ABB TPL67-C36 Operation Manual

Operation Manual
TPL67-C36
ABB Turbo Systems Ltd

CH 5401 Baden
Type TPL67-C36 HT564846

n Mmax 475 t Mmax 650
1/s °C
n Bmax 475 t Bmax 620
01330 kg 35 50 50
Application according to
Year 2016 the Operation Manual
made in Switzerland
Original Operation Manual
HZTL2488 English
ABB Turbocharging

Operating condition and replacement intervals
The operational limits for the turbocharger nBmax, tBmax, nMmax, tMmax, inspection- and replacement intervals for the compon-
ents concerned on the rating plate are valid for the operational mode and compressor inlet condition, which has been agreed upon
between the engine builder and ABB.
Note: Replacement intervals of components depends on the load profile, turbine inlet temperature, suction air temperature and
turbocharger speed. In case the operation conditions differs significantly from what is considered to be normal for the cur-
rent application, it is recommended to contact ABB for a re-calculation of replacement intervals. Frequent load alterations,
high temperatures and high speed lower the life of components.
Unless otherwise agreed, the application limits nMmax, tMmax are valid for the test operation for a limited time.
Operation Manual / TPL67-C.. - TPL71-C..
Table of contents Page 1
Table of contents
April 2016
1 Preliminary remarks
1.1 Purpose of this manual
1.2 Layout and function
1.3 Intended use of the turbocharger
1.4 Storage of new turbochargers and spare parts
1.5 Essential information
1.6 Symbols and definitions
1.7 Turbocharger rating plate
1.8 Contact information
2 Safety
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2.1 Introduction
2.2 CE conformity
2.3 Definition of mandatory signs
2.4 Definition of Safety instructions
2.5 Warning plates on the turbocharger
2.6 Safe operation and maintenance
2.7 Hazards during operation and maintenance
2.8 Periodic checking of the pressure vessel
2.9 Lifting loads
3 Commissioning
3.1 Oil supply
3.2 Inspection work
3.3 Commissioning after taking out of operation
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4 Operation
4.1 Noise emissions
4.2 Servicing work
4.3 Replacement intervals for turbocharger components
4.4 Speed measurement
4.5 Stopping the engine
© Copyright 2016 ABB. All rights reserved.

5 Maintenance
5.1 Foreword to Maintenance
5.2 Cleaning the filter silencer
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5.3 Cleaning the compressor during operation
5.4 Cleaning turbine blades and nozzle ring in operation
6 Troubleshooting
6.1 Malfunctions when starting
6.2 Surging of the turbocharger
6.3 Malfunctions during operation
6.4 Malfunctions when stopping
6.5 Speed measurement system
7 Removal and installation

7.1 Turbocharger weights
7.2 Remove the turbocharger
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7.3 Installing the turbocharger
8 Disassembly and assembly

8.1 Introduction
8.2 Module weights
8.3 Removing and fitting filter silencer or air suction branch
8.4 Axial clearance
8.5 Removing cartridge group
8.6 Dismantling and installing the turbine diffuser and nozzle ring
8.7 Installing cartridge group
8.8 Dismantling and fitting nozzle ring at turbine end
8.9 Table of tightening torques
9 Taking out of operation at short notice

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9.1 Possibilities for emergency repair

9.2 Locking the rotor
9.3 Fit cover plate
9.4 Blocking the inlets and outlets
9.5 Bypass the turbocharger

10 Mothballing turbocharger
10.1 Taking out of operation for up to 12 months
10.2 Taking out of operation for more than 12 months
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11 Disposing of turbocharger components
12 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)
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Preliminary remarks 1
Purpose of this manual 1.1 Page 5
1 Preliminary remarks
1.1 Purpose of this manual
April 2016
1.1
This operation manual belongs to the turbocharger with the identical HT

number (01), see the cover sheet of the operation manual and the turbo-
charger rating plate.
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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.
This Operation Manual complements and expands existing national regu-

lations concerning work safety and accident prevention.
Target group
This Operation Manual is intended for engineers and qualified mechanics

who are responsible for operating the engine and the turbocharger in-
stalled on it.
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Availability of operation manual
An operation manual must be available at all times at the place where the
turbocharger is used.
Everyone who operates or works on the turbocharger must have first read
and understood the operation manual.

Layout and function 1.2 Page 6
1.2
1.2 Layout and function
TPL67/71-C
April 2016
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01 Filter silencer 08 Nozzle ring
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
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Layout and function 1.2 Page 7
Mode of operation
The turbocharger is a turbomachine and consists of the following main

components:
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 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.
The turbine wheel (09) uses the energy contained in the exhaust gas to
drive the compressor wheel (12). The compressor then draws in fresh air,
compresses it and then forces it into the cylinders.
The exhaust gases escape to free air through an exhaust gas pipe which
is connected to the gas outlet casing (06).
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The air which is necessary for operation of the diesel engine and is com-
pressed in the turbocharger is drawn through the suction branch or the fil-
ter silencer (01) into the compressor wheel (12). This air then passes
through the diffuser (11) and leaves the turbocharger through the com-
pressor casing (13).
The rotor runs in two radial plain bearings (02/05). One plain bearing is in
the bearing bush (04), and the second one is in the axial thrust bearing
(03) at the compressor end.
The plain bearings are connected to a central lubricating oil duct which is
fed with oil from the engine's lubricating oil circuit. The oil outlet is always
at the lowest point of the bearing casing (10).
Turbocharger version with compressor wheel cooling system
Depending on its range of use, the turbocharger is provid-

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ed with a compressor wheel cooling system. Compressor

wheel cooling means that, after the charge air cooler at the
engine end, cooled compressor air is delivered to the tur-
bocharger to cool the compressor wheel.
In view of the respective operating conditions, it is abso-
lutely essential that the compressor wheel is cooled in or-
der to guarantee its reliability and replacement intervals. 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.

Intended use of the turbocharger 1.3 Page 8
1.3
1.3 Intended use of the turbocharger
This turbocharger supplied by ABB Turbo Systems has been developed
April 2016
for use on diesel engines to generate the volume of air and the charg-
ing pressure required to operate the engine.
NOTICE The enginebuilder has provided ABB Turbo Systems with information
regarding the intended purpose of use of the engine, from which the
specific operating limits shown on the turbocharger rating plate (such as
speeds, temperatures and replacement intervals) have been deter-
mined.
Any other use is considered to be a special application, which must first
be clarified with ABB Turbo Systems. The manufacturer accepts no lia-
bility for any other type of use. If the equipment is used for any other
purpose, ABB Turbo Systems reserves the right to reject all warranty
claims.
State of the art This turbocharger was built according to state-of-the-art technology and is
operationally safe according to recognised safety regulations.
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Improper operation and maintenance of the turbocharger can result in
danger to life and limb of the user or third parties. In addition, improper
use may cause damage to the machine.
WARNING  The machine may be operated only by trained personnel.
Use of the turbocharger as intended also includes observance of the in-

stallation / fitting, disassembly / removal, operating, maintenance / servic-
ing and repair conditions specified by the manufacturer. Disposal regula-
tions set down by local authorities must be observed.
Perfect condition The turbocharger may be installed only when in technically perfect condi-
tion while observing the instructions given in the engine builder's manual.
It may be used only for the intended purpose and operated in compliance
with the operation manual.
 Malfunctions which could affect safety must be eliminated immediate-

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ly.
The manufacturer accepts no liability for any damage resulting from unau-
thorised alterations to the turbocharger.

Storage of new turbochargers and 1.4 Page 9

spare parts
1.4 Storage of new turbochargers and spare

1.4
parts
April 2016
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).
Volatile Corrosion Inhibitor (VCI)
Only dry rooms in which the relative humidity is between 40…70 % and
no condensation can form are suitable for storage.
Storage of new turbochargers and spare parts for more than 6 months (VCI)
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Protection of health when handling VCIs

VCI products are not hazardous in the sense of the Hazardous Sub-
stances Ordinance. Nevertheless, the following points are to be ob-
WARNING
served when handling VCIs:
 Ensure good room ventilation.
 Do not eat, drink or keep food at the workplace while working with
VCIs.
 Wear safety gloves.
 Clean hands and face after working with VCIs.
 For further information refer to www.branopac.com.
Wear safety gloves against chemical risks.
The following mothballing measures are required every 6 months:

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 Open the package.

 Remove the VCI corrosion protection emitter from the package and
replace it with a new, identical VCI corrosion protection emitter. New
VCI corrosion protection emitters can be obtained at
www.branopac.com.
 Dispose of the old VCI corrosion protection emitter in an environmen-
tally compatible manner, professionally and in accordance with local
regulations.
 Seal the package. The better the external seal is designed, the more
permanent the protection.

Storage of new turbochargers and 1.4 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-
April 2016
rometer (see illustration).
The following measures are required every 6 months:
 Check the hygrometer (02) in the sight-glass. There is an opening (01)

in the wooden crate which allows this check to be carried out. When
the display field has changed colour at the 70% level, the maximum
permissible humidity has been exceeded. In this case the turbocharger
or rotor must be inspected by an ABB Turbocharging Service Station
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and repacked.
 Inspect the package for damage. If the package is damaged, the tur-
bocharger or cartridge group must be inspected by an ABB Turbo-
charging Service Station and repacked.
After every 3 years the following work steps must be performed by an

ABB Turbocharging Service Station:
 Inspect the components

 Exchange the desiccant agent
 Repackage the components.
Replacement components ready for operation

If the 70% display field of the hygrometer (02) has not changed colour
and the package is undamaged, the replacement turbocharger or re-
NOTICE
placement cartridge group can be placed into operation without any pri-
or testing by an ABB Turbocharging Service Station.
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Unpacking replacement turbochargers or spare parts
The corrosion protection effect ends after the material is unpacked from
the VCI package.
To avoid the formation of condensation, the surroundings and the content

of the package must have the same temperature during unpacking.

Essential information 1.5 Page 11
1.5
1.5 Essential information
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Organisational measures
In addition to this manual, the general, statutory regulations applicable in

the respective country for the prevention of accidents and the protection of
the environment must be observed.
This also applies to the provision and wearing of personnel protection

equipment.
The safety and risk consciousness of the personnel working on and

with the turbocharger must be checked regularly with reference to this
manual.
NOTICE
 The turbocharger must be shut down immediately by stopping the en-

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gine in the event of alterations affecting safety or of corresponding op-

erating behaviour. 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
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Original parts and safety
Original parts and accessories are specially designed for the turbocharger
supplied by ABB Turbo Systems.
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Use original parts
Operation of the turbocharger with non-original parts can impair the
safety of the turbocharger and can cause serious damage to property
WARNING
and injury to personnel.
 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-
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thorised personnel. Basic mechanical training is a prerequisite.
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Design variants
This document is valid for different design variants of turbochargers.

There may be sections and descriptions of components that are not rele-
April 2016
vant for a specific turbocharger variant.
ABB Turbocharging Service Stations will be happy to provide information

on questions regarding a design variant (see Contact information at
www.abb.com/turbocharging).
Accuracy of illustrations
The illustrations in this document are general in nature and intended for
ease of understanding. Differences in detail are therefore possible.
Registered trademarks
Registered trademarks of external companies are used in this document.

The trademarks are marked with ®.
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Symbols and definitions 1.6 Page 14
1.6
1.6 Symbols and definitions
The following symbols are used in the documents:
April 2016
 Prerequisite
 Step of a procedure
 List, first level
- List, second level
[➙ ] Refers to a page number
Definition of notes
Note
A note provides suggestions which facilitate the work on the product.
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NOTICE
Definition of mandatory signs
Mandatory signs show the protective equipment to be worn for a task. The
mandatory signs are described in chapter Safety and must be complied
with.
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

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Systems.
Official ABB Turbo Systems Service Stations
In this document, official service stations are referred to as ABB Turbo-

charging Service Stations. They are inspected and certified regularly by
ABB Turbo Systems. See also chapter Contact information [➙ 17].

Turbocharger rating plate 1.7 Page 15
1.7
1.7 Turbocharger rating plate
April 2016
Operating limits
01 Turbocharger operating limits at engine overload (110%).
Only when operating in the test rig unless otherwise agreed with the en-
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ginebuilder.
02 Turbocharger operating limits during operation
Recommended replace-
03 Replacement interval for plain bearings in 1000 h
ment intervals for turbo-
charger components 04 Replacement interval for compressor in 1000 h
05 Replacement interval for turbine in 1000 h
Further information
06 Part number for customer
07 Designation of special design
08 Turbocharger weight in kg
09 Turbocharger type
10 Serial number
11 Year of turbocharger construction
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Turbocharger rating plate 1.7 Page 16
1.7.1 Explanation of the rating plate
The recommended replacement intervals and the corresponding opera-
April 2016
tional limits are jointly defined with the engine manufacturer. This informa-
tion is specific to the system.
Operation above the indicated values nBmax, tBmax can considerably shorten the
recommended replacement intervals. In such cases, we recommend that you
contact the nearest official ABB Turbocharging service station.
nMmaxand tMmax normally apply only when running at overload (110%) during tri-
als on the engine test bed. These limits can also be permitted during operation
for special applications. Operation above nMmax and tMmax is not permitted.
Non-observance of the recommended replacement intervals can increase the
risk of unpredictable component failures.
1.7.2 Positions of the rating plates
A rating plate is attached to the turbocharger foot, one on the left and one
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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.
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Contact information 1.8 Page 17
1.8
1.8 Contact information
April 2016
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
CH-5401 Baden
Switzerland
www.abb.com/turbocharging
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Safety 2
Introduction 2.1 Page 19
2 Safety
2.1 Introduction
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2.1
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:
 originate from the turbocharger itself and its accessories

 originate from the operating and auxiliary materials used
 are the consequence of insufficient observance of the safety instruc-
tions
 are the consequence of unsatisfactory and improper execution of
maintenance and inspection work
The operator is responsible for access to the turbocharger as well as the

organisational measures which regulate the safe handling of the turbo-
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charger by his personnel.
All instructions in this chapter must be observed to ensure safe and trou-
ble-free turbocharger operation and during work on the turbocharger.
In the same vein, all other specially marked safety instructions in every
chapter of this manual must be observed (see the section entitled Defini-
tion of safety instructions).
2.2
2.2 CE conformity
Information
ABB turbochargers fulfil Directive 2006/42/EC on machinery and are con-

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sidered partly completed machinery in the sense of Article 2 g.

Safety 2
Definition of mandatory signs 2.3 Page 20
2.3
2.3 Definition of mandatory signs
To be worn at all times
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Protective clothing Safety footwear against
mechanical hazards
To be worn according to the specific work

Safety glasses Safety goggles
Safety gloves against Respiratory mask against

- mechanical hazards - dust
- chemical hazards - gases
- heat hazards
Safety helmet Ear protection
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2.4
2.4 Definition of Safety instructions
The following symbols and terms used in this manual concern safety or
refer to possible hazards:
Definition of warning
Serious personal injuries and even accidents with fatal consequences
may occur if work and operating instructions marked with this symbol
WARNING
and the word WARNING are either not followed or not followed precise-
ly.
 Warning signs must be observed at all times.
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Definition of caution
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.

Safety 2
Warning plates on the turbocharger 2.5 Page 21
2.5
2.5 Warning plates on the turbocharger
Warnings that have been attached to turbochargers by ABB Turbo Sys-
April 2016
tems must not be removed. Illegible warnings must be replaced with new
ones. Further information is available from ABB Turbocharging service
stations.
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Part number Size [mm] Product

81080 105 x 74 TPL / TPR
When uninsulated turbochargers are delivered to the engine builder, the

warning plates must be subsequently attached to the insulation. This is
the responsibility of the engine builder.
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Safety 2
Safe operation and maintenance 2.6 Page 22
2.6
2.6 Safe operation and maintenance
The instructions specified in this section are for the safety of personnel.
April 2016
Together with the instructions in the Hazards during operation and
maintenance section, they allow the user to safely use the turbocharger.
Work safety and work area safety
Risk of falling
There is the risk that someone can fall when working on the turbo-
charger.
WARNING
 Do not climb on the turbocharger or on parts attached to it or use
these as climbing aids.
 When working at levels above the head, use climbing aids and work
platforms suitable for this purpose.
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 Observe all general regulations for the prevention of accidents.
 Do not work on the turbocharger if you are under physical or mental
stress.
 Work only with suitable tools as well as equipment and working mate-
rials that are in perfect condition.
 Electric tools must be solidly earthed, and connecting cables may not
be damaged.
 Keep the workplace clean, clear away loose objects and remove ob-
stacles on the floor.
 Keep the floor, equipment and the turbocharger clean.
 Have oil binding materials ready at hand and keep oil catch pans
ready or in position
 Eliminate leaks.
 Keep fire-protection materials and fire-extinguishing equipment ready.
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Welding work
 If welding work is being carried out above the turbocharger, make sure
to cover the filter silencer so that the filter mat is not damaged.
 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.

Safety 2
Safety during start-up / commissioning and operation
 Before starting work, carry out visual inspection of working area.

 Remove any obstacles and objects lying around.
April 2016
 Before start-up / commissioning, check all pipes from and to turbo-

charger for damage and leaks.
 Don't work in any way that could impair safety when working on turbo-
charger.
 After about every 12 hours of operation or at least once a day, inspect
turbocharger for visible damage and defects.
 Immediately report any damage or changes in operational perfor-
mance to person responsible.
 If damage is discovered, immediately shut down turbocharger and se-
cure it against inadvertent or unauthorized use.
 When switching on auxiliary power sources (hydraulics, pneumatics,
electricity, water), keep an eye open for any hazards resulting from
supplying these power sources.
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Safety during cleaning
It is possible that detergents or solvents will be used for cleaning. In this

case, the safety instructions of the Hazard due to operating materials and
supplies section in this chapter must always be observed.
 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.
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Safety 2
Safety during disassembly, assembly, maintenance and troubleshooting
 Always perform the specified adjustments, servicing as well as inspec-

tion work and observe inspection intervals.
April 2016
 Inform operating personnel about all service and repair work before
beginning.
 Before opening a cover or removing a protective device on a turbo-
charger, the engine must be switched off and the turbocharger must
have come to a standstill.
 Ensure that the supply of oil is interrupted, especially with an external
oil supply.
 Put the engine into operation only after all parts have been refitted
properly.
Mechanical work on the turbocharger

Possible damage to or destruction of components on the turbocharger.
CAUTION  Perform only those tasks that are described in this manual.
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 Perform work only for which training has been carried out.
Safety when taking out of operation or mothballing
 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.
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Safety 2
Hazards during operation and 2.7 Page 25

maintenance
2.7
2.7 Hazards during operation and maintenance
April 2016
Mechanical hazards during operation
During normal operation, no mechanical hazards emanate from the turbo-

charger if it has been installed properly.
Risk of injury
Contact with rotating parts can lead to serious injuries. The turbo-
charger must never be operated without a filter silencer or an air suction
WARNING
branch. When the engine is at a standstill, the rotor can turn on its own
because of stack draught.
 Operate the turbocharger in accordance with instructions.
 During maintenance work, secure the rotor against unintentional ro-
tation.
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Mechanical hazards when working on the turbocharger
During maintenance work, various risks can occur through the improper
handling of components, through the non-observance of work instructions,
due to inadequate care or as a consequence of insufficient training.
Mechanical hazards
Severe injuries to personnel or fatal accidents can be caused by me-
chanical influences as a consequence of hazardous and inadequate
WARNING
operational procedures.
 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 in-
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struction or training.

Safety 2

maintenance
Hazards due to noise
The development of noise during operation is influenced by the installation

and operating conditions. Noise with a sound pressure level exceeding
April 2016
85 dB(A) is harmful.

Noise can cause impaired hearing, damage to health, mental disturb-
ances, diminished attention and irritation.
WARNING
 Always wear ear protection when the engine is running.
 When the sound pressure level is above 85 dB(A), always wear ear
protection.
Wear ear protection.
Hazards due to hot surfaces and substances
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During operation, turbocharger surfaces and attached parts as well as op-
erating materials (lubricating oil) become hot. The surface temperature is
dependent on the effectiveness of the insulation being used. The tem-
perature can become high enough so that it falls into ranges where burns
are possible.
Risk of burning
Touching hot surfaces or contact with hot operating materials can lead
to serious burns.
WARNING
 Do not touch hot surfaces and heed the warning plate on the turbo-
charger.
 Wear heat-resistant safety gloves and protective clothing.
 Allow the turbocharger to cool down before carrying out any work.
Wear safety gloves against thermal risks.

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Safety 2

maintenance
Hot surfaces on uninsulated turbochargers

Uninsulated turbochargers can cause serious personal injuries (burns).
April 2016
WARNING The turbocharger is supplied by ABB Turbo Systems without insulation

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.
 The engine builder's instructions and specifications about protection
against hot turbocharger surfaces must be observed in every case.
Hazards due to operating and auxiliary materials
Operating and auxiliary materials are substances used for operation or the
execution of maintenance work. Oils, greases, coolants, cleaning agents
and solvents, acids, etc. can be regarded as hazardous materials. Operat-
ing and auxiliary materials can be combustible and easily ignited.
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Handling operating and auxiliary materials

Ingestion or inhalation of vapours of operating and auxiliary materials or
contact with such can cause damage to health.
WARNING
 Avoid inhalation and contact with the skin.
 Ensure good ventilation.
 Observe details in the safety data sheets of the operating and auxil-
iary materials.
 Observe local laws.
Wear safety goggles.
Wear a respiratory mask to protect against gases.

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Safety 2

maintenance
Risk of fire, explosion

Combustible or easily ignited operating and auxiliary materials can
April 2016
burst into flame, or vapours from them can cause explosions.
WARNING
 Observe specifications in the safety data sheets of the operating and
auxiliary materials.
 Observe local legislation.
 Do not allow any exposed flame during cleaning work.
 Perform cleaning outdoors or ensure for adequate aeration and ven-
tilation.
Risk of environmental damage

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.
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 Heed the instructions for use, safety data sheets and hazard notices
on the containers of the operating and auxiliary materials.
 Avoid inhalation and contact with the skin.
 Ensure that the work space is adequately ventilated.
 Seal containers tightly immediately after use and put them away.
 Collect used working and auxiliary materials safely, store them sepa-
rately in suitable containers and dispose of them properly and in an
environmentally compatible manner in accordance with statutory regu-
lations.
 In the event of leaks or after spilling, immediately spread a suitable
binding agent and dispose of it properly and in an environmentally
compatible manner in accordance with statutory regulations.
Revision C

Safety 2

maintenance
Hazards when handling insulating materials

April 2016
Hazards due to insulating materials

Dust and fibres from insulating materials can cause damage to health
or irritations. Unsuitable, combustible insulating materials signify a fire
WARNING
hazard.
 Use only suitable, non-combustible insulating materials.
 Ensure that the work area is well ventilated.
 Avoid stirring up dust.
 Use tools and processes which keep dust to a minimum.
 Remove packing materials only in the work area.
 Take particular care when removing old insulating materials.
 Dispose of insulating materials properly and in an environmentally
compatible way in accordance with applicable local regulations.

HZTL2488_EN
Wear a respiratory mask to protect against particles.
 Use only suitable, non-combustible insulating materials.

 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.
 Remove packing materials only in the work area.
 Take particular care when removing old insulating materials.
 Dispose of insulating materials properly and in an environmentally
compatible way in accordance with applicable local regulations.
Revision C

Safety 2
Periodic checking of the pressure 2.8 Page 30

vessel
Hazards due to electrical components
April 2016
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.
2.8
2.8 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".
HZTL2488_EN
 The local, statutory regulations covering periodic checks of pressure
vessels must be observed.
 The operator is responsible for the safe operation of the pressure ves-
sel.
Hazards from pressure vessels

The operator must keep the pressure vessel in a proper condition and
monitor it. Necessary repair or maintenance work must be carried out
WARNING
without delay and the required safety precautions must be taken.
 Pressure equipment must not be operated if it has defects.
Revision C

Safety 2
Lifting loads 2.9 Page 31
2.9
2.9 Lifting loads
April 2016
Suspended loads
Loads not suspended in compliance with regulations may lead to per-
sonal injury or accidents with fatal consequences.
WARNING
 Loads must always be fastened to technically perfect lifting gear with
sufficient loading capacity.
 Make sure the load is suspended properly on the crane hook.
 Do not let anyone stand beneath a suspended load.
Wear safety gloves against mechanical risks.
Wear safety helmet.

HZTL2488_EN
In the case of two or more suspension points, the slinging angle must not
exceed 45°. This avoids excessive loading due to inclined tensile loading.
 Fasten turbocharger assemblies / components as described in respec-

tive handling steps.
Revision C
 Before attaching slings, allow turbocharger components to cool down

(maximum 80°C).
 Use suitable protection at sharp edges.
 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.

Commissioning 3
Oil supply 3.1 Page 33
3 Commissioning
3.1 Oil supply
April 2016
3.1
A carefully designed and installed oil supply, which functions in all possi-
ble operational conditions, is an important prerequisite for trouble-free tur-
bocharger operation.
The turbocharger is normally lubricated with oil from the engine oil circuit.
With regard to the oil supply, please observe the engine builder's speci-
fications for lubricating oil selection, oil change intervals, oil filtration, oil
pressure and oil temperature.
NOTICE
Oil filtration
HZTL2488_EN
Filtration of the lubricating oil using a filter mesh size ≤ 0.034 mm is ade-
quate for TPL67-C turbochargers and a mesh size ≤0.050 mm for TPL71-
C turbochargers.
This filtration can also be carried out using an additional self-cleaning

fine filter.
NOTICE
Revision C

Commissioning 3
Oil pressure
The oil pressure in front of the turbocharger must be maintained precisely

to ensure trouble-free operation.
April 2016
The permissible oil pressure ranges at measuring point M (blind connec-
tion) on the turbocharger are listed below.
Status for operation Oil pressure in front of the turbo-

charger [bar]
HZTL2488_EN
Permissible, for normal operation 1.3 … 2.5
Permissible, during engine warm-up 1.3 … 5.0
Temporarily permissible ( < 1h ) -> alarm 1.1 … 1.3
Not permissible -> emergency stop 0.0 … 1.1
Permissible, during pre- and post-lubrication 0.2 … 2.5
(engine stopped)
Oil orifice
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.
Revision C

Commissioning 3
Lubricating oil temperature at the inlet

April 2016
Machine damage
If the oil temperature at the oil inlet exceeds the admissible range, this
may lead to engine damage.
CAUTION
 Observe oil temperature at the oil inlet according to the following ta-
ble.
Oil temperature at the

Status for operation inlet
Toil,inlet [°C]
Permissible 30 … 90
Temporarily permissible (< 1h) -> alarm > 90
Not permissible -> stop the engine > 95
Not permissible -> Do not start the engine < 30
HZTL2488_EN
(before starting: preheat the oil)
Lubricating oil temperature at the outlet
The oil temperature at the outlet is mainly dependant on:
 Lubricating oil temperature and pressure at the oil inlet

 Engine load and turbocharger speed
 Exhaust gas temperature
The maximum admissible oil temperature at the outlet is listed in the fol-
lowing table. The specified oil outlet temperature is to be considered as
alarm value for the turbocharger operation and must be monitored accord-
ing to the current regulations.
Oil temperature at the outlet

Revision C
Status for operation Toil,outlet [°C]

Permissible ≤ 140
Temporarily permissible -> alarm > 140
Not permissible -> stop the engine > 160
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.

Commissioning 3
Inspection work 3.2 Page 36
3.2
3.2 Inspection work
Inspection work includes preventive visual controls plus monitoring and
April 2016
measuring work before and during commissioning. Inspections help detect
changes to the turbocharger. Machine damage can be avoided.
3.2.1 Inspection before commissioning
Monitoring devices  Check for correct functioning.
Air filter mat  Inspect for damage.
HZTL2488_EN
Lubricating system  Check oil filter for cleanliness before commissioning.
Contaminated oil
Particles of dirt and solid matter in the oil can cause serious damage to
the machine or property.
CAUTION
 During initial commissioning and after all service work, the complete
lubricating system must be flushed thoroughly with warm oil.
 When running in the engine and after all service work on the lubricat-
ing system, special running-in filters must be used.
 Check oil pressure in oil supply lines.

Revision C
Warning plates on tur-  Check whether the warning plates are present and legible.
bocharger
 Check whether the protective sheets have been removed.

Commissioning 3
Inspection work 3.2 Page 37
3.2.2 Check after start-up (engine at idling speed)

April 2016
Lubricating system
 Check oil pressure in oil supply lines.

 Check oil inlet temperature.
The permissible values are listed in the section Oil supply.
Gas, air and oil lines
 Check all gas, air and oil lines for leaks after starting the engine.
3.2.3 Check when running up engine

HZTL2488_EN
 Measure speed, oil pressure and charging pressure at various engine

performance levels.
 Measure exhaust gas temperature in front of and behind turbine.
 Measure air temperature in front of and behind compressor.
The measured values must be compared with the values in the ac-
ceptance test report, while taking different operating conditions into ac-
count.
Lubricants and pastes used during assembly of the turbocharger liquefy

or vaporise and might escape as an oily liquid in the first few hours after
commissioning. 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.
Revision C
3.2.4 Inspection after 100 service hours
Clean or replace lubricating oil filters after the first 100 service hours.

Commissioning 3
Commissioning after taking out of 3.3 Page 38

operation
3.3
3.3 Commissioning after taking out of operation
If provided  Remove cover plates (blind flanges) between compressor casing out-
April 2016
let and charge air duct, before gas inlet and after gas outlet.
 Inspect exhaust gas duct / line in front of and after turbine for any
combustion deposits, foreign matter or residual water. Clean and re-
move.
 Inspect air supply line or filter silencer for any foreign matter. Clean
and remove.
 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.
HZTL2488_EN
Revision C

Operation 4
Noise emissions 4.1 Page 39
4 Operation
4.1 Noise emissions
April 2016
4.1

Noise can cause impaired hearing, damage to health, mental disturb-
ances, diminished attention and irritation.
WARNING
 Always wear ear protection when the engine is running.
 When the sound pressure level is above 85 dB(A), always wear ear
protection.
Wear ear protection.
The sound pressure level (A-weighted) of emissions is measured at a dis-

tance of 1 metre from the turbocharger.
HZTL2488_EN
The highest sound pressure level of emissions1) reaches a maximum of

105 dB(A) near the filter silencer and over the entire speed range.
The following prerequisites must be fulfilled on the turbocharger in order

to observe this limit value:
 Fitted air-inlet system

 All standard, noise-reducing measures have been taken2).
 The bellows at the air outlet have been perfectly insulated acoustically
by the engine builder. He is also responsible for insulating the charge
air / scavenging air line and the charge air cooler.
Revision C
1) Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 :

A-weighted emission sound pressure level
2) In the event of divergent insulation designs, the engine builder must en-
sure that equivalent acoustic insulating measures are taken.

Operation 4
Noise emissions 4.1 Page 40
Suggestion for noise insulation of the bellows
April 2016
01 Compressor casing 04 Insulation pads
HZTL2488_EN
02 Bellows 05 Insulation mat (at least 15 mm)
03 Charge air duct / scavenging 06 Sheet metal cover
air line
Revision C

Operation 4
Servicing work 4.2 Page 41
4.2
4.2 Servicing work
Service work to be carried out during operation involves visual checks,
April 2016
monitoring, measuring, inspection work and functional checks. It is then

possible for changes to the turbocharger to be identified and rectified. In
this way, it can be ensured that the turbocharger remains in full working
order.
Service intervals
Service work on the turbocharger that is neglected or carried out too
late can lead to excessive contamination and wear as well as operating
CAUTION
failures.
 Carry out service work at specified time intervals.
Shortened service intervals

Despite observance of the service intervals, unusual loads, such as
HZTL2488_EN
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

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.
 Record operating data and enter it in the engine logbook.
Revision C
 Clarify the cause of any variances.
Unknown changes during operation

The consequences can range from an impairment to a breakdown.
CAUTION  Have unknown causes clarified by an ABB Turbocharging service
station.

Operation 4
4.2.2 Entries in engine logbook
April 2016
By monitoring the engine, conclusions can be drawn about the turbo-
charger performance.
The following operating data and measured values must be entered regu-
larly in the engine manufacturer's engine logbook:
 Engine performance and speed

 Air intake temperature
 Exhaust gas temperature in front of and behind the turbine
 Pressure of charge air
 Pressure drop in charge air cooler
 Lubricating oil pressure and lubricating oil temperature
If provided  Air temperature behind compressor and charge air cooler
HZTL2488_EN
 Turbocharger speed
 Pressure loss in air filter
4.2.3 Servicing work according to the engine manufacturer's instructions
Oil filter  Clean or replace oil filter in supply line to turbocharger when engine is
not running.
Revision C

Operation 4
The inspection and assessment of the rotor and the bearing parts must be
April 2016
carried out by an official ABB Turbocharging service station.
 Disassemble turbocharger.
 Measure clearances.
 Clean the turbine and compressor wheels and inspect for damage.
 Clean the turbine and compressor casings and inspect for any cracks
and erosion or corrosion.
 Clean bearing casing and blow air through oil ports.
 Clean nozzle ring and check for cracks and erosion.
 Inspect and assess bearing parts and rotor.

HZTL2488_EN
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.
 Clean the turbine and compressor wheels and inspect for damage.
 Clean the turbine and compressor casings and inspect for any cracks
and erosion or corrosion.
 Clean bearing casing and blow air through oil ports.
 Clean nozzle ring and check for cracks and erosion.
 Inspection and assessment of the rotor
 Replace plain bearings with original parts from ABB Turbo Systems.
Revision C

Operation 4
Replacement intervals for turbocharger 4.3 Page 44

components
4.3 Replacement intervals for turbocharger com-

4.3
ponents
April 2016
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. They can be found on the turbo-
charger rating plate. Incalculable influencing parameters can shorten the
recommended replacement intervals for the rotor, see Influencing pa-
rameters.
Non-rotating components The expected replacement intervals for non-rotating components and
bearing parts are extremely dependent upon system-specific operating
conditions, see Influencing parameters.
When the specified, periodic inspections are carried out, the individual
components are inspected for wear and tear and replaced if necessary. In
this way, trouble-free operation is ensured.
HZTL2488_EN
Influencing parameters The following parameters influence the replacement intervals for turbo-
charger components:
Parameters influencing bearing parts
 Poor quality of the lubricating oil (lubrication oil filter system, condition
of lubricating oil)
 Unusual loads (vibration, start/stop frequency)
 Non-permissible state of rotor unbalance
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
Revision C
 Turbine cleaning frequency

 Procedure for turbine cleaning

Operation 4
Replacement intervals for turbocharger 4.3 Page 45

components
Parameters influencing rotating components exposed to exhaust gas
 Fuel quality (gas, MDO, HFO)

April 2016
 Turbine cleaning frequency

 Procedure for turbine cleaning
 Load profile
Expected replacement
Component GAS / MDO HFO
intervals [h]
Gas inlet casing 50000 … 100000 25000 … 50000
Gas outlet casing 50000 … 100000 35000 … 100000
Nozzle ring 35000 … 50000 25000 … 50000
Turbine diffuser / cover ring 35000 … 50000 25000 … 50000
Other casings 100000 100000
Axial bearing components 24000 … 36000 24000 … 36000
Radial bearing components 24000 … 36000 24000 … 36000
Turbine blades - ≥ 12000
(due to wear)
HZTL2488_EN
Recommended replace-
Rotor components See the data on the rating plate
ment intervals [h]
GAS = Gas Engine

MDO = Marine Diesel Oil
HFO = Heavy Fuel Oil
The specified values are guides and not guaranteed. (See Influencing
parameters.)
NOTICE
Revision C

Operation 4
Speed measurement 4.4 Page 46
4.4
4.4 Speed measurement
A speed measuring system permits continuous monitoring of the turbo-
April 2016
charger speed.
Do not use cables as a climbing aid

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 HZTL2488_EN
42047 Screw plug

86505 Speed sensor
Revision C
86515 Cable connector for 86505

86526 F/I converter
86528 Tachometer

Operation 4
4.4.1 Speed differences with multiple turbochargers per engine
The speeds of all turbochargers on one engine differ only slightly from
April 2016
each other in normal operation.
The difference between the highest and the lowest turbocharger speed
must not be more than 3 % relative to the speed limit nBmax.
If this permissible range of difference is exceeded, the following steps

must be carried out:
 Reduce engine performance immediately until the highest turbo-

charger speed no longer exceeds 70% of nBmax.
 If the engine cannot be stopped, continue to run at this reduced engine
performance or turbocharger speed.
 If the turbocharger surges continuously, engine performance must be
reduced further.
 Measure the temperatures in the air and gas lines to and from the tur-
bochargers and compare them with standard values.
HZTL2488_EN
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.
Revision C

Operation 4
4.4.2 Assembly
If the speed sensor is not fitted on the turbocharger, the following proce-
April 2016
dure must be adopted to fit it:
 Engine and turbocharger are not running.

 The turbocharger lubricating system is switched off.
 Remove screw plug (42047) from bearing casing.
Part position
The position of the screw plug for measuring the speed is marked "n"
on the bearing casing.
NOTICE
 Screw in speed sensor (86505) as far as it will go and tighten to torque

specified in table. (See chapter Table of tightening torques.)
 Connect speed sensor using cable connector (86515).
HZTL2488_EN
Revision C

Operation 4
4.4.3 Replacing the speed sensor

April 2016
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.
WARNING
 Wear safety gloves when removing the cable connector and speed
sensor.
 Reduce engine performance to the idling speed, then stop the engine.
 Switch off the lubricating oil supply to the turbocharger.
 Disconnect the cable connector from the speed sensor.
 Screw out defective speed sensor.
HZTL2488_EN
 Screw in a new speed sensor up to the limit block.

 Observe the tightening torque (see the table of tightening torques in
the chapter entitled Disassembly and assembly).
Sealing the speed sensor

The speed sensor is designed with a sealing lip and does not require an
additional gasket when fitted.
NOTICE
 Connect cable connector to speed sensor.

 Switch on lubricating oil supply to turbocharger.
Revision C
4.4.4 Failure of speed measuring system
Possible reasons for failure of the speed measuring system are described
in the chapter Troubleshooting.

Operation 4
Stopping the engine 4.5 Page 50
4.5
4.5 Stopping the engine
April 2016
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.
HZTL2488_EN
Revision C

Maintenance 5
Foreword to Maintenance 5.1 Page 51
5 Maintenance
5.1 Foreword to Maintenance
April 2016
5.1
Maintenance and servicing work involves regular visual checks and clean-
ing to ensure that the turbocharger and its attached units function trouble-
free.
 The external condition and how dirty the cleaning points specified in
this chapter are, must be established by visual checks at the specified
intervals.
 The safety precautions must be observed during all maintenance and
servicing work.
The cleaning points described in the following are:

HZTL2488_EN
 Filter silencer
 Compressor
 Turbine and nozzle ring
Revision C

Maintenance 5
Cleaning the filter silencer 5.2 Page 52
5.2
5.2 Cleaning the filter silencer
April 2016
5.2.1 Filter silencer and connecting rod
HZTL2488_EN
81265 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
E Insert unit = absorption segment + sheetmetal covering
Revision C

Maintenance 5
Removing and cleaning filter silencer

April 2016
If provided  Remove filter strip (81265).

 Rinse filter strip (81265) using water with detergent additive or, if very
dirty, soak it and squeeze out carefully. Rinse it in cold water. Avoid
rough treatment (not a jet of water).
How dirty the filter strip (81265) is, depends on how clean the drawn-in
air is. Clean filter strip every 500 hours of service or more frequently if
necessary.
NOTICE
 Unscrew and remove lock nuts (81273).

 Unscrew and remove screws (81272) for connecting rods (81269).
 Remove connecting rods (81269).
 Carefully remove cover grids (81266).
HZTL2488_EN
 Pull out insert units (E), bend open sheet-metal coverings (81137) and
then remove absorption segments (81136).
 Clean the absorption segments (81136).
During cleaning, ensure that the absorption segments (81136) are only
cleaned with a mild jet of compressed air, soft brush or a damp cloth.
Otherwise there is a risk of damage or deformation.
Replace heavily contaminated or damaged parts with original parts from

ABB Turbo Systems.
NOTICE
Revision C

Maintenance 5
Fitting the filter silencer
 Assemble the insert units (E) by inserting the absorption segments

(81136) into the sheet metal coverings (81137).
April 2016
 Bend sheet metal coverings (81137) back to original shape.
 Insert the insert units (E) into slot guides in filter silencer unit (81135).
HZTL2488_EN
 Uniformly place cover grids (81266) in correct position.
 Push connecting rods (81269) through lugs of cover grids (81266).
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
 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
Revision C
reached:
Screw Tightening torque [Nm]
81272 20
 Screw lock nuts (81273) onto screw (81272) and tighten to following
torque:

Maintenance 5
Lock nut Tightening torque [Nm]

April 2016
81273 40
If provided  Fit filter strip (81265).

HZTL2488_EN
Revision C

Maintenance 5
Cleaning the compressor during 5.3 Page 56

operation
5.3
5.3 Cleaning the compressor during operation
Approval by enginebuilder These instructions for wet cleaning only apply when cleaning is carried out
April 2016
with clean water and under the precondition that the enginebuilder ap-
proves the process.
General The degree of contamination of the compressor stage (compressor wheel

and diffuser) depends on how clean the drawn-in air is.
Deposits can build up in the flow channels if salt, oil mist or dust are in the
intake air.
Consequences of contamination:
 Impaired compressor efficiency

 Higher exhaust gas temperatures
 Increased fuel consumption
 Increased rotor unbalance
HZTL2488_EN
Periodic cleaning of the compressor during operation prevents or delays a
severe increase of the contamination. It does not, however, replace the
regular service work, during which the turbocharger is completely disman-
tled and the compressor is cleaned mechanically.
Cleaning interval The interval between periodic cleaning is very dependent on the operating
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.
Revision C

Maintenance 5

operation
Cleaning method
Cleaning of the compressor during operation is carried out using the

cleaning method described in the following:
April 2016
 Wet cleaning
This cleaning method has been tested and approved by ABB Turbo Sys-
tems.
Principle of wet cleaning To clean the compressor stage during operation, water is injected in front
of the compressor wheel through an injection pipe fitted in the filter silenc-
er or the suction branch.
The water does not act as a solvent, but the dirt deposit is removed by the
mechanical impact of the droplets. This is a very suitable process, provid-
ed that the degree of contamination is not too high.
Corrosion and deposits when cleaning

HZTL2488_EN
Damage and impairment of turbocharger parts due to salt water and

cooling water additives
CAUTION
 Don't use salt water for cleaning, but only clean fresh water.
V-engines In the case of V-engines with several turbochargers on each engine, we

recommend parallel cleaning of the compressors. This cleaning process is
faster and the risk of turbocharger surging is reduced.
Revision C

Maintenance 5

operation
5.3.1 Wet cleaning with orifice plate on filter silencer (XC2)
April 2016
Operating state prerequisites for wet cleaning XC2
In the case of V-engines with several turbochargers on each engine, it is

recommended that both turbochargers are cleaned in parallel. This clean-
ing process is faster and the risk of turbocharger surging is reduced.
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
WARNING
can be increased.
 No personnel is allowed to be present in the vicinity of the turbo-
charger during compressor cleaning.
 Compressor cleaning must be activated from the engine control pan-
el.
HZTL2488_EN
Compressor wet cleaning operation with XC2
 Trigger water injection according to the specifications of the en-

ginebuilder.
 The specified water pressure upstream of the connection to the turbo-
charger must be maintained.
 Operate engine for at least five additional minutes after cleaning.
The cleaning process can be repeated up to two times.
How successful the cleaning was, can be seen from the charging pres-
sure or the exhaust gas temperature.
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.
Revision C
Cleaning parameters per turbocharger compressor
Product Engine load Water injection time Orifice diame-

[sec] ter
[mm]
TPL67-C 50 … 85% 10 2.1
TPL71-C 2.5

Maintenance 5

operation
5.3.2 Wet cleaning using external water-pressure vessel (XC3)

April 2016
Operating state prerequisites for wet cleaning XC3
In the case of V-engines with several turbochargers on each engine, it is

recommended that both turbochargers are cleaned in parallel. This clean-
ing process is faster and the risk of turbocharger surging is reduced.
Compressor wet cleaning procedure with XC3

HZTL2488_EN
Operating the water pres-  It is mandatory to fulfil the operating condition prerequisites before
Revision C
sure vessel cleaning compressors with XC3.

 Remove the sealing plug (X).
 Fill the vessel with the required volume of clean water (see the Table
of cleaning parameters).
 Screw in the sealing plug (X).
 Push the valve activator (Y) against the spring and hold it for 10 to 15
seconds until the entire volume of water has been injected.
 After cleaning, wait at least 5 minutes to allow the turbocharger to dry.

Maintenance 5

operation
If the cleaning operation is not satisfactory, it may be repeated up to

two times.
If the cleaning results are still not satisfactory after three attempts and
April 2016
NOTICE the engine values are also unsatisfactory, we recommend that you have
the turbocharger inspected and cleaned by an official ABB Turbocharg-
ing Service Station.
Cleaning parameters per turbocharger compressor
Product Engine load Contents of water vessel

[dm3]
TPL67-C + 71-C 50 … 85% 0.4 or 1
HZTL2488_EN
Revision C

Maintenance 5
Cleaning turbine blades and nozzle ring 5.4 Page 61

in operation
5.4 Cleaning turbine blades and nozzle ring in

5.4
operation
April 2016
The combustion of heavy fuel oil in diesel engines contaminates the tur-
bine blades and nozzle rings of turbochargers. The deposits on the tur-
bine components originate from the following combustion products:
 Soot
 Molten ash
 Cinder
 Incompletely burned fuel
 Sodium vanadyl vanadate
It is advisable to use fuels with a low ash, sulphur, sodium and vanadium
content. The fuel must also be correctly stored, prepared and handled.
We recommend using fuels with a vanadium-to-sodium mass ratio of less

than 3:1 so that the melting temperature of the sodium vanadyl vanadate
is as high as possible.
HZTL2488_EN
The amount of contamination increases over time, which is why regular

and correctly performed cleaning is important in order to remove the de-
posits that have formed.
Contaminated turbine components can cause a slight increase in charging

pressure because of narrowing of the turbine cross-section. The contami-
nation causes a drop in turbine efficiency, and the engine temperatures
downstream of the cylinder can increase. The engine performance must
therefore be reduced if necessary.
The contamination of the turbine also causes rotor unbalance. Extremely

heavy contamination can lead to non-permissibly high unbalance of the
rotor.
Operating experience has shown that, in spite of regular cleaning during

operation, it is essential to carry out the overhauls during which the tur-
bine and the nozzle ring are cleaned mechanically. However, if cleaning is
carried out properly and the cleaning system is properly dimensioned, the
Revision C
intervals between overhauls can be increased.
Wet cleaning interval The interval between periodic cleaning is very dependent on the operating
conditions. As a rule, cleaning should be carried out every 50 to 200 op-
erating hours.

Maintenance 5

in operation
Cleaning method When cleaning the turbine components during operation, use wet clean-
ing. This cleaning method has been tested and approved by ABB Turbo
Systems.
April 2016
Prerequisites for wet cleaning are that the engine builder approves the
process and his instructions are followed.
Principle of wet cleaning During wet cleaning using droplets of water, the water does not act as a
solvent. Instead, the deposit is removed by the mechanical impact of the
drops.
Corrosion and deposits when cleaning

Damage and impairment of turbocharger parts due to salt water and
cooling water additives
CAUTION
 Don't use salt water for cleaning, but only clean fresh water.
HZTL2488_EN
Components at the turbine end are not cleaned until the engine has been
started or the engine load reduced. The exhaust gas temperature must
not exceed the value specified in the respective cleaning instructions (see
section Prerequisites [➙ 63]).
Exhaust gas temperature, stabilising and drying time

Drastically reduced lifetime of component due to excessive inlet tem-
perature and varying temperature stresses in the component.
CAUTION
 Always adhere to the respective cleaning instructions.
V-engines In the case of V-engines with several turbochargers on each engine, we

recommend parallel cleaning of both turbochargers. This cleaning process
is faster and the risk of turbocharger surging is reduced. We recommend
finding the most suitable method by performing trials.
Revision C

Maintenance 5

in operation
5.4.1 Wet cleaning turbine and nozzle ring during operation

April 2016
Prerequisites for turbine wet cleaning
In the case of V-engines with several turbochargers on each engine, we

recommend parallel cleaning of both turbochargers. This cleaning process
is faster and the risk of turbocharger surging is reduced. We recommend
finding the most suitable method by performing trials.
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:
HZTL2488_EN
 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%).
 As soon as the turbine inlet temperature is stable and below 430°C,
wait at least another 10 minutes for the charger parts to cool down.
 Start cleaning cycle according to following description Wet cleaning
Revision C
procedure.

Maintenance 5

in operation
Layout of cleaning pipes
April 2016
1 Water supply (fresh water only) 6 Other engine
2 Regulating valve 7 Injection nozzle
3 Manometer 8 Drain pipe
4 Air supply with 3-way valve 9 Drain cock
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5 Water pipe (stainless steel) 10 Drain
G Pipes on gas inlet casing 11 Flowmeter
Wet cleaning procedure for turbine during operation
 Meet prerequisites and operating condition requirements without fail

before cleaning.
 Make sure water supply (1) is connected, turned on and guaranteed.
 Open drain pipe (8,9) if provided.
 Switch over 3-way valve (4) from scavenging air mode to water supply.
Set the required volume of water on the flow meter as shown in the ta-
ble in the following chapter Cleaning parameters.
Revision C
NOTICE
 After injecting required volume of water, shut off water supply again by
switching over 3-way valve (4) to scavenging air mode.
 Finish injection procedure this way.
 Close drain hole (if provided) above drain pipe (8,9).

Maintenance 5

in operation
 After cleaning, wait with engine running for at least 10 minutes without
changing load to allow turbocharger to dry.
To obtain the correct water flow rate, a certain pressure in the water pipe
April 2016
Recommendation for
water pressure is necessary. (See table of Cleaning Parameters). If this water pressure is
too low, the water flow rate specified in the table will not be obtained. In
this case, cleaning will not be so good. An improvement can be achieved
by reducing the load to below 10%.
Repeating cleaning cycles immediately after each other must be avoid-

ed as this can lead to high mechanical loading and consequently to a
reduction in the service life of the components.
NOTICE If cleaning is unsatisfactory, the length of the process can be extended.
If the injection time is extended, it must be ensured that no unaccepta-
ble volume of water collects in the gas outlet casing. To avoid this, a
drainage system for the gas outlet casing must be installed and open
during the cleaning process. If a drainage system is not provided, the
injected volume of water can be controlled by a flow meter in the water
supply. 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 boil-
HZTL2488_EN
er, must be clarified by the operator.
Points to remember when The following must be observed where drainage of the gas outlet casing is
cleaning concerned:
 The exhaust gas temperature behind the turbocharger drops signifi-

cantly when cleaning (by 50 to 150°C).
 Depending on the engine load, water might run out of the drain pipe.
This outflow might not start for 2 or 3 minutes, or it might not occur at
all.
 If the gas outlet casing is not drained, the turbocharger speed and / or
the gas inlet temperature must be monitored during the cleaning pro-
cess. If the load is too low, water can collect in the gas outlet casing.
Signs of this are a sudden significant drop in turbocharger speed or a
very strong increase in the gas inlet temperature. In such cases,
cleaning must be stopped and the cleaning cycle repeated from the
beginning using a lower water pressure or higher engine load.
Revision C

Maintenance 5

in operation
Wet cleaning parameters for turbine and nozzle ring
Table of cleaning parame-

Product Maximum tem- Injection time Water flow rate per turbocharger
April 2016
ters
perature at start t i [min] at pWater = 3 bar
of cleaning pro- MW [l/min]
cess
TTI [°C]
TPL67-C 430 10 18
TPL71-C 24
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Revision C

Troubleshooting 6
Malfunctions when starting 6.1 Page 67
6 Troubleshooting
6.1 Malfunctions when starting
April 2016
6.1
Sluggish start-up
Possible causes Elimination

Turbochar- Turbocharger contaminated Clean it
ger Damaged bearing Contact an ABB Turbocharging
Rubbing rotor Service Station
Foreign object in turbocharger
Vibrations

HZTL2488_EN
Turbochar- Rotor unbalance Contact an ABB Turbocharging

ger Damaged turbine or compressor Service Station
Damaged bearing
Rubbing of rotating parts
Normal behaviour, no malfunction

Turbochar- Minor uniform wear around the periphery of rotor components,
ger caused by slight local rubbing of adjacent components, is permis-
sible. The compressor blades and turbine blades are then short-
ened somewhat. 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.
Revision C

Troubleshooting 6
Surging of the turbocharger 6.2 Page 68
6.2
6.2 Surging of the turbocharger
April 2016
Turbocharger surging

Engine Guard in front of the turbo- Clean / replace it
charger is contaminated or
damaged
Turbocharger Filter silencer or diffuser con- Clean it
taminated
Heavy deposits of dirt in the
turbine or nozzle ring
Charge air Cooler contaminated Clean it
cooler Charge air duct blocked
Prolonged or periodic surging
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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
by an ABB Turbocharging service station.
Sporadic surge blows
Surging of the turbocharger can occur during certain operating conditions

such as when reducing the engine performance quickly when manoeu-
vring. At the same time, the flow direction in the compressor is momentari-
ly reversed. Such sporadic surge blows do not impair the safe operation of
the turbocharger.
 A surge blow is accompanied by a loud bang and escape of hot air

from the filter silencer.
Revision C

Troubleshooting 6
Malfunctions during operation 6.3 Page 69
6.3
6.3 Malfunctions during operation
April 2016
Lubricating oil pressure too low

Engine Oil filter heavily contaminated Clean it
Defective oil pump in lubricating Check / replace it
system
Manometer display wrong Replace the manometer
Turbochar- Rotor axial clearance too large Contact an ABB Turbocharging
ger Service Station
Reduction in speed

Engine Defects of connected cylinders Contact the enginebuilder
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when pulse charging

Turbochar- Heavy contamination of the tur- Clean it
ger bine
Damaged rotor components or Contact an ABB Turbocharging
bearing Service Station
Pipes Defects such as leaks in the Make repairs
exhaust gas pipes or charge air
ducts
Increase in speed

Turbochar- Heavily contaminated nozzle Contact an ABB Turbocharging
ger ring (with 4-stroke application) Service Station
Revision C

Troubleshooting 6
Exhaust gas temperature too high
Engine performance and engine speed unchanged
April 2016
Engine Malfunctioning injection sys- Repair it or contact the manufac-
tem turer
Turbocharger Air starvation, for example Clean it
filter silencer clogged with
dirt
Compressor / turbine conta-
minated
Exhaust counterpressure too Clean or repair the boiler or ex-
high haust silencer
Damaged or eroded turbine Contact an ABB Turbocharging
Service Station
Charge air Cooler contaminated Clean it
cooler Cooling water volume too Top up the water
low
HZTL2488_EN
Entry temperature of cooling Inspect / clean the cooling sys-
water too high tem
Inadequate ventilation Improve the ventilation
Revision C

Troubleshooting 6
Charge air pressure too low
Engine performance and engine speed unchanged, air intake condition

normal
April 2016

Engine Air receiver leaking Make repairs
Gas piping between the engine
and the turbine leaking
Poorly adjusted injection system Correct it
Poorly adjusted valve control
Turbochar- Manometer display wrong Replace the manometer
ger Line to manometer leaking Repair the leak
Contaminated filter silencer Clean it
causing excessive loss of pres-
sure
Compressor / turbine contami-
nated
HZTL2488_EN
Damaged compressor / turbine Contact an ABB Turbocharging

Service Station
Exhaust counterpressure too Clean or repair the boiler or ex-
high haust silencer
Charge air pressure too high
Engine performance and engine speed unchanged, air intake condition

normal

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
Revision C
Turbochar- Manometer display wrong Replace the manometer

ger

Troubleshooting 6
Malfunctions when stopping 6.4 Page 72
6.4
6.4 Malfunctions when stopping
April 2016
Noises during run-down

Run-down time too short

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Revision C

Troubleshooting 6
Speed measurement system 6.5 Page 73
6.5
6.5 Speed measurement system
April 2016

Signal ampli- Fitting error The screw plug for the sensor is fitted with a
tude non exist- gasket.
ent or poor When fitting the speed sensor, this gasket
must be removed. If it is fitted by mistake,
the distance from the sensor tip to the sig-
nal-generating sealing disc increases. As a
result, the voltage amplitude of the speed
signal decreases, which can cause problems
for the evaluation electronics.
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. As a result, the dis-
high tance to the auxiliary bearing decreases,
HZTL2488_EN
which can lead to amplification of the noise

component and consequently to faulty trig-
gering.
Remove the sensor, clean its tip and refit the
sensor using the specified tightening torque.
Measured -- Contact ABB Turbocharging service station.
speed too low
Other sources -- If none of the above measures eliminates
of errors the problem, we recommend that you have
the speed measuring system inspected by
an official ABB Turbocharging service sta-
tion.
Revision C

Removal and installation 7
Turbocharger weights 7.1 Page 75
7 Removal and installation

7.1 Turbocharger weights
April 2016
7.1
Lifting gear with a sufficient load limit must be used for removing and in-
stalling the turbocharger. The following weight specification is the heaviest
possibility. This guide value can differ from data on the rating plate, de-
pending on the specification.
Weights [kg]
TPL67-C TPL71-C
1330 2040
HZTL2488_EN
Revision C

Remove the turbocharger 7.2 Page 76
7.2
7.2 Remove the turbocharger
 Disconnect all gas, air and oil lines in accordance with engine manu-
April 2016
facturer’s instructions.
Oil orifice plates

An orifice plate for adjusting the oil pressure is fitted in each of the two
oil inlet channels in the bearing casing. When the cartridge group, the
CAUTION
bearing casing or the turbocharger is fitted to the engine, it must be en-
sured that the orifice plates that are specified for the turbocharger have
been installed in the two oil inlet channels.
 Check correct installation of oil orifice plates.
HZTL2488_EN
Use the two suspension eyes on the bearing casing (observe the marking
on the insulation). The lifting gear around the gas inlet casing serves to
align the turbocharger horizontally.
 Remove the insulation shell (S) from the bearing casing and possibly
Revision C
the insulation on the gas inlet casing. Leave any remaining insulation
on the turbocharger.
Version with compressor wheel cooling system
 Remove air supply line. (See also chapter entitled Preliminary remarks
/ Layout and functionality)
 Inspect the lifting gear.
 Attach one lifting gear each to the two ribs of the bearing casing pro-
vided for this purpose.

Remove the turbocharger 7.2 Page 77

April 2016
 Ribs (01) not in the middle at the top:

 Completely remove the bearing casing insulation (02) and place a
HZTL2488_EN
sling around the bearing casing.
 Loosen the fixing screws at the foot.

 Lift the turbocharger off the engine and set it down to one side.
Beware of tilting
If support for the turbocharger is not provided or is inadequate, the tur-
bocharger could tip over during installation or removal and cause a se-
WARNING
rious or even fatal injury.
 Support the turbocharger at a suitable point.
 If possible secure it using lifting gear.
Wear safety helmet.

Revision C
 Cover the oil connection.

Installing the turbocharger 7.3 Page 78
7.3
7.3 Installing the turbocharger
 Remove the cover from the oil connection.
April 2016
 Inspect the lifting gear.
 Fasten a separate lifting gear to each of the two ribs on the bearing
casing provided for this purpose.
Oil orifice plates

CAUTION
 Fit the turbocharger to the engine.

 Tighten the fixing screws at the foot in accordance with the engine
HZTL2488_EN
builder's instructions.
 Fasten the gas, air and oil lines in accordance with the engine build-
er’s instructions.
 Fit the air supply line (also see the chapter entitled Preliminary re-
marks / Layout and functioning).
 Refit the parts of insulation which had been removed.

 Plug in the cable connector on the speed sensor.
Revision C

Disassembly and assembly 8
8 Disassembly and assembly

8.1 Introduction
April 2016
8.1
Further work
Further tasks, which are not described here, may be carried out only by
trained personnel from an ABB Turbocharging service station.
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
HZTL2488_EN
Identifying assembly devices
Not all assembly devices are marked with a part number. They can be
identified using the tool list. This list is enclosed in the toolbox.
Maintaining assembly devices

Assembly devices must be checked for damage before and after use.
WARNING  Visually check for corrosion, cracks, deformation and wear.
 Don't use damaged assembly devices, but replace them.
Customer spare parts set
Before beginning work, ensure that the required customer spare parts
sets are available.
Revision C
 See chapter Spare parts.
Tightening torques for turbocharger components
The specified tightening torques of screw connections for turbocharger

components must be observed. (See section Table of tightening torques.)

Tightening torques for assembly devices of ABB Turbo Systems
If nothing else is described, the screws and nuts of the assembly devices
must be tightened down firmly.
April 2016
Suspended loads
Loads not suspended in compliance with regulations may lead to per-
sonal injury or accidents with fatal consequences.
WARNING
 Attach turbochargers, assemblies or individual components only to
lifting gear which is in technically perfect condition and has sufficient
load capacity.
 Make sure the load is suspended properly on the crane hook.
 Do not let anyone stand beneath a suspended load.
Wear safety helmet.
HZTL2488_EN
Definition of terms
 Suspension point
Defined load carrying point on a component or an assembly (blind hole
thread, eye, lug).
 Assembly device
Devices mounted on the turbocharger to create a suspension point.
Assembly devices are calculated and designed especially for the de-
fined application. 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. Revision C

Module weights 8.2 Page 81
8.2
8.2 Module weights
The specified weights of individual parts or assemblies are guides round-
April 2016
ed off to the next highest value.
Assemblies
HZTL2488_EN
Weights [kg]
Description TPL67-C TPL71-C
1 Filter silencer 130 180
2 Radial air suction branch 50 70
3 Compressor casing 180 260
4 Wall insert 40 65
Revision C
5 Diffuser 19 35
6 Cartridge group 290 460
7 Turbine diffuser 40 60
8 Nozzle ring 10 13
9 Radial gas inlet casing 110 150
10 Segment 7 12
11 Axial gas inlet casing 65 80

Module weights 8.2 Page 82
Complete compressor casing
Weight [kg]
TPL67-C TPL71-C
April 2016
240 360
The total weight of the complete compressor casing is an addition of the

weights of the compressor casing, the diffuser and the wall insert.
NOTICE
HZTL2488_EN
Revision C

Removing and fitting filter silencer or air 8.3 Page 83

suction branch
8.3 Removing and fitting filter silencer or air

8.3
suction branch
April 2016
Removing the air suction  Disconnect all air lines in accordance with the engine builder’s instruc-
branch tions.
 Dismantle the insulation where necessary.
HZTL2488_EN
 Pass a lifting gear around the air suction branch. It is permissible to

pass the lifting gear through holes possibly provided in the ribs to im-
prove stability.
 Unscrew the nuts (72027) and remove them together with the washers
(72018).
 Remove the air suction branch and set it down to one side.
Installing the air suction  Fit the air suction branch in reverse order.
branch
Revision C

Removing and fitting filter silencer or air 8.3 Page 84

suction branch
Removing filter silencer  Remove insulation where necessary.
April 2016
 Pass lifting gear through rib on filter silencer.
 Pass lifting gear through lugs on back.
HZTL2488_EN
 Unscrew nuts (72027) and remove them together with washers
(72018).
 Remove filter silencer and it set down to one side.
Installing the filter silencer  Install filter silencer in reverse order.
Revision C

Axial clearance 8.4 Page 85
8.4
8.4 Axial clearance
April 2016
Physical hazards due to sharp edges on compressor wheel

The compressor wheel has sharp edges which can result in injury.
WARNING  Wear safety gloves.

HZTL2488_EN
The axial clearance (A) must be measured before removing and after fit-
ting the cartridge group.
 Measure and note the axial clearance (A).

Clearance A [mm]
TPL67-C TPL71-C
0.31 … 0.49 0.33 … 0.50
Clearances outside the tolerance

Serious damage to engines or property can be caused by clearances
Revision C
outside the tolerance and excessively worn parts.

CAUTION
 Have the components assessed and, if necessary, replaced by an
ABB Turbocharging Service Station.

Removing cartridge group 8.5 Page 86
8.5
8.5 Removing cartridge group
 Remove insulation.
April 2016
 Remove the air supply line. (Also see the chapter Preliminary remarks
/ Layout and functioning.)
 Disconnect the oil lines in accordance with the engine builder's instruc-
tions.
Oil orifice plates

CAUTION
HZTL2488_EN
Revision C


April 2016
HZTL2488_EN
 Remove three studs (72029) at top.

 Attach lifting device (90190) to compressor casing (72000), then fas-
ten and secure it to crane using lifting gear.
 Loosen and remove the nuts (61037).
 Uniformly press off compressor casing (72000) using three press-off
nuts (61090) fitted on bearing casing side.
 Slightly lift compressor casing (72000) and withdraw it.
 Remove the O-ring (42012).
Revision C

 Turn compressor casing (72000) together with wall insert and diffuser
and set them down with surface (F) on underlay.
April 2016
Make sure that the underlay does not shift.
 Allow compressor casing to rest only on surface (F).
 Check the underlay and adjust it if necessary.
WARNING
HZTL2488_EN
Revision C
 Remove the screws (72002).

 Remove diffuser (79000) using swivel lifting eyes (90235).
 Remove wall insert (77000) using swivel lifting eyes (90235).
 Remove O-ring (77005) from wall insert.


April 2016
HZTL2488_EN
 Unplug the cable connector (86515) and screw out the speed sensor
(86505) with the O-ring (86506).
 Fasten separate lifting gear to each of the two ribs on the bearing cas-
ing provided for this purpose.
 Unscrew the three screws (61059) and remove them together with the
Verbus Ripp® washers (61058).
 Uniformly press off the cartridge group using the press-off screws
(90900) in the holes provided.
If the blades have insufficient or no clearance between the rotor and the
casing, this can lead to damage to the blades and the casing.
Turn rotor to check that blades do not rub against turbine diffuser.
Revision C
CAUTION
 Withdraw the cartridge group.

 Fit supports (90450) using screws and set down cartridge group.
 Cover the oil connections.

Dismantling and installing the turbine 8.6 Page 90

diffuser and nozzle ring
8.6 Dismantling and installing the turbine diffuser

8.6
and nozzle ring
April 2016
Releasing the turbine
diffuser
HZTL2488_EN
 Put clamp (90921) over stud (61036) until it rests on inner radius of
gas outlet casing.
 Pass extension (A) of torque spanner (B) through hole in clamp and
only loosen screws (61056) one after other.
 Do not yet remove the screws (61056) and Verbus Ripp® washers
Revision C
(61057).


Removing the turbine

diffuser
April 2016
 Replace two screws (61056) in the gas outlet casing with two guide
studs (90320) in the upper section of the turbine diffuser (63000).
HZTL2488_EN
 Fit clamps (90921) over guide studs (90320) and studs (61036).
 To secure the work, screw nuts (61037) onto start of stud threads
(61036).
 Remove the remaining screws (61056) and Verbus Ripp® washers
(61057).
 Press the turbine diffuser (63000) free using the press-off screws
(90901) and pull it out it until the clamp (90921) is touching the nut
(61037).
 Loop the lifting gear around the turbine diffuser (63000) and secure it
to a crane.
 Remove the nuts (61037) and clamps (90921) from the stud.
 Withdraw the turbine diffuser all the way and remove it.
 Remove guide stud (90320).
Revision C


Removing the nozzle ring
April 2016
HZTL2488_EN
After the turbine diffuser has been removed, the nozzle ring (56001) is
only clamped lightly with the gas outlet casing. By pulling forward, the
nozzle ring (56001) is released and can drop down.
CAUTION
 Pull nozzle ring (56001) forward and remove.
Installing the turbine diffuser and nozzle ring
 Install the nozzle ring and turbine diffuser in the reverse order of re-
moval.
Revision C
 Coat the screw threads with high-temperature grease.

 Align nozzle ring with holes or cams in gas inlet casing.

Installing cartridge group 8.7 Page 93
8.7
8.7 Installing cartridge group
April 2016
Oil orifice plates

CAUTION
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Revision C

April 2016
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 Remove the cover from the oil connection.
 Fasten separate lifting gear to each of the two ribs on the bearing cas-
ing provided for this purpose.
 Remove supports (90450) and carefully insert cartridge group.
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.
CAUTION
Revision C
 Uniformly tighten the three screws (61059) with Verbus Ripp® wash-
ers (61058).
 Remove the lifting gear.
 Screw in the speed sensor (86505) along with the O-ring (86506) and
plug in the cable connector (86515).


April 2016
HZTL2488_EN
 Fit the O-ring (77005) to the wall insert (77000).

 Fit the swivel lifting eyes (90235) and attach lifting gear.
 Align the wall insert (77000) using the centering screw (90187) and fit
it.
 Put the diffuser (79000) in place using the swivel lifting eyes (90235).
 Remove the swivel lifting eyes (90235).
 Fit the screws (72002).
Revision C

April 2016
HZTL2488_EN
 Fit the O-ring (42012).
 Attach lifting gear to shackle of lifting device (90190) and turn com-
pressor casing (72000).
 By hand, screw three press-off nuts (61090) onto bearing casing
studs, equally spaced around circumference, and up to end of thread.
 Push compressor casing (72000) fully onto cartridge group and fasten
it using nuts (61037).
 Secure three press-off nuts (61090) against compressor casing
(72000) by tightening them to specified torque. (See chapter Table of
tightening torques.)
 Remove lifting device (90190).
Revision C

 Measure and note the axial clearance (A) (see the section on axial
April 2016
clearance).
If the axial clearance (A) is out of tolerance, an ABB Turbocharger ser-

vice station must be contacted.
CAUTION
 Connect oil lines and all air lines in accordance with engine builder’s
instructions.
 Fit the air supply line. (Also see the chapter Preliminary remarks /
Layout and functioning.)
HZTL2488_EN
 Fit the filter silencer or air suction branch.

 Fit the insulation.
Revision C

Dismantling and fitting nozzle ring at 8.8 Page 98

turbine end
8.8 Dismantling and fitting nozzle ring at turbine

8.8
end
April 2016
If only the nozzle ring must be dismantled, this can be done at the tur-
bine end.
NOTICE
If provided
 The fitted spiral-wound gasket (61050) may only be used once!
 Provide a new spiral-wound gasket (61050).
Disassembly
HZTL2488_EN
 Remove the insulation from the gas inlet casing (51001) and discon-
nect the cleaning pipe (if provided).
 Secure the gas inlet casing using a lifting gear.
When looping the rope around the casing, make sure that no cleaning
pipes are crushed or damaged. Do not under any circumstances fasten
the lifting gear to the cleaning pipes.
CAUTION
The nozzle ring hangs loosely on the gas inlet casing and can fall down.
CAUTION
Revision C
Mark the positions of the gas inlet casing and the segments.
NOTICE


turbine end
April 2016
HZTL2488_EN
Segment connection  Remove screws (61044) and one segment (51012) in the lower sec-
tion.
 Fit two guide studs (90320) as a safety measure.
 Loosen and remove remaining screws (61044) and segments (51012).
Flange connection  Remove two screws (61044) in lower section.

 Fit two guide studs (90320) as a safety measure.
 Remove remaining screws (61044).
 Pull gas inlet casing complete with nozzle ring away from gas outlet
casing until nozzle ring can be lifted away.
 Remove gas inlet casing and put it down.
Revision C
Use suitable underlays when putting down gas inlet casing.
CAUTION
1) If present  Remove spiral-wound gasket (61050).


turbine end
Assembly
 Carefully clean grooves and contact surfaces in / on casing and keep

free from metal chips.
April 2016
 Keep grooves and spiral-wound gasket free from oil and grease.
1) If provided  Fix a new spiral-wound gasket (61050) using a little instant adhesive
(for example "Loctite 454 gel") applied at three equally spaced points
in groove.
 Fit nozzle ring to gas inlet casing and fix it.

 Fit gas inlet casing.
 Use guide studs (90320) as a centering aid and remove them after-
wards.
 Brush screw threads (61044) with high temperature grease.
HZTL2488_EN
Segment connection  Position segments (51012) using screws (61044).
Checking Make sure that collars (C) of segments (51012) rest in groove (S).
Revision C
Flange connection  Position screws (61044).


turbine end
 Tighten screws (61044) in accordance with following procedure and in

following order:
April 2016
Segment connection Flange connection
 Begin with two middle screws of

HZTL2488_EN
individual segments and then  Tighten diametrically opposite

continue outwards alternately. screws alternately.
Screw tightening sequence

The screw positioning numbers must be marked on the component.
This enables simple and efficient tightening.
NOTICE
Tightening torques for

Tightening TPL67-C TPL71-C
screws (61044) [Nm]
with spiral-wound gasket Step 1 Screw in all screws by hand.
Step 2 40 60
Step 3 80 130
Tightening torques for
Tightening TPL67-C TPL71-C
screws (61044) [Nm]
without spiral-wound gas- Step 1 Screw in all screws by hand.
Revision C
ket Step 3 80 130
Checking the tightening  Beginning with screw 1, tighten all screws in a clockwise direction us-
torque ing tightening torque from step 3.
 Remove lifting gear from gas inlet casing (51001).
 Connect cleaning line (if provided) and fasten insulation to gas inlet
casing (51001).

Table of tightening torques 8.9 Page 102
8.9
8.9 Table of tightening torques
April 2016
HZTL2488_EN
Revision C

Table of tightening torques 8.9 Page 103
Tightening torques [Nm]

Part number TPL67-C TPL71-C
1 82005 M16x1.5 M16x1.5
45 45
April 2016
3 72002 M10 M12

50 80
4 72027 M14 M16
with washer 95 125
5 72029 M14 M16
with washer 30 30
6 61037 M16 M18
110 160
6a 61090 M16 M18
10 15
7 61036 M16 M18
30 40
8 61059 M16 M18
200 280
HZTL2488_EN
9 42059 M12 M16

80 180
17 61044 M12 M14
80 130
21 61056 M12 M14
105 130
29 86505 M18x1.5 M18x1.5
150 150
Revision C

Taking out of operation at short notice 9
Possibilities for emergency repair 9.1 Page 105
9 Taking out of operation at short notice

9.1 Possibilities for emergency repair
April 2016
9.1
Danger of fire and explosion due to lubricating oil leaks

Leaking oil may ignite on hot surfaces. This can cause severe personal
injury or fatal accidents can result.
WARNING
 Cordon off danger area.
 Sound an alarm and depending on the situation, stop the engine.
 Seal oil leaks.
 Soak up oil and dispose of in an environmentally compatible manner.
Directives for taking out of operation

HZTL2488_EN
Serious damage to engine or property can be caused by non-

compliance with the directives for locking/blanking off the turbocharger
CAUTION
on the engine.
 Follow the directives of the enginebuilder.
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
Revision C

Locking the rotor 9.2 Page 106
9.2
9.2 Locking the rotor
A locked rotor must be removed and checked for unbalance after the
April 2016
turbocharger repair.
CAUTION
An exception is a test rig run up to a maximum of 25% of the engine

load in the case of new engines with one or several turbochargers. This
is sometimes requested by customers. As operation with a locked rotor
is only brief and the loads are low in these cases, subsequent removal
NOTICE
of the rotor is not necessary.
During operation of the engine with a blocked turbocharger, the lubricat-

ing oil system must remain connected to this turbocharger also and be
turned on if the gas inlet cannot be blocked. (See section Further
measures and information for operation with a blocked rotor for 4-stroke
CAUTION
engines.) Otherwise components that are still intact can be damaged
HZTL2488_EN
through overheating.
Shut off the oil supply in the event of lubricating oil leaking from the tur-
bocharger.
Revision C

Table of tightening tor-

Part no. TPL67-C TPL71-C
ques
72027 M14 M16
75 Nm 105 Nm
April 2016
94007 M8 M8
25 Nm 25 Nm
 Remove silencer or air suction branch.
Carry out the work as described in the chapter Disassembly and As-
sembly.
NOTICE
 Insert locking flange (94003) into compressor wheel.

 Put screws (94007) into unoccupied threaded holes in compressor
wheel and tighten to values shown in Table of tightening torques.
HZTL2488_EN
Do not remove any balancing screws from compressor wheel. Use only
unoccupied threaded holes to fit lifting spigot.
CAUTION
 Position assembly / disassembly device (90020) over studs (72026)

and locking flange (94003).
 Turn compressor wheel so that locking flange hexagon aligns with
hexagon in assembly / disassembly device (90020).
 Secure assembly / disassembly device (90020) to compressor casing
by screwing nuts (72027) complete with washers (72018) onto studs
(72026) and then tightening to values shown in preceding Table of
tightening torques.
Revision C
Make sure all components are clean and free from grease.
CAUTION

Further measures and information for operation with blocked rotor for 4-
stroke engines
April 2016
4-stroke engine with one turbocharger
No further measures are necessary. The engine can be operated as a

naturally-aspirated engine according to the engine builder's instructions.
4-stroke engine with several turbochargers
Separate receivers No further measures are necessary on engines with separate air and ex-
haust gas receivers. The engine can be operated as a naturally-aspirated
engine according to the engine builder's instructions.
Common air receiver If the engine is equipped with a common air receiver and separate ex-
HZTL2488_EN
haust gas receivers, the bellows at the compressor outlet of the damaged
turbocharger must be removed and the air duct on the engine side must
be closed off. If this is not done, the undamaged turbocharger can race
under no load and run at overspeed.
Depending on the engine turbocharging system, more or less powerful

pulses from the exhaust gas system act on the locked rotor. The locking
device is then heavily stressed, particularly in the case of pulse charging
(turbine casing with more than one gas inlet). With this in mind, the follow-
ing operating limits should not be exceeded:
 In systems similar to those with constant pressure (1 gas inlet), the

engine can be operated up to a maximum of 25% engine load. The
pressure in the charge air receiver must not exceed 0.9 bar overpres-
sure.
 In the case of pulse charging (2...4 gas inlets), the engine can be op-
erated up to a maximum of 20% engine load. The pressure in the
charge air receiver must not exceed 0.5 bar overpressure.
Revision C
Attention must always be paid to the speed of the undamaged turbo-

charger. The speed limit nBmax given on the rating plate must not be ex-
ceeded.
CAUTION

Fit cover plate 9.3 Page 109
9.3
9.3 Fit cover plate
The cover plate (material: General structural steel, in accordance with
April 2016
DIN EN 10025-2) must be manufactured in-house according to the

drawing.
NOTICE
HZTL2488_EN
Cover plate dimensions

Product B1 B2 B3 B4 B5 B6 B7 B8
[mm]
TPL67-C 13 325 30 30 8 10 6 70
TPL71-C 13 385 30 30 8 10 6 84
Product Ø1 Ø2 Ø3 Ø4 Ø 5 min. Ø 6 min.

Revision C
TPL67-C 616 694 660 16 22 15

TPL71-C 726 818 779 18 25 15
Product ⍺1 ⍺2 ⍺3
TPL67-C 4 x 90° 37.5° 24 x 15°
TPL71-C 4 x 90° 37.5° 24 x 15°

April 2016
HZTL2488_EN
Carry out the work as described in the chapter Disassembly and As-
sembly.
NOTICE
 Removing the cartridge group
Revision C


April 2016
HZTL2488_EN
 Close 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
Revision C

Further measures and information for operation with a turbocharger with

cover plate on 4-stroke engines
April 2016
4-stroke engine with one turbocharger
No further measures are necessary. The engine can be operated as a

naturally-aspirated engine according to the engine builder's instructions.
4-stroke engine with several turbochargers
Separate receivers No further measures are necessary on engines with separate air and ex-
haust gas receivers. The engine can be operated as a naturally-aspirated
engine according to the engine builder's instructions.
Common receiver The air line must be closed off at the engine end because the undamaged
turbochargers build up a receiver pressure.
HZTL2488_EN
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 nBmax given on the rating plate must not
be exceeded.
CAUTION
Revision C

Blocking the inlets and outlets 9.4 Page 113
9.4
9.4 Blocking the inlets and outlets
Shut off the lubricating oil supply to the turbocharger.
April 2016
CAUTION
 Shut off compressor casing outlet, gas inlet and gas outlet by fitting
cover plates.
In this respect, refer to the engine manufacturer's instructions.
NOTICE
HZTL2488_EN
9.5
9.5 Bypass the turbocharger
Shut off the lubricating oil supply to the turbocharger.
CAUTION
 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.

Revision C
NOTICE

Mothballing turbocharger 10
Taking out of operation for up to 12 10.1 Page 115

months
10 Mothballing turbocharger
10.1 Taking out of operation for up to 12 months
April 2016
10.1
Condition of engine lubricating oil
The turbocharger normally remains mounted on the engine. Mothballing a

turbocharger depends on the condition of the lubricating oil:
 If the total acid number (TAN) is lower than 2 mg KOH/g, no measures

have to be taken.
 If the engine lubricating oil is replaced by preserving oil before taking
the engine out of operation and this is circulated by the prelubrication
pump, no measures have to be taken. Any remaining old engine oil will
thus be flushed away and the bearing sections largely protected
against corrosion.
Mothballing measures
HZTL2488_EN
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 opera-
tion:
 Remove turbocharger.
 Rotor and bearing parts must be removed by an official ABB Turbo-
charging service station and refitted afterwards.
 Clean all parts.
 Oil machined, bright surfaces of steel and cast parts using anticorro-
sive oil.
 Reassemble complete turbocharger.
Rotor turns in stack draught
If the rotor turns as a result of the stack draught:

Revision C
 Install blind flange between compressor casing outlet flange and

charge air duct.

Mothballing turbocharger 10
Taking out of operation for more than 10.2 Page 116

12 months
10.2 Taking out of operation for more than

10.2
12 months
April 2016
If the engine is taken out of service, the following can be done with the
turbocharger:
 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.
 The turbocharger is removed completely, either as a whole or in indi-
vidual parts.
See the section Taking out of operation for up to 12 months, under Moth-
balling measures, for the measures always necessary when mothballing
turbocharger parts.
HZTL2488_EN
If the turbocharger remains mounted on the engine, refer to the section
Taking out of operation for up to 12 months, under Rotating the rotor in
stack draught.
If the entire turbocharger is removed or if the turbocharger is re-

assembled next to the engine using the individual parts:
 Close all turbocharger openings using wooden covers and paraffin pa-
per.
Suitable storage locations are only dry rooms where the relative humidity
is between 40 to 70 % and no condensation can form.
Condition of the mothballed turbocharger

Revision C
 Check the mothballed turbocharger parts for corrosion every year.

 If there are signs of rust: Clean parts thoroughly and renew protection
against corrosion.

Disposing of turbocharger components 11
Taking out of operation for more than 10.2 Page 117

12 months
11 Disposing of turbocharger components

April 2016
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.
WARNING
 Avoid the formation of dust.
 Vacuum up dust with a suitable vacuum cleaner.
 Wear a respiratory mask to protect against particles (P1 or P2 mask).
 Wear work gloves made of leather.
Wear a respiratory mask to protect against particles.

HZTL2488_EN
Disposal must be environmentally compatible, professional, and in com-

pliance with locally applicable regulations.
The turbocharger consists largely of metal (cast iron materials, steel,

nickel-steel alloys, aluminium and bearing brass).
Further components are: Non-metallic materials (filter components of felt

and polyethylene), lubricants (engine oil), electronic parts (speed sensor
and associated components), and thermal insulation.
 Dispose of metals as scrap metal for recycling.

 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.
Revision C

Spare parts 12
Ordering spare parts 12.1 Page 119
12 Spare parts
12.1 Ordering spare parts
April 2016
12.1
When making inquiries or ordering spare parts, the following data must be
specified:
 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.
Storage of spare parts

HZTL2488_EN
All spare parts ordered with the turbocharger must be kept complete
and ready for use.
CAUTION
 Parts showing signs of rust should be carefully cleaned and greased.
 Dispose of replaced and unusable parts in a professional and envi-

ronmentally compatible way.
Required customer spare part set (97070)
The customer spare part set (97070) is required for the work described in
this operation manual. These parts are available only as a complete set.
Quantity Description Part number

1 O-ring 42012
1 Gasket 42041
Revision C
1 Gasket 42045
2 Verbus Ripp® washer 42058
2 Hexagon-head screw 42059
3 Hex nut 61037

Spare parts 12

1 Gasket 77005
April 2016
1 O-ring (speed sensor) 86506
Spare parts set (97078) for turbine cleaning system (if provided)
Leaks
Improper assembly of the cleaning pipe and the nozzles can lead to
leaks and failure of the turbine cleaning system.
CAUTION
 Work on turbine cleaning system should be carried out only by an
ABB Turbocharging service station.
Axial gas inlet casing

6 Locking plate 51255
HZTL2488_EN
3 Gasket 52200
3 Nozzle 52208
Radial gas inlet casing

3 Gasket 52200
1 Nozzle 52208
1 Nozzle 52209
Revision C
1 Nozzle 52210
1 Hollow (banjo) screw 52219
4 Verbus Ripp® Washer 52258

Spare parts 12

April 2016
HZTL2488_EN
Revision C

Spare parts 12
View of turbocharger with part numbers 12.2 Page 122
12.2
12.2 View of turbocharger with part numbers
April 2016
HZTL2488_EN
Revision C

Spare parts 12
View of turbocharger with part numbers 12.2 Page 123
Part number Description

42012 (in customer spare part set) O-ring
51001 Gas inlet casing
April 2016
51012 Segment
56001 Nozzle ring
61001 Gas outlet casing
61037 (in customer spare part set) Hexagon nut
61044 Hexagon-head screw
61050 (if provided) Gasket
61056 (in customer spare part set) Hexagon-head screw
61057 (in customer spare part set) Verbus Ripp® Washer
61058 (in customer spare part set) Verbus Ripp® Washer
61059 (in customer spare part set) Hexagon-head screw
63000 Turbine diffuser
68001 Foot at compressor end
68002 Foot at turbine end
HZTL2488_EN
68003 Slide plate

68006 Cup spring
68007 Bush
72000 Compressor casing
77000 Wall insert
77005 (in customer spare part set) O-ring
79000 Diffuser
81000 Filter silencer
82000 Radial air suction branch
Revision C

Spare parts 12
View of turbine cleaning system with 12.3 Page 124

part numbers (optional)
12.3 View of turbine cleaning system with part

12.3
numbers (optional)
April 2016
Axial gas inlet casing
HZTL2488_EN
51229 Cleaning pipe
52249 Holder complete
51255 (in spare parts set) Locking plate
52200 (in spare part set) Gasket
52204 (in spare part set) Hexagon-head screw
52208 (in spare part set) Nozzle
Revision C

Spare parts 12
View of turbine cleaning system with 12.3 Page 125

part numbers (optional)
Radial gas inlet casing

April 2016
HZTL2488_EN

51229 Cleaning pipe
52249 Holder complete
51255 (in spare parts set) Locking plate
52200 (in spare part set) Gasket
52213 (in spare part set) Locking plate
Revision C
52219 (in spare part set) Hollow screw

52258 (in spare part set) Verbus Ripp® washer

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

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Operation Manual

ABB Turbo Systems Ltd

Type TPL67-C36 HT564846

ABB Turbocharging 

Table of contents Page 1

© Copyright 2016 ABB. All rights reserved.

Table of contents Page 2

7 Removal and installation

8 Disassembly and assembly

9 Taking out of operation at short notice

9.1 Possibilities for emergency repair

© Copyright 2016 ABB. All rights reserved.

Table of contents Page 3

11 Disposing of turbocharger components

© Copyright 2016 ABB. All rights reserved.

Purpose of this manual 1.1 Page 5

This operation manual belongs to the turbocharger with the identical HT

It provides important information in order that the turbocharger can be op-

This Operation Manual complements and expands existing national regu-

This Operation Manual is intended for engineers and qualified mechanics

Availability of operation manual

© Copyright 2016 ABB. All rights reserved.

Layout and function 1.2 Page 6

© Copyright 2016 ABB. All rights reserved.

Layout and function 1.2 Page 7

The turbocharger is a turbomachine and consists of the following main

These are both mounted on a common shaft.

Turbocharger version with compressor wheel cooling system

Depending on its range of use, the turbocharger is provid-

ed with a compressor wheel cooling system. Compressor

© Copyright 2016 ABB. All rights reserved.

Intended use of the turbocharger 1.3 Page 8

Use of the turbocharger as intended also includes observance of the in-

 Malfunctions which could affect safety must be eliminated immediate-

© Copyright 2016 ABB. All rights reserved.

Storage of new turbochargers and 1.4 Page 9

1.4 Storage of new turbochargers and spare

Storage of new turbochargers and spare parts up to 6 months

Volatile Corrosion Inhibitor (VCI)

Protection of health when handling VCIs

Wear safety gloves against chemical risks.

The following mothballing measures are required every 6 months:

 Open the package.

© Copyright 2016 ABB. All rights reserved.

Storage of new turbochargers and 1.4 Page 10

Long-term storage of replacement turbochargers or spare parts

Per order, turbochargers or cartridge groups will be prepared by ABB Tur-

The following measures are required every 6 months:

 Check the hygrometer (02) in the sight-glass. There is an opening (01)

After every 3 years the following work steps must be performed by an

 Inspect the components

Replacement components ready for operation

Unpacking replacement turbochargers or spare parts

To avoid the formation of condensation, the surroundings and the content

© Copyright 2016 ABB. All rights reserved.

Essential information 1.5 Page 11

In addition to this manual, the general, statutory regulations applicable in

This also applies to the provision and wearing of personnel protection

The safety and risk consciousness of the personnel working on and

 The turbocharger must be shut down immediately by stopping the en-

ABB Turbocharging