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- Operation Manual
ABB TPL69-A10 Operation Manual
Summary of TPL69-A10
Page 1
Operation manual abb turbocharging abb turbo systems ltd ch 5401 baden type tpl69-a10 ht842690 n mmax 426 t mmax 650 n bmax 405 t bmax 620 1/s °c 01780 36 50 50 year 2017 made in switzerland application according to the operation manual kg hztl2481 english tpl69-a10 original operation manual.
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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...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 table of contents page 1 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b 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...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 table of contents page 2 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b 5 maintenance 5.1 foreword to maintenance 5.2 cleaning the filter silencer 5.3 cleaning the compressor during operation 5.4 clean...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 table of contents page 3 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b 10.1 taking the engine out of operation for up to 12 months 10.2 taking the engine out of operation for more than 12 months 11 di...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 preliminary remarks 1 purpose of this manual 1.1 page 5 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b preliminary remarks purpose of this manual 1.1 this operation manual belongs to the turbocharger w...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 preliminary remarks 1 layout and function 1.2 page 6 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b layout and function 1.2 01 filter silencer 08 nozzle ring 02 radial plain bearing 09 turbine wheel 03...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 preliminary remarks 1 layout and function 1.2 page 7 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b mode of operation the turbocharger is a turbomachine and consists of the following main components: t...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 preliminary remarks 1 intended use of the turbocharger 1.3 page 8 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b intended use of the turbocharger 1.3 notice this turbocharger supplied by abb turbo syst...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 preliminary remarks 1 storage of new turbochargers and spare parts 1.4 page 9 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b storage of new turbochargers and spare parts 1.4 storage of new turbocharger...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 preliminary remarks 1 storage of new turbochargers and spare parts 1.4 page 10 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b long-term storage of replacement turbochargers or spare parts per order, tu...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 preliminary remarks 1 essential information 1.5 page 11 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b essential information 1.5 organisational measures in addition to this manual, the general, statuto...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 preliminary remarks 1 essential information 1.5 page 12 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b original parts and safety original parts and accessories are specially designed for the turbocharg...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 preliminary remarks 1 symbols and definitions 1.6 page 13 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b symbols and definitions 1.6 the following symbols are used in the documents: prerequisite step o...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 preliminary remarks 1 turbocharger rating plate 1.7 page 14 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b turbocharger rating plate 1.7 01 turbocharger operating limits at engine overload (110 %). Onl...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 preliminary remarks 1 turbocharger rating plate 1.7 page 15 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b explanation of the rating plate the recommended replacement intervals and the corresponding op...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 preliminary remarks 1 contact information 1.8 page 16 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b contact information 1.8 contact information contact information for the official service stations of...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 safety 2 introduction 2.1 page 17 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b safety introduction 2.1 turbochargers manufactured by abb turbo systems are state of the art and comply with the pertine...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 safety 2 definition of mandatory signs 2.3 page 18 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h ztl 2481_ en r ev is ion b definition of mandatory signs 2.3 to be worn at all times protective clothing safety footwear against m...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 safety 2 warning plates on the turbocharger 2.5 page 19 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b warning plates on the turbocharger 2.5 warnings that have been attached to turbochargers by abb tu...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 safety 2 safe operation and maintenance 2.6 page 20 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h ztl 2481_ en r ev is ion b safe operation and maintenance 2.6 the instructions specified in this section are for the safety of pe...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 safety 2 safe operation and maintenance 2.6 page 21 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b safety during start-up / commissioning and operation before starting work, carry out visual inspection...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 safety 2 safe operation and maintenance 2.6 page 22 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h ztl 2481_ en r ev is ion b safety during disassembly, assembly, maintenance and troubleshooting always perform the specified adju...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 safety 2 hazards during operation and maintenance 2.7 page 23 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b hazards during operation and maintenance 2.7 mechanical hazards during operation during norm...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 safety 2 hazards during operation and maintenance 2.7 page 24 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h ztl 2481_ en r ev is ion b hazards due to noise the development of noise during operation is influenced by the installa...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 safety 2 hazards during operation and maintenance 2.7 page 25 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b hazards due to operating and auxiliary materials operating and auxiliary materials are subst...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 safety 2 hazards during operation and maintenance 2.7 page 26 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h ztl 2481_ en r ev is ion b heed the instructions for use, safety data sheets and hazard notices on the containers of th...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 safety 2 2.8 page 27 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b remove packing materials only in the work area. Take particular care when removing old insulating materials. Dispose of insulating ma...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 safety 2 lifting loads 2.9 page 28 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h ztl 2481_ en r ev is ion b lifting loads 2.9 warning suspended loads loads not suspended in compliance with regulations may lead to per- sonal inj...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 start-up 3 oil supply 3.1 page 29 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b start-up oil supply 3.1 a carefully designed and installed oil supply, which functions in all possi- ble operational con...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 start-up 3 oil supply 3.1 page 30 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b oil pressure the oil pressure in front of the turbocharger must be maintained precisely to ensure trouble-free operation...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 start-up 3 oil supply 3.1 page 31 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b oil temperature lubricating oil temperature at the inlet caution machine damage if the oil temperature at the oil inlet ...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 start-up 3 inspection work 3.2 page 32 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b inspection work 3.2 inspection work includes preventive visual controls plus monitoring and measuring work before a...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 start-up 3 inspection work 3.2 page 33 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b check after start-up (engine at idling speed) lubricating system check oil pressure in oil supply lines. Check oil ...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 start-up 3 commissioning after taking out of operation 3.3 page 34 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b commissioning after taking out of operation 3.3 remove cover plates (blind flanges) bet...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 operation 4 noise emissions 4.1 page 35 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b operation noise emissions 4.1 warning hazards due to noise noise can cause impaired hearing, damage to health, men...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 operation 4 noise emissions 4.1 page 36 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b suggestion for noise insulation of the bellows 01 compressor casing 04 insulation pads 02 bellows 05 insulation ma...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 operation 4 servicing work 4.2 page 37 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b servicing work 4.2 service work to be carried out during operation involves visual checks, monitoring, measuring, i...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 operation 4 servicing work 4.2 page 38 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b entries in engine logbook by monitoring the engine, conclusions can be drawn about the turbo- charger performance. ...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 operation 4 servicing work 4.2 page 39 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b service work every 8000 … 12000 hours the inspection and assessment of the rotor and the bearing parts must be carr...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 operation 4 replacement intervals for turbocharger components 4.3 page 40 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b replacement intervals for turbocharger com- ponents 4.3 the recommended replacem...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 operation 4 replacement intervals for turbocharger components 4.3 page 41 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b parameters influencing rotating components exposed to exhaust gas fuel quality (...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 operation 4 speed measurement 4.4 page 42 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b speed measurement 4.4 a speed measuring system permits continuous monitoring of the turbo- charger speed. Cautio...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 operation 4 speed measurement 4.4 page 43 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b the difference between the highest and the lowest turbocharger speed must not be more than 3 % relative to the s...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 operation 4 speed measurement 4.4 page 44 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b replacing the speed sensor warning hot cable connector and hot speed sensor risk of burning. During operation, t...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 operation 4 underpressure measurement on filter silencer 4.5 page 45 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b underpressure measurement on filter silencer 4.5 a u-tube manometer can be ordered fr...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 operation 4 stopping the engine 4.6 page 46 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b stopping the engine 4.6 caution stopping the engine heat in the turbocharger must be dissipated by the further...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 foreword to maintenance 5.1 page 47 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b maintenance foreword to maintenance 5.1 maintenance and servicing work involves regular visual checks an...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning the filter silencer 5.2 page 48 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b cleaning the filter silencer 5.2 filter silencer with tension band 81265 filter ring (if provided) ...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning the filter silencer 5.2 page 49 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b removing and cleaning the filter silencer remove filter ring (81265). Rinse the filter ring (81265)...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning the filter silencer 5.2 page 50 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b filter silencer and connecting rod 81265 filter ring (if provided) 81136 absorption segment 81269 c...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning the filter silencer 5.2 page 51 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b removing and cleaning filter silencer remove filter strip (81265). Rinse filter strip (81265) using...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning the filter silencer 5.2 page 52 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b fitting the filter silencer assemble the insert units (e) by inserting the absorption segments (811...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning the filter silencer 5.2 page 53 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b join connecting rods (81269) using screws (81272). When tightening the screws (81272), ensure that ...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning the compressor during operation 5.3 page 54 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b cleaning the compressor during operation 5.3 these instructions for wet cleaning only a...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning the compressor during operation 5.3 page 55 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b cleaning method cleaning of the compressor during operation is carried out using the cl...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning the compressor during operation 5.3 page 56 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b wet cleaning with orifice plate on filter silencer (xc2) compressor wet cleaning operat...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning the compressor during operation 5.3 page 57 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b wet cleaning using external water-pressure vessel (xc3) operating state prerequisites f...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning the compressor during operation 5.3 page 58 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b screw in sealing plug (x). Push the valve activator (y) against the spring and hold it ...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning turbine blades and nozzle ring in operation 5.4 page 59 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b cleaning turbine blades and nozzle ring in operation 5.4 the combustion of ...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning turbine blades and nozzle ring in operation 5.4 page 60 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b when cleaning the turbine components during operation, use wet clean- ing. ...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning turbine blades and nozzle ring in operation 5.4 page 61 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b wet cleaning turbine and nozzle ring during operation recommended operating...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning turbine blades and nozzle ring in operation 5.4 page 62 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b layout of cleaning pipes wet cleaning procedure for turbine during operatio...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning turbine blades and nozzle ring in operation 5.4 page 63 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b to obtain the correct water flow rate, a certain pressure in the water pipe...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning turbine blades and nozzle ring in operation 5.4 page 64 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b wet cleaning parameters for turbine and nozzle ring product maximum temper-...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning components mechanically 5.5 page 65 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b cleaning components mechanically 5.5 introduction compressor wheels can be heavily contaminated...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning components mechanically 5.5 page 66 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b turbine-end, non-rotating parts warning handling operating materials and supplies swallowing or...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning components mechanically 5.5 page 67 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the turbocharge...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning components mechanically 5.5 page 68 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b clean compressor wheel with a scouring cloth or soft brush soaked in water with household clean...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning components mechanically 5.5 page 69 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b 1. Suspend cartridge group from normal suspension point and suspend from first crane. 2. Secure...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning components mechanically 5.5 page 70 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b cartridge group with two side suspension points or use two swivel lifting eyes at top. Caution ...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning components mechanically 5.5 page 71 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b 4. When the cartridge group is suspended horizontally, attach a chain block to the swivel lifti...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning components mechanically 5.5 page 72 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b notice heating the liquid to shorten the soaking time the liquid can be heated to maximum 60 ºc...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 maintenance 5 cleaning components mechanically 5.5 page 73 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b remove contamination manually with a soft brush or wire brush. Caution water and contamination ...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 troubleshooting 6 malfunctions when starting 6.1 page 75 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b troubleshooting malfunctions when starting 6.1 sluggish start-up possible causes elimination turb...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 troubleshooting 6 surging of the turbocharger 6.2 page 76 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b surging of the turbocharger 6.2 turbocharger surging possible causes elimination engine guard in...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 troubleshooting 6 malfunctions during operation 6.3 page 77 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b malfunctions during operation 6.3 lubricating oil pressure too low possible causes elimination...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 troubleshooting 6 malfunctions during operation 6.3 page 78 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b exhaust gas temperature too high engine performance and engine speed unchanged possible causes...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 troubleshooting 6 malfunctions during operation 6.3 page 79 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b charge air pressure too low engine performance and engine speed unchanged, air intake conditio...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 troubleshooting 6 malfunctions when stopping 6.4 page 80 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b malfunctions when stopping 6.4 noises during run-down possible causes elimination turbo- charger ...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 troubleshooting 6 speed measurement system 6.5 page 81 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b speed measurement system 6.5 possible causes elimination signal amplitu- de non existent or poor fi...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 removal and installation 7 turbocharger weights 7.1 page 83 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b removal and installation turbocharger weights 7.1 lifting gear with a sufficient load limit mu...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 removal and installation 7 removing the turbocharger 7.2 page 84 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b removing the turbocharger 7.2 disconnect all gas, air and oil pipes in accordance with th...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 removal and installation 7 removing the turbocharger 7.2 page 85 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b ribs (01) not in the middle at the top: completely remove the bearing casing insulation (...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 removal and installation 7 installing the turbocharger 7.3 page 86 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b installing the turbocharger 7.3 remove cover from oil connection. Inspect lifting gear....
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 introduction 8.1 page 87 © copyright 2016 abb. All rights reserved. D ec em ber 2016 hz tl2481_ en r ev is ion b disassembly and assembly introduction 8.1 caution further work further tasks, which are not described h...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 introduction 8.1 page 88 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b tightening torques for turbocharger components the specified tightening torques of screw connections f...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 module weights 8.2 page 89 © copyright 2016 abb. All rights reserved. D ec em ber 2016 hz tl2481_ en r ev is ion b module weights 8.2 the specified weights of individual parts or assemblies are guides round- ed off t...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 module weights 8.2 page 90 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b complete compressor casing internal part tpl69-a tpl73-a tpl77-a 210 350 620 notice the total weight...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 removing and fitting filter silencer or air suction branch 8.3 page 91 © copyright 2016 abb. All rights reserved. D ec em ber 2016 hz tl2481_ en r ev is ion b removing and fitting filter silencer or air suc- tion bra...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 removing and fitting filter silencer or air suction branch 8.3 page 92 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b remove insulation where necessary. Fit swivel lifting ey...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 axial clearance 8.4 page 93 © copyright 2016 abb. All rights reserved. D ec em ber 2016 hz tl2481_ en r ev is ion b axial clearance 8.4 warning physical hazards due to sharp edges on compressor wheel the compressor w...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 removing cartridge group 8.5 page 94 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b removing cartridge group 8.5 caution locked safety segments (76080) during disassembly obs...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 removing cartridge group 8.5 page 95 © copyright 2016 abb. All rights reserved. D ec em ber 2016 hz tl2481_ en r ev is ion b unscrew and remove nuts (74027) together with washers (74018). Remove six studs (74026/7402...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 removing cartridge group 8.5 page 96 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b loop the lifting device around the rear of the flange (f). Carefully rotate the compressor...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 removing cartridge group 8.5 page 97 © copyright 2016 abb. All rights reserved. D ec em ber 2016 hz tl2481_ en r ev is ion b remove screws (76002). Loop lifting gear around diffuser (79000) and remove diffuser. Caref...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 removing cartridge group 8.5 page 98 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b fasten the lifting device (90190) with shackle (90195) to the compres- sor casing external...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 removing cartridge group 8.5 page 99 © copyright 2016 abb. All rights reserved. D ec em ber 2016 hz tl2481_ en r ev is ion b unplug cable connector (86515) and unscrew speed sensor (86505) with o-ring (86506). Discon...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 removing cartridge group 8.5 page 100 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b remove the o-ring (42012). Remove the three screws (61059) together with their verbus rip...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 dismantling and installing the turbine diffuser and nozzle ring 8.6 page 101 © copyright 2016 abb. All rights reserved. D ec em ber 2016 hz tl2481_ en r ev is ion b dismantling and installing the turbine diffuser and...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 dismantling and installing the turbine diffuser and nozzle ring 8.6 page 102 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b position clamp (90921) over stud (61036) until it ...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 dismantling and installing the turbine diffuser and nozzle ring 8.6 page 103 © copyright 2016 abb. All rights reserved. D ec em ber 2016 hz tl2481_ en r ev is ion b replace two screws (61056) in the gas outlet casing...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 dismantling and installing the turbine diffuser and nozzle ring 8.6 page 104 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b fasten the holder (90490) to the gas outlet casing...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 installing cartridge group 8.7 page 105 © copyright 2016 abb. All rights reserved. D ec em ber 2016 hz tl2481_ en r ev is ion b installing cartridge group 8.7 caution oil orifice plates an orifice plate for adjusting...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 installing cartridge group 8.7 page 106 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b caution if the rotor blades have insufficient or no clearance, the blades and cas- ing ...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 installing cartridge group 8.7 page 107 © copyright 2016 abb. All rights reserved. D ec em ber 2016 hz tl2481_ en r ev is ion b fasten set-down compressor casing external part (74000) to crane us- ing lifting device ...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 installing cartridge group 8.7 page 108 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b fit o-rings (77005 and 77006) to wall insert (77000). Fit lifting gear and swivel lifti...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 installing cartridge group 8.7 page 109 © copyright 2016 abb. All rights reserved. D ec em ber 2016 hz tl2481_ en r ev is ion b secure the lifting device (90190) and the shackle (90195) to the rear of the flange (f)....
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 installing cartridge group 8.7 page 110 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b check that nuts (90458) on three safety segments have been tight- ened. Fasten lifting ...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 installing cartridge group 8.7 page 111 © copyright 2016 abb. All rights reserved. D ec em ber 2016 hz tl2481_ en r ev is ion b caution locked safety segments (76080) during assembly the safety segments (76080) are n...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 dismantling and fitting nozzle ring at turbine end 8.8 page 112 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b dismantling and fitting nozzle ring at turbine end 8.8 notice i...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 dismantling and fitting nozzle ring at turbine end 8.8 page 113 © copyright 2016 abb. All rights reserved. D ec em ber 2016 hz tl2481_ en r ev is ion b flange connection disassembly remove two hexagon-head screws (61...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 dismantling and fitting nozzle ring at turbine end 8.8 page 114 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b remove holder (90175) and then nozzle ring (56001). Segment con...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 dismantling and fitting nozzle ring at turbine end 8.8 page 115 © copyright 2016 abb. All rights reserved. D ec em ber 2016 hz tl2481_ en r ev is ion b flange connection assembly carefully clean grooves and contact s...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 dismantling and fitting nozzle ring at turbine end 8.8 page 116 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b segment connection assembly carefully clean slots and contact s...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 dismantling and fitting nozzle ring at turbine end 8.8 page 117 © copyright 2016 abb. All rights reserved. D ec em ber 2016 hz tl2481_ en r ev is ion b collars (c) of segments (51012) must be in slot (s). Check.
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 dismantling and fitting nozzle ring at turbine end 8.8 page 118 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b tightening procedure and order: segment connection begin with t...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 dismantling and fitting nozzle ring at turbine end 8.8 page 119 © copyright 2016 abb. All rights reserved. D ec em ber 2016 hz tl2481_ en r ev is ion b.
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 table of tightening torques 8.9 page 120 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b table of tightening torques 8.9 8.9.
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disassembly and assembly 8 table of tightening torques 8.9 page 121 © copyright 2016 abb. All rights reserved. D ec em ber 2016 hz tl2481_ en r ev is ion b item part number tpl69-a tpl73-a tpl77-a 01 82005 m16x1.5 45 m16x1.5 45 m16x1.5 45 03 1...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 taking out of operation at short notice 9 possibilities for emergency repair 9.1 page 123 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b taking out of operation at short notice possibilities for emerge...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 taking out of operation at short notice 9 locking the rotor 9.2 page 124 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b locking the rotor 9.2 caution a locked rotor must be removed after the turbocharg...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 taking out of operation at short notice 9 locking the rotor 9.2 page 125 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b part number tpl69-a tpl73-a tpl77-a 74027 m16 105 m18 135 m20 175 94006 m8 25 m8 ...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 taking out of operation at short notice 9 locking the rotor 9.2 page 126 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b fit locking flange (94003) using nuts (74027) and then screws (94007 / 94006) and...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 taking out of operation at short notice 9 locking the rotor 9.2 page 127 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b caution make sure all components are clean and free from grease. Push intermediat...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 taking out of operation at short notice 9 locking the rotor 9.2 page 128 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b further measures and information for operation with blocked rotor for 4-stroke en...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 taking out of operation at short notice 9 fit cover plate 9.3 page 129 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b fit cover plate 9.3 notice the cover plate (material: general structural steel, in ...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 taking out of operation at short notice 9 fit cover plate 9.3 page 130 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b notice carry out the work as described in the chapter removal and fitting. Remove c...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 taking out of operation at short notice 9 fit cover plate 9.3 page 131 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b close off opening in gas outlet casing using cover plate. Fasten cover plate using ...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 taking out of operation at short notice 9 fit cover plate 9.3 page 132 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b further measures and information for operation with a turbocharger with cover plate...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 taking out of operation at short notice 9 blocking the inlets and outlets 9.4 page 133 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b blocking the inlets and outlets 9.4 caution shut off the lubricatin...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 mothballing the turbocharger 10 taking the engine out of operation for up to 12 months 10.1 page 135 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b mothballing the turbocharger taking the engine out of...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 mothballing the turbocharger 10 taking the engine out of operation for up to 12 months 10.1 page 136 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b if the total acid number (tan) is greater than 2 mg k...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 mothballing the turbocharger 10 taking the engine out of operation for more than 12 months 10.2 page 137 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b taking the engine out of operation for more than ...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 disposing of turbocharger components 11 taking the engine out of operation for more than 12 months 10.2 page 139 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b disposing of turbocharger components warn...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 spare parts 12 ordering spare parts 12.1 page 141 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b spare parts ordering spare parts 12.1 when making inquiries or ordering spare parts, the following data ...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 spare parts 12 ordering spare parts 12.1 page 142 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b quantity description part number 2 hexagon-head screw 42059 / 42064 2 verbus ripp® washer 42058 / 42063 ...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 spare parts 12 ordering spare parts 12.1 page 143 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b spare parts set (97078) for turbine cleaning system (if provided) caution leaks improper assembly of the...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 spare parts 12 view of turbocharger with part numbers 12.2 page 144 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b view of turbocharger with part numbers 12.2 12.2.
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 spare parts 12 view of turbocharger with part numbers 12.2 page 145 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b part number description 10900 cartridge group 42012 (in customer spare part set) o-rin...
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Operation manual / tpl69-a10 / -a30 ... Tpl77-a10 / -a30 spare parts 12 view of turbine cleaning system with part numbers (optional) 12.3 page 146 © copyright 2016 abb. All rights reserved. D ec em ber 2016 h zt l2481_ en r ev is ion b view of turbine cleaning system with part numbers (optional) 12....
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Abb turbo systems ag bruggerstrasse 71a ch-5400 baden switzerland abb.