Page 1 Operation Manual TPL65-A32 ABB Turbo Systems Ltd CH 5401 Baden Type TPL65-A32 HT565080 Mmax Mmax °C Bmax Bmax 01230 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
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Table of contents Page 1 Table of contents Preliminary remarks Purpose of this manual Layout and function Correct use of the turbocharger Storage of new turbochargers and spare parts...
Page 4 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Table of contents Page 2 Maintenance Foreword to Maintenance Cleaning the filter silencer Cleaning the compressor during operation Cleaning turbine blades and nozzle ring in operation Troubleshooting Malfunctions when starting...
Page 5 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Table of contents Page 3 Mothballing the turbocharger 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...
Page 7: Preliminary Remarks
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Purpose of this manual Page 5 Preliminary remarks Purpose of this manual This operation manual belongs to the turbocharger with the identical HT number (1), see the cover sheet of the operation manual and the turbocharger rating plate.
Page 8: Layout And Function
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Layout and function Page 6 Layout and function 1 Filter silencer 8 Nozzle ring 2 Radial plain bearing 9 Turbine wheel 3 Thrust bearing 10 Bearing casing...
Page 9 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Layout and function Page 7 Working principle The turbocharger is a turbo-machine and consists of the following main components:  Turbine  Compressor These are both mounted on a common shaft.
Page 10 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Layout and function Page 8 Turbocharger version with compressor wheel cooling system Depending on its range of use, the turbocharger is provided with a compressor wheel cooling system.
Page 11: Correct Use Of The Turbocharger
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Correct use of the turbocharger Page 9 Correct use of the turbocharger This turbocharger supplied by ABB Turbo Systems has been developed for use on diesel engines to generate the volume of air and the charging pressure required to operate the engine.
Page 12: Storage Of New Turbochargers And Spare Parts
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Storage of new turbochargers and Page 10 spare parts Storage of new turbochargers and spare parts Storage of new turbochargers and spare parts up to 6 months...
Page 13 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Storage of new turbochargers and Page 11 spare parts Long-term storage of replacement turbochargers or spare parts Per order, turbochargers or cartridge groups will be prepared by ABB Turbo Systems for prolonged storage.
Page 14: Essential Information
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Essential information Page 12 Essential information Organisational measures In addition to this manual, the general, statutory regulations applicable in the respective country for the prevention of accidents and the protection of the environment must be observed.
Page 15 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Essential information Page 13 Original parts and safety Original parts and accessories are specially designed for turbochargers supplied by ABB Turbo Systems. We herewith expressly state that parts and accessories not supplied by us have also not been tested and approved by us.
Page 16 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Essential information Page 14 Design variants This operating manual is valid for various turbocharger design variants. This means that some sections and component descriptions in this operating manual do not apply to your turbocharger.
Page 17: Symbols And Definitions
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Symbols and definitions Page 15 Symbols and definitions The following symbols are used in the documents: Prerequisite  Work step   Enumeration, first level - Enumeration, second level...
Page 18: Turbocharger Rating Plate
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Turbocharger rating plate Page 16 Turbocharger rating plate Operating limits Turbocharger operating limits at engine overload (110%). Only when operating in the test rig unless otherwise agreed with the engine builder.
Page 19 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Turbocharger rating plate Page 17 1.7.1 Explanation of the rating plate The recommended replacement intervals and the corresponding operational limits are jointly defined with the engine manufacturer. This information is specific to the system.
Page 20: Contact Address And After-Sales Service
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Preliminary remarks Contact address and after-sales service 1.8 Page 18 Contact address and after-sales service Contact address ABB Turbo Systems AG Bruggerstrasse 71a CH-5401 Baden Switzerland www.abb.com/turbocharging After-sales service...
Page 21: Safety
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Introduction Page 19 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.
Page 22: Definition Of Mandatory Signs
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Definition of mandatory signs Page 20 Definition of mandatory signs To be worn at all times Protective clothing Safety footwear against mechanical hazards To be worn according to the specific work...
Page 23: Warning Plates On The Turbocharger
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Warning plates on the turbocharger Page 21 Warning plates on the turbocharger Warnings that have been attached to turbochargers by ABB Turbo Systems must not be removed. Illegible warnings must be replaced with new ones.
Page 24: Safe Operation And Maintenance
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Safe operation and maintenance Page 22 Safe operation and maintenance The instructions specified in this section are for the safety of personnel. Together with the instructions in the Hazards during operation and maintenance section, they allow the user to safely use the turbocharger.
Page 25 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Safe operation and maintenance Page 23 Safety during start-up / commissioning and operation Before starting work, carry out visual inspection of working area.  Remove any obstacles and objects lying around.
Page 26 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Safe operation and maintenance Page 24 Safety during disassembly, assembly, maintenance and troubleshooting Always perform the specified adjustments, servicing as well as  inspection work and observe inspection intervals.
Page 27: Hazards During Operation And Maintenance
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Hazards during operation and Page 25 maintenance Hazards during operation and maintenance Mechanical hazards during operation During normal operation, no mechanical hazards emanate from the turbocharger if it has been installed properly.
Page 28 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Hazards during operation and Page 26 maintenance Hazards due to noise The generation of noise during operation is influenced by the installation and operating conditions. Noise with a level exceeding 85 dB(A) is harmful.
Page 29 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Hazards during operation and Page 27 maintenance Hazards due to operating and auxiliary materials Operating and auxiliary materials are substances used for operation or the execution of maintenance work. Oils, greases, coolants, cleaning agents and solvents, acids, etc.
Page 30 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Hazards during operation and Page 28 maintenance Heed the instructions for use, safety data sheets and hazard notices  on the containers of the operating and auxiliary materials.
Page 31: Periodic Checking Of The Pressure Vessel
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Page 29 Hazards due to electrical components Hazards due to electrical components Electrical components operate with voltages which can present hazards to humans. WARNING All work on or with electrical components may only be performed by ...
Page 32: Lifting Loads
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Safety Lifting loads Page 30 Lifting loads Suspended loads Loads not suspended in compliance with regulations may lead to personal injury or accidents with fatal consequences. WARNING Attach turbochargers, assemblies or individual components only to ...
Page 33: Commissioning
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Commissioning Oil supply Page 31 Commissioning Oil supply A carefully designed oil supply, which functions under all operating conditions, is an important precondition for trouble-free operation of the turbocharger.
Page 34 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Commissioning Oil supply Page 32 Oil pressure The oil pressure in front of the turbocharger must be maintained precisely to ensure trouble-free operation. The permissible oil pressure ranges at measuring point M (blind connection) on the turbocharger are listed below.
Page 35 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Commissioning Oil supply Page 33 Oil temperature Lubricating oil temperature at the inlet Machine damage If the oil temperature at the oil inlet exceeds the admissible range, this may lead to engine damage.
Page 36: Inspection Work
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Commissioning Inspection work Page 34 Inspection work Inspection work includes preventive visual controls plus monitoring and measuring work before and during commissioning. Inspections help detect changes to the turbocharger. Machine damage can be avoided.
Page 37 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Commissioning Inspection work Page 35 3.2.2 Check after start-up (engine at idling speed) Lubricating system Check oil pressure in oil supply lines.  Check oil inlet temperature. ...
Page 38: Commissioning After Taking Out Of Operation
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Commissioning Commissioning after taking out of Page 36 operation Commissioning after taking out of operation Remove cover plates (blind flanges) between compressor casing If provided  outlet and charge air duct, before gas inlet and after gas outlet.
Page 39: Operation
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Operation Noise emissions Page 37 Operation Noise emissions Hazards due to noise Noise can cause impaired hearing, damage to health, mental disturbances, irritation and diminished attention. WARNING Always wear ear protection when the engine is running.
Page 40 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Operation Noise emissions Page 38 Suggestion for noise insulation of the bellows A Compressor casing D Insulation pads B Bellows E Insulation mat (at least 15 mm) C Charge air duct / scavenging air...
Page 41: Servicing Work
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Operation Servicing work Page 39 Servicing work Service work to be carried out during operation involves visual checks, monitoring, measuring, inspection work and functional checks. It is then possible for changes to the turbocharger to be identified and rectified.
Page 42 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Operation Servicing work Page 40 4.2.2 Entries in engine logbook By monitoring the engine, conclusions can be drawn about the turbocharger performance. The following operating data and measured values must be entered regularly in the engine manufacturer's engine logbook: ...
Page 43 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Operation Servicing work Page 41 4.2.4 Service work every 8000 … 12000 hours The inspection and assessment of the rotor and the bearing parts must be carried out by an official ABB Turbocharging service station.
Page 44: Replacement Intervals For Turbocharger Components
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Operation Replacement intervals for turbocharger Page 42 components Replacement intervals for turbocharger components The recommended replacement intervals for the compressor and turbine Rotating components wheels due to stressing caused by centrifugal forces and load cycles are calculated under consideration of the operating conditions while applying the safety concept for rotating components.
Page 45 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Operation Replacement intervals for turbocharger Page 43 components Expected replacement Component GAS / MDO intervals [h] Gas inlet casing 50000 … 100000 25000 … 50000 Gas outlet casing 50000 …...
Page 46: Speed Measurement
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Operation Speed measurement Page 44 Speed measurement A speed-measuring system enables the continuous monitoring of turbocharger speed. Part number Description 42047 Screw plug 86505 Speed sensor 86515 Cable connector for 86505...
Page 47 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Operation Speed measurement Page 45 The difference between the highest and the lowest turbocharger speed must not be more than 3 % relative to the speed limit n...
Page 48 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Operation Speed measurement Page 46 4.4.3 Replacing the speed sensor Hot cable connector and hot speed sensor Risk of burning. During operation, the cable connector and the speed sensor can reach temperatures exceeding 100 °C.
Page 49: Stopping The Engine
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Operation Stopping the engine Page 47 Stopping the engine Before the engine is shut down, it must be allowed to idle for about 5 to 10 minutes so that the circulating lubricating oil can take away heat from the turbocharger bearings.
Page 51: Maintenance
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Foreword to Maintenance Page 49 Maintenance Foreword to Maintenance Maintenance and servicing work involves regular visual checks and cleaning to ensure that the turbocharger and its attached units function trouble-free.
Page 52: Cleaning The Filter Silencer
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning the filter silencer Page 50 Cleaning the filter silencer 5.2.1 Filter silencer and connecting rod 81265 Filter strip (if provided) 81136 Absorption segment 81269 Connecting rods...
Page 53 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning the filter silencer Page 51 Removing and cleaning filter silencer Remove filter strip (81265). If provided  Rinse filter strip (81265) using water with detergent additive or, if very ...
Page 54 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning the filter silencer Page 52 Mounting filter silencer Assemble insert units (E) by putting fleece segments (81136) into  cover sheet metal (81137). Bend back cover sheet metal (81137) to original shape.
Page 55 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning the filter silencer Page 53 Join connecting rods (81269) using screws (81272). When tensioning  screws (81272), ensure that connecting rods (81269) are located correctly in recesses in filter silencer body (81135). Now alternately...
Page 56: Cleaning The Compressor During Operation
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning the compressor during Page 54 operation Cleaning the compressor during operation These instructions for wet cleaning apply only when cleaning is carried out with clean water and the engine manufacturer permits the process.
Page 57 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning the compressor during Page 55 operation Cleaning method 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 Systems.
Page 58 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning the compressor during Page 56 operation 5.3.1 Wet cleaning with orifice plate on filter silencer (XC2) Operating state prerequisites for cleaning compressor with XC2 To be able to carry out a satisfactory cleaning process that has been...
Page 59 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning the compressor during Page 57 operation 5.3.2 Wet cleaning using external water-pressure vessel (XC3) Operating state prerequisites for compressor cleaning with XC3 To be able to carry out a satisfactory cleaning process that has been...
Page 60 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning the compressor during Page 58 operation After cleaning, wait at least 5 minutes to allow the turbocharger to dry.  If the cleaning operation is not satisfactory, it may be repeated up to two times.
Page 61: Cleaning Turbine Blades And Nozzle Ring In Operation
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning turbine blades and nozzle ring Page 59 in operation Cleaning turbine blades and nozzle ring in operation The combustion of heavy fuel oil in diesel engines leaves dirty deposits on the turbocharger turbine blades and nozzle rings.
Page 62 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning turbine blades and nozzle ring Page 60 in operation The interval between periodic cleaning is very dependent on the operating Wet cleaning interval conditions. In general, cleaning should be carried out every 50 to 200 operating hours.
Page 63 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning turbine blades and nozzle ring Page 61 in operation Wet cleaning turbine and nozzle ring during operation 5.4.1 Prerequisites for turbine wet cleaning Corrosion and deposits when cleaning...
Page 64 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning turbine blades and nozzle ring Page 62 in operation Layout of cleaning pipes 1 Water supply (fresh water only) 6 Other engine 2 Regulating valve 7 Injection nozzle...
Page 65 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Maintenance Cleaning turbine blades and nozzle ring Page 63 in operation To obtain the correct water flow rate, a certain pressure in the water pipe Recommendation for is necessary. (See table of Cleaning Parameters). If this water pressure is water pressure too low, the water flow rate specified in the table will not be obtained.
Page 67: Troubleshooting
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 68: Surging Of The Turbocharger
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Troubleshooting Surging of the turbocharger Page 66 Surging of the turbocharger Surging of the turbocharger Possible causes Remedy Engine Protective grating in front of the Clean/Replace turbocharger fouled or...
Page 69: Malfunctions During Operation
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Troubleshooting Malfunctions during operation Page 67 Malfunctions during operation Lubricating oil pressure too low Possible causes Elimination Engine Very dirty oil filter Clean it. Defective oil pump in Check / replace it.
Page 70 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Troubleshooting Malfunctions during operation Page 68 Exhaust gas temperature too high Engine output and engine speed unchanged Possible causes Elimination Engine Malfunctioning of injection Repair it, or contact system manufacturer.
Page 71 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Troubleshooting Malfunctions during operation Page 69 Charge air pressure too low Engine output and engine speed unchanged, air intake condition normal Possible causes Elimination Engine Air receiver leaky Repair it.
Page 72: Malfunctions When Stopping
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Troubleshooting Malfunctions when stopping Page 70 Malfunctions when stopping Noises during run-down Possible causes Elimination Turbocharger Dirty turbocharger Clean it. Damaged bearing Contact ABB Turbocharging service station. Touching rotor...
Page 73: Speed Measurement System
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Troubleshooting Speed measurement system Page 71 Speed measurement system Possible causes Elimination Signal Fitting error The screw plug for the sensor is fitted with a amplitude non gasket.
Page 75: Removal And Installation
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Removal and installation Turbocharger weights Page 73 Removal and installation Turbocharger weights Lifting gear with a sufficient load limit must be used for removing and installing the turbocharger. The following weight specification is the heaviest possibility.
Page 76: Remove The Turbocharger
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Removal and installation Remove the turbocharger Page 74 Remove the turbocharger Disconnect all gas, air and oil lines in accordance with engine  manufacturer’s instructions. Oil orifice plate An orifice plate is fitted in each of the two oil inlet channels in the bearing casing.
Page 77 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Removal and installation Remove the turbocharger Page 75 Ribs (1) not in the middle at the top:  Completely remove the bearing casing insulation (2) and place a sling ...
Page 78: Installing The Turbocharger
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Removal and installation Installing the turbocharger Page 76 Installing the turbocharger Remove cover from oil connection.  Inspect lifting gear.  Fasten separate lifting gear to each of two bearing casing ribs ...
Page 79: Disassembly And Assembly
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Introduction Page 77 Disassembly and assembly Introduction Further work Further tasks, which are not described here, may be carried out only by trained personnel from an ABB Turbocharging service station.
Page 80 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Introduction Page 78 Tightening torques for turbocharger components The specified tightening torques of screw connections for turbocharger components must be observed. (See section Table of tightening torques.)
Page 81: Module Weights
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Module weights Page 79 Module weights The specified weights of individual parts or assemblies are guides rounded off to the next highest value. Assemblies Weights [kg]...
Page 82 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Module weights Page 80 Complete compressor casing Weight [kg] TPL65-A32 / A33 / A36 TPL69-A32 / -A33 Complete compressor casing The total weight of the complete compressor casing is an addition of the weights of the compressor casing, the diffuser and the wall insert.
Page 83: Removing And Fitting Filter Silencer Or Air Suction Branch
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Removing and fitting filter silencer or air Page 81 suction branch Removing and fitting filter silencer or air suction branch Disconnect all air lines in accordance with the engine builder’s Removing the air suction ...
Page 84 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Removing and fitting filter silencer or air Page 82 suction branch Dismantle insulation where necessary. Removing the filter  silencer Pass the lifting gear through the rib on the filter silencer.
Page 85: Axial Clearance
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Axial clearance Page 83 Axial clearance Physical hazards due to sharp edges on compressor wheel The compressor wheel has sharp edges which can result in injury.
Page 86: Removing Cartridge Group
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Removing cartridge group Page 84 Removing cartridge group Remove insulation.  Version with compressor wheel cooling system Remove the air supply line. (Also see the chapter Preliminary remarks ...
Page 87 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Removing cartridge group Page 85 Turn the compressor casing (72000) together with the wall insert and  diffuser and set them down with surface (F) on an underlay.
Page 88 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Removing cartridge group Page 86 Unplug cable connector (86515) and unscrew speed sensor (86505)  with O-ring (86506). Unscrew the three screws (61059) and remove them together with the TPL65-A32/33 ...
Page 89 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Removing cartridge group Page 87 Withdraw the cartridge group and fit the supports (90450).  Cover the oil connections.  © Copyright 2014 ABB. All rights reserved.
Page 90: Dismantling And Installing The Turbine Diffuser And Nozzle Ring
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Dismantling and installing the turbine Page 88 diffuser and nozzle ring Dismantling and installing the turbine diffuser and nozzle ring Falling nozzle ring The nozzle ring hangs only loosely on the positioning pins.
Page 91 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Dismantling and installing the turbine Page 89 diffuser and nozzle ring Position clamp (90921) over stud (61036) until it lies flat against inner  radius of gas outlet casing.
Page 92 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Dismantling and installing the turbine Page 90 diffuser and nozzle ring Replace two screws (61056) in the gas outlet casing with two guide  studs (90320) in the upper section of the turbine diffuser (63000).
Page 93: Installing Cartridge Group
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Installing cartridge group Page 91 Installing cartridge group Oil orifice plate An orifice plate is fitted in each of the two oil inlet channels in the bearing casing.
Page 94 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Installing cartridge group Page 92 If the rotor blades have insufficient or no clearance, the blades and casing could be damaged. Turn rotor to check that blades do not rub against turbine diffuser.
Page 95 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Installing cartridge group Page 93 Attach lifting gear to lifting device (90190) and turn compressor casing  (72000). Fit O-ring (42012) to bearing casing. ...
Page 96: Turbine-End Removal / Fitting Of The Nozzle Ring
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Turbine-end removal / fitting of the Page 94 nozzle ring Turbine-end removal / fitting of the nozzle ring If only the nozzle ring has to be removed, this can be done at the turbine end.
Page 97 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Turbine-end removal / fitting of the Page 95 nozzle ring To secure, screw hexagon nuts (90178) onto studs (90177).  Loosen and remove the remaining screws (61044) and Verbus Ripp®...
Page 98: Table Of Tightening Torques
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Table of tightening torques Page 96 Table of tightening torques © Copyright 2014 ABB. All rights reserved.
Page 99 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Table of tightening torques Page 97 Tightening torques [Nm] Item Part number TPL65-A32 / A33 / A36 TPL69-A32 / -A33 82005 M16x1.5 M16x1.5 72027 with washer...
Page 101: Taking Out Of Operation At Short Notice
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Possibilities for emergency repair Page 99 Taking out of operation at short notice Possibilities for emergency repair Danger of fire and explosion due to lubricating oil leaks Leaking oil may ignite on hot surfaces.
Page 102: Locking The Rotor
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Locking the rotor Page 100 Locking the rotor A locked rotor must be removed and checked for unbalance after the turbocharger repair.
Page 103 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Locking the rotor Page 101 Locking rotor TPL65-A32 / A33 / A36 Remove silencer or air suction branch.  Carry out work as described in chapter Removing and fitting.
Page 104 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Locking the rotor Page 102 Table of tightening Part number TPL65-A32 / A33 / A36 torques 72027 75 Nm 94007 25 Nm Make sure all components are clean and free from grease.
Page 105 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Locking the rotor Page 103 Locking rotor TPL69-A32 / -A33 Remove silencer or air suction branch.  Carry out work as described in chapter Removing and fitting.
Page 106 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Locking the rotor Page 104 Table of tightening Part number TPL69-A32 / -A33 torques 72027 105 Nm 94006 10 Nm 94007 10 Nm Make sure all components are clean and free from grease.
Page 107 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Locking the rotor Page 105 Further measures and information for operation with blocked rotor for 4- stroke engines 4-stroke engine with one turbocharger No further measures are necessary.
Page 108: Fit Cover Plate
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Fit cover plate Page 106 Fit cover plate The cover plate (material: General structural steel, in accordance with DIN EN 10025-2) must be manufactured in-house according to the drawing.
Page 109 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Fit cover plate Page 107 Carry out the work as described in the chapter Removal and fitting. NOTICE Remove cartridge group.
Page 110 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Fit cover plate Page 108 Close off opening in gas outlet casing using cover plate.  Fasten cover plate using spacer sleeves and nuts (61037).
Page 111 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Fit cover plate Page 109 Further measures and information for operation with a turbocharger with cover plate on 4-stroke engines 4-stroke engine with one turbocharger No further measures are necessary.
Page 112: Blocking The Inlets And Outlets
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Blocking the inlets and outlets Page 110 Blocking the inlets and outlets Shut off the lubricating oil supply to the turbocharger.
Page 113: Mothballing The Turbocharger
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Mothballing the turbocharger Taking the engine out of operation for 10.1 Page 111 up to 12 months Mothballing the turbocharger 10.1 Taking the engine out of operation for up to 12 months 10.1...
Page 114: Taking The Engine Out Of Operation For Up To 12 Months
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Mothballing the turbocharger Taking the engine out of operation for 10.1 Page 112 up to 12 months The rotor and bearing parts must be dismantled and subsequently ...
Page 115: Taking The Engine Out Of Operation For More Than 12 Months
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Mothballing the turbocharger Taking the engine out of operation for 10.2 Page 113 more than 12 months 10.2 Taking the engine out of operation for more than 12 months 10.2...
Page 117: Disposing Of Turbocharger Components
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disposing of turbocharger components Taking the engine out of operation for 10.2 Page 115 more than 12 months Disposing of turbocharger components Handling damaged thermal insulation Damaged thermal insulation can lead to dust exposure. The glass fibres can cause mechanical irritation of the eyes, skin, and respiratory tracts.
Page 119: Spare Parts
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Spare parts Ordering spare parts 12.1 Page 117 Spare parts 12.1 Ordering spare parts 12.1 When making inquiries or ordering spare parts, the following data must be specified: ...
Page 120 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Spare parts Ordering spare parts 12.1 Page 118 Required customer spare parts set (97070) TPL65-A32 / A33 / A36 Quantity Description Part number O-ring 42012 Gasket 42041 Gasket 42045 Verbus Ripp®...
Page 121 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Spare parts Ordering spare parts 12.1 Page 119 Spare parts set (97078) for turbine cleaning system (if provided) Leaks Improper assembly of the cleaning pipe and the nozzles can lead to leaks and failure of the turbine cleaning system.
Page 122: View Of The Turbocharger With Part Numbers
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Spare parts View of the turbocharger with part 12.2 Page 120 numbers 12.2 View of the turbocharger with part numbers 12.2 © Copyright 2014 ABB. All rights reserved.
Page 123 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Spare parts View of the turbocharger with part 12.2 Page 121 numbers Part number Description – Cartridge group 42012 (in spare part set) O-ring 51001 Gas inlet casing...
Page 124: View Of Cartridge Group With Part Numbers Tpl65-A32 / -A33 / -A36
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Spare parts View of cartridge group with part 12.3 Page 122 numbers TPL65-A32 / -A33 / -A36 12.3 View of cartridge group with part numbers TPL65-A32 / -A33 / -A36 12.3...
Page 125 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Spare parts View of cartridge group with part 12.3 Page 123 numbers TPL65-A32 / -A33 / -A36 Part number Description 21000 Shaft 25000 Compressor wheel 32001 Thrust bearing...
Page 126 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Spare parts View of cartridge group with part 12.4 Page 124 numbers TPL69-A32 / -A33 12.4 View of cartridge group with part numbers TPL69-A32 / -A33 12.4 © Copyright 2014 ABB. All rights reserved.
Page 127 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Spare parts View of cartridge group with part 12.4 Page 125 numbers TPL69-A32 / -A33 Part number Description 21000 Shaft 25000 Compressor wheel 25008 Threaded stud 25009 Ring nut...
Page 128: View Of Turbine Cleaning System With Part Numbers (Optional)
Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Spare parts View of turbine cleaning system with 12.5 Page 126 part numbers (optional) 12.5 View of turbine cleaning system with part numbers (optional) 12.5 Part number Description...
Page 129 ABB Turbo Systems AG Bruggerstrasse 71a CH-5400 Baden Switzerland...

ABB TPL65-A32 Operation Manual

1 Preliminary Remarks

2 Safety

3 Commissioning

4 Operation

5 Maintenance

6 Troubleshooting

7 Removal and Installation

8 Disassembly and Assembly

9 Taking out of Operation at Short Notice

10 Mothballing the Turbocharger

11 Disposing of Turbocharger Components

12 Spare Parts

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