ABB TPL65VA33 Operation Manual

Operation Manual

TPL65VA33

ABB Turbo Systems Ltd

CH 5401 Baden

Type TPL65VA33 n

Mmax

503

1/s

n

Bmax

486

HT564931 t

Mmax

650 t

Bmax

620

°C

Year 2016

01210

kg

35 50 50

Application according to the Operation Manual made in Switzerland

ABB Turbocharging

Operating condition and replacement intervals

The operational limits for the turbocharger nBmax, tBmax, nMmax, tMmax, inspection- and replacement intervals for the components 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 profi le, turbine inlet temperature, suction air temperature and turbocharger speed. In case the operation conditions differs signifi cantly from what is considered to be normal for the current 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.

Table of contents

Operation Manual / TPL65VA32/33

Page 1

Table of contents

2.4

2.5

2.6

2.7

2

2.1

2.2

2.3

2.8

2.9

3

3.1

3.2

3.3

1.4

1.5

1.6

1.7

1.8

1

1.1

1.2

1.3

4

4.1

4.2

4.3

4.4

4.5

4.6

© Copyright 2015 ABB. All rights reserved.

Preliminary remarks

Purpose of this manual

Layout and function

Intended use of the turbocharger

Storage of new turbochargers and spare parts

Essential information

Symbols and definitions

Turbocharger rating plate

Contact information

Safety

Introduction

CE conformity

Definition of mandatory signs

Definition of Safety instructions

Warning plates on the turbocharger

Safe operation and maintenance

Hazards during operation and maintenance

Periodic checking of the pressure vessel

Lifting loads

Commissioning

Oil supply

Inspection work

Commissioning after taking out of operation

Operation

Noise emissions

Servicing work

Replacement intervals for turbocharger components

Speed measurement

Emergency operation TPL..VA

Stopping the engine


Table of contents

6

6.1

6.2

6.3

6.4

6.5

6.6

5

5.1

5.2

5.3

5.4

7

7.1

7.2

7.3

Maintenance

Foreword to Maintenance

Cleaning the filter silencer

Cleaning the compressor during operation

Cleaning turbines and guide vanes during operation

Troubleshooting

Malfunctions when starting

Surging of the turbocharger

Malfunctions during operation

Malfunctions when stopping

Speed measurement system

Variable Turbine Geometry

Removal and installation

Turbocharger weights

Removing the turbocharger

Installing the turbocharger

9

9.1

9.2

9.3

9.4

10

8.4

8.5

8.6

8.7

8

8.1

8.2

8.3

8.8

Disassembly and assembly

Introduction

Module weights

Removing and fitting filter silencer or air suction branch

Axial clearance

Removing cartridge group

Removing and fitting turbine diffuser

Removing variable turbine geometry module with gas inlet casing

Fitting the variable turbine geometry module and the gas inlet casing

8.9 Installing cartridge group

8.10 Table of tightening torques

Taking out of operation at short notice

Possibilities for emergency repair

Fitting the cover plate

Blocking the inlets and outlets

Turbocharger bypass

Mothballing the turbocharger


Page 2

Table of contents


10.1 Taking the engine out of operation for up to 12 months

10.2 Taking the engine out of operation for more than 12 months

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 cartridge group with part numbers

Page 3


1.1

Preliminary remarks


1

1.1

Preliminary remarks



1

1.1 Page 5

This operation manual belongs to the turbocharger with the identical HT number (01), see the cover sheet of the operation manual and the turbocharger rating plate.

Operation Manual

This Operation Manual enables you to familiarize yourself with the turbocharger supplied by ABB Turbo Systems and to use it as intended.

It provides important information in order that the turbocharger can be operated safely, correctly and efficiently.

This Operation Manual complements and expands existing national regulations 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 installed on it.

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.


1.2

Preliminary remarks

Layout and function

1.2 Layout and function


1

1.2 Page 6

01 Filter silencer

02 Radial plain bearing

03 Thrust bearing

04 Bearing bush

05 Radial plain bearing

06 Gas outlet casing

07 Gas inlet casing

08 Nozzle ring

09 Turbine wheel

10 Bearing casing

11 Diffuser

12 Compressor wheel

13 Air outlet casing


Preliminary remarks

Layout and function


1

1.2 Page 7

Mode of operation

The turbocharger is a turbomachine and consists of the following main components:

 Turbine

 Compressor

These are both mounted on a common shaft.

The exhaust gases from the diesel engine flow through the gas inlet casing (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 and forces precompressed air into the cylinders.

The exhaust gases escape to free air through an exhaust gas pipe which is connected to the gas outlet casing (06).

The air which is necessary for operation of the diesel engine and is compressed in the turbocharger is drawn through the suction branch or the filter silencer (01) into the compressor wheel (12). It then passes through the diffuser (11) and leaves the turbocharger through the air outlet 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 provided 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 turbocharger to cool the compressor wheel.

In view of the respective operating conditions, it is absolutely essential that the compressor wheel is cooled in order 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.


Preliminary remarks

Layout and function


1

1.2 Page 8

Additional function TPL..V.

These turbocharger types have adjustable guide vanes at the turbine end instead of a nozzle ring.


Preliminary remarks

Intended use of the turbocharger


1

1.3 Page 9

1.3

NOTICE

1.3 Intended use of the turbocharger

This turbocharger supplied by ABB Turbo Systems has been developed for use on diesel engines to generate the volume of air and the charging pressure required to operate the engine.

The engine builder has provided ABB Turbo Systems with information

State of the art

WARNING operating speeds, temperatures, exchange intervals / replacement intervals) have been derived. installed in a potentially explosive environment, and precautionary measures must be taken to ensure that the machine room as a whole is classified as not potentially explosive.

Any other use will be regarded as a special application which must first liability for other applications. If it is used otherwise, ABB Turbo

Systems reserves the right to reject all warranty claims.

This turbocharger was built according to state-of-the-art technology and is operationally safe according to recognised safety regulations. danger to life and limb of the user or third parties. In addition, improper use may cause damage to the machine.

 The machine may be operated only by trained personnel.

Use of the turbocharger as intended also includes observance of the installation / fitting, disassembly / removal, operating, maintenance / servicing and repair conditions specified by the manufacturer. Disposal regulations set down by local authorities must be observed.

Perfect condition The turbocharger may be installed only when in technically perfect condition 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 immediately.

The manufacturer accepts no liability for any damage resulting from unauthorised alterations to the turbocharger.


1.4

Preliminary remarks



1

1.4 Page 10

1.4 Storage of new turbochargers and spare parts

Storage of new turbochargers and spare parts up to 6 months

New turbochargers and spare parts from ABB 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)

WARNING

Protection of health when handling VCIs

VCI products are not hazardous in the sense of the Hazardous

Substances Ordinance. Nevertheless, the following points are to be observed 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:

 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 environmentally compatible manner, professionally and in accordance with local regulations.

 Seal the package. The better the external seal is designed, the more permanent the protection.


Preliminary remarks



1

1.4 Page 11

Long-term storage of replacement turbochargers or spare parts

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

Turbo Systems for prolonged storage. The package is equipped with a hygrometer (see illustration).

NOTICE

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 and repacked.

 Inspect the package for damage. If the package is damaged, the turbocharger or cartridge group must be inspected by an ABB

Turbocharging 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 and the package is undamaged, the replacement turbocharger or prior testing by an ABB Turbocharging Service Station.

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.


1.5

Preliminary remarks



1

1.5 Page 12

NOTICE

NOTICE

1.5 Essential information

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 manual.

 The turbocharger must be shut down immediately by stopping the engine in the event of alterations affecting safety or of corresponding operating behaviour. The fault must be reported to the person or department responsible. could compromise safety require the prior approval of ABB Turbo

Systems.


Preliminary remarks



1

1.5 Page 13

WARNING

Original parts and safety

Original parts and accessories are specially designed for the turbocharger supplied by ABB Turbo Systems.

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 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 authorised personnel. Basic mechanical training is a prerequisite.


Preliminary remarks



1

1.5 Page 14

Design variants

This document is valid for different design variants of turbochargers.

There may be sections and descriptions of components that are not relevant 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 ®.


1.6

Preliminary remarks

Symbols and definitions


1

1.6 Page 15

NOTICE

1.6 Symbols and definitions

The following symbols are used in the documents:

 Prerequisite

 Work step

 Enumeration, first level

- Enumeration, second level

Definition of notes

Note

A note provides suggestions which facilitate the work on the product.


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

Systems.

Official ABB Turbo Systems Service Stations

In this document, official service stations are referred to as ABB

Turbocharging Service Stations. They are inspected and certified regularly

by ABB Turbo Systems. See also chapter Contact information [➙ 18].


1.7

Preliminary remarks


1.7 Turbocharger rating plate


1

1.7 Page 16

Operating limits

Recommended replacement intervals for turbocharger components

01 Turbocharger operating limits at engine overload (110%).

Only when operating in the test rig unless otherwise agreed with the enginebuilder.

02 Turbocharger operating limits during operation

03 Replacement interval for plain bearings in 1000 h

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


Preliminary remarks



1

1.7 Page 17

1.7.1 Explanation of the rating plate

The recommended replacement intervals and the corresponding operational limits are jointly defined with the engine manufacturer. This information is specific to the system.

Operation above the indicated values n

Bmax

, t

Bmax

can considerably shorten the recommended replacement intervals. In such cases, we recommend that you contact the nearest official ABB Turbocharging service station. n

Mmax and t

Mmax

normally apply only when running at overload (110%) during trials on the engine test bed. These limits can also be permitted during operation for special applications. Operation above n

Mmax

and t

Mmax

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 on the right. In the case of turbochargers with insulation supplied by ABB

Turbo Systems, at least one additional rating plate is attached to the insulation of the gas outlet casing.


1.8

Preliminary remarks

Contact information


1

1.8 Page 18

1.8 Contact information

Contact information

Contact information for the official service stations of ABB Turbo Systems is available online.

 Scan the QR code to access our website.

ABB Turbo Systems AG

Bruggerstrasse 71a

CH-5401 Baden

Switzerland www.abb.com/turbocharging


2.1

Safety

Introduction


2

2.1 Page 19

2

2.1

Safety

Introduction

Turbochargers manufactured by ABB Turbo Systems are state of the art and comply with the pertinent safety and health-protection requirements that applied when the turbocharger was manufactured. Consequently, the turbocharger is safe to operate. Nevertheless, during turbocharger operation 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 instructions

 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 turbocharger by his personnel.

All instructions in this chapter must be observed to ensure safe and trouble-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

Definition of safety instructions).


2.2

Safety

CE conformity


2

2.2 Page 20

2.2 CE conformity

Information

ABB turbochargers fulfil Directive 2006/42/EC on machinery and are considered partly completed machinery in the sense of Article 2 g.


2.3

Safety



2

2.3 Page 21

2.3 Definition of mandatory signs

To be worn at all times

Protective clothing Safety footwear against mechanical hazards

To be worn according to the specific work

Safety glasses Safety goggles

Safety gloves against

- mechanical hazards

- chemical hazards

- heat hazards

Safety helmet

Respiratory mask against

- dust

- gases

Ear protection


Safety

Definition of Safety instructions


2

2.4 Page 22

2.4

WARNING

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 and the word WARNING are either not followed or not followed precisely.

 Warning signs must be observed at all times.

Definition of caution

CAUTION instructions marked with this symbol and the word CAUTION are either not followed or not followed precisely.

 Caution signs must be observed at all times.


2.5

Safety


2

Warning plates on the turbocharger 2.5 Page 23

2.5 Warning plates on the turbocharger

Warnings that have been attached to turbochargers by ABB Turbo

Systems must not be removed. Illegible warnings must be replaced with new ones. Further information is available from ABB Turbocharging service stations.

Part number

81080

Size [mm]

105 x 74

Product

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.


Safety



2

2.6 Page 24

2.6

WARNING

2.6 Safe operation and maintenance

The instructions specified in this section are for the safety of personnel.

Together with the instructions in the Hazards during operation and maintenance section, they allow the user to safely use the turbocharger.

Work safety and work area safety

Risk of falling

There is the risk that someone can fall when working on the turbocharger.

 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.

 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 materials 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 obstacles 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.

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

2.6 Page 25

Safety during start-up / commissioning and operation

 Before starting work, carry out visual inspection of working area.

 Remove any obstacles and objects lying around.

 Before start-up / commissioning, check all pipes from and to turbocharger for damage and leaks.

 Don't work in any way that could impair safety when working on turbocharger.

 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 performance to person responsible.

 If damage is discovered, immediately shut down turbocharger and secure 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.

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 solvents before starting cleaning operations.

 Wear appropriate protective clothing.

 Inspect the electric cables for abrasion and damaged areas before and after your cleaning work.


Safety



2

2.6 Page 26

CAUTION

Safety during disassembly, assembly, maintenance and troubleshooting

 Always perform the specified adjustments, servicing as well as inspection work and observe inspection intervals.

 Inform operating personnel about all service and repair work before beginning.

 Before opening a cover or removing a protective device on a turbocharger, 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.

 Perform only those tasks that are described in this manual.

 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.



2.7

WARNING

WARNING

Safety



2

2.7 Page 27

2.7 Hazards during operation and maintenance

Mechanical hazards during operation

During normal operation, no mechanical hazards emanate from the turbocharger if it has been installed properly.

Risk of injury

Contact with rotating parts can lead to serious injuries. The turbocharger must never be operated without a filter silencer or an air suction 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 rotation.

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

Serious personal injuries or accidents with fatal consequences can occur through mechanical influences as a result of risky, improper working methods.

 Heed the general rules for work safety and accident prevention.

 Ensure the safety of the work area.

 Perform only those tasks that are described in this manual.

 Perform work only for which training has been carried out.


WARNING

WARNING

Safety



2

2.7 Page 28

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

85 dB(A) is harmful.


Noise can cause impaired hearing, damage to health, mental disturbances, diminished attention and irritation.

 Always wear ear protection when the engine is running.

 When the sound pressure level is above 85 dB(A), always wear ear protection.

Wear ear protection.

Hazards due to hot surfaces and substances

During operation, turbocharger surfaces and attached parts as well as operating materials (lubricating oil) become hot. The surface temperature is dependent on the effectiveness of the insulation being used. The temperature 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.

 Do not touch hot surfaces and heed the warning plate on the

 turbocharger.

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.


WARNING

WARNING

Safety



2

2.7 Page 29

Hot surfaces on uninsulated turbochargers

Uninsulated turbochargers can cause serious personal injuries (burns).

The turbocharger is supplied by ABB Turbo Systems without insulation 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.

Operating and auxiliary materials can be combustible and easily ignited.

Handling operating and auxiliary materials contact with such can cause damage to health.

 Avoid inhalation and contact with the skin.

 Ensure good ventilation.

 Observe details in the safety data sheets of the operating and

 auxiliary materials.

Observe local laws.

Wear safety goggles.


Wear a respiratory mask to protect against gases.


WARNING

CAUTION

Safety



2

2.7 Page 30

Risk of fire, explosion

Combustible or easily ignited operating and auxiliary materials can burst into flame, or vapours from them can cause explosions.

 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 ventilation.

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 lead to environmental damage.

 Handle operating and auxiliary materials carefully.

 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 separately in suitable containers and dispose of them properly and in an environmentally compatible manner in accordance with statutory regulations.

 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.


WARNING

Safety



2

2.7 Page 31

Hazards when handling insulating materials

Hazards due to insulating materials

Dust and fibres from insulating materials can cause damage to health or irritations. Unsuitable, combustible insulating materials signify a fire hazard.

 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.


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.


WARNING

Safety



2

2.7 Page 32

Hazards due to electrical components

Hazards due to electrical components

Electrical components operate with voltages which can present hazards to humans.

 All work on or with electrical components may only be performed by

 trained specialists.

Heed any country-specific regulations.


2.8

Safety

Periodic checking of the pressure vessel


2

2.8 Page 33

WARNING

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".

 The local, statutory regulations covering periodic checks of pressure vessels must be observed.

 The operator is responsible for the safe operation of the pressure vessel.

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 without delay and the required safety precautions must be taken.

 Pressure equipment must not be operated if it has defects.


Safety

Lifting loads


2

2.9 Page 34

2.9

WARNING

2.9 Lifting loads

Suspended loads

Loads not suspended in compliance with regulations may lead to personal injury or accidents with fatal consequences.

 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.

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 respective handling steps.

 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 securely.


Commissioning

Oil supply


3

3.1 Page 35

3.1

NOTICE

3

3.1

Commissioning

Oil supply

A carefully designed and installed oil supply, which functions in all possible operational conditions, is an important prerequisite for troublefree turbocharger 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 filtration, oil pressure and oil temperature.

Oil filtration

A lubricating oil filter system with a filter mesh size of ≤ 0.034 mm is adequate for this turbocharger.


Commissioning

Oil supply


3

3.1 Page 36

Oil pressure

The oil pressure in front of the turbocharger must be maintained precisely to ensure trouble-free operation.

NOTICE

The permissible oil pressure ranges at measuring point M (blind connection) on the turbocharger are listed below.

Status for operation

Permissible, for normal operation

Permissible, during engine warm-up

Temporarily permissible ( < 1h ) -> alarm

Not permissible -> emergency stop

Permissible, during pre- and post-lubrication

(engine stopped)

Oil pressure in front of the turbocharger [bar]

1.3 … 2.5

1.3 … 5.0

1.1 … 1.3

0.0 … 1.1

0.2 … 2.5

Oil orifice

To make sure these oil pressures are obtained, a regulating orifice is builder and secured by a safety ring.


Commissioning

Oil supply


3

3.1 Page 37

CAUTION

Oil temperature

Lubricating oil temperature at the inlet

Machine damage

If the oil temperature at the oil inlet exceeds the admissible range, this may lead to engine damage.

 Observe oil temperature at the oil inlet according to the following table.


Permissible

Temporarily permissible (< 1h) -> alarm

Not permissible -> stop the engine

Not permissible -> Do not start the engine

(before starting: preheat the oil)

Oil temperature at the inlet

T oil,inlet

[°C]

30 … 90

> 90

> 95

< 30

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 following table. The specified oil outlet temperature is to be considered as alarm value for the turbocharger operation and must be monitored according to the current regulations.


Permissible

Temporarily permissible -> alarm

Not permissible -> stop the engine

Oil temperature at the outlet

T oil,outlet

[°C]

≤ 140

> 140

> 160

If the turbocharger was operated for a longer period of time outside of the admissible range, ABB Turbo Systems recommends to have the turbocharger inspected by an ABB Turbocharging Service Station.


3.2

Commissioning

Inspection work


3

3.2 Page 38

3.2 Inspection work

Inspection work includes preventive visual controls plus monitoring and measuring work before and during commissioning. Inspections help detect changes to the turbocharger. Machine damage can be avoided.

Monitoring equipment

Air filter mat

Lubricating system

TPL..VA

CAUTION

CAUTION

3.2.1 Inspection before commissioning

 Check for correct functioning.

 Inspect for damage.

 Check oil filter for cleanliness before commissioning. thoroughly with warm oil using a bypass pipe before starting up the first time (commissioning) and after all service work on the lubricating system.

It is urgently recommended that a running-in filter is used when running in the engine and after all service work on the lubricating system.

 Check the oil pressure in the oil supply lines.

 Check that variable turbine geometry module can be adjusted.

TPL65: Version with compressor wheel cooling system

 Check whether compressor wheel cooling system is fitted to bearing casing.

Failure of compressor wheel cooling system

The service life of the compressor wheel will be impaired if the breakdown of the compressor wheel cooling system lasts long.

 Ensure supply of cooling air.


Commissioning

Inspection work


3

3.2 Page 39

3.2.2 Check after start-up (engine at idling speed)

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.

NOTICE

3.2.3 Check when running up engine

 Measure the speed, oil pressure and charging pressure at various engine performance levels.

 Measure the exhaust gas temperature in front of and behind the turbine.

 Measure the air temperature in front of and behind the compressor.

 Check the functioning of the variable turbine geometry module.

The measured values must be compared with the values in the acceptance test report while taking different operating conditions into account. 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, the operator is to search for the cause of a possible oil leak. The first step is proper condition, contact an official ABB Turbocharging service station.

3.2.4 Inspection after 100 service hours

Clean or replace lubricating oil filters after the first 100 service hours.


3.3

If provided

Commissioning

Commissioning after taking out of operation


3

3.3 Page 40

3.3 Commissioning after taking out of operation

 Remove cover plates (blind flanges) between compressor casing outlet 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 remove.

 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.


 Remove screw plug on cooling air connection and fit cooling air line.


Operation

Noise emissions


4

4.1 Page 41

4.1

WARNING

4 Operation

4.1 Noise emissions


Noise can cause impaired hearing, damage to health, mental disturbances, diminished attention and irritation.

 Always wear ear protection when the engine is running.

 When the sound pressure level is above 85 dB(A), always wear ear protection.

Wear ear protection.

The sound pressure level (A-weighted) of emissions is measured at a distance of 1 metre from the turbocharger.

The highest sound pressure level of emissions 1) 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 taken 2) .

 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.

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 ensure that equivalent acoustic insulating measures are taken.


Operation

Noise emissions


4

4.1

Suggestion for noise insulation of the bellows

Page 42

01 Compressor casing

02 Bellows

03 Charge air duct / scavenging air line

04 Insulation pads

05 Insulation mat (at least 15 mm)

06 Sheet metal cover


4.2

Operation

Servicing work


4

4.2 Page 43

CAUTION

4.2 Servicing work

Service work to be carried out during operation involves visual checks, 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 failures.

 Carry out service work at specified time intervals.

Shortened service intervals

CAUTION or heavy installation vibration can lead to premature machine damage.

 A shortened service interval must be arranged with ABB Turbo

Systems.

Service inspection after 5 years

NOTICE by an ABB Turbocharging Service Station is recommended at the latest

5 years after the last service.

CAUTION

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.

 Clarify the cause of any variances.

Unknown changes during operation

The consequences can range from an impairment to a breakdown.

 Have unknown causes clarified by an ABB Turbocharging service station.


Operation

Servicing work


4

4.2 Page 44

If provided

4.2.2 Entries in engine logbook

By monitoring the engine, conclusions can be drawn about the turbocharger performance.

The following operating data and measured values must be entered regularly 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

 Air temperature behind compressor and charge air cooler

 Turbocharger speed

 Pressure loss in air filter

Oil filter

4.2.3 Servicing work according to the engine manufacturer's instructions

 Clean or replace oil filter in supply line to turbocharger when engine is not running.


Operation

Servicing work


4

4.2 Page 45

4.2.4 Service work every 15000 hours

Inspection and assessment of the rotor and bearing parts as well as replacement of the variable turbine geometry module with a CPEX variable turbine geometry module must be carried out by an ABB

Turbocharging Service Station.

 It is recommended that the turbocharger is inspected once a year, but at least after every 15000 operating hours.

 Disassemble turbocharger

 Clearance measurement

 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

 Inspect and assess sealing air lines

 Inspect and assess rotor and bearing parts

 Have the variable turbine geometry module overhauled by ABB Turbo

Systems. ABB Turbocharging Service Stations have variable turbine geometry modules replaced with overhauled ones as part of the CPEX

(Customer Part Exchange) programme.

4.2.5 Service work every 30000 hours

The replacement of bearing parts as well as the inspection and assessment of the rotor must be carried out by an ABB Turbocharging

Service Station.

 Disassemble turbocharger.

 Measure clearances.

 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.

 Inspect and assess rotor and bearing parts.

 Replace bearings (original parts from ABB Turbo Systems).


Operation


4


4.3 Page 46

4.3

Rotating components

4.3 Replacement intervals for turbocharger components

The recommended replacement intervals for the compressor and turbine wheels due to stress caused by centrifugal forces and load cycles are calculated under consideration of the operating conditions while applying the safety concept for rotating components. They can be found on the turbocharger rating plate. Incalculable influencing parameters can shorten the recommended replacement intervals for the rotor,

see Influencing parameters

.

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.

Influencing parameters The following parameters influence the replacement intervals for turbocharger 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

 Turbine cleaning frequency

 Procedure for turbine cleaning


Operation


4


4.3 Page 47

Expected replacement intervals [h]

Recommended replacement intervals [h]

Parameters influencing rotating components exposed to exhaust gas

 Fuel quality (gas, MDO, HFO)

 Turbine cleaning frequency

 Procedure for turbine cleaning

 Load profile

Gas inlet casing

Gas outlet casing

Variable turbine geometry module

(The variable turbine geometry module can be replaced with a CPEX variable turbine geometry module by an ABB Turbocharging service station.)

Turbine diffuser / cover ring

Other casings

Axial bearing components

Radial bearing components

Turbine blades

(due to wear)

GAS / MDO

50000 … 100000

50000 … 100000

15000

35000 … 50000

100000

24000 … 36000

24000 … 36000

- -

Rotor components See the data on the rating plate

GAS

MDO

parameters

.)

= Gas Engine

= Marine Diesel Oil

See Influencing

NOTICE


Operation

Speed measurement


4

4.4 Page 48

4.4

CAUTION

4.4 Speed measurement

A speed measuring system permits continuous monitoring of the turbocharger speed.

Do not use cables as a climbing aid

If you pull the speed measurement cables too hard, contacts can be pulled out.

 Do not tension the speed measurement cables.

Part number

42047

86505

86515

86526

86528

Description

Screw plug

Speed sensor

Cable connector for 86505

F/I converter

Tachometer


Operation

Speed measurement


4

4.4 Page 49

4.4.1 Speed differences with multiple turbochargers per engine

The speeds of all turbochargers on one engine differ only slightly from each other in normal operation.

The difference between the highest and the lowest turbocharger speed must not be more than 3 % relative to the speed limit n

Bmax

.

If this permissible range of difference is exceeded, the following steps must be carried out:

 Reduce engine performance immediately until the highest turbocharger speed no longer exceeds 70% of n

Bmax

.

 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 turbochargers and compare them with standard values.

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



Operation

Speed measurement


4

4.4 Page 50

NOTICE

4.4.2 Assembly

If the speed sensor is not fitted on the turbocharger, the following procedure 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

 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).


Operation

Speed measurement


4

4.4 Page 51

WARNING

4.4.3 Replacing the speed sensor

Hot cable connector and hot speed sensor

NOTICE sensor can reach temperatures exceeding 100 °C.

 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.

 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.

 Connect cable connector to speed sensor.

 Switch on lubricating oil supply to turbocharger.

4.4.4 Failure of speed measuring system

Possible reasons for failure of the speed measuring system are described in the chapter Troubleshooting.


4.5

Operation

Emergency operation TPL..VA


4

4.5 Page 52

4.5 Emergency operation TPL..VA

Detail A

In the event of failure of the control system or the drive, the variable turbine geometry module can be fixed by clamping the ring lever (B) using at least 3 washers (C) spaced around the circumference.

When fixing, the position of the variable turbine geometry module and / or the blades must be specified by the enginebuilder.


4.6

Operation

Stopping the engine


4

4.6 Page 53

CAUTION

4.6 Stopping the engine

Stopping the engine

Heat in the turbocharger must be dissipated by the further circulating lubricating oil.

 Allow the engine to continue running at idling speed for a further 10 minutes before stopping.


5.1

Maintenance



5

5.1 Page 55

5

5.1

Maintenance


Maintenance and servicing work involves regular visual checks and cleaning 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:

 Filter silencer

 Compressor

 Turbine and Guide Blades


5.2

Maintenance



5

5.2 Page 56

5.2 Cleaning the filter silencer

5.2.1 Filter silencer and connecting rod

81265

81269

81266

81272

E

Filter ring (if provided)

Connecting rods

Cover grid

Screwdriver

81136 Absorption segment

81137 Sheet-metal covering

81135 Filter silencer body

81273 Lock nut

Insert unit = absor ption segment + sheetmetal covering


Maintenance



5

5.2 Page 57

If provided

NOTICE

Removing and cleaning filter silencer

 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 necessary.

 Unscrew and remove lock nuts (81273).

 Unscrew and remove screws (81272) for connecting rods (81269).

 Remove connecting rods (81269).

 Carefully remove cover grids (81266).

 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.

NOTICE


Maintenance



5

5.2 Page 58

Fitting the filter silencer

 Assemble the insert units (E) by inserting the absorption segments

(81136) into the sheet metal coverings (81137).

 Bend sheet metal coverings (81137) back to original shape.

 Insert the insert units (E) into slot guides in filter silencer unit (81135).

CAUTION

 Uniformly place cover grids (81266) in correct position.

 Push connecting rods (81269) through lugs of cover grids (81266). recesses on the filter silencer unit (81135), the cover grid (81266) can getting into the compressor.


If provided

Maintenance



5

5.2 Page 59

 Join connecting rods (81269) using screws (81272). When tightening the screws (81272), ensure that connecting rods (81269) are located correctly in recesses in filter silencer body (81135). Now tighten screws (81272) alternately until the following maximum torque is reached:

Screw

81272

Tightening torque [Nm]

20

 Screw lock nuts (81273) onto screw (81272) and tighten to following torque:

Lock nut

81273

Tightening torque [Nm]

40

 Fit filter strip (81265).


5.3

Maintenance



5

5.3 Page 60

NOTICE

5.3 Cleaning the compressor during operation

These instructions for wet cleaning apply only when cleaning is carried out with clean water and the enginebuilder permits the process.

The degree of contamination of the compressor stage (compressor wheel and diffuser) depends on how clean the drawn-in air is.

Deposits of dirt can build up in the flow channels if the following substances are in the intake air:

 Oily or salty mist

 Solid combustion residues

 Various kinds of dust

Contamination of the compressor stage has a negative influence on the compressor efficiency and the charging pressure.

This results in higher exhaust gas temperatures and higher fuel consumption by the engine. Contamination of the compressor can also increase rotor unbalance.

Under no circumstances is periodic cleaning of the compressor during operation a substitute for the service work carried out when the turbocharger is completely dismantled 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 to 100 operating hours.

Cleaning intervals

NOTICE


Maintenance



5

5.3 Page 61

Cleaning method

Cleaning of the compressor during operation is carried out using the cleaning method described in the following:

 Wet cleaning

This cleaning method has been tested and approved by ABB Turbo

Systems.

Principle of wet cleaning

V-engines

CAUTION

To clean the compressor stage during operation, water is injected in front of the compressor wheel through an injection pipe fitted in the filter silencer 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, provided that the degree of contamination is not too high.

Corrosion and deposits when cleaning

Damage and impairment of turbocharger parts due to salt water and cooling water additives

 Don't use salt water for cleaning, but only clean fresh water.

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.


Maintenance



5

5.3 Page 62

NOTICE

NOTICE

5.3.1 Wet cleaning with orifice plate on filter silencer (XC2)

Operating state prerequisites for cleaning compressor with XC2 tested and is recommended by ABB Turbo Systems, the following prerequisites must be fulfilled:

 Engine load 50 ... 85%

 Start of cleaning cycle in accordance with following description of wet cleaning operation with XC2.

Compressor wet cleaning operation with XC2

 Maintain water pressure before connection to turbocharger (during water injection time) must be maintained as shown in table Cleaning parameters.

 After cleaning, wait at least 5 minutes to allow turbocharger to dry.

If the cleaning process is unsatisfactory, it can be repeated up to

2 times. engine values are also unsatisfactory, we recommend that you have the

Service Station.

Cleaning parameters per turbocharger compressor

Product Engine load

TPL65VA32/33 50 … 85%

Water pressure

[bar]

3

Water injection time

[sec]

10

Orifice diameter

[mm]

2.1


Maintenance



5

5.3 Page 63

NOTICE

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

Operating state prerequisites for compressor cleaning with XC3 tested and is recommended by ABB Turbo Systems, the following prerequisites must be fulfilled:

 Engine load 50 ... 85%

 Start of cleaning cycle in accordance with following description for wet cleaning operation with XC3.

Compressor wet cleaning procedure with XC3

Operating the water pressure vessel

 It is mandatory to fulfil the operating condition prerequisites before 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).


NOTICE

Maintenance



5

5.3 Page 64

 Screw in the sealing plug (X).

 Push the valve activator (Y) against the spring and hold it for

10 ... 15 seconds until the entire volume of water has been injected.

 After cleaning, wait at least 5 minutes to allow the turbocharger to dry. two times.

If the cleaning results are still not satisfactory after three attempts and the turbocharger inspected and cleaned by an official ABB


Cleaning parameters per turbocharger compressor

Product Engine load

TPL65 50 … 85%

Contents of water vessel

[dm 3 ]

0.4


5.4

Maintenance

Cleaning turbines and guide vanes during operation


5

5.4 Page 65

NOTICE

5.4 Cleaning turbines and guide vanes during operation

HFO applications

The TPL65VA.. has not been released for HFO applications. Wet neither required nor planned.


6.1

Troubleshooting



6

6.1 Page 67

6

6.1

Troubleshooting


Sluggish start-up

Possible causes

Turbocharger

Turbocharger contaminated

Damaged bearing

Rubbing rotor

Foreign object in turbocharger

Elimination

Clean it

Contact an ABB Turbocharging

Service Station

Vibrations

Possible causes

Turbocharger

Rotor unbalance

Damaged turbine or compressor

Damaged bearing

Elimination


Service Station

Rubbing of rotating parts

Normal behaviour, no malfunction

Turbocharger

Minor uniform wear around the periphery of rotor components, caused by slight local rubbing of adjacent components, is permissible. The compressor blades and turbine blades are then shortened 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.


Troubleshooting

Surging of the turbocharger


6

6.2 Page 68

6.2

CAUTION

6.2 Surging of the turbocharger

Turbocharger surging

Possible causes

Engine Guard in front of the turbocharger is contaminated or damaged

Turbocharger Filter silencer or diffuser contaminated

Heavy deposits of dirt in the turbine or nozzle ring

Charge air cooler

Cooler contaminated

Charge air duct blocked

Elimination

Clean / replace it

Clean it

Clean it

Prolonged or periodic surging

Possible damage to components, such as the compressor wheel, turbine blades, bearings and filter silencer

 Have the cause clarified immediately by an ABB Turbocharging

 service 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 manoeuvring. At the same time, the flow direction in the compressor is momentarily 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.


6.3

Troubleshooting



6

6.3 Page 69

6.3 Malfunctions during operation

Lubricating oil pressure too low

Possible causes

Engine Oil filter heavily contaminated

Elimination

Clean it

Turbocharger

Defective oil pump in lubricating system

Manometer display wrong

Check / replace it

Replace the manometer

Rotor axial clearance too large Contact an ABB Turbocharging

Service Station

Reduction in speed

Possible causes

Engine Defects of connected cylinders when pulse charging

Turbocharger

Heavy contamination of the turbine

Damaged rotor components or bearing

Pipes Defects such as leaks in the exhaust gas pipes or charge air ducts

Elimination

Contact the enginebuilder

Clean it


Service Station

Make repairs

Increase in speed

Possible causes

Turbocharger

Heavily contaminated nozzle ring (with 4-stroke application)

Elimination


Service Station


Troubleshooting



6

6.3 Page 70

Exhaust gas temperature too high

Engine performance and engine speed unchanged

Possible causes

Engine Malfunctioning injection system

Turbocharger Air starvation, for example filter silencer clogged with dirt

Charge air cooler

Elimination

Repair it or contact the manufacturer

Clean it

Compressor / turbine contaminated

Exhaust counterpressure too high

Cooling water volume too low

Clean or repair the boiler or exhaust silencer

Damaged or eroded turbine Contact an ABB Turbocharging

Service Station

Cooler contaminated Clean it

Top up the water

Entry temperature of cooling water too high

Inadequate ventilation

Inspect / clean the cooling system

Improve the ventilation


Troubleshooting



6

6.3 Page 71

Charge air pressure too low

Engine performance and engine speed unchanged, air intake condition normal

Possible causes

Engine Air receiver leaking

Turbocharger

Elimination

Make repairs

Gas piping between the engine and the turbine leaking

Poorly adjusted injection system Correct it

Poorly adjusted valve control

Manometer display wrong

Line to manometer leaking

Contaminated filter silencer causing excessive loss of pressure

Replace the manometer

Repair the leak

Clean it

Compressor / turbine contaminated

Damaged compressor / turbine Contact an ABB Turbocharging

Service Station

Exhaust counterpressure too high

Clean or repair the boiler or exhaust silencer

Charge air pressure too high

Engine performance and engine speed unchanged, air intake condition normal

Possible causes

Engine

Elimination

Malfunctioning injection system Repair it or contact the manufacturer

Turbocharger

Poorly adjusted injection system Correct it

Engine performance higher than expected

Check engine performance

Manometer display wrong Replace the manometer


6.4

Troubleshooting

Malfunctions when stopping


6

6.4 Page 72

6.4 Malfunctions when stopping

Noises during run-down

Possible causes

Turbocharger


Damaged bearing

Rubbing rotor


Elimination

Clean it


Service Station

Run-down time too short

Possible causes

Turbocharger


Damaged bearing

Rubbing rotor


Elimination

Clean it


Service Station


6.5

Troubleshooting

Speed measurement system


6

6.5 Page 73

6.5 Speed measurement system

Possible causes

Signal amplitude non existent or poor

Measured speeds too high

Fitting error

Elimination

The screw plug for the sensor is fitted with a gasket.

When fitting the speed sensor, this gasket must be removed. If it is fitted by mistake, the distance from the sensor tip to the signal-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.

Dirty sensor tip The sensor tip is magnetic and can thus attract metal particles. As a result, the distance to the auxiliary bearing decreases, which can lead to amplification of the noise component and consequently to faulty triggering.

Remove the sensor, clean its tip and refit the sensor using the specified tightening torque.

- - Contact ABB Turbocharging service station. Measured speed too low

Other sources of errors

- - If none of the above measures eliminates the problem, we recommend that you have the speed measuring system inspected by an official ABB Turbocharging service station.


6.6

Troubleshooting

Variable Turbine Geometry


6

6.6 Page 74

6.6 Variable Turbine Geometry

Variable Turbine Geometry (VTG) not adjustable

Possible causes

Turbocharger Heavy turbine contamination

Drive unit

(electrical components)

VTG bearing damaged

No drive energy

Elimination


Service Station


Service Station





7

7.1 Page 75

7.1

Weight [kg]

7

7.1



Lifting gear with a sufficient load limit must be used for removing and installing the turbocharger. The following weight specification is the heaviest possibility. This guide value can differ from data on the rating plate, depending on the specification.

TPL65VA32/33

1210





7

7.2 Page 76

7.2

CAUTION

7.2 Removing the turbocharger

 Disconnect all gas, air and oil lines in accordance with engine manufacturer’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 bearing casing or the turbocharger is fitted to the engine, it must be ensured 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.

 Unplug the cable connector on the speed sensor.

 Remove the insulation at the suspension ribs.


 Remove air supply line. (See also chapter entitled Preliminary remarks / Layout and functionality)

 Inspect the lifting gear.

 Fasten separate lifting gear to each of the two ribs on the bearing casing provided for this purpose.





7

7.2 Page 77

WARNING

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

 Completely remove the bearing casing insulation (02) and place a 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 turbocharger could tip over during installation or removal and cause a serious or even fatal injury.

 Support the turbocharger at a suitable point.

 If possible secure it using lifting gear.

Wear safety helmet.

 Cover the oil connection.



Installing the turbocharger


7

7.3 Page 78

7.3

CAUTION

7.3 Installing the turbocharger

 Remove cover from oil connection.

 Inspect lifting gear.

 Fasten separate lifting gear to each of two bearing casing ribs provided for this purpose.

Oil orifice plates



 Adapt turbocharger to suit engine.

 Tighten fixing screws in foot in accordance with engine builder's instructions.

 Fasten gas, air and oil lines in accordance with engine builder’s instructions.


 Fit air supply line. (See also chapter Preliminary remarks / Layout and functioning.)

 Refit removed parts of insulation.

 Plug in cable connector on speed sensor.



Introduction


8

8.1 Page 79

8.1

CAUTION

8 Disassembly and assembly

8.1 Introduction

Further work

Further tasks, which are not described here, may be carried out only by trained personnel from an ABB Turbocharging service station.

 Only carry out those tasks that are described in this chapter.

Marking casing positions for assembly

NOTICE

WARNING

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.

 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.

 See chapter Spare parts.



Introduction


8

8.1 Page 80

WARNING

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.

Suspended loads

Loads not suspended in compliance with regulations may lead to personal injury or accidents with fatal consequences.

 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.

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 defined 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.


8.2


Module weights


8

8.2 Page 81

8.2 Module weights

The specified weights of individual parts or assemblies are guides rounded off to the next highest value.

Assemblies

Weights [kg]

03

04

05

06

01

02

07

08

09

10

Description

Radial air suction branch

Axial air suction branch

Filter silencer

Compressor casing

Wall insert

Diffuser

Cartridge group

Turbine diffuser


Radial gas inlet casing

TPL65VA32/33

50

35

130

180

40

19

290

30

55

50


Weight [kg]

NOTICE


Module weights


8

8.2 Page 82

Complete compressor casing

TPL65VA32/33

240




8


8.3

8.3

Removing the filter silencer

8.3 Removing and fitting filter silencer or air suction branch

 Remove insulation where necessary.

Page 83

 Pass lifting gear through rib on filter silencer.

 Pass lifting gear through lugs on back.

 Unscrew nuts (72027) and remove them together with washers

(72018).

 Remove filter silencer and set it down to one side.

Installing the filter silencer  Install filter silencer in reverse order.




8


8.3 Page 84

Removing the air suction branch

 Disconnect all air lines in accordance with the engine builder’s instructions.

 Dismantle the insulation where necessary.

Installing the air suction branch

 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 improve 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.

 Fit the air suction branch in reverse order.


8.4


Axial clearance


8

8.4 Page 85

WARNING

8.4 Axial clearance

Physical hazards due to sharp edges on compressor wheel

The compressor wheel has sharp edges which can result in injury.

 Wear safety gloves.


Clearance A [mm]

CAUTION

 The axial clearance (A) must be measured before removing and after fitting the cartridge group.

 Measure and note the axial clearance (A).

TPL65VA32/33

0.31 … 0.49

Clearances out of tolerance

Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property.

 Have components assessed and, if necessary, replaced by an ABB






8

8.5 Page 86

8.5

CAUTION

8.5 Removing cartridge group

 Remove insulation.

Version with compressor wheel cooling system

 Remove air supply line. (See also chapter entitled Preliminary remarks / Layout and functionality)

 Disconnect oil pipes in accordance with enginebuilder's instructions.

Oil orifice plates



 Loosen and remove sealing air line (56501) between compressor casing (72000) and variable turbine geometry module (56100).

 Remove three studs (72029) at top.

 Attach lifting device (90190) to compressor casing (72000), then fasten and secure it to crane using lifting gear.

 Unscrew nuts (61037).

 Uniformly press apart compressor casing (72000) using three press-off nuts (61090).

 Slightly lift compressor casing (72000) and withdraw it.





8

8.5 Page 87

WARNING

 Turn the compressor casing (72000) together with the wall insert and diffuser and set them down with surface (F) on an underlay.

Tipping the compressor casing

Make sure the underlay does not shift.

 Allow the compressor casing to rest only on surface (F).

 Check the underlay and adjust it if necessary.

 Remove the screws (72002).

 Remove the diffuser (79000).

 Remove the wall insert (77000) using swivel lifting eyes (90235).

 Remove the O-ring (77005) from the wall insert.





8

8.5 Page 88

CAUTION

 Unplug the cable connector (86515) and screw out the speed sensor

(86505) complete with the O-ring (86506).

 Remove the O-ring (42012).

 Remove the three screws (61059) and Verbus Ripp® washers

(61058).


 Uniformly press off the cartridge group using the press-off screws

(90900) in the holes provided. casing could be damaged.

 Turn the rotor to check that the blades do not rub against the turbine diffuser.





8

8.5 Page 89

 Withdraw the cartridge group and fit the supports (90450).

 Cover the oil connections.


8.6



8

Removing and fitting turbine diffuser 8.6 Page 90

8.6 Removing and fitting turbine diffuser

NOTICE

 Replace two screws (61032) with two studs (90903) in upper section of turbine diffuser.

 Screw out the remaining screws (61032), press off the turbine diffuser

(63000) using the press-off screws (90901), then withdraw and remove it.

Fitting the turbine diffuser

 Fit the turbine diffuser in reverse order of removal.

Brush high-temperature grease on all screws at and in the gas outlet casing.


8.7


Removing variable turbine geometry module with gas inlet casing


8

8.7 Page 91

8.7 Removing variable turbine geometry module with gas inlet casing

 Disconnect semi-circular section of sealing air line (A) from variable turbine geometry module.

 Retaining clips (56121) are fitted.

 Unscrew nuts (61042).

 Remove gas inlet casing (51001) together with variable turbine geometry module (56100).

CAUTION

 Loosen screws (56122) together with retaining clips (56121) and remove with clamping ring (56112).

 Remove clamping ring (56112).

 Carefully separate gas inlet casing (51001) from variable turbine geometry module (56100) and remove it.

Have the variable turbine geometry module overhauled by ABB Turbo

Systems. ABB Turbocharging Service Stations have variable turbine

CAUTION


8.8




8

8.8 Page 92

8.8 Fitting the variable turbine geometry module and the gas inlet casing

 Push variable turbine geometry module (56100) over studs

 Push gas inlet casing (56001) over studs

 Slide clamping ring (56112) onto studs

 Tighten nuts (61042) to specified torque

 Fit retaining clips (56121) using screws (56122)

 Fit semi-circular section of sealing air line (A) to variable turbine geometry module





8

8.8 Page 93

 Fit sealing air line (56501) to semi-circular section of line (A).



Installing cartridge group


8

8.9 Page 94

8.9

CAUTION

8.9 Installing cartridge group

Oil orifice plates



 Remove the cover from the oil connection.


 Remove the supports (90450) and carefully insert the cartridge group.

 Uniformly tighten the screws (61059) together with the Verbus Ripp® washers (61058).





8

8.9 Page 95

CAUTION and the turbine diffuser, the blades and the turbine diffuser (casing) can be damaged.

 Turn the rotor to check that the blades do not rub against the turbine diffuser.

 Remove the lifting gear.

 Fit the O-ring (42012).

 Screw in the speed sensor (86505) along with the O-ring (86506) and plug in the cable connector (86515).

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

 Fit the lifting gear and the swivel lifting eye (90235).

 Align and fit the wall insert (77000) using the centring screw (90187).

 Place the diffuser (79000) in position using the swivel lifting eye

(90235).

 Remove the swivel lifting eye (90235).

 Fit the screws (72002).





8

8.9 Page 96

 Attach lifting gear to lifting device (90190) and turn compressor 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) onto cartridge group to fit snugly 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).

 Fit sealing air line (56501) between compressor casing (72000) and variable turbine geometry module (56100).





8

8.9 Page 97

CAUTION

 Measure and note the axial clearance (A) (see the section on axial clearance).

Clearances out of tolerance

Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property.

 Have components assessed and, if necessary, replaced by an ABB


 Connect oil pipes and all air lines in accordance with engine builder’s instructions.

Version with compressor wheel cooling system

 Fit the air supply line. (Also see the chapter Preliminary remarks /

Layout and functioning.)

 Fit the filter silencer or air suction branch.

 Fit the insulation.


8.10


Table of tightening torques


8

8.10 Page 98

8.10 Table of tightening torques


Tightening torques [Nm]


Table of tightening torques

19

24

30

09

13

17

18

01

03

04

06

07

08

51075

56110

56114

61042

56122

86505

61036

61041

72029

61059

42059

42064

61056

Part number

82005

72027

With washer

72002

61037

61090


8

8.10 Page 99

M14

160

M12

50

M14

150

M8

25

M14

130

M10

50

M18x1.5

160

TPL65VA32/33

M16x1.5

50

M14

100

M10

50

M14

80

M14

10

M14

50

Tightening angle [°]

29

Part number

56501

TPL65VA32/33

M26x1.5

30°



Taking out of operation at short notice 9

Possibilities for emergency repair 9.1 Page 101

9.1

WARNING

9 Taking out of operation at short notice

9.1 Possibilities for emergency repair

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.

 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.


CAUTION

Directives for taking out of operation

Serious damage to engine or property can be caused by noncompliance with the directives for locking/blanking off the turbocharger on the engine.

 Follow the directives of the enginebuilder.

If the diesel engine must be capable of operation again as soon as possible after damage to the turbocharger (emergency repair), the following possibilities are available:

 Fitting cover plate

 Shutting off inlets and outlets

 Bypass around turbocharger


9.2



Fitting the cover plate 9.2 Page 102

NOTICE

9.2 Fitting the cover plate

The cover plate (material: General structural steel, in accordance with drawing.

Cover plate dimensions

[mm]

Product

TPL65

Product

TPL65

Product

TPL65

B1

13

Ø 1

616

α 1

4 x 90°

B2

325

Ø 2

694

B3

30

B4

30

Ø 3

660

α 2

37.5°

B5

8

Ø 4

16

B6

10

B7

6

Ø 5

22

α 3

24 x 15°

B8

70

Ø 6

15





NOTICE

Carry out the work as described in the chapter Removal and fitting.

 Remove cartridge group.





CAUTION

 Close off opening in gas outlet casing using cover plate.

 Fasten cover plate using spacer sleeves and nuts (61037).

Shut off the supply of lubricating oil to the turbocharger.





Separate receivers

Common receiver

CAUTION

Further measures and information for operation with a turbocharger with cover plate on 4-stroke engines

4-stroke engine with one turbocharger

No further measures are necessary. The engine can be operated as a naturally-aspirated engine according to the engine builder's instructions.

4-stroke engine with several turbochargers

No further measures are necessary on engines with separate air and exhaust gas receivers. The engine can be operated as a naturallyaspirated engine according to the engine builder's instructions.

The air line must be closed off at the engine end because the undamaged turbochargers build up a receiver pressure.

The engine can be operated according to the engine builder's undamaged turbocharger. The speed limit n

Bmax plate must not be exceeded.

given on the rating




Blocking the inlets and outlets 9.3 Page 106

9.3

CAUTION

9.3 Blocking the inlets and outlets

Shut off the lubricating oil supply to the turbocharger.

 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




Turbocharger bypass 9.3 Page 107

CAUTION

9.4 Turbocharger bypass

Shut off the lubricating oil supply to the turbocharger.

 This applies to engines with one turbocharger only:

 The connections are ready and pipes for the bypass are available.

 Fit bypass around turbocharger.

In this respect, refer to the engine manufacturer's instructions.

NOTICE


10.1


Taking the engine out of operation for up to 12 months


10

10.1 Page 109

10 Mothballing the turbocharger

10.1 Taking the engine out of operation for up to

12 months

WARNING

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 pre-lubrication pump, no measures have to be taken. Any remaining old engine oil will therefore be flushed away and the bearing sections largely protected against corrosion.

Mothballing measures

Handling operating materials and supplies

Swallowing or inhaling vapours of operating materials and supplies or contact with them may be harmful to health.

 Do not breathe in these substances and avoid contact with the skin.

 Ensure proper ventilation.

 Observe the information in the material safety data sheet for the

 operating materials and supplies.

Comply with local legislation.



Wear a respiratory mask to protect against gases.



Taking the engine out of operation for up to 12 months


10

10.1 Page 110

If the total acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking an engine out of operation:

 Dismantle the turbocharger.

 The rotor and the bearing parts must be removed by an official ABB

Turbocharging service station and refitted afterwards.

 Clean all parts.

 Machined, bright surfaces of steel and cast parts must be oiled with anticorrosive oil.

 Reassemble complete turbocharger.

Rotor turning in stack draught

If the rotor turns as a result of the stack draught:

 Install blind flange between compressor casing outlet flange and charge air duct.


10.2


Taking the engine out of operation for more than 12 months


10

10.2 Page 111

10.2 Taking the engine out of operation for more than 12 months

If the engine is taken out of service, the following alternatives are possible 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 by an ABB


 The turbocharger is removed completely, either as a whole or in individual parts.

See the section Taking out of operation for up to 12 months, under

Mothballing measures, for the measures always necessary when mothballing turbocharger parts.

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 reassembled from the individual components thereof:

 Close all turbocharger openings using wooden covers and paraffin paper.

Suitable storage locations are only dry rooms where the relative humidity is between 40 … 70 % and no condensation can form.

Condition of the mothballed turbocharger

 Check the mothballed turbocharger parts for corrosion once per annum.

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



Disposing of turbocharger components 11

Taking the engine out of operation for more than 12 months

10.2 Page 113

WARNING

11 Disposing of turbocharger components

Handling damaged thermal insulation

Damaged thermal insulation can lead to dust exposure. The glass fibres can cause mechanical irritation of the eyes, skin, and respiratory tracts.

 Avoid the formation of dust.

 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.


Disposal must be environmentally compatible, professional, and in compliance 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.


Spare parts

Ordering spare parts


12

12.1 Page 115

12.1

12

12.1

Spare parts

Ordering spare parts

CAUTION

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

All spare parts ordered with the turbocharger must be kept complete and ready for use.

 Parts showing signs of rust should be carefully cleaned and greased.

 Dispose of replaced and unusable parts in a professional and environmentally compatible way.

Required customer spare parts set (97070)

3

1

1

1

2

1

Quantity

2

2

15

15

Description

Hexagon-head screw

Verbus Ripp® Washer

Hexagon-head screw


Hexagon nut

Gasket

Gasket

O-ring

O-ring

O-ring

Part number

42059

42058

61056 / 61059

61057 / 61058

61037

42041

42045

42012

77005

86506


12.2

Spare parts


12

View of turbocharger with part numbers 12.2 Page 116

12.2 View of turbocharger with part numbers


Spare parts


12

View of turbocharger with part numbers 12.2 Page 117

Part number

-

56100

51001

61001

61035

61037 (in customer spare parts set)

61042







63000

68000

72000

72018

72029

72027

77000


79000

81000

82000

82000

Description

Cartridge group


Gas inlet casing

Gas outlet casing

Hexagon-head screw

Hexagon nut

Hexagon nut


Hexagon-head screw

Hexagon-head screw



Hexagon-head screw

Turbine diffuser

Foot

Compressor casing

Washer

Stud

Hexagon nut

Wall insert

O-ring

Diffuser

Filter silencer

Radial air suction branch

Axial air suction branch


12.3

Spare parts

View of cartridge group with part numbers


12

12.3 Page 118

12.3 View of cartridge group with part numbers


Spare parts

View of cartridge group with part numbers


12

12.3 Page 119

Part number

21000

25000

32001

32101

32102

32104

32105

32106

32107

42001

42002

42011

42015

42041 (in customer spare part set)




42063

42064

43002 (option with compressor wheel cooling system)

43001

43005

43006

43007

86505


Description

Shaft

Compressor wheel

Thrust bearing

Radial bearing at compressor end

Radial bearing at turbine end

Auxiliary bearing

Floating disc

Axial bearing

Bearing bush

Bearing casing

Hood

O-ring

Sealing cover

Gasket

Gasket


Hexagon-head screw


Hexagon-head screw

Plate

Partition wall

O-ring

O-ring

O-ring

Speed sensor

O-ring


ABB

ABB Turbo Systems AG

Bruggerstrasse 71a

CH-5400 Baden

Switzerland

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