Page 1 Operation Manual TPL85-B14 ABB Turbo Systems Ltd CH 5401 Baden Type TPL85-B14 HT842305 Mmax Mmax °C Bmax Bmax 12000 Application according to Year 2016 the Operation Manual made in Switzerland ABB Turbocharging...
Page 2 In case the operation conditions differs signiﬁ cantly from what is considered to be normal for the cur- rent application, it is recommended to contact ABB for a re-calculation of replacement intervals. Frequent load alterations, high temperatures and high speed lower the life of components.
Page 3: Table Of Contents
Periodic checking of the pressure vessel Lifting loads Start-up Oil supply Inspection work Commissioning after taking out of operation Operation Noise emissions Servicing work Expected exchange intervals Speed measurement Underpressure measurement on filter silencer Flexible cut-out © Copyright 2016 ABB. All rights reserved.
Page 4 Fitting gas inlet casing Fitting internal part of compressor casing 8.10 Dry-cleaning device 8.11 Table of tightening torques Short-term turbocharger shut-down Possibilities for emergency repair Locking the rotor Shutting off inlets and outlets Bypass the turbocharger © Copyright 2016 ABB. All rights reserved.
Page 5 Taking out of operation for more than 12 months Disposing of turbocharger components Spare parts 12.1 Ordering spare parts 12.2 View of turbocharger with part numbers 12.3 View of cartridge group with part numbers © Copyright 2016 ABB. All rights reserved.
Page 7: Preliminary Remarks
Operation Manual This Operation Manual enables you to familiarize yourself with the turbo- charger supplied by ABB Turbo Systems and to use it as intended. It provides important information in order that the turbocharger can be op- erated safely, correctly and efficiently.
Page 8: Layout And Function
2 Radial plain bearing 8 Turbine wheel 3 Thrust bearing 9 Bearing casing 4 Radial plain bearing 10 Diffuser 5 Gas outlet casing 11 Compressor wheel 6 Gas inlet casing 12 Compressor casing © Copyright 2016 ABB. All rights reserved.
Page 9 During an emergency stop caused by a failure of the lubrication oil system, this emergency lubrica- tion unit supplies oil to the bearings until the rotor comes to a standstill. © Copyright 2016 ABB. All rights reserved.
Page 10: Intended Use Of The Turbocharger
Any other use will be regarded as a special application which must first be discussed with ABB Turbo Systems. The manufacturer accepts no liability for other applications. If it is used otherwise, ABB Turbo Sys- tems reserves the right to reject all warranty claims.
Page 11: Storage Of New Turbochargers And Spare Parts
Storage of new turbochargers and spare parts Storage of new turbochargers and spare parts up to 6 months New turbochargers and spare parts from ABB Turbo Systems can be stored in sealed packaging without additional mothballing measures for up to 6 months from the date of delivery (marked by the VCI label on the package).
Page 12 Page 10 spare parts Long-term storage of replacement turbochargers or spare parts Per order, turbochargers or cartridge groups will be prepared by ABB Tur- bo Systems for prolonged storage. The package is equipped with a hyg- rometer (see illustration). The following measures are required every 6 months: Check the hygrometer (02) in the sight-glass.
Page 13: Essential Information
The fault must be reported to the person or depart- ment responsible. Additions and alterations to, and conversions of the turbocharger that could compromise safety require the prior approval of ABB Turbo Sys- tems. NOTICE © Copyright 2016 ABB. All rights reserved.
Page 14 Only use original parts from ABB Turbo Systems.  ABB Turbo Systems accepts no liability for any damage resulting from the use of non-original parts and corresponding accessories. Competence of personnel The turbocharger must only be operated and serviced by trained and au- thorised personnel.
Page 15: Symbols And Definitions
Definition of caution / warning The caution and warning signs are described in the chapter Safety. ABB Turbo Systems In this document, ABB Turbo Systems Ltd is abbreviated to ABB Turbo Systems. Official ABB Turbo Systems Service Stations In this document, official service stations are referred to as ABB Turbo- charging Service Stations.
Page 16: Turbocharger Rating Plate
Replacement interval for compressor in 1000 h charger components Replacement interval for turbine in 1000 h Further information Part number for customer Designation of special design Turbocharger weight in kg Turbocharger type Serial number Year of turbocharger construction © Copyright 2016 ABB. All rights reserved.
Page 17 A rating plate is attached to the turbocharger foot, one on the left and one on the right. In the case of turbochargers with insulation supplied by ABB Turbo Systems, at least one additional rating plate is attached to the insu- lation of the gas outlet casing.
Page 18: Contact Information
Operation Manual / TPL85-B14/-B15/-B16 Preliminary remarks Contact information Page 16 Contact information Contact information Contact information for the official service stations of ABB Turbo Systems is available online. Scan the QR code to access our website.  ABB Turbo Systems Ltd Bruggerstrasse 71a...
Page 19: Safety
Page 17 Safety Introduction Turbochargers manufactured by ABB Turbo Systems are state of the art and comply with the pertinent safety and health-protection requirements that applied when the turbocharger was manufactured. Consequently, the turbocharger is safe to operate. Nevertheless, during turbocharger opera- tion and when working on the turbocharger, residual risks can exist which: ...
Page 20: Definition Of Mandatory Signs
Serious machine or property damage may occur if work and operating instructions marked with this symbol and the word CAUTION are either CAUTION not followed or not followed precisely. Caution signs must be observed at all times.  © Copyright 2016 ABB. All rights reserved.
Page 21: Warning Plates On The Turbocharger
Warning plates on the turbocharger Page 19 Warning plates on the turbocharger Warnings that have been attached to turbochargers by ABB Turbo Sys- tems must not be removed. Illegible warnings must be replaced with new ones. Further information is available from ABB Turbocharging service stations.
Page 22: Safe Operation And Maintenance
Remove combustible objects and substances out of the range of flying  sparks. Cover all connections on the turbocharger so that no foreign objects  can get into the turbocharger. © Copyright 2016 ABB. All rights reserved.
Page 23 Protect the floor against unintentional penetration of detergents or sol-  vents before starting cleaning operations. Wear appropriate protective clothing.  Inspect the electric cables for abrasion and damaged areas before and  after your cleaning work. © Copyright 2016 ABB. All rights reserved.
Page 24 Secure the rotor so it cannot turn. The rotor can turn on its own from  the force of the stack draught. Clean the turbocharger before mothballing it.  Wear appropriate protective clothing.  © Copyright 2016 ABB. All rights reserved.
Page 25 Observe the general rules for occupational safety and prevention of  accidents. Ensure workplace safety.  Only perform operations that are described in this document.  Only perform operations for which you have previously received in-  struction or training. © Copyright 2016 ABB. All rights reserved.
Page 26 Wear safety gloves against thermal risks. Hot surfaces on uninsulated turbochargers Uninsulated turbochargers can cause serious personal injuries (burns). The turbocharger is supplied by ABB Turbo Systems without insulation WARNING depending on the order from the engine builder. In this case, the engine builder is responsible for insulating the turbocharger properly or for providing protection against hot surfaces being touched.
Page 27 The escape of operating and auxiliary materials into the atmosphere or contamination of the ground and water due to improper disposal can CAUTION lead to environmental damage. Handle operating and auxiliary materials carefully.  © Copyright 2016 ABB. All rights reserved.
Page 28 Wear safety gloves against chemical risks. Use only suitable, non-combustible insulating materials.  Ensure that the work area is well ventilated.  Wear suitable work clothing (safety glasses, respiratory mask).  Avoid stirring up dust.  © Copyright 2016 ABB. All rights reserved.
Page 29: Periodic Checking Of The Pressure Vessel
Heed any country-specific regulations.  Periodic checking of the pressure vessel The pressure vessels used by ABB Turbo Systems, such as those for wet or dry cleaning, are so-called "simple pressure vessels".  The local, statutory regulations covering periodic checks of pressure vessels must be observed.
Page 30: Lifting Loads
Completely screw in assembly / fitting devices without fail so that they  cannot work loose during use. Use assembly / fitting devices only for applications described.  Make sure removed turbocharger components stand safely and se-  curely. © Copyright 2016 ABB. All rights reserved.
Page 32 If a separate lubricating system has been designed for operation in the viscosity range of the engine lubrication system, i.e. 45 ... 170 cSt, then the oil pressure limits according to the engine lubrication information may be applied for such a system. NOTICE © Copyright 2016 ABB. All rights reserved.
Page 33 Not permissible -> stop the engine > 140 If the turbocharger has been operated outside the permissible range for a prolonged period of time, ABB Turbo Systems recommends having the turbocharger inspected by an ABB Turbocharging Service Station. © Copyright 2016 ABB. All rights reserved.
Page 34: Inspection Work
Check oil pressure in oil supply lines.  Check whether the warning plates are present and legible. Warning plates on tur-  bocharger Check whether the protective sheets have been removed.  © Copyright 2016 ABB. All rights reserved.
Page 35 If oily liquid continues to escape after this period, an oil leak must be suspected. The first step is to check for leakage of the oil NOTICE supply to the turbocharger. If this is leaky, contact an official ABB Tur- bocharging service station. 3.2.4 Inspection after 100 service hours Clean or replace lubricating oil filters after the first 100 service hours.
Page 36: Commissioning After Taking Out Of Operation
Start up turbocharger oil circulation system at engine end.  Prepare turbocharger for operation as instructed in section "Inspection  work before start-up / commissioning" of chapter headed "Start-up / commissioning". Start up turbocharger.  © Copyright 2016 ABB. All rights reserved.
Page 37: Operation
Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 : A-weighted emission sound pressure level In the event of divergent insulation designs, the engine builder must en- sure that equivalent acoustic insulating measures are taken. © Copyright 2016 ABB. All rights reserved.
Page 38 Operation Noise emissions Page 36 Suggestion for noise insulation of the bellows Compressor casing Insulation pads Bellows Insulation mat (at least 15 mm) Charge air duct / scavenging Sheet metal cover air line © Copyright 2016 ABB. All rights reserved.
Page 39: Servicing Work
Despite observance of the service intervals, unusual loads, such as several start-stops a day, harsh environmental factors, poor fuel quality CAUTION or heavy installation vibration can lead to premature machine damage. A shortened service interval must be arranged with ABB Turbo Sys-  tems. Service inspection after 5 years...
Page 40  Pressure loss in air filter 4.2.3 Servicing work according to the engine manufacturer's instructions Clean or replace oil filter in supply line to turbocharger when engine is Oil filter  not running. © Copyright 2016 ABB. All rights reserved.
Page 41 4.2.5 Service work every 36,000 hours The replacement of bearing parts and the inspection and assessment of the rotor must be carried out by an ABB Turbocharging Service Station. Remove the filter silencer  Clean the filter silencer and inspect for damage ...
Page 42: Expected Exchange Intervals
Decisive in this respect are various influencing parameters, which can drastically shorten the replacement intervals of these parts in extreme cases. During the specified periodic service work, the individual components are inspected for wear and, if necessary, replaced. © Copyright 2016 ABB. All rights reserved.
Page 43 The specified values are only guide values and not guaranteed. They can vary significantly due, for example, to inadequate servicing, NOTICE frequent emergency shutdowns and the use of fuel or lubricating oil of inferior quality. © Copyright 2016 ABB. All rights reserved.
Page 44: Speed Measurement
If you pull the speed measurement cables too hard, contacts can be pulled out. CAUTION Do not tension the speed measurement cables.  Part number Description 42047 Screw plug 86505 Speed sensor 86515 Cable connector for 86505 86526 F/I converter 86528 Tachometer © Copyright 2016 ABB. All rights reserved.
Page 45 If the engine can be stopped for a short time: Inspect the air and gas lines as well as the turbocharger and eliminate  any problems. In any event, it is recommended that you contact the nearest ABB  Turbocharging Service Station. © Copyright 2016 ABB. All rights reserved.
Page 46 Connect cable connector to speed sensor.  Switch on lubricating oil supply to turbocharger.  4.4.3 Failure of speed measuring system Possible reasons for failure of the speed measuring system are described in the chapter Troubleshooting. © Copyright 2016 ABB. All rights reserved.
Page 47: Underpressure Measurement On Filter Silencer
Page 45 silencer Underpressure measurement on filter silencer A U-tube manometer can be ordered from ABB Turbo Systems for meas- uring the negative pressure at the filter silencer. The measurement can be used for the following purposes:  To measure the correction factor for calculating the turbocharger effi- ciency during the engine acceptance test.
Page 48 The measuring rod on the U-tube manometer can be withdrawn to the bottom water level so that the pressure differential (A) can be easily NOTICE read off. The U-tube manometer can be read off more easily if slightly coloured water is poured in. © Copyright 2016 ABB. All rights reserved.
Page 49: Flexible Cut-Out
These can result in damage with serious consequenc- es or even a total loss of the turbocharger. Never open the gas inlet flap during cut-out operation.  Never close the air-outlet flap during normal operation.  © Copyright 2016 ABB. All rights reserved.
Page 50: Stopping The Engine
Stopping the engine Before shutting down the engine, it must be allowed to idle for about 3 minutes longer so that the circulating lubricating oil can take away heat from the turbocharger bearings. CAUTION © Copyright 2016 ABB. All rights reserved.
Page 51: Maintenance
 The safety precautions must be observed during all maintenance and servicing work. The cleaning points described in the following are:  Filter silencer  Compressor  Turbine and nozzle ring © Copyright 2016 ABB. All rights reserved.
Page 52: Cleaning The Filter Silencer
81266 Cover grid 81270 Tension band 81136 Absorption segment 81271 Lock 81137 Cover sheet metal 81268 Connecting strip 81135 Filter silencer body E Insert unit - absorption segment / cover sheet metal fitted © Copyright 2016 ABB. All rights reserved.
Page 53 Otherwise there is a risk of damage or change of shape. Very dirty absorption segments and filter strip as well as damaged con- necting strips should be replaced with original parts from ABB Turbo Systems. NOTICE...
Page 54 Fit cover grids (81266) and connecting strips (81268) to filter silencer  body (81135). Run tension bands (81270) through lugs (eyelets) on connecting  strips. Tighten all tension bands at locks (81271).  Fit filter strip (81265). If provided  © Copyright 2016 ABB. All rights reserved.
Page 55 Removing / installing the cleaning line Disassembling the cleaning pipe Disconnect feed pipe (02) from injection pipe (01) and remove pipe  connector from feed pipe. Withdraw feed pipe (02) from guide tube (03).  © Copyright 2016 ABB. All rights reserved.
Page 56 Fitting complete cleaning pipe Refit guide tube (03) and peen fix it after putting insert units (E) in  place. Fit feed pipe (02) and screw onto injection pipe (01) using connector.  © Copyright 2016 ABB. All rights reserved.
Page 57: Changing The Filter Strip On The Filter Silencer Casing
This chapter is only applicable to turbochargers with a filter silencer cas- ing. The filter strip (81265) is replaced when a filter silencer is fitted. Dismantle the circumferential part (9).  Open the lock for the filter strip (81265).  © Copyright 2016 ABB. All rights reserved.
Page 58 Pull the old filter strip until the new filter strip is wound completely  around filter silencer. Loosen the connection between the new and old filter strips.  Fasten the newly fitted filter strip (81265) and then refit the circumfer-  ential part (9). © Copyright 2016 ABB. All rights reserved.
Page 59: Cleaning The Compressor During Operation
The interval between periodic cleaning is very dependent on the operating Cleaning interval conditions. In general, cleaning should be carried out every 25 ... 100 op- erating hours. Should the specified cleaning intervals prove incompatible with engine operation, please contact ABB Turbo Systems. © Copyright 2016 ABB. All rights reserved.
Page 60 Cleaning of the compressor during operation is carried out using the cleaning method described in the following:  Wet cleaning This cleaning method has been tested and approved by ABB Turbo Sys- tems. To clean the compressor stage during operation, water is injected in front...
Page 61 Operating state prerequisites for compressor cleaning with XC3 In order to carry out a successful cleaning procedure which has been tested and is recommended by ABB Turbo Systems, the following pre- requisite must be met: Engine load 25 to 85 % ...
Page 62 If the cleaning results are still not satisfactory after three attempts and the engine values are also unsatisfactory, we recommend that you have NOTICE the turbocharger inspected and cleaned by an official ABB Turbocharg- ing Service Station. Cleaning parameters per turbocharger compressor...
Page 63 Operating state prerequisites for compressor cleaning with XC4 In order to carry out a successful cleaning procedure which has been tested and is recommended by ABB Turbo Systems, the following pre- requisite must be met: Engine load 25 to 85 % ...
Page 64 If the cleaning result is still not satisfactory after three attempts and the engine values are also unsatisfactory, we recommend that you have the NOTICE turbocharger inspected and cleaned by an official ABB Turbocharging Service Station. Cleaning parameters per turbocharger compressor...
Page 65: Cleaning Turbine Blades And Nozzle Ring In Operation
Cleaning methods Several methods are possible for cleaning the turbine and nozzle ring dur- ing operation. The cleaning methods described in the following have been tested and are recommended by ABB Turbo Systems:  Wet cleaning  Dry cleaning © Copyright 2016 ABB. All rights reserved.
Page 66 Always adhere to the respective cleaning instructions.  If several turbochargers are installed on one engine, we recommend Cleaning more than one cleaning one turbocharger turbine with nozzle ring after the other. turbocharger turbine © Copyright 2016 ABB. All rights reserved.
Page 67 Operating state prerequisites for wet cleaning In order to be able to carry out a satisfactory cleaning process which has been tested and recommended by ABB Turbo Systems, the follow- ing prerequisites must be met: After an engine start-up or during operation, the engine performance ...
Page 68 3 ... 3.5 bar. Inject water for 5 minutes (injection nozzle 7a) or 10 minutes (injection  nozzle 7b) at constant engine output. Check whether the exhaust gas temperature decreases following the  turbine. © Copyright 2016 ABB. All rights reserved.
Page 69 If the cleaning result is still not satisfactory after three attempts and the engine values are also unsatisfactory, we recommend that you have the NOTICE turbocharger inspected and cleaned by an official ABB Turbocharging Service Station. While the water is being injected, grinding noises might be heard at the turbine end.
Page 70 NOTICE Operating state prerequisites for integrated dry-cleaning device In order to carry out a successful cleaning procedure which has been tested and is recommended by ABB Turbo Systems, the following pre- requisite must be met: Engine load 25 to 85% ...
Page 71 10 Heat protection hose (51516) 05 On-Off valve (51505) 11 Screw insert (51514) 06 Ball valve (51513) 12 Cleaning instructions (51517) The air system must be protected against overpressure (> 10 bar) . CAUTION © Copyright 2016 ABB. All rights reserved.
Page 72 If the cleaning result is still not satisfactory after three attempts and the engine values are also unsatisfactory, we recommend that you have the NOTICE turbocharger inspected and cleaned by an official ABB Turbocharging Service Station. © Copyright 2016 ABB. All rights reserved.
Page 73 The cleaning granulate must be stored in a dry and clean location to prevent blockage of the pipes when cleaning. Possible suppliers of material for dry cleaning can be found on the In- ternet. NOTICE © Copyright 2016 ABB. All rights reserved.
Page 74 Operating state prerequisites for the non-integrated dry-cleaning device In order to carry out a successful cleaning procedure which has been tested and is recommended by ABB Turbo Systems, the following pre- requisite must be met: Engine load 25 to 85 % ...
Page 75 03 Double nipple G2" 08 Compressed air shut-off valve 04 Copper gasket 09 Compressed air line (inner diameter 8 mm) 05 Plug cock or slide valve G1'' 10 Compressed air maximum 6 bar © Copyright 2016 ABB. All rights reserved.
Page 76 If the cleaning result is still not satisfactory after three attempts and the engine values are also unsatisfactory, we recommend that you have the NOTICE turbocharger inspected and cleaned by an official ABB Turbocharging Service Station. © Copyright 2016 ABB. All rights reserved.
Page 77 Cleaning parameters for non-integrated dry cleaning device The choice of material takes place according to chapter Integrated dry cleaning of turbine and nozzle ring during operation. NOTICE Amount of granulate per Product Amount of granulate [dm turbocharger TPL85-B © Copyright 2016 ABB. All rights reserved.
Page 79: Malfunctions When Starting
Certain tolerances must be observed to avoid a significant loss of efficiency.  If there is any doubt about the extent of rubbing, then an ABB Turbocharging Service Station must be contacted.  Have a dimension check carried out by an ABB Turbocharging Service Station.
Page 80: Surging Of The Turbocharger
Possible damage to components, such as the compressor wheel, tur- bine blades, bearings and filter silencer CAUTION Have the cause clarified immediately by an ABB Turbocharging ser-  vice station and rectified. Have components inspected for damage and, if necessary, replaced ...
Page 81: Malfunctions During Operation
Defects such as leaks in the ex- Repair them haust gas pipes or charge air ducts Increase in speed Possible causes Elimination Turbo- Heavily contaminated nozzle Contact an ABB Turbocharging charger ring (with 4-stroke application) Service Station © Copyright 2016 ABB. All rights reserved.
Page 82 Charge air Cooler contaminated Clean it cooler Cooling water volume too Top up the water Entry temperature of cooling Inspect / clean the cooling sys- water too high Inadequate ventilation Improve the ventilation © Copyright 2016 ABB. All rights reserved.
Page 83 Engine Malfunctioning injection system Repair it or contact the manufac- turer Poorly adjusted injection system Correct it Engine performance higher than Check engine performance expected Turbo- Manometer display wrong Replace the manometer charger © Copyright 2016 ABB. All rights reserved.
Page 84: Malfunctions When Stopping
Rubbing rotor Foreign object in turbocharger Run-down time too short Possible causes Elimination Turbo- Turbocharger contaminated Clean it charger Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger © Copyright 2016 ABB. All rights reserved.
Page 85: Speed Measurement System
This problem is eliminated by removing the gasket. Defective sensor Contact ABB Turbocharging service station. Measured Dirty sensor tip The sensor tip is magnetic and can thus at- speeds too tract metal particles.
Page 87: Removal And Installation
Lifting gear with a sufficient load limit must be used for removing and in- stalling the turbocharger. The following weight specification is the heaviest possibility. This guide value can differ from data on the rating plate, de- pending on the specification. Weight [kg] TPL85-B 12000 © Copyright 2016 ABB. All rights reserved.
Page 88: Remove The Turbocharger
Fasten each of two sets of lifting gear to each of two bearing casing  ribs provided for this purpose. Unscrew fixing screws in foot.  Lift turbocharger off engine and put it down to one side.  © Copyright 2016 ABB. All rights reserved.
Page 89 If support for the turbocharger is missing or defective when setting it aside, the turbocharger could tip over and cause serious or even fatal injuries. WARNING Support turbocharger at a suitable point.  Cover oil connection.  © Copyright 2016 ABB. All rights reserved.
Page 90: Installing The Turbocharger
Fasten gas, air and oil lines in accordance with engine builder’s in-  structions. Adapt insulating shell to suit bearing casing and fasten it.  Plug in cable connector on speed sensor.  © Copyright 2016 ABB. All rights reserved.
Page 91: Disassembly And Assembly
CAUTION Only carry out those tasks that are described in this chapter.  Marking casing positions for assembly ABB Turbo Systems recommends that the casing positions are marked before disassembling the turbocharger. NOTICE Identifying assembly devices Not all assembly devices are marked with a part number. They can be identified using the tool list.
Page 92 They are not commercially available products. Use assembly / fitting devices only for the applications described.  Lifting gear Equipment for lifting and transporting loads (ropes, chain hoists, cranes). Lifting gear is not supplied by ABB Turbo Systems. © Copyright 2016 ABB. All rights reserved.
Page 93: Module Weights
Weights [kg] Item Description TPL85-B Filter silencer Compressor casing internal part Wall insert Diffuser Compressor casing external part 1200 Cartridge group 3000 Cover ring Nozzle ring Radial gas inlet casing © Copyright 2016 ABB. All rights reserved.
Page 94 Compressor casing internal part assembly Weight [kg] TPL85-B 1630 The total weight of the complete internal part of the compressor casing includes the internal part of the compressor casing, the diffuser and the wall insert. NOTICE © Copyright 2016 ABB. All rights reserved.
Page 95: Silencer Casing
Only the assembly of the silencer casing is described in detail. Its disassembly is carried out in the reverse order of its assembly. Item Description Item Description Bottom part 5,6,9 Circumferential part 3,4,7,8 Side part 10,11 Flange Part number Complete silencer casing 81500 © Copyright 2016 ABB. All rights reserved.
Page 96 The position of screw (A) serves as a reference for correct fitting of the silencer casing. NOTICE Before removal of bottom part (1), mark position of screw (A).  Fit all remaining screws on bottom part (1).  © Copyright 2016 ABB. All rights reserved.
Page 97 Fit side parts (3) and (4) to filter silencer and to bottom part (1) using  screws. Fit side parts (7) and (8) to filter silencer, to bottom part (2) and to side  parts (3, 4) using screws. © Copyright 2016 ABB. All rights reserved.
Page 98 Insert flanges (10) and (11) from the side between side parts and fit  screws. Fit circumferential part (5) using screws.  Fit circumferential part (6) using screws.  Fit circumferential part (9) using screws.  © Copyright 2016 ABB. All rights reserved.
Page 99 Tighten all screws of side parts (3, 4, 7 and 8) and flanges (10 and 11).  Tighten all screws of circumferential parts (5, 6 and 9).  Compensator Fit bellows (C) to silencer casing using frame (F), screws (S) and nuts (N).  © Copyright 2016 ABB. All rights reserved.
Page 100: Removing And Installing The Filter Silencer
Unscrew the nuts (74027) and remove them together with the washers  (74018). Remove the filter silencer and it set down to one side.  Install the filter silencer in the reverse order. Installing the filter silencer  © Copyright 2016 ABB. All rights reserved.
Page 101: Axial Clearance
Measure and note the axial clearance (A).  Clearance A [mm] TPL85-B 0.54 … 0.79 If the axial clearance A is out of tolerance, an ABB Turbocharging Ser- vice Station must be contacted. CAUTION © Copyright 2016 ABB. All rights reserved.
Page 102: Removing Internal Part Of Compressor Casing
Note the control dimension (u). NOTICE Control dimension (u) Dimension TPL85-B [mm] 27.6 The compressor casing internal part (76000) has now been detached from the compressor casing external part (74000) and can be removed. © Copyright 2016 ABB. All rights reserved.
Page 103 Remove screws (42059) together with flange. Also remove possible  contamination behind the flange. Fit flange with screws (42059) and new gasket (42041) after cleaning.  © Copyright 2016 ABB. All rights reserved.
Page 104 Set down the casing with the flange (F) on an underlay.  Make sure that the underlay does not slip. Allow the compressor casing internal part to rest only on the flange (F).  Check underlay and adjust if necessary.  WARNING © Copyright 2016 ABB. All rights reserved.
Page 105 Loop lifting gear around diffuser (79000) and remove diffuser.  Carefully press off the wall insert (77000) using the press-off screws  (90900) and remove it using the swivel lifting eye (90230). Remove O-rings (77005, 77006).  © Copyright 2016 ABB. All rights reserved.
Page 106: Removing Gas Inlet Casing
Remove screws (56014), sleeves (56013) and nozzle ring (56001).  Undo and remove screws (57005).  Fit two guide studs (90320).  Press away cover ring (51085) using press-off screws (90901) and  remove over guide studs (90907). © Copyright 2016 ABB. All rights reserved.
Page 107: Fitting Gas Inlet Casing
Fit gas inlet casing (51001) complete with nozzle ring to gas outlet  casing (61001) using screws (61044). Remove lifting gear complete with shackle (90195).  Fit insulation to gas inlet casing (51001).  © Copyright 2016 ABB. All rights reserved.
Page 108: Fitting Internal Part Of Compressor Casing
Tighten screws (76002) as far as they will go and then back them off a  ¼ turn. Leave screws loose and diffuser moveable. Fasten lifting gear to lifting device (90190) and shackles (90195) of  support angle (90025). © Copyright 2016 ABB. All rights reserved.
Page 109 Insert internal part of compressor casing as far as it will go.  Remove guide studs (90320) and fit studs (74026/74029).  Use studs [10x 74029 and 2x 74026 (each screwed in at top and  bottom)]. © Copyright 2016 ABB. All rights reserved.
Page 110 Note control dimension (s). The safety segments (76080) are again in the operating position. NOTICE Control dimension (s) Dimension TPL85-B [mm] 18.5 Put the nuts (90458) back in the toolbox.  © Copyright 2016 ABB. All rights reserved.
Page 111 Measure and note the axial clearance (A).  Clearance A [mm] TPL85-B 0.54 … 0.79 If the axial clearance A is out of tolerance, an ABB Turbocharging Ser- vice Station must be contacted. CAUTION Unscrew nuts (74027) and remove them together with washers ...
Page 112: Dry-Cleaning Device
51515 51520 51521 51522 51518 R3/4" – G1/2" – M18x1.5 M30x2 G1/2" – G3/4" R1/2" G1/2A Screw in the screw connection hand tight at first, then tighten by another 2 to 3 turns. © Copyright 2016 ABB. All rights reserved.
Page 114: Table Of Tightening Torques
Operation Manual / TPL85-B14/-B15/-B16 Disassembly and assembly Table of tightening torques 8.11 Page 112 8.11 Table of tightening torques 8.11 © Copyright 2016 ABB. All rights reserved.
Page 115 M22 x 1.5 56014 57005 90458 Screw in the screw (76002) as far as it will go and then back it off ¼ turn. The screw must be loose and the diffuser moveable. © Copyright 2016 ABB. All rights reserved.
Page 117: Short-Term Turbocharger Shut-Down
(emergency repair), the following possibilities are available:  Locking turbocharger rotor  Shutting off inlets and outlets  Turbocharger bypass Emergency repairs that can be carried out quickest have been de- scribed first. NOTICE © Copyright 2016 ABB. All rights reserved.
Page 118: Locking The Rotor
As, in these cases, operation with a locked rotor is only brief and the loads are low, subsequent removal of the rotor is not necessary (if no balancing screws have been unscrewed). © Copyright 2016 ABB. All rights reserved.
Page 119 The locking flange (94003) must be fitted to the compressor wheel using at least 9 screws (94008), tightened according to the Table of tightening torques. Table of tightening tor- Part number TPL85-B14/-B15/-B16 ques [Nm] 94006 94008 © Copyright 2016 ABB. All rights reserved.
Page 120 Operation Manual / TPL85-B14/-B15/-B16 Short-term turbocharger shut-down Locking the rotor Page 118 TPL85-B14/-B15/-B16 Compressor type CV11 Compressor type CV12, CV13, CV16 © Copyright 2016 ABB. All rights reserved.
Page 121  Maximum permissible engine load: 50%. Attention must be paid to the speed of the undamaged turbochargers in any event. The speed limit n given on the turbocharger rating plate Bmax must not be exceeded. CAUTION © Copyright 2016 ABB. All rights reserved.
Page 122: Shutting Off Inlets And Outlets
This applies to engines with one turbocharger only:  The connections are ready and pipes for the bypass are available.  Fit bypass around turbocharger.  In this respect, refer to the engine manufacturer's instructions. NOTICE © Copyright 2016 ABB. All rights reserved.
Page 123: Storing Turbocharger
If the total acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking an engine out of opera- tion: Remove turbocharger.  Rotor and bearing parts must be removed by an official ABB Turbo-  charging service station and refitted afterwards. Clean all parts. ...
Page 124: Taking Out Of Operation For More Than 12 Months
40 to 70 % and no condensation can form. Condition of the mothballed turbocharger Check the mothballed turbocharger parts for corrosion every year.  If there are signs of rust: Clean parts thoroughly and renew protection  against corrosion. © Copyright 2016 ABB. All rights reserved.
Page 125: Disposing Of Turbocharger Components
 Dispose of non-metallic materials as waste.  Dispose of residues of lubricants as waste oil.  Dispose of electronic components as electronic waste.  Dispose of thermal insulation as hazardous waste.  © Copyright 2016 ABB. All rights reserved.
Page 127: Spare Parts
 Turbocharger type  Serial number (HT……)  Description and part number Spare parts can be ordered from an official ABB Turbocharging Service Station. If different design versions have not been taken into consideration in  this document, please contact an ABB Turbocharging Service Station.
Page 128 Customer spare part set (97070) for service work every 36000 h Quantity Description Part number O-ring 42012, 76040 Gasket 42041, 42069 Hexagon-head screw 42059, 42064 Gasket 42045 Hexagon-head screw 56014, 57005 Hexagon nut 61037 Gasket 61041 O-ring 77005, 77006 O-ring 86506 © Copyright 2016 ABB. All rights reserved.
Page 130: View Of Turbocharger With Part Numbers
Operation Manual / TPL85-B14/-B15/-B16 Spare parts View of turbocharger with part numbers 12.2 Page 128 12.2 View of turbocharger with part numbers 12.2 © Copyright 2016 ABB. All rights reserved.
Page 131 Compressor casing internal part 76040 (in customer spare parts set) O-ring 76080 Safety segment 77000 Wall insert 77005 (in customer spare parts set) O-ring 77006 (in customer spare parts set) O-ring 79000 Diffuser 81000 Filter silencer © Copyright 2016 ABB. All rights reserved.
Page 132: View Of Cartridge Group With Part Numbers
Operation Manual / TPL85-B14/-B15/-B16 Spare parts View of cartridge group with part 12.3 Page 130 numbers 12.3 View of cartridge group with part numbers 12.3 © Copyright 2016 ABB. All rights reserved.
Page 133 42059 (in customer spare parts set) Hexagon-head screw 42064 (in customer spare parts set) Hexagon-head screw 42295 Non-return flap 43001 Partition wall 43005 O-ring 86505 Speed sensor 86506 (in customer spare parts set) O-ring © Copyright 2016 ABB. All rights reserved.
Page 134 ABB Turbo Systems AG Bruggerstrasse 71a CH-5400 Baden Switzerland...

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