Page 1 Operation Manual TPL69-A32 ABB Turbo Systems Ltd CH 5401 Baden Type TPL69-A32 HT843535 Mmax Mmax °C Bmax Bmax 01780 Application according to Year 2017 the Operation Manual made in Switzerland ABB Turbocharging...
Page 2 In case the operation conditions differs signiﬁ cantly from what is considered to be normal for the cur- rent application, it is recommended to contact ABB for a re-calculation of replacement intervals. Frequent load alterations, high temperatures and high speed lower the life of components.
Page 3: Table Of Contents
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Table of contents Page 1 Table of contents Preliminary remarks Purpose of this manual Layout and function Intended use of the turbocharger Storage of new turbochargers and spare parts...
Page 4 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Table of contents Page 2 Foreword to Maintenance Cleaning the filter silencer Cleaning the compressor during operation Cleaning turbine blades and nozzle ring in operation Cleaning components mechanically...
Page 5 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Table of contents Page 3 10.2 Taking the engine out of operation for more than 12 months Disposing of turbocharger components Spare parts 12.1 Ordering spare parts 12.2 View of the turbocharger with part numbers 12.3...
Page 7: Preliminary Remarks
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Purpose of this manual Page 5 Preliminary remarks Purpose of this manual This Operation Manual belongs to the turbocharger with the identical seri- al number (01), see the cover sheet of the Operation Manual and the tur- bocharger rating plate.
Page 8: Layout And Function
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Layout and function Page 6 Layout and function 01 Filter silencer 08 Nozzle ring 02 Radial plain bearing 09 Turbine wheel 03 Thrust bearing 10 Bearing casing...
Page 9 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Layout and function Page 7 Mode of operation The turbocharger is a turbomachine and consists of the following main components:  Turbine  Compressor These are both mounted on a common shaft.
Page 10: Intended Use Of The Turbocharger
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Intended use of the turbocharger Page 8 Intended use of the turbocharger This turbocharger supplied by ABB Turbo Systems has been developed for use on diesel engines to generate the volume of air and the charg- ing pressure required to operate the engine.
Page 11: Storage Of New Turbochargers And Spare Parts
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Storage of new turbochargers and Page 9 spare parts Storage of new turbochargers and spare parts Storage of new turbochargers and spare parts up to 6 months...
Page 12 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Storage of new turbochargers and Page 10 spare parts Long-term storage of replacement turbochargers or spare parts Per order, turbochargers or cartridge groups will be prepared by ABB Tur- bo Systems for prolonged storage.
Page 13: Essential Information
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Essential information Page 11 Essential information Organisational measures In addition to this manual, the general, statutory regulations applicable in the respective country for the prevention of accidents and the protection of the environment must be observed.
Page 14 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Essential information Page 12 Original parts and safety Original parts and accessories are specially designed for the turbocharger supplied by ABB Turbo Systems. Use original parts...
Page 15: Symbols And Definitions
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Symbols and definitions Page 13 Symbols and definitions The following symbols are used in the documents: Prerequisite  Step of a procedure   List, first level - List, second level [➙...
Page 16: Turbocharger Rating Plate
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Turbocharger rating plate Page 14 Turbocharger rating plate Operating limits Turbocharger operating limits at engine overload (110 %). Only when operating in the test rig unless otherwise agreed with the en- ginebuilder.
Page 17 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Turbocharger rating plate Page 15 1.7.1 Explanation of the rating plate The recommended replacement intervals and the corresponding opera- tional limits are jointly defined with the engine manufacturer. This information is specific to the system.
Page 18: Contact Information
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Contact information Page 16 Contact information Contact information Contact information for the official service stations of ABB Turbo Systems is available online. Scan the QR code to access our website.
Page 19: Safety
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Introduction Page 17 Safety Introduction Turbochargers manufactured by ABB Turbo Systems are state of the art and comply with the pertinent safety and health-protection requirements that applied when the turbocharger was manufactured. Consequently, the turbocharger is safe to operate.
Page 20: Definition Of Mandatory Signs
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Definition of mandatory signs Page 18 Definition of mandatory signs To be worn at all times Protective clothing Safety footwear against mechanical hazards To be worn according to the specific work...
Page 21: Warning Plates On The Turbocharger
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Warning plates on the turbocharger Page 19 Warning plates on the turbocharger Warnings that have been attached to turbochargers by ABB Turbo Sys- tems must not be removed. Illegible warnings must be replaced with new ones.
Page 22: Safe Operation And Maintenance
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Safe operation and maintenance Page 20 Safe operation and maintenance The instructions specified in this section are for the safety of personnel. Together with the instructions in the Hazards during operation and maintenance section, they allow the user to safely use the turbocharger.
Page 23 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Safe operation and maintenance Page 21 Safety during start-up / commissioning and operation Before starting work, carry out visual inspection of working area.  Remove any obstacles and objects lying around.
Page 24 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Safe operation and maintenance Page 22 Safety during disassembly, assembly, maintenance and troubleshooting Always perform the specified adjustments, servicing as well as inspec-  tion work and observe inspection intervals.
Page 25: Hazards During Operation And Maintenance
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Hazards during operation and Page 23 maintenance Hazards during operation and maintenance Mechanical hazards during operation During normal operation, no mechanical hazards emanate from the turbo- charger if it has been installed properly.
Page 26 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Hazards during operation and Page 24 maintenance Hazards due to noise The development of noise during operation is influenced by the installation and operating conditions. Noise with a sound pressure level exceeding 85 dB(A) is harmful.
Page 27 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Hazards during operation and Page 25 maintenance 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.
Page 28 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Hazards during operation and Page 26 maintenance Heed the instructions for use, safety data sheets and hazard notices  on the containers of the operating and auxiliary materials.
Page 29: Periodic Checking Of The Pressure Vessel
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Page 27 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.
Page 30: Lifting Loads
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Lifting loads Page 28 Lifting loads Suspended loads Loads not suspended in compliance with regulations may lead to per- sonal injury or accidents with fatal consequences. WARNING Loads must always be fastened to technically perfect lifting gear with ...
Page 31: Commissioning
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Commissioning Oil supply Page 29 Commissioning Oil supply A carefully designed and installed oil supply, which functions in all possi- ble operational conditions, is an important prerequisite for trouble-free tur- bocharger operation.
Page 32 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Commissioning Oil supply Page 30 Oil pressure The oil pressure in front of the turbocharger must be maintained precisely to ensure trouble-free operation. The permissible oil pressure ranges at measuring point M (blind connec- tion) on the turbocharger are listed below.
Page 33 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Commissioning Oil supply Page 31 Oil temperature Lubricating oil temperature at the inlet Machine damage If the oil temperature at the oil inlet exceeds the admissible range, this may lead to engine damage.
Page 34: Inspection Work
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Commissioning Inspection work Page 32 Inspection work Inspection work includes preventive visual controls plus monitoring and measuring work before and during commissioning. Inspections help detect changes to the turbocharger. Machine damage can be avoided.
Page 35 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Commissioning Inspection work Page 33 3.2.2 Check after start-up (engine at idling speed) Lubricating system Check oil pressure in oil supply lines.  Check oil inlet temperature. ...
Page 36: Commissioning After Taking Out Of Operation
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Commissioning Commissioning after taking out of Page 34 operation Commissioning after taking out of operation Remove cover plates (blind flanges) between compressor casing out- If provided  let and charge air duct, before gas inlet and after gas outlet.
Page 37: Operation
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Operation Noise emissions Page 35 Operation Noise emissions Hazards due to noise Noise can cause impaired hearing, damage to health, mental disturb- ances, diminished attention and irritation. WARNING Always wear ear protection when the engine is running.
Page 38 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Operation Noise emissions Page 36 Suggestion for noise insulation of the bellows Compressor casing Insulation pads Bellows Insulation mat (at least 15 mm) Charge air duct / scavenging...
Page 39: Servicing Work
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Operation Servicing work Page 37 Servicing work Service work to be carried out during operation involves visual checks, monitoring, measuring, inspection work and functional checks. It is then possible for changes to the turbocharger to be identified and rectified.
Page 40 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Operation Servicing work Page 38 4.2.2 Entries in engine logbook By monitoring the engine, conclusions can be drawn about the turbo- charger performance. The following operating data and measured values must be entered regu- larly in the engine manufacturer's engine logbook: ...
Page 41 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Operation Servicing work Page 39 4.2.4 Service work every 8000 … 12000 hours The inspection and assessment of the rotor and the bearing parts must be carried out by an official ABB Turbocharging service station.
Page 42: Replacement Intervals For Turbocharger Components
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Operation Replacement intervals for turbocharger Page 40 components Replacement intervals for turbocharger com- ponents The recommended replacement intervals for the compressor and turbine Rotating components wheels due to stress caused by centrifugal forces and load cycles are cal- culated under consideration of the operating conditions while applying the safety concept for rotating components.
Page 43 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Operation Replacement intervals for turbocharger Page 41 components Parameters influencing rotating components exposed to exhaust gas  Fuel quality (gas, MDO, HFO)  Turbine cleaning frequency  Procedure for turbine cleaning ...
Page 44: Speed Measurement
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Operation Speed measurement Page 42 Speed measurement A speed measuring system permits continuous monitoring of the turbo- charger speed. Do not use cables as a climbing aid If you pull the speed measurement cables too hard, contacts can be pulled out.
Page 45 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Operation Speed measurement Page 43 The difference between the highest and the lowest turbocharger speed must not be more than 3 % relative to the speed limit n...
Page 46 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Operation Speed measurement Page 44 4.4.3 Replacing the speed sensor 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.
Page 47: Stopping The Engine
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Operation Stopping the engine Page 45 Stopping the engine Stopping the engine Heat in the turbocharger must be dissipated by the further circulating lubricating oil. CAUTION Allow the engine to continue running at idling speed for a further 10 ...
Page 49: Maintenance
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Foreword to Maintenance Page 47 Maintenance Foreword to Maintenance Maintenance and servicing work involves regular visual checks and clean- ing to ensure that the turbocharger and its attached units function trouble- free.
Page 50: Cleaning The Filter Silencer
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning the filter silencer Page 48 Cleaning the filter silencer 5.2.1 Filter silencer and connecting rod 81265 Filter ring (if provided) 81136 Absorption segment 81269 Connecting rods...
Page 51 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning the filter silencer Page 49 Removing and cleaning filter silencer Remove filter strip (81265). If provided  Rinse filter strip (81265) using water with detergent additive or, if very ...
Page 52 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning the filter silencer Page 50 Fitting the filter silencer Assemble the insert units (E) by inserting the absorption segments  (81136) into the sheet metal coverings (81137).
Page 53 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning the filter silencer Page 51 Join connecting rods (81269) using screws (81272). When tightening  the screws (81272), ensure that connecting rods (81269) are located correctly in recesses in filter silencer body (81135). Now tighten...
Page 54: Cleaning The Compressor During Operation
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning the compressor during Page 52 operation Cleaning the compressor during operation These instructions for wet cleaning only apply when cleaning is carried out Approval by enginebuilder with clean water and under the precondition that the enginebuilder ap- proves the process.
Page 55 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning the compressor during Page 53 operation Cleaning method Cleaning of the compressor during operation is carried out using the cleaning method described in the following:  Wet cleaning This cleaning method has been tested and approved by ABB Turbo Sys- tems.
Page 56 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning the compressor during Page 54 operation 5.3.1 Wet cleaning with orifice plate on filter silencer (XC2) Operating state prerequisites for wet cleaning XC2 Increased stress on material...
Page 57 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning the compressor during Page 55 operation 5.3.2 Wet cleaning using external water-pressure vessel (XC3) Operating state prerequisites for wet cleaning XC3 To be able to carry out a satisfactory cleaning process which has been...
Page 58 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning the compressor during Page 56 operation Screw in the sealing plug (X).  Push the valve activator (Y) against the spring and hold it for 10 to 15 ...
Page 59: Cleaning Turbine Blades And Nozzle Ring In Operation
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning turbine blades and nozzle ring Page 57 in operation Cleaning turbine blades and nozzle ring in operation The combustion of heavy fuel oil in diesel engines contaminates the tur- bine blades and nozzle rings of turbochargers.
Page 60 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning turbine blades and nozzle ring Page 58 in operation When cleaning the turbine components during operation, use wet clean- Cleaning method ing. This cleaning method has been tested and approved by ABB Turbo Systems.
Page 61 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning turbine blades and nozzle ring Page 59 in operation 5.4.1 Wet cleaning turbine and nozzle ring during operation Prerequisites for turbine wet cleaning In the case of V-engines with several turbochargers on each engine, we recommend parallel cleaning of both turbochargers.
Page 62 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning turbine blades and nozzle ring Page 60 in operation Layout of cleaning pipes Wet cleaning procedure for turbine during operation Meet prerequisites and operating state requirements without fail before ...
Page 63 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning turbine blades and nozzle ring Page 61 in operation To obtain the correct water flow rate, a certain pressure in the water pipe Recommendation for is necessary (see table Cleaning parametersTPL-C: 3 nozzles - Cleaning water pressure parameters for wet cleaning of turbine and nozzle ring).
Page 64 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning turbine blades and nozzle ring Page 62 in operation Wet cleaning parameters for turbine and nozzle ring Table of cleaning Product Maximum tempera- Injection time Water flow rate per...
Page 65: Cleaning Components Mechanically
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning components mechanically Page 63 Cleaning components mechanically 5.5.1 Introduction Compressor wheels can be heavily contaminated by badly filtered intake air, as can turbines by heavy fuel oil operation or coked oil. Such contam-...
Page 66 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning components mechanically Page 64 5.5.2 Turbine-end, non-rotating parts Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or contact with them may be harmful to health.
Page 67 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning components mechanically Page 65 Spray cleaned surfaces with penetrating oil. Do not spray the outer  surfaces of the turbocharger. Dispose of contaminated water and cleaning agent in accordance with ...
Page 68 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning components mechanically Page 66 Clean compressor wheel with a scouring cloth or soft brush soaked in  water with household cleaning agent. Do not use any wire brushes! Dry the compressor wheel and the gap between the compressor and ...
Page 69 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning components mechanically Page 67 1. Suspend cartridge group from normal suspension point and suspend from first crane. 2. Secure two lifting loops with swivel lifting eyes in the lower push-off threads and suspend from a second crane.
Page 70 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning components mechanically Page 68 Cartridge group with two side suspension points Or use two swivel lifting eyes at top. Damage to compressor wheel The lifting gear must not touch the compressor wheel at any time during rotation.
Page 71 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning components mechanically Page 69 4. When the cartridge group is suspended horizontally, attach a chain block to the swivel lifting eye and attach to the first crane.
Page 72 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning components mechanically Page 70 Heating the liquid To shorten the soaking time the liquid can be heated to maximum 60 ºC. NOTICE Heating up of cleaning agents and operating fluids When cleaning agents or operating fluids are heated up, explosive va- pours can be produced which are hazardous to health.
Page 73 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning components mechanically Page 71 Remove contamination manually with a soft brush or wire brush.  Water and contamination in the cartridge group If water or contamination gets into the cartridge group, the turbocharger...
Page 75: Troubleshooting
Certain tolerances must be observed to avoid a significant loss of efficiency.  If there is any doubt about the extent of rubbing, then an ABB Turbocharging Service Station must be contacted.  Have a dimension check carried out by an ABB Turbocharging Service Station.
Page 76: Surging Of The Turbocharger
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Troubleshooting Surging of the turbocharger Page 74 Surging of the turbocharger Turbocharger surging Possible causes Elimination Engine Guard in front of the turbo- Clean / replace it charger is contaminated or...
Page 77: Malfunctions During Operation
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Troubleshooting Malfunctions during operation Page 75 Malfunctions during operation Lubricating oil pressure too low Possible causes Elimination Engine Oil filter heavily contaminated Clean it Defective oil pump in lubricating...
Page 78 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Troubleshooting Malfunctions during operation Page 76 Exhaust gas temperature too high Engine performance and engine speed unchanged Possible causes Elimination Engine Malfunctioning injection Repair it or contact the manufac-...
Page 79 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Troubleshooting Malfunctions during operation Page 77 Charge air pressure too low Engine performance and engine speed unchanged, air intake condition normal Possible causes Elimination Engine Air receiver leaking...
Page 80: Malfunctions When Stopping
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Troubleshooting Malfunctions when stopping Page 78 Malfunctions when stopping Noises during run-down Possible causes Elimination Turbo- Turbocharger contaminated Clean it charger Damaged bearing Contact an ABB Turbocharging Service Station...
Page 81: Speed Measurement System
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Troubleshooting Speed measurement system Page 79 Speed measurement system Possible causes Elimination Signal Fitting error The screw plug for the sensor is fitted with a amplitude non gasket.
Page 83: Removal And Installation
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Removal and installation Turbocharger weights Page 81 Removal and installation Turbocharger weights Lifting gear with a sufficient load limit must be used for removing and in- stalling the turbocharger. The following weight specification is the heaviest variant possible.
Page 84: Removing The Turbocharger
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Removal and installation Removing the turbocharger Page 82 Removing the turbocharger Disconnect all gas, air and oil lines in accordance with engine manu-  facturer’s instructions. Oil orifice plates An orifice plate for adjusting the oil pressure is fitted in each of the two oil inlet channels in the bearing casing.
Page 85 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Removal and installation Removing the turbocharger Page 83 Ribs (01) not in the middle at the top:  Completely remove the bearing casing insulation (02) and place a ...
Page 86: Installing The Turbocharger
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Removal and installation Installing the turbocharger Page 84 Installing the turbocharger Remove cover from oil connection.  Inspect lifting gear.  Fasten separate lifting gear to each of two bearing casing ribs provid- ...
Page 87: Disassembly And Assembly
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Introduction Page 85 Disassembly and assembly Introduction Further work Further tasks, which are not described here, may be carried out only by trained personnel from an ABB Turbocharging service station.
Page 88 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Introduction Page 86 Tightening torques for turbocharger components The specified tightening torques of screw connections for turbocharger components must be observed. (See section Table of tightening torques.)
Page 89: Module Weights
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Module weights Page 87 Module weights The specified weights of individual parts or assemblies are guides round- ed off to the next highest value. Assemblies...
Page 90 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Module weights Page 88 Complete compressor casing Weight [kg] TPL65-A32 / -A33 / -A36 TPL69-A32 / -A33 Complete compressor casing The total weight of the complete compressor casing is an addition of the weights of the compressor casing, the diffuser and the wall insert.
Page 91: Removing And Fitting Filter Silencer Or Air Suction Branch
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Removing and fitting filter silencer or air Page 89 suction branch Removing and fitting filter silencer or air suc- tion branch Disconnect all air lines in accordance with the engine builder’s instruc- Removing the air suction ...
Page 92 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Removing and fitting filter silencer or air Page 90 suction branch Remove insulation where necessary. Removing the filter  silencer Pass lifting gear through rib on filter silencer.
Page 93: Axial Clearance
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Axial clearance Page 91 Axial clearance Physical hazards due to sharp edges on compressor wheel The compressor wheel has sharp edges which can result in injury.
Page 94: Removing Cartridge Group
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Removing cartridge group Page 92 Removing cartridge group Remove insulation.  Version with compressor wheel cooling system Remove air supply line. (See also chapter entitled Preliminary remarks ...
Page 95 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Removing cartridge group Page 93 Turn the compressor casing (72000) together with the wall insert and  diffuser and set them down with surface (F) on an underlay.
Page 96 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Removing cartridge group Page 94 Figure 1 Unplug cable connector (86515) and unscrew speed sensor (86505)  with O-ring (86506). Unscrew the three screws (61059) and remove them together with the TPL65-A32/33 ...
Page 97 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Removing cartridge group Page 95 Withdraw cartridge group and fit supports (90450).  Remove screws (42064), flange (42044) and gasket (42045) and  clean oil space.
Page 98: Dismantling And Installing The Turbine Diffuser And Nozzle Ring
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Dismantling and installing the turbine Page 96 diffuser and nozzle ring Dismantling and installing the turbine diffuser and nozzle ring Falling nozzle ring The nozzle ring hangs only loosely on the positioning pins.
Page 99 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Dismantling and installing the turbine Page 97 diffuser and nozzle ring Position clamp (90921) over stud (61036) until it lies flat against inner  radius of gas outlet casing.
Page 100 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Dismantling and installing the turbine Page 98 diffuser and nozzle ring Replace two screws (61056) in the gas outlet casing with two guide  studs (90320) in the upper section of the turbine diffuser (63000).
Page 101: Installing Cartridge Group
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Installing cartridge group Page 99 Installing cartridge group 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.
Page 102 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Installing cartridge group Page 100 If the rotor blades have insufficient or no clearance, the blades and cas- ing could be damaged. Turn rotor to check that blades do not rub against turbine diffuser.
Page 103 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Installing cartridge group Page 101 Attach lifting gear to lifting device (90190) and turn compressor casing  (72000). Fit O-ring (42012) to bearing casing. ...
Page 104: Dismantling And Fitting Nozzle Ring At Turbine End
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Dismantling and fitting nozzle ring at Page 102 turbine end Dismantling and fitting nozzle ring at turbine If only the nozzle ring has to be removed, this can be done at the tur- bine end.
Page 105 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Dismantling and fitting nozzle ring at Page 103 turbine end Loosen and remove the remaining screws (61044) and Verbus Ripp®  washers (61043) from the gas inlet casing flange (61001).
Page 106: Table Of Tightening Torques
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Table of tightening torques Page 104 Table of tightening torques © Copyright 2016 ABB. All rights reserved.
Page 107 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Table of tightening torques Page 105 Tightening torques [Nm] Position Part number TPL65-A32 / -A33 / -A36 TPL69-A32 / -A33 82005 M16x1.5 M16x1.5 72027 with washer...
Page 109: Taking Out Of Operation At Short Notice
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Possibilities for emergency repair Page 107 Taking out of operation at short notice Possibilities for emergency repair Danger of fire and explosion due to lubricating oil leaks Leaking oil may ignite on hot surfaces.
Page 110: Locking The Rotor
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Locking the rotor Page 108 Locking the rotor A locked rotor must be removed and checked for unbalance after the turbocharger repair.
Page 111 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Locking the rotor Page 109 Locking rotor TPL65-A32 / A33 / A36 Remove silencer or air suction branch.  Carry out the work as described in the chapter Disassembly and As- sembly.
Page 112 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Locking the rotor Page 110 Table of tightening Part number TPL65-A32 / -A33 / -A36 torques 72027 75 Nm 94007 25 Nm Make sure all components are clean and free from grease.
Page 113 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Locking the rotor Page 111 Locking rotor TPL69-A32 / -A33 Remove silencer or air suction branch.  Carry out work as described in chapter Removing and fitting.
Page 114 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Locking the rotor Page 112 Tighten nuts (74027) complete with washers (72018) on compressor  casing as specified in following Table of tightening torques.
Page 115 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Locking the rotor Page 113 Further measures and information for operation with blocked rotor for 4-stroke engines 4-stroke engine with one turbocharger No further measures are necessary.
Page 116 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Fit cover plate Page 114 Fit cover plate The cover plate (material: General structural steel, in accordance with DIN EN 10025-2) must be manufactured in-house according to the drawing.
Page 117 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Fit cover plate Page 115 Carry out the work as described in the chapter Removal and fitting. NOTICE Remove cartridge group.
Page 118 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Fit cover plate Page 116 Close off opening in gas outlet casing using cover plate.  Fasten cover plate using spacer sleeves and nuts (61037).
Page 119: Fit Cover Plate
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Fit cover plate Page 117 Further measures and information for operation with a turbocharger with cover plate on 4-stroke engines 4-stroke engine with one turbocharger No further measures are necessary.
Page 120: Blocking The Inlets And Outlets
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Blocking the inlets and outlets Page 118 Blocking the inlets and outlets Shut off the lubricating oil supply to the turbocharger.
Page 121: Mothballing The Turbocharger
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Mothballing the turbocharger Taking the engine out of operation for 10.1 Page 119 up to 12 months Mothballing the turbocharger 10.1 Taking the engine out of operation for up to 12 months 10.1...
Page 122: Taking The Engine Out Of Operation For Up To 12 Months
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Mothballing the turbocharger Taking the engine out of operation for 10.1 Page 120 up to 12 months If the total acid number (TAN) is greater than 2 mg KOH/g, the following...
Page 123: Taking The Engine Out Of Operation For More Than 12 Months
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Mothballing the turbocharger Taking the engine out of operation for 10.2 Page 121 more than 12 months 10.2 Taking the engine out of operation for more than 12 months 10.2...
Page 125: Disposing Of Turbocharger Components
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disposing of turbocharger components Taking the engine out of operation for 10.2 Page 123 more than 12 months Disposing of turbocharger components Handling damaged thermal insulation Damaged thermal insulation can lead to dust exposure. The glass fibres can cause mechanical irritation of the eyes, skin, and respiratory tracts.
Page 127: Spare Parts
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Spare parts Ordering spare parts 12.1 Page 125 Spare parts 12.1 Ordering spare parts 12.1 When making inquiries or ordering spare parts, the following data must be specified: ...
Page 128 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Spare parts Ordering spare parts 12.1 Page 126 Required customer spare part set (97070) TPL65-A32 / -A33 / -A36 Quantity Description Part number O-ring 42012 Gasket 42041 Gasket 42045 Verbus Ripp®...
Page 129 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Spare parts Ordering spare parts 12.1 Page 127 Spare parts set (97078) for turbine cleaning system (if provided) Leaks Improper assembly of the cleaning pipe and the nozzles can lead to leaks and failure of the turbine cleaning system.
Page 130 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Spare parts View of the turbocharger with part 12.2 Page 128 numbers 12.2 View of the turbocharger with part numbers 12.2 © Copyright 2016 ABB. All rights reserved.
Page 131: View Of The Turbocharger With Part Numbers
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Spare parts View of the turbocharger with part 12.2 Page 129 numbers Part number Description – Cartridge group 42012 (in spare part set) O-ring 51001 Gas inlet casing...
Page 132: View Of Turbine Cleaning System With Part Numbers (Optional)
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Spare parts View of turbine cleaning system with 12.3 Page 130 part numbers (optional) 12.3 View of turbine cleaning system with part numbers (optional) 12.3 Part number Description...
Page 133 ABB Turbo Systems AG Bruggerstrasse 71a CH-5400 Baden Switzerland...

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