Manual / TPL76-C 5 Maintenance / 5.3 Cleaning the compressor during operation Surging of the compressor stage Should repeated surging of the compressor stage occur during com- pressor cleaning, first the cleaning parameters as well as the engine-side system must be checked with regard to deviations (e.g. an increased pressure loss in the charge air cooler) and corrected if necessary.
Page 55 Operating state prerequisites for compressor cleaning with XC3 In order to carry out a successful cleaning procedure that has been tested and is recommended by ABB Turbo Systems, the following pre- requisite must be met: Engine load 50 ... 85% Start cleaning cycle according to following description Wet cleaning operation with XC3.
Page 56 The cleaning process can be repeated up to two times. If the cleaning is still unsuccessful after three cleaning processes and the engine values are unsatisfactory, it is recommended to have the tur- bocharger checked and cleaned by an ABB Turbocharging Service Sta- tion. Cleaning parameters per turbocharger compressor...
Page 57: Cleaning Turbine Blades And Nozzle Ring In Operation
Cleaning method When cleaning the turbine components during operation, use wet clean- ing. This cleaning method has been tested and approved by ABB Turbo Systems. Prerequisites for wet cleaning are that the engine builder approves the process and his instructions are followed.
Page 58 Operation Manual / TPL76-C 5 Maintenance / 5.4 Cleaning turbine blades and nozzle ring in opera- tion ¡ Erosion The dirt is removed by the mechanical action of the impacting water droplets. ¡ Solubility Water solubility of the contamination deposits in water. ¡...
Page 59 Prerequisites for wet cleaning of turbine The following operating state and prerequisites have been tested and approved by ABB Turbo Systems for the cleaning process: The engine has just been started or the engine load has been reduced as far as possible (best cleaning is achieved at a load level of roughly 10 ... 15%).
Page 60 Operation Manual / TPL76-C 5 Maintenance / 5.4 Cleaning turbine blades and nozzle ring in opera- tion Layout of cleaning pipes Wet cleaning procedure for turbine during operation Meet prerequisites and operating state requirements without fail be- fore cleaning! Make sure water supply (01) is connected, turned on and guaranteed. Open drain pipe (08, 09), if provided.
Page 61 The maximum volume of water allowed in individual cases must be determined together with an ABB Turbocharging Service Station. The influence of the cleaning water on peripheral equipment, such as a boiler, must be clarified by the operator.
Page 62: Cleaning Components Mechanically
(see chapter entitled Service work). Professional overhauling of the components by an ABB Turbocharging Service Station is required, preferably using the cleaning method de- scribed in the following.
Page 63 Operation Manual / TPL76-C 5 Maintenance / 5.5 Cleaning components mechanically 5.5.2 Turbine-end, non-rotating parts WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or contact with them may be harmful to health. Do not breathe in these substances and avoid contact with the skin. Ensure proper ventilation.
Page 64 Operation Manual / TPL76-C 5 Maintenance / 5.5 Cleaning components mechanically 5.5.3 Cartridge group – General CAUTION Corrosion If the cartridge group is not put into operation again immediately after cleaning, parts may corrode. Re-install and use the cartridge group immediately after cleaning. Remove turbocharger from the engine (see chapter Removal and in- stallation).
Page 65 Operation Manual / TPL76-C 5 Maintenance / 5.5 Cleaning components mechanically Baked layers of contamination from fuel residue or coked oil may occur at the turbine end. The contamination can be removed by soaking and brushing. The procedure for soaking the layers of contamination as well as for cleaning the turbine are described in the following.
Page 66 Operation Manual / TPL76-C 5 Maintenance / 5.5 Cleaning components mechanically 4. When the cartridge group is horizontal, secure one chain block to one of the upper push-off threads using a swivel lifting eye and suspend from the second crane. 5.
Page 67 Operation Manual / TPL76-C 5 Maintenance / 5.5 Cleaning components mechanically Cartridge group with two side suspension points Or use two swivel lifting eyes at top. CAUTION Damage to compressor wheel The lifting gear must not touch the compressor wheel at any time dur- ing rotation.
Page 68 Operation Manual / TPL76-C 5 Maintenance / 5.5 Cleaning components mechanically 4. When the cartridge group is suspended horizontally, attach a chain block to the swivel lifting eye and attach to the first crane. 5. Tighten chain block until entire cartridge group is suspended from first crane.
Page 69 Operation Manual / TPL76-C 5 Maintenance / 5.5 Cleaning components mechanically WARNING Heating up of cleaning agents and operating fluids When cleaning agents or operating fluids are heated up, explosive va- pours can be produced which are hazardous to health. Observe the information in the material safety data sheet.
Page 70 Operation Manual / TPL76-C 5 Maintenance / 5.5 Cleaning components mechanically CAUTION Water and contamination in the cartridge group If water or contamination gets into the cartridge group, the turbochar- ger function may be impaired and parts in the cartridge group may be damaged.
Page 71: Troubleshooting
If there is any doubt about the extent of rubbing, then an ABB Turbocharging Service Station must be contacted. ¡ Have a dimension check carried out by an ABB Turbochar- ging Service Station. © Copyright 2018 . All rights reserved.
Page 72: Surging Of The Turbocharger
Prolonged or periodic surging Possible damage to components, such as the compressor wheel, tur- bine blades, bearings and filter silencer Have the cause clarified immediately by an ABB Turbocharging ser- vice station and rectified. Have components inspected for damage and, if necessary, replaced by an ABB Turbocharging service station.
Page 73: Malfunctions During Operation
Defective oil pump in lubricat- Check / replace it ing system Manometer display wrong Replace the manometer Turbochar- Rotor axial clearance too large Contact an ABB Turbocharging Service Station Reduction in speed Possible causes Elimination Engine Defects of connected cylinders...
Page 74 Exhaust counterpressure Clean or repair the boiler or ex- too high haust silencer Enlarged flow cross-section Contact an ABB Turbocharging of the nozzle ring due to de- Service Station formed blade trailing edges Damaged or eroded turbine Charge air...
Page 75 Contaminated filter silencer Clean it causing excessive loss of pres- sure Compressor / turbine contam- inated Damaged compressor / tur- Contact an ABB Turbocharging bine Service Station Exhaust counterpressure too Clean or repair the boiler or ex- high haust silencer...
Page 76: Malfunctions When Stopping
6 Troubleshooting / 6.4 Malfunctions when stopping 6.4 Malfunctions when stopping Noises during run-down Possible causes Elimination Turbochar- Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Run-down time too short Possible causes Elimination Turbochar- Turbocharger contaminated...
Page 77: Speed Measurement System
This problem is eliminated by removing the gasket. Defective sensor Contact ABB Turbocharging service sta- tion. Measured Dirty sensor tip The sensor tip is magnetic and can thus at- speeds too tract metal particles.
Page 78: Removal And Installation
Operation Manual / TPL76-C 7 Removal and installation / 7.1 Turbocharger weight 7 Removal and installation 7.1 Turbocharger weight Lifting gear with a sufficient load limit must be used for removing and installing the turbocharger. The following weight specification is the heaviest variant possible.
Page 79: Removing The Turbocharger
A suitable suspension device (as illustrated) must be used when re- moving and installing the turbocharger. The suspension device is not supplied by ABB Turbo Systems. Disconnect all gas, air and oil pipes in accordance with the engineb- uilder’s instructions.
Page 80 Operation Manual / TPL76-C 7 Removal and installation / 7.2 Removing the turbocharger Version with compressor wheel cooling system Dismantle air supply line. (See also chapter entitled Preliminary re- marks / Layout and functionality) Inspect the lifting gear. Secure lifting gear to the suspension eyes of the bearing casing and the turbine-end foot.
Page 81: Installing The Turbocharger
Tighten the fixing screws on the foot. NOTICE The fastening specifications for the foot fixing screws are supplied to the engine builder by ABB Turbo Systems and given in his manual. Fasten the gas, air and oil lines in accordance with the engine builder’s instructions.
Page 82: Disassembly And Assembly
Further work Further tasks, which are not described here, may be carried out only by trained personnel from an ABB Turbocharging service station. Only carry out those tasks that are described in this chapter. Mark the casing position for assembly.
Page 83 The specified tightening torques of screw connections for turbocharger components must be observed. (See section Table of tightening torques.) Tightening torques for assembly devices of ABB Turbo Systems If nothing else is described, the screws and nuts of the assembly devices must be tightened down firmly.
Page 84: Module Weights
Operation Manual / TPL76-C 8 Disassembly and assembly / 8.2 Module weights 8.2 Module weights The specified weights of individual parts or assemblies are guides roun- ded off to the next highest value. Assemblies Weights [kg] Item Description TPL76-C Filter silencer Axial air suction branch Radial air suction branch Compressor casing internal part...
Page 85 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.2 Module weights Complete compressor casing internal part Weight [kg] TPL76-C NOTICE 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.
Page 86: Removing And Fitting Filter Silencer Or Air Suction Branch
Operation Manual / TPL76-C 8 Disassembly and assembly / 8.3 Removing and fitting filter silencer or air suction branch 8.3 Removing and fitting filter silencer or air suction branch Disconnect all air lines / ducts in accordance with engine builder’s in- structions.
Page 87 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.3 Removing and fitting filter silencer or air suction branch Removing filter silencer Remove insulation where necessary. Pass lifting gear through rib on filter silencer and through eyelets at rear. Unscrew nuts (74027) and remove them together with washers (74018).
Page 88: Axial Clearance
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Turbocharging Service Station. © Copyright 2018 . All rights reserved. HZTL2485_EN...
Page 89: Removing Cartridge Group
Operation Manual / TPL76-C 8 Disassembly and assembly / 8.5 Removing cartridge group 8.5 Removing cartridge group CAUTION Locked safety segments (76080) during disassembly Observe the maximum tightening torque for the nuts (90458) so as not to shear off the threaded studs of the safety segments (76080). Fit four nuts (74027) complete with washers (74018), equally spaced around circumference, and tighten.
Page 90 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.5 Removing cartridge group Removing the compressor casing internal part Remove two studs (74029 / 74026) at the point where the lifting device (90190) will be fitted later. Using press-off screws (90900), push apart the compressor casing in- ternal part (76000) until the lifting device (90190/90195) can be at- tached.
Page 91 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.5 Removing cartridge group Transporting / turning internal part of compressor casing Carefully turn internal part of compressor casing complete with wall insert and diffuser about support angle (90025) and put onto under- lay.
Page 92 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.5 Removing cartridge group Removing diffuser and wall insert Remove screws (76002). Remove diffuser (79000) using swivel lifting eyes (90235). Press away wall insert (77000) using press-off screws (90230) and re- move from internal part of compressor casing (76000) using swivel lifting eyes (90235).
Page 93 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.5 Removing cartridge group Removing external part of compressor casing Fasten lifting device (90190/90195) to external part of compressor casing (74000) using screws and secure to crane. Remove screws (42280). Uniformly press away external part of compressor casing (74000) us- ing press-off screws (90900) and remove.
Page 94 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.5 Removing cartridge group Removing the cartridge group Unplug cable connector (86515) and unscrew speed sensor (86505) with O-ring (86506). Disconnect oil inlet and oil outlet pipes. CAUTION Oil orifice plates An orifice plate for adjusting the oil pressure is fitted in each of the two oil inlet channels in the bearing casing.
Page 95 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.5 Removing cartridge group * When pressing off, use diametrically opposite press-off threads. Other- wise the bearing casing can jam and damage the turbine blades. Check lifting gear and attach to bearing casing (42001). Loosen nuts (61037) and remove Verbus Ripp®...
Page 96: Dismantling And Installing The Turbine Diffuser And Nozzle Ring
Operation Manual / TPL76-C 8 Disassembly and assembly / 8.6 Dismantling and installing the tur- bine diffuser and nozzle ring 8.6 Dismantling and installing the turbine diffuser and nozzle ring Removing turbine diffuser Put assembly plate (90020) over strain bolts (61036). Insert extension (A) of torque spanner (B) through hole in assembly plate and loosen screws (61056) one after other.
Page 97 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.6 Dismantling and installing the tur- bine diffuser and nozzle ring Replace two screws (61056) with guide studs (90320). Fit assembly plate (90020) over studs (61036). Screw nuts (61037) onto start of threads of studs (61036) to secure. Remove remaining screws (61056).
Page 98 Clogged areas on the nozzle ring If a nozzle ring is clogged in some areas or is covered by loose parts, it is recommended to appoint an ABB Turbocharging Service Station to inspect the turbine blades and carry out a crack inspection.
Page 99 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.6 Dismantling and installing the tur- bine diffuser and nozzle ring Installing the nozzle ring CAUTION Fastening the nozzle ring When fitting the nozzle ring, new threaded studs (56021), nuts (56022) and locking plates (56018) from the customer spare part set (97070) must be used.
Page 100: Installing Cartridge Group
Operation Manual / TPL76-C 8 Disassembly and assembly / 8.7 Installing cartridge group Fitting turbine diffuser Coat all screw threads on and in the gas casings with high-temperat- ure grease. Fasten turbine diffuser (63000) to lifting gear. Align marking "TOP" with the position of the gas outlet flange and pay attention to where the positioning pin is in the gas outlet casing.
Page 101 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.7 Installing cartridge group Remove cover from oil connection. Fit flange (42044) with new gasket (42045) and screws (42064). Check lifting gear and attach to bearing casing (42001) in such a way that cartridge group is suspended in a straight position.
Page 102 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.7 Installing cartridge group Remove the lifting gear. Remove guide rod (90490). Screw in the speed sensor (86505) together with the O-ring (86506) and plug in the cable connector (86515). Reconnect oil and air lines. Version with compressor wheel cooling system Fit the air supply line.
Page 103 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.7 Installing cartridge group Fitting external part of compressor casing Fasten lifting device (90190/90195) to external part (74000) of com- pressor casing and secure it with crane. Fit O-ring (42012). Fit external part of compressor casing (74000) and fasten using screws (42280).
Page 104 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.7 Installing cartridge group Fitting diffuser and wall insert Screw swivel lifting eyes (90235) into holes in wall insert (77000). Align mark (A) with notch (B). Fit centering screws (90230) in such a way that spigots on centering screws protrude maximum 5 mm.
Page 105 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.7 Installing cartridge group Turning / transporting internal part of compressor casing Fasten lifting device (90190/90195) to front side of flange (F). Carefully turn internal part of compressor casing (76000) complete with wall insert and diffuser about support angle (90025) and lift up vertically.
Page 106 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.7 Installing cartridge group Fitting compressor casing internal part * The two compressor casing parts are centred via the long cylindrical flange. No guide pieces are needed. Check whether the nuts (90458) of the three safety segments have been tightened (safety segments are in the "not engaged"...
Page 107 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.7 Installing cartridge group NOTICE Align the compressor casing internal part (76000) with the notch (see the arrow) so that the notch is positioned at the rib of the compressor casing external part (74000) (see the arrow). Fully insert the compressor casing internal part (76000).
Page 108 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.7 Installing cartridge group Engaging safety elements / securing casing CAUTION Locked safety segments (76080) during assembly The safety segments (76080) are not in the operating position. Addi- tional axial securing of the two compressor casings (74000/76000) is not guaranteed.
Page 109 Clearance A [mm] TPL76-C 0.43 … 0.69 CAUTION If the axial clearance (A) is out of tolerance, an official ABB Turbo Sys- tems service station must be contacted. Connect oil lines and all air lines in accordance with engine builder specifications.
Page 110: Dismantling And Fitting Nozzle Ring At Turbine End
If a nozzle ring is found to be clogged over partial areas or covered by loose parts, it is recommended that you have a turbine blade inspection including a crack inspection carried out by an ABB Turbocharging Ser- vice Station.
Page 111 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.8 Dismantling and fitting nozzle ring at turbine end Segment connection Undo screws (61044) and remove segments (51012). Flange connection Undo and remove screws (61044). Pull gas inlet casing (51001) complete with nozzle ring (56001) away from gas outlet casing (61001).
Page 112 Clogged areas on the nozzle ring If a nozzle ring is clogged in some areas or is covered by loose parts, it is recommended to appoint an ABB Turbocharging Service Station to inspect the turbine blades and carry out a crack inspection.
Page 113 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.8 Dismantling and fitting nozzle ring at turbine end Push in nozzle ring (56001) as far as it will go at the cover of the gas inlet casing. Coat threads of threaded studs (56021) with high-temperature grease and fit threaded studs.
Page 114 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.8 Dismantling and fitting nozzle ring at turbine end Tightening of segment connection NOTICE Radial gas inlet casing with segment 51012 In the case of the radial inlet casing with segments, the segments are positioned by a pin in the slot on the casing.
Page 115 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.8 Dismantling and fitting nozzle ring at turbine end Tighten screws (61044) in accordance with following procedure and in following order: Segment connection Begin with two middle screws of individual segments and then con- tinue outwards alternately.
Page 116 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.8 Dismantling and fitting nozzle ring at turbine end Tightening flange connection Fit screws (61044). Tighten screws (61044) in accordance with following procedure and in following order: Flange connection Tighten screws crosswise NOTICE Screw tightening sequence The screw positioning numbers must be marked on the component.
Page 117 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.8 Dismantling and fitting nozzle ring at turbine end Tightening torques for Tightening TPL76-C screws (61044) [Nm] Step 1 Screw in all screws hand-tight with spiral-wound gasket Step 2 Step 3 Tightening torques for Tightening TPL76-C...
Page 118: Table Of Tightening Torques
Operation Manual / TPL76-C 8 Disassembly and assembly / 8.9 Table of tightening torques 8.9 Table of tightening torques © Copyright 2018 . All rights reserved. HZTL2485_EN Revision F April 2018...
Page 119 Operation Manual / TPL76-C 8 Disassembly and assembly / 8.9 Table of tightening torques Tightening torques [Nm] Position Part number TPL76-C 82005 M16 x 1.5 76002 74027 With washer 74026/74029 42280 61036 61051 (VR) 2,3) 61037 MV 80 / DW 90° 42059 42064 61044...
Page 120: Taking Out Of Operation At Short Notice
Operation Manual / TPL76-C 9 Taking out of operation at short notice / 9.1 Possibilities for emer- gency repair 9 Taking out of operation at short notice 9.1 Possibilities for emergency repair WARNING Danger of fire and explosion due to lubricating oil leaks Leaking oil may ignite on hot surfaces.
Page 121: Locking The Rotor
Operation Manual / TPL76-C 9 Taking out of operation at short notice / 9.2 Locking the rotor 9.2 Locking the rotor CAUTION A locked rotor must be removed and checked for unbalance after the turbocharger repair. NOTICE An exception is a test rig run up to a maximum of 25% of the engine load in the case of new engines with one or several turbochargers.
Page 122 Operation Manual / TPL76-C 9 Taking out of operation at short notice / 9.2 Locking the rotor Locking rotor Table of tightening Part no. TPL76-C torques 74027 135 Nm 94006 25 Nm NOTICE Carry out work as described in the chapter Disassembly and assembly. Remove silencer or air suction branch.
Page 123 Operation Manual / TPL76-C 9 Taking out of operation at short notice / 9.2 Locking the rotor Put assembly/disassembly device (90020) over studs (74026) and lift- ing device (90427). Turn compressor wheel until holes in lifting device (90427) align with holes in assembly/disassembly device (90020).
Page 124 Operation Manual / TPL76-C 9 Taking out of operation at short notice / 9.2 Locking the rotor Further measures and information for operation with blocked rotor for 4-stroke engines 4-stroke engine with one turbocharger No further measures are necessary. The engine can be operated as a nat- urally-aspirated engine according to the engine builder's instructions.
Page 125: Fit Cover Plate
Operation Manual / TPL76-C 9 Taking out of operation at short notice / 9.3 Fit cover plate 9.3 Fit cover plate NOTICE The cover plate (material: General structural steel, in accordance with DIN EN 10025-2) must be manufactured in-house according to the drawing.
Page 126 Operation Manual / TPL76-C 9 Taking out of operation at short notice / 9.3 Fit cover plate NOTICE Carry out the work as described in the chapter Removal and fitting. Remove cartridge group. © Copyright 2018 . All rights reserved. HZTL2485_EN Revision F April 2018...
Page 127 Operation Manual / TPL76-C 9 Taking out of operation at short notice / 9.3 Fit cover plate Close off opening in gas outlet casing using cover plate. Fasten cover plate using spacer sleeves and nuts (61037). CAUTION Shut off the supply of lubricating oil to the turbocharger. ©...
Page 128 Operation Manual / TPL76-C 9 Taking out of operation at short notice / 9.3 Fit cover plate Further measures and information for operation with a turbocharger with cover plate on 4-stroke engines 4-stroke engine with one turbocharger No further measures are necessary. The engine can be operated as a nat- urally-aspirated engine according to the engine builder's instructions.
Page 129: Blocking The Inlets And Outlets
Operation Manual / TPL76-C 9 Taking out of operation at short notice / 9.4 Blocking the inlets and outlets 9.4 Blocking the inlets and outlets CAUTION Shut off the lubricating oil supply to the turbocharger. Shut off compressor casing outlet, gas inlet and gas outlet by fitting cover plates.
Page 130: Mothballing The Turbocharger
Remove turbocharger. Rotor and bearing parts must be removed by an official ABB Tur- bocharging service station and refitted afterwards. Clean all parts. Oil machined, bright surfaces of steel and cast parts using anticorros- ive oil.
Page 131: Taking Out Of Operation For More Than 12 Months
Operation Manual / TPL76-C 10 Mothballing the turbocharger / 10.2 Taking out of operation for more than 12 months 10.2 Taking out of operation for more than 12 months If the engine is taken out of service, the following can be done with the turbocharger: ¡...
Page 132: Disposing Of Turbocharger Components
Operation Manual / TPL76-C 11 Disposing of turbocharger components / 11 Disposing of turbocharger components WARNING Handling damaged thermal insulation Damaged thermal insulation can lead to dust exposure. The glass fibres can cause mechanical irritation of the eyes, skin, and respiratory tracts. Avoid the formation of dust.
Page 133: Spare Parts
Serial number (HT……) ¡ Designation and part number Spare parts can be ordered from an official ABB Turbocharging service station. If different design versions have not been taken into consideration in this document, please contact an ABB Turbocharging service station.
Page 134: View Of Turbocharger With Part Numbers
Operation Manual / TPL76-C 12 Spare parts / 12.2 View of turbocharger with part numbers 12.2 View of turbocharger with part numbers © Copyright 2018 . All rights reserved. HZTL2485_EN Revision F April 2018...
Page 135 Operation Manual / TPL76-C 12 Spare parts / 12.2 View of turbocharger with part numbers Part number Description Cartridge group 42012 (in customer spare part set) O-ring 51001 Gas inlet casing 51012 Segment 56001 Nozzle ring 56018 (in customer spare part set) Locking plate 56021 (in customer spare part set) Threaded stud...
Page 136 ABB Turbo Systems AG Bruggerstrasse 71a CH-5400 Baden Switzerland...

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