Page 1 Operation Manual TPL69-A10 ABB Turbo Systems Ltd CH 5401 Baden Type TPL69-A10 HT842691 Mmax Mmax °C Bmax Bmax 01780 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
Lifting loads Start-up Oil supply Inspection work Commissioning after taking out of operation Operation Noise emissions Servicing work Replacement intervals for turbocharger components Speed measurement Underpressure measurement on filter silencer Stopping the engine © Copyright 2016 ABB. All rights reserved.
Page 4 Dismantling and fitting nozzle ring at turbine end Table of tightening torques Taking out of operation at short notice Possibilities for emergency repair Locking the rotor Fit cover plate Blocking the inlets and outlets Bypass the turbocharger Mothballing the turbocharger © Copyright 2016 ABB. All rights reserved.
Page 5 Taking the engine out of operation for more than 12 months Disposing of turbocharger components Spare parts 12.1 Ordering spare parts 12.2 View of turbocharger with part numbers 12.3 View of turbine cleaning system with part numbers (optional) © Copyright 2016 ABB. All rights reserved.
Page 7: Preliminary Remarks
Operation Manual This Operation Manual enables you to familiarize yourself with the turbo- charger supplied by ABB Turbo Systems and to use it as intended. It provides important information in order that the turbocharger can be op- erated safely, correctly and efficiently.
Page 8: Layout And Function
02 Radial plain bearing 09 Turbine wheel 03 Thrust bearing 10 Bearing casing 04 Bearing bush 11 Diffuser 05 Radial plain bearing 12 Compressor wheel 06 Gas outlet casing 13 Compressor casing 07 Gas inlet casing © Copyright 2016 ABB. All rights reserved.
Page 9 In the case of the turbocharger version with compressor wheel cooling, the cooling air is supplied through the side connection (15) in the bearing casing. © Copyright 2016 ABB. All rights reserved.
Page 10: Intended Use Of The Turbocharger
Any other use will be regarded as a special application which must first be discussed with ABB Turbo Systems. The manufacturer accepts no liability for other applications. If it is used otherwise, ABB Turbo Sys- tems reserves the right to reject all warranty claims.
Page 11: 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 12 Page 10 spare parts Long-term storage of replacement turbochargers or spare parts Per order, turbochargers or cartridge groups will be prepared by ABB Tur- bo Systems for prolonged storage. The package is equipped with a hyg- rometer (see illustration). The following measures are required every 6 months: Check the hygrometer (02) in the sight-glass.
Page 13: Essential Information
The fault must be reported to the person or depart- ment responsible. Additions and alterations to, and conversions of the turbocharger that could compromise safety require the prior approval of ABB Turbo Sys- tems. NOTICE © Copyright 2016 ABB. All rights reserved.
Page 14 Only use original parts from ABB Turbo Systems.  ABB Turbo Systems accepts no liability for any damage resulting from the use of non-original parts and corresponding accessories. Competence of personnel The turbocharger must only be operated and serviced by trained and au- thorised personnel.
Page 15: 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 Turbo- charging Service Stations.
Page 16: Turbocharger Rating Plate
Replacement interval for turbine in 1000 h Further information Customer part number Designation of the special design Turbocharger weight in kg Turbocharger type Serial number Year of construction of turbocharger Manufacturing plant © Copyright 2016 ABB. All rights reserved.
Page 17 A rating plate is attached to the turbocharger foot, one on the left and one on the right. In the case of turbochargers with insulation supplied by ABB Turbo Systems, at least one additional rating plate is attached to the insu- lation of the gas outlet casing.
Page 18: Contact Information
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Preliminary remarks Contact information Page 16 Contact information Contact information Contact information for the official service stations of ABB Turbo Systems is available online. Scan the QR code to access our website.  ABB Turbo Systems Ltd Bruggerstrasse 71a...
Page 19: Safety
Page 17 Safety Introduction Turbochargers manufactured by ABB Turbo Systems are state of the art and comply with the pertinent safety and health-protection requirements that applied when the turbocharger was manufactured. Consequently, the turbocharger is safe to operate. Nevertheless, during turbocharger opera- tion and when working on the turbocharger, residual risks can exist which: ...
Page 20: Definition Of Mandatory Signs
Serious machine or property damage may occur if work and operating instructions marked with this symbol and the word CAUTION are either CAUTION not followed or not followed precisely. Caution signs must be observed at all times.  © Copyright 2016 ABB. All rights reserved.
Page 21: Warning Plates On The Turbocharger
Warning plates on the turbocharger Page 19 Warning plates on the turbocharger Warnings that have been attached to turbochargers by ABB Turbo Sys- tems must not be removed. Illegible warnings must be replaced with new ones. Further information is available from ABB Turbocharging service stations.
Page 22: Safe Operation And Maintenance
Remove combustible objects and substances out of the range of flying  sparks. Cover all connections on the turbocharger so that no foreign objects  can get into the turbocharger. © Copyright 2016 ABB. All rights reserved.
Page 23 Protect the floor against unintentional penetration of detergents or sol-  vents before starting cleaning operations. Wear appropriate protective clothing.  Inspect the electric cables for abrasion and damaged areas before and  after your cleaning work. © Copyright 2016 ABB. All rights reserved.
Page 24 Secure the rotor so it cannot turn. The rotor can turn on its own from  the force of the stack draught. Clean the turbocharger before mothballing it.  Wear appropriate protective clothing.  © Copyright 2016 ABB. All rights reserved.
Page 25: Hazards During Operation And Maintenance
Observe the general rules for occupational safety and prevention of  accidents. Ensure workplace safety.  Only perform operations that are described in this chapter.  Only perform operations for which you have previously received in-  struction or training. © Copyright 2016 ABB. All rights reserved.
Page 26 Wear safety gloves to protect against thermal hazards. Hot surfaces on uninsulated turbochargers Uninsulated turbochargers can cause serious personal injuries (burns). The turbocharger is supplied by ABB Turbo Systems without insulation WARNING depending on the order from the engine builder. In this case, the engine builder is responsible for insulating the turbocharger properly or for providing protection against hot surfaces being touched.
Page 27 The escape of operating and auxiliary materials into the atmosphere or contamination of the ground and water due to improper disposal can CAUTION lead to environmental damage. Handle operating and auxiliary materials carefully.  © Copyright 2016 ABB. All rights reserved.
Page 28 Ensure that the work area is well ventilated.  Wear suitable work clothing (safety glasses, respiratory mask).  Avoid stirring up dust.  Use tools and processes which keep dust to a minimum.  © Copyright 2016 ABB. All rights reserved.
Page 29: Periodic Checking Of The Pressure Vessel
Heed any country-specific regulations.  Periodic checking of the pressure vessel The pressure vessels used by ABB Turbo Systems, such as those for wet or dry cleaning, are so-called "simple pressure vessels".  The local, statutory regulations covering periodic checks of pressure vessels must be observed.
Page 30: Lifting Loads
Completely screw in assembly / fitting devices without fail so that they  cannot work loose during use. Use assembly / fitting devices only for applications described.  Make sure removed turbocharger components stand safely and se-  curely. © Copyright 2016 ABB. All rights reserved.
Page 32 A metering orifice is installed in the oil inlet of the turbocharger to en- sure these oil pressures. The orifice is installed by the enginebuilder NOTICE and it is fixed in place with a locking ring. © Copyright 2016 ABB. All rights reserved.
Page 33 > 150 If the turbocharger was operated for a longer period of time outside of the admissible range, ABB Turbo Systems recommends to have the turbo- charger inspected by an ABB Turbocharging Service Station. © Copyright 2016 ABB. All rights reserved.
Page 34: Inspection Work
Check oil pressure in oil supply lines.  Check whether the warning plates are present and legible. Warning plates on tur-  bocharger Check whether the protective sheets have been removed.  © Copyright 2016 ABB. All rights reserved.
Page 35 If oily liquid continues to escape after this period, an oil leak must be suspected. The first step is to check for leakage of the oil NOTICE supply to the turbocharger. If this is leaky, contact an official ABB Tur- bocharging service station. 3.2.4 Inspection after 100 service hours Clean or replace lubricating oil filters after the first 100 service hours.
Page 36: Commissioning After Taking Out Of Operation
Start up turbocharger oil circulation system at engine end.  Prepare turbocharger for operation as instructed in section "Inspection  work before start-up / commissioning" of chapter headed "Start-up / commissioning". Start up turbocharger.  © Copyright 2016 ABB. All rights reserved.
Page 37: Operation
Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 : A-weighted emission sound pressure level In the event of divergent insulation designs, the engine builder must en- sure that equivalent acoustic insulating measures are taken. © Copyright 2016 ABB. All rights reserved.
Page 38 Operation Noise emissions Page 36 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 2016 ABB. All rights reserved.
Page 39: Servicing Work
Despite observance of the service intervals, unusual loads, such as several start-stops a day, harsh environmental factors, poor fuel quality CAUTION or heavy installation vibration can lead to premature machine damage. A shortened service interval must be arranged with ABB Turbo Sys-  tems. Service inspection after 5 years...
Page 40  Pressure loss in air filter 4.2.3 Servicing work according to the engine manufacturer's instructions Clean or replace oil filter in supply line to turbocharger when engine is Oil filter  not running. © Copyright 2016 ABB. All rights reserved.
Page 41  4.2.5 Service work every 24000 … 36000 hours The replacement of bearing parts as well as the inspection and assess- ment of the rotor must be carried out by an ABB Turbocharging Service Station. Disassemble turbocharger.  Measure clearances.
Page 42: Replacement Intervals For Turbocharger Components
Parameters influencing non-rotating components exposed to exhaust gas  Fuel quality (gas, MDO, HFO)  Load profile (thermal load changes, number of starts/stops)  Temperature level of exhaust gas  Turbine cleaning frequency  Procedure for turbine cleaning © Copyright 2016 ABB. All rights reserved.
Page 43 See the data on the rating plate ment intervals [h] = Gas Engine = Marine Diesel Oil = Heavy Fuel Oil See Influencing The specified values are guides and not guaranteed. ( parameters NOTICE © Copyright 2016 ABB. All rights reserved.
Page 44: Speed Measurement
Cable connector for 86505 86526 F/I converter 86528 Tachometer 4.4.1 Speed differences with multiple turbochargers per engine The speeds of all turbochargers on one engine differ only slightly from each other in normal operation. © Copyright 2016 ABB. All rights reserved.
Page 45 If the engine can be stopped for a short time: Inspect the air and gas lines as well as the turbocharger and eliminate  any problems. In any event, it is recommended that you contact the nearest ABB  Turbocharging Service Station. 4.4.2...
Page 46 Connect cable connector to speed sensor.  Switch on lubricating oil supply to turbocharger.  4.4.4 Failure of speed measuring system Possible reasons for failure of the speed measuring system are described in the chapter Troubleshooting. © Copyright 2016 ABB. All rights reserved.
Page 47: Underpressure Measurement On Filter Silencer
Page 45 silencer Underpressure measurement on filter silencer A U-tube manometer can be ordered from ABB Turbo Systems for meas- uring the negative pressure at the filter silencer. The measurement can be used for the following purposes:  To measure the correction factor for calculating the turbocharger effi- ciency during the engine acceptance test.
Page 48: Stopping The Engine
Stopping the engine Heat in the turbocharger must be dissipated by the further circulating lubricating oil. CAUTION Allow the engine to continue running at idling speed for a further 10  minutes before stopping. © Copyright 2016 ABB. All rights reserved.
Page 49: Maintenance
 The safety precautions must be observed during all maintenance and servicing work. The cleaning points described in the following are:  Filter silencer  Compressor  Turbine and nozzle ring © Copyright 2016 ABB. All rights reserved.
Page 50: Cleaning The Filter Silencer
81265 Filter ring (if provided) 81266 Cover grid 81270 Tension band 81136 Absorption segment 81271 Lock 81137 Sheet-metal covering 81268 Connecting strip 81135 Filter silencer body E Insert unit = absorption segment + sheet-metal covering fitted © Copyright 2016 ABB. All rights reserved.
Page 51 Otherwise there is a risk of damage or deformation. Replace heavily contaminated absorption segments, filter ring and damaged connecting strips with original parts from ABB Turbo Sys- tems. NOTICE...
Page 52 Filter ring (if provided) 81136 Absorption segment 81269 Connecting rods 81137 Sheet-metal covering 81266 Cover grid 81135 Filter silencer body 81272 Screwdriver 81273 Lock nut Insert unit = absorption segment + sheetmetal covering © Copyright 2016 ABB. All rights reserved.
Page 54 If the connecting rods (81269) are not correctly positioned in their re- cesses on the filter silencer unit (81135), the cover grid (81266) can twist and shift. There is then a risk of foreign matter and contamination getting into the compressor. CAUTION © Copyright 2016 ABB. All rights reserved.
Page 55 (81272) alternately until the following maximum torque is reached: Screw Tightening torque [Nm] 81272 Screw lock nuts (81273) onto screw (81272) and tighten to following  torque: Lock nut Tightening torque [Nm] 81273 Fit filter strip (81265). If provided  © Copyright 2016 ABB. All rights reserved.
Page 56: Cleaning The Compressor During Operation
The interval between periodic cleaning is very dependent on the operating Cleaning interval conditions. In general, cleaning should be carried out every 25 ... 100 op- erating hours. Should the specified cleaning intervals prove incompatible with engine operation, please contact ABB Turbo Systems. © Copyright 2016 ABB. All rights reserved.
Page 57 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. To clean the compressor stage during operation, water is injected in front...
Page 58 If the cleaning is still unsuccessful after three cleaning processes and the engine values are unsatisfactory, it is recommended to have the turbo- charger checked and cleaned by an ABB Turbocharging Service Station. Cleaning parameters for XC2 for each turbocharger compressor...
Page 59 Operating state prerequisites for wet cleaning XC3 To be able to carry out a satisfactory cleaning process which has been tested and is recommended by ABB Turbo Systems, the following pre- requisites must be fulfilled: Engine load 50 ... 85% ...
Page 60 If the cleaning result is still not satisfactory after three attempts and the engine values are also unsatisfactory, we recommend that you have the NOTICE turbocharger inspected and cleaned by an official ABB Turbocharging Service Station. Cleaning parameters per turbocharger compressor...
Page 61: Cleaning Turbine Blades And Nozzle Ring In Operation
The interval between periodic cleaning is very dependent on the operating Wet cleaning interval conditions. As a rule, cleaning should be carried out every 50 to 200 op- erating hours. © Copyright 2016 ABB. All rights reserved.
Page 62 When cleaning the turbine components during operation, use wet clean- Cleaning method 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 63 Recommended operating state for turbine wet cleaning The following operating state and prerequisites have been tested and ap- proved by ABB Turbo Systems for the cleaning process: The engine has just been started or the engine load has been reduced ...
Page 64 The injection process has been completed.  Close drain hole (if provided) above drain pipe (08, 09).  After cleaning, wait with engine running for at least 10 minutes without  changing load to allow turbocharger to dry. © Copyright 2016 ABB. All rights reserved.
Page 65 The maximum volume of water allowed in individual cases must be determined together with an ABB Turbocharging Service Station. The influence of the cleaning water on peripheral equipment, such as a boiler, must be clari- fied by the operator.
Page 66 Table of cleaning Product Maximum temper- Injection time Water flow rate per turbo- parameters ature at start of charger at p = 2 bar [min] Water cleaning process [l/min] [°C] TPL69-A TPL73-A TPL77-A © Copyright 2016 ABB. All rights reserved.
Page 67: 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 68 Brush off the contamination or remove it with a steam cleaner.  Repeat the soaking and brushing if necessary.  Completely remove any solvents from the parts in clean water.  Dry components completely.  © Copyright 2016 ABB. All rights reserved.
Page 69 If water or contamination penetrates the cartridge group, this can impair the function of the turbocharger and damage parts inside the cartridge CAUTION group. Make sure that no water or contamination can enter into the cartridge  group. © Copyright 2016 ABB. All rights reserved.
Page 70 Cartridge group with a central suspension point Damage to compressor wheel The lifting gear must not touch the compressor wheel at any time during rotation. CAUTION Choose appropriate lifting gear length.  © Copyright 2016 ABB. All rights reserved.
Page 72 2. Attach third lifting loop with swivel lifting eye to thread of oil outlet flange. 3. Rotate the cartridge group into a horizontal position by lifting. © Copyright 2016 ABB. All rights reserved.
Page 73 Use only pH-neutral cleaning agents which do not attack metals.  CAUTION Observe safety data sheet.  Fill the tank with soaking liquid.  Only immerse the cartridge group until all blades are covered with  cleaning agent. © Copyright 2016 ABB. All rights reserved.
Page 74 Wear a respiratory mask to protect against particles (P1 or P2 mask).  Wear safety goggles.  Wear safety goggles. Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against mechanical hazards. Raise the cartridge group and align horizontally.  © Copyright 2016 ABB. All rights reserved.
Page 75 Cleaning the cartridge group on the turbine end [➙ 68]). Dispose of contaminated water and cleaning agent in accordance with  the specifications in the safety data sheet. © Copyright 2016 ABB. All rights reserved.
Page 77: Troubleshooting
Certain tolerances must be observed to avoid a significant loss of efficiency.  If there is any doubt about the extent of rubbing, then an ABB Turbocharging Service Station must be contacted.  Have a dimension check carried out by an ABB Turbocharging Service Station.
Page 78: Surging Of The Turbocharger
Possible damage to components, such as the compressor wheel, tur- bine blades, bearings and filter silencer CAUTION Have the cause clarified immediately by an ABB Turbocharging ser-  vice station and rectified. Have components inspected for damage and, if necessary, replaced ...
Page 79: Malfunctions During Operation
Defects such as leaks in the Make repairs exhaust gas pipes or charge air ducts Increase in speed Possible causes Elimination Turbo- Heavily contaminated nozzle Contact an ABB Turbocharging charger ring (with 4-stroke application) Service Station © Copyright 2016 ABB. All rights reserved.
Page 80 Charge air Cooler contaminated Clean it cooler Cooling water volume too Top up the water Entry temperature of cooling Inspect / clean the cooling sys- water too high Inadequate ventilation Improve the ventilation © Copyright 2016 ABB. All rights reserved.
Page 81 Engine Malfunctioning injection system Repair it or contact the manufac- turer Poorly adjusted injection system Correct it Engine performance higher than Check engine performance expected Turbo- Manometer display wrong Replace the manometer charger © Copyright 2016 ABB. All rights reserved.
Page 82: Malfunctions When Stopping
Rubbing rotor Foreign object in turbocharger Run-down time too short Possible causes Elimination Turbo- Turbocharger contaminated Clean it charger Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger © Copyright 2016 ABB. All rights reserved.
Page 83: Speed Measurement System
This problem is eliminated by removing the gasket. Defective sensor Contact ABB Turbocharging service station. Measured Dirty sensor tip The sensor tip is magnetic and can thus at- speeds too tract metal particles.
Page 85: Removal And Installation
The following weight specification is the heaviest variant possible. This standard value may deviate from the data on the rating plate depending on the specification. Weights [kg] TPL69-A TPL73-A TPL77-A 1780 3070 4840 © Copyright 2016 ABB. All rights reserved.
Page 86: Removing The Turbocharger
Remove the insulation at the suspension ribs.  Version with compressor wheel cooling system Remove air supply line. (See also chapter entitled Preliminary remarks  / Layout and functionality) Inspect the lifting gear.  © Copyright 2016 ABB. All rights reserved.
Page 87 If support for the turbocharger is missing or defective, the turbocharger can tip over during installation and removal and cause serious injuries or even fatal accidents. WARNING Support the turbocharger at a suitable point.  Cover the oil connection.  © Copyright 2016 ABB. All rights reserved.
Page 88: Installing The Turbocharger
Version with compressor wheel cooling system Fit air supply line. (See also chapter Preliminary remarks / Layout and  functioning.) Refit removed parts of insulation.  Plug in cable connector on speed sensor.  © Copyright 2016 ABB. All rights reserved.
Page 89: Disassembly And Assembly
CAUTION Only carry out those tasks that are described in this chapter.  Marking casing positions for assembly ABB Turbo Systems recommends that the casing positions are marked before disassembling the turbocharger. NOTICE Identifying assembly devices Not all assembly devices are marked with a part number. They can be identified using the tool list.
Page 90 They are not commercially available products. Use assembly / fitting devices only for the applications described.  Lifting gear Equipment for lifting and transporting loads (ropes, chain hoists, cranes). Lifting gear is not supplied by ABB Turbo Systems. © Copyright 2016 ABB. All rights reserved.
Page 91: Module Weights
01 Radial air suction branch 02 Filter silencer 03 Compressor casing internal part 04 Wall insert 05 Diffuser 06 Compressor casing external part 07 Cartridge group 08 Turbine diffuser 09 Nozzle ring 10 Gas inlet casing, radial © Copyright 2016 ABB. All rights reserved.
Page 92 Complete compressor casing internal part Weights [kg] TPL69-A TPL73-A TPL77-A The total weight of the complete internal part of the compressor casing includes the internal part of the compressor casing, the diffuser and the wall insert. NOTICE © Copyright 2016 ABB. All rights reserved.
Page 93: Removing And Fitting Filter Silencer Or Air Suction Branch
Unscrew nuts (74027) and remove together with washers (74018).  Remove air suction branch and set down to one side.  Install air suction branch in reverse order. Install air suction branch  © Copyright 2016 ABB. All rights reserved.
Page 94  Unscrew nuts (74027) and remove them together with their washers  (74018). Remove filter silencer and set down to one side.  Fit filter silencer in reverse order. Fitting filter silencer  © Copyright 2016 ABB. All rights reserved.
Page 95: Axial Clearance
Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property. CAUTION Have components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. © Copyright 2016 ABB. All rights reserved.
Page 96: Removing Cartridge Group
NOTICE Control dimension u [mm] Dimension [mm] TPL69-A TPL73-A TPL77-A 17.8 18.6 19.0 The compressor casing internal part has now been detached from the compressor casing external part (74000) and can be removed. © Copyright 2016 ABB. All rights reserved.
Page 97 (90320) and then withdraw. Fit support angle (90025).  Set down compressor casing internal part complete with wall insert  and diffuser onto support angle and underlay. Remove the O-ring (76040).  © Copyright 2016 ABB. All rights reserved.
Page 98 (90025) and set it down with the front side of the flange (F) on the underlay. Make sure that underlay does not shift. Check underlay and adjust if necessary.  CAUTION © Copyright 2016 ABB. All rights reserved.
Page 99 Loop lifting gear around diffuser (79000) and remove diffuser.  Carefully press off the wall insert (77000) using the press-off screws  (90900) and remove it using the swivel lifting eye (90230). Remove O-rings (77005 and 77006).  © Copyright 2016 ABB. All rights reserved.
Page 100 (74000) and secure it to the crane. Loosen nuts (61037).  Uniformly press off compressor casing external part (74000) using  three press-off nuts (61090), remove it and set down to one side. © Copyright 2016 ABB. All rights reserved.
Page 101 Check correct installation of oil orifice plates.  Version with compressor wheel cooling system Remove the O-ring (42124).  Remove air supply line. (See also chapter entitled Preliminary remarks /  Layout and functionality) © Copyright 2016 ABB. All rights reserved.
Page 102 Check that the blades do not rub on the turbine diffuser by rotating  the rotor. CAUTION Withdraw cartridge group and fit supports (90450).  Remove screws (42064) together with flange (42044). Also remove  possible contamination behind the flange. Cover the oil connections.  © Copyright 2016 ABB. All rights reserved.
Page 103: Dismantling And Installing The Turbine Diffuser And Nozzle Ring
Before removing the turbine diffuser, secure the nozzle to prevent it  CAUTION from falling. Before disassembling the turbine diffuser, if possible secure the nozzle  ring against falling with a lashing strap and a wooden block. © Copyright 2016 ABB. All rights reserved.
Page 104 Insert extension (A) of torque spanner (B) through hole in clamp and  loosen screws (61056) (61057) one after other. Do not yet remove the screws (61056) and Verbus Ripp® washers  (61057). © Copyright 2016 ABB. All rights reserved.
Page 105 Loop the lifting gear around the turbine diffuser (63000) and secure it  to a crane. Remove the nuts (61037) and clamps (90921) from the studs.  Fully withdraw the turbine diffuser and remove it.  Remove clamps (90921) and guide studs (90320).  © Copyright 2016 ABB. All rights reserved.
Page 106 Install the nozzle ring and turbine diffuser in the reverse order of re-  moval. Coat the screw threads with high-temperature grease.  Align nozzle ring with holes or cams in gas inlet casing.  © Copyright 2016 ABB. All rights reserved.
Page 107: Installing Cartridge Group
Attach one lifting gear each to the two fins of the bearing casing pro-  vided for this purpose. Remove supports (90450) and carefully insert cartridge group.  Tighten screws (61059) and Verbus Ripp® washers (61058) evenly.  © Copyright 2016 ABB. All rights reserved.
Page 108 (86515). Reconnect oil pipes.  Version with compressor wheel cooling system Fit the O-ring (42124).  Fit the air supply line. (See also chapter entitled Preliminary remarks /  Layout and functionality) © Copyright 2016 ABB. All rights reserved.
Page 109 Fit the compressor casing external part (74000) and secure with nuts  (61037). Secure three press-off nuts (61090) against compressor casing  (74000) by tightening them to specified torque (see chapter Table of tightening torques). © Copyright 2016 ABB. All rights reserved.
Page 111 Secure the lifting device (90190) and the shackle (90195) to the rear of  the flange (F). Carefully turn compressor casing internal part complete with wall insert  and diffuser about support angle (90025) into vertical position and set down on underlay and support angle. © Copyright 2016 ABB. All rights reserved.
Page 112 Remove the guide studs (90320) and fit the studs (74026/74029).  Use studs [10x 74029 and 2x 74026 (each screwed in at top and bot- If provided  tom)]. © Copyright 2016 ABB. All rights reserved.
Page 113 Put the nuts (90458) back in the toolbox.  Measure and note axial clearance (see section Axial clearance).  If the axial clearance (A) is out of tolerance, an ABB Turbocharger ser- vice station must be contacted. CAUTION Remove four nuts (74027) and washers (74018) again.
Page 114: Dismantling And Fitting Nozzle Ring At Turbine End
CAUTION Mark the positions of the gas inlet casing and the segments. NOTICE The nozzle ring hangs loosely on the gas inlet casing and can fall down. CAUTION © Copyright 2016 ABB. All rights reserved.
Page 115 When setting down the gas inlet casing to one side, use suitable under- lays and take care not to damage the angles of the insulation. CAUTION Remove spiral-wound gasket (61050). 1) If provided  © Copyright 2016 ABB. All rights reserved.
Page 116 (61001) until the nozzle ring can be lifted out. Fully withdraw the gas inlet casing and remove it.  When setting down gas inlet casing, use suitable underlays. CAUTION Remove gasket (61050). 1) If provided  © Copyright 2016 ABB. All rights reserved.
Page 117 Fit gas inlet casing flange to gas outlet casing using finger-tight screws  (61044) and Verbus Ripp® washers (61043). Remove the hexagon nuts (90178) from the studs (90177).  Replace the studs (90177) with hexagon-head screws (61044) and  Verbus Ripp® washers (61043). © Copyright 2016 ABB. All rights reserved.
Page 118 Fit the segment (51012) with the recess on the cam on the gas inlet  casing and fit it loosely using screws (61044). Put remaining segments (51012) in place on gas inlet casing (51001)  and fit them loosely using screws (61044). © Copyright 2016 ABB. All rights reserved.
Page 119 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Dismantling and fitting nozzle ring at Page 117 turbine end Check Collars (C) of segments (51012) must be in slot (S).  © Copyright 2016 ABB. All rights reserved.
Page 120 Checking the tightening  tightening torque from step 3. torque Remove lifting gear from gas inlet casing (51001).  Connect cleaning pipe (if present) and attach insulation to gas inlet  casing (51001). © Copyright 2016 ABB. All rights reserved.
Page 122: Table Of Tightening Torques
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Disassembly and assembly Table of tightening torques Page 120 Table of tightening torques © Copyright 2016 ABB. All rights reserved.
Page 123 86505 M18x1.5 M18x1.5 M18x1.5 90458 Tighten the screw (76002) as far as it will go and then unscrew it by ¼ turn. The screw must be loose and the diffuser must be movable. © Copyright 2016 ABB. All rights reserved.
Page 125: Taking Out Of Operation At Short Notice
If the diesel engine must be capable of operation again as soon as possi- ble after damage to the turbocharger (emergency repair), the following possibilities are available:  Locking turbocharger rotor  Fitting the cover plate  Shutting off inlets and outlets  Turbocharger bypass © Copyright 2016 ABB. All rights reserved.
Page 126: Locking The Rotor
4-stroke CAUTION engines.) Otherwise components that are still intact can be damaged through overheating. Shut off the oil supply in the event of lubricating oil leaking from the tur- bocharger. © Copyright 2016 ABB. All rights reserved.
Page 127 Carried out work as described in the chapter Disassembly and assem- bly. NOTICE Remove silencer or air suction branch and compressor casing internal  part complete with wall insert and diffuser. Fit partition wall clamp (94005) using screws (90442).  © Copyright 2016 ABB. All rights reserved.
Page 128 In the case of engines with one or two turbochargers, eight screws are  enough to securely fasten the locking flange. Locking rotor Compressor type CV10 © Copyright 2016 ABB. All rights reserved.
Page 129 (94003) using screws (94006) according to values shown in preceding Table of tightening torques. Now tighten assembly-disassembly device to compressor casing using  nuts (74027) and studs according to values shown in preceding Table of tightening torques. © Copyright 2016 ABB. All rights reserved.
Page 130 0.5 bar overpressure. Attention must always be paid to the speed of the undamaged turbo- charger. The speed limit n given on the rating plate must not be ex- Bmax ceeded. CAUTION © Copyright 2016 ABB. All rights reserved.
Page 132 Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Taking out of operation at short notice Fit cover plate Page 130 Carry out the work as described in the chapter Removal and fitting. NOTICE Remove cartridge group.  © Copyright 2016 ABB. All rights reserved.
Page 133 Page 131 Close off opening in gas outlet casing using cover plate.  Fasten cover plate using spacer sleeves and nuts (61037).  Shut off the supply of lubricating oil to the turbocharger. CAUTION © Copyright 2016 ABB. All rights reserved.
Page 134 The engine can be operated according to the engine builder's instruc- tions. Attention must always be paid to the speed of the undamaged turbocharger. The speed limit n given on the rating plate must not Bmax be exceeded. CAUTION © Copyright 2016 ABB. All rights reserved.
Page 135: Blocking The Inlets And Outlets
This applies to engines with one turbocharger only:  The connections are ready and pipes for the bypass are available.  Fit bypass around turbocharger.  In this respect, refer to the engine manufacturer's instructions. NOTICE © Copyright 2016 ABB. All rights reserved.
Page 137: Mothballing The Turbocharger
Observe the information in the material safety data sheet for the op-  erating materials and supplies. Comply with local legislation.  Wear safety goggles. Wear safety gloves to protect against mechanical hazards. Wear a respiratory mask to protect against gases. © Copyright 2016 ABB. All rights reserved.
Page 138 Dismantle the turbocharger.  The rotor and the bearing parts must be removed by an official ABB  Turbocharging service station and refitted afterwards. Clean all parts. ...
Page 139  The turbocharger remains mounted on the engine.  The turbocharger casing remains mounted on the engine, but the rotor and the bearing parts are removed and stored separately by an ABB Turbocharging Service Station.  The turbocharger is removed completely, either as a whole or in indi- vidual parts.
Page 141: Disposing Of Turbocharger Components
 Dispose of non-metallic materials as waste.  Dispose of residues of lubricants as waste oil.  Dispose of electronic components as electronic waste.  Dispose of thermal insulation as hazardous waste.  © Copyright 2016 ABB. All rights reserved.
Page 143: Spare Parts
 Turbocharger type  Serial number (HT……)  Description and part number Spare parts can be ordered from an official ABB Turbocharging Service Station. If different design versions have not been taken into consideration in  this document, please contact an ABB Turbocharging Service Station.
Page 144 42059 / 42064 / 61044 / 61056 / 61059 Verbus Ripp® washer 42058 / 42063 / 61043 / 61057 / 61058 Hexagon nut 61037 Gasket 42041 Gasket 42045 O-ring 42012 / 76040 O-ring 42124 O-ring 77005 / 77006 O-ring 86506 © Copyright 2016 ABB. All rights reserved.
Page 145 Work on turbine cleaning system should be carried out only by an  ABB Turbocharging service station. Quantity Description Part number Locking plate 51255 Nozzle 52208 Sleeve 52212 Locking plate 52213 Strain bolt 52217 52218 © Copyright 2016 ABB. All rights reserved.
Page 146: View Of Turbocharger With Part Numbers
Operation Manual / TPL69-A10 / -A30 ... TPL77-A10 / -A30 Spare parts View of turbocharger with part numbers 12.2 Page 144 12.2 View of turbocharger with part numbers 12.2 © Copyright 2016 ABB. All rights reserved.
Page 147 Wall insert 77005 (in customer spare part set) O-ring 77006 (in customer spare part set) O-ring 79000 Diffuser 81000 Filter silencer 82000 Radial air suction branch 82000 Axial air suction branch TPL69-A only © Copyright 2016 ABB. All rights reserved.
Page 148: View Of Turbine Cleaning System With Part Numbers (Optional)
Locking plate 52208 (in spare parts set) Nozzle 52212 (in spare parts set) Bush 52213 (in spare parts set) Locking plate 52217 (in spare parts set) Strain bolt 52218 (in spare parts set) © Copyright 2016 ABB. All rights reserved.
Page 149 ABB Turbo Systems AG Bruggerstrasse 71a CH-5400 Baden Switzerland...

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