Page 1 Operation Manual TPL65-A32 ABB Turbo Systems Ltd CH 5401 Baden Type TPL65-A32 HT595952 Mmax Mmax °C Bmax Bmax 01230 Application according to Year 2020 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 / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Table of contents Operation Manual Preliminary remarks....................3 Purpose of this manual ....................3 Layout and function......................4 Intended use of the turbocharger ................6 Storage of new turbochargers and spare parts ............7 Essential information.....................
Page 4 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Table of contents Troubleshooting....................67 Malfunctions when starting..................67 Surging of the turbocharger..................68 Malfunctions during operation ................. 69 Malfunctions when stopping ..................72 Speed measurement system ..................73 Removal and installation..................
Page 5: Operation Manual
Operation Manual This Operation Manual helps familiarise the user with the turbocharger from ABB Turbocharging and how 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 / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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...
Page 7 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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 Of The Turbocharger
Any other use is considered to be a special application, which must first be clarified with ABB Turbocharging. The manufacturer accepts no liab- ility for any other type of use. If the equipment is used for any other purpose, ABB Turbocharging reserves the right to reject all warranty claims.
Page 9: Storage Of New Turbochargers And Spare Parts
1.4 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 Turbocharging 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 10 Seal the package. The better the external seal is designed, the more permanent the protection. Long-term storage of turbochargers The turbochargers will be prepared for prolonged storage by ABB Tur- bocharging on request. The package is equipped with a hygrometer (see illustration).
Page 11: Essential Information
The malfunction must be reported to the per- son or department responsible. NOTICE Any modifications, additions or conversions made to the turbocharger that could impair safety require the prior approval of ABB Turbochar- ging. © Copyright 2020 . All rights reserved. HZTL2498_EN Rev.E...
Page 12 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: Symbols And Definitions
ABB Turbocharging ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging in this document. Official service stations of ABB Turbocharging Official service stations are regularly audited and certified by ABB Tur- bocharging. See also chapter Contact information →13. © Copyright 2020 . All rights reserved.
Page 14: Turbocharger Rating Plate
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 1 Preliminary remarks / 1.7 Turbocharger rating plate 1.7 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.
Page 15: 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 16: 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 17: Definition Of Mandatory Signs
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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...
Page 18: Warning Plates On The Turbocharger
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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 19: Safe Operation And Maintenance
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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.
Page 20 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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 21 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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 22: Hazards During Operation And Maintenance
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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.
Page 23 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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.
Page 24 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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.
Page 25 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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 26 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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.
Page 27: 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 28 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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.
Page 29: Commissioning
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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.
Page 30 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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 31 Not permissible -> stop the engine > 160 If the turbocharger has been operated for a longer period of time out- side the admissible range, ABB Turbocharging recommends having the turbocharger inspected by an ABB Turbocharging Service Station. © Copyright 2020 . All rights reserved.
Page 32: Inspection Work
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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 33 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 34: Commissioning After Taking Out Of Operation
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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.
Page 35: Operation
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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.
Page 36 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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 ©...
Page 37: Servicing Work
NOTICE Service inspection after 5 years To prevent age- and stoppage-related machine damage, an inspection by an ABB Turbocharging Service Station is recommended at the latest 5 years after the last service. 4.2.1 Service work every 25 … 50 hours Visual inspection for air, exhaust gas, water and oil leaks.
Page 38 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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 39 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 40: Replacement Intervals For Turbocharger Components
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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 41 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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 ¡...
Page 42: Speed Measurement
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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 43 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 44 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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.
Page 45: Stopping The Engine
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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 46: Maintenance
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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.
Page 47: Cleaning The Filter Silencer
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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...
Page 48 Otherwise there is a risk of damage or deformation. NOTICE Replace heavily contaminated or damaged parts with original parts from ABB. © Copyright 2020 . All rights reserved. HZTL2498_EN Rev.E...
Page 49 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 5 Maintenance / 5.2 Cleaning the filter silencer Fitting the filter silencer Assemble the insert units (E) by inserting the absorption segments (81136) into the sheet metal coverings (81137). Bend sheet metal coverings (81137) back to original shape.
Page 50: 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 Turbocharging. © Copyright 2020 . All rights reserved. HZTL2498_EN Rev.E...
Page 51 ¡ Wet cleaning This cleaning method is tested and approved by ABB Turbocharging. Principle of wet cleaning To clean the compressor stage during operation, water is injected in front of the compressor wheel through an injection pipe fitted in the fil- ter silencer or the suction branch.
Page 52 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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 53 Operating state prerequisites for wet cleaning XC3 NOTICE To be able to carry out a satisfactory cleaning process which has been tested and is recommended by ABB Turbocharging, the following pre- requisites must be fulfilled: Engine load 50 … 85% Start of cleaning cycle in accordance with following description for wet cleaning operation with XC3.
Page 54 If the cleaning result is still not satisfactory after three attempts and the engine values are also unsatisfactory, we recommend that you have the turbocharger inspected and cleaned by an official ABB Turbochar- ging Service Station. Cleaning parameters per turbocharger compressor...
Page 55: Cleaning Turbine Blades And Nozzle Ring In Operation
Cleaning method When cleaning the turbine components during operation, use wet clean- ing. This cleaning method is tested and approved by ABB Turbocharging. Prerequisites for wet cleaning are that the enginebuilder approves the process and his instructions are followed.
Page 56 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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. ¡...
Page 57 Prerequisites for wet cleaning of turbine The following operating state and prerequisites have been tested and approved by ABB Turbocharging 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 58 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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.
Page 59 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 60: 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 61 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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.
Page 62 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 5 Maintenance / 5.5 Cleaning components mechanically Repeat the soaking and brushing if necessary. Completely remove any solvents from the parts in clean water. Dry components completely. Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the turbocharger.
Page 63 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 5 Maintenance / 5.5 Cleaning components mechanically Dry the compressor wheel and the gap between the compressor and the bearing casing with a weak jet of compressed air. Lightly spray the gap between the compressor and the bearing casing with penetrating oil.
Page 64 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 5 Maintenance / 5.5 Cleaning components mechanically 1. Suspend cartridge group from normal suspension point and suspend from first crane. 2. Secure two lifting loops with swivel lifting eyes in the lower push-off threads and suspend from a second crane.
Page 65 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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 66 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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.
Page 67 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 5 Maintenance / 5.5 Cleaning components mechanically NOTICE Heating the liquid To shorten the soaking time the liquid can be heated to maximum 60 ºC. 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.
Page 68 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 5 Maintenance / 5.5 Cleaning components mechanically Remove contamination manually with a soft brush or wire brush. 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 69: 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 2020 . All rights reserved.
Page 70: 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 71: 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 72 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 73 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 74: 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 75: 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 76: Removal And Installation
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 7 Removal and installation / 7.1 Turbocharger weights 7 Removal and installation 7.1 Turbocharger weights Lifting gear with a sufficient load limit must be used for removing and installing the turbocharger.
Page 77 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 7 Removal and installation / 7.2 Removing the turbocharger Fasten separate lifting gear to each of the two ribs on the bearing casing provided for this purpose. Ribs (01) not in the middle at the top: Completely remove the bearing casing insulation (02) and place a sling around the bearing casing.
Page 78: Installing The Turbocharger
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 7 Removal and installation / 7.3 Installing the turbocharger WARNING Beware of tilting If support for the turbocharger is not provided or is inadequate, the turbocharger could tip over during installation or removal and cause a serious or even fatal injury.
Page 79: Disassembly And Assembly
For safety and product liability reasons, work on the cartridge group that is not described in the operation manual should only be carried out by trained specialists at an ABB Turbocharging Service Station. Unqualified work on the cartridge group can lead to total system failure and void the warranty.
Page 80 Use assembly devices only for the described applications. ¡ Lifting gear Equipment for lifting and transporting loads (lifting slings, chain block, crane). Lifting gear is not supplied by ABB. © Copyright 2020 . All rights reserved. HZTL2498_EN Rev.E March 2020...
Page 81: Module Weights
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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] Description...
Page 82: Removing And Fitting Filter Silencer Or Air Suction Branch
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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 Removing the air suction Disconnect all air lines in accordance with the engine builder’s instruc- branch tions.
Page 83 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 8 Disassembly and assembly / 8.3 Removing and fitting filter silencer or air suction branch Removing the filter silen- Remove insulation where necessary. Pass lifting gear through rib on filter silencer. Pass lifting gear through lugs on back.
Page 84: Axial Clearance
Clearances out of tolerance Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property. Have components assessed and, if necessary, replaced by an ABB Turbocharging Service Station. © Copyright 2020 . All rights reserved.
Page 85: Removing Cartridge Group
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 8 Disassembly and assembly / 8.5 Removing cartridge group 8.5 Removing cartridge group Remove insulation. Version with compressor wheel cooling system Remove air supply line. (See also chapter entitled Preliminary re- marks / Layout and functionality) Disconnect oil pipes in accordance with enginebuilder's instructions.
Page 86 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 8 Disassembly and assembly / 8.5 Removing cartridge group Turn the compressor casing (72000) together with the wall insert and diffuser and set them down with surface (F) on an underlay. WARNING Tipping the compressor casing Make sure the underlay does not shift.
Page 87 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 8 Disassembly and assembly / 8.5 Removing cartridge group Fig. 2 Unplug cable connector (86515) and unscrew speed sensor (86505) with O-ring (86506). TPL65-A32/33 Unscrew the three screws (61059) and remove them together with the Verbus Ripp®...
Page 88 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 8 Disassembly and assembly / 8.5 Removing cartridge group Withdraw cartridge group and fit supports (90450). Remove screws (42064), flange (42044) and gasket (42045) and clean oil space. Cover the oil connections.
Page 89: Dismantling And Installing The Turbine Diffuser And Nozzle Ring
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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 CAUTION Falling nozzle ring The nozzle ring hangs only loosely on the positioning pins.
Page 90 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 8 Disassembly and assembly / 8.6 Dismantling and installing the tur- bine diffuser and nozzle ring Position clamp (90921) over stud (61036) until it lies flat against inner radius of gas outlet casing.
Page 91 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 8 Disassembly and assembly / 8.6 Dismantling and installing the tur- bine diffuser and nozzle ring Replace two screws (61056) in the gas outlet casing with two guide studs (90320) in the upper section of the turbine diffuser (63000).
Page 92: Installing Cartridge Group
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 8 Disassembly and assembly / 8.7 Installing cartridge group 8.7 Installing cartridge group CAUTION Oil orifices There is an orifice for adjusting the oil pressure in each of the two oil supply pipes of the bearing casing.
Page 93 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 8 Disassembly and assembly / 8.7 Installing cartridge group CAUTION If the rotor blades have insufficient or no clearance, the blades and cas- ing could be damaged. Turn rotor to check that blades do not rub against turbine diffuser. Remove the lifting gear.
Page 94 Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property. Have components assessed and, if necessary, replaced by an ABB Turbocharging Service Station. Connect oil lines and all air lines in accordance with engine builder’s instructions.
Page 95: Dismantling And Fitting Nozzle Ring At Turbine End
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 8 Disassembly and assembly / 8.8 Dismantling and fitting nozzle ring at turbine end 8.8 Dismantling and fitting nozzle ring at turbine If only the nozzle ring needs to be removed, this can be done at the tur- bine end.
Page 96 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 8 Disassembly and assembly / 8.8 Dismantling and fitting nozzle ring at turbine end Pull gas inlet casing complete with nozzle ring just far enough away from gas outlet casing that nozzle ring (56001) can be lifted away. Loosen the hexagon nuts (90178) on the studs.
Page 97 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 8 Disassembly and assembly / 8.8 Dismantling and fitting nozzle ring at turbine end © Copyright 2020 . All rights reserved. HZTL2498_EN Rev.E March 2020...
Page 98: Table Of Tightening Torques
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 8 Disassembly and assembly / 8.9 Table of tightening torques 8.9 Table of tightening torques © Copyright 2020 . All rights reserved. HZTL2498_EN Rev.E March 2020...
Page 99 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 8 Disassembly and assembly / 8.9 Table of tightening torques Tightening torques [Nm] Position Part number TPL65-A32 / -A33 / - TPL69-A32 / -A33 82005 M16x1.5 M16x1.5 72027 with washer 72029 61044...
Page 100: Taking Out Of Operation At Short Notice
45% of n . Take note of the rating plate. Bmax After locking the turbocharger, contact an ABB Turbocharging Ser- vice Station and find the nearest port. Observe the safety regulations. Follow the directives of the enginebuilder.
Page 101: Locking The Rotor
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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.
Page 102 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 9 Taking out of operation at short notice / 9.2 Locking the rotor Locking rotor TPL65-A32 / A33 / A36 Remove silencer or air suction branch. NOTICE Carry out the work as described in the chapter Disassembly and As- sembly.
Page 103 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 9 Taking out of operation at short notice / 9.2 Locking the rotor CAUTION Make sure all components are clean and free from grease. Locking rotor TPL69-A32 / -A33 Remove silencer or air suction branch.
Page 104 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 9 Taking out of operation at short notice / 9.2 Locking the rotor As specified in following Table of tightening torques, tighten inter- mediate ring, assembly-disassembly device (90020) and locking flange (94003) using screws (94006).
Page 105 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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.
Page 106: Fit Cover Plate
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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 107 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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. ©...
Page 108 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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 109 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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.
Page 110: Blocking The Inlets And Outlets
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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 111: Mothballing The Turbocharger
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 10 Mothballing the turbocharger / 10.1 Taking the engine out of opera- tion for up to 12 months 10 Mothballing the turbocharger 10.1 Taking the engine out of operation for up to 12 months Condition of engine lubricating oil The turbocharger normally remains mounted on the engine.
Page 112 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. Machined, bright surfaces of steel and cast parts must be oiled with anticorrosive oil.
Page 113: Taking The Engine Out Of Operation For More Than 12 Months
The turbocharger casing remains mounted on the engine, but the ro- tor 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 114: Disposing Of Turbocharger Components
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 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.
Page 115: 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 116 CAUTION Leaks Improper assembly of the cleaning pipe and the nozzles can lead to leaks and failure of the turbine cleaning system. Have work on the turbine cleaning system carried out by an ABB Tur- bocharging Service Station. Quantity Description...
Page 118: View Of The Turbocharger With Part Numbers
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 12 Spare parts / 12.2 View of the turbocharger with part numbers 12.2 View of the turbocharger with part numbers © Copyright 2020 . All rights reserved. HZTL2498_EN Rev.E March 2020...
Page 119 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 12 Spare parts / 12.2 View of the turbocharger with part numbers Part number Description – Cartridge group 42012 (in spare part set) O-ring 51001 Gas inlet casing 51012 (if provided) Segment 56001...
Page 120: View Of Turbine Cleaning System With Part Numbers (Optional)
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 12 Spare parts / 12.3 View of turbine cleaning system with part num- bers (optional) 12.3 View of turbine cleaning system with part numbers (optional) Part number Description 51229 Cleaning pipe 52249...
Page 121 ABB Turbo Systems AG Bruggerstrasse 71a CH-5400 Baden Switzerland...

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