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- Operation Manual
ABB TPL67-C36 Operation Manual - 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 insulation
Damaged thermal insulation can lead to dust exposure. The glass fibres
can cause mechanical irritation of the eyes, skin, and respiratory tracts.
Avoid the formation of dust.
Vacuum up dust with a suitable vacuum cleaner.
Wear a respiratory mask to protect against particles (P1 or P2 mask).
Wear work gloves made of leather.
Wear safety goggles.
Wear a respiratory mask to protect against particles.
Wear safety gloves against mechanical risks.
Disposal must be environmentally compatible, professional, and in com-
pliance 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.
11
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 ...
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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...
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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...
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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...
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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 ...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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-...
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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 ...
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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...
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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...
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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...
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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...
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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...
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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...
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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 (...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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.
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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...
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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...
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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 ...
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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...
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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...
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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 ...
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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 ...
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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...
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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 ...
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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...
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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- ...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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 ...
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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...
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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...
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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...
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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 ...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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.
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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 ...
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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...
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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...
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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...
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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...
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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...
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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...
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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 (...
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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 ...
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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...
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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...
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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...
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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...
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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...
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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...
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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.
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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.
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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...
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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...
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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...
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Abb turbo systems ag bruggerstrasse 71a ch-5400 baden switzerland abb.