List of Contents: Operation Manual

Operation Manual
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
List of contents
List of contents
1
Preliminary remarks
1.1
Purpose of the manual
1.2
Layout and function
1.3
Correct use of the turbocharger
1.4
Essential information
1.5
Abbreviations and symbols
1.6
Turbocharger rating plate
Safety
2.1
Basic safety instructions
2.2
General safety instructions
2.3
Special safety instructions
2.4
Safety instructions and hazard protection
2.5
Warnings on the turbocharger
Commissioning
3.1
Oil supply
3.2
Inspection work
3.3
Putting into operation after laying up
Operation
4.1
Servicing work
4.2
Monitoring
4.3
Surging of turbocharger
4.4
Contact with rotating parts
4.5
Shutting the engine down
Maintenance
5.1
Foreword to Maintenance
5.2
Cleaning the filter silencer
5.3
Cleaning the compressor during operation
5.4
Cleaning turbine blades and nozzle ring in operation
5.5
Suppliers of materials for dry cleaning
ABB Turbo Systems Ltd
Page 1
Operation Manual
6.1
Possible remedies for failures
Removal and installation
7.1
Turbocharger weights
7.2
Remove the turbocharger
7.3
Installing the turbocharger
Disassembly and assembly
8.1
Module weights
8.2
Removing and fitting the filter silencer or air suction branch
8.3
Axial clearance
8.4
Dismantling the internal part of the compressor casing
8.5
Dismantling gas inlet casing
8.6
Fitting gas inlet casing
8.7
Fitting the internal part of the compressor casing
8.8
Table of tightening torques
Taking out of operation temporarily
9.1
Possibilities for emergency repair
9.2
Locking the rotor
9.3
Blocking the inlets and outlets
9.4
Bypass the turbocharger
10
Mothballing the turbocharger
10.1
Taking out of operation for up to 12 months
10.2
Taking out of operation for more than 12 months
11
Reserve and spare parts
11.1
Ordering spare parts
11.2
Directory of part numbers
11.3
General view of turbocharger
11.4
General view of cartridge group
January 2007
Troubleshooting
HZTL2491_EN (TPL85-B14/-B15/-B16)
Page 2
Version 4
List of contents
Operation Manual
Preliminary remarks
Purpose of the manual
1.1
Page 1
1.1 Purpose of the manual

Operation manual
This operation manual will help you to become familiar with your ABB
Turbo Systems Ltd turbocharger and to use it to full effect in its intended
application. You will find important instructions as to the safe, correct, and
economical operation of the turbocharger.
Target group
The content of this operation manual is intended for persons such as engineers, marine mechanics and service technicians who are responsible
for the running of the engine and the turbocharger installed thereon.
Content of operation manual
This operation manual includes helpful information on the following topics:

Information on the operation of the turbocharger and ways to prolong
the turbocharger's service life.

Early awareness and avoidance of hazards.
Minimising repair costs and failure times.
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
1 Preliminary remarks
This operation manual is a complement to, and an extension of, existing

national regulations on accident protection and prevention.
NOTE
An operation manual must be available at all times at the site where the
turbocharger is used. It is essential that this operation manual is read
before beginning work by all persons working with or on the turbocharger. Personnel who only work occasionally on the machine (e.g.
during installation and maintenance) must also have read and fully understood the operating manual before beginning work.
Version 4
The instructions included in this operation manual must be followed under

all circumstances.
WARNING
This applies especially to the general and special safety instructions

preceding and in the respective chapters. Ignoring hazards and the safety instructions can lead to serious personal injury and damage to equipment.
In the event of doubt, consult the officer for safety and accident protection
responsible for your area.
Operation Manual
Preliminary remarks
Layout and function
1.2
Page 2
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
1.2 Layout and function
1.2.
Filter silencer
Nozzle ring
Radial plain bearing
Turbine wheel
Thrust bearing
Bearing casing
Radial plain bearing
10
Diffuser
Gas outlet casing
11
Compressor wheel
Gas inlet casing
12
Air outlet casing
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Operation Manual
Preliminary remarks
Layout and function
1.2
Page 3
January 2007
Mode of operation
The turbocharger is a turbo-machine and consists of the following main
components:
Turbine
Compressor
These are both are mounted on a common shaft.
The exhaust gases from the diesel engine flow through the gas inlet casing (6) and nozzle ring (7) to the turbine wheel (8).
HZTL2491_EN (TPL85-B14/-B15/-B16)
The turbine wheel (8) uses the energy contained in the exhaust gas to
drive the compressor wheel (11), whereby the compressor draws in fresh
air, and the compressed air is forced into the cylinders.
The exhaust gases escape through the exhaust pipe which is connected
to the gas outlet casing (5).
The air which is necessary for the operation of the diesel engine and
which is compressed in the turbocharger is drawn through the suction
branch or the filter silencer (1) into the compressor wheel (11). It then
passes through the diffuser (10) and leaves the turbocharger through the
compressor outlet on the air outlet casing (12).
The rotor runs in two radial plain bearings (2/4), which are located in the
bearing casing (9) between the compressor and the turbine. The axial
thrust bearing (3) is on the compressor side.
The plain bearings are connected to a central lubricating oil feed which is
normally supplied by the oil lubrication circuit of the engine. The oil outlet
is always at the lowest point of the bearing casing (9).
Version 4
The turbocharger is equipped with an emergency lubrication oil tank,

which is integrated in the bearing casing. With a failure of the lubrication
oil system, the bearings are supplied with oil with this emergency lubrication until the rotor comes to a standstill.
Operation Manual
Preliminary remarks
Correct use of the turbocharger
1.3
Page 4
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.
NOTE
January 2007
1.3 Correct use of the turbocharger
The engine manufacturer has provided ABB Turbo Systems with information regarding the intended purpose of the engine, from which the
operating parameters specific to the turbocharger (such as rotating
speeds, temperatures, replacement periods / exchange intervals) have
been derived and are indicated on the rating plate.
Latest technology
WARNING
This turbocharger was built according to state-of-the-art technology and is

operationally safe according to prevailing safety regulations.
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. The machine may only be operated by trained personnel.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Any other usage shall be regarded as a special application which must

be discussed with ABB Turbo Systems. The manufacturer accepts no
liability for other applications. If it is used otherwise, ABB Turbo Systems reserves the right to reject all claims under the warranty.
Correct use of the turbocharger also includes observation of the assembly, disassembly, operating, maintenance and repair conditions specified
by the manufacturer. Regulations set out by local authorities must be observed when disposing of the turbine.
The turbocharger must only be installed in a technically perfect condition,
corresponding to its intended purpose and following the instructions in the
Engine Manufacturers' Manual, and must be operated and used in compliance with the Operation Manual.
X Defects which could affect safety must be eliminated immediately.
The manufacturer shall not accept liability for damages resulting from unauthorised alterations to the turbocharger.
Version 4
Perfect condition
Operation Manual
Preliminary remarks
1.4
Page 5
January 2007
1.4 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.
NOTE
X The turbocharger must be shut down immediately in the event of al-
terations affecting safety or of corresponding operating behaviour. The

fault should be reported to the person or department responsible.
Additions and alterations to, and conversions of the turbocharger that

could compromise safety require the prior approval of ABB Turbo Systems.
NOTE
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
The safety and risk consciousness of the personnel working on and

with the turbocharger must be checked regularly with reference to this
manual.
Operation Manual
1
1.4
Page 6
Original parts and safety

Original parts and accessories are especially designed for the turbocharger supplied by ABB Turbo Systems Ltd.
January 2007
Preliminary remarks
We herewith expressly state that parts and accessories not supplied by

us have also not been tested and approved by us.
If components and assemblies not manufactured and tested by ABB

Turbo Systems are used, this may have a negative effect on the technical design specifications of the turbocharger.
WARNING
Moreover, the active and/or passive safety of the turbocharger may be

compromised by the use of non-original parts. Note that such improper
use may endanger personnel and the machine.
ABB Turbo Systems shall not be liable for any damage caused by using
non-original parts and accessories.
Qualification of personnel
HZTL2491_EN (TPL85-B14/-B15/-B16)
NOTE
The turbocharger must only be operated and maintained by trained and

authorised personnel.
Work on mechanical components, such as bearings or rotors, must only
be performed by qualified fitters from an official service station of ABB
Turbo Systems Ltd.!
It must be ensured that only authorised personnel work on the turbocharger.
Version 4
CAUTION
Operation Manual
Preliminary remarks
1.4
Page 7
January 2007
After-sales service
The Contact Information brochure contains an overview of official ABB
Turbo Systems Ltd. service stations worldwide.
Design variants
This operating manual is valid for various turbocharger design variants.
This means that some sections and component descriptions in this operating manual do not apply to your turbocharger.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Our service stations and agencies will gladly answer your questions relating specifically to your model.
Accuracy of illustrations
The graphics and images shown in this manual are of a general nature
and are intended to assist understanding of the work steps and instructions. Differences may exist in certain details.
Storage of new turbochargers

New turbochargers supplied by ABB Turbo Systems Ltd. can be stored
without additional safeguarding measures for a period of 6 months after
the delivery date.
Ensure that the storage area is dry with humidity of 40-70% and free of
condensation.
X After 6 months, rust-proofing oil should be sprayed on exposed sur-
Version 4
faces and all accessible areas of the turbocharger.

X To do this, the insulating materials must be removed.
Repeat the steps described for rust-proofing your turbocharger every 6

months.
NOTE
Operation Manual
Preliminary remarks
Abbreviations and symbols
1.5
Page 8
The following abbreviations are used in this document:

Z Prerequisite
X Work step
January 2007
1.5 Abbreviations and symbols
D Result
Basic Instructions
The following symbol is used for notes in this manual:
This note provides suggestions and tips to make work on the turbocharger easier.
NOTE
The note provides further essential information.
HZTL2491_EN (TPL85-B14/-B15/-B16)
9 Positive checkpoint (activity that must be carried out without fail)

U Negative checkpoint (activity that must not be carried out under any
circumstances)
ABB Turbo Systems
Official ABB Turbo Systems service station

The term used in this manual Official ABB Turbo Systems service station
signifies ABB Turbocharger service stations, that have been tested and
certified by ABB Turbo Systems Ltd.
Version 4
The term ABB Turbo Systems used in this manual signifies ABB Turbo
Systems Ltd.
Operation Manual
Preliminary remarks
1.6
Page 9
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
1.6 Turbocharger rating plate
L_00012
Operational limits
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Recommended replacement periods / exchange

intervals for turbocharger
components
3
4
5
Turbocharger operational limits at engine overload (110 %).

In test rig operation only, unless otherwise agreed with the
engine manufacturer.
Turbocharger operational limits in service.
Replacement interval for the plain bearings in 1000 h

Exchange interval for the compressor in 1000 h (no data for
100,000 h)
Exchange interval for the turbine in 1000 h (no data for
100,000 h)
Operation Manual
1
1.6
6
7
8
9
10
11
12
Page 10
Customer part number

Field for special design designation
Weight of the turbocharger in kg
CE = Conformit Europenne
Turbocharger type
Series number
Year of construction of the turbocharger
January 2007
Additional specifications:
Preliminary remarks
The recommended exchange intervals and the corresponding operation

limits are defined together with the engine builder. These specifications
are system-specific.
CAUTION
Continuous running above the indicated nBmax, tBmax values may considerably reduce the recommended exchange intervals. In such cases, we
recommend you contact the nearest official service station of ABB
Turbo Systems Ltd.
nMmax , tMmax normally apply only when running at overload (110 %) during trials on the engine test bed. These limits may also be permitted in
service for special applications. The operation over nMmax , tMmax is not
permitted.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Explanations of the rating plate
Version 4
Non-compliance with the recommended exchange intervals may increase the risk of unpredictable component failure.
Operation Manual
Safety
Basic safety instructions
2.1
Page 1
2 Safety
January 2007
2.1 Basic safety instructions

The following symbols and terms are used for the safety instructions in
this manual:
Failure to follow work steps and operating instructions marked with this
symbol completely and rigorously may result in serious personal injury
or even fatal accidents.
Warning signs must be strictly observed at all times.
Serious damage to the machine or to other property may result if the

working and operation instructions marked with this symbol are not, or
only partly, observed.
CAUTION
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
WARNING
Caution signs must be strictly observed at all times.
Operation Manual
Safety
General safety instructions
2.2
Page 2
The instructions listed here are designed to ensure your safety and to
promote safe handling of the turbocharger and its associated operating
materials.
January 2007
2.2 General safety instructions
The following safety instructions must be followed when operating and

when working on the turbocharger.
WARNING
Do not work on the turbocharger if you are under physical or mental
stress.
Version 4
Helmet
Ear protection
Protective glasses
Protective suit
Oil and petrol resistant gloves
Protective shoes
Attach individual parts and larger component modules carefully to suitable hoists/lifting devices which are in technically perfect condition and
which have adequate load-bearing capacity.
Do not stand under suspended loads.
If welding work is to be carried out above the turbocharger, the air filter
must be covered to prevent damage to the filter mat.
When working on the turbocharger, be aware of the risk of it falling.
For overhead assembly work, use the steps and platforms provided for
this purpose.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Wear protective clothing at all times.
Operation Manual
Safety
2.3
Page 3
January 2007
2.3 Special safety instructions

Safety when connecting
Work only on those connections for which you are qualified.
Safety when commissioning and during operation

Before starting work, make a visual inspection of the working area.
Remove obstacles and any objects lying around from the work area.
Before commissioning check the turbocharger for damage and leaks.
Refrain from any activity which could compromise safety while working
with the turbocharger.
Inspect the turbocharger after about 12 hours of operation or at least
once a day for visible damage and defects.
Report any damage or changes in operational performance to the person/department responsible immediately.
In the event of damage, shut down the turbocharger immediately and
secure it against inadvertent or unauthorized use.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Safety when cleaning

When handling detergents, solvents, acids and alkalis be sure to observe
the respective safety directions on the manufacturers' labels.
Follow directions regarding the environmentally compatible collection, storage and disposal of these liquids.
Explosion hazard
Version 4
WARNING
Cleaning work should be carried out outdoors due to explosion hazard.

If this is not possible, ensure that there is adequate ventilation and air
circulation. Before beginning cleaning work in confined spaces, extinguish naked flames (including cigarettes!) due to the risk of explosion.
Operation Manual
Safety
2.3
Page 4
operation materials.
You must wear protective clothing (see section General safety instructions).
Handle operation materials and detergents with utmost caution.
When handling solvents, wear protective clothing and observe the following rules:
Avoid skin contact with solvents.
Avoid inhaling vapours under all circumstances.
Do not allow solvents to soak protective clothing.
After cleaning, check electric cables for signs of wear or damage.
January 2007
Before cleaning, protect the floor against unintended leaks of oil and
Follow the prescribed maintenance and inspection schedules for all ad
Assembly and disassembly work must only be performed by trained

personnel. Work on mechanical components, such as bearings or rotors, must only be performed by qualified fitters from an official service
station of ABB Turbo Systems.
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CAUTION
justment, maintenance and inspection work.

Inform operating personnel about special work and repairs before starting.
Ensure that absorbent materials are available to clean up any operation materials that escape accidentally.
Ensure safe and environmentally-friendly drainage, collection and disposal of operating and auxiliary materials.
Before opening a cover or removing a protective component on the
turbocharger, the engine must have been switched off and must not be
started up again until all parts have been properly re-assembled.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Safety during disassembly, assembly, maintenance and troubleshooting
Operation Manual
Safety
2.3
Page 5
January 2007
Safety when taking out of operation or putting into storage
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Secure the rotor against turning.

Clean the turbocharger before mothballing.
Wear protective clothing when mothballing the turbocharger.
Keep the work area clean and free of oil and operating materials.
Remove any obstacles lying around on the floor.
Operation Manual
Safety
Safety instructions and hazard

protection
2.4
Page 6
Associated hazards may arise during operation of and work on the turbocharger:
from the turbocharger and its accessories.

from the operating materials used.
due to failure to comply with the safety instructions.
from inadequate performance of maintenance and inspection work.
January 2007
2.4 Safety instructions and hazard protection
Mechanical influences
Personal injury
Unconsciousness and injury due to:
crushing
shearing
cutting
winding
smashing
drawing in
knocking
stabbing
rubbing
Escape of liquids under high pressure and / or at high temperature
slipping
tripping
falling
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WARNING
HZTL2491_EN (TPL85-B14/-B15/-B16)
Mechanical influences can cause serious injury or even fatal injury.
Operation Manual
Safety

protection
2.4
Page 7
sharp edges, pointed parts

crush, shear and winding areas
fragmentation / ejection of parts
fracture or rupture of parts due to overload
Elastic elements (springs), liquids and / or gases under pressure/in a
vacuum
slippery, oily work area, obstacles on the floor
Protective measures
Wear leather protective gloves

Wear close-fitting protective clothing
Tie up long hair and beards (wear hair protection)
Wear face and eye protection
Wear protective shoes
Keep floor, equipment and the turbocharger clean
Ensure the availability of oil absorbing materials and have oil collector
basins ready or in position
9 Eliminate leaks
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Causes
9
9
9
9
9
9
9
Operation and process materials

Operation and process materials refer to chemical and hazardous substances:
Oils
Grease
Coolants
Detergents and solvents
Acids
Note that operation and process materials are harmful to the environment if they penetrate soil or water.
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CAUTION
Operation Manual
2

protection
2.4
Page 8
Allergies
Skin disease
Loss of consciousness
Poisoning or nausea after inhalation
Inhalation of toxic gases, smoke and vapours

Skin contact with aggressive fluids
Clothing wet or soaked with hazardous substances
Spilling and tipping over of vessels containing substances used during
operation
Escape due to leakage
Tanks and collectors which are not gas-tight and which do not comply
with the regulations on hazardous substances
Burning cigarettes or open flame in the proximity of operation materials
Causes
Protective measures
9
9
9
9
9
9
9
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Utmost caution when handling process and operation materials

Protective clothing must be worn
Avoid skin contact and inhalation under all circumstances
Ensure that the workroom is properly ventilated
Observe the hazard indications on the containers for operation and
process materials
Immediately after use, seal the hazardous substance container tight
Used operation materials must be collected safely in accordance with
the legal provisions, stored separately in suitable containers as prescribed, and disposed of as special waste in a technically and environmentally compatible manner
Ensure that containers for new / used operation materials are sealed
tight
In the event of leaks or spills immediately apply a suitable absorbent
material and dispose of this in a technically and environmentally compatible manner as special waste
January 2007
The following injuries can be caused by operation and process materials:
HZTL2491_EN (TPL85-B14/-B15/-B16)
Personal injury
Safety
Operation Manual
Safety

protection
2.4
Page 9
January 2007
Handling insulating materials

9
9
9
9
9
9
9
HZTL2491_EN (TPL85-B14/-B15/-B16)
9
9
9
9
Ensure that the work area is well ventilated

Keep the work area clean
Avoid disturbing dust
Dust-suppressing tools and processing steps
Remove from packaging only in the work area
Exercise particular care when removing old insulating materials
Dispose of insulating materials in a technically and environmentally
compatible manner
If large quantities of dust are created, wear protective glasses
Use half or quarter masks
Wear suitable work clothing and gloves
For sensitive skin, apply moisturising, protective barrier cream
Noise
The effects of noise above a legally permitted level can cause personal injury.
Loss of hearing
Deafness
Impaired hearing
Health disorders such as loss of balance or of consciousness
Cardiac and circulatory disturbances
Personal injury
Causes
Machine noise level above 85 dB (A)
Protective measures
9 Wear ear protection

Heat hazard
Version 4
When the turbocharger is operated, surfaces become very hot.

Personal injury
Burns
Causes
Missing or incorrectly fitted insulation.
Protective measures
9 Wear leather protective gloves.
Operation Manual
Safety
Warnings on the turbocharger
2.5
Page 10
L_00227
Apply warnings so that they are clearly visible in the positions intended
for that purpose. Please contact an official ABB Turbo Systems service
station for further information.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Warnings that have been applied to turbochargers by ABB Turbo Systems

must not be removed, painted over or obscured with other stickers. Missing or illegible warnings must be replaced by new warnings.
January 2007
2.5 Warnings on the turbocharger
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NOTE
Operation Manual
Commissioning
Oil supply
3.1
Page 1
3 Commissioning
January 2007
3.1 Oil supply

A carefully designed oil supply, which functions under all operating conditions, is an important precondition for trouble-free operation of the turbocharger.
Lubrication of the turbocharger is normally carried out with oil from the
engine oil circuit.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Regarding the oil supply, follow the engine manufacturer's instructions

concerning selection of lubricating oil, oil change intervals, oil filtration,
and oil pressure and temperature.
NOTE
Oil filtration
A lubrication oil filter system with a mesh size 0.050 mm is adequate for
TPL ..-B turbochargers.
Oil pressure
The oil pressure before the bearings must be maintained precisely to ensure fault-free operation.
The permissible oil pressures are specified in the following tables dependent on the lubrication (engine lubrication or separate lubricating system).
Version 4
Engine lubrication
Kinetic viscosity 45 - 170 cST
Oil pressure [bar]
Impermissible oil-pressure range ->

Engine Shut Down (without delay)
0.0 - 0.6
Short-term (<1h) permissible oil-pressure range ->

Alarm
0.6 - 0.8
Permissible oil-pressure range for normal operation
0.8 - 2.5
Permissible oil-pressure range during engine warmup phase
0.8 - 4.0
Operation Manual
3
Oil supply
3.1
Kinetic viscosity 12 - 170 cST
Page 2
Oil pressure [bar]
Impermissible oil-pressure range ->

Engine Shut Down (without delay)
0.0 - 0.9
Short-term (<1h) permissible oil-pressure range ->

Alarm
0.9 - 1.1
Permissible oil-pressure range for normal operation
1.1 - 2.5
Permissible oil-pressure range during engine warmup phase
1.1 - 4.0
January 2007
Separate lubrication system
Commissioning
Oil inlet
temperature
[ C ]
Engine load
[%]
Oil inlet pressure

[ bar ]
Oil outlet
temperature
[ C ]
45
100
1.5 - 2
70 - 90
70
100
1.5 - 2
90 - 110
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Engine lubrication
HZTL2491_EN (TPL85-B14/-B15/-B16)
Oil temperature during normal operation
Operation Manual
Commissioning
Inspection work
3.2
Page 3
3.2 Inspection work

January 2007
This inspection work includes preventive visual controls, as well as monitoring and measurement to ensure the correct functioning of the turbocharger. These serve as an aid to detecting anomalies before and during
commissioning, thus preventing possible damage to the machine.
The safety instructions must be followed before and during all inspec-
tion work.
HZTL2491_EN (TPL85-B14/-B15/-B16)
3.2.1 Inspection before commissioning

Monitoring equipment
X To be checked for correct functioning.
Air filter mat
X Inspect for damage.
Lubricating system
X Check oil filter for cleanliness before commissioning.
It is urgently recommended that the entire lubrication system be flushed

thoroughly with warm oil using a bypass pipe before commissioning and
after every servicing operation on the lubrication system.
CAUTION
We strongly recommend the use of a starting filter when running the

engine in and after every servicing operation on the lubrication system.
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X Check oil pressure in oil supply lines.
Operation Manual
Inspection work
3.2
Page 4
3.2.2 Inspection after commissioning

Lubricating system
X Check oil pressure in oil supply lines.
Charger speed
X Measuring
Charger pressure
X Measuring
Temperatures
X Measure upstream/downstream from turbine, compressor and oil feed
Gas, air, and oil lines
X After the engine has been started up, check all gas, air and oil lines for
for various engine speeds
leaks.
Further must be observed:
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
Commissioning
NOTE
X Measure the speed, oil pressure, charging pressure and temperatures
before and after the turbine and the compressor at various engine
speeds.
X Compare the measured values with those of the inspection report, taking into account the different operating conditions.
3.2.3 Inspection after 100 service hours

Clean or replace lubricating oil filters after the first 100 service hours.
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Lubricants and pastes are liquefied or vaporised during assembly of the

turbocharger and may escape as an oily liquid in the first few hours after commissioning. If oily liquid continues to escape after this period,
the cause must be treated as an oil leak and located. The first step in
this process is to check the oil supply to the turbocharger for leaks. If
this is not in order, contact an official ABB Turbo Systems service station.
Operation Manual
Commissioning
Putting into operation after laying up
3.3
Page 5
January 2007
3.3 Putting into operation after laying up

If provided
X Remove the cover plates (blind flanges) between the compressor cas-
ing outlet and charge-air receiver, upstream of the gas inlet, downstream of the gas outlet.
X Inspect the exhaust pipe before and after the turbine for any combusX
X
X
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
tion residue, clean / remove foreign bodies or residual water.

Inspect air supply line or filter silencer for any foreign bodies, clean /
remove.
Start up the turbocharger's engine end oil circulation system.
Prepare the turbocharger for operation as instructed in the section Inspection work before commissioning in the chapter entitled Commissioning.
Start up the turbocharger.
Operation Manual
Operation
Servicing work
4.1
Page 1
4 Operation
January 2007
4.1 Servicing work

Servicing work during operation includes visual checks, monitoring and
measuring as well as inspection and function checks in order to ensure
correct functioning of the turbocharger. It serves as an aid to detecting
anomalies during operation, thus preventing damage to the machine.
The inspection, measurement and servicing operations listed must be carried out at the intervals indicated.
HZTL2491_EN (TPL85-B14/-B15/-B16)
The pertinent safety instructions must be observed during all servicing

work.
WARNING
Servicing work must be carried out at the prescribed intervals in order

to avoid damage to and malfunctioning of the turbocharger.
CAUTION
4.1.1 Servicing work every 25 to 50 hours

Operation data
X must be recorded
X Enter in the machine logbook
X In the event of significant anomalies, establish the cause
If you are unable to establish the cause of the anomalies, contact an

official ABB Turbo Systems service station.
Version 4
CAUTION
Operation Manual
4
Servicing work
4.1
Page 2
4.1.2 Entries in the machine logbook

Monitoring of the machine plant provides information about the performance of the turbocharger.
January 2007
Operation
Output and speed of the engine

Air intake temperature
Exhaust temperature before and after the turbine
Pressure of the charge-air
Pressure drop in the charge-air cooler
Lubricating oil pressure, lubricating oil temperature
Air temperature after compressor and after the charge-air cooler

Speed of the turbocharger
Pressure loss in the air filter
If provided
4.1.3 Servicing work according to the engine manufacturer's instructions

X With the engine at standstill clean or replace oil filters
Version 4
Oil filters
HZTL2491_EN (TPL85-B14/-B15/-B16)
The following operation data and measurement values must be entered

regularly in the engine manufacturer's machine log book:
Operation Manual
4
Servicing work
4.1
Page 3
January 2007
4.1.4 Inspection work every 18,000 hours

Remove filter silencer or air suction branch
Clean filter silencer as far as accessible, and inspect for damage
Remove the internal part of the compressor casing
Check clearance A (axial bearing clearance)
Clean accessible parts (compressor wheel, diffuser, wall insert), and
inspect for damage
X Visual inspection of the turbine parts (nozzle ring, turbine diffuser/cover
ring, turbine blades) without dismantling, using the endoscope, for possible soiling and damage. As an option, this inspection can also be performed after the disassembly of the gas inlet casing.
X Refit the internal part of the compressor casing
X Re-install the filter silencer or air suction branch.
X
X
X
X
X
This inspection work and the checks are to be carried out by an official
service station of ABB Turbo Systems Ltd.
NOTE
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation
Operation Manual
Servicing work
4.1
Page 4
4.1.5 Servicing work every 36,000 hours

Remove filter silencer or air suction branch
Clean filter silencer as far as accessible, and inspect for damage
Remove the internal part of the compressor casing
Check clearance A (axial bearing clearance)
Clean accessible parts (diffuser, wall insert), and inspect for damage
Remove gas inlet casing, and dismantle nozzle ring
Clean nozzle ring, and check for damage/wear
Clean turbine diffuser/cover ring, and check for damage/wear
Replacement of the radial bearing and axial bearing with original parts
from ABB Turbo Systems Ltd.
X Inspection and assessment of the rotor
X
X
X
X
X
X
X
X
X
The replacement of the bearing parts as well as the inspection and assessment of the rotor must be carried out by an official ABB Turbo Systems service station.
Version 4
NOTE
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation
Operation Manual
Operation
Monitoring
4.2
Page 5
4.2.1 Speed measurement
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
4.2 Monitoring
Version 4
86505_001
Bearing casing
Connecting cable
Axial bearing
Line amplifier (option)
Guide in the axial bearing
Speed transmitter
Gasket ring
Installation variant of the

speed transmitter
Screw plug
The speed transmitter system for the measurement of the turbocharger

speed also permits, in conjunction with the corresponding measuring instruments and/or monitoring systems (not included in the scope of delivery), a constant remote monitoring of the turbocharger speed. With continuous monitoring of the machine installation, the turbocharger speed can
be used as a suitable control parameter. The line amplifier can be purchased as an optional addition to the described speed measuring system.
Operation Manual
Operation
Monitoring
4.2
Page 6
Defects in the speed transmitter, the connecting cable and plug to the
measuring unit, in the measuring unit itself or the power supply.

Turbocharger damage.
January 2007
Possible reasons for failure of the speed indicator:
Failure of the speed indicator
We recommend that subsequent assembly or replacement of the speed

transmitter system should be carried out only by an official ABB Turbo
Systems service station.
NOTE
A reduction in speed of a charger can signify:
Version 4
Damaged turbine or bearing

Severe soiling of the turbine
HZTL2491_EN (TPL85-B14/-B15/-B16)
CAUTION
If the speed indication fails, it is recommended that the engine output

be reduced to idling speed and the engine stopped. The cause of the
failure should then be determined.
Operation Manual
Operation
Monitoring
4.2
Page 7
January 2007
4.2.2 Underpressure measurement on filter silencer

A U-tube manometer can be ordered from ABB Turbo Systems Ltd. for
measuring the underpressure at the filter silencer.
The measurement can be used for the following purposes:
To measure the correction factor for calculating the efficiency of the
U-tube manometer
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
turbocharger when accepting the engine

The use of a filter mat on the filter silencer can cause a loss of pressure. More significant pressure loss is an indication of increased soiling
of the filter material.
L_00003
L_00004
Felt discs
A [mm H2O]
Pressure differential / pressure loss
Operation Manual
Operation
Monitoring
4.2
Page 8
Mechanical vibration of the U-tube manometer is reduced by the installation of additional felt discs (1).
The U-tube manometer must be exposed to minimum possible mechanical shock or vibration.
January 2007
All parts required for assembly are supplied in a separate package.
NOTE
X Fit the U-tube manometer to the filter silencer as shown in the preced-
ing description.
X For best readability, the U-tube manometer can be filled with slightly
Under as-new conditions (new or clean filter silencer and filter mat), the
maximum pressure loss (A) is 120 mm H2O under full loading.
X Clean the filter as soon as the loss of pressure (A) reaches a value of
200 mm H2O if not before.
For better readability of the pressure differential (A) on the U-tube manometer, the measuring rod can be withdrawn to the level of the lower
water level indicators.
Version 4
NOTE
HZTL2491_EN (TPL85-B14/-B15/-B16)
coloured water.
Operation Manual
Operation
Surging of turbocharger
4.3
Page 9
4.3 Surging of turbocharger

January 2007
Surging of the turbocharger can occur with certain engine operating states, such as rapid load removal or while manoeuvring. The direction of
flow in the compressor is then briefly reversed. However, sporadic surging
of this kind does not generally affect the safe operation of the turbocharger.
Prolonged or periodic surging
HZTL2491_EN (TPL85-B14/-B15/-B16)
CAUTION
If surging is prolonged or occurs periodically, the following components

may be damaged:
- Compressor wheel (vibration fractures, ...)
- Turbine blades (cracks)
- Bearing (overheating)
- Filter silencer
Action to be taken:
Version 4
The operating safety of the turbocharger is no longer ensured with continuous or periodically recurring surging. The operator must take immediate steps to correct the surging together with the closest official ABB
Turbo Systems service station.
The components listed above must be inspected for damage by an official
ABB Turbo Systems service station, and replaced in cases of doubt.
Operation Manual
Operation
Contact with rotating parts
4.4
Page 10
Mild, uniform wear around the circumference of rotor components, caused

by slight local grazing against adjacent components, is non-hazardous
and permissible. This slightly reduces the length of the blades in the compressor and/or the turbine. Certain tolerances must be observed to avoid
significant loss of efficiency.
January 2007
4.4 Contact with rotating parts
X A check on dimensions must be carried out by an official ABB Turbo
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Systems service station.
Operation Manual
Operation
Shutting the engine down
4.5
Page 11
January 2007
4.5 Shutting the engine down

Before shutting the engine down, it must be allowed to idle for about 3
minutes longer so that the circulating lubricating oil can dissipate the
heat in the turbocharger bearings.
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
CAUTION
Operation Manual
Maintenance
Foreword to Maintenance
5.1
Page 1
January 2007
5 Maintenance
5.1 Foreword to Maintenance
Cleaning work includes regular visual checks and washing to ensure the
correct functioning of the turbocharger and its auxiliary appliances.
The external condition and the degree of contamination of the cleaning
points specified in this chapter must be established by visual checks at

the intervals indicated.
The safety instructions must be observed during all cleaning work.
HZTL2491_EN (TPL85-B14/-B15/-B16)
The cleaning points described in the following are:
Version 4
Filter silencer
Compressor
Turbine and nozzle ring
Operation Manual
Maintenance
5.2
Page 2
January 2007
5.2 Cleaning the filter silencer
HZTL2491_EN (TPL85-B14/-B15/-B16)
5.2.1 Filter silencer with tension band
81265
Filter ring (if provided)
81266
Cover grids
81270
Tension ring
81136
Fleece segment
38271
Trap cover
81137
Cover panel
81268
Connecting strip
81135
Filter silencer body
Slide-in module = fleece segment + cover panel installed
Version 4
L_00210
Operation Manual
Maintenance
5.2
Page 3
January 2007
Disassembling and cleaning the filter silencer

X Remove filter ring (81265).
X Rinse filter ring (81265) with water using detergent or, if very dirty, so-
If provided
ak it. Squeeze out carefully. Rinse in cold water. Avoid high mechanical stress (water jet).
The dirt in the filter ring (81265) depends on the cleanness of the air
drawn in. Wash or replace the filter ring as necessary or every 500 service hours.
NOTE
HZTL2491_EN (TPL85-B14/-B15/-B16)
X Loosen tension bands (81270) on trap covers (81271) and carefully
remove cover grid (81266) from connecting strips (81268).
NOTE
In the case of a slide-in module (E), with a cleaning container attached

to the filter silencer (available as option depending on turbocharger type) the water injection line must first be removed (see also following
section Disassembling the cleaning line).
X Pull the slide-in modules (E) out, bend the cover panels (81137) open,
and then take out the fleece segments (81136).
X Clean fleece segments (81136).
When cleaning, ensure that the fleece segments (81136) are cleaned
only with a mild jet of compressed air, a soft brush or damp cloth. Otherwise the segments may be damaged or lose their shape.
Version 4
Heavily soiled fleece segments and filter ring as well as damaged connecting strips should be replaced with original parts from ABB Turbo
Systems.
NOTE
Operation Manual
Maintenance
5.2
Page 4
X Assemble the slide-in modules (E) by inserting fleece segments
(81136) in the cover panels (81137).
X Bend the cover panels back to their original shape.

X Insert slide-in modules (E) in the grooves in the filter silencer body
January 2007
Assembling the filter silencer
(81135).
With a cleaning container fitted to the filter silencer (available as option

depending on turbocharger type) the water injection line must now be
re-installed (see also following section Assembling the cleaning line).
X When fitting, insert the cover grid (81266) into the connecting strips
(81268).
X Fit the tension bands (81270) and tighten on the trap covers (81271).
X Fit filter ring (81265).
Version 4
If provided
HZTL2491_EN (TPL85-B14/-B15/-B16)
NOTE
Maintenance
5.2
5.2.2 Removing / installing the cleaning line
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Operation Manual
Version 4
L_00192
Injection pipe
Guide tube
Pipe
Page 5
Operation Manual
Maintenance
5.2
Page 6
X Disconnect the line (2) at the injection pipe (1) and remove the screw
coupling from the pipe.
X Withdraw the pipe (2) from the guide tube (3).
January 2007
Removing the cleaning line
HZTL2491_EN (TPL85-B14/-B15/-B16)
Punch out the guide tube
L_00193
X Punch the guide tube (3) out of the caulking with a bolt (diameter = 16
mm) and withdraw it.
NOTE
Version 4
Heavily soiled components of the cleaning line must be replaced with

original parts from ABB Turbo Systems.
Operation Manual
Maintenance
5.2
Page 7
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Installing the cleaning line
L_00194
X After fitting the slide-in modules (E), re-fit the guide tube (3) and re-
Version 4
caulk it.
X Fit the pipe (2) and screw to the injection pipe (1).
Operation Manual
Maintenance
Cleaning the compressor during

operation
5.3
Page 8
These guidelines for wet cleaning apply exclusively for cleaning with
clean water and are subject to permission for the procedure being obtained from the engine manufacturer.
January 2007
5.3 Cleaning the compressor during operation
NOTE
The dirt in the compressor stage (compressor wheel and diffuser) depends on the cleanness of the air drawn in and the operating point.
Oil or saline mist

Solid combustion residues
Dust of various kinds
Soiling of the compressor stage has a negative effect on compressor efficiency and charging pressure, particularly for smaller turbochargers.
This results in higher exhaust temperatures and increased fuel consumption by the engine. Contamination of the compressor also increases the
rotor imbalance.
Periodic cleaning of the compressor in operation prevents or retards a severe increase in soiling, but in no way replaces the regular servicing work,
during which the turbocharger is completely dismantled.
The interval between periodic cleaning depends in large measure on the

operating conditions. In general, cleaning should be carried out every 25
to 100 operating hours.
Should the prescribed cleaning intervals prove incompatible with the
operation of the ship, please contact ABB Turbo Systems.
NOTE
Version 4
Interval between cleanings
HZTL2491_EN (TPL85-B14/-B15/-B16)
A deposit of dirt in the flow ducts will be formed if the following substances
are present in the intake air:
Operation Manual
Maintenance

operation
5.3
Page 9
Cleaning method
January 2007
The compressor is cleaned while operating using the cleaning method described in the following. This method has been tested and is approved by
ABB Turbo Systems:
Wet cleaning
Principle of wet cleaning
Water is injected before the compressor wheel via an injection pipe fitted
in the filter silencer or the suction branch in order to clean the compressor
stage in operation.
Due to the danger of corrosion, only clean water may be used, and on
no account salt water. The water should also contain no cooling additives, which could form deposits in the flow ducts.
CAUTION
Cleaning more than one

turbocharger compressor
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
The water does not act as a solvent in the process, but the deposit is removed by the mechanical impact of the drops. The process is ideal, provided the soiling is not too advanced.
If several turbochargers are installed on one engine, we recommend cleaning the turbocharger compressors one after the other.
Operation Manual
5

operation
5.3
Page 10
5.3.1 Wet cleaning the compressor with external pressurised water container (XC3)
NOTE
The water feed with the externally mounted dosing vessel is only suitable for applications with underpressure upstream of the compressor
wheel (cannot be used for: Blower connected upstream of the compressor or high-pressure compressor stage in the case of two-stage
charging).
January 2007
Maintenance
In order to carry out a successful cleaning procedure that has been

tested and is recommended by ABB Turbo Systems, the following preconditions must be met:
NOTE
Z Engine warm from running (engine under full loading as far as possi-
Version 4
ble)
Z High turbocharger speed
X Cleaning cycle started according to the following description in Procedure for wet cleaning with XC3.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operating state preconditions for cleaning compressors with XC3
Operation Manual
Maintenance

operation
5.3
Page 11
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Procedure for compressor wet cleaning with XC3
L_00198
Operating the pressure

water vessel
Version 4
Screw plug
Valve lever
X The Operating state preconditions for cleaning compressors with XC3

X
X
X
X
X
must be met before cleaning can begin.

Remove the screw plug (X).
Fill the vessel with pure water.
Tighten screw plug (X).
Actuate valve lever (Y) against the spring and hold it for 10 to 15 seconds until all the water has been injected.
After cleaning, a waiting time of at least 5 minutes is necessary to allow
the turbocharger to dry.
Operation Manual
5

operation
5.3
Page 12
If the cleaning operation is unsuccessful, it can be repeated up to 2 times.

NOTE
If cleaning is still unsuccessful after three attempts and the engine operating values are unsatisfactory, we recommend that the turbocharger
be checked and cleaned by an official ABB Turbo Systems service station.
January 2007
Maintenance
Turbocharger type
Turbocharger
speed
Contents of the
dosing vessel
[dm3]
Water injection
time
t1 [s]
TPL 69BA
Possible
nBmax
0.4
4 ... 15
TPL 73-B
TPL 77-B
TPL 80-B
TPL 85-B
Version 4
TPL 91-B
HZTL2491_EN (TPL85-B14/-B15/-B16)
Cleaning parameters for each turbocharger compressor
Operation Manual
Maintenance

operation
5.3
Page 13
January 2007
5.3.2 Wet cleaning compressors with water vessel (XC4)

Operating state preconditions for cleaning compressors with XC4

NOTE
Z Engine warm from running (engine under full loading as far as possi-
HZTL2491_EN (TPL85-B14/-B15/-B16)
ble)
Z High turbocharger speed
X Cleaning cycle started according to the following description in Procedure for wet cleaning with XC4.
Version 4
Procedure for compressor wet cleaning with XC4
L_00197
Cleaning container
2 Pipe
Injection pipe
4 Cleaning instructions
Cover
6 Valve
Operation Manual
5

operation
5.3
Page 14
If the cleaning container on the filter silencer is used, the detailed cleaning instructions provided on the plate (4) fitted to the filter silencer
should be followed.
NOTE
X The Operating state preconditions for cleaning compressors with XC4

X
X
X
X
X
X
must be met before cleaning can begin.

Open filling cap (5) on cleaning container (1).
Fill with clean water.
Screw filling cap (5) back into place.
Open valve (6) for about 3 minutes.
Close valve (6) and check that all the water has been sucked out.
After cleaning, a waiting time of at least 5 minutes with the engine running must be allowed so that the turbocharger can dry.

NOTE
HZTL2491_EN (TPL85-B14/-B15/-B16)
Use of cleaning container
January 2007
Maintenance
Turbocharger type
Turbocharger
speed
Contents of the
dosing vessel
[dm3]
Water injection
time
t1 [s]
TPL 69BA
Possible
nBmax
4 ... 15
TPL 73-B
TPL 77-B
TPL 80-B
TPL 85-B
TPL 91-B
Version 4
Cleaning parameters for each turbocharger compressor
Operation Manual
Maintenance
Cleaning turbine blades and nozzle ring

in operation
5.4
Page 15
January 2007
5.4 Cleaning turbine blades and nozzle ring in

operation
Combustion of heavy fuel oil in diesel engines causes soiling of the turbine blades and nozzle rings of the turbochargers.
Soiling increases with time, so that regular and properly performed cleaning is important to remove the accumulated deposits.
The exhaust gas temperature downstream of the cylinders can rise and
the charging pressure at the air receiver can fall if turbine components become soiled.
Experience in operation has shown that despite periodic cleaning during

operation, it is impossible to dispense with overhauls during which the turbine and nozzle ring are mechanically cleaned. However, if cleaning is
performed correctly and the cleaning system is properly dimensioned, the
intervals between overhauls can be extended.
Wet cleaning interval

Interval for dry cleaning

Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
A soiled turbine also results in rotor unbalance. Severe soiling can lead to
impermissibly high rotor imbalance.
Operation Manual
Maintenance

in operation
5.4
Page 16
Several methods are possible for cleaning the turbine and nozzle ring during operation. The cleaning methods described in the following have been
tested and are recommended by ABB Turbo Systems:
January 2007
Cleaning methods
Wet cleaning
Dry 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.
Due to the danger of corrosion, only clean water may be used, and on
no account salt water. The water should also contain no cooling additives, which could form deposits in the flow ducts.
CAUTION
Principle of dry cleaning
During dry cleaning using dry solid particles in granulate form, the deposit
is removed by the mechanical impact of the grains hitting the surface.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Principle of wet cleaning
Wet and dry cleaning are equally effective. However, it may be useful to
apply both methods together.
Version 4
NOTE
January 2007
Operation Manual
5

in operation
5.4
Page 17
Stabilising and drying time
NOTE
CAUTION
Cleaning more than one

turbocharger turbine
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Maintenance
Cleaning of the turbine-side components begins after engine start or

reduction of engine load. The exhaust temperature must not exceed the
value specified in the corresponding cleaning instructions (see the respective section Operating state preconditions).
Failure to maintain the prescribed exhaust temperature upstream of the

turbine, and to allow the minimum stabilising time before and between
cleaning procedures and the drying time after cleaning in accordance
with the pertinent cleaning instructions will shorten the expected service
life of the components significantly.
If several turbochargers are installed on one engine, we recommend cleaning the turbocharger turbines with nozzle rings one after the other.
Operation Manual
5

in operation
5.4
Page 18
5.4.1 Wet cleaning the turbine and nozzle ring during operation at partial
power
The maximum exhaust gas temperature specified by the engine manufacturer and the TMmax temperature as shown on the turbocharger rating plate
must not be exceeded under any circumstances. During wet cleaning, the
turbine is braked and the turbocharger operates at reduced speed. As a
result, less air is supplied to the engine and the temperature after the engine cylinder and exhaust valve rises.
January 2007
Maintenance

NOTE
Z After the engine has been started or during operation, the engine
Version 4
output must be adjusted until the scavenging air pressure pscav is

within the range of 0.3 0.6 bar (gauge pressure).
Z Wait 10 to 15 minutes (stabilising time), until the exhaust temperature at the turbine inlet is stable and below 430C, the auxiliary
blower must also be operating.
X Cleaning cycle started according to the following description in Procedure for wet cleaning.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operating state precondition for wet cleaning
Operation Manual
Maintenance

in operation
5.4
Page 19
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Procedure for wet cleaning
L_00394
Operating the wet cleaning system
Water supply (fresh water

only) at least 6.0 bar
Drainage line
Regulating valve
Drain cock
Manometer
10
Outflow
Air supply with 3-way-valve
11
Orifice (integrated in turbocharger)
Stainless steel piping
21
Air duct from compressor casing
Other turbochargers
Position 1
Injection pipe
Position 2
Z The Operating state preconditions for wet cleaning must be satisfied
before cleaning is begun.
X Check that the water supply (1) is open and ensured, and also con-
nected to the regulating value (2) in front of the turbocharger.

X Set the shut-off valve (9) of the drain pipe (8) on the gas outlet casing
to Position 1 and check whether exhaust gas escapes.
X Firstly, slowly open the 3-way-valve (4) (if fitted), then the regulating
valve (2) until the manometer (3) shows a pressure of 1 0.2 bar.
Operation Manual
5

in operation
5.4
Page 20
Inject water for 5 minutes at constant engine output.

Check whether the exhaust-gas temperature after the turbine drops.
Close the regulating valve (2) and the 3-way-valve (4).
Set drain cock (9) of the drain pipe (8) on the gas outlet casing to Position 2, in order to keep the drain pipe clean with air from the compressor casing (21).
X The water supply connection (1) to the regulating valve (2) must be
disconnected.
X After cleaning, a waiting time of at least 10 minutes with the engine
running must be allowed so that the turbocharger can dry.
X
X
X
X
January 2007
Maintenance
NOTE
Points to remember when

cleaning
The gas outlet casing must be drained of water via the drain pipe (8)
when cleaning.
The exhaust-gas temperature after the turbocharger falls significantly
Version 4
during cleaning (by 50 to 150C).

Outflow can (but need not) take place through the drain-pipe, depending on the engine load. This outflow might not start for 2 - 3 minutes, or
it may not occur at all.
If draining is not carried out, the turbocharger speed and / or gas inlet
temperature must be monitored closely during the washing operation. If
the load is too low, water can collect in the gas outlet casing. Signs of
this are a sudden fall in the turbocharger speed or very rapid increase
in the gas inlet temperature. In either of these cases, the washing operation must be terminated and the washing cycle begun again with a
lower water pressure or higher engine loading.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation Manual
Maintenance

in operation
5.4
Page 21
January 2007
5.4.2 Integrated dry cleaning of the turbine and nozzle ring during operation
This cleaning method is not suitable for removing thick dirt deposits and
must therefore be carried out more often (see chapter Cleaning turbine
blades and nozzle ring in operation).
NOTE

NOTE
Z High engine output (50 to 100%) and high turbocharger speed.

Z Gas inlet temperature upstream of the turbine must be below 590C.
Otherwise, there is considerable danger that the dry cleaning agent

will be burnt off.
X Start the cleaning cycle with reference to the following description
Operating procedure for integrated dry cleaning device.
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operating state preconditions for integrated dry cleaning device
Operation Manual
Maintenance

in operation
5.4
Page 22
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Operation of integrated dry cleaning device
Container for granulated material
ON/OFF valve
Trap-cover
Safety valve
Compressed air supply [4 to 10

bar]
Combined air valve/pressure

relief valve
Pipe made from stainless steel
Cleaning instructions
The air system must be protected against overpressure (> 10 bar).

CAUTION
Version 4
L_00094
January 2007
Operation Manual
Operation of the dry

cleaning device
Maintenance

in operation
5.4
Z The Operating state preconditions for integrated dry cleaning must be

X
X
X
X
X
X
X
X
X
X
X
HZTL2491_EN (TPL85-B14/-B15/-B16)
Page 23
satisfied before cleaning is begun.

Ensure that the ON/OFF valve (5) is closed.
Check that the combined air valve/pressure relief valve (7) is in the
pressure relief position.
Open the trap-cover (2) carefully.
Fill the container (1) with the prescribed amount of granulate.
Close and seal the trap-cover (2).
Open the air valve (7).
Open the safety valve (6).
Whilst cleaning the turbine, open the ON/OFF valve (5) and leave it
open for approx. 1 minute.
Close the ON/OFF valve (5).
Close the safety valve (6).
Set the combined air valve/pressure relief valve (7) to the pressure relief position.
Check whether the exhaust gas temperature has dropped downstream
of the turbine.
In order to obtain the best possible cleaning effect, it is essential that

the prescribed quantity of granulate is blown in.
NOTE
The drain openings in the gas outlet casing must remain closed while
the turbine is being cleaned. Careless handling can cause incompletely
combusted soot particles to escape.
Version 4

NOTE
Operation Manual
Maintenance

in operation
5.4
Page 24
Selection of materials
January 2007
Cleaning parameters for integrated dry cleaning device
The following materials are suitable for use in dry cleaning:

Hard, granulated materials (such as natural core granulates)
Softblast media
Activated carbon particles
The specific weight of the cleaning granulate must not exceed 1.2 kg/dm3.
Granulate quantity per

turbocharger [litres]
TPL 69BA
TPL 73-B
TPL 77-B
TPL 80-B
TPL 85-B
TPL 91-B
1.0
1.0
1.5
2.0
3.0
3.5
The cleaning granulate must be stored in a dry, clean place in order to

avoid clogging the pipes during cleaning.
The table in chapter Suppliers of dry cleaning agents lists possible suppliers of dry cleaning agents.
Version 4
NOTE
HZTL2491_EN (TPL85-B14/-B15/-B16)
The average grain size of the cleaning granulate must be between 1.2
and 2.0 mm.
Operation Manual
Maintenance

in operation
5.4
Page 25
January 2007
5.4.3 Non-integrated dry cleaning device for the turbine and nozzle ring
during opration
As an alternative to the built-in dry cleaning system, a non-integrated dry
cleaning device can be installed upstream of the gas inlet casing by the
engine manufacturer.

NOTE
Z High engine output (50 to 100%) and high turbocharger speed.

Z Gas inlet temperature upstream of the turbine must be below 590C.
Otherwise, there is considerable danger that the dry cleaning agent

will be burnt off.
X Start the cleaning cycle with reference to the following description
Operating procedure for non-integrated dry cleaning device.
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operating state preconditions for non-integrated dry cleaning device
Operation Manual
Maintenance

in operation
5.4
Page 26
L_00208
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Operation of non-integrated dry cleaning device
January 2007
Operation Manual
Maintenance

in operation
5.4
Page 27
Trap-cover G2
Strap for securing the container
Poss. copper gasket
Safety valve with ventilation
Double nipple G2
Compressed air shut-off valve
Copper gasket
Compressed air pipe

(internal diameter 8mm)
Friction cock or slide controller

G1''
10
Compressed air max. 6 bar
The air system must be protected against overpressure (> 6 bar).
HZTL2491_EN (TPL85-B14/-B15/-B16)
CAUTION
Operation of the dry

cleaning device
Z The Operating state preconditions for non-integrated dry cleaning deZ

X
X
X
X
X
X
Version 4
X
X
X
X
X
X
X
X
X
X
vice must be satisfied before cleaning is begun.

Friction cock or slide controller (5) closed and safety valve with ventilation (7) open.
Close the safety valve with ventilation (7).
Tighten the trap-cover (1).
Open the compressed air shut-off valve (8) so that deposits and any
condensation are blown off.
Close the compressed air shut-off valve (8) again after about 3 minutes.
Close the friction cock / slide controller (5).
Open the safety valve with ventilation (7) to blow out the exhaust gases.
Open the trap-cover (1) on the granulate container carefully.
Fill the granulate container with the prescribed quantity of granulate.
Close and seal the trap-cover (1).
Close the safety valve with ventilation (7).
Open the compressed air shut-off valve (8).
Open the friction cock or slide controller (5) for approx. 1 minute.
Close the friction cock or slide controller (5).
Close the compressed air shut-off valve (8).
Open the safety valve with ventilation (7).
Check whether the exhaust gas temperature has dropped downstream
of the turbine.
Operation Manual
5

in operation
5.4
Page 28
In order to obtain the best possible cleaning effect, it is essential that

the prescribed quantity of granulate is blown in.
NOTE
The drain openings in the gas outlet casing must remain closed while
the turbine is being cleaned. Careless handling can cause incompletely
combusted soot particles to escape.
January 2007
Maintenance
Cleaning parameters for the non-integrated dry cleaning device
The choice of material takes place according to chapter Integrated dry

cleaning of the turbine and nozzle ring during operation.
NOTE
Granulate quantity per

turbocharger
Turbocharger type
Amount of granulate
[dm3]
Container size
TPL 69BA
1.0
II
TPL 73-B
1.0
II
TPL 77-B
1.5
II
TPL 80-B
2.0
II
TPL 85-B
3.0
III
TPL 91-B
3.5
III
Version 4
NOTE
HZTL2491_EN (TPL85-B14/-B15/-B16)
Operation Manual
Maintenance
Suppliers of materials for dry cleaning
5.5
Page 29
Manufacturer
Country
Address
Number for contact
ABB Service
Australia
20 Queen Street
Revesby Sydney
NSW 2212
Tel. +61 2 9795310

Fax. +61 2 9773 8855
Paul Auer GmbH
Germany
Bad Kreuznacher Str. 81

68309 Mannheim-Kfertal
Tel. +49,621,727 69 -0
Fax. +49 621 717 6988
Email: vertrieb@auer-strahltechnik.de
BRIGANTINE
Service Ltd.
Hong Kong
48 Wang Lok Street

Yuen Long Industrial Estate
N.T. Hong Kong
Tel. +852 24737900

Fax. +852 24786657
Email: asibrgcorp@brigantinegroup.com
LEERING HENGELO B.V.
Netherlands
Barnsteenstraat 1
NL-7554 TC Hengelo
The Netherlands
Tel. +31 74 255 8282

Fax. +31 74 242 2373
Email: info@leering.nl
GUYSON
International Ltd.
UK
Snaygill Industrial Estate

Keighley Rd.
Skipton, N Yorks BD 23
2QR
United Kingdom
Tel. +44 1756 799911

Fax. +44 1756 790213
Email: info@guyson.co.uk
DASIC
International Ltd.
UK
Winchester Hill
Romsey SO51 7YD
United Kingdom
Tel. +44 1794 5124198

Fax. +44 1794 522346
Email: info@dasicinter.co.uk
PAN
Abrasives (Pte) Ltd.
Singapore
Pioneer Sector 2
Jurong
628382 Singapore
Tel. +65 6861 6988

Fax. +65 6861 0919
Email: pagroup@pan-abrasives.com
CARLANDER & Co.
Sweden
Valtersang 9
S-442 49 Kungalv
Sweden
Tel. +46 30 363075

Fax. +46 30 363077
Email: lars@carlander.com
BOSUNG Engineering Co., Ltd.
Korea
1189-1, Choryang-3 Dong,

Dong-Ku, Busan, 601-013
Tel. +82 51 466 0881-5

Fax. +82 51 466 0886-9
Email: master@bosung.com
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
5.5 Suppliers of materials for dry cleaning
Operation Manual
Troubleshooting
6.1
6 Troubleshooting
January 2007
6.1 Possible remedies for failures

Exhaust temperature too high
HZTL2491_EN (TPL85-B14/-B15/-B16)
Engine output and speed unchanged
Engine
Z Malfunction in the injection system

X Repair, or contact the manufacturer.
Turbocharger
Z Air starvation, e.g. air filter clogged with dirt

X Clean
Z Compressor / turbine soiled
X Clean
Z Exhaust counterpressure too high
X Clean or repair boiler or exhaust silencer
Z Turbine damaged or worn
X Contact an official ABB Turbo Systems service station.
Charge-air cooler
Z Cooler soiled
X Clean
Z Insufficient coolant water quantity
X Replenish
Version 4
Z Coolant water inlet temperature too hot

X Clean/inspect cooling system
Z Ventilation inadequate
X Improve ventilation
Page 1
Operation Manual
Troubleshooting
6.1
Page 2

Intake condition normal
Engine
January 2007
Charge-air pressure too low
Z Air receiver leaking

X Repair
Z Injection misadjusted
X Correct adjustment
Z Valve control misadjusted
Turbocharger
Z Manometer display faulty

X Replace manometer
Z Leak in line to the manometer
X Repair leak
HZTL2491_EN (TPL85-B14/-B15/-B16)
Z Gas line between engine and turbine leaking

X Repair
Z Air filter dirty, causing excessive loss of pressure

X Clean
Z Compressor / turbine soiled
X Clean
Z Excessive exhaust counterpressure

X Clean boiler or exhaust silencer
Version 4
Z Compressor / turbine damaged

Operation Manual
Troubleshooting
6.1
January 2007
Charge-air pressure too high

Intake condition normal
Engine
Z Malfunction in the injection system

HZTL2491_EN (TPL85-B14/-B15/-B16)
Z Engine output higher than expected

X Check engine output
Z Injection misadjusted
Turbocharger
Z Manometer display faulty

X Replace manometer
Vibrations
Turbocharger
Z
Z
Z
X
Rotor imbalance due to heavy fouling of compressor/turbine

Turbine or compressor damaged
Bearing defective
Contact an official ABB Turbo Systems service station.
Noises during run-out

Turbocharger
Z Turbocharger dirty
X Clean
Version 4
Z
Z
Z
X
Bearing damaged
Rotor grazing
Foreign bodies in the turbocharger
Page 3
Operation Manual
Troubleshooting
6.1
Page 4
Turbocharger
X Clean
Z
Z
Z
X
Bearing damaged
Rotor grazing
January 2007
Run-out time too short
Turbocharger
X Clean
Z
Z
Z
X
Bearing damaged
Rotor grazing
Lubricating oil pressure too low

Engine
Z Oil filter heavily soiled

X Clean
HZTL2491_EN (TPL85-B14/-B15/-B16)
Sluggish start-up
Z Oil pump in the lubricating system defective

X Inspect
Turbocharger
Z Axial clearance of the rotor too big

Version 4
Z Manometer provides false reading

X Replace manometer
Operation Manual
Troubleshooting
6.1
Page 5
January 2007
Constant surging of the turbocharger

Z Exhaust pressure after the turbine elevated because boiler or exhaust
Engine
silencer is dirty
Z Trap dirty
X Clean
Z Charge-air cooler or silencer dirty

Z Heavy deposits of contamination in the turbine
X Clean
If it is not possible to determine the reason for the surging, contact an

official ABB Turbo Systems service station.
NOTE
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Turbocharger
Operation Manual
7.1
Page 1
7 Removal and installation

January 2007
7.1 Turbocharger weights

WARNING
Loads that are not suspended in accordance with the regulations during
disassembly and assembly may fall and can cause serious or even fatal
injury.
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
X Select a suitable rope taking into account the weight of the load.
X Hang rope crossed over on the crane hook
X Do not stand under suspended loads.
L_00082
Operation Manual
7.1
Page 2
Weight [kg]
TPL 85-B
9745
January 2007
Turbocharger complete unit without filter silencer/air suction branch
Turbocharger complete unit with filter silencer

Weight [kg]
TPL 85-B
10700
Weight [kg]
TPL 85-B
Version 4
10035
HZTL2491_EN (TPL85-B14/-B15/-B16)
Turbocharger complete unit with air suction branch
Operation Manual
7.2
Page 3
7.2 Remove the turbocharger

January 2007
X Disconnect all gas, air, and oil lines in accordance with the engine ma-
nufacturers instructions.
NOTE
The two oil supply channels in the bearing casing are fitted with one orifice each. In order to obtain the required oil pressure, the of this orifice has been individually adjusted by the engine builder. Whenever
these orifices are removed, or if the bearing casing or the complete turbocharger is replaced, it is essential to ensure that the orifice with the
correct is fitted into the oil supplying oil-inlet channel.
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
X Check the lifting equipment.

X Secure lifting equipment to the suspension lugs on the bearing casing.
7.2
Operation Manual
7
7.2
Page 4
During removal, a turbocharger that is not lifted in compliance with

regulations may fall, and can cause serious or even fatal injury.
WARNING
X Select a suitable rope taking into account the weight of the turbo-
charger.
X Suspend the complete turbocharger using the two ribs on the bearing casing provided for this purpose.
X The turbocharger must be transported as horizontally as possible.
January 2007
If the support for the turbocharger is missing or defective when setting

aside, the turbocharger may tip over and can cause serious or even fatal injury.
WARNING
Version 4
X Support turbocharger in a suitable location.

X Cover oil connector.
HZTL2491_EN (TPL85-B14/-B15/-B16)
X Release the fixing screws on the foot.

X Lift the turbocharger from the engine and place it aside.
Operation Manual
Installing the turbocharger
7.3
Page 5
January 2007
7.3 Installing the turbocharger

During installation, a turbocharger that is not lifted in compliance with
regulations may fall, and can cause serious or even fatal injury.
WARNING
X Select a suitable rope taking into account the weight of the turbo-
charger.
X Suspend the complete turbocharger using the two ribs on the bearing casing provided for this purpose.
X The turbocharger must be transported as horizontally as possible.
Remove cover from the oil connector.

Check the lifting equipment.
Secure lifting equipment to the suspension lugs on the bearing casing.
Mate turbocharger with the engine.
Tighten the fixing screws on the foot, in accordance with the engine
manufacturer's instructions.
X Secure all gas, air, and oil lines in accordance with the engine manufacturers instructions.
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
X
X
X
X
X
Operation Manual
Module weights
8.1
Page 1
8 Disassembly and assembly

January 2007
8.1 Module weights

WARNING
Loads that are not suspended in accordance with the regulations during
disassembly and assembly may fall and can cause serious or even fatal
injury.
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
X Select a suitable rope taking into account the weight of the load.
X Hang rope crossed over on the crane hook
L_00082
Operation Manual
Module weights
8.1
Page 2
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Modules
Version 4
8.1
Operation Manual
Module weights
8.1
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Weights [kg]
Page 3
Description
TPL 85-B
Air suction branch, radial
290
Filter silencer
955
Compressor casing, internal

part
550
Wall insert
850
Diffuser
225
Compressor casing external

part
1200
Cartridge group
3000
Cover ring
145
Nozzle ring
95
10
Gas inlet casing radial
495
Compressor casing, internal part, complete

Weight [kg]
TPL 85-B
1625
The total weight of the complete internal part of the compressor casing
includes the internal part of the compressor casing, the diffuser and the
wall insert.
Version 4
NOTE
Operation Manual
8
Removing and fitting the filter silencer or 8.2

air suction branch
Page 4
8.2 Removing and fitting the filter silencer or air

suction branch
Not all tools are identified with a part number. The identification of the
tools is ensured with the tools list (included in the toolbox).
January 2007
NOTE
X Remove insulation where necessary.

X Disconnect all air ducts in accordance with the engine manufacturers
L_00011
X Fit safety ring bolt (90231) in the bearing plate (P) on the filter silencer.
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
instructions.
Operation Manual
8
Page 5
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Removing and fitting the filter silencer or 8.2

air suction branch
L_00226
X Mount shackle (90195) on the fin on the filter silencer.
Remove filter silencer
X Sling lifting gear through the loops at the rear and secure to the
Install the filter silencer
X The filter silencer or air suction branch is installed in the reverse se-
shackle (90195) or to the safety ring bolt (90231) with a shackle.

X Release nuts (74027) with Verbus washers (74028) and remove the filter silencer or air suction branch.
quence.
During removal and assembly, turbocharger components that have not

been suspended in compliance with regulations may fall, and can cause
serious or even fatal injury.
WARNING
Operation Manual
Axial clearance
8.3
Page 6
8.3
X Before disassembly and after assembly of the internal part of the com-
pressor casing, as well as of the gas inlet casing (if dismantled), the
axial clearance (A) must be measured.
X Measure and note the axial clearance A.
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
8.3 Axial clearance
If the axial clearance A is out of tolerance, an official ABB Turbo Systems service station must be contacted.
Clearance A [mm]
TPL 85-B
0.54 0.79
Version 4
CAUTION
Operation Manual
Dismantling the internal part of the

compressor casing
8.4
Page 7
January 2007
8.4 Dismantling the internal part of the compressor casing

Not all tools are identified with a part number. The identification of the
tools is ensured with the tools list (included in the toolbox).
NOTE
X Take nuts (90458) from the toolbox and fit them on the threaded pins
of the three safety segments (Y) in the internal part of the compressor
casing (76000).
HZTL2491_EN (TPL85-B14/-B15/-B16)
Position of the safety

segments before disassembly
L_00269
X Tighten nuts (90458) with a maximum torque of 30 Nm.

D The internal part of the compressor casing (76000) is now detached
from the external part of the compressor casing (74000) and can be
removed.
Version 4
Note control dimension (u).

NOTE
Control dimension (u)

[mm]
Dimension
u
TPL 85-B
27.6
Operation Manual

compressor casing
8.4
Page 8
gear.
HZTL2491_EN (TPL85-B14/-B15/-B16)
Dismantling the internal

part of the compressor
casing
January 2007
X Remove 4 studs (74026) in the upper area.

X Hoist the lifting device (90190) using the shackle (90195) and lifting
8.4.2
X
X
X
X
off screws (90900) so far, until the lifting device (90190/90195) can be
fitted.
Fit the lifting device to the internal part of the compressor casing
(76000).
Remove internal part of the compressor casing (76000) with wall insert
and diffuser.
Fit support angle (90025).
Set down internal part of compressor casing (76000) in a horizontal
position.
Version 4
X Press off the internal part of the compressor casing (76000) with press-
Operation Manual
January 2007
If necessary

compressor casing
8.4
Page 9
X Attach two shackles (90195) to the support angle (90025) and fasten a
second lifting gear to the two shackles (90195).

X With lifting device (90190) slightly raise internal part of compressor
casing (76000) with wall insert and diffuser.
X By actuating the second lifting gear bring the internal part of the compressor casing (76000) carefully to the vertical position.
X Rest the casing on shim with flange (F).
Ensure that the shim does not slip.
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
WARNING
X Rest the internal part of the compressor casing only on flange (F).
X Check shim and adjust as necessary.
Operation Manual

compressor casing
8.4
Page 10
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Remove diffuser
X Remove screws (76002).

X Remove diffuser (79000).
X Press off wall insert (77000) with press-off screws (90900) and remove
using ring bolts (90235).

X Remove O-ring gaskets (77005, 77006).
Work that exceeds the scope of the description in this chapter must only be performed by a trained fitter from an official ABB Turbo Systems
service station.
CAUTION
Version 4
8.4
Operation Manual
Dismantling gas inlet casing
8.5
Page 11
8.5 Dismantling gas inlet casing

January 2007
X Remove the insulation on the gas inlet casing (51001).

X Fix lifting gear to the eyes on the gas inlet casing with shackle (90195).
Do not stand under or near the suspended gas inlet casing.
HZTL2491_EN (TPL85-B14/-B15/-B16)
WARNING
L_00022
X Loosen the screws (61044) and remove gas inlet casing (51001) with
Version 4
X
X
X
X
nozzle ring (56001).

Remove screws (56014), bushings (56013) and nozzle ring (56001).
Loosen and remove screws (57005).
Fit two guide studs (90320).
Press off the cover ring (51085) with press-off screws (90320) and remove over the guide bolts (90907).
Work that exceeds the scope of the description in this chapter must only be performed by a trained fitter from an official ABB Turbo Systems
service station.
CAUTION
Operation Manual
Fitting gas inlet casing
8.6
Page 12
X Fit cover ring (51085) with the help of the two guide bolts (90320) and
If removed:
fasten tight with screws (57005).

X Remove guide bolts (90320).
January 2007
8.6 Fitting gas inlet casing
X Mount nozzle ring (56001) on the gas inlet casing (51001) with screws
(56014) and bushings (56013).
Smear all screws in and on the gas casings with Anti Scuff Paste 868
from SPANJAARD.
X Fit gas inlet casing (51001) with nozzle ring onto the gas outlet casing
(61044) with screws (61009).

X Remove lifting gear with shackle (90195).
Version 4
X Fit the insulation on the gas inlet casing (51001).
HZTL2491_EN (TPL85-B14/-B15/-B16)
NOTE
Fitting the internal part of the

compressor casing
8.7
Page 13
8.7 Fitting the internal part of the compressor

casing
Fitting the diffuser
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Operation Manual
Version 4
8.4
X Seat O-ring gaskets (77005, 77006) on the wall insert (77000).

X Mount wall insert (77000) and diffuser (79000) in the internal part of the
compressor casing (76000).

X Tighten the screws (76002), then loosen again by -turn.
X Secure the lifting gear to the lifting device (90190) and to the shackles
(90195) of the support bracket (90025).
X Lift internal part of compressor casing (76000) with wall insert and diffuser using two hoists.
Operation Manual

compressor casing
8.7
Page 14
through this bring the internal part of the compressor casing (76000) to
a horizontal position.
X Remove support bracket (90025) with shackle (90195).
HZTL2491_EN (TPL85-B14/-B15/-B16)
Fitting the internal part of

the compressor casing
January 2007
X Carefully slacken the lifting gear on the support bracket (90025) and
8.4.2
X Seat O-ring gasket (76040) to the internal part of the compressor cas-
insert and diffuser over the guide bolts (90320) into the external part of
the compressor casing (74000).
X Remove the lifting device (90190/90195).
X Insert the internal part of the compressor casing as far as it will go.
X Remove guide bolts (90320) and fit studs (74026).
Version 4
ing (76000).
X Fit guide bolts (90320).

X Carefully insert internal part of the compressor casing (76000) with wall
Operation Manual

compressor casing
8.7
Page 15
X Release the nuts (90458) on the threaded pins of the three safety
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
segments (Y) on the internal part of the compressor casing (76000).
D The internal part of the compressor casing (76000) is now secured a-
gainst the external part of the compressor casing (74000).
Position of the safety

segments after assembly
L_00276
Note control dimension (s). Safety segments (Y) are in an operating

state again.
NOTE
Control dimension (s)

[mm]
Dimension
TPL 85-B
18.5
X Replace the nuts (90458) back in the toolbox.
X Measure and note the axial clearance A.
Version 4
If the axial clearance A is out of tolerance, an official ABB Turbo Systems service station must be contacted.
CAUTION
Clearance A [mm]
TPL 85-B
0.54 0.79
Operation Manual
8

compressor casing
8.7
Page 16
and Verbus washers (76028) (see section Removing and installing the
filter silencer or air suction branch).
X Connect all air lines in accordance with the engine manufacturers instructions.
X Install all insulation that has been removed.
January 2007
X Fit the filter silencer or air suction branch and secure with nuts (76027)
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
Install the filter silencer
Operation Manual
8.8
Page 17
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
8.8 Table of tightening torques
L_00059
Version 4
The following tightening torques must be maintained for the specified

screwed connections:
Operation Manual
8.8
Tightening torque [Nm]
1)
Page 18
Part number
TPL 85-B
42059, 42064
M12
110
56014
M16
160
57005
M16
160
61044
M24
480
74026
M24
80
74027
M24
300
76002
M20
- 1)
82005
M16 x 1.5
50
86505
M22 x 1.5
220
90458
M12
30
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
Tighten so that the diffuser can still be moved.
Version 4
86505
L_00228
Operation Manual
Possibilities for emergency repair
9.1
Page 1
9 Taking out of operation temporarily

January 2007
9.1 Possibilities for emergency repair

Lubricating oil leaks are a fire hazard.
WARNING
The instructions of the engine manufacturer for operation of the engine

with locked / isolated turbocharger must be followed precisely in all cases!
HZTL2491_EN (TPL85-B14/-B15/-B16)
CAUTION
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:
Lock the turbocharger rotor
Those emergency repairs that can be performed fastest are to be performed first.
Version 4
NOTE
Operation Manual
Locking the rotor
9.2
Page 2
A locked rotor must be disassembled following turbocharger repair and

given an imbalance check.
January 2007
9.2 Locking the rotor
CAUTION
NOTE
The only exceptions are test rig runs up to a maximum of 25% engine
load on new engines with one or a number of turbochargers, which are
requested by some customers. Since in these cases operation with a
locked rotor is brief and the loads are small, subsequent disassembly of
the rotor is unnecessary.
NOTE
CAUTION
Various intermediate rings are provided with the locking device for different compressor wheels. The compressor wheel type CV (for the
balancing screw holes) must be noted. The space between the locking
flange (94003) and the assembly-disassembly device (90020) must be
compensated by the intermediate rings (94001 and/or 94002) depending on the version of compressor wheel.
During operation of the engine with a locked turbocharger, the lubrication oil system must also remain connected to this turbocharger and turned on if the gas inlet cannot be blocked (see section Further measures
and information for operation with a locked rotor for 2-stroke engines).
Otherwise components that are still intact can be damaged by overheating.
HZTL2491_EN (TPL85-B14/-B15/-B16)
U Once unscrewed, balancing screws must not be screwed in again.
Version 4
The supply of lubricating oil to the turbocharger must be shut off in the
event of a lubricating oil leak on the turbocharger.
Operation Manual
Locking the rotor
9.2
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Locking rotor with polygon connection
Version 4
L_00261
Page 3
Operation Manual
9
Locking the rotor
9.2
Page 4
These operations must be carried out as described in the chapter Disassembly and assembly.
NOTE
X Remove the filter silencer or air suction branch and the compressor
January 2007
casing internal part together with the wall insert and the diffuser.
X Fix partition wall with press-off tools (90920).
Fit locking flange (94003) to the compressor wheel with at least 9

screws (94007 or 94008) (refer to Table of tightening torques).
Table of tightening torques [Nm]
Part number
TPL85-B
94006
M12
75
94007 / 94008
M12
60
X Fit the locking flange (94003) with screws (94007 or 94008, using the
Version 4
longest possible screws) as well as the adjustment ring (94004) and intermediate ring (94031).
HZTL2491_EN (TPL85-B14/-B15/-B16)
CAUTION
Operation Manual
Locking the rotor
9.2
Page 5
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Compressor type CV11
94000_15
Version 4
It must be ensured that all components are clean and free from grease.
CAUTION
X Push correct intermediate rings (94001 and/or 94002) on to the locking
flange (94003).
X Fit assembly-disassembly device (90020) in each case with 2 washers
(94032).
X Insert the remaining intermediate rings (94001 and/or 94002) and
mount the locking flange (94003) with screws (94006).
Operation Manual
Locking the rotor
9.2
Page 6
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
Compressor type CV12, CV13
94000_012
It must be ensured that all components are clean and free from grease.
CAUTION
flange (94003).
X Fit assembly-disassembly device (90020) in each case with 2 washers
(94032).
X Insert the remaining intermediate rings (94001 and/or 94002) and
mount the locking flange (94003) with screws (94006).
Version 4
X Push correct intermediate rings (94001 and/or 94002) on to the locking
Operation Manual
Locking the rotor
9.2
Page 7
January 2007
Further measures and information for operation with a locked rotor for 2stroke engines
2-stroke engine with one
turbocharger:
No further measures are necessary. The engine can be operated with the
auxiliary blower according to the instructions of the manufacturer.
9 The lubrication oil system must remain connected and turned on.
HZTL2491_EN (TPL85-B14/-B15/-B16)
2-stroke engine with several turbochargers:
X The compensator at the compressor outlet must be dismantled and the
air duct blocked at the engine end, as undamaged turbochargers develop a receiver pressure.
X The operating limit of the engine can be raised by additionally blocking
the gas inlet, as the exhaust gas is then used to drive the undamaged
turbocharger. The loading and temperature of the locked rotor are also
reduced.
If the gas inlet cannot be blocked, the following operating limits must be
observed:
The pressure in the charge-air receiver must not exceed 1 bar over-
pressure.
Max. permissible engine load: 50%.
Attention must be paid to the speed of the undamaged turbochargers in

all cases. The rotating speed limit nBmax according to the turbocharger
rating plate must not be exceeded.
Version 4
CAUTION
Operation Manual
9.3
Page 8
Shut off the supply of lubricating oil to the turbocharger.

CAUTION
January 2007
9.3 Blocking the inlets and outlets
X Block the compressor casing outlet, gas inlet and gas outlet by fitting
cover plates.
For information about how to do this, see the manufacturer's instructions.
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
NOTE
Operation Manual
9.4
Page 9
January 2007
9.4 Bypass the turbocharger

Shut off the supply of lubricating oil to the turbocharger.
CAUTION
Z For engines with one turbocharger only:

Z The connections are ready and pipes for the bypass are to hand.
X Fit the bypass around the turbocharger.
NOTE
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
For information about how to do this, see the manufacturer's instructions.
Operation Manual
10
Taking out of operation for up to 12

months
10.1
Page 1
January 2007
10 Mothballing the turbocharger

10.1 Taking out of operation for up to 12 months
If a turbocharger has to be laid up for up to 12 months, the decision
whether the turbocharger needs special protection or not depends mainly
on the condition of the lubricating oil before laying up.
If the Total Acid Number (TAN) is lower than 2 mg KOH/g no special
measures need to be taken. However, if the neutralisation factor is higher
the turbocharger must be dismantled after laying up, cleaned and protective oil must be applied to the naked parts.
HZTL2491_EN (TPL85-B14/-B15/-B16)
If the turbocharger is left mounted on the engine, and the engine oil is replaced by a protective oil which is circulated with a pre-lubrication pump
prior to laying up, no measures need to be taken in respect of the turbocharger. The remains of the old engine oil will be washed away and the
sensitive bearing parts will be largely protected against corrosion.
Version 4
If the rotor turns due to a draught from the flue, fit a blind flange between
the compressor casing and the charge-air duct.
Operation Manual
10
Taking out of operation for more than 12 10.2

months
Page 2
10.2 Taking out of operation for more than 12

months
If the turbocharger has to be removed from the engine and stored for a
prolonged period of time, disassembly and mothballing of the turbocharger must be done by an official ABB Turbo Systems service station.
January 2007
Ensure that the storage area is dry with humidity of 40-70% and free of
condensation.
Check mothballed turbochargers yearly for corrosion.
In the event of rust, clean and renew the corrosion protection.
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
NOTE
Operation Manual
11
11.1
Page 1
January 2007
11 Reserve and spare parts

11.1 Ordering spare parts
When making inquiries or ordering spare parts, the following data should
be specified:
Turbocharger type
HT number
Description and part number
Our service stations and agents accept orders for spare parts.
X If special variants/cases are not addressed in these general instruc-
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
tions, contact an official ABB Turbo Systems Ltd. service station or an

ABB agent.
Operation Manual
11
11.1
Page 2
NOTE
Spare parts set (97070)
Quantity
Description
Part number
O-ring gasket
42012, 76040
Gasket
42041, 42069
12
Hexagon head screw
42059, 42064
Gasket
42045
Hexagon head screw
56014, 57005
Hexagon nut
61037
Gasket
61041
O-ring gasket
77005, 77006
O-ring gasket
86506
All spare parts that were ordered with the turbocharger should be kept
as a complete set and ready for use.
CAUTION
HZTL2491_EN (TPL85-B14/-B15/-B16)
To carry out the work described in this manual, you need a set of spare
parts (97070). These spare parts in this set are available only as a
complete set.
January 2007
Spare-parts set
X Parts showing signs of rust should be carefully cleaned and greased.

X Dispose of parts, which have been replaced and are no longer usable,
Version 4
in a proper and environmentally compatible manner.
Operation Manual
11
11.2
Page 3
The following part numbers and descriptions must be used in ALL correspondence or orders:
Turbocharger
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
11.2 Directory of part numbers
Part number
Description
Cartridge group
51001
Gas inlet casing
51085
Cover ring
56001
Nozzle ring
61001
Gas outlet casing
61035
Hexagon head screw
61037 (in spare parts set)
Hexagon nut
68000
Foot
74000
Compressor casing external part
76000
Compressor casing, internal part
O-ring gasket
76080
Safety segment
77000
Wall insert
O-ring gasket
O-ring gasket
79000
Diffuser
81000
Filter silencer
82000
Air suction branch, radial
Operation Manual
11.2
Part number
Description
21000
Shaft
25000
Compressor wheel
25008
Threaded pin
25009
Ring nut
32001
Thrust bearing
32101
Radial bearing, compressor end
32102
Radial bearing, turbine end
32104
Auxiliary bearing
32105
Floating disc
32106
Axial bearing
42001
Bearing casing
42002
Hood
42011
O-ring gasket
O-ring gasket
42015
Sealing cover
Gasket
Gasket
Hexagon head screw
Hexagon head screw
42295
Non-return valve
43001
Partition wall
43005
O-ring gasket
86505
Speed sensor
O-ring gasket
Page 4
January 2007
HZTL2491_EN (TPL85-B14/-B15/-B16)
11
Version 4
Cartridge group - polygon

connection
Operation Manual
11
General view of turbocharger
11.3
Version 4
HZTL2491_EN (TPL85-B14/-B15/-B16)
January 2007
11.3 General view of turbocharger
11.3_page1
Page 5
L_00906
43005
42012
42059
86505
January 2007
11.4
86506
42064
42295
General view of cartridge group
HZTL2491_EN (TPL85-B14/-B15/-B16)
42041
42001
42002
21000
11
Version 4
25000
43001
32001
25008
42011
25009
32104
32101
32106
32105
42045
32102
42015
Operation Manual
Page 6
11.4 General view of cartridge group

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Operation Manual

Purpose of the manual

Layout and function

Correct use of the turbocharger

Abbreviations and symbols

Turbocharger rating plate

Basic safety instructions

General safety instructions

Special safety instructions

Safety instructions and hazard protection

Warnings on the turbocharger

Putting into operation after laying up

Contact with rotating parts

Shutting the engine down

Cleaning the filter silencer

Cleaning the compressor during operation

Cleaning turbine blades and nozzle ring in operation

Suppliers of materials for dry cleaning

ABB Turbo Systems Ltd

Possible remedies for failures

Removal and installation

Remove the turbocharger

Installing the turbocharger

Disassembly and assembly

Removing and fitting the filter silencer or air suction branch

Dismantling the internal part of the compressor casing

Dismantling gas inlet casing

Fitting gas inlet casing

Fitting the internal part of the compressor casing

Table of tightening torques

Taking out of operation temporarily

Possibilities for emergency repair

Locking the rotor

Blocking the inlets and outlets

Bypass the turbocharger

Mothballing the turbocharger

Taking out of operation for up to 12 months

Taking out of operation for more than 12 months

Reserve and spare parts

Ordering spare parts

Directory of part numbers

General view of turbocharger

General view of cartridge group

ABB Turbo Systems Ltd

Purpose of the manual

1.1 Purpose of the manual

Content of operation manual

This operation manual includes helpful information on the following topics:

the turbocharger's service life.

This operation manual is a complement to, and an extension of, existing

The instructions included in this operation manual must be followed under

This applies especially to the general and special safety instructions

ABB Turbo Systems Ltd

Layout and function

1.2 Layout and function

Radial plain bearing

Radial plain bearing

Gas outlet casing

Gas inlet casing

Air outlet casing

ABB Turbo Systems Ltd

Layout and function

These are both are mounted on a common shaft.