Page 1 Operation Manual TPL65VA32 Type TPL65VA32 HT604576 Mmax Mmax °C Bmax Bmax 01210 Application according to Year 2021 the Operation Manual 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 / TPL65VA32 / VA33 Table of contents Operation Manual Preliminary remarks....................3 Purpose of this manual ....................3 Layout and function......................4 Intended use of the turbocharger ................7 Storage of new turbochargers and spare parts ............8 Essential information....................
Page 4 Operation Manual / TPL65VA32 / VA33 Table of contents Troubleshooting....................64 Malfunctions when starting..................64 Surging of the turbocharger..................64 Malfunctions during operation ................. 66 Malfunctions when stopping ..................68 Speed measurement system ..................69 Variable Turbine Geometry ..................69 Removal and installation..................
Page 5: Operation Manual
Operation Manual This Operation Manual helps familiarise the user with the turbocharger from ABB Turbocharging and how to use it as intended. It provides important information in order that the turbocharger can be operated safely, correctly and efficiently.
Page 6: Layout And Function
Operation Manual / TPL65VA32 / VA33 1 Preliminary remarks / 1.2 Layout and function 1.2 Layout and function 01Filter silencer 08Nozzle ring 02Radial plain bearing 09Turbine wheel 03Thrust bearing 10Bearing casing 04Bearing bush 11Diffuser 05Radial plain bearing 12Compressor wheel 06Gas outlet casing 13Air outlet casing 07Gas inlet casing ©...
Page 7 Operation Manual / TPL65VA32 / VA33 1 Preliminary remarks / 1.2 Layout and function Mode of operation The turbocharger is a turbomachine and consists of the following main components: ¡ Turbine ¡ Compressor These are both mounted on a common shaft. The exhaust gases from the diesel engine flow through the gas inlet cas- ing (07) and nozzle ring (08) to the turbine wheel.
Page 8 Operation Manual / TPL65VA32 / VA33 1 Preliminary remarks / 1.2 Layout and function Additional function TPL..V. These turbocharger types have adjustable guide vanes at the turbine end instead of a nozzle ring. © Copyright 2020 . All rights reserved. HZTL2464_EN Rev.E March 2020...
Page 9: Intended Use Of The Turbocharger
Any other use is considered to be a special application, which must first be clarified with ABB Turbocharging. The manufacturer accepts no liab- ility for any other type of use. If the equipment is used for any other purpose, ABB Turbocharging reserves the right to reject all warranty claims.
Page 10: Storage Of New Turbochargers And Spare Parts
1.4 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 Turbocharging 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 11 Seal the package. The better the external seal is designed, the more permanent the protection. Long-term storage of turbochargers The turbochargers will be prepared for prolonged storage by ABB Tur- bocharging on request. The package is equipped with a hygrometer (see illustration).
Page 12: Essential Information
The malfunction must be reported to the per- son or department responsible. NOTICE Any modifications, additions or conversions made to the turbocharger that could impair safety require the prior approval of ABB Turbochar- ging. © Copyright 2020 . All rights reserved. HZTL2464_EN Rev.E...
Page 13 Only use original parts from ABB. ABB 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 14 This document is valid for different design variants of turbochargers. There may be sections and descriptions of components that are not rel- evant for a specific turbocharger variant. ABB Turbocharging Service Stations will be happy to provide information on questions regarding a design variant (see Contact information at www.abb.com/turbocharging).
Page 15: Symbols And Definitions
ABB Turbocharging ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging in this document. Official service stations of ABB Turbocharging Official service stations are regularly audited and certified by ABB Tur- bocharging. See also chapter Contact information →15. © Copyright 2020 . All rights reserved.
Page 16: Turbocharger Rating Plate
Operation Manual / TPL65VA32 / VA33 1 Preliminary remarks / 1.7 Turbocharger rating plate 1.7 Turbocharger rating plate Operating limits 01 Turbocharger operating limits at engine overload (110 %). Only when operating in the test rig unless otherwise agreed with the enginebuilder.
Page 17: Contact Information
A rating plate is attached to the turbocharger foot, one on the left and one on the right. On turbochargers with insulation from ABB, at least one additional rating plate is attached to the insulation of the gas outlet cas- ing.
Page 18: Safety
2 Safety / 2.1 Introduction 2 Safety 2.1 Introduction Turbochargers manufactured by ABB are state of the art and comply with the pertinent safety and health-protection requirements that ap- plied when the turbocharger was manufactured. Consequently, the tur- bocharger is safe to operate. Nevertheless, during turbocharger opera-...
Page 19: Definition Of Mandatory Signs
Operation Manual / TPL65VA32 / VA33 2 Safety / 2.3 Definition of mandatory signs 2.3 Definition of mandatory signs To be worn at all times Protective clothing Safety footwear to pro- tect against mechanical hazard and risk of fall- To be worn according to the specific work Safety glasses Safety goggles Safety gloves against...
Page 20: Warning Plates On The Turbocharger
Operation Manual / TPL65VA32 / VA33 2 Safety / 2.5 Warning plates on the turbocharger 2.5 Warning plates on the turbocharger Warning 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.
Page 21 Operation Manual / TPL65VA32 / VA33 2 Safety / 2.6 Safe operation and maintenance Electric tools must be solidly earthed, and connecting cables may not be damaged. Keep the workplace clean, clear away loose objects and remove obstacles on the floor. Keep the floor, equipment and the turbocharger clean.
Page 22 Operation Manual / TPL65VA32 / VA33 2 Safety / 2.6 Safe operation and maintenance Observe the material safety data sheet for the cleaning agent or solvent. Wear personal protective equipment (PPE) according to the material safety data sheet. Inspect the electric cables for abrasion and damage before and after your cleaning work.
Page 23: Hazards During Operation And Maintenance
Operation Manual / TPL65VA32 / VA33 2 Safety / 2.7 Hazards during operation and maintenance Safety during disassembly, assembly, maintenance and troubleshooting Always perform the specified adjustments, servicing as well as in- spection work and observe inspection intervals. Inform operating personnel about all service and repair work before beginning.
Page 24 Operation Manual / TPL65VA32 / VA33 2 Safety / 2.7 Hazards during operation and maintenance WARNING Risk of injury Contact with rotating parts can lead to serious injuries. The turbochar- ger must never be operated without a filter silencer or an air suction branch.
Page 25 Operation Manual / TPL65VA32 / VA33 2 Safety / 2.7 Hazards during operation and maintenance Hazards due to noise The development of noise during operation is influenced by the installa- tion and operating conditions. Noise with a sound pressure level exceed- ing 85 dB(A) is harmful.
Page 26 Operation Manual / TPL65VA32 / VA33 2 Safety / 2.7 Hazards during operation and maintenance WARNING Hot surfaces on uninsulated turbochargers Uninsulated turbochargers can cause serious personal injuries (burns). The turbocharger is supplied with or without insulation in accordance with the purchase order received from the enginebuilder. If supply is without insulation, the enginebuilder is responsible for providing the turbocharger with proper insulation and for providing protection against contact with hot surfaces.
Page 27 Operation Manual / TPL65VA32 / VA33 2 Safety / 2.7 Hazards during operation and maintenance WARNING Risk of fire, explosion Flammable and combustible operating materials and supplies can catch fire or resulting vapours can lead to an explosion. Observe the details in the material safety data sheets of the operat- ing and auxiliary materials.
Page 28 Operation Manual / TPL65VA32 / VA33 2 Safety / 2.7 Hazards during operation and maintenance Hazards when handling insulating materials WARNING Hazards due to insulating materials Dust and fibres from insulating materials can cause damage to health or irritations. Unsuitable, combustible insulating materials signify a fire hazard.
Page 29: Periodic Checking Of The Pressure Vessel
Heed any country-specific regulations. 2.8 Periodic checking of the pressure vessel The pressure vessels used by ABB, such as those for wet or dry cleaning, are so-called "simple pressure vessels". ¡ The locally applicable legal regulations regarding periodic checks of the pressure vessels must be observed.
Page 30 Operation Manual / TPL65VA32 / VA33 2 Safety / 2.9 Lifting loads In the case of two or more suspension points, the slinging angle must not exceed 45°. This avoids excessive loading due to inclined tensile loading. Fasten turbocharger assemblies / components as described in re- spective handling steps.
Page 31: Commissioning
Operation Manual / TPL65VA32 / VA33 3 Commissioning / 3.1 Oil supply 3 Commissioning 3.1 Oil supply A carefully designed and installed oil supply, which functions in all pos- sible operational conditions, is an important prerequisite for trouble- free turbocharger operation. The turbocharger is normally lubricated with oil from the engine oil cir- cuit.
Page 32 Operation Manual / TPL65VA32 / VA33 3 Commissioning / 3.1 Oil supply Oil pressure The oil pressure in front of the turbocharger must be maintained pre- cisely to ensure trouble-free operation. The permissible oil pressure ranges at measuring point M (blind connec- tion) on the turbocharger are listed below.
Page 33 Not permissible -> stop the engine > 160 If the turbocharger has been operated for a longer period of time out- side the admissible range, ABB Turbocharging recommends having the turbocharger inspected by an ABB Turbocharging Service Station. © Copyright 2020 . All rights reserved.
Page 34: Inspection Work
Operation Manual / TPL65VA32 / VA33 3 Commissioning / 3.2 Inspection work 3.2 Inspection work Inspection work includes preventive visual controls plus monitoring and measuring work before and during commissioning. Inspections help de- tect changes to the turbocharger. Machine damage can be avoided. 3.2.1 Inspection before commissioning Monitoring devices Check for correct functioning.
Page 35: Commissioning After Taking Out Of Operation
The first step is to check the seal for the oil supply to the turbocharger. If this is not in proper condition, contact an official ABB Turbocharging service station.
Page 36 Operation Manual / TPL65VA32 / VA33 3 Commissioning / 3.3 Commissioning after taking out of operation Inspect exhaust gas duct / line in front of and after turbine for any combustion deposits, foreign matter or residual water. Clean and re- move.
Page 37: Operation
Operation Manual / TPL65VA32 / VA33 4 Operation / 4.1 Noise emissions 4 Operation 4.1 Noise emissions WARNING Hazards due to noise Noise can cause impaired hearing, damage to health, mental disturb- ances, diminished attention and irritation. Always wear ear protection when the engine is running. When the sound pressure level is above 85 dB(A), always wear ear protection.
Page 38: Servicing Work
Despite observance of the service intervals, unusual loads, such as sev- eral start-stops a day, harsh environmental factors, poor fuel quality or heavy installation vibration can lead to premature machine damage. A shortened service interval must be arranged with ABB Turbochar- ging. © Copyright 2020 . All rights reserved.
Page 39 NOTICE Service inspection after 5 years To prevent age- and stoppage-related machine damage, an inspection by an ABB Turbocharging Service Station is recommended at the latest 5 years after the last service. 4.2.1 Service work every 25 … 50 hours Visual inspection for air, exhaust gas, water and oil leaks.
Page 40: Replacement Intervals For Turbocharger Components
(Customer Part Exchange) programme. 4.2.5 Service work every 30000 … 32000 hours The replacement of bearing parts as well as the inspection and assess- ment of the rotor must be carried out by an ABB Turbocharging Service Station. Disassemble turbocharger...
Page 41 Operation Manual / TPL65VA32 / VA33 4 Operation / 4.3 Replacement intervals for turbocharger components turbocharger rating plate. Incalculable influencing parameters can shorten the recommended replacement intervals for the rotor, see Influ- encing parameters . Non-rotating components The expected replacement intervals for non-rotating components and bearing parts are extremely dependent upon system-specific operating conditions, see Influencing parameters .
Page 42: Speed Measurement
50000 … 100000 Variable turbine geometry module 15000 (The variable turbine geometry module can be re- placed with a CPEX variable turbine geometry mod- ule by an ABB Turbocharging service station.) Turbine diffuser / cover ring 35000 … 50000 Other casings 100000 Axial bearing components 24000 … 36000...
Page 43 Operation Manual / TPL65VA32 / VA33 4 Operation / 4.4 Speed measurement CAUTION Do not use cables as a climbing aid If you pull the speed measurement cables too hard, contacts can be pulled out. Do not tension the speed measurement cables. Part number Description 42047...
Page 44 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 Tur- bocharging Service Station. © Copyright 2020 . All rights reserved.
Page 45 Operation Manual / TPL65VA32 / VA33 4 Operation / 4.4 Speed measurement 4.4.2 Assembly If the speed sensor is not fitted on the turbocharger, the following pro- cedure must be adopted to fit it: Engine and turbocharger are not running. The turbocharger lubricating system is switched off.
Page 46: Emergency Operation Tpl
Operation Manual / TPL65VA32 / VA33 4 Operation / 4.5 Emergency operation TPL..VA 4.4.3 Replacing the speed sensor WARNING 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. Wear safety gloves when removing the cable connector and speed sensor.
Page 47: Stopping The Engine
Operation Manual / TPL65VA32 / VA33 4 Operation / 4.6 Stopping the engine Detail A In the event of failure of the control system or the drive, the variable tur- bine geometry module can be fixed by clamping the ring lever (B) using at least 3 washers (C) spaced around the circumference.
Page 49: Maintenance
Operation Manual / TPL65VA32 / VA33 5 Maintenance / 5.1 Foreword to Maintenance 5 Maintenance 5.1 Foreword to Maintenance Maintenance and servicing work involves regular visual checks and clean- ing to ensure that the turbocharger and its attached units function trouble-free.
Page 50: Cleaning The Filter Silencer
Operation Manual / TPL65VA32 / VA33 5 Maintenance / 5.2 Cleaning the filter silencer 5.2 Cleaning the filter silencer 5.2.1 Filter silencer and connecting rod 81265 Filter ring (if provided) 81136 Absorption segment 81269 Connecting rods 81137 Sheet-metal covering 81266 Cover grid 81135 Filter silencer body...
Page 51 Otherwise there is a risk of damage or deformation. NOTICE Replace heavily contaminated or damaged parts with original parts from ABB. © Copyright 2020 . All rights reserved. HZTL2464_EN Rev.E...
Page 52 Operation Manual / TPL65VA32 / VA33 5 Maintenance / 5.2 Cleaning the filter silencer Fitting the filter silencer Assemble the insert units (E) by inserting the absorption segments (81136) into the sheet metal coverings (81137). Bend sheet metal coverings (81137) back to original shape. Insert the insert units (E) into slot guides in filter silencer unit (81135).
Page 53: Cleaning The Compressor During Operation
The interval between periodic cleaning is very dependent on the operat- ing conditions. In general, cleaning should be carried out every 25 ... 100 operating hours. Should the specified cleaning intervals prove incompatible with engine operation, please contact ABB Turbocharging. © Copyright 2020 . All rights reserved. HZTL2464_EN Rev.E...
Page 54 ¡ Wet cleaning This cleaning method is tested and approved by ABB Turbocharging. Principle of wet cleaning To clean the compressor stage during operation, water is injected in front of the compressor wheel through an injection pipe fitted in the fil- ter silencer or the suction branch.
Page 55 Operation Manual / TPL65VA32 / VA33 5 Maintenance / 5.3 Cleaning the compressor during operation 5.3.1 Wet cleaning with orifice plate on filter silencer (XC2) Operating state prerequisites for wet cleaning XC2 WARNING Increased stress on material During cleaning of the compressor at an engine load of 85 to 100 %, the stress on the material of the compressor-end turbocharger parts can be increased.
Page 56 Operating state prerequisites for wet cleaning XC3 NOTICE To be able to carry out a satisfactory cleaning process which has been tested and is recommended by ABB Turbocharging, the following pre- requisites must be fulfilled: Engine load 50 … 85% Start of cleaning cycle in accordance with following description for wet cleaning operation with XC3.
Page 57: Cleaning Turbines And Guide Vanes During Operation
If the cleaning result is still not satisfactory 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 parameters per turbocharger compressor...
Page 58 Operation Manual / TPL65VA32 / VA33 5 Maintenance / 5.5 Cleaning components mechanically CAUTION Choosing cleaning tools Turbocharger components are sensitive to mechanical damage. The use of needle guns or other impact tools, for example, damages the components. Depending on the specification, nozzle rings have pro- tective coatings, which can also be damaged.
Page 59 Operation Manual / TPL65VA32 / VA33 5 Maintenance / 5.5 Cleaning components mechanically 5.5.3 Cleaning the cartridge group on the compressor end CAUTION Selection of the cleaning agent Cleaning agents that contain chlorine corrode metals. Only use pH-neutral cleaning agents that do not corrode metals. Observe the material safety data sheet.
Page 60 Operation Manual / TPL65VA32 / VA33 5 Maintenance / 5.5 Cleaning components mechanically Cartridge group with one central suspension point CAUTION Damage to compressor wheel The lifting gear must not touch the compressor wheel at any time dur- ing rotation. Choose appropriate lifting gear length.
Page 61 Operation Manual / TPL65VA32 / VA33 5 Maintenance / 5.5 Cleaning components mechanically 6. Remove loop from first crane. © Copyright 2020 . All rights reserved. HZTL2464_EN Rev.E March 2020...
Page 62 Operation Manual / TPL65VA32 / VA33 5 Maintenance / 5.5 Cleaning components mechanically Cartridge group with two side suspension points Or use two swivel lifting eyes at top. CAUTION Damage to compressor wheel The lifting gear must not touch the compressor wheel at any time dur- ing rotation.
Page 63 Operation Manual / TPL65VA32 / VA33 5 Maintenance / 5.5 Cleaning components mechanically 4. When the cartridge group is suspended horizontally, attach a chain block to the swivel lifting eye and attach to the first crane. 5. Tighten chain block until entire cartridge group is suspended from first crane.
Page 64 Operation Manual / TPL65VA32 / VA33 5 Maintenance / 5.5 Cleaning components mechanically NOTICE Heating the liquid To shorten the soaking time the liquid can be heated to maximum 60 ºC. WARNING Heating up of cleaning agents and operating fluids When cleaning agents or operating fluids are heated up, explosive va- pours can be produced which are hazardous to health.
Page 65 Operation Manual / TPL65VA32 / VA33 5 Maintenance / 5.5 Cleaning components mechanically Remove contamination manually with a soft brush or wire brush. CAUTION Water and contamination in the cartridge group If water or contamination gets into the cartridge group, the turbochar- ger function may be impaired and parts in the cartridge group may be damaged.
Page 66: Troubleshooting
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 Turbochar- ging Service Station. 6.2 Surging of the turbocharger Turbocharger surging...
Page 67 Prolonged or periodic surging Possible damage to components, such as the compressor wheel, tur- bine blades, bearings and filter silencer Have the cause clarified immediately by an ABB Turbocharging ser- vice station and rectified. Have components inspected for damage and, if necessary, replaced by an ABB Turbocharging service station.
Page 68: Malfunctions During Operation
Defective oil pump in lubricat- Check / replace it ing system Manometer display wrong Replace the manometer Turbochar- Rotor axial clearance too large Contact an ABB Turbocharging Service Station Reduction in speed Possible causes Elimination Engine Defects of connected cylinders...
Page 69 Exhaust counterpressure Clean or repair the boiler or ex- too high haust silencer Enlarged flow cross-section Contact an ABB Turbocharging of the nozzle ring due to de- Service Station formed blade trailing edges Damaged or eroded turbine Charge air...
Page 70: Malfunctions When Stopping
Contaminated filter silencer Clean it causing excessive loss of pres- sure Compressor / turbine contam- inated Damaged compressor / tur- Contact an ABB Turbocharging bine Service Station Exhaust counterpressure too Clean or repair the boiler or ex- high haust silencer...
Page 71: Speed Measurement System
This problem is eliminated by removing the gasket. Defective sensor Contact ABB Turbocharging service sta- tion. Measured Dirty sensor tip The sensor tip is magnetic and can thus at- speeds too tract metal particles.
Page 72 Operation Manual / TPL65VA32 / VA33 6 Troubleshooting / 6.6 Variable Turbine Geometry Possible causes Elimination Drive unit No drive energy Contact an ABB Turbocharging (electrical com- Service Station ponents) © Copyright 2020 . All rights reserved. HZTL2464_EN Rev.E March 2020...
Page 73: Removal And Installation
Operation Manual / TPL65VA32 / VA33 7 Removal and installation / 7.1 Turbocharger weights 7 Removal and installation 7.1 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 variant possible.
Page 74 Operation Manual / TPL65VA32 / VA33 7 Removal and installation / 7.2 Removing the turbocharger Fasten separate lifting gear to each of the two ribs on the bearing casing provided for this purpose. Ribs (01) not in the middle at the top: Completely remove the bearing casing insulation (02) and place a sling around the bearing casing.
Page 75: Installing The Turbocharger
Operation Manual / TPL65VA32 / VA33 7 Removal and installation / 7.3 Installing the turbocharger WARNING Beware of tilting If support for the turbocharger is not provided or is inadequate, the turbocharger could tip over during installation or removal and cause a serious or even fatal injury.
Page 76: Disassembly And Assembly
For safety and product liability reasons, work on the cartridge group that is not described in the operation manual should only be carried out by trained specialists at an ABB Turbocharging Service Station. Unqualified work on the cartridge group can lead to total system failure and void the warranty.
Page 77: Module Weights
¡ Lifting gear Equipment for lifting and transporting loads (lifting slings, chain block, crane). Lifting gear is not supplied by ABB. 8.2 Module weights The specified weights of individual parts or assemblies are guides roun- ded off to the next highest value.
Page 78 Operation Manual / TPL65VA32 / VA33 8 Disassembly and assembly / 8.2 Module weights Weights [kg] Description TPL65VA32/33 Radial air suction branch Axial air suction branch Filter silencer Compressor casing Wall insert Diffuser Cartridge group Turbine diffuser Variable turbine geo- metry module Radial gas inlet casing ©...
Page 79: Removing And Fitting Filter Silencer Or Air Suction Branch
Operation Manual / TPL65VA32 / VA33 8 Disassembly and assembly / 8.3 Removing and fitting filter silencer or air suction branch Complete compressor casing Weight [kg] TPL65VA32/33 NOTICE 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 80 Operation Manual / TPL65VA32 / VA33 8 Disassembly and assembly / 8.3 Removing and fitting filter silencer or air suction branch Pass lifting gear through lugs on back. Unscrew nuts (72027) and remove them together with washers (72018). Remove filter silencer and set it down to one side. Installing the filter silen- Install filter silencer in reverse order.
Page 81: Axial Clearance
Clearances out of tolerance Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property. Have components assessed and, if necessary, replaced by an ABB Turbocharging Service Station. 8.5 Removing cartridge group Remove insulation.
Page 82 Operation Manual / TPL65VA32 / VA33 8 Disassembly and assembly / 8.5 Removing cartridge group Disconnect oil pipes in accordance with enginebuilder's instructions. CAUTION Oil orifices There is an orifice for adjusting the oil pressure in each of the two oil supply pipes of the bearing casing.
Page 83 Operation Manual / TPL65VA32 / VA33 8 Disassembly and assembly / 8.5 Removing cartridge group Turn the compressor casing (72000) together with the wall insert and diffuser and set them down with surface (F) on an underlay. WARNING Tipping the compressor casing Make sure the underlay does not shift.
Page 84 Operation Manual / TPL65VA32 / VA33 8 Disassembly and assembly / 8.5 Removing cartridge group Unplug cable connector (86515) and unscrew speed sensor (86505) with O-ring (86506). Remove the O-ring (42012). Remove the three screws (61059) together with their Verbus Ripp® washers (61058).
Page 85 Operation Manual / TPL65VA32 / VA33 8 Disassembly and assembly / 8.5 Removing cartridge group Withdraw cartridge group and fit supports (90450). Remove screws (42054) together with flange (42044) and also remove possible contamination behind the flange. Cover the oil connections. ©...
Page 86: Removing And Fitting Turbine Diffuser
Operation Manual / TPL65VA32 / VA33 8 Disassembly and assembly / 8.6 Removing and fitting turbine dif- fuser 8.6 Removing and fitting turbine diffuser Replace two screws (61032) with two studs (90903) in upper section of turbine diffuser. Screw out the remaining screws (61032), press off the turbine diffuser (63000) using the press-off screws (90901), then withdraw and re- move it.
Page 87: Removing Variable Turbine Geometry Module With Gas Inlet Casing
Carefully separate gas inlet casing (51001) from variable turbine geo- metry module (56100) and remove it. CAUTION Have the variable turbine geometry module overhauled by ABB Tur- bocharging. ABB Turbocharging Service Stations have variable turbine geometry modules replaced with overhauled ones as part of the CPEX (Customer Part Exchange) programme.
Page 88: Fitting The Variable Turbine Geometry Module And The Gas Inlet Casing
Operation Manual / TPL65VA32 / VA33 8 Disassembly and assembly / 8.8 Fitting the variable turbine geo- metry module and the gas inlet casing 8.8 Fitting the variable turbine geometry module and the gas inlet casing Push variable turbine geometry module (56100) over studs Push gas inlet casing (56001) over studs Slide clamping ring (56112) onto studs Tighten nuts (61042) to specified torque...
Page 89: Installing Cartridge Group
Operation Manual / TPL65VA32 / VA33 8 Disassembly and assembly / 8.9 Installing cartridge group Fit sealing air line (56501) to semi-circular section of line (A). 8.9 Installing cartridge group CAUTION Oil orifices There is an orifice for adjusting the oil pressure in each of the two oil supply pipes of the bearing casing.
Page 90 Operation Manual / TPL65VA32 / VA33 8 Disassembly and assembly / 8.9 Installing cartridge group Remove the cover from the oil connection. Fit flange (42044) with screws (42054) and new gasket (42045). Attach one lifting gear each to the two fins of the bearing casing provided for this purpose.
Page 91 Operation Manual / TPL65VA32 / VA33 8 Disassembly and assembly / 8.9 Installing cartridge group Fit the O-ring (77005) to the wall insert (77000). Fit the lifting gear and the swivel lifting eye (90235). Align and fit the wall insert (77000) using the centring screw (90187). Place the diffuser (79000) in position using the swivel lifting eye (90235).
Page 92 Operation Manual / TPL65VA32 / VA33 8 Disassembly and assembly / 8.9 Installing cartridge group Attach lifting gear to lifting device (90190) and turn compressor cas- ing (72000). By hand, screw three press-off nuts (61090) onto bearing casing studs, equally spaced around circumference and up to end of thread. Push compressor casing (72000) onto cartridge group to fit snugly and fasten it using nuts (61037).
Page 93 Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property. Have components assessed and, if necessary, replaced by an ABB Turbocharging Service Station. Connect oil lines and all air lines in accordance with engine builder’s instructions.
Page 95: Table Of Tightening Torques
Operation Manual / TPL65VA32 / VA33 8 Disassembly and assembly / 8.10 Table of tightening torques 8.10 Table of tightening torques © Copyright 2020 . All rights reserved. HZTL2464_EN Rev.E March 2020...
Page 96 Operation Manual / TPL65VA32 / VA33 8 Disassembly and assembly / 8.10 Table of tightening torques Tightening torques [Nm] Part number TPL65VA32/33 82005 M16x1.5 72027 With washer 72002 61037 61090 61036 61041 72029 61059 42059 42064 61056 51075 56110 56114 61042 56122 86505...
Page 97: Taking Out Of Operation At Short Notice
45% of n . Take note of the rating plate. Bmax After locking the turbocharger, contact an ABB Turbocharging Ser- vice Station and find the nearest port. Observe the safety regulations. Follow the directives of the enginebuilder.
Page 98: Fit Cover Plate
Operation Manual / TPL65VA32 / VA33 9 Taking out of operation at short notice / 9.2 Fit cover plate 9.2 Fit cover plate NOTICE The cover plate (material: General structural steel, in accordance with DIN EN 10025-2) must be manufactured in-house according to the drawing.
Page 99 Operation Manual / TPL65VA32 / VA33 9 Taking out of operation at short notice / 9.2 Fit cover plate NOTICE Carry out the work as described in the chapter Removal and fitting. Remove cartridge group. © Copyright 2020 . All rights reserved. HZTL2464_EN Rev.E March 2020...
Page 100 Operation Manual / TPL65VA32 / VA33 9 Taking out of operation at short notice / 9.2 Fit cover plate Close off opening in gas outlet casing using cover plate. Fasten cover plate using spacer sleeves and nuts (61037). CAUTION Shut off the supply of lubricating oil to the turbocharger. ©...
Page 101: Blocking The Inlets And Outlets
Operation Manual / TPL65VA32 / VA33 9 Taking out of operation at short notice / 9.3 Blocking the inlets and outlets 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 102 Operation Manual / TPL65VA32 / VA33 9 Taking out of operation at short notice / 9.4 Bypass the turbochar- NOTICE In this respect, refer to the engine manufacturer's instructions. © Copyright 2020 . All rights reserved. HZTL2464_EN Rev.E March 2020...
Page 103: Mothballing The Turbocharger
Operation Manual / TPL65VA32 / VA33 10 Mothballing the turbocharger / 10.1 Taking the engine out of opera- tion for up to 12 months 10 Mothballing the turbocharger 10.1 Taking the engine out of operation for up to 12 months Condition of engine lubricating oil The turbocharger normally remains mounted on the engine.
Page 104: Taking The Engine Out Of Operation For More Than 12 Months
Dismantle the turbocharger. The rotor and the bearing parts must be removed by an official ABB Turbocharging service station and refitted afterwards. Clean all parts. Machined, bright surfaces of steel and cast parts must be oiled with anticorrosive oil.
Page 105 Operation Manual / TPL65VA32 / VA33 10 Mothballing the turbocharger / 10.2 Taking the engine out of oper- ation for more than 12 months Condition of the mothballed turbocharger Check the mothballed turbocharger parts for corrosion once per an- num. If there are signs of rust: Clean parts thoroughly and renew protection against corrosion.
Page 106: Disposing Of Turbocharger Components
Operation Manual / TPL65VA32 / VA33 11 Disposing of turbocharger components / 11 Disposing of turbocharger components WARNING 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. Avoid the formation of dust.
Page 107: Spare Parts
Serial number (HT……) ¡ Designation 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 109: View Of Turbocharger With Part Numbers
Operation Manual / TPL65VA32 / VA33 12 Spare parts / 12.2 View of turbocharger with part numbers 12.2 View of turbocharger with part numbers © Copyright 2020 . All rights reserved. HZTL2464_EN Rev.E March 2020...
Page 110 Operation Manual / TPL65VA32 / VA33 12 Spare parts / 12.2 View of turbocharger with part numbers Part number Description Cartridge group 56100 Variable turbine geometry module 51001 Gas inlet casing 61001 Gas outlet casing 61035 Hexagon-head screw 61037 (in customer spare parts set) Hexagon nut 61042 Hexagon nut...
Page 111  ABB Switzerland Ltd Turbocharging Bruggerstrasse 71a CH-5401 Baden Switzerland...

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