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ABB TPL67-C36 Operation Manual

Summary of TPL67-C36

  • Page 1

    Operation manual abb turbocharging abb turbo systems ltd ch 5401 baden type tpl67-c36 ht564846 n mmax 475 t mmax 650 n bmax 475 t bmax 620 1/s °c 01330 35 50 50 year 2016 made in switzerland application according to the operation manual kg hztl2488 english tpl67-c36 original operation manual.

  • Page 2

    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...

  • Page 3

    Operation manual / tpl67-c.. - tpl71-c.. Table of contents page 1 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c table of contents 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 tur...

  • Page 4

    Operation manual / tpl67-c.. - tpl71-c.. Table of contents page 2 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c 5 maintenance 5.1 foreword to maintenance 5.2 cleaning the filter silencer 5.3 cleaning the compressor during operation 5.4 cleaning turbine blades an...

  • Page 5

    Operation manual / tpl67-c.. - tpl71-c.. Table of contents page 3 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c 10 mothballing turbocharger 10.1 taking out of operation for up to 12 months 10.2 taking out of operation for more than 12 months 11 disposing of turb...

  • Page 7

    Operation manual / tpl67-c.. - tpl71-c.. Preliminary remarks 1 purpose of this manual 1.1 page 5 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c preliminary remarks purpose of this manual 1.1 this operation manual belongs to the turbocharger with the identical ht ...

  • Page 8

    Operation manual / tpl67-c.. - tpl71-c.. Preliminary remarks 1 layout and function 1.2 page 6 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c layout and function 1.2 01 filter silencer 08 nozzle ring 02 radial plain bearing 09 turbine wheel 03 thrust bearing 10 be...

  • Page 9

    Operation manual / tpl67-c.. - tpl71-c.. Preliminary remarks 1 layout and function 1.2 page 7 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c mode of operation the turbocharger is a turbomachine and consists of the following main components: turbine compressor the...

  • Page 10

    Operation manual / tpl67-c.. - tpl71-c.. Preliminary remarks 1 intended use of the turbocharger 1.3 page 8 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c intended use of the turbocharger 1.3 notice this turbocharger supplied by abb turbo systems has been develope...

  • Page 11

    Operation manual / tpl67-c.. - tpl71-c.. Preliminary remarks 1 storage of new turbochargers and spare parts 1.4 page 9 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c storage of new turbochargers and spare parts 1.4 storage of new turbochargers and spare parts up ...

  • Page 12

    Operation manual / tpl67-c.. - tpl71-c.. Preliminary remarks 1 storage of new turbochargers and spare parts 1.4 page 10 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c long-term storage of replacement turbochargers or spare parts per order, turbochargers or cartri...

  • Page 13

    Operation manual / tpl67-c.. - tpl71-c.. Preliminary remarks 1 essential information 1.5 page 11 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c essential information 1.5 organisational measures in addition to this manual, the general, statutory regulations applic...

  • Page 14

    Operation manual / tpl67-c.. - tpl71-c.. Preliminary remarks 1 essential information 1.5 page 12 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c original parts and safety original parts and accessories are specially designed for the turbocharger supplied by abb tu...

  • Page 15

    Operation manual / tpl67-c.. - tpl71-c.. Preliminary remarks 1 essential information 1.5 page 13 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c design variants this document is valid for different design variants of turbochargers. There may be sections and descri...

  • Page 16

    Operation manual / tpl67-c.. - tpl71-c.. Preliminary remarks 1 symbols and definitions 1.6 page 14 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c symbols and definitions 1.6 the following symbols are used in the documents: prerequisite step of a procedure list, f...

  • Page 17

    Operation manual / tpl67-c.. - tpl71-c.. Preliminary remarks 1 turbocharger rating plate 1.7 page 15 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c turbocharger rating plate 1.7 01 turbocharger operating limits at engine overload (110%). Only when operating in th...

  • Page 18

    Operation manual / tpl67-c.. - tpl71-c.. Preliminary remarks 1 turbocharger rating plate 1.7 page 16 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c explanation of the rating plate the recommended replacement intervals and the corresponding opera- tional limits ar...

  • Page 19

    Operation manual / tpl67-c.. - tpl71-c.. Preliminary remarks 1 contact information 1.8 page 17 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c contact information 1.8 contact information contact information for the official service stations of abb turbo systems is...

  • Page 21

    Operation manual / tpl67-c.. - tpl71-c.. Safety 2 introduction 2.1 page 19 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c safety introduction 2.1 turbochargers manufactured by abb turbo systems are state of the art and comply with the pertinent safety and health-...

  • Page 22

    Operation manual / tpl67-c.. - tpl71-c.. Safety 2 definition of mandatory signs 2.3 page 20 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c definition of mandatory signs 2.3 to be worn at all times protective clothing safety footwear against mechanical hazards to ...

  • Page 23

    Operation manual / tpl67-c.. - tpl71-c.. Safety 2 warning plates on the turbocharger 2.5 page 21 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c warning plates on the turbocharger 2.5 warnings that have been attached to turbochargers by abb turbo sys- tems must no...

  • Page 24

    Operation manual / tpl67-c.. - tpl71-c.. Safety 2 safe operation and maintenance 2.6 page 22 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c safe operation and maintenance 2.6 the instructions specified in this section are for the safety of personnel. Together wit...

  • Page 25

    Operation manual / tpl67-c.. - tpl71-c.. Safety 2 safe operation and maintenance 2.6 page 23 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c safety during start-up / commissioning and operation before starting work, carry out visual inspection of working area. Rem...

  • Page 26

    Operation manual / tpl67-c.. - tpl71-c.. Safety 2 safe operation and maintenance 2.6 page 24 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c safety during disassembly, assembly, maintenance and troubleshooting always perform the specified adjustments, servicing as...

  • Page 27

    Operation manual / tpl67-c.. - tpl71-c.. Safety 2 hazards during operation and maintenance 2.7 page 25 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c hazards during operation and maintenance 2.7 mechanical hazards during operation during normal operation, no mech...

  • Page 28

    Operation manual / tpl67-c.. - tpl71-c.. Safety 2 hazards during operation and maintenance 2.7 page 26 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c hazards due to noise the development of noise during operation is influenced by the installation and operating co...

  • Page 29

    Operation manual / tpl67-c.. - tpl71-c.. Safety 2 hazards during operation and maintenance 2.7 page 27 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c warning hot surfaces on uninsulated turbochargers uninsulated turbochargers can cause serious personal injuries (...

  • Page 30

    Operation manual / tpl67-c.. - tpl71-c.. Safety 2 hazards during operation and maintenance 2.7 page 28 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c warning risk of fire, explosion combustible or easily ignited operating and auxiliary materials can burst into fl...

  • Page 31

    Operation manual / tpl67-c.. - tpl71-c.. Safety 2 hazards during operation and maintenance 2.7 page 29 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c hazards when handling insulating materials warning hazards due to insulating materials dust and fibres from insul...

  • Page 32

    Operation manual / tpl67-c.. - tpl71-c.. Safety 2 periodic checking of the pressure vessel 2.8 page 30 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c hazards due to electrical components warning hazards due to electrical components electrical components operate w...

  • Page 33

    Operation manual / tpl67-c.. - tpl71-c.. Safety 2 lifting loads 2.9 page 31 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c lifting loads 2.9 warning suspended loads loads not suspended in compliance with regulations may lead to per- sonal injury or accidents with...

  • Page 35

    Operation manual / tpl67-c.. - tpl71-c.. Commissioning 3 oil supply 3.1 page 33 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c commissioning oil supply 3.1 a carefully designed and installed oil supply, which functions in all possi- ble operational conditions, is...

  • Page 36

    Operation manual / tpl67-c.. - tpl71-c.. Commissioning 3 oil supply 3.1 page 34 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c oil pressure the oil pressure in front of the turbocharger must be maintained precisely to ensure trouble-free operation. The permissibl...

  • Page 37

    Operation manual / tpl67-c.. - tpl71-c.. Commissioning 3 oil supply 3.1 page 35 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c lubricating oil temperature at the inlet caution machine damage if the oil temperature at the oil inlet exceeds the admissible range, th...

  • Page 38

    Operation manual / tpl67-c.. - tpl71-c.. Commissioning 3 inspection work 3.2 page 36 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c inspection work 3.2 inspection work includes preventive visual controls plus monitoring and measuring work before and during commis...

  • Page 39

    Operation manual / tpl67-c.. - tpl71-c.. Commissioning 3 inspection work 3.2 page 37 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c check after start-up (engine at idling speed) lubricating system check oil pressure in oil supply lines. Check oil inlet temperatur...

  • Page 40

    Operation manual / tpl67-c.. - tpl71-c.. Commissioning 3 commissioning after taking out of operation 3.3 page 38 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c commissioning after taking out of operation 3.3 remove cover plates (blind flanges) between compressor ...

  • Page 41

    Operation manual / tpl67-c.. - tpl71-c.. Operation 4 noise emissions 4.1 page 39 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c operation noise emissions 4.1 warning hazards due to noise noise can cause impaired hearing, damage to health, mental disturb- ances, d...

  • Page 42

    Operation manual / tpl67-c.. - tpl71-c.. Operation 4 noise emissions 4.1 page 40 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c suggestion for noise insulation of the bellows 01 compressor casing 04 insulation pads 02 bellows 05 insulation mat (at least 15 mm) 03...

  • Page 43

    Operation manual / tpl67-c.. - tpl71-c.. Operation 4 servicing work 4.2 page 41 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c servicing work 4.2 service work to be carried out during operation involves visual checks, monitoring, measuring, inspection work and fu...

  • Page 44

    Operation manual / tpl67-c.. - tpl71-c.. Operation 4 servicing work 4.2 page 42 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c entries in engine logbook by monitoring the engine, conclusions can be drawn about the turbo- charger performance. The following operati...

  • Page 45

    Operation manual / tpl67-c.. - tpl71-c.. Operation 4 servicing work 4.2 page 43 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c service work every 8000 … 12000 hours the inspection and assessment of the rotor and the bearing parts must be carried out by an officia...

  • Page 46

    Operation manual / tpl67-c.. - tpl71-c.. Operation 4 replacement intervals for turbocharger components 4.3 page 44 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c replacement intervals for turbocharger com- ponents 4.3 the recommended replacement intervals for the...

  • Page 47

    Operation manual / tpl67-c.. - tpl71-c.. Operation 4 replacement intervals for turbocharger components 4.3 page 45 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c parameters influencing rotating components exposed to exhaust gas fuel quality (gas, mdo, hfo) turbin...

  • Page 48

    Operation manual / tpl67-c.. - tpl71-c.. Operation 4 speed measurement 4.4 page 46 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c speed measurement 4.4 a speed measuring system permits continuous monitoring of the turbo- charger speed. Caution do not use cables a...

  • Page 49

    Operation manual / tpl67-c.. - tpl71-c.. Operation 4 speed measurement 4.4 page 47 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c speed differences with multiple turbochargers per engine the speeds of all turbochargers on one engine differ only slightly from each...

  • Page 50

    Operation manual / tpl67-c.. - tpl71-c.. Operation 4 speed measurement 4.4 page 48 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c assembly if the speed sensor is not fitted on the turbocharger, the following proce- dure must be adopted to fit it: engine and turbo...

  • Page 51

    Operation manual / tpl67-c.. - tpl71-c.. Operation 4 speed measurement 4.4 page 49 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c replacing the speed sensor warning hot cable connector and hot speed sensor risk of burning. During operation, the cable connector an...

  • Page 52

    Operation manual / tpl67-c.. - tpl71-c.. Operation 4 stopping the engine 4.5 page 50 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c stopping the engine 4.5 caution stopping the engine heat in the turbocharger must be dissipated by the further circulating lubricat...

  • Page 53

    Operation manual / tpl67-c.. - tpl71-c.. Maintenance 5 foreword to maintenance 5.1 page 51 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c maintenance foreword to maintenance 5.1 maintenance and servicing work involves regular visual checks and clean- ing to ensur...

  • Page 54

    Operation manual / tpl67-c.. - tpl71-c.. Maintenance 5 cleaning the filter silencer 5.2 page 52 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c cleaning the filter silencer 5.2 filter silencer and connecting rod 81265 filter ring (if provided) 81136 absorption seg...

  • Page 55

    Operation manual / tpl67-c.. - tpl71-c.. Maintenance 5 cleaning the filter silencer 5.2 page 53 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c removing and cleaning filter silencer remove filter strip (81265). Rinse filter strip (81265) using water with detergent...

  • Page 56

    Operation manual / tpl67-c.. - tpl71-c.. Maintenance 5 cleaning the filter silencer 5.2 page 54 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c fitting the filter silencer assemble the insert units (e) by inserting the absorption segments (81136) into the sheet me...

  • Page 57

    Operation manual / tpl67-c.. - tpl71-c.. Maintenance 5 cleaning the filter silencer 5.2 page 55 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c lock nut tightening torque [nm] 81273 40 fit filter strip (81265). If provided.

  • Page 58

    Operation manual / tpl67-c.. - tpl71-c.. Maintenance 5 cleaning the compressor during operation 5.3 page 56 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c cleaning the compressor during operation 5.3 these instructions for wet cleaning only apply when cleaning is...

  • Page 59

    Operation manual / tpl67-c.. - tpl71-c.. Maintenance 5 cleaning the compressor during operation 5.3 page 57 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c cleaning method cleaning of the compressor during operation is carried out using the cleaning method describ...

  • Page 60

    Operation manual / tpl67-c.. - tpl71-c.. Maintenance 5 cleaning the compressor during operation 5.3 page 58 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c wet cleaning with orifice plate on filter silencer (xc2) operating state prerequisites for wet cleaning xc2 ...

  • Page 61

    Operation manual / tpl67-c.. - tpl71-c.. Maintenance 5 cleaning the compressor during operation 5.3 page 59 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c wet cleaning using external water-pressure vessel (xc3) operating state prerequisites for wet cleaning xc3 i...

  • Page 62

    Operation manual / tpl67-c.. - tpl71-c.. Maintenance 5 cleaning the compressor during operation 5.3 page 60 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c notice if the cleaning operation is not satisfactory, it may be repeated up to two times. If the cleaning re...

  • Page 63

    Operation manual / tpl67-c.. - tpl71-c.. Maintenance 5 cleaning turbine blades and nozzle ring in operation 5.4 page 61 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c cleaning turbine blades and nozzle ring in operation 5.4 the combustion of heavy fuel oil in die...

  • Page 64

    Operation manual / tpl67-c.. - tpl71-c.. Maintenance 5 cleaning turbine blades and nozzle ring in operation 5.4 page 62 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c when cleaning the turbine components during operation, use wet clean- ing. This cleaning method ...

  • Page 65

    Operation manual / tpl67-c.. - tpl71-c.. Maintenance 5 cleaning turbine blades and nozzle ring in operation 5.4 page 63 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c wet cleaning turbine and nozzle ring during operation prerequisites for turbine wet cleaning in ...

  • Page 66

    Operation manual / tpl67-c.. - tpl71-c.. Maintenance 5 cleaning turbine blades and nozzle ring in operation 5.4 page 64 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c layout of cleaning pipes 1 water supply (fresh water only) 6 other engine 2 regulating valve 7 i...

  • Page 67

    Operation manual / tpl67-c.. - tpl71-c.. Maintenance 5 cleaning turbine blades and nozzle ring in operation 5.4 page 65 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c after cleaning, wait with engine running for at least 10 minutes without changing load to allow ...

  • Page 68

    Operation manual / tpl67-c.. - tpl71-c.. Maintenance 5 cleaning turbine blades and nozzle ring in operation 5.4 page 66 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c wet cleaning parameters for turbine and nozzle ring product maximum tem- perature at start of cl...

  • Page 69

    Operation manual / tpl67-c.. - tpl71-c.. Troubleshooting 6 malfunctions when starting 6.1 page 67 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c troubleshooting malfunctions when starting 6.1 sluggish start-up possible causes elimination turbochar- ger turbocharg...

  • Page 70

    Operation manual / tpl67-c.. - tpl71-c.. Troubleshooting 6 surging of the turbocharger 6.2 page 68 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c surging of the turbocharger 6.2 turbocharger surging possible causes elimination engine guard in front of the turbo- ...

  • Page 71

    Operation manual / tpl67-c.. - tpl71-c.. Troubleshooting 6 malfunctions during operation 6.3 page 69 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c malfunctions during operation 6.3 lubricating oil pressure too low possible causes elimination engine oil filter he...

  • Page 72

    Operation manual / tpl67-c.. - tpl71-c.. Troubleshooting 6 malfunctions during operation 6.3 page 70 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c exhaust gas temperature too high engine performance and engine speed unchanged possible causes elimination engine m...

  • Page 73

    Operation manual / tpl67-c.. - tpl71-c.. Troubleshooting 6 malfunctions during operation 6.3 page 71 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c charge air pressure too low engine performance and engine speed unchanged, air intake condition normal possible cau...

  • Page 74

    Operation manual / tpl67-c.. - tpl71-c.. Troubleshooting 6 malfunctions when stopping 6.4 page 72 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c malfunctions when stopping 6.4 noises during run-down possible causes elimination turbochar- ger turbocharger contamin...

  • Page 75

    Operation manual / tpl67-c.. - tpl71-c.. Troubleshooting 6 speed measurement system 6.5 page 73 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c speed measurement system 6.5 possible causes elimination signal ampli- tude non exist- ent or poor fitting error the scr...

  • Page 77

    Operation manual / tpl67-c.. - tpl71-c.. Removal and installation 7 turbocharger weights 7.1 page 75 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c removal and installation turbocharger weights 7.1 lifting gear with a sufficient load limit must be used for removi...

  • Page 78

    Operation manual / tpl67-c.. - tpl71-c.. Removal and installation 7 remove the turbocharger 7.2 page 76 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en re vi si on c remove the turbocharger 7.2 disconnect all gas, air and oil lines in accordance with engine manu- facturer’s ins...

  • Page 79

    Operation manual / tpl67-c.. - tpl71-c.. Removal and installation 7 remove the turbocharger 7.2 page 77 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c ribs (01) not in the middle at the top: completely remove the bearing casing insulation (02) and place a sling a...

  • Page 80

    Operation manual / tpl67-c.. - tpl71-c.. Removal and installation 7 installing the turbocharger 7.3 page 78 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en re vi si on c installing the turbocharger 7.3 remove the cover from the oil connection. Inspect the lifting gear. Fasten a...

  • Page 81

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 introduction 8.1 page 79 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c disassembly and assembly introduction 8.1 caution further work further tasks, which are not described here, may be carried ...

  • Page 82

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 introduction 8.1 page 80 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c tightening torques for assembly devices of abb turbo systems if nothing else is described, the screws and nuts of the assem...

  • Page 83

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 module weights 8.2 page 81 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c module weights 8.2 the specified weights of individual parts or assemblies are guides round- ed off to the next highest v...

  • Page 84

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 module weights 8.2 page 82 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c complete compressor casing tpl67-c tpl71-c 240 360 notice the total weight of the complete compressor casing is an additi...

  • Page 85

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 removing and fitting filter silencer or air suction branch 8.3 page 83 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c removing and fitting filter silencer or air suction branch 8.3 disconnect all...

  • Page 86

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 removing and fitting filter silencer or air suction branch 8.3 page 84 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c remove insulation where necessary. Pass lifting gear through rib on filter si...

  • Page 87

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 axial clearance 8.4 page 85 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c axial clearance 8.4 warning physical hazards due to sharp edges on compressor wheel the compressor wheel has sharp edges...

  • Page 88

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 removing cartridge group 8.5 page 86 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c removing cartridge group 8.5 remove insulation. Version with compressor wheel cooling system remove the air sup...

  • Page 89

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 removing cartridge group 8.5 page 87 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c remove three studs (72029) at top. Attach lifting device (90190) to compressor casing (72000), then fas- ten an...

  • Page 90

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 removing cartridge group 8.5 page 88 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c turn compressor casing (72000) together with wall insert and diffuser and set them down with surface (f) on und...

  • Page 91

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 removing cartridge group 8.5 page 89 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c unplug the cable connector (86515) and screw out the speed sensor (86505) with the o-ring (86506). Fasten separ...

  • Page 92

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 dismantling and installing the turbine diffuser and nozzle ring 8.6 page 90 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c dismantling and installing the turbine diffuser and nozzle ring 8.6 put ...

  • Page 93

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 dismantling and installing the turbine diffuser and nozzle ring 8.6 page 91 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c replace two screws (61056) in the gas outlet casing with two guide studs...

  • Page 94

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 dismantling and installing the turbine diffuser and nozzle ring 8.6 page 92 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c caution after the turbine diffuser has been removed, the nozzle ring (56...

  • Page 95

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 installing cartridge group 8.7 page 93 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c installing cartridge group 8.7 caution oil orifice plates an orifice plate for adjusting the oil pressure is ...

  • Page 96

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 installing cartridge group 8.7 page 94 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c remove the cover from the oil connection. Fasten separate lifting gear to each of the two ribs on the bearing...

  • Page 97

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 installing cartridge group 8.7 page 95 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c fit the o-ring (77005) to the wall insert (77000). Fit the swivel lifting eyes (90235) and attach lifting gea...

  • Page 98

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 installing cartridge group 8.7 page 96 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c fit the o-ring (42012). Attach lifting gear to shackle of lifting device (90190) and turn com- pressor casing...

  • Page 99

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 installing cartridge group 8.7 page 97 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c measure and note the axial clearance (a) (see the section on axial clearance). Caution if the axial clearance...

  • Page 100

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 dismantling and fitting nozzle ring at turbine end 8.8 page 98 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c dismantling and fitting nozzle ring at turbine end 8.8 notice if only the nozzle ring...

  • Page 101

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 dismantling and fitting nozzle ring at turbine end 8.8 page 99 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c remove screws (61044) and one segment (51012) in the lower sec- tion. Fit two guide s...

  • Page 102

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 dismantling and fitting nozzle ring at turbine end 8.8 page 100 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c assembly carefully clean grooves and contact surfaces in / on casing and keep free f...

  • Page 103

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 dismantling and fitting nozzle ring at turbine end 8.8 page 101 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c tighten screws (61044) in accordance with following procedure and in following order...

  • Page 104

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 table of tightening torques 8.9 page 102 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c table of tightening torques 8.9 8.9.

  • Page 105

    Operation manual / tpl67-c.. - tpl71-c.. Disassembly and assembly 8 table of tightening torques 8.9 page 103 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c part number tpl67-c tpl71-c 1 82005 m16x1.5 45 m16x1.5 45 3 72002 m10 50 m12 80 4 72027 with washer m14 95 ...

  • Page 107

    Operation manual / tpl67-c.. - tpl71-c.. Taking out of operation at short notice 9 possibilities for emergency repair 9.1 page 105 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c taking out of operation at short notice possibilities for emergency repair 9.1 warnin...

  • Page 108

    Operation manual / tpl67-c.. - tpl71-c.. Taking out of operation at short notice 9 locking the rotor 9.2 page 106 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c locking the rotor 9.2 caution a locked rotor must be removed and checked for unbalance after the turbo...

  • Page 109

    Operation manual / tpl67-c.. - tpl71-c.. Taking out of operation at short notice 9 locking the rotor 9.2 page 107 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c part no. Tpl67-c tpl71-c 72027 m14 75 nm m16 105 nm 94007 m8 25 nm m8 25 nm remove silencer or air suc...

  • Page 110

    Operation manual / tpl67-c.. - tpl71-c.. Taking out of operation at short notice 9 locking the rotor 9.2 page 108 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c further measures and information for operation with blocked rotor for 4- stroke engines 4-stroke engin...

  • Page 111

    Operation manual / tpl67-c.. - tpl71-c.. Taking out of operation at short notice 9 fit cover plate 9.3 page 109 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c fit cover plate 9.3 notice the cover plate (material: general structural steel, in accordance with din e...

  • Page 112

    Operation manual / tpl67-c.. - tpl71-c.. Taking out of operation at short notice 9 fit cover plate 9.3 page 110 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c notice carry out the work as described in the chapter disassembly and as- sembly. Removing the cartridge...

  • Page 113

    Operation manual / tpl67-c.. - tpl71-c.. Taking out of operation at short notice 9 fit cover plate 9.3 page 111 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c close opening in gas outlet casing using cover plate. Fasten cover plate using spacer sleeves and nuts (...

  • Page 114

    Operation manual / tpl67-c.. - tpl71-c.. Taking out of operation at short notice 9 fit cover plate 9.3 page 112 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c further measures and information for operation with a turbocharger with cover plate on 4-stroke engines ...

  • Page 115

    Operation manual / tpl67-c.. - tpl71-c.. Taking out of operation at short notice 9 blocking the inlets and outlets 9.4 page 113 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c blocking the inlets and outlets 9.4 caution shut off the lubricating oil supply to the t...

  • Page 117

    Operation manual / tpl67-c.. - tpl71-c.. Mothballing turbocharger 10 taking out of operation for up to 12 months 10.1 page 115 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c mothballing turbocharger taking out of operation for up to 12 months 10.1 condition of en...

  • Page 118

    Operation manual / tpl67-c.. - tpl71-c.. Mothballing turbocharger 10 taking out of operation for more than 12 months 10.2 page 116 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c taking out of operation for more than 12 months 10.2 if the engine is taken out of se...

  • Page 119

    Operation manual / tpl67-c.. - tpl71-c.. Disposing of turbocharger components 11 taking out of operation for more than 12 months 10.2 page 117 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c disposing of turbocharger components warning handling damaged thermal ins...

  • Page 121

    Operation manual / tpl67-c.. - tpl71-c.. Spare parts 12 ordering spare parts 12.1 page 119 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c spare parts ordering spare parts 12.1 when making inquiries or ordering spare parts, the following data must be specified: tu...

  • Page 122

    Operation manual / tpl67-c.. - tpl71-c.. Spare parts 12 ordering spare parts 12.1 page 120 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c quantity description part number 3 hexagon-head screw 61059 1 gasket 77005 1 o-ring (speed sensor) 86506 spare parts set (970...

  • Page 123

    Operation manual / tpl67-c.. - tpl71-c.. Spare parts 12 ordering spare parts 12.1 page 121 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c.

  • Page 124

    Operation manual / tpl67-c.. - tpl71-c.. Spare parts 12 view of turbocharger with part numbers 12.2 page 122 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c view of turbocharger with part numbers 12.2 12.2.

  • Page 125

    Operation manual / tpl67-c.. - tpl71-c.. Spare parts 12 view of turbocharger with part numbers 12.2 page 123 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c part number description 42012 (in customer spare part set) o-ring 51001 gas inlet casing 51012 segment 5600...

  • Page 126

    Operation manual / tpl67-c.. - tpl71-c.. Spare parts 12 view of turbine cleaning system with part numbers (optional) 12.3 page 124 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c view of turbine cleaning system with part numbers (optional) 12.3 axial gas inlet cas...

  • Page 127

    Operation manual / tpl67-c.. - tpl71-c.. Spare parts 12 view of turbine cleaning system with part numbers (optional) 12.3 page 125 © copyright 2016 abb. All rights reserved. Apr il 2016 h zt l2488_ en r ev is ion c radial gas inlet casing part number description 51229 cleaning pipe 52249 holder comp...

  • Page 128

    Abb turbo systems ag bruggerstrasse 71a ch-5400 baden switzerland abb.