Page 1 Operation Manual TPL76-C35 ABB Turbo Systems Ltd CH 5401 Baden Type TPL76-C35 HT564896 Mmax Mmax °C Bmax Bmax 04070 Application according to Year 2016 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
Periodic checking of the pressure vessel Lifting loads Commissioning Oil supply Inspection work Commissioning after taking out of operation Operation Noise emissions Servicing work Replacement intervals for turbocharger components Speed measurement 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 out of operation for up to 12 months 10.2 Taking 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 © Copyright 2016 ABB. All rights reserved.
Page 7: Preliminary Remarks
Operation Manual This Operation Manual enables you to familiarize yourself with the turbocharger 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 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
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 11: 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 unauthorized modifications to the turbocharger or improper operation.
Page 12: Storage Of New Turbochargers And Spare Parts
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 13 Page 11 spare parts Long-term storage of replacement turbochargers or spare parts Per order, turbochargers or cartridge groups will be prepared by ABB Turbo Systems for prolonged storage. The package is equipped with a hygrometer (see illustration). The following measures are required every 6 months: Check the hygrometer (02) in the sight-glass.
Page 14: Essential Information
The fault must be reported to the person or department responsible. Additions and alterations to, and conversions of the turbocharger that could compromise safety require the prior approval of ABB Turbo Systems. NOTICE © Copyright 2016 ABB. All rights reserved.
Page 15 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 authorised personnel.
Page 16 The illustrations in this document are general in nature and intended for ease of understanding. Differences in detail are therefore possible. Storage of new turbochargers New turbochargers supplied by ABB Turbo Systems can be stored without additional safeguarding measures for a period of 6 months after the delivery date.
Page 17: 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 Turbocharging Service Stations.
Page 18: Turbocharger Rating Plate
Replacement interval for compressor in 1000 h turbocharger components Replacement interval for turbine in 1000 h Further information Part number for customer Designation of special design Turbocharger weight in kg Turbocharger type Serial number Year of turbocharger construction © Copyright 2016 ABB. All rights reserved.
Page 19 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 insulation of the gas outlet casing.
Page 20: Contact Information
Operation Manual / TPL76-C Preliminary remarks Contact information Page 18 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 21: Safety
Page 19 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...
Page 22: 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 23: Warning Plates On The Turbocharger
Warning plates on the turbocharger Page 21 Warning plates on the turbocharger Warnings that have been attached to turbochargers by ABB Turbo Systems must not be removed. Illegible warnings must be replaced with new ones. Further information is available from ABB Turbocharging service stations.
Page 24: 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 25 Protect the floor against unintentional penetration of detergents or  solvents 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 26 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 27: 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 document.  Only perform operations for which you have previously received  instruction or training. © Copyright 2016 ABB. All rights reserved.
Page 28 Wear safety gloves against thermal risks. 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 29 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 30 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 31 Hazards due to electrical components Electrical components operate with voltages which can present hazards to humans. WARNING All work on or with electrical components may only be performed by  trained specialists. Heed any country-specific regulations.  © Copyright 2016 ABB. All rights reserved.
Page 32: Periodic Checking Of The Pressure Vessel
Page 30 vessel 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 33: 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  securely. © Copyright 2016 ABB. All rights reserved.
Page 35: Commissioning
Oil filtration A lubrication oil filter system with a mesh size ≤0.050 mm is adequate for TPL76-C turbochargers. This filter system can also be achieved by using an additional self- cleaning fine filter. NOTICE © Copyright 2016 ABB. All rights reserved.
Page 36 To make sure these oil pressures are obtained, a regulating orifice is fitted in the turbocharger oil inlet. The orifice is fitted by the engine NOTICE builder and secured by a safety ring. © Copyright 2016 ABB. All rights reserved.
Page 37 > 150 If the turbocharger was operated for a longer period of time outside of the admissible range, ABB Turbo Systems recommends to have the turbocharger inspected by an ABB Turbocharging Service Station. © Copyright 2016 ABB. All rights reserved.
Page 38: Inspection Work
Check oil pressure in oil supply lines.  Check whether the warning plates are present and legible. Warning plates on  turbocharger Check whether the protective sheets have been removed.  © Copyright 2016 ABB. All rights reserved.
Page 39 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 Turbocharging service station. 3.2.4 Inspection after 100 service hours Clean or replace lubricating oil filters after the first 100 service hours.
Page 40: 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 41: 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 ensure that equivalent acoustic insulating measures are taken. © Copyright 2016 ABB. All rights reserved.
Page 42 Operation Noise emissions Page 40 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 43: Servicing Work
 Systems. Service inspection after 5 years To prevent age- and stoppage-related machine damage, an inspection by an ABB Turbocharging Service Station is recommended at the latest NOTICE 5 years after the last service. 4.2.1 Service work every 25 … 50 hours Visual inspection for air, exhaust gas, water and oil leaks.
Page 44  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 45 Inspect and assess bearing parts and rotor.  4.2.5 Service work every 24000 … 36000 hours The replacement of bearing parts as well as the inspection and assessment of the rotor must be carried out by an ABB Turbocharging Service Station. Disassemble turbocharger.  Measure clearances.
Page 46: 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 47 See the data on the rating plate replacement 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 48: Speed Measurement
If you pull the speed measurement cables too hard, contacts can be pulled out. CAUTION Do not tension the speed measurement cables.  Part number Description 42047 Screw plug 86505 Speed sensor 86515 Cable connector for 86505 86526 F/I converter 86528 Tachometer © Copyright 2016 ABB. All rights reserved.
Page 49 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 50 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 51: 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 53: 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 54: Cleaning The Filter Silencer
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 56 Join connecting rods (81269) using screws (81272). When tightening  the screws (81272), ensure that connecting rods (81269) are located correctly in recesses in filter silencer body (81135). Now tighten screws (81272) alternately until the following maximum torque is reached: © Copyright 2016 ABB. All rights reserved.
Page 57 Operation Manual / TPL76-C Maintenance Cleaning the filter silencer Page 55 Screw Tightening torque [Nm] 81272 Screw lock nuts (81273) onto screw (81272) and tighten to following  torque: Lock nut Tightening torque [Nm] 81273 © Copyright 2016 ABB. All rights reserved.
Page 58: Cleaning The Compressor During Operation
Cleaning interval conditions. In general, cleaning should be carried out every 25 to 100 operating hours. Cleaning intervals Should the specified cleaning intervals prove incompatible with engine operation, please contact ABB Turbo Systems. NOTICE © Copyright 2016 ABB. All rights reserved.
Page 59 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 Systems. To clean the compressor stage during operation, water is injected in front...
Page 60 Operating state prerequisites for cleaning compressor with XC2 To be able to carry out a satisfactory cleaning process which has been tested and is recommended by ABB Turbo Systems, the following prerequisites must be fulfilled: Engine load 50 ... 85% ...
Page 61 Operating state prerequisites for compressor cleaning with XC3 To be able to carry out a satisfactory cleaning process which has been tested and is recommended by ABB Turbo Systems, the following prerequisites must be fulfilled: Engine load 50 ... 85% ...
Page 62 If the cleaning results are still not satisfactory after three attempts and the engine values are also unsatisfactory, we recommend that you have NOTICE the turbocharger inspected and cleaned by an official ABB Turbocharging Service Station. Cleaning parameters per turbocharger compressor...
Page 63: Cleaning Turbine Blades And Nozzle Ring In Operation
However, if cleaning is carried out properly and the cleaning system is properly dimensioned, the intervals between overhauls can be increased. © Copyright 2016 ABB. All rights reserved.
Page 64 When cleaning the turbine components during operation, use wet Cleaning method cleaning. 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 65 Recommended operating state for turbine wet cleaning 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 ...
Page 66 After injecting required volume of water, shut off water supply again by  switching over 3-way valve (04) to scavenging air mode. The injection process has been completed.  Close drain hole (if provided) above drain pipe (08, 09).  © Copyright 2016 ABB. All rights reserved.
Page 67 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 68 Wet cleaning parameters for turbine and nozzle ring Product Maximum Injection time Water flow rate per temperature at turbocharger at [min] start of cleaning = 3 bar Water process [l/min] [°C] TPL76-C © Copyright 2016 ABB. All rights reserved.
Page 69: 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 described in the following.
Page 70 Spray cleaned surfaces with penetrating oil. Do not spray the outer  surfaces of the turbocharger. Dispose of contaminated water and cleaning agent in accordance with  the specifications in the safety data sheet. © Copyright 2016 ABB. All rights reserved.
Page 71 Lightly spray the compressor wheel and the gap between the  compressor and the bearing casing with penetrating oil. Dispose of contaminated water and cleaning agent in accordance with  the safety data sheet. © Copyright 2016 ABB. All rights reserved.
Page 72 The lifting gear must not touch the compressor wheel at any time during rotation. CAUTION Choose appropriate lifting gear length.  1. Suspend cartridge group from normal suspension point and suspend from first crane. © Copyright 2016 ABB. All rights reserved.
Page 74 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 75  Only immerse the cartridge group until all blades are covered with  cleaning agent. Heating the liquid To shorten the soaking time the liquid can be heated to maximum 60 ºC. NOTICE © Copyright 2016 ABB. All rights reserved.
Page 76 Wear a respiratory mask to protect against particles. Wear safety gloves against mechanical risks. Raise the cartridge group and align horizontally.  Remove contamination manually with a soft brush or wire brush.  © Copyright 2016 ABB. All rights reserved.
Page 77 Cleaning the cartridge group on the turbine end [➙ 70]). Dispose of contaminated water and cleaning agent in accordance with  the specifications in the safety data sheet. © Copyright 2016 ABB. All rights reserved.
Page 79: 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 80: Surging Of The Turbocharger
Prolonged or periodic surging Possible damage to components, such as the compressor wheel, turbine blades, bearings and filter silencer CAUTION Have the cause clarified immediately by an ABB Turbocharging  service station and rectified. Have components inspected for damage and, if necessary, replaced ...
Page 81: 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 82 Charge air Cooler contaminated Clean it cooler Cooling water volume too low Top up the water Entry temperature of cooling Inspect / clean the cooling water too high system Inadequate ventilation Improve the ventilation © Copyright 2016 ABB. All rights reserved.
Page 83 Elimination Engine Malfunctioning injection system Repair it or contact the manufacturer 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 84: 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 85: 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 speeds too attract metal particles.
Page 87: Removal And Installation
Lifting gear with a sufficient load limit must be used for removing and installing the turbocharger. The following weight specification is the heaviest possibility. This guide value can differ from data on the rating plate, depending on the specification. Weight [kg] TPL76-C 4070 © Copyright 2016 ABB. All rights reserved.
Page 88: Remove The Turbocharger
Use the two suspension lugs (L1, L2) on the bearing casing (observe the marking on the insulation). The two suspension lugs on the foot at the turbine end (T1, T2) serve to align the turbocharger horizontally. © Copyright 2016 ABB. All rights reserved.
Page 89 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. WARNING Support the turbocharger at a suitable point.  Cover the oil connection.  © Copyright 2016 ABB. All rights reserved.
Page 90: Installing The Turbocharger
Tighten the fixing screws on the foot.  The fastening specifications for the foot fixing screws are supplied to the engine builder by ABB Turbo Systems and given in his manual. NOTICE Fasten the gas, air and oil lines in accordance with the engine ...
Page 91: 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 92 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 93: Module Weights
Radial air suction branch Compressor casing internal part Wall insert Diffuser Compressor casing external part Cartridge group Turbine diffuser Nozzle ring Radial gas inlet casing with segment connection Segment Radial gas inlet casing with flange connection © Copyright 2016 ABB. All rights reserved.
Page 94 Complete compressor casing internal part Weight [kg] TPL76-C 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 95: Removing And Fitting Filter Silencer Or Air Suction Branch
Unscrew the nuts (74027) and remove them together with their  washers (74018). Remove the air suction branch and set it down to one side.  Install the air suction branch in reverse order. Installing the air suction  branch © Copyright 2016 ABB. All rights reserved.
Page 96 Unscrew nuts (74027) and remove them together with washers  (74018). Remove filter silencer and it set down to one side.  Fit filter silencer in reverse order. Fitting the filter silencer  © Copyright 2016 ABB. All rights reserved.
Page 97: Axial Clearance
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. CAUTION Have the components assessed and, if necessary, replaced by an  ABB Turbocharging Service Station. © Copyright 2016 ABB. All rights reserved.
Page 98: Removing Cartridge Group
The internal part of the compressor casing (76000) has now been separated from the external part (74000) and can be removed. Note the control dimension (u). NOTICE Check dimension (u) [mm] Dimension TPL76-C 21.8 © Copyright 2016 ABB. All rights reserved.
Page 99 Attach the support angle (90025) using screws (90021) and nuts  (74027). Put down the compressor casing internal part including the wall insert  and diffuser on the support angle and an underlay. Remove the O-ring (76040).  © Copyright 2016 ABB. All rights reserved.
Page 100 (90190/90195) can be removed. Ensure that the shim does not slip. Rest the internal part of the compressor casing only on flange (F).  Check shim and adjust as necessary.  WARNING © Copyright 2016 ABB. All rights reserved.
Page 101 Remove diffuser (79000) using swivel lifting eyes (90235).  Press away wall insert (77000) using press-off screws (90230) and  remove from internal part of compressor casing (76000) using swivel lifting eyes (90235). © Copyright 2016 ABB. All rights reserved.
Page 102 Insulation on external part of compressor casing The insulation on the external part of the compressor casing does not need to be taken off when removing or fitting the casing. NOTICE Remove O-ring (42012).  © Copyright 2016 ABB. All rights reserved.
Page 103 Check correct installation of oil orifice plates.  Version with compressor wheel cooling system Remove air supply line. (See also chapter entitled Preliminary remarks /  Layout and functionality) © Copyright 2016 ABB. All rights reserved.
Page 104 Withdraw cartridge group.  Remove screws (42064), flange (42044) and gasket (42045) and  clean oil space. Fit supports (90450) using screws (42280) and put down cartridge  group. Cover the oil connections.  © Copyright 2016 ABB. All rights reserved.
Page 105: Dismantling And Installing The Turbine Diffuser And Nozzle Ring
Put assembly plate (90020) over strain bolts (61036).  Insert extension (A) of torque spanner (B) through hole in assembly  plate and loosen screws (61056) one after other. Don't remove screws (61056) yet.  © Copyright 2016 ABB. All rights reserved.
Page 106 Loop lifting gear around turbine diffuser (63000) and secure to crane.  Remove nuts (61037) and assembly plate (90020) from studs.  Fully withdraw turbine diffuser and remove.  Remove guide studs (90320).  © Copyright 2016 ABB. All rights reserved.
Page 107 If a nozzle ring is found to be clogged over partial areas or covered by loose parts, it is recommended that you have a turbine blade inspection CAUTION including a crack inspection carried out by an ABB Turbocharging Service Station. © Copyright 2016 ABB. All rights reserved.
Page 108 Coat thread of screws (56019) with high-temperature grease and fit  with locking plates (56018). Tighten screws (56019) and bend locking plates (56018) over.  Correct assembly The nozzle ring must be easy to move after assembly. CAUTION © Copyright 2016 ABB. All rights reserved.
Page 109 Using three screws (61056), alternately and uniformly screw in turbine  diffuser as far as it will go. Insert torque spanner extension through hole in assembly plate and  tighten screws (61056) one after other. (See illustration in section Removing turbine diffuser.) © Copyright 2016 ABB. All rights reserved.
Page 110: Installing Cartridge Group
Screw guide rod (90490) onto threaded stud (X) to balance cartridge  group. Remove supports (90450) and carefully insert cartridge group.  Fit three oiled nuts (61037) complete with new Verbus Ripp® washers  (61051) around circumference at 120° intervals. © Copyright 2016 ABB. All rights reserved.
Page 111 (86515). Reconnect oil and air lines.  Version with compressor wheel cooling system Fit the air supply line. (See also chapter entitled Preliminary remarks /  Layout and functionality) © Copyright 2016 ABB. All rights reserved.
Page 112 Fasten lifting device (90190/90195) to external part (74000) of  compressor casing and secure it with crane. Fit O-ring (42012).  Fit external part of compressor casing (74000) and fasten using  screws (42280). Remove lifting device (90190/90195).  © Copyright 2016 ABB. All rights reserved.
Page 113 Remove swivel lifting eyes (90235) and centering screws (90230).  Put the diffuser (79000) in place using the swivel lifting eyes (90235).  Remove the swivel lifting eyes (90235).  Fit screws (76002).  © Copyright 2016 ABB. All rights reserved.
Page 114 Fasten lifting device (90190/90195) to front side of flange (F).  Carefully turn internal part of compressor casing (76000) complete  with wall insert and diffuser about support angle (90025) and lift up vertically. Ensure that the shim does not slip. WARNING © Copyright 2016 ABB. All rights reserved.
Page 115 Carefully insert the compressor casing internal part (76000) including  the wall insert and diffuser into the compressor casing external part and then remove the lifting device (90190/90195). © Copyright 2016 ABB. All rights reserved.
Page 117 (74000). Note the control dimension (s). The safety segments (76080) are in the operating condition again ("engaged"). NOTICE Check dimension (s) [mm] Dimension TPL76-C 16.5 Put nuts (90458) back into toolbox.  © Copyright 2016 ABB. All rights reserved.
Page 118  Clearance A [mm] TPL76-C 0.43 … 0.69 If the axial clearance (A) is out of tolerance, an official ABB Turbo Systems service station must be contacted. CAUTION Connect oil lines and all air lines in accordance with engine builder ...
Page 119: 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 CAUTION including a crack inspection carried out by an ABB Turbocharging Service Station. If provided The fitted spiral-wound gasket (61050) may be used only once! ...
Page 120 Pull gas inlet casing (51001) complete with nozzle ring (56001) away  from gas outlet casing (61001). Use suitable underlays when putting down gas inlet casing. CAUTION Remove gasket (61050). 1) If present  © Copyright 2016 ABB. All rights reserved.
Page 121 When fitting the nozzle ring, new screws (56019) and locking plates (56018) from the customer spare part set (97070) must be used. CAUTION Push in nozzle ring (56001) as far as it will go up to cover of gas inlet  casing. © Copyright 2016 ABB. All rights reserved.
Page 122 First place segment (51012) complete with roll pin on gas inlet casing,  fix it in correct radial position using centering bolt (90177) and then fit it loosely using screws (61044). © Copyright 2016 ABB. All rights reserved.
Page 123 Put remaining segments (51012) in place on gas inlet casing (51001)  and fit them loosely using screws (61044). Replace centering bolts (90177) with screws (61044).  Check Collars (C) of segments (51012) must be in groove (S).  © Copyright 2016 ABB. All rights reserved.
Page 124 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 125 Tighten screws (61044) in accordance with following procedure and in  following order: Flange connection Tighten screws crosswise  Screw tightening sequence The screw positioning numbers must be marked on the component. This enables simple and efficient tightening. NOTICE © Copyright 2016 ABB. All rights reserved.
Page 126 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 128: Table Of Tightening Torques
After putting a new Verbus Ripp® washer under each nut (8), tighten with pre-tightening torque of MV 80 Nm, then mark the 0° point and tighten (under tightening angle control) to a DW of 90°. Verbus Ripp® Washer Pre-tightening torque Tightening angle © Copyright 2016 ABB. All rights reserved.
Page 129 Tightening torques [Nm] Item Part number TPL76-C 82005 M16 x 1.5 76002 74027 With washer 74026/74029 42280 61036 61051 (VR) 61037 2,3) MV 80 / DW 90° 42059 42064 61044 61056 56019 86505 M18x1.5 © Copyright 2016 ABB. All rights reserved.
Page 131: Taking Out Of Operation At Short Notice
If the diesel engine must be capable of operation again as soon as possible 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 132: Locking The Rotor
Further measures and information for operation with a blocked rotor for CAUTION 4-stroke 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 turbocharger. © Copyright 2016 ABB. All rights reserved.
Page 133 Remove silencer or air suction branch.  Insert lifting device (90427) into compressor wheel.  Twist screws (94006) into free threaded holes in compressor wheel  and tighten to values shown in Table of tightening torques. © Copyright 2016 ABB. All rights reserved.
Page 134  by screwing nuts (74027) onto studs (74026). (See also chapter Table of tightening torques.) Fitted assembly plate CV 33, CV 34 Make sure all components are clean and free from grease. CAUTION © Copyright 2016 ABB. All rights reserved.
Page 135 0.5 bar overpressure. 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 136: Fit Cover Plate
Cover plate dimensions Product [mm] TPL76-C Product Ø 1 Ø 2 Ø 3 Ø 4 Ø 5 Ø 6 TPL76-C Product ⍺ 1 ⍺ 2 ⍺ 3 TPL76-C 4 x 90° 37.5° 24 x 15° © Copyright 2016 ABB. All rights reserved.
Page 137 Operation Manual / TPL76-C Taking out of operation at short notice Fit cover plate Page 135 Carry out the work as described in the chapter Removal and fitting. NOTICE Remove cartridge group.  © Copyright 2016 ABB. All rights reserved.
Page 138 Page 136 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 139 The engine can be operated according to the engine builder's instructions. Attention must always be paid to the speed of the undamaged turbocharger. The speed limit n given on the rating Bmax plate must not be exceeded. CAUTION © Copyright 2016 ABB. All rights reserved.
Page 140: 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 141: Mothballing The Turbocharger
If the total acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking an engine out of operation: Remove turbocharger.  Rotor and bearing parts must be removed by an official ABB  Turbocharging service station and refitted afterwards. Clean all parts. ...
Page 142: Taking Out Of Operation For More Than 12 Months
40 to 70 % and no condensation can form. Condition of the mothballed turbocharger Check the mothballed turbocharger parts for corrosion every year.  If there are signs of rust: Clean parts thoroughly and renew protection  against corrosion. © Copyright 2016 ABB. All rights reserved.
Page 143: 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 145: 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 146 42041 Gasket 42045 Hexagon-head screw 42059, 42064 Locking plate 56018 Hexagon-head screw 56019 Hex nut 61037 Hexagon-head screw 61044, 61056 Verbus Ripp® Washer 61051 Socket screw 76002 O-ring 76040 O-ring 77005 O-ring 86506 © Copyright 2016 ABB. All rights reserved.
Page 148: View Of Turbocharger With Part Numbers
Operation Manual / TPL76-C Spare parts View of turbocharger with part numbers 12.2 Page 146 12.2 View of turbocharger with part numbers 12.2 © Copyright 2016 ABB. All rights reserved.
Page 149 76002 (in customer spare part set) Socket screw 76040 (in customer spare part set) O-ring 76080 Safety segments 77000 Wall insert 77005 (in customer spare part set) O-ring 79000 Diffuser 81000 Filter silencer 82000 Radial air suction branch © Copyright 2016 ABB. All rights reserved.
Page 150 ABB Turbo Systems AG Bruggerstrasse 71a CH-5400 Baden Switzerland...

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