ABB TPL85-B12 Operation Manual Download

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Operation Manual

ABB Turbocharging

Type

TPL85-B12

HT846086

Mmax

200

Mmax

550

Bmax

190

Bmax

520

1/s

°C

12000

100

Year

2021

Application according to

the Operation Manual

HZTL2480 English

TPL85-B12

Original Operation Manual

Summary of Contents for TPL85-B12

Page 1: ...BB Turbocharging Type TPL85 B12 HT846086 nMmax 200 t Mmax 550 nBmax 190 t Bmax 520 1 s C 12000 36 100 100 Year 2021 Application according to the Operation Manual kg HZTL2480 English TPL85 B12 Original...

Page 2: ...eplacement intervals of components depends on the load profile turbine inlet temperature suction air temperature and turbocharger speed In case the operation conditions differs significantly from what...

Page 3: ...on of Safety instructions 16 2 5 Warning plates on the turbocharger 17 2 6 Safe operation and maintenance 18 2 7 Hazards during operation and maintenance 21 2 8 Periodic checking of the pressure vesse...

Page 4: ...2 Module weights 92 8 3 Silencer casing 94 8 4 Removing and installing the filter silencer 99 8 5 Axial clearance 101 8 6 Removing cartridge group 102 8 7 Inspection and assessment of valve block 109...

Page 5: ...Manual TPL73 B 85 B11 B12 Table of contents Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 12 2 View of turbocharger with part numbers 148 12 3 View of cartridge group with part n...

Page 6: ...Systems and to use it as intended It provides important information in order that the turbocharger can be operated safely correctly and efficiently This Operation Manual complements and expands existi...

Page 7: ...ZTL2480_EN Revision D July 2018 1 2 Layout and function 1 Filter silencer 8Nozzle ring 2 Radial plain bearing 9Turbine wheel 3 Thrust bearing 10Bearing casing 4 Bearing bush 11Diffuser 5 Radial plain...

Page 8: ...to the gas outlet casing 06 The air which is necessary for operation of the diesel engine and is com pressed in the turbocharger is routed through the filter silencer 01 to the compressor wheel 12 Th...

Page 9: ...other pur pose ABB Turbo Systems reserves the right to reject all warranty claims State of the art This turbocharger was built according to state of the art technology and is operationally safe accord...

Page 10: ...roducts are not hazardous in the sense of the Hazardous Sub stances Ordinance Nevertheless the following points are to be ob served when handling VCIs u Ensure good room ventilation u Do not eat drink...

Page 11: ...g Service Sta tion and repacked u Inspect the package for damage If the package is damaged the tur bocharger or cartridge group must be inspected by an ABB Tur bocharging Service Station and repacked...

Page 12: ...and wearing of personal protective equipment NOTICE The manner in which personnel work on and with the turbocharger with regard to safety and risks is to be checked on a regular basis in accord ance w...

Page 13: ...nce of personnel The turbocharger must only be operated and serviced by trained and au thorised personnel Basic mechanical training is a prerequisite Design variants This document is valid for differe...

Page 14: ...uct Definition of mandatory signs Mandatory signs show the protective equipment to be worn for a task The mandatory signs are described in chapter Safety and must be com plied with Definition of cauti...

Page 15: ...agreed with the enginebuilder 02 Turbocharger operating limits during operation Recommended replace ment intervals for tur bocharger components 03 Replacement interval for plain bearings in 1000 h 04...

Page 16: ...tMmax normally apply only when running at overload 110 during trials on the engine test bed Operation above nMmax and tMmax is not permit ted Non observance of the recommended replacement intervals i...

Page 17: ...ce of insufficient observance of the safety instruc tions are the consequence of unsatisfactory and improper execution of maintenance and inspection work The operating company is responsible for acces...

Page 18: ...r protection 2 4 Definition of Safety instructions The following symbols and terms used in this manual concern safety or refer to possible hazards WARNING Definition of warning Serious personal injuri...

Page 19: ...ing plates that must be observed are attached to the turbocharger The warning plates must always be present in the intended locations and must be legible Part number Size mm Product 81080 105 x 74 TPL...

Page 20: ...on the turbocharger if you are under physical or mental stress u Work only with suitable tools as well as equipment and working ma terials that are in perfect condition u Electric tools must be solidl...

Page 21: ...mage or changes in operational perform ance to person responsible u If damage is discovered immediately shut down turbocharger and se cure it against inadvertent or unauthorized use u When switching o...

Page 22: ...t the supply of oil is interrupted especially with an external oil supply u Put the engine into operation only after all parts have been refitted properly CAUTION Mechanical work on the turbocharger P...

Page 23: ...ocharger in accordance with instructions u During maintenance work secure the rotor against unintentional ro tation Mechanical hazards when working on the turbocharger During maintenance work various...

Page 24: ...85 dB A always wear ear protection Wear ear protection Hazards due to hot surfaces and substances During operation turbocharger surfaces and attached parts as well as operating materials lubricating...

Page 25: ...harger surfaces is compuls ory Wear safety gloves to protect against thermal hazards Hazards due to operating and auxiliary materials Operating and auxiliary materials are substances used for operatio...

Page 26: ...tamination of the ground and water due to improper disposal can lead to environmental damage u Handle operating and auxiliary materials carefully u Heed the instructions for use safety data sheets and...

Page 27: ...area u Take particular care when removing old insulating materials u Dispose of insulating materials properly and in an environmentally compatible way in accordance with applicable local regulations W...

Page 28: ...ls must be observed The operating company is responsible for the safe operation of the pressure vessel WARNING Danger due to pressure vessels The operating company must make sure the pressure vessels...

Page 29: ...loading u Fasten turbocharger assemblies components as described in re spective handling steps u Before attaching slings allow turbocharger components to cool down maximum 80 C u Use suitable protect...

Page 30: ...ditions is an important prerequisite for trouble free turbocharger operation The turbocharger is normally lubricated with oil from the engine oil cir cuit NOTICE With regard to the oil supply please o...

Page 31: ...Temporarily permissible 1h alarm 0 6 0 8 Permissible oil pressure range for normal opera tion 0 8 2 5 Permissible oil pressure range during engine warm up phase 0 8 4 0 Separate lubricating sys tem K...

Page 32: ...the outlet is mainly dependant on Lubricating oil temperature and pressure at the oil inlet Engine load and turbocharger speed Exhaust gas temperature The maximum admissible oil temperature at the ou...

Page 33: ...ontaminated oil Particles of dirt and solid matter in the oil can cause serious damage to the machine or property u During initial commissioning and after all service work the complete lubricating sys...

Page 34: ...temperature in front of and behind turbine u Measure air temperature in front of and behind compressor The measured values must be compared with the values in the accept ance test report while taking...

Page 35: ...uct before gas inlet and after gas outlet u Inspect exhaust gas duct line in front of and after turbine for any combustion deposits foreign matter or residual water Clean and re move u Inspect air sup...

Page 36: ...bocharger The highest sound pressure level of emissions1 reaches a maximum of 105 dB A near the filter silencer and over the entire speed range The following prerequisites must be fulfilled on the tur...

Page 37: ...opyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 Suggestion for noise insulation of the bellows 01 Compressor casing 04 Insulation pads 02 Bellows 05 Insulation mat at least 15 mm 03...

Page 38: ...out too late can lead to excessive contamination and wear as well as operating failures u Carry out service work at specified time intervals CAUTION Shortened service intervals Despite observance of t...

Page 39: ...work Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 CAUTION Unknown changes during operation The consequences can range from an impairment to a breakdown u Have unknown causes cl...

Page 40: ...cturer s engine logbook Engine performance and speed Air intake temperature Exhaust gas temperature in front of and behind the turbine Pressure of charge air Pressure drop in charge air cooler Lubrica...

Page 41: ...ine blades using a bore scope for any contamination or damage Optionally this inspection can be carried out after removing the gas inlet casing u Refit the compressor casing internal part u Refit the...

Page 42: ...hese intervals can be found on the turbocharger rating plate Non rotating components Depending on the system specific operating conditions a distinction is made between the replacement interval for th...

Page 43: ...r cover ring 25000 50000 Other casings 100000 Hose ball valve turbine dry cleaning 18000 36000 HFO heavy fuel oil Recommended replace ment intervals h Rotor components See the data on the rating plate...

Page 44: ...ng system permits continuous monitoring of the tur bocharger speed CAUTION Do not use cables as a climbing aid If you pull the speed measurement cables too hard contacts can be pulled out u Do not ten...

Page 45: ...ing steps must be carried out u Reduce engine performance immediately until the highest turbochar ger speed no longer exceeds 70 of nBmax u If the engine cannot be stopped continue to run at this redu...

Page 46: ...top the engine u Switch off the lubricating oil supply to the turbocharger u Disconnect the cable connector from the speed sensor u Screw out defective speed sensor u Screw in a new speed sensor to th...

Page 47: ...ilencer can cause a loss of pres sure A significant pressure loss indicates an increase in dirt build up in the filter material 4 6 1 U tube manometer on filter silencer if present 81000 Filter silenc...

Page 48: ...ation and imme diate repair is not possible the turbocharger can be operated without an emergency oil supply until a repair is possible u Remove pipe leading from valve unit or branch to tank u Fit bl...

Page 49: ...witching of the flaps During automatic flap control there is a risk of the turbocharger rotat ing opposite the intended direction of rotation if the air outlet flap is open further than the gas inlet...

Page 50: ...h closed flaps To limit the deposits of dirt when operating with closed flaps we re commend you open them at least every 500 hours of operation 4 9 Stopping the engine CAUTION Before shutting down the...

Page 51: ...hecks and clean ing to ensure that the turbocharger and its attached units function trouble free The external condition and how dirty the cleaning points specified in this chapter are must be establis...

Page 52: ...D July 2018 5 2 Cleaning the filter silencer 5 2 1 Filter silencer with tension band 81265 Filter ring if provided 81266 Cover grid 81270 Tension band 81136 Absorption segment 81271 Lock 81137 Sheet...

Page 53: ...ension bands 81270 at the locks 81271 and remove them along with the cover grids 81266 and connecting strips 81268 NOTICE If the cleaning medium vessel is attached to the filter silencer option depend...

Page 54: ...e insert units E into the slot guides in the filter silencer body 81135 NOTICE If the cleaning medium vessel is attached to the filter silencer option depends on type of turbocharger the water injecti...

Page 55: ...ed HZTL2480_EN Revision D July 2018 5 2 2 Filter silencer and connecting rod 81265Filter ring if provided 81136Absorption segment 81269Connecting rods 81137Sheet metal covering 81266Cover grid 81135Fi...

Page 56: ...u Loosen and remove screws 81272 to the connecting rods 81269 u Remove connecting rods 81269 u Carefully remove cover grids 81266 NOTICE If the cleaning medium vessel is attached to the filter silenc...

Page 57: ...now be reattached See also following section entitled Fitting cleaning pipe u Uniformly place the cover grids 81266 in the correct position u Push the connecting rods 81269 through the lugs of the cov...

Page 58: ...leaning the filter silencer Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 u Screw lock nuts 81273 onto screw 81272 and tighten to following torque Lock nut Tightening torque Nm 8...

Page 59: ...yright 2018 All rights reserved HZTL2480_EN Revision D July 2018 5 2 3 Removing installing the cleaning line Disassembling the cleaning pipe u Disconnect feed pipe 02 from injection pipe 01 and remove...

Page 60: ...u Hammer guide tube 03 free from peen fixing using a bolt diameter 16 mm and withdraw it Replace damaged parts of the complete cleaning pipe with original parts from ABB Turbo Systems Fitting complet...

Page 61: ...erved HZTL2480_EN Revision D July 2018 5 3 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 8126...

Page 62: ...ion D July 2018 u Secure a new filter strip 81265 so that it overlaps the filter strip be ing replaced u Pull the old filter strip until the new filter strip is wound completely around filter silencer...

Page 63: ...channels if salt oil mist exhaust gas or dust are sucked in with the air Consequences of contamination Impaired compressor efficiency Higher exhaust gas temperatures Increased fuel consumption Increa...

Page 64: ...nt of the compressor wheel through an injection pipe fitted in the fil ter silencer The water does not act as a solvent but the contamination deposit is re moved by the mechanical impact of the drople...

Page 65: ...ne load 25 85 w If the engine compartment temperature is less than 0 C during wet cleaning of the compressor precautionary measures must be taken to prevent ice formation u Start cleaning cycle accord...

Page 66: ...wait at least 5 minutes to allow turbocharger to dry NOTICE If the cleaning operation is not satisfactory it may be repeated up to two times If the cleaning result is still not satisfactory after thre...

Page 67: ...be met w Engine load 25 85 w If the engine compartment temperature is less than 0 C during wet cleaning of the compressor precautionary measures must be taken to prevent ice formation u Start cleanin...

Page 68: ...bout 3 minutes u Close valve 06 and check that all water has been sucked out u After cleaning wait at least 5 minutes with engine running to allow turbocharger to dry If the cleaning operation is not...

Page 69: ...nce Experience in operation has shown that despite periodic cleaning during operation it is impossible to dispense with overhauls during which the turbine and nozzle ring are mechanically cleaned Howe...

Page 70: ...ry cleaning using dry solid matter in granulate form dirty depos its are removed mechanically by the grains impacting the surface NOTICE Wet and dry cleaning are equally effective However it may be us...

Page 71: ...cylinder and exhaust valve rises Operating state prerequisites for wet cleaning In order to be able to carry out a satisfactory cleaning process that has been tested and is recommended by ABB Turbo Sy...

Page 72: ...n nozzle 7a or 10 minutes injec tion nozzle 7b at constant engine output u Check whether the exhaust gas temperature decreases following the turbine u Close regulating valve 2 u Set drain cock 9 in dr...

Page 73: ...ow out of the drain pipe de pending on the engine load This flow might not start for 2 3 minutes or it might not occur at all If the drainage of the gas outlet casing is omitted the turbocharger speed...

Page 74: ...thick dirt deposits and must therefore be carried out more often see chapter Cleaning turbine blades and nozzle ring in operation Operating state prerequisites for integrated dry cleaning device In or...

Page 75: ...leaning device 01 Granulate container 51502 07 Combined air valve Pressure re lief valve 51504 02 Cover cap 51503 08 Clamp 51515 03 Compressed air supply 4 to 10 bar 09 Pipe elbow 51521 04 Hose 51512...

Page 76: ...ne u Close the On Off valve 05 u Close the ball valve 06 u Set combined air valve pressure relief valve 07 to pressure relief position u Check whether the exhaust gas temperature after the turbine has...

Page 77: ...ble for dry cleaning hard granulated materials such as natural core granulates Soft blast media activated carbon particles The average grain size of the cleaning granulate must be 1 2 2 0 mm The speci...

Page 78: ...system a non integrated dry cleaning device can be installed in front of the gas inlet casing by the en gine manufacturer Operating state prerequisites for non integrated dry cleaning device In order...

Page 79: ...480_EN Revision D July 2018 Operating non integrated dry cleaning device 01Cover cap G2 06Strap to secure container 02Possible copper gasket 07Safety valve with vent 03Double nipple G2 08Compressed ai...

Page 80: ...3 minutes u Close plug cock slide valve 05 u Open safety valve with ventilation 07 to blow out the exhaust gases u Carefully open cover cap 01 of granulate container u Pour specified amount of granula...

Page 81: ...y after three attempts and the engine values are also unsatisfactory we recommend that you have the turbocharger inspected and cleaned by an official ABB Turbochar ging Service Station Cleaning parame...

Page 82: ...Rotor unbalance Contact an ABB Turbocharging Service Station Damaged turbine or com pressor Damaged bearing Rubbing of rotating parts Normal behaviour no malfunction Turbochar ger Minor uniform wear...

Page 83: ...surging Possible damage to components such as the compressor wheel tur bine blades bearings and filter silencer u Have the cause clarified immediately by an ABB Turbocharging ser vice station and rec...

Page 84: ...splay wrong Replace the manometer Turbochar ger Rotor axial clearance too large Contact an ABB Turbocharging Service Station Reduction in speed Possible causes Elimination Turbochar ger Heavy contamin...

Page 85: ...vation for example filter silencer clogged with dirt Clean it Compressor turbine con taminated Exhaust counterpressure too high Clean or repair the boiler or ex haust silencer Enlarged flow cross sect...

Page 86: ...manometer Line to manometer leaking Repair the leak Contaminated filter silencer causing excessive loss of pres sure Clean it Compressor turbine contam inated Damaged compressor tur bine Contact an A...

Page 87: ...wn Possible causes Elimination Turbochar ger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Run down time...

Page 88: ...lems for the evaluation electronics This problem is eliminated by removing the gasket Defective sensor Contact ABB Turbocharging service sta tion Measured speeds too high Dirty sensor tip The sensor...

Page 89: ...rdance with engine builder s instructions CAUTION Oil orifice plates An orifice plate for adjusting the oil pressure is fitted in each of the two oil inlet channels in the bearing casing When the cart...

Page 90: ...y 2018 u Unscrew fixing screws in foot u Lift turbocharger off engine and put it down to one side WARNING If the support for the turbocharger is not provided or unsuitable the turbocharger could tip o...

Page 91: ...tes An orifice plate for adjusting the oil pressure is fitted in each of the two oil inlet channels in the bearing casing When the cartridge group the bearing casing or the turbocharger is fitted to t...

Page 92: ...ed in this chapter u Mark the casing position for assembly Identifying assembly devices Not all assembly devices are marked with a part number They can be identified using the tool list This list is e...

Page 93: ...gers assemblies or individual components only to lifting gear which is in technically perfect condition and has suffi cient load capacity u Make sure the load is suspended properly on the crane hook u...

Page 94: ...d off to the next highest value Weights kg Item Description TPL B 73 77 80 85 1 Filter silencer 250 410 580 960 2 Compressor casing internal part 150 260 360 550 3 Wall insert 140 280 430 850 4 Diffus...

Page 95: ...ved HZTL2480_EN Revision D July 2018 Compressor casing internal part assembly Weights kg TPL73 B TPL77 B TPL80 B TPL85 B 350 620 930 1630 NOTICE The total weight of the complete internal part of the c...

Page 96: ...of the silencer casing This section is applicable only to turbochargers with a filter silencer casing Only the assembly of the silencer casing is described in detail Its disassembly is carried out in...

Page 97: ...may be tightened only when assembly work is finished Only then is it possible for all parts to be fitted u Do not tighten screws during assembly u Fit bottom part 1 to filter silencer using screws A a...

Page 98: ...018 All rights reserved HZTL2480_EN Revision D July 2018 u Fit bottom part 2 to filter silencer using screws u Fit side parts 3 and 4 to filter silencer and to bottom part 1 using screws u Fit side pa...

Page 99: ...Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 u Insert flanges 10 and 11 from the side between side parts and fit screws u Fit circumferential part 5 using screws u Fit circumfe...

Page 100: ...ques Nm Screws for fastening individual parts to the filter silencer Screws for fastening indi vidual parts M10 30 M8 25 u Tighten all screws of bottom parts 1 and 2 u Tighten all screws of side parts...

Page 101: ...4 Removing and installing the filter silencer Removing filter silencer u Remove insulation where necessary u Pass lifting gear through rib on filter silencer and through eyelets at rear u Unscrew nuts...

Page 102: ...n cer TPL77 91 B u Remove insulation where necessary u Secure the shackle 90195 to a rib fin on the filter silencer u Pass the lifting gear through the eyelets on the back side u Unscrew the nuts 7402...

Page 103: ...jury u Wear safety gloves Wear safety gloves to protect against mechanical hazards u Screw on at least four nuts 74027 along with washers 74018 equally spaced around the circumference and tighten them...

Page 104: ...tridge group the bearing casing or the turbocharger is fitted to the engine it must be ensured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet...

Page 105: ...000 and can be removed Removing the compressor casing internal part u Unscrew nuts 74027 and remove them together with washers 74018 u Remove six studs 74026 74029 from the upper section and screw in...

Page 106: ...and the diffuser 79000 down on the support angle and an underlay u Remove the O ring 76040 u Loop the lifting device around the rear of the flange F u Carefully rotate the compressor casing internal p...

Page 107: ...reserved HZTL2480_EN Revision D July 2018 Removing the diffuser u Remove screws 76002 u Loop lifting gear around diffuser 79000 and remove diffuser u Carefully press off the wall insert 77000 using t...

Page 108: ...evision D July 2018 Removing the compressor casing external part u Fasten the lifting device 90190 with shackle 90195 to the com pressor casing external part 74000 and secure it to the crane u Unscrew...

Page 109: ...gether with their washers 61058 u Attach separate lifting gear to each of two ribs on the bearing casing 42001 provided for this purpose NOTICE To correct the slight inclined position of the cartridge...

Page 110: ...the casing may be damaged u Check that the blades do not rub on the turbine diffuser 63000 by rotating the rotor u Withdraw cartridge group u Remove screws 42064 together with flange 42044 Also remov...

Page 111: ...essment of valve block If provided 1 Valve flap 2 O ring 42234 3 Valve seat On the removed valve block 42230 u Check for free movement of valve flap 1 u Check valve seat 3 using finger u If necessary...

Page 112: ...ling and installing the turbine diffuser and nozzle ring CAUTION The nozzle ring 56001 must be secured to prevent it from falling be fore pulling out the turbine diffuser 63000 The nozzle ring just ha...

Page 113: ...ed HZTL2480_EN Revision D July 2018 u Place the clamp 90921 over the stud 61036 until the clamp is lying flat against the inner radius of the gas outlet casing u Insert the extension A of the torque s...

Page 114: ...the guide studs 90320 and fit the studs 61036 u Screw nuts 61037 onto the first few threads of the stud 61036 for protection u Remove the remaining screws 61056 and Verbus Ripp washers 61057 u Press t...

Page 115: ...utlet casing On the TPL85 raise the holder 90490 with the lifting gear and secure it u Pull the nozzle ring 56001 forwards attach it to the lifting gear and remove it Installing the turbine dif fuser...

Page 116: ...il inlet channels in the bearing casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be ensured that the orifice plates that are specified for the tu...

Page 117: ...If the turbine blades on the rotor have insufficient or no clearance the blades and the casing may be damaged u Check that the blades do not rub on the turbine diffuser 63000 by rotating the rotor u U...

Page 118: ...g external part 74000 and secure to a crane u Screw the press off nuts 61090 evenly distributed around the cir cumference of the bearing casing onto the studs up to the end of the thread u Fit the com...

Page 119: ...lifting eyes 90230 and attach lifting gear u Align the wall insert 77000 with the threaded holes in the com pressor casing internal part 76000 using the dog points at the swivel lifting eyes 90230 and...

Page 120: ...HZTL2480_EN Revision D July 2018 Compressor casing in ternal part u Secure the lifting device 90190 and the shackle 90195 to the rear of the flange F u Carefully rotate the compressor casing internal...

Page 121: ...he compressor casing internal part 76000 u Fit O ring 76040 u Remove the support angle 90025 u Fit four guide studs 90320 u Carefully position the compressor casing internal part 76000 with wall inser...

Page 122: ...it four nuts 74027 complete with washers 74018 equally spaced around circumference and tighten u Loosen the nuts 90458 on the threaded studs of the three securing segments 76080 on the compressor casi...

Page 123: ...ote the axial clearance A CAUTION If the axial clearance A is out of tolerance an ABB Turbocharging Ser vice Station must be contacted Axial clearance A mm TPL73 B TPL77 B TPL80 B TPL85 B 0 40 0 58 0...

Page 124: ...op lifting gear through lugs of gas inlet casing If present u Remove two hexagon head screws 61044 and Verbus Ripp washers 61043 from the bottom section and replace them with two studs 90177 u Screw h...

Page 125: ...with high temperature grease u Fit nozzle ring 56001 and tighten down holder 90175 using screw 61044 u Fit gas inlet casing 51001 and secure by screwing hexagon nuts 90178 onto studs 90177 u Remove ho...

Page 126: ...stud 51086 becomes loose when the nut 51087 is re moved after disassembling the gas outlet casing it must be screwed back into the gas inlet casing hand tight as far as it will go If the nut 51087 ca...

Page 127: ...e ring 56001 using suitable lifting gear Assembly u Coat threaded stud 51086 with high temperature grease screw into gas outlet casing 61001 as far as it will go and tighten hand tight u Fit nozzle ri...

Page 128: ...necting plate 51511 onto the gas outlet casing with hexagon head screws 51520 u Fit the screw insert 51514 onto the gas inlet casing u Fit the straight screw in coupling 51522 on the ball valve 51513...

Page 130: ...tion Manual TPL73 B 85 B11 B12 8 Disassembly and assembly 8 12 Table of tightening torques Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 8 12 Table of tightening torques Page 128...

Page 131: ...washer M18 170 M20 220 M22 300 M24 400 5 61036 74026 74029 M18 80 M20 80 M22 80 M24 80 6a 61056 61059 M18 370 M20 480 M22 480 M24 480 6b 61044 51087 M18 200 M20 280 M22 380 M24 480 7 42059 42064 M16 1...

Page 132: ...Soak up oil and dispose of in an environmentally compatible manner Wear safety gloves to protect against thermal hazards CAUTION Directives for taking out of operation Serious damage to engine or prop...

Page 133: ...lubricating oil supply without fail during engine operation with locked tur bocharger See section Further information about operation with locked rotor on 2 stroke engines u Shut off oil supply in ev...

Page 134: ...e the intermediate rings the spacer ring and the adapter ring are fitted correctly All parts must be kept clean and free from grease Table of tools Part number Description 74027 Hexagon nut 90020 Lock...

Page 135: ...ual TPL73 B 85 B11 B12 9 Shut down at short notice 9 2 Locking the rotor Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 TPL73 B Compressor type CV11 Compressor type CV12 CV13 CV14...

Page 136: ...TPL73 B 85 B11 B12 9 Shut down at short notice 9 2 Locking the rotor Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 TPL77 B TPL80 B Compressor type CV11 Compressor type CV12 CV13...

Page 137: ...e 9 2 Locking the rotor Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 TPL85 B11 B12 If possible use the longer hexagon head screws 94008 when fitting the locking flange 94003 Com...

Page 138: ...be removed and the air line at the engine end closed off because the undamaged turbochargers develop a receiver pressure u The operating limit of the engine can be raised by additionally closing off...

Page 139: ...common air as well as exhaust gas receivers u Shut off compressor casing outlet gas inlet and gas outlet by fitting cover plates NOTICE In this respect refer to the engine manufacturer s instructions...

Page 140: ...5 Fit cover plate Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 9 5 Fit cover plate NOTICE The cover plate material General structural steel in accordance with DIN EN 10025 2 mu...

Page 141: ...B12 9 Shut down at short notice 9 5 Fit cover plate Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 NOTICE Carry out the work as described in the chapter Removal and fitting u Remo...

Page 142: ...ver plate Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 u Close off opening in gas outlet casing using cover plate u Fasten cover plate using spacer sleeves and nuts 61037 CAUTIO...

Page 143: ...the manufacturer s instructions 2 stroke engine with several turbochargers u Block air line on engine side as undamaged turbochargers develop a receiver pressure u Significantly raise operating limit...

Page 144: ...nd this is circulated by the prelubrica tion pump no measures have to be taken Any remaining old engine oil will thus be flushed away and the bearing sections largely protec ted against corrosion Moth...

Page 145: ...ion for up to 12 months under Mothballing measures for the measures always necessary when moth balling turbocharger parts If the turbocharger remains mounted on the engine refer to the section Taking...

Page 146: ...spiratory mask to protect against dusts Wear safety gloves to protect against mechanical hazards Disposal must be environmentally compatible professional and in com pliance with locally applicable reg...

Page 147: ...ABB Turbocharging service station CAUTION Storage of spare parts All spare parts ordered with the turbocharger must be kept complete and ready for use u Parts showing signs of rust should be carefully...

Page 148: ...p washer 42058 42063 15 Hexagon head screw 61044 61056 61059 15 Verbus Ripp washer 61043 61057 61058 3 Hex nut 61037 1 Gasket 42041 2 Gasket 42045 2 O ring 42012 76040 2 O ring 77005 77006 1 O ring 86...

Page 150: ...Manual TPL73 B 85 B11 B12 12 Spare parts 12 2 View of turbocharger with part numbers Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 12 2 View of turbocharger with part numbers Pag...

Page 151: ...r spare part set Hexagon nut 61044 61043 in customer spare part set Hexagon bolt Verbus Ripp washer 61056 61057 in customer spare part set Hexagon bolt Verbus Ripp washer 61059 61058 in customer spare...

Page 152: ...ual TPL73 B 85 B11 B12 12 Spare parts 12 3 View of cartridge group with part numbers Copyright 2018 All rights reserved HZTL2480_EN Revision D July 2018 12 3 View of cartridge group with part numbers...

Page 153: ...5 Floating disc 32106 Axial bearing 32107 Bearing bush 42001 Bearing casing 42002 Hood 42011 TPL80 B TPL85 B O ring 42012 in customer spare part set O ring 42015 Sealing cover 42041 in customer spare...

Page 154: ...ABB Switzerland Ltd Turbocharging Bruggerstrasse 71a CH 5401 Baden Switzerland...

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