Operation Manual: TPL65VA33

Operation Manual
TPL65VA33
ABB Turbo Systems Ltd

CH 5401 Baden
Type TPL65VA33 HT564931

n Mmax 503 t Mmax 650
1/s °C
n Bmax 486 t Bmax 620
01210 kg 35 50 50
Application according to
Year 2016 the Operation Manual
made in Switzerland
Original Operation Manual
HZTL2464 English
ABB Turbocharging

Operating condition and replacement intervals
The operational limits for the turbocharger nBmax, tBmax, nMmax, tMmax, inspection- and replacement intervals for the compon-
ents concerned on the rating plate are valid for the operational mode and compressor inlet condition, which has been agreed upon
between the engine builder and ABB.
Note: Replacement intervals of components depends on the load profile, turbine inlet temperature, suction air temperature and
turbocharger speed. In case the operation conditions differs significantly from what is considered to be normal for the cur-
rent application, it is recommended to contact ABB for a re-calculation of replacement intervals. Frequent load alterations,
high temperatures and high speed lower the life of components.
Unless otherwise agreed, the application limits nMmax, tMmax are valid for the test operation for a limited time.
Operation Manual / TPL65VA32/33
Table of contents Page 1
Table of contents
September 2015
1 Preliminary remarks
1.1 Purpose of this manual
1.2 Layout and function
1.3 Intended use of the turbocharger
1.4 Storage of new turbochargers and spare parts
1.5 Essential information
1.6 Symbols and definitions
1.7 Turbocharger rating plate
1.8 Contact information
2 Safety
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2.1 Introduction
2.2 CE conformity
2.3 Definition of mandatory signs
2.4 Definition of Safety instructions
2.5 Warning plates on the turbocharger
2.6 Safe operation and maintenance
2.7 Hazards during operation and maintenance
2.8 Periodic checking of the pressure vessel
2.9 Lifting loads
3 Commissioning
3.1 Oil supply
3.2 Inspection work
3.3 Commissioning after taking out of operation
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4 Operation
4.1 Noise emissions
4.2 Servicing work
4.3 Replacement intervals for turbocharger components
4.4 Speed measurement
4.5 Emergency operation TPL..VA
4.6 Stopping the engine
© Copyright 2015 ABB. All rights reserved.

5 Maintenance
5.1 Foreword to Maintenance
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5.2 Cleaning the filter silencer
5.3 Cleaning the compressor during operation
5.4 Cleaning turbines and guide vanes during operation
6 Troubleshooting
6.1 Malfunctions when starting
6.2 Surging of the turbocharger
6.3 Malfunctions during operation
6.4 Malfunctions when stopping
6.5 Speed measurement system
6.6 Variable Turbine Geometry
7 Removal and installation

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

8.1 Introduction
8.2 Module weights
8.3 Removing and fitting filter silencer or air suction branch
8.4 Axial clearance
8.5 Removing cartridge group
8.6 Removing and fitting turbine diffuser
8.7 Removing variable turbine geometry module with gas inlet casing
Fitting the variable turbine geometry module and the gas inlet
8.8
casing
8.9 Installing cartridge group
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8.10 Table of tightening torques
9 Taking out of operation at short notice

9.1 Possibilities for emergency repair
9.2 Fitting the cover plate
9.3 Blocking the inlets and outlets
9.4 Turbocharger bypass
10 Mothballing the turbocharger

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

10.2 Taking the engine out of operation for more than 12 months
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11 Disposing of turbocharger components
12 Spare parts
12.1 Ordering spare parts
12.2 View of turbocharger with part numbers
12.3 View of cartridge group with part numbers
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Preliminary remarks 1
Purpose of this manual 1.1 Page 5
1 Preliminary remarks
September 2015
1.1
1.1 Purpose of this manual
This operation manual belongs to the turbocharger with the identical HT

number (01), see the cover sheet of the operation manual and the
turbocharger rating plate.
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Operation Manual
This Operation Manual enables you to familiarize yourself with the

turbocharger supplied by ABB Turbo Systems and to use it as intended.
It provides important information in order that the turbocharger can be

operated safely, correctly and efficiently.
This Operation Manual complements and expands existing national

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

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

Layout and function 1.2 Page 6
1.2
1.2 Layout and function
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01 Filter silencer 08 Nozzle ring
02 Radial plain bearing 09 Turbine wheel
03 Thrust bearing 10 Bearing casing
04 Bearing bush 11 Diffuser
05 Radial plain bearing 12 Compressor wheel
06 Gas outlet casing 13 Air outlet casing
07 Gas inlet casing
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Mode of operation
The turbocharger is a turbomachine and consists of the following main

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components:
 Turbine
 Compressor
These are both mounted on a common shaft.
The exhaust gases from the diesel engine flow through the gas inlet
casing (07) and nozzle ring (08) to the turbine wheel.
The turbine wheel (09) uses the energy contained in the exhaust gas to
drive the compressor wheel (12). The compressor then draws in fresh air
and forces precompressed air into the cylinders.
The exhaust gases escape to free air through an exhaust gas pipe which
is connected to the gas outlet casing (06).
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The air which is necessary for operation of the diesel engine and is
compressed in the turbocharger is drawn through the suction branch or
the filter silencer (01) into the compressor wheel (12). It then passes
through the diffuser (11) and leaves the turbocharger through the air outlet
casing (13).
The rotor runs in two radial plain bearings (02/05). One plain bearing is in
the bearing bush (04), and the second one is in the axial thrust bearing
(03) at the compressor end.
The plain bearings are connected to a central lubricating oil duct which is
fed with oil from the engine's lubricating oil circuit. The oil outlet is always
at the lowest point of the bearing casing (10).
Turbocharger version with compressor wheel cooling system
Depending on its range of use, the turbocharger is

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provided with a compressor wheel cooling system.

Compressor wheel cooling means that, after the charge air
cooler at the engine end, cooled compressor air is
delivered to the turbocharger to cool the compressor
wheel.
In view of the respective operating conditions, it is
absolutely essential that the compressor wheel is cooled in
order to guarantee its reliability and replacement intervals.
In the case of the turbocharger version with compressor
wheel cooling, the cooling air is supplied through the side
connection (15) in the bearing casing.

Additional function TPL..V.
These turbocharger types have adjustable guide vanes at the turbine end
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instead of a nozzle ring.
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Intended use of the turbocharger 1.3 Page 9
1.3
1.3 Intended use of the turbocharger
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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.
NOTICE The engine builder has provided ABB Turbo Systems with information
regarding the intended use of the engine, from which the operating
limits specific to the turbocharger shown on the rating plate (such as
operating speeds, temperatures, exchange intervals / replacement
intervals) have been derived.
If it is used in conjunction with a gas engine, the engine must not be
installed in a potentially explosive environment, and precautionary
measures must be taken to ensure that the machine room as a whole is
classified as not potentially explosive.
Any other use will be regarded as a special application which must first
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 warranty claims.
State of the art This turbocharger was built according to state-of-the-art technology and is
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operationally safe according to recognised 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.
WARNING  The machine may be operated only by trained personnel.
Use of the turbocharger as intended also includes observance of the

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

immediately.
The manufacturer accepts no liability for any damage resulting from

unauthorised alterations to the turbocharger.

Storage of new turbochargers and 1.4 Page 10

spare parts
1.4
1.4 Storage of new turbochargers and spare parts
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Storage of new turbochargers and spare parts up to 6 months
New turbochargers and spare parts from ABB Turbo Systems can be
stored in sealed packaging without additional mothballing measures for up
to 6 months from the date of delivery (marked by the VCI label on the
package).
Volatile Corrosion Inhibitor (VCI)
Only dry rooms in which the relative humidity is between 40…70 % and
no condensation can form are suitable for storage.
Storage of new turbochargers and spare parts for more than 6 months (VCI)
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Protection of health when handling VCIs
VCI products are not hazardous in the sense of the Hazardous
Substances Ordinance. Nevertheless, the following points are to be
WARNING
observed when handling VCIs:
 Ensure good room ventilation.
 Do not eat, drink or keep food at the workplace while working with
VCIs.
 Wear safety gloves.
 Clean hands and face after working with VCIs.
 For further information refer to www.branopac.com.
Wear safety gloves against chemical risks.
The following mothballing measures are required every 6 months:

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 Open the package.

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

Storage of new turbochargers and 1.4 Page 11

spare parts
Long-term storage of replacement turbochargers or spare parts
Per order, turbochargers or cartridge groups will be prepared by ABB

September 2015
Turbo Systems for prolonged storage. The package is equipped with a

hygrometer (see illustration).
The following measures are required every 6 months:
 Check the hygrometer (02) in the sight-glass. There is an opening (01)

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

ABB Turbocharging Service Station:
 Inspect the components

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

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

of the package must have the same temperature during unpacking.

Essential information 1.5 Page 12
1.5
1.5 Essential information
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Organisational measures
In addition to this manual, the general, statutory regulations applicable in

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

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

with the turbocharger must be checked regularly with reference to this
manual.
NOTICE
 The turbocharger must be shut down immediately by stopping the
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engine in the event of alterations affecting safety or of corresponding
operating behaviour. The fault must be reported to the person or
department responsible.
Additions and alterations to, and conversions of the turbocharger that

could compromise safety require the prior approval of ABB Turbo
Systems.
NOTICE
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Original parts and safety
Original parts and accessories are specially designed for the turbocharger
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supplied by ABB Turbo Systems.
Use original parts

Operation of the turbocharger with non-original parts can impair the
safety of the turbocharger and can cause serious damage to property
WARNING
and injury to personnel.
 Only use original parts from ABB Turbo Systems.
ABB Turbo Systems accepts no liability for any damage resulting from the
use of non-original parts and corresponding accessories.
Competence of personnel
The turbocharger must only be operated and serviced by trained and

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authorised personnel. Basic mechanical training is a prerequisite.

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Design variants
This document is valid for different design variants of turbochargers.
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There may be sections and descriptions of components that are not
relevant for a specific turbocharger variant.
ABB Turbocharging Service Stations will be happy to provide information

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

The trademarks are marked with ®.
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Symbols and definitions 1.6 Page 15
1.6
1.6 Symbols and definitions
September 2015
The following symbols are used in the documents:
 Prerequisite
 Work step
 Enumeration, first level
- Enumeration, second level
Definition of notes
Note
A note provides suggestions which facilitate the work on the product.
NOTICE
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Definition of mandatory signs
Mandatory signs show the protective equipment to be worn for a task. The
mandatory signs are described in chapter Safety and must be complied
with.
Definition of caution / warning
The caution and warning signs are described in the chapter Safety.
ABB Turbo Systems
In this document, ABB Turbo Systems Ltd is abbreviated to ABB Turbo

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

Turbocharging Service Stations. They are inspected and certified regularly
by ABB Turbo Systems. See also chapter Contact information [➙ 18].

Turbocharger rating plate 1.7 Page 16
1.7
1.7 Turbocharger rating plate
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Operating limits
01 Turbocharger operating limits at engine overload (110%).
Only when operating in the test rig unless otherwise agreed with the
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enginebuilder.
02 Turbocharger operating limits during operation
Recommended
03 Replacement interval for plain bearings in 1000 h
replacement intervals for
turbocharger components 04 Replacement interval for compressor in 1000 h
05 Replacement interval for turbine in 1000 h
Further information
06 Part number for customer
07 Designation of special design
08 Turbocharger weight in kg
09 Turbocharger type
10 Serial number
11 Year of turbocharger construction
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Turbocharger rating plate 1.7 Page 17
1.7.1 Explanation of the rating plate

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The recommended replacement intervals and the corresponding

operational limits are jointly defined with the engine manufacturer. This
information is specific to the system.
Operation above the indicated values nBmax, tBmax can considerably shorten the
recommended replacement intervals. In such cases, we recommend that you
contact the nearest official ABB Turbocharging service station.
nMmaxand tMmax normally apply only when running at overload (110%) during
trials on the engine test bed. These limits can also be permitted during operation
for special applications. Operation above nMmax and tMmax is not permitted.
Non-observance of the recommended replacement intervals can increase the
risk of unpredictable component failures.
1.7.2 Positions of the rating plates
A rating plate is attached to the turbocharger foot, one on the left and one
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on the right. In the case of turbochargers with insulation supplied by ABB

Turbo Systems, at least one additional rating plate is attached to the
insulation of the gas outlet casing.
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Contact information 1.8 Page 18
1.8
1.8 Contact information
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Contact information
Contact information for the official service stations of ABB Turbo Systems
is available online.
 Scan the QR code to access our website.
ABB Turbo Systems AG

Bruggerstrasse 71a
CH-5401 Baden
Switzerland
www.abb.com/turbocharging
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Safety 2
Introduction 2.1 Page 19
2 Safety
September 2015
2.1
2.1 Introduction
Turbochargers manufactured by ABB Turbo Systems are state of the art
and comply with the pertinent safety and health-protection requirements
that applied when the turbocharger was manufactured. Consequently, the
turbocharger is safe to operate. Nevertheless, during turbocharger
operation and when working on the turbocharger, residual risks can exist
which:
 originate from the turbocharger itself and its accessories

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

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organisational measures which regulate the safe handling of the

turbocharger by his personnel.
All instructions in this chapter must be observed to ensure safe and

trouble-free turbocharger operation and during work on the turbocharger.
In the same vein, all other specially marked safety instructions in every
chapter of this manual must be observed (see the section entitled
Definition of safety instructions).
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Safety 2
CE conformity 2.2 Page 20
2.2
2.2 CE conformity
September 2015
Information
ABB turbochargers fulfil Directive 2006/42/EC on machinery and are

considered partly completed machinery in the sense of Article 2 g.
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Safety 2
Definition of mandatory signs 2.3 Page 21
2.3
2.3 Definition of mandatory signs
To be worn at all times
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Protective clothing Safety footwear against

mechanical hazards
To be worn according to the specific work

Safety glasses Safety goggles
Safety gloves against Respiratory mask against

- mechanical hazards - dust
- chemical hazards - gases
- heat hazards
Safety helmet Ear protection
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Safety 2
Definition of Safety instructions 2.4 Page 22
2.4
2.4 Definition of Safety instructions
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The following symbols and terms used in this manual concern safety or
refer to possible hazards:
Definition of warning
Serious personal injuries and even accidents with fatal consequences
may occur if work and operating instructions marked with this symbol
WARNING
and the word WARNING are either not followed or not followed
precisely.
 Warning signs must be observed at all times.
Definition of caution
Serious machine or property damage may occur if work and operating
instructions marked with this symbol and the word CAUTION are either
CAUTION
not followed or not followed precisely.
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 Caution signs must be observed at all times.
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Safety 2
Warning plates on the turbocharger 2.5 Page 23
2.5
2.5 Warning plates on the turbocharger
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Warnings that have been attached to turbochargers by ABB Turbo

Systems must not be removed. Illegible warnings must be replaced with
new ones. Further information is available from ABB Turbocharging
service stations.
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Part number Size [mm] Product

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

warning plates must be subsequently attached to the insulation. This is
the responsibility of the engine builder.
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Safety 2
Safe operation and maintenance 2.6 Page 24
2.6
2.6 Safe operation and maintenance
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The instructions specified in this section are for the safety of personnel.
Together with the instructions in the Hazards during operation and
maintenance section, they allow the user to safely use the turbocharger.
Work safety and work area safety
Risk of falling
There is the risk that someone can fall when working on the
turbocharger.
WARNING
 Do not climb on the turbocharger or on parts attached to it or use
these as climbing aids.
 When working at levels above the head, use climbing aids and work
platforms suitable for this purpose.
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 Observe all general regulations for the prevention of accidents.
 Do not work on the turbocharger if you are under physical or mental
stress.
 Work only with suitable tools as well as equipment and working
materials that are in perfect condition.
 Electric tools must be solidly earthed, and connecting cables may not
be damaged.
 Keep the workplace clean, clear away loose objects and remove
obstacles on the floor.
 Keep the floor, equipment and the turbocharger clean.
 Have oil binding materials ready at hand and keep oil catch pans
ready or in position
 Eliminate leaks.
 Keep fire-protection materials and fire-extinguishing equipment ready.
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Welding work
 If welding work is being carried out above the turbocharger, make sure
to cover the filter silencer so that the filter mat is not damaged.
 Remove combustible objects and substances out of the range of flying
sparks.
 Cover all connections on the turbocharger so that no foreign objects
can get into the turbocharger.

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

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 Remove any obstacles and objects lying around.

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

case, the safety instructions of the Hazard due to operating materials and
supplies section in this chapter must always be observed.
 Protect the floor against unintentional penetration of detergents or

solvents before starting cleaning operations.
 Wear appropriate protective clothing.
 Inspect the electric cables for abrasion and damaged areas before and
after your cleaning work.
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Safety 2
Safety during disassembly, assembly, maintenance and troubleshooting
 Always perform the specified adjustments, servicing as well as
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inspection work and observe inspection intervals.
 Inform operating personnel about all service and repair work before
beginning.
 Before opening a cover or removing a protective device on a
turbocharger, the engine must be switched off and the turbocharger
must have come to a standstill.
 Ensure that the supply of oil is interrupted, especially with an external
oil supply.
 Put the engine into operation only after all parts have been refitted
properly.
Mechanical work on the turbocharger

Possible damage to or destruction of components on the turbocharger.
CAUTION  Perform only those tasks that are described in this manual.
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 Perform work only for which training has been carried out.
Safety when taking out of operation or mothballing
 Secure the rotor so it cannot turn. The rotor can turn on its own from
the force of the stack draught.
 Clean the turbocharger before mothballing it.
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Safety 2
Hazards during operation and 2.7 Page 27

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

turbocharger if it has been installed properly.
Risk of injury
Contact with rotating parts can lead to serious injuries. The
turbocharger must never be operated without a filter silencer or an air
WARNING
suction branch. When the engine is at a standstill, the rotor can turn on
its own because of stack draught.
 Operate the turbocharger in accordance with instructions.
 During maintenance work, secure the rotor against unintentional
rotation.
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Mechanical hazards when working on the turbocharger
During maintenance work, various risks can occur through the improper
handling of components, through the non-observance of work instructions,
due to inadequate care or as a consequence of insufficient training.
Mechanical hazards
Serious personal injuries or accidents with fatal consequences can
occur through mechanical influences as a result of risky, improper
WARNING
working methods.
 Heed the general rules for work safety and accident prevention.
 Ensure the safety of the work area.
 Perform only those tasks that are described in this manual.
 Perform work only for which training has been carried out.
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Safety 2

maintenance
Hazards due to noise
The development of noise during operation is influenced by the installation
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and operating conditions. Noise with a sound pressure level exceeding
85 dB(A) is harmful.

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

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Safety 2

maintenance
Hot surfaces on uninsulated turbochargers

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

depending on the order from the engine builder. In this case, the engine
builder is responsible for insulating the turbocharger properly or for
providing protection against hot surfaces being touched.
 The engine builder's instructions and specifications about protection
against hot turbocharger surfaces must be observed in every case.
Hazards due to operating and auxiliary materials
Operating and auxiliary materials are substances used for operation or the
execution of maintenance work. Oils, greases, coolants, cleaning agents
and solvents, acids, etc. can be regarded as hazardous materials.
Operating and auxiliary materials can be combustible and easily ignited.
Handling operating and auxiliary materials

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Ingestion or inhalation of vapours of operating and auxiliary materials or

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

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Safety 2

maintenance
Risk of fire, explosion

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

The escape of operating and auxiliary materials into the atmosphere or
contamination of the ground and water due to improper disposal can
CAUTION
lead to environmental damage.
 Handle operating and auxiliary materials carefully.
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 Heed the instructions for use, safety data sheets and hazard notices
on the containers of the operating and auxiliary materials.
 Avoid inhalation and contact with the skin.
 Ensure that the work space is adequately ventilated.
 Seal containers tightly immediately after use and put them away.
 Collect used working and auxiliary materials safely, store them
separately in suitable containers and dispose of them properly and in
an environmentally compatible manner in accordance with statutory
regulations.
 In the event of leaks or after spilling, immediately spread a suitable
binding agent and dispose of it properly and in an environmentally
compatible manner in accordance with statutory regulations.
Revision C

Safety 2

maintenance
Hazards when handling insulating materials

September 2015
Hazards due to insulating materials

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

HZTL2464_EN
Wear a respiratory mask to protect against particles.
 Use only suitable, non-combustible insulating materials.

 Ensure that the work area is well ventilated.
 Wear suitable work clothing (safety glasses, respiratory mask).
 Avoid stirring up dust.
 Use tools and processes which keep dust to a minimum.
 Remove packing materials only in the work area.
 Take particular care when removing old insulating materials.
 Dispose of insulating materials properly and in an environmentally
compatible way in accordance with applicable local regulations.
Revision C

Safety 2

maintenance
Hazards due to electrical components
September 2015
Hazards due to electrical components
Electrical components operate with voltages which can present hazards
to humans.
WARNING
 All work on or with electrical components may only be performed by
trained specialists.
 Heed any country-specific regulations.
HZTL2464_EN
Revision C

Safety 2
Periodic checking of the pressure 2.8 Page 33

vessel
2.8
2.8 Periodic checking of the pressure vessel
September 2015
The pressure vessels used by ABB Turbo Systems, such as those for wet
or dry cleaning, are so-called "simple pressure vessels".
 The local, statutory regulations covering periodic checks of pressure

vessels must be observed.
 The operator is responsible for the safe operation of the pressure
vessel.
Hazards from pressure vessels

The operator must keep the pressure vessel in a proper condition and
monitor it. Necessary repair or maintenance work must be carried out
WARNING
without delay and the required safety precautions must be taken.
 Pressure equipment must not be operated if it has defects.
HZTL2464_EN
Revision C

Safety 2
Lifting loads 2.9 Page 34
2.9
2.9 Lifting loads
September 2015
Suspended loads
Loads not suspended in compliance with regulations may lead to
personal injury or accidents with fatal consequences.
WARNING
 Loads must always be fastened to technically perfect lifting gear with
sufficient loading capacity.
 Make sure the load is suspended properly on the crane hook.
 Do not let anyone stand beneath a suspended load.
Wear safety gloves against mechanical risks.
Wear safety helmet.
HZTL2464_EN
In the case of two or more suspension points, the slinging angle must not
exceed 45°. This avoids excessive loading due to inclined tensile loading.
 Fasten turbocharger assemblies / components as described in

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

(maximum 80°C).
 Use suitable protection at sharp edges.
 Completely screw in assembly / fitting devices without fail so that they
cannot work loose during use.
 Use assembly / fitting devices only for applications described.
 Make sure removed turbocharger components stand safely and
securely.

Commissioning 3
Oil supply 3.1 Page 35
3 Commissioning
September 2015
3.1
3.1 Oil supply
A carefully designed and installed oil supply, which functions in all
possible operational conditions, is an important prerequisite for trouble-
free turbocharger operation.
The turbocharger is normally lubricated with oil from the engine oil circuit.
With regard to the oil supply, please observe the engine builder's
specifications for lubricating oil selection, oil change intervals, oil
filtration, oil pressure and oil temperature.
NOTICE
Oil filtration
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A lubricating oil filter system with a filter mesh size of ≤ 0.034 mm is

adequate for this turbocharger.
Revision C

Commissioning 3
Oil pressure
The oil pressure in front of the turbocharger must be maintained precisely
September 2015
to ensure trouble-free operation.
The permissible oil pressure ranges at measuring point M (blind

connection) on the turbocharger are listed below.
Status for operation Oil pressure in front of the

turbocharger [bar]
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Permissible, for normal operation 1.3 … 2.5
Permissible, during engine warm-up 1.3 … 5.0
Temporarily permissible ( < 1h ) -> alarm 1.1 … 1.3
Not permissible -> emergency stop 0.0 … 1.1
Permissible, during pre- and post-lubrication 0.2 … 2.5
(engine stopped)
Oil orifice
To make sure these oil pressures are obtained, a regulating orifice is
fitted in the turbocharger oil inlet. The orifice is fitted by the engine
NOTICE
builder and secured by a safety ring. Revision C

Commissioning 3
Oil temperature
September 2015
Lubricating oil temperature at the inlet
Machine damage
If the oil temperature at the oil inlet exceeds the admissible range, this
may lead to engine damage.
CAUTION
 Observe oil temperature at the oil inlet according to the following
table.
Oil temperature
Status for operation at the inlet
Toil,inlet [°C]
Permissible 30 … 90
Temporarily permissible (< 1h) -> alarm > 90
Not permissible -> stop the engine > 95
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Not permissible -> Do not start the engine < 30

(before starting: preheat the oil)
Lubricating oil temperature at the outlet
The oil temperature at the outlet is mainly dependant on:
 Lubricating oil temperature and pressure at the oil inlet

 Engine load and turbocharger speed
 Exhaust gas temperature
The maximum admissible oil temperature at the outlet is listed in the

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

Status for operation Toil,outlet [°C]
Permissible ≤ 140
Temporarily permissible -> alarm > 140
Not permissible -> stop the engine > 160
If the turbocharger was operated for a longer period of time outside of the
admissible range, ABB Turbo Systems recommends to have the
turbocharger inspected by an ABB Turbocharging Service Station.

Commissioning 3
Inspection work 3.2 Page 38
3.2
3.2 Inspection work
September 2015
Inspection work includes preventive visual controls plus monitoring and
measuring work before and during commissioning. Inspections help detect
changes to the turbocharger. Machine damage can be avoided.
3.2.1 Inspection before commissioning
Monitoring equipment  Check for correct functioning.
Air filter mat  Inspect for damage.
Lubricating system  Check oil filter for cleanliness before commissioning.
It is urgently recommended that the entire lubricating system be flushed

thoroughly with warm oil using a bypass pipe before starting up the first
HZTL2464_EN
time (commissioning) and after all service work on the lubricating
system.
CAUTION
It is urgently recommended that a running-in filter is used when running
in the engine and after all service work on the lubricating system.
 Check the oil pressure in the oil supply lines.
TPL..VA  Check that variable turbine geometry module can be adjusted.
TPL65: Version with compressor wheel cooling system
 Check whether compressor wheel cooling system is fitted to bearing

casing.
Failure of compressor wheel cooling system

Revision C
The service life of the compressor wheel will be impaired if the

breakdown of the compressor wheel cooling system lasts long.
CAUTION
 Ensure supply of cooling air.

Commissioning 3
Inspection work 3.2 Page 39
3.2.2 Check after start-up (engine at idling speed)

September 2015
Lubricating system
 Check oil pressure in oil supply lines.

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

HZTL2464_EN
 Measure the speed, oil pressure and charging pressure at various

engine performance levels.
 Measure the exhaust gas temperature in front of and behind the
turbine.
 Measure the air temperature in front of and behind the compressor.
 Check the functioning of the variable turbine geometry module.
The measured values must be compared with the values in the

acceptance test report while taking different operating conditions into
account.
Lubricants and pastes used during assembly of the turbocharger liquefy

or vaporise and might escape as an oily liquid in the first few hours after
commissioning. If oily liquid continues to escape after this period, the
operator is to search for the cause of a possible oil leak. The first step is
NOTICE
to check the seal for the oil supply to the turbocharger. If this is not in
proper condition, contact an official ABB Turbocharging service station.
Revision C
3.2.4 Inspection after 100 service hours
Clean or replace lubricating oil filters after the first 100 service hours.

Commissioning 3
Commissioning after taking out of 3.3 Page 40

operation
3.3
3.3 Commissioning after taking out of operation
September 2015
If provided  Remove cover plates (blind flanges) between compressor casing
outlet and charge air duct, before gas inlet and after gas outlet.
 Inspect exhaust gas duct / line in front of and after turbine for any
combustion deposits, foreign matter or residual water. Clean and
remove.
 Inspect air supply line or filter silencer for any foreign matter. Clean
and remove.
 Start up turbocharger oil circulation system at engine end.
 Prepare turbocharger for operation as instructed in section "Inspection
work before start-up / commissioning" of chapter headed "Start-up /
commissioning".
 Start up turbocharger.
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 Remove screw plug on cooling air connection and fit cooling air line.
Revision C

Operation 4
Noise emissions 4.1 Page 41
4 Operation
September 2015
4.1
4.1 Noise emissions

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

distance of 1 metre from the turbocharger.
HZTL2464_EN
The highest sound pressure level of emissions1) reaches a maximum of

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

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

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

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

Operation 4
Noise emissions 4.1 Page 42
Suggestion for noise insulation of the bellows
September 2015
01 Compressor casing 04 Insulation pads
HZTL2464_EN
02 Bellows 05 Insulation mat (at least 15 mm)
03 Charge air duct / scavenging 06 Sheet metal cover
air line
Revision C

Operation 4
Servicing work 4.2 Page 43
4.2
4.2 Servicing work
September 2015
Service work to be carried out during operation involves visual checks,

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

Despite observance of the service intervals, unusual loads, such as
HZTL2464_EN
several start-stops a day, harsh environmental factors, poor fuel quality

CAUTION
or heavy installation vibration can lead to premature machine damage.
 A shortened service interval must be arranged with ABB Turbo
Systems.
Service inspection after 5 years

To prevent age- and stoppage-related machine damage, an inspection
by an ABB Turbocharging Service Station is recommended at the latest
NOTICE
5 years after the last service.
4.2.1 Service work every 25 … 50 hours
 Visual inspection for air, exhaust gas, water and oil leaks.
 Record operating data and enter it in the engine logbook.
Revision C
 Clarify the cause of any variances.
Unknown changes during operation

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

Operation 4
September 2015
4.2.2 Entries in engine logbook
By monitoring the engine, conclusions can be drawn about the

turbocharger performance.
The following operating data and measured values must be entered

regularly in the engine manufacturer's engine logbook:
 Engine performance and speed

 Air intake temperature
 Exhaust gas temperature in front of and behind the turbine
 Pressure of charge air
 Pressure drop in charge air cooler
 Lubricating oil pressure and lubricating oil temperature
If provided  Air temperature behind compressor and charge air cooler
HZTL2464_EN
 Turbocharger speed
 Pressure loss in air filter
4.2.3 Servicing work according to the engine manufacturer's instructions
Oil filter  Clean or replace oil filter in supply line to turbocharger when engine is
not running.
Revision C

Operation 4
4.2.4 Service work every 15000 hours

September 2015
Inspection and assessment of the rotor and bearing parts as well as

replacement of the variable turbine geometry module with a CPEX
variable turbine geometry module must be carried out by an ABB
Turbocharging Service Station.
 It is recommended that the turbocharger is inspected once a year, but

at least after every 15000 operating hours.
 Disassemble turbocharger
 Clearance measurement
 Clean the turbine and compressor wheels and inspect for damage
 Clean the turbine and compressor casings and inspect for any cracks
and erosion or corrosion
 Clean bearing casing and blow air through oil ports
 Inspect and assess sealing air lines
 Inspect and assess rotor and bearing parts
HZTL2464_EN
 Have the variable turbine geometry module overhauled by ABB Turbo

Systems. ABB Turbocharging Service Stations have variable turbine
geometry modules replaced with overhauled ones as part of the CPEX
(Customer Part Exchange) programme.
4.2.5 Service work every 30000 hours
The replacement of bearing parts as well as the inspection and

assessment of the rotor must be carried out by an ABB Turbocharging
Service Station.
 Disassemble turbocharger.
 Measure clearances.
 Clean the turbine and compressor wheels and inspect for damage.
 Clean the turbine and compressor casings and inspect for any cracks
Revision C
and erosion or corrosion.

 Clean bearing casing and blow air through oil ports.
 Inspect and assess rotor and bearing parts.
 Replace bearings (original parts from ABB Turbo Systems).

Operation 4
Replacement intervals for turbocharger 4.3 Page 46

components
4.3 Replacement intervals for turbocharger

components
September 2015
4.3
Rotating components The recommended replacement intervals for the compressor and turbine
wheels due to stress caused by centrifugal forces and load cycles are
calculated under consideration of the operating conditions while applying
the safety concept for rotating components. They can be found on the
turbocharger rating plate. Incalculable influencing parameters can shorten
the recommended replacement intervals for the rotor, see Influencing
parameters.
Non-rotating components The expected replacement intervals for non-rotating components and
bearing parts are extremely dependent upon system-specific operating
conditions, see Influencing parameters.
When the specified, periodic inspections are carried out, the individual
components are inspected for wear and tear and replaced if necessary. In
this way, trouble-free operation is ensured.
HZTL2464_EN
Influencing parameters The following parameters influence the replacement intervals for
turbocharger components:
Parameters influencing bearing parts
 Poor quality of the lubricating oil (lubrication oil filter system, condition
of lubricating oil)
 Unusual loads (vibration, start/stop frequency)
 Non-permissible state of rotor unbalance
Parameters influencing non-rotating components exposed to exhaust gas
 Fuel quality (gas, MDO, HFO)

 Load profile (thermal load changes, number of starts/stops)
 Temperature level of exhaust gas
Revision C
 Turbine cleaning frequency

 Procedure for turbine cleaning

Operation 4
Replacement intervals for turbocharger 4.3 Page 47

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

September 2015
 Turbine cleaning frequency

 Procedure for turbine cleaning
 Load profile
Expected replacement
GAS / MDO
intervals [h]
Gas inlet casing 50000 … 100000
Gas outlet casing 50000 … 100000
Variable turbine geometry module 15000
(The variable turbine geometry module can be
replaced with a CPEX variable turbine geometry
module by an ABB Turbocharging service station.)
Turbine diffuser / cover ring 35000 … 50000
Other casings 100000
Axial bearing components 24000 … 36000
HZTL2464_EN
Radial bearing components 24000 … 36000

Turbine blades --
(due to wear)
Recommended
Rotor components See the data on the rating plate
replacement intervals [h]
GAS = Gas Engine

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

Operation 4
Speed measurement 4.4 Page 48
4.4
4.4 Speed measurement
September 2015
A speed measuring system permits continuous monitoring of the
turbocharger speed.
Do not use cables as a climbing aid

If you pull the speed measurement cables too hard, contacts can be
pulled out.
CAUTION
 Do not tension the speed measurement cables.
HZTL2464_EN
Revision C
Part number Description

42047 Screw plug
86505 Speed sensor
86515 Cable connector for 86505
86526 F/I converter
86528 Tachometer

Operation 4

September 2015
4.4.1 Speed differences with multiple turbochargers per engine
The speeds of all turbochargers on one engine differ only slightly from
each other in normal operation.
The difference between the highest and the lowest turbocharger speed
must not be more than 3 % relative to the speed limit nBmax.
If this permissible range of difference is exceeded, the following steps

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

turbocharger speed no longer exceeds 70% of nBmax.
 If the engine cannot be stopped, continue to run at this reduced engine
performance or turbocharger speed.
 If the turbocharger surges continuously, engine performance must be
reduced further.
HZTL2464_EN
 Measure the temperatures in the air and gas lines to and from the
turbochargers and compare them with standard values.
If the engine can be stopped for a short time:
 Inspect the air and gas lines as well as the turbocharger and eliminate
any problems.
 In any event, it is recommended that you contact the nearest ABB
Revision C

Operation 4
4.4.2 Assembly
September 2015
If the speed sensor is not fitted on the turbocharger, the following
procedure must be adopted to fit it:
 Engine and turbocharger are not running.

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

specified in table. (See chapter Table of tightening torques.)
 Connect speed sensor using cable connector (86515).
HZTL2464_EN
Revision C

Operation 4
4.4.3 Replacing the speed sensor

September 2015
Hot cable connector and hot speed sensor

Risk of burning. During operation, the cable connector and the speed
sensor can reach temperatures exceeding 100 °C.
WARNING
 Wear safety gloves when removing the cable connector and speed
sensor.
 Reduce engine performance to the idling speed, then stop the engine.
 Switch off the lubricating oil supply to the turbocharger.
 Disconnect the cable connector from the speed sensor.
 Screw out defective speed sensor.
HZTL2464_EN
 Screw in a new speed sensor up to the limit block.

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

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

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

Operation 4
Emergency operation TPL..VA 4.5 Page 52
4.5
4.5 Emergency operation TPL..VA
September 2015
HZTL2464_EN
Detail A
In the event of failure of the control system or the drive, the variable
turbine geometry module can be fixed by clamping the ring lever (B) using
Revision C
at least 3 washers (C) spaced around the circumference.
When fixing, the position of the variable turbine geometry module and / or
the blades must be specified by the enginebuilder.

Operation 4
Stopping the engine 4.6 Page 53
4.6
4.6 Stopping the engine
September 2015
Stopping the engine

Heat in the turbocharger must be dissipated by the further circulating
lubricating oil.
CAUTION
 Allow the engine to continue running at idling speed for a further 10
minutes before stopping.
HZTL2464_EN
Revision C

Maintenance 5
Foreword to Maintenance 5.1 Page 55
5 Maintenance
September 2015
5.1
5.1 Foreword to Maintenance
Maintenance and servicing work involves regular visual checks and
cleaning to ensure that the turbocharger and its attached units function
trouble-free.
 The external condition and how dirty the cleaning points specified in
this chapter are, must be established by visual checks at the specified
intervals.
 The safety precautions must be observed during all maintenance and
servicing work.
The cleaning points described in the following are:

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 Filter silencer
 Compressor
 Turbine and Guide Blades
Revision C

Maintenance 5
Cleaning the filter silencer 5.2 Page 56
5.2
5.2 Cleaning the filter silencer
September 2015
5.2.1 Filter silencer and connecting rod
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81265 Filter ring (if provided) 81136 Absorption segment
81269 Connecting rods 81137 Sheet-metal covering
81266 Cover grid 81135 Filter silencer body
81272 Screwdriver 81273 Lock nut
E Insert unit = absorption segment + sheetmetal covering
Revision C

Maintenance 5
Removing and cleaning filter silencer

September 2015
If provided  Remove filter strip (81265).

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

 Unscrew and remove screws (81272) for connecting rods (81269).
 Remove connecting rods (81269).
 Carefully remove cover grids (81266).
HZTL2464_EN
 Pull out insert units (E), bend open sheet-metal coverings (81137) and
then remove absorption segments (81136).
 Clean the absorption segments (81136).
During cleaning, ensure that the absorption segments (81136) are only
cleaned with a mild jet of compressed air, soft brush or a damp cloth.
Otherwise there is a risk of damage or deformation.
Replace heavily contaminated or damaged parts with original parts from

ABB Turbo Systems.
NOTICE
Revision C

Maintenance 5
Fitting the filter silencer
 Assemble the insert units (E) by inserting the absorption segments
September 2015
(81136) into the sheet metal coverings (81137).
 Bend sheet metal coverings (81137) back to original shape.
 Insert the insert units (E) into slot guides in filter silencer unit (81135).
HZTL2464_EN
 Uniformly place cover grids (81266) in correct position.
 Push connecting rods (81269) through lugs of cover grids (81266).
If the connecting rods (81269) are not correctly positioned in their

recesses on the filter silencer unit (81135), the cover grid (81266) can
twist and shift. There is then a risk of foreign matter and contamination
getting into the compressor.
CAUTION
Revision C

Maintenance 5
 Join connecting rods (81269) using screws (81272). When tightening

the screws (81272), ensure that connecting rods (81269) are located
September 2015
correctly in recesses in filter silencer body (81135). Now tighten

screws (81272) alternately until the following maximum torque is
reached:
Screw Tightening torque [Nm]
81272 20
 Screw lock nuts (81273) onto screw (81272) and tighten to following
torque:
Lock nut Tightening torque [Nm]
81273 40
If provided  Fit filter strip (81265).

HZTL2464_EN
Revision C

Maintenance 5
Cleaning the compressor during 5.3 Page 60

operation
5.3
5.3 Cleaning the compressor during operation
September 2015
These instructions for wet cleaning apply only when cleaning is carried
out with clean water and the enginebuilder permits the process.
NOTICE
The degree of contamination of the compressor stage (compressor wheel

and diffuser) depends on how clean the drawn-in air is.
Deposits of dirt can build up in the flow channels if the following

substances are in the intake air:
 Oily or salty mist

 Solid combustion residues
 Various kinds of dust
Contamination of the compressor stage has a negative influence on the
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compressor efficiency and the charging pressure.
This results in higher exhaust gas temperatures and higher fuel

consumption by the engine. Contamination of the compressor can also
increase rotor unbalance.
Under no circumstances is periodic cleaning of the compressor during

operation a substitute for the service work carried out when the
turbocharger is completely dismantled and the compressor is cleaned
mechanically.
Cleaning interval The interval between periodic cleaning is very dependent on the operating
conditions. In general, cleaning should be carried out every 25 to 100
operating hours.
Cleaning intervals
Revision C
Should the specified cleaning intervals prove incompatible with engine

operation, please contact ABB Turbo Systems.
NOTICE

Maintenance 5

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

September 2015
cleaning method described in the following:
 Wet cleaning
This cleaning method has been tested and approved by ABB Turbo
Systems.
Principle of wet cleaning To clean the compressor stage during operation, water is injected in front
of the compressor wheel through an injection pipe fitted in the filter
silencer or the suction branch.
The water does not act as a solvent, but the dirt deposit is removed by the
mechanical impact of the droplets. This is a very suitable process,
provided that the degree of contamination is not too high.
Corrosion and deposits when cleaning

HZTL2464_EN
Damage and impairment of turbocharger parts due to salt water and

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

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

Maintenance 5

operation
5.3.1 Wet cleaning with orifice plate on filter silencer (XC2)
September 2015
Operating state prerequisites for cleaning compressor with XC2
To be able to carry out a satisfactory cleaning process which has been

tested and is recommended by ABB Turbo Systems, the following
prerequisites must be fulfilled:
NOTICE  Engine load 50 ... 85%
 Start of cleaning cycle in accordance with following description of wet
cleaning operation with XC2.
Compressor wet cleaning operation with XC2
 Maintain water pressure before connection to turbocharger (during

water injection time) must be maintained as shown in table Cleaning
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parameters.
 After cleaning, wait at least 5 minutes to allow turbocharger to dry.
If the cleaning process is unsatisfactory, it can be repeated up to

2 times.
If the cleaning result is still not satisfactory after three attempts and the
NOTICE engine values are also unsatisfactory, we recommend that you have the
turbocharger inspected and cleaned by an official ABB Turbocharging
Service Station.
Cleaning parameters per turbocharger compressor
Product Engine load Water Water injection Orifice

pressure time diameter
[bar] [sec] [mm]
Revision C
TPL65VA32/33 50 … 85% 3 10 2.1

Maintenance 5

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

September 2015
Operating state prerequisites for compressor cleaning with XC3
To be able to carry out a satisfactory cleaning process which has been

tested and is recommended by ABB Turbo Systems, the following
prerequisites must be fulfilled:
NOTICE  Engine load 50 ... 85%
 Start of cleaning cycle in accordance with following description for
wet cleaning operation with XC3.
Compressor wet cleaning procedure with XC3

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Revision C
Operating the water  It is mandatory to fulfil the operating condition prerequisites before
pressure vessel cleaning compressors with XC3.
 Remove the sealing plug (X).
 Fill the vessel with the required volume of clean water (see the Table
of cleaning parameters).

Maintenance 5

operation
 Screw in the sealing plug (X).

 Push the valve activator (Y) against the spring and hold it for
10 ... 15 seconds until the entire volume of water has been injected.
September 2015
 After cleaning, wait at least 5 minutes to allow the turbocharger to dry.
If the cleaning operation is not satisfactory, it may be repeated up to

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

[dm3]
TPL65 50 … 85% 0.4
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Revision C

Maintenance 5
Cleaning turbines and guide vanes 5.4 Page 65

during operation
5.4 Cleaning turbines and guide vanes during

operation
September 2015
5.4
HFO applications
The TPL65VA.. has not been released for HFO applications. Wet
cleaning of the turbine blades and guide vanes during operation is thus
NOTICE
neither required nor planned.
HZTL2464_EN
Revision C

Troubleshooting 6
Malfunctions when starting 6.1 Page 67
6 Troubleshooting
September 2015
6.1
6.1 Malfunctions when starting
Sluggish start-up
Possible causes Elimination

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

HZTL2464_EN
Turbo- Rotor unbalance Contact an ABB Turbocharging

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

Turbo- Minor uniform wear around the periphery of rotor components,
charger caused by slight local rubbing of adjacent components, is
permissible. The compressor blades and turbine blades are then
shortened somewhat. Certain tolerances must be observed to
avoid a significant loss of efficiency.
 If there is any doubt about the extent of rubbing, then an ABB
Turbocharging Service Station must be contacted.
 Have a dimension check carried out by an ABB Turbocharging
Service Station.
Revision C

Troubleshooting 6
Surging of the turbocharger 6.2 Page 68
6.2
6.2 Surging of the turbocharger
September 2015
Turbocharger surging

Engine Guard in front of the Clean / replace it
turbocharger is contaminated
or damaged
Turbocharger Filter silencer or diffuser Clean it
contaminated
Heavy deposits of dirt in the
turbine or nozzle ring
Charge air Cooler contaminated Clean it
cooler Charge air duct blocked
Prolonged or periodic surging
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Possible damage to components, such as the compressor wheel,
turbine blades, bearings and filter silencer
CAUTION
 Have the cause clarified immediately by an ABB Turbocharging
service station and rectified.
 Have components inspected for damage and, if necessary, replaced
by an ABB Turbocharging service station.
Sporadic surge blows
Surging of the turbocharger can occur during certain operating conditions

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

from the filter silencer.
Revision C

Troubleshooting 6
Malfunctions during operation 6.3 Page 69
6.3
6.3 Malfunctions during operation
September 2015
Lubricating oil pressure too low

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

Engine Defects of connected cylinders Contact the enginebuilder
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when pulse charging

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

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

Troubleshooting 6
Exhaust gas temperature too high
Engine performance and engine speed unchanged
September 2015
Engine Malfunctioning injection Repair it or contact the
system manufacturer
Turbocharger Air starvation, for example Clean it
filter silencer clogged with
dirt
Compressor / turbine
contaminated
Exhaust counterpressure too Clean or repair the boiler or
high exhaust silencer
Damaged or eroded turbine Contact an ABB Turbocharging
Service Station
Charge air Cooler contaminated Clean it
cooler Cooling water volume too Top up the water
low
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Entry temperature of cooling Inspect / clean the cooling
water too high system
Inadequate ventilation Improve the ventilation
Revision C

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

September 2015
normal

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

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

normal

Engine Malfunctioning injection system Repair it or contact the
manufacturer
Poorly adjusted injection system Correct it
Engine performance higher than Check engine performance
expected
Revision C
Turbo- Manometer display wrong Replace the manometer

charger

Troubleshooting 6
Malfunctions when stopping 6.4 Page 72
6.4
6.4 Malfunctions when stopping
September 2015
Noises during run-down

Run-down time too short

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Revision C

Troubleshooting 6
Speed measurement system 6.5 Page 73
6.5
6.5 Speed measurement system
September 2015

Signal Fitting error The screw plug for the sensor is fitted with a
amplitude non gasket.
existent or When fitting the speed sensor, this gasket
poor must be removed. If it is fitted by mistake,
the distance from the sensor tip to the
signal-generating sealing disc increases. As
a result, the voltage amplitude of the speed
signal decreases, which can cause problems
for the evaluation electronics.
This problem is eliminated by removing the
gasket.
Defective sensor Contact ABB Turbocharging service station.
Measured Dirty sensor tip The sensor tip is magnetic and can thus
speeds too attract metal particles. As a result, the
high distance to the auxiliary bearing decreases,
HZTL2464_EN
which can lead to amplification of the noise

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

Troubleshooting 6
Variable Turbine Geometry 6.6 Page 74
6.6
6.6 Variable Turbine Geometry
September 2015
Variable Turbine Geometry (VTG) not adjustable

Turbocharger Heavy turbine Contact an ABB Turbocharging
contamination Service Station
VTG bearing damaged
Drive unit No drive energy Contact an ABB Turbocharging
(electrical Service Station
components)
HZTL2464_EN
Revision C

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

September 2015
7.1
7.1 Turbocharger weights
Lifting gear with a sufficient load limit must be used for removing and
installing the turbocharger. The following weight specification is the
heaviest possibility. This guide value can differ from data on the rating
plate, depending on the specification.
Weight [kg]
TPL65VA32/33
1210
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Revision C

Removing the turbocharger 7.2 Page 76
7.2
7.2 Removing the turbocharger
September 2015
 Disconnect all gas, air and oil lines in accordance with engine
manufacturer’s instructions.
Oil orifice plates

An orifice plate for adjusting the oil pressure is fitted in each of the two
oil inlet channels in the bearing casing. When the cartridge group, the
CAUTION
bearing casing or the turbocharger is fitted to the engine, it must be
ensured that the orifice plates that are specified for the turbocharger
have been installed in the two oil inlet channels.
 Check correct installation of oil orifice plates.
 Unplug the cable connector on the speed sensor.

 Remove the insulation at the suspension ribs.
HZTL2464_EN
 Remove air supply line. (See also chapter entitled Preliminary
remarks / Layout and functionality)
 Inspect the lifting gear.
Revision C
 Fasten separate lifting gear to each of the two ribs on the bearing
casing provided for this purpose.

Removing the turbocharger 7.2 Page 77

September 2015
 Ribs (01) not in the middle at the top:

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

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

Revision C
 Cover the oil connection.

Installing the turbocharger 7.3 Page 78
7.3
7.3 Installing the turbocharger
September 2015
 Remove cover from oil connection.
 Inspect lifting gear.
 Fasten separate lifting gear to each of two bearing casing ribs
provided for this purpose.
Oil orifice plates

CAUTION
 Adapt turbocharger to suit engine.

 Tighten fixing screws in foot in accordance with engine builder's
HZTL2464_EN
instructions.
 Fasten gas, air and oil lines in accordance with engine builder’s
instructions.
 Fit air supply line. (See also chapter Preliminary remarks / Layout and
functioning.)
 Refit removed parts of insulation.

 Plug in cable connector on speed sensor.
Revision C

Disassembly and assembly 8
8 Disassembly and assembly

September 2015
8.1
8.1 Introduction
Further work
Further tasks, which are not described here, may be carried out only by
trained personnel from an ABB Turbocharging service station.
CAUTION
 Only carry out those tasks that are described in this chapter.
Marking casing positions for assembly

ABB Turbo Systems recommends that the casing positions are marked
before disassembling the turbocharger.
NOTICE
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Identifying assembly devices
Not all assembly devices are marked with a part number. They can be
identified using the tool list. This list is enclosed in the toolbox.
Maintaining assembly devices

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

Tightening torques for turbocharger components
The specified tightening torques of screw connections for turbocharger
September 2015
components must be observed. (See section Table of tightening torques.)
Tightening torques for assembly devices of ABB Turbo Systems
If nothing else is described, the screws and nuts of the assembly devices
must be tightened down firmly.
Suspended loads
Loads not suspended in compliance with regulations may lead to
personal injury or accidents with fatal consequences.
WARNING
 Attach turbochargers, assemblies or individual components only to
lifting gear which is in technically perfect condition and has sufficient
load capacity.
 Make sure the load is suspended properly on the crane hook.
HZTL2464_EN
 Do not let anyone stand beneath a suspended load.
Wear safety helmet.
Definition of terms
 Suspension point
Defined load carrying point on a component or an assembly (blind hole
thread, eye, lug).
 Assembly device
Devices mounted on the turbocharger to create a suspension point.
Assembly devices are calculated and designed especially for the
defined application. They are not commercially available products. Use
assembly / fitting devices only for the applications described.
Revision C
 Lifting gear
Equipment for lifting and transporting loads (ropes, chain hoists,
cranes). Lifting gear is not supplied by ABB Turbo Systems.

Module weights 8.2 Page 81
8.2
8.2 Module weights
September 2015
The specified weights of individual parts or assemblies are guides

rounded off to the next highest value.
Assemblies
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Weights [kg]
Description TPL65VA32/33
01 Radial air suction branch 50
02 Axial air suction branch 35
03 Filter silencer 130
04 Compressor casing 180
05 Wall insert 40
Revision C
06 Diffuser 19
07 Cartridge group 290
08 Turbine diffuser 30
09 Variable turbine 55
geometry module
10 Radial gas inlet casing 50

Module weights 8.2 Page 82
Complete compressor casing
September 2015
Weight [kg]
TPL65VA32/33
240
The total weight of the complete compressor casing is an addition of the

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

Removing and fitting filter silencer or air 8.3 Page 83

suction branch
8.3 Removing and fitting filter silencer or air

suction branch
September 2015
8.3
Removing the filter  Remove insulation where necessary.

silencer
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 Pass lifting gear through rib on filter silencer.
 Pass lifting gear through lugs on back.

 Unscrew nuts (72027) and remove them together with washers
Revision C
(72018).
 Remove filter silencer and set it down to one side.
Installing the filter silencer  Install filter silencer in reverse order.

Removing and fitting filter silencer or air 8.3 Page 84

suction branch
Removing the air suction  Disconnect all air lines in accordance with the engine builder’s
branch instructions.
September 2015
 Dismantle the insulation where necessary.
 Pass a lifting gear around the air suction branch. It is permissible to
HZTL2464_EN
pass the lifting gear through holes possibly provided in the ribs to
improve stability.
 Unscrew the nuts (72027) and remove them together with the washers
(72018).
 Remove the air suction branch and set it down to one side.
Installing the air suction  Fit the air suction branch in reverse order.
branch
Revision C

Axial clearance 8.4 Page 85
8.4
8.4 Axial clearance
September 2015
Physical hazards due to sharp edges on compressor wheel

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

HZTL2464_EN
 The axial clearance (A) must be measured before removing and after
fitting the cartridge group.
 Measure and note the axial clearance (A).
Clearance A [mm]
TPL65VA32/33
0.31 … 0.49
Revision C
Clearances out of tolerance

Clearances out of tolerance and excessively worn components can be
the cause of serious damage to machinery and property.
CAUTION
 Have components assessed and, if necessary, replaced by an ABB

Removing cartridge group 8.5 Page 86
8.5
8.5 Removing cartridge group
September 2015
 Remove insulation.
Version with compressor wheel cooling system
 Remove air supply line. (See also chapter entitled Preliminary

remarks / Layout and functionality)
 Disconnect oil pipes in accordance with enginebuilder's instructions.
Oil orifice plates

CAUTION
HZTL2464_EN
 Loosen and remove sealing air line (56501) between compressor
casing (72000) and variable turbine geometry module (56100).
Revision C
 Remove three studs (72029) at top.

 Attach lifting device (90190) to compressor casing (72000), then
fasten and secure it to crane using lifting gear.
 Unscrew nuts (61037).
 Uniformly press apart compressor casing (72000) using three press-off
nuts (61090).
 Slightly lift compressor casing (72000) and withdraw it.

 Turn the compressor casing (72000) together with the wall insert and
diffuser and set them down with surface (F) on an underlay.
September 2015
Tipping the compressor casing

Make sure the underlay does not shift.
WARNING  Allow the compressor casing to rest only on surface (F).
 Check the underlay and adjust it if necessary.
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Revision C
 Remove the screws (72002).

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

September 2015
HZTL2464_EN
 Unplug the cable connector (86515) and screw out the speed sensor
(86505) complete with the O-ring (86506).
 Remove the O-ring (42012).
 Remove the three screws (61059) and Verbus Ripp® washers
(61058).
 Uniformly press off the cartridge group using the press-off screws
(90900) in the holes provided.
If the rotor blades have insufficient or no clearance, the blades and

casing could be damaged.
 Turn the rotor to check that the blades do not rub against the turbine
Revision C
CAUTION diffuser.


September 2015
 Withdraw the cartridge group and fit the supports (90450).

 Cover the oil connections.
HZTL2464_EN
Revision C

Removing and fitting turbine diffuser 8.6 Page 90
8.6
8.6 Removing and fitting turbine diffuser
September 2015
HZTL2464_EN
 Replace two screws (61032) with two studs (90903) in upper section
of turbine diffuser.
 Screw out the remaining screws (61032), press off the turbine diffuser
(63000) using the press-off screws (90901), then withdraw and
remove it.
Fitting the turbine diffuser
 Fit the turbine diffuser in reverse order of removal.

Revision C
Brush high-temperature grease on all screws at and in the gas outlet

casing.
NOTICE

Removing variable turbine geometry 8.7 Page 91

module with gas inlet casing
8.7 Removing variable turbine geometry module

with gas inlet casing
September 2015
8.7
HZTL2464_EN
 Disconnect semi-circular section of sealing air line (A) from variable

turbine geometry module.
 Retaining clips (56121) are fitted.

 Unscrew nuts (61042).
 Remove gas inlet casing (51001) together with variable turbine
geometry module (56100).
After removing screws (56122) and retaining clips (56121), gas inlet
casing (51001) is no longer secured.
CAUTION
Revision C
 Loosen screws (56122) together with retaining clips (56121) and

remove with clamping ring (56112).
 Remove clamping ring (56112).
 Carefully separate gas inlet casing (51001) from variable turbine
geometry module (56100) and remove it.
Have the variable turbine geometry module overhauled by ABB Turbo

Systems. ABB Turbocharging Service Stations have variable turbine
geometry modules replaced with overhauled ones as part of the CPEX
(Customer Part Exchange) programme.
CAUTION

Fitting the variable turbine geometry 8.8 Page 92

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

and the gas inlet casing
September 2015
8.8
 Push variable turbine geometry module (56100) over studs

 Push gas inlet casing (56001) over studs
 Slide clamping ring (56112) onto studs
 Tighten nuts (61042) to specified torque
 Fit retaining clips (56121) using screws (56122)
 Fit semi-circular section of sealing air line (A) to variable turbine
geometry module
HZTL2464_EN
Revision C

Fitting the variable turbine geometry 8.8 Page 93

module and the gas inlet casing
 Fit sealing air line (56501) to semi-circular section of line (A).

September 2015
HZTL2464_EN
Revision C

Installing cartridge group 8.9 Page 94
8.9
8.9 Installing cartridge group
September 2015
Oil orifice plates
CAUTION
HZTL2464_EN
Revision C
 Remove the cover from the oil connection.

 Remove the supports (90450) and carefully insert the cartridge group.
 Uniformly tighten the screws (61059) together with the Verbus Ripp®
washers (61058).

If there is no or insufficient clearance between the rotor turbine blades

and the turbine diffuser, the blades and the turbine diffuser (casing) can
be damaged.
September 2015
CAUTION  Turn the rotor to check that the blades do not rub against the turbine
diffuser.
 Remove the lifting gear.

 Fit the O-ring (42012).
 Screw in the speed sensor (86505) along with the O-ring (86506) and
plug in the cable connector (86515).
HZTL2464_EN
Revision C
 Fit the O-ring (77005) to the wall insert (77000).

 Fit the lifting gear and the swivel lifting eye (90235).
 Align and fit the wall insert (77000) using the centring screw (90187).
 Place the diffuser (79000) in position using the swivel lifting eye
(90235).
 Remove the swivel lifting eye (90235).
 Fit the screws (72002).

September 2015
 Attach lifting gear to lifting device (90190) and turn compressor casing
(72000).
 By hand, screw three press-off nuts (61090) onto bearing casing
studs, equally spaced around circumference and up to end of thread.
HZTL2464_EN
 Push compressor casing (72000) onto cartridge group to fit snugly and
fasten it using nuts (61037).
 Secure three press-off nuts (61090) against compressor casing
(72000) by tightening them to specified torque. (See chapter Table of
tightening torques.)
 Remove lifting device (90190).
 Fit sealing air line (56501) between compressor casing (72000) and
variable turbine geometry module (56100).
Revision C

 Measure and note the axial clearance (A) (see the section on axial
clearance).
September 2015
Clearances out of tolerance

Clearances out of tolerance and excessively worn components can be
the cause of serious damage to machinery and property.
CAUTION
 Have components assessed and, if necessary, replaced by an ABB
 Connect oil pipes and all air lines in accordance with engine builder’s
instructions.
Version with compressor wheel cooling system
 Fit the air supply line. (Also see the chapter Preliminary remarks /
Layout and functioning.)
HZTL2464_EN
 Fit the filter silencer or air suction branch.

 Fit the insulation.
Revision C

Table of tightening torques 8.10 Page 98
8.10
8.10 Table of tightening torques
September 2015
HZTL2464_EN
Revision C

Table of tightening torques 8.10 Page 99
Tightening torques [Nm]

Part number TPL65VA32/33
01 82005 M16x1.5
September 2015
50
03 72027 M14
With washer 100
04 72002 M10
50
06 61037 M14
80
07 61090 M14
10
08 61036 M14
61041 50
72029
09 61059 M14
160
13 42059 M12
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42064 50
17 61056 M14
150
18 51075 M8
56110 25
56114
19 61042 M14
130
24 56122 M10
50
30 86505 M18x1.5
160
Tightening angle [°]

Revision C
Part number TPL65VA32/33

29 56501 M26x1.5
30°

Taking out of operation at short notice 9
Possibilities for emergency repair 9.1 Page 101
9 Taking out of operation at short notice

September 2015
9.1
9.1 Possibilities for emergency repair
Danger of fire and explosion due to lubricating oil leaks

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

HZTL2464_EN
Serious damage to engine or property can be caused by non-

compliance with the directives for locking/blanking off the turbocharger
CAUTION
on the engine.
 Follow the directives of the enginebuilder.
If the diesel engine must be capable of operation again as soon as

possible after damage to the turbocharger (emergency repair), the
following possibilities are available:
 Fitting cover plate

 Shutting off inlets and outlets
 Bypass around turbocharger
Revision C

Fitting the cover plate 9.2 Page 102
9.2
9.2 Fitting the cover plate
September 2015
The cover plate (material: General structural steel, in accordance with
DIN EN 10025-2) must be manufactured in-house according to the
drawing.
NOTICE
HZTL2464_EN
Cover plate dimensions
Product B1 B2 B3 B4 B5 B6 B7 B8
[mm]
TPL65 13 325 30 30 8 10 6 70
Product Ø1 Ø2 Ø3 Ø4 Ø5 Ø6
TPL65 616 694 660 16 22 15
Revision C
Product α1 α2 α3
TPL65 4 x 90° 37.5° 24 x 15°


September 2015
HZTL2464_EN
Carry out the work as described in the chapter Removal and fitting.
NOTICE
 Remove cartridge group.

Revision C

September 2015
HZTL2464_EN
 Close off opening in gas outlet casing using cover plate.
 Fasten cover plate using spacer sleeves and nuts (61037).
Shut off the supply of lubricating oil to the turbocharger.
CAUTION Revision C

Further measures and information for operation with a turbocharger with

cover plate on 4-stroke engines
September 2015
4-stroke engine with one turbocharger
No further measures are necessary. The engine can be operated as a

naturally-aspirated engine according to the engine builder's instructions.
4-stroke engine with several turbochargers
Separate receivers No further measures are necessary on engines with separate air and
exhaust gas receivers. The engine can be operated as a naturally-
aspirated engine according to the engine builder's instructions.
Common receiver The air line must be closed off at the engine end because the undamaged
turbochargers build up a receiver pressure.
HZTL2464_EN
The engine can be operated according to the engine builder's

instructions. Attention must always be paid to the speed of the
undamaged turbocharger. The speed limit nBmax given on the rating
plate must not be exceeded.
CAUTION
Revision C

Blocking the inlets and outlets 9.3 Page 106
9.3
9.3 Blocking the inlets and outlets
September 2015
Shut off the lubricating oil supply to the turbocharger.
CAUTION
 Shut off compressor casing outlet, gas inlet and gas outlet by fitting
cover plates.
In this respect, refer to the engine manufacturer's instructions.
NOTICE
HZTL2464_EN
Revision C

Turbocharger bypass 9.3 Page 107
9.4 Turbocharger bypass

September 2015
Shut off the lubricating oil supply to the turbocharger.
CAUTION
 This applies to engines with one turbocharger only:

 The connections are ready and pipes for the bypass are available.
 Fit bypass around turbocharger.
In this respect, refer to the engine manufacturer's instructions.
NOTICE
HZTL2464_EN
Revision C

Mothballing the turbocharger 10
Taking the engine out of operation for 10.1 Page 109

up to 12 months
10 Mothballing the turbocharger

September 2015
10.1 Taking the engine out of operation for up to

10.1
12 months
Condition of engine lubricating oil
The turbocharger normally remains mounted on the engine. Mothballing a

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

have to be taken.
 If the engine lubricating oil is replaced by preserving oil before taking
the engine out of operation and this is circulated by the pre-lubrication
pump, no measures have to be taken. Any remaining old engine oil will
therefore be flushed away and the bearing sections largely protected
against corrosion.
HZTL2464_EN
Mothballing measures
Handling operating materials and supplies

Swallowing or inhaling vapours of operating materials and supplies or
contact with them may be harmful to health.
WARNING
 Do not breathe in these substances and avoid contact with the skin.
 Ensure proper ventilation.
 Observe the information in the material safety data sheet for the
operating materials and supplies.
 Comply with local legislation.

Revision C
Wear a respiratory mask to protect against gases.


up to 12 months
If the total acid number (TAN) is greater than 2 mg KOH/g, the following
mothballing measures are necessary after taking an engine out of
September 2015
operation:
 Dismantle the turbocharger.

 The rotor and the bearing parts must be removed by an official ABB
Turbocharging service station and refitted afterwards.
 Clean all parts.
 Machined, bright surfaces of steel and cast parts must be oiled with
anticorrosive oil.
 Reassemble complete turbocharger.
Rotor turning in stack draught
If the rotor turns as a result of the stack draught:
 Install blind flange between compressor casing outlet flange and

charge air duct.
HZTL2464_EN
Revision C


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

than 12 months
September 2015
10.2
If the engine is taken out of service, the following alternatives are possible
with the turbocharger:
 The turbocharger remains mounted on the engine.

 The turbocharger casing remains mounted on the engine, but the rotor
and the bearing parts are removed and stored separately by an ABB
 The turbocharger is removed completely, either as a whole or in
individual parts.
See the section Taking out of operation for up to 12 months, under

Mothballing measures, for the measures always necessary when
mothballing turbocharger parts.
HZTL2464_EN
If the turbocharger remains mounted on the engine, refer to the section

Taking out of operation for up to 12 months, under Rotating the rotor in
stack draught.
If the entire turbocharger is removed, or if the turbocharger is re-

assembled from the individual components thereof:
 Close all turbocharger openings using wooden covers and paraffin

paper.
Suitable storage locations are only dry rooms where the relative humidity
is between 40 … 70 % and no condensation can form.
Revision C
Condition of the mothballed turbocharger
 Check the mothballed turbocharger parts for corrosion once per

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

Disposing of turbocharger components 11

more than 12 months
11 Disposing of turbocharger components

September 2015
Handling damaged thermal insulation

Damaged thermal insulation can lead to dust exposure. The glass fibres
can cause mechanical irritation of the eyes, skin, and respiratory tracts.
WARNING
 Avoid the formation of dust.
 Vacuum up dust with a suitable vacuum cleaner.
 Wear a respiratory mask to protect against particles (P1 or P2 mask).
 Wear work gloves made of leather.
Wear a respiratory mask to protect against particles.

HZTL2464_EN
Disposal must be environmentally compatible, professional, and in

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

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

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

 Dispose of non-metallic materials as waste.
 Dispose of residues of lubricants as waste oil.
 Dispose of electronic components as electronic waste.
 Dispose of thermal insulation as hazardous waste.
Revision C

Spare parts 12
Ordering spare parts 12.1 Page 115
12 Spare parts
September 2015
12.1
12.1 Ordering spare parts
When making inquiries or ordering spare parts, the following data must be
specified:
 Turbocharger type
 Serial number (HT……)
 Description and part number
Spare parts can be ordered from an official ABB Turbocharging Service

Station.
 If different design versions have not been taken into consideration in

this document, please contact an ABB Turbocharging Service Station.
Storage of spare parts

HZTL2464_EN
All spare parts ordered with the turbocharger must be kept complete
and ready for use.
CAUTION
 Parts showing signs of rust should be carefully cleaned and greased.
 Dispose of replaced and unusable parts in a professional and

environmentally compatible way.
Required customer spare parts set (97070)
Quantity Description Part number

2 Hexagon-head screw 42059
2 Verbus Ripp® Washer 42058
15 Hexagon-head screw 61056 / 61059
15 Verbus Ripp® Washer 61057 / 61058
Revision C
3 Hexagon nut 61037

1 Gasket 42041
1 Gasket 42045
1 O-ring 42012
2 O-ring 77005
1 O-ring 86506

Spare parts 12
View of turbocharger with part numbers 12.2 Page 116
12.2
12.2 View of turbocharger with part numbers
September 2015
HZTL2464_EN
Revision C

Spare parts 12
View of turbocharger with part numbers 12.2 Page 117

- Cartridge group
September 2015
56100 Variable turbine geometry module

51001 Gas inlet casing
61001 Gas outlet casing
61035 Hexagon-head screw
61037 (in customer spare parts set) Hexagon nut
61042 Hexagon nut
61043 (in customer spare parts set) Verbus Ripp® Washer
61044 (in customer spare parts set) Hexagon-head screw
63000 Turbine diffuser
68000 Foot
HZTL2464_EN
72000 Compressor casing

72018 Washer
72029 Stud
72027 Hexagon nut
77000 Wall insert
77005 (in customer spare parts set) O-ring
79000 Diffuser
81000 Filter silencer
82000 Radial air suction branch
82000 Axial air suction branch
Revision C

Spare parts 12
View of cartridge group with part 12.3 Page 118

numbers
12.3
12.3 View of cartridge group with part numbers
September 2015
HZTL2464_EN
Revision C

Spare parts 12
View of cartridge group with part 12.3 Page 119

numbers

21000 Shaft
September 2015
25000 Compressor wheel

32001 Thrust bearing
32101 Radial bearing at compressor end
32102 Radial bearing at turbine end
32104 Auxiliary bearing
32105 Floating disc
32106 Axial bearing
32107 Bearing bush
42001 Bearing casing
42002 Hood
42011 O-ring
42015 Sealing cover
42041 (in customer spare part set) Gasket
42045 (in customer spare part set) Gasket
HZTL2464_EN
42058 (in customer spare part set) Verbus Ripp® Washer

42059 (in customer spare part set) Hexagon-head screw
42063 Verbus Ripp® Washer
42064 Hexagon-head screw
43002 (option with compressor wheel Plate
cooling system)
43001 Partition wall
43005 O-ring
43006 O-ring
43007 O-ring
86505 Speed sensor
86506 (in customer spare part set) O-ring
Revision C

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

Operation Manual: TPL65VA33

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Operation Manual

ABB Turbo Systems Ltd

Type TPL65VA33 HT564931

ABB Turbocharging 

Table of contents Page 1

© Copyright 2015 ABB. All rights reserved.

Table of contents Page 2

7 Removal and installation

8 Disassembly and assembly

8.10 Table of tightening torques

9 Taking out of operation at short notice

10 Mothballing the turbocharger

© Copyright 2015 ABB. All rights reserved.

Table of contents Page 3

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

11 Disposing of turbocharger components

© Copyright 2015 ABB. All rights reserved.

Purpose of this manual 1.1 Page 5

This operation manual belongs to the turbocharger with the identical HT

This Operation Manual enables you to familiarize yourself with the

It provides important information in order that the turbocharger can be

This Operation Manual complements and expands existing national

This Operation Manual is intended for engineers and qualified mechanics

Availability of operation manual

© Copyright 2015 ABB. All rights reserved.

Layout and function 1.2 Page 6

© Copyright 2015 ABB. All rights reserved.

Layout and function 1.2 Page 7

The turbocharger is a turbomachine and consists of the following main

These are both mounted on a common shaft.

Turbocharger version with compressor wheel cooling system

Depending on its range of use, the turbocharger is

provided with a compressor wheel cooling system.

© Copyright 2015 ABB. All rights reserved.

Layout and function 1.2 Page 8

Additional function TPL..V.

© Copyright 2015 ABB. All rights reserved.

Intended use of the turbocharger 1.3 Page 9

This turbocharger supplied by ABB Turbo Systems has been developed

operationally safe according to recognised safety regulations.

Improper operation and maintenance of the turbocharger can result in

Use of the turbocharger as intended also includes observance of the

compliance with the operation manual.

 Malfunctions which could affect safety must be eliminated

The manufacturer accepts no liability for any damage resulting from

© Copyright 2015 ABB. All rights reserved.

Storage of new turbochargers and 1.4 Page 10

Volatile Corrosion Inhibitor (VCI)

Wear safety gloves against chemical risks.

The following mothballing measures are required every 6 months:

 Open the package.

© Copyright 2015 ABB. All rights reserved.

Storage of new turbochargers and 1.4 Page 11

Long-term storage of replacement turbochargers or spare parts

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

Turbo Systems for prolonged storage. The package is equipped with a

The following measures are required every 6 months:

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

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

ABB Turbocharging