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- TPL69-A10
- Operation Manual
ABB TPL69-A10 Operation Manual - page 93
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 branch
8.3
Disconnect all air lines / ducts in accordance with engine builder’s in-
structions.
Remove insulation where necessary.
Loop lifting gear around air suction branch. Pass lifting gear through
possibly provided holes in ribs to improve stability.
Unscrew nuts (74027) and remove together with washers (74018).
Remove air suction branch and set down to one side.
Install air suction branch in reverse order.
8.3
Install air suction branch
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.
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 / 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...
Page 4
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...
Page 5
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...
Page 7
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...
Page 8
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...
Page 9
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...
Page 10
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...
Page 11
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...
Page 12
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...
Page 13
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...
Page 14
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...
Page 15
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...
Page 16
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...
Page 17
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...
Page 18
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...
Page 19
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...
Page 20
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...
Page 21
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...
Page 22
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...
Page 23
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...
Page 24
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...
Page 25
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...
Page 26
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...
Page 27
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...
Page 28
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...
Page 29
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...
Page 30
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...
Page 31
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...
Page 32
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...
Page 33
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 ...
Page 34
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...
Page 35
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 ...
Page 36
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...
Page 37
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...
Page 38
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...
Page 39
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...
Page 40
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. ...
Page 41
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...
Page 42
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...
Page 43
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 (...
Page 44
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...
Page 45
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...
Page 46
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...
Page 47
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...
Page 48
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...
Page 49
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...
Page 50
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) ...
Page 51
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)...
Page 52
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...
Page 53
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...
Page 54
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...
Page 55
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 ...
Page 56
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...
Page 57
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...
Page 58
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...
Page 59
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...
Page 60
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 ...
Page 61
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 ...
Page 62
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. ...
Page 63
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...
Page 64
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...
Page 65
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...
Page 66
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-...
Page 67
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...
Page 68
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...
Page 69
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...
Page 70
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...
Page 71
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...
Page 72
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 ...
Page 73
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...
Page 74
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 ...
Page 77
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...
Page 78
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...
Page 79
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...
Page 80
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...
Page 81
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...
Page 82
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 ...
Page 83
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...
Page 85
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...
Page 86
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...
Page 87
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 (...
Page 88
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....
Page 89
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...
Page 90
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...
Page 91
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.