ABB TPL76-C35 Operation Manual

nBmax 332 t Bmax 620 1/s °C STPL97 04070 35 50 50 Year 2021 Application according to the Operation Manual kg HZTL2485 English TPL76-C35 Original Operation Manual

The operational limits for the turbocharger nBmax, tBmax, nMmax, tMmax, inspection- and replacement intervals for the compon- ents concerned on the rating plate are valid for the operational mode and compressor inlet condition, which has been agreed upon between the engine builder and ABB. Note: Replacement intervals of components depends on the load profi le, turbine inlet temperature, suction air temperature and turbocharger speed. 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. Unless otherwise agreed, the application limits nMmax, tMmax are valid for the test operation for a limited time.

Table of contents © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Operation Manual 1 Preliminary remarks................................................................................................. 3 1.1 Purpose of this manual.................................................................................................. 3 1.2 Layout and function........................................................................................................ 4 1.3 Intended use..................................................................................................................... 6 1.4 Deflagration on gas engines......................................................................................... 7 1.5 Storage of new turbochargers and spare parts ....................................................... 8 1.6 Essential information................................................................................................... 10 1.7 Symbols and definitions.............................................................................................. 12 1.8 Turbocharger rating plate........................................................................................... 13 1.9 Contact information..................................................................................................... 14 2 Safety....................................................................................................................... 15 2.1 Introduction ................................................................................................................... 15 2.2 CE conformity ................................................................................................................ 15 2.3 Definition of mandatory signs ................................................................................... 16 2.4 Definition 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 vessel................................................................. 26 2.9 Lifting loads ................................................................................................................... 26 3 Commissioning...................................................................................................... 28 3.1 Oil supply ........................................................................................................................ 28 3.2 Inspection work............................................................................................................. 31 3.3 Commissioning after taking out of operation........................................................ 33 4 Operation ............................................................................................................... 34 4.1 Noise emissions ............................................................................................................ 34 4.2 Servicing work ............................................................................................................... 36 4.3 Replacement intervals for turbocharger components.......................................... 39 4.4 Speed measurement .................................................................................................... 41 4.5 Stopping the engine.................................................................................................... 44 5 Maintenance .......................................................................................................... 45 5.1 Foreword to Maintenance.......................................................................................... 45 5.2 Cleaning the filter silencer.......................................................................................... 46 5.3 Cleaning the compressor during operation ........................................................... 49 5.4 Cleaning turbine blades and nozzle ring in operation........................................... 55 5.5 Cleaning components mechanically......................................................................... 60

Table of contents © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 6 Troubleshooting.................................................................................................... 69 6.1 Malfunctions when starting....................................................................................... 69 6.2 Surging of the turbocharger....................................................................................... 70 6.3 Malfunctions during operation .................................................................................. 71 6.4 Malfunctions when stopping...................................................................................... 74 6.5 Speed measurement system ...................................................................................... 75 7 Removal and installation...................................................................................... 76 7.1 Turbocharger weight.................................................................................................... 76 7.2 Removing the turbocharger........................................................................................ 77 7.3 Installing the turbocharger ......................................................................................... 79 8 Disassembly and assembly.................................................................................. 80 8.1 Introduction .................................................................................................................. 80 8.2 Module weights ............................................................................................................. 82 8.3 Removing and fitting filter silencer or air suction branch................................... 84 8.4 Axial clearance .............................................................................................................. 86 8.5 Removing cartridge group .......................................................................................... 87 8.6 Dismantling and installing the turbine diffuser and nozzle ring........................ 94 8.7 Installing cartridge group........................................................................................... 99 8.8 Dismantling and fitting nozzle ring at turbine end............................................. 108 8.9 Table of tightening torques...................................................................................... 116 9 Taking out of operation at short notice ........................................................... 118 9.1 Possibilities for emergency repair........................................................................... 118 9.2 Locking the rotor......................................................................................................... 119 9.3 Fit cover plate .............................................................................................................. 123 9.4 Blocking the inlets and outlets................................................................................. 127 9.5 Bypass the turbocharger........................................................................................... 127 10 Mothballing the turbocharger........................................................................... 128 10.1 Taking out of operation for up to 12 months........................................................ 128 10.2 Taking out of operation for more than 12 months............................................... 129 11 Disposing of turbocharger components.......................................................... 130 12 Spare parts............................................................................................................ 131 12.1 Ordering spare parts.................................................................................................. 131 12.2 View of turbocharger with part numbers .............................................................. 132

1 Preliminary remarks / 1.1 Purpose of this manual © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 1 Preliminary remarks 1.1 Purpose of this manual This Operation Manual belongs to the turbocharger with the identical serial number (01), see the cover sheet of the Operation Manual and the turbocharger rating plate. 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. This Operation Manual complements and expands existing national reg- ulations concerning work safety and accident prevention. Target group This Operation Manual is intended for engineers and qualified mechan- ics who are responsible for operating the engine and the turbocharger installed on it. Availability of operation manual An operation manual must be available at all times at the place where the turbocharger is used. Everyone who operates or works on the turbocharger must have first read and understood the operation manual. Page 3 / 133

1 Preliminary remarks / 1.2 Layout and function © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 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 13Compressor casing 07Gas inlet casing Page 4 / 133

1 Preliminary remarks / 1.2 Layout and function © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 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. The turbine wheel (09) uses the energy contained in the exhaust gas to drive the compressor wheel (12). The compressor then draws in fresh air, compresses it and then forces it into the cylinders. The exhaust gases escape to free air through an exhaust gas pipe which is connected 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 drawn through the suction branch or the filter silencer (01) into the compressor wheel (12). This air then passes through the diffuser (11) and leaves the turbocharger through the com- pressor casing (13). The rotor runs in two radial plain bearings (02/05). One plain bearing is in the bearing bush (04), and the second one is in the axial thrust bearing (03) at the compressor end. The plain bearings are connected to a central lubricating oil duct which is fed with oil from the engine's lubricating oil circuit. The oil outlet is al- ways at the lowest point of the bearing casing (10). Turbocharger version with compressor wheel cooling system Depending on its range of use, the turbocharger is provided with a compressor wheel cooling system. Com- pressor wheel cooling means that, after the charge air cooler at the engine end, cooled compressor air is de- livered to the turbocharger to cool the compressor wheel. Depending on the respective operating conditions, it is absolutely essential that the compressor wheel is cooled in order to guarantee its reliability and the replacement intervals. In the case of the turbocharger version with compressor wheel cooling, the cooling air is supplied through the side connection (15) in the bearing casing. Page 5 / 133

1 Preliminary remarks / 1.3 Intended use © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 1.3 Intended use Use on internal combustion engines in general ABB turbochargers are intended for turbocharging internal combustion engines. To ensure compliance with the machinery directive 2006/42/EC when using on gas engines, the turbocharger must be operated in an engine room classified as "not at risk of explosion". This is in accordance with the position paper [2] relating to ATEX issued by EUROMOT [1]. The turbocharger supplies the engine with the air volume or air/gas mix- ture and the associated charging pressure required for operation. The turbocharger is solely intended to be operated with a clockwise dir- ection of rotation as viewed from the turbine end. The specific operating limits of the turbocharger were determined on the basis of information from the enginebuilder about the intended use. These data are given on the rating plate. ABB Turbocharging is not liable for any unintended applications and shall reject all warranty claims. [1]Euromot = The European Association of Internal Combustion Engine Manufacturers [2]Directive 94/9/EC concerning equipment and protective systems in- tended for use in potentially explosive atmospheres (ATEX) The Eur- omot Position as of November 2003, ATEX Euromot Position 191103 WARNING Unapproved operation Any operation of the turbocharger outside of its operating limits can be hazardous to personnel. u Only operate the turbocharger within the operating limits. u Only trained personnel must operate the turbocharger. The intended use of the turbocharger includes compliance with all regu- lations and conditions. In particular, the following must be observed: ¡ Operation Manual ¡ Instructions of the enginebuilder State of the art The turbocharger is designed and built according to the state of the art and is safe to operate. Page 6 / 133

1 Preliminary remarks / 1.4 Deflagration on gas engines © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Perfect condition The turbocharger must be operated in technically perfect condition and in accordance with its intended application. ABB Turbocharging shall not accept any liability for damage caused by unauthorised modifications to the turbocharger or improper operation. 1.4 Deflagration on gas engines ABB turbochargers can withstand a deflagration with a transient pres- sure increase of 12 bar. ABB Turbocharging recommends that, following a deflagration event, the turbocharger undergoes a visual inspection. Items to check during this inspection are the position of the turbine casing, of the compressor casing to the bearing casing, as well as a shifting of the bearing casing in relation to the bracket. A crack inspection of the casings and the bellows is also recommended. The nearest ABB Turbocharging Service Station should be commissioned with this inspection and assessment. Page 7 / 133

1 Preliminary remarks / 1.5 Storage of new turbochargers and spare parts © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 1.5 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). Volatile Corrosion Inhibitor (VCI) Only dry rooms in which the relative humidity is between 40…70 % and no condensation can form are suitable for storage. Storage of new turbochargers and spare parts for more than 6 months (VCI) WARNING Protection of health when handling VCIs VCI products 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 or keep food at the workplace while working with VCIs. u Wear safety gloves. u Clean hands and face after working with VCIs. u For further information refer to www.branopac.com. Wear safety gloves to protect against chemical hazards. The following mothballing measures are required every 6 months: u Open the package. u Remove the VCI corrosion protection emitter from the package and replace it with a new, identical VCI corrosion protection emitter. New VCI corrosion protection emitters can be obtained at www.brano- pac.com. u Dispose of the old VCI corrosion protection emitter in an environ- mentally compatible manner, professionally and in accordance with local regulations. Page 8 / 133

1 Preliminary remarks / 1.5 Storage of new turbochargers and spare parts © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 u 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). The following measures are required every 6 months: u Check the hygrometer (02) in the sight-glass. There is an opening (01) in the wooden crate which allows this check to be carried out. When the display field has changed colour at the 70% level, the maximum permissible humidity has been exceeded. In this case, the turbochar- ger must be inspected by an ABB Turbocharging Service Station and repacked. u Inspect the package for damage. If the package is damaged, the tur- bocharger must be inspected by an ABB Turbocharging Service Sta- tion and repacked. After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station: ¡ Inspect the component ¡ Replace the desiccant agent ¡ Repackage the component. NOTICE Turbocharger ready for operation If the 70% field of the hygrometer (02) has not changed colour and the package is undamaged, the turbocharger can be put into operation without any prior inspection by an ABB Turbocharging Service Station. Unpacking the turbochargers The corrosion protection effect ends after the material is unpacked from the VCI package. To avoid the formation of condensation, the surroundings and the con- tent of the package must have the same temperature during unpacking. Page 9 / 133

1 Preliminary remarks / 1.6 Essential information © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 1.6 Essential information Organisational measures In addition to the Operation Manual, the general statutory regulations for the prevention of accidents and protection of the environment are also to be observed. This also applies for the provision 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 with the Operation Manual. u If the turbocharger shows modifications affecting safety or any cor- responding operating behaviour, it must be shut down immediately by stopping the engine. 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. Original parts and safety Original parts and accessories are specially designed for the turbochar- ger supplied by ABB. WARNING Use original parts Operation of the turbocharger with non-original parts can impair the safety of the turbocharger and can cause serious damage to property and injury to personnel. u 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. Basic mechanical training is a prerequisite. Page 10 / 133

1 Preliminary remarks / 1.6 Essential information © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Design variants 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). Accuracy of illustrations The illustrations in this document are general in nature and intended for ease of understanding. Differences in detail are therefore possible. Storage of new turbochargers New turbochargers supplied by ABB Turbocharging can be stored without additional mothballing measures for a period of 6 months after the delivery date. Suitable storage locations are dry rooms only where the relative humid- ity is between 40-70% and no condensation can form. u After 6 months, the surfaces and all accessible areas of the turbochar- ger must be sprayed with anticorrosive oil. u The insulation must be removed for this purpose. NOTICE Repeat the measures listed for the corrosion protection of your tur- bocharger every 6 months. Page 11 / 133

1 Preliminary remarks / 1.7 Symbols and definitions © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 1.7 Symbols and definitions The following symbols are used in the documents: w Prerequisite u Work step ¡ Enumeration, first level - Enumeration, second level → Refers to a page number Definition of notes NOTICE Note A note provides suggestions which facilitate the work on the product. 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 caution / warning The caution and warning signs are described in the chapter Safety. 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 →14. Page 12 / 133

1 Preliminary remarks / 1.8 Turbocharger rating plate © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 1.8 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. 02 Turbocharger operating limits during operation Recommended replace- ment intervals for tur- bocharger components 03 Replacement interval for plain bearings in 1000 h 04 Replacement interval for compressor in 1000 h 05 Replacement interval for turbine in 1000 h Further information 06 Part number for customer 07 Designation of special design 08 Turbocharger weight in kg 09 Turbocharger type 10 Serial number 11 Year of turbocharger construction 12 Manufacturing plant Page 13 / 133

1 Preliminary remarks / 1.9 Contact information © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 1.8.1 Explanation of the rating plate The recommended replacement intervals and the corresponding opera- tional limits are jointly defined with the engine manufacturer. This in- formation is specific to the system. Operation above the indicated values nBmax, tBmax can considerably shorten the recommended replacement intervals. In such cases, we recommend that you contact the nearest official ABB Turbocharging service station. nMmaxand 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 increases the risk of unpredictable component failures. 1.8.2 Positions of the rating plates 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. 1.9 Contact information Contact information for the official service stations of ABB Turbochar- ging is available online. u Scan the QR code to access our website. ABB Switzerland Ltd, Turbocharging Bruggerstrasse 71a CH-5401 Baden Switzerland www.abb.com/turbocharging Page 14 / 133

2 Safety / 2.1 Introduction © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 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- tion and when working on the turbocharger, residual risks can exist which: ¡ originate from the turbocharger itself and its accessories ¡ originate from the operating and auxiliary materials used ¡ are the consequence 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 access to the turbocharger as well as the organisational measures that regulate the safe handling of the turbocharger by its personnel. All instructions contained in this chapter must be observed for safe and trouble-free operation of the turbocharger and during all work on the turbocharger. All further safety instructions contained and specifically identified in every chapter of this manual (see section Definition of Safety Instruc- tions) must also be observed. 2.2 CE conformity Information ABB turbochargers fulfil Directive 2006/42/EC on machinery and are considered partly completed machinery in the sense of Article 2 g. Page 15 / 133

2 Safety / 2.3 Definition of mandatory signs © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 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- ing To be worn according to the specific work Safety glasses Safety goggles Safety gloves against - Mechanical hazard - Chemical hazard - Thermal hazard Respiratory mask against - Dusts - Gases Safety helmet Ear 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 injuries and even accidents with fatal consequences may occur if work and operating instructions marked with this symbol and the word WARNING are either not followed or not followed pre- cisely. u Warning signs must be observed at all times. CAUTION Definition of caution Serious machine or property damage may occur if work and operating instructions marked with this symbol and the word CAUTION are either not followed or not followed precisely. u Caution signs must be observed at all times. Page 16 / 133

2 Safety / 2.5 Warning plates on the turbocharger © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 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. Fig. 1: Warning plate Part number Size [mm] Product 81080 105 x 74 TPL When uninsulated turbochargers are delivered to the engine builder, the warning plates must be subsequently attached to the insulation. This is the responsibility of the engine builder. Page 17 / 133

2 Safety / 2.6 Safe operation and maintenance © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 2.6 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. Work safety and work area safety WARNING Risk of falling There is the risk that someone can fall when working on the turbochar- ger. u Do not climb on the turbocharger or on parts attached to it or use these as climbing aids. u When working at levels above the head, use climbing aids and work platforms suitable for this purpose. u Observe all general regulations for the prevention of accidents. u Do not work 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 solidly earthed, and connecting cables may not be damaged. u Keep the workplace clean, clear away loose objects and remove obstacles on the floor. u Keep the floor, equipment and the turbocharger clean. u Have oil binding materials ready at hand and keep oil catch pans ready or in position u Eliminate leaks. u Keep fire-protection materials and fire-extinguishing equipment ready. Welding work close to the turbocharger u If welding work is being carried out in the vicinity of the turbocharger, cover the filter silencer so that the filter mat is not damaged. u Remove combustible objects and substances out of the range of fly- ing sparks. u Cover all connections on the turbocharger so that no foreign objects can get into the turbocharger. u Wear personal protective equipment (PPE) for welding operations. Page 18 / 133

2 Safety / 2.6 Safe operation and maintenance © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Safety during start-up / commissioning and operation u Before starting work, carry out visual inspection of working area. u Remove any obstacles and objects lying around. u Before start-up / commissioning, check all pipes from and to tur- bocharger for damage and leaks. u Don't work in any way that could impair safety when working on tur- bocharger. u After about every 12 hours of operation or at least once a day, inspect turbocharger for visible damage and defects. u Immediately report any damage 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 on auxiliary power sources (hydraulics, pneumatics, electricity, water), keep an eye open for any hazards resulting from supplying these power sources. Safety during cleaning If cleaning agents or solvents are used for cleaning, the corresponding material safety data sheet and the safety instructions in section "Haz- ards due to operating and auxiliary materials" must be observed. u Observe the material safety data sheet for the cleaning agent or solvent. u Wear personal protective equipment (PPE) according to the material safety data sheet. u Inspect the electric cables for abrasion and damage before and after your cleaning work. Page 19 / 133

2 Safety / 2.6 Safe operation and maintenance © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Safety during disassembly, assembly, maintenance and troubleshooting u Always perform the specified adjustments, servicing as well as in- spection work and observe inspection intervals. u Inform operating personnel about all service and repair work before beginning. u Before opening a cover or removing a protective device on a tur- bocharger, the engine must be switched off and the turbocharger must have come to a standstill. u Ensure that 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 Possible damage to or destruction of components on the turbocharger. u Perform only those tasks that are described in this manual. u Perform work only for which training has been carried out. Safety when taking out of operation or preparing for mothballing u Secure the rotor so it cannot turn. The rotor can turn on its own from the force of the stack draught. u Clean the turbocharger before mothballing it. u Observe the material safety data sheet for the cleaning and moth- balling agents. u Wear personal protective equipment (PPE) according to the material safety data sheet. Page 20 / 133

2 Safety / 2.7 Hazards during operation and maintenance © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 2.7 Hazards during operation and maintenance Mechanical hazards during operation During normal operation, no mechanical hazards emanate from the tur- bocharger if it has been installed properly. 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. When the engine is at a standstill, the rotor can turn on its own because of stack draught. u Operate the turbocharger 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 risks can occur through the improper handling of components, through the non-observance of work instruc- tions, due to inadequate care or as a consequence of insufficient train- ing. WARNING Mechanical hazard Severe injuries to personnel or fatal accidents can be caused by mech- anical influences as a consequence of hazardous and inadequate opera- tional procedures. u Observe the general rules for occupational safety and prevention of accidents. u Ensure workplace safety. u Only perform operations that are described in this chapter. u Only perform operations for which you have previously received in- struction or training. Page 21 / 133

2 Safety / 2.7 Hazards during operation and maintenance © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 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. WARNING Hazards due to noise Noise can cause impaired hearing, damage to health, mental disturb- ances, diminished attention and irritation. u Always wear ear protection when the engine is running. u When the sound pressure level is above 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 oil) become hot. The surface temperat- ure is dependent on the effectiveness of the insulation being used. The temperature can become high enough so that it falls into ranges where burns are possible. WARNING Risk of burning Touching hot surfaces or contact with hot operating materials can lead to serious burns. u Do not touch hot surfaces and heed the warning plate on the tur- bocharger. u Wear heat-resistant safety gloves and protective clothing. u Allow the turbocharger to cool down before carrying out any work. Wear safety gloves to protect against thermal hazards. Page 22 / 133

2 Safety / 2.7 Hazards during operation and maintenance © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 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. u Compliance with the instructions and specifications given by the en- ginebuilder to protect against hot turbocharger 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 operation or the execution of maintenance work. Oils, greases, coolants, cleaning agents and solvents, acids, etc. can be regarded as hazardous materials. Operating and auxiliary materials can be combustible and easily ignited. WARNING Handling operating and auxiliary materials Ingestion or inhalation of vapours of operating and auxiliary materials or contact with such can cause damage to health. u Avoid inhalation and contact with the skin. u Ensure good ventilation. u Observe details in the safety data sheets of the operating and auxili- ary materials. u Observe local laws. Wear safety goggles. Wear safety gloves to protect against chemical hazards. Wear a respiratory mask to protect against gases. Page 23 / 133

2 Safety / 2.7 Hazards during operation and maintenance © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 WARNING Risk of fire, explosion Flammable and combustible operating materials and supplies can catch fire or resulting vapours can lead to an explosion. u Observe the details in the material safety data sheets of the operat- ing and auxiliary materials. u Comply with local legislation. u Do not allow any exposed flame or ignition source during cleaning work. u Carry out cleaning in the open or provide sufficient aeration and ventilation. CAUTION Risk of environmental damage The escape of operating and auxiliary materials into the atmosphere or contamination 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 hazard notices on the containers of the operating and auxiliary materials. u Wear appropriate protective clothing. u Avoid inhalation and contact with the skin. u Ensure that the work space is adequately ventilated. u Seal containers tightly immediately after use and put them away. u Collect used working and auxiliary materials safely, store them separ- ately in suitable containers and dispose of them properly and in an environmentally compatible manner in accordance with statutory reg- ulations. u In the event of leaks or after spilling, immediately spread a suitable binding agent and dispose of it properly and in an environmentally compatible manner in accordance with statutory regulations. Page 24 / 133

2 Safety / 2.7 Hazards during operation and maintenance © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 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. u Use only suitable, non-combustible insulating materials. u Ensure that the work area is well ventilated. u Avoid stirring up dust. u Use tools and processes which keep dust to a minimum. u Remove packing materials only in the work 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. Wear safety goggles. Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against chemical hazards. u Use only suitable, non-combustible insulating materials. u Ensure that the work area is well ventilated. u Wear suitable work clothing (safety glasses, respiratory mask). u Avoid stirring up dust. u Use tools and processes which keep dust to a minimum. u Remove packing materials only in the work 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. Page 25 / 133

2 Safety / 2.8 Periodic checking of the pressure vessel © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Hazards due to electrical components WARNING Hazards due to electrical components Electrical components operate with voltages which can present hazards to humans. u All work on or with electrical components may only be performed by trained specialists. u 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. ¡ 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 are in proper working condition and monitor them. Necessary repair or main- tenance work must be carried out without delay and the required safety precautions must be taken. u Pressure equipment must not be operated if it has defects. 2.9 Lifting loads WARNING Suspended loads Loads not suspended in compliance with regulations may lead to per- sonal injury or accidents with fatal consequences. u Loads must always be fastened to technically perfect lifting gear with sufficient loading capacity. u Make sure the load is suspended properly on the crane hook. u Do not let anyone stand beneath a suspended load. Wear safety gloves to protect against mechanical hazards. Wear safety helmet. Page 26 / 133

2 Safety / 2.9 Lifting loads © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 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. 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 protection at sharp edges. u Completely screw in assembly / fitting devices without fail so that they cannot work loose during use. u Use assembly / fitting devices only for applications described. u Make sure removed turbocharger components stand safely and se- curely. Page 27 / 133

3 Commissioning / 3.1 Oil supply © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 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. NOTICE With regard to the oil supply, please observe the engine builder's spe- cifications for lubricating oil selection, oil change intervals, oil filtration, oil pressure and oil temperature. Oil filtration A lubrication oil filter system with a mesh size ≤0.050 mm is adequate for TPL76-C turbochargers. NOTICE This filter system can also be achieved by using an additional self-clean- ing fine filter. Page 28 / 133

3 Commissioning / 3.1 Oil supply © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 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. Status for operation Oil pressure at measuring point M poil,in [bar] Permissible, for normal operation 1.3 … 2.5 Permissible, during engine warm-up 1.3 … 5.0 Temporarily admissible ( < 1 h ) -> alarm 1.1 … 1.3 Not permissible -> emergency stop 0.0 … 1.1 Permissible, during pre- and post-lubrication (engine stopped) 0.2 … 2.5 Oil orifice A metering orifice is installed in the oil inlet of the turbocharger to en- sure these oil pressures. The orifice is installed by the enginebuilder and it is fixed in place with a locking ring. Page 29 / 133

3 Commissioning / 3.1 Oil supply © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Lubricating oil temperature at the inlet CAUTION Machine damage If the oil temperature at the oil inlet exceeds the admissible range, this may lead to engine damage. u Observe oil temperature at the oil inlet according to the following table. Status for operation Oil temperature at the in- let Toil,inlet [°C] Admissible 30 … 80 Temporarily admissible (< 1 h) -> alarm > 80 Not admissible -> stop engine > 85 Not admissible -> do not start engine (before start: preheat oil) < 30 Lubricating oil temperature at outlet The oil temperature at 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 outlet is listed in the fol- lowing table. The specified oil outlet temperature is to be considered as alarm value for the turbocharger operation and must be monitored ac- cording to the current regulations. Status for operation Oil temperature at outlet Toil,outlet [°C] Permissible ≤ 130 Temporarily permissible -> alarm > 130 Not permissible -> stop engine > 150 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. Page 30 / 133

3 Commissioning / 3.2 Inspection work © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 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 u Check for correct functioning. Filter mat u Inspect for damage. Lubricating system u Check oil filter for cleanliness before commissioning. CAUTION Contaminated 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 system must be flushed thoroughly with warm oil. u When running in the engine and after all service work on the lubricat- ing system, special running-in filters must be used. u Check oil pressure in oil supply lines. CAUTION Prelubrication Serious machine or property damage might result if the turbocharger is not supplied with oil when the engine is starting. u Activate prelubrication device before starting engine. Warning plates on tur- bocharger u Check whether the warning plates are present and legible. u Check whether the protective sheets have been removed. Page 31 / 133

3 Commissioning / 3.2 Inspection work © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 3.2.2 Check after start-up (engine at idling speed) Lubricating system u Check oil pressure in oil supply lines. u Check oil inlet temperature. The permissible values are listed in the section Oil supply. Gas, air and oil lines u Check all gas, air and oil lines for leaks after starting the engine. 3.2.3 Check when running up engine u Measure speed, oil pressure and charging pressure at various engine performance levels. u Measure exhaust gas 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 different operating conditions into ac- count. NOTICE Lubricants and pastes used during assembly of the turbocharger li- quefy or vaporise and might escape as an oily liquid in the first few hours after commissioning. If oily liquid continues to escape after this period, an oil leak must be suspected. The first step is to check for leak- age of the oil supply to the turbocharger. If this is leaky, contact an offi- cial ABB Turbocharging service station. 3.2.4 Inspection after 100 service hours Clean or replace lubricating oil filters after the first 100 service hours. Page 32 / 133

3 Commissioning / 3.3 Commissioning after taking out of operation © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 3.3 Commissioning after taking out of operation If provided u Remove cover plates (blind flanges) between compressor casing out- let and charge air duct, 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 supply line or filter silencer for any foreign matter. Clean and remove. u Start up turbocharger oil circulation system at engine end. u Prepare turbocharger for operation as instructed in section "Inspec- tion work before start-up / commissioning" of chapter headed "Start- up / commissioning". u Start up turbocharger. Page 33 / 133

4 Operation / 4.1 Noise emissions © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 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. u Always wear ear protection when the engine is running. u When the sound pressure level is above 85 dB(A), always wear ear protection. Wear ear protection. The sound pressure level (A-weighted) of emissions is measured at a dis- tance of 1 metre from the turbocharger. 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 turbocharger in or- der to observe this limit value: ¡ Fitted air-inlet system ¡ All standard, noise-reducing measures have been taken2). ¡ The bellows at the air outlet have been perfectly insulated acoustic- ally by the engine builder. He is also responsible for insulating the charge air / scavenging air line and the charge air cooler. 1) Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 : A-weighted emission sound pressure level 2) In the event of divergent insulation designs, the engine builder must ensure that equivalent acoustic insulating measures are taken. Page 34 / 133

4 Operation / 4.1 Noise emissions © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Suggestion for noise insulation of the bellows 01 Compressor casing 04 Insulation pads 02 Bellows 05 Insulation mat (at least 15 mm) 03 Charge air duct / scavenging air line 06 Sheet metal cover Page 35 / 133

4 Operation / 4.2 Servicing work © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 4.2 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. In this way, it can be ensured that the turbocharger remains in full work- ing order. CAUTION Service intervals Service work on the turbocharger that is neglected or carried 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 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. u A shortened service interval must be arranged with ABB Turbochar- ging. 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 u Visual inspection for air, exhaust gas, water and oil leaks. u Record operating data and enter it in the engine logbook. u Clarify the cause of any variances. CAUTION Unknown changes during operation The consequences can range from an impairment to a breakdown. u Have unknown causes clarified by an ABB Turbocharging service sta- tion. Page 36 / 133

4 Operation / 4.2 Servicing work © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 4.2.2 Entries in engine logbook By monitoring the engine, conclusions can be drawn about the tur- bocharger performance. The following operating data and measured values must be entered reg- ularly in the engine manufacturer'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 ¡ Lubricating oil pressure and lubricating oil temperature If provided ¡ Air temperature behind compressor and charge air cooler ¡ Turbocharger speed ¡ Pressure loss in air filter 4.2.3 Servicing work according to the engine manufacturer's instructions Oil filter u Clean or replace oil filter in supply line to turbocharger when engine is not running. Page 37 / 133

4 Operation / 4.2 Servicing work © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 4.2.4 Service work every 8000 … 16000 hours The inspection and assessment of the rotor and the bearing parts must be carried out by an official ABB Turbocharging service station. u Disassemble turbocharger. u Measure clearances. u Clean the turbine and compressor wheels and inspect for damage. u Clean the turbine and compressor casings and inspect for any cracks and erosion or corrosion. u Clean bearing casing and blow air through oil ports. u Clean nozzle ring and check for cracks and erosion. u Inspect and assess bearing parts and rotor. 4.2.5 Service work every 24000 … 36000 hours The replacement of bearing parts and the inspection and assessment of the rotor must be carried out by an ABB Turbocharging Service Station. u Disassemble turbocharger. u Clearance measurement. u Clean the turbine and compressor wheels and inspect for damage. u Clean turbine casing as well as compressor casing and check for any cracks and erosion or corrosion. u Clean bearing casing and blow air through oil ports. u Clean nozzle ring and check for cracks and erosion. u Dismantle, inspect and balance the rotor. u Replace plain bearings with original parts from ABB Turbocharging. Page 38 / 133

4 Operation / 4.3 Replacement intervals for turbocharger components © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 4.3 Replacement intervals for turbocharger components Rotating components The recommended replacement intervals for the compressor and turbine wheels due to stress caused by centrifugal forces and load cycles are cal- culated under consideration of the operating conditions while applying the safety concept for rotating components. They can be found on the 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. When the specified, periodic inspections are carried out, the individual components are inspected for wear and tear and replaced if necessary. In this way, trouble-free operation is ensured. Influencing parameters The following parameters influence the replacement intervals for tur- bocharger components: Parameters influencing bearing parts ¡ Poor quality of the lubricating oil (lubrication oil filter system, condi- tion of lubricating oil) ¡ Unusual loads (vibration, start/stop frequency) ¡ Non-permissible state of rotor unbalance Parameters influencing non-rotating components exposed to exhaust gas ¡ Fuel quality (gas, MDO, HFO) ¡ Load profile (thermal load changes, number of starts/stops) ¡ Temperature level of exhaust gas ¡ Turbine cleaning frequency ¡ Procedure for turbine cleaning Page 39 / 133

4 Operation / 4.3 Replacement intervals for turbocharger components © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Parameters influencing rotating components exposed to exhaust gas ¡ Fuel quality (gas, MDO, HFO) ¡ Turbine cleaning frequency ¡ Procedure for turbine cleaning ¡ Load profile Expected replacement in- tervals [h] Component GAS / MDO HFO Gas inlet casing 50000 … 100000 25000 … 50000 Gas outlet casing 50000 … 100000 35000 … 100000 Nozzle ring 35000 … 50000 25000 … 50000 Turbine diffuser / cover ring 35000 … 50000 25000 … 50000 Other casings 100000 100000 Axial bearing components 24000 … 36000 24000 … 36000 Radial bearing components 24000 … 36000 24000 … 36000 Turbine blades (due to wear) - - ≥ 12000 Recommended replace- ment intervals [h] Rotor components See rating plate information GAS = Gas Engine MDO = Marine Diesel Oil HFO = Heavy Fuel Oil NOTICE The specified values are guides and not guaranteed. (See Influencing parameters.) Page 40 / 133

4 Operation / 4.4 Speed measurement © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 4.4 Speed measurement A speed measuring 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 tension the speed measurement cables. Part number Description 42047 Screw plug 86505 Speed sensor 86515 Cable connector for 86505 86526 F/I converter 86528 Tachometer Page 41 / 133

4 Operation / 4.4 Speed measurement © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 4.4.1 Speed differences with multiple turbochargers per engine The speeds of all turbochargers on one engine differ only slightly from each other in normal operation. The difference between the highest and the lowest turbocharger speed must not be more than 3 % relative to the speed limit nBmax. If this permissible range of difference is exceeded, the following 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 reduced en- gine performance or turbocharger speed. u If the turbocharger surges continuously, engine performance must be reduced further. u Measure the temperatures in the air and gas lines to and from the tur- bochargers and compare them with standard values. If the engine can be stopped for a short time: u Inspect the air and gas lines as well as the turbocharger and eliminate any problems. u In any event, it is recommended that you contact the nearest ABB Tur- bocharging Service Station. 4.4.2 Assembly If the speed sensor is not fitted on the turbocharger, the following pro- cedure must be adopted to fit it: w Engine and turbocharger are not running. w The turbocharger lubricating system is switched off. u Remove screw plug (42047) from bearing casing. NOTICE Part position The position of the screw plug for measuring the speed is marked "n" on the bearing casing. u Screw in speed sensor (86505) as far as it will go and tighten to torque specified in table. (See chapter Table of tightening torques.) u Connect speed sensor using cable connector (86515). Page 42 / 133

4 Operation / 4.4 Speed measurement © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 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. u Wear safety gloves when removing the cable connector and speed sensor. Wear safety gloves to protect against thermal hazards. u Reduce engine performance to the idling speed, then stop 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 the stop. u Observe the tightening torque (see the table of tightening torques in the chapter entitled Disassembly and assembly). NOTICE Sealing of the speed sensor The speed sensor is designed with a sealing lip and does not require any additional gasket for assembly. u Connect cable connector to speed sensor. u Switch on lubricating oil supply to turbocharger. 4.4.4 Failure of speed measuring system Possible reasons for failure of the speed measuring system are de- scribed in the chapter Troubleshooting. Page 43 / 133

4 Operation / 4.5 Stopping the engine © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 4.5 Stopping the engine CAUTION Stopping the engine Heat in the turbocharger must be dissipated by the further circulating lubricating oil. u Allow the engine to continue running at idling speed for a further 10 minutes before stopping. Page 44 / 133

5 Maintenance / 5.1 Foreword to Maintenance © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 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. ¡ The external condition and how dirty the cleaning points specified in this chapter are, must be established by visual checks at the spe- cified intervals. ¡ The safety precautions must be observed during all maintenance and servicing work. The cleaning points described in the following are: ¡ Filter silencer ¡ Compressor ¡ Turbine and nozzle ring Page 45 / 133

5 Maintenance / 5.2 Cleaning the filter silencer © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 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 81272 Screw 81273 Lock nut E Insert unit = absorption segment + sheetmetal covering Page 46 / 133

5 Maintenance / 5.2 Cleaning the filter silencer © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Removing and cleaning filter silencer If provided u Remove filter strip (81265). u Rinse filter strip (81265) using water with detergent additive or, if very dirty, soak it and squeeze out carefully. Rinse it in cold water. Avoid rough treatment (not a jet of water). NOTICE How dirty the filter strip (81265) is, depends on how clean the drawn-in air is. Clean filter strip every 500 hours of service or more frequently if necessary. u Loosen and remove lock nuts (81273). u Loosen and remove screws (81272) for connecting rods (81269). u Remove connecting rods (81269). u Carefully remove cover grids (81266). u Pull out insert units (E), bend open sheet metal coverings (81137) and then remove absorption segments (81136). u Clean absorption segments (81136). When cleaning, make sure that the absorption segments (81136) are only cleaned lightly with pressurized air, a soft brush or with moist cleaning cloths. Otherwise there is a risk of damage or deformation. NOTICE Replace heavily contaminated or damaged parts with original parts from ABB Turbocharging. Fitting filter silencer u Assemble insert units (E) by putting fleece segments (81136) into sheet-metal cover (81137). u Bend back sheet-metal cover (81137) to original shape. u Put insert units (E) into slot guides in filter silencer body (81135). NOTICE If a cleaning container is fitted to the filter silencer (optional depending on turbocharger type), the water injection line must now be refitted. (See also following section Fitting cleaning pipe.) u Put cover grids (81266) uniformly into correct position. u Push connecting rods (81269) through clips on cover grids (81266). Page 47 / 133

5 Maintenance / 5.2 Cleaning the filter silencer © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 CAUTION If the connecting rods (81269) are not located correctly in their recesses on the filter silencer body (81135), the cover grids (81266) can twist and shift. There is then a risk of foreign matter and dirt getting into the compressor. u Join connecting rods (81269) using screws (81272). When tightening the screws (81272), ensure that connecting rods (81269) are located correctly in recesses in filter silencer body (81135). Now tighten screws (81272) alternately until the following maximum torque is reached: Screw Tightening torque [Nm] 81272 20 u Screw lock nuts (81273) onto screw (81272) and tighten to following torque: Lock nut Tightening torque [Nm] 81273 40 Page 48 / 133

5 Maintenance / 5.3 Cleaning the compressor during operation © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 5.3 Cleaning the compressor during operation Approval by enginebuilder These instructions for wet cleaning only apply when cleaning is carried out with clean water and under the precondition that the enginebuilder approves the process. General The contamination of the compressor stage (compressor wheel, wall in- sert and diffuser) depends on the degree of purity of the air that is drawn in. Deposits can form in the flow 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 ¡ Increased rotor unbalance Periodic cleaning of the compressor during operation prevents or delays any major increase in contamination. It does not, however, replace the regular service work, during which the turbocharger is completely dis- mantled and the compressor is cleaned mechanically. Cleaning interval 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. Page 49 / 133

5 Maintenance / 5.3 Cleaning the compressor during operation © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Cleaning method Cleaning of the compressor during operation is carried out using the cleaning method described in the following: ¡ 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. The water does not act as a solvent, but the contamination deposit is re- moved by the mechanical impact of the droplets. This is a very suitable process, provided that the degree of contamination is not too high. CAUTION Corrosion and deposits when cleaning Damage and impairment of turbocharger parts due to salt water and cooling water additives u Don't use salt water for cleaning, but only clean fresh water. CAUTION Uncontrolled volumes of water Uncontrolled volumes of water can damage the turbocharger and the engine. u Never connect the water line without the orifice specified for the tur- bocharger. CAUTION Formation of ice at low temperatures Damage to turbocharger due to the formation of ice during wet clean- ing if the intake air temperatures are too low. u Never carry out wet cleaning if intake air temperatures are under 5 °C. V-engines In the case of V-engines with several turbochargers on each engine, we recommend parallel cleaning of the compressors. This cleaning process is faster and the risk of turbocharger surging is reduced. Page 50 / 133

5 Maintenance / 5.3 Cleaning the compressor during operation © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 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. u No personnel is allowed to be present in the vicinity of the tur- bocharger during compressor cleaning. u Compressor cleaning must be activated from the engine control panel. Wet cleaning procedure for compressor with XC2 u Trigger water injection according to the specifications of the en- ginebuilder. u The specified water pressure upstream of the connection to the tur- bocharger must be maintained. u Operate engine for at least five additional minutes after cleaning. Not more than three cleaning cycles should be conducted consecutively. Cleaning parameters per turbocharger compressor Product Engine load Water pres- sure [bar] Water injection time [sec] Water temper- ature [°C] Ø orifice [mm] TPL76-C 50 … 100% 3 10 5 … 50 2.9 Page 51 / 133

5 Maintenance / 5.3 Cleaning the compressor during operation © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Surging of the compressor stage Should repeated surging of the compressor stage occur during com- pressor cleaning, first the cleaning parameters as well as the engine-side system must be checked with regard to deviations (e.g. an increased pressure loss in the charge air cooler) and corrected if necessary. If, despite correct settings, surging of the compressor stage occurs while cleaning the compressor, as a remedial measure the engine load can be reduced further while cleaning the compressor. The reduction of the engine load can lead to a reduction in the effectiveness of the com- pressor cleaning. u To avoid a decreased engine availability, the compressor stage can be cleaned at reduced engine load during the drying time after wet cleaning of the turbine has been completed. (see section Wet cleaning turbine and nozzle ring during operation). In this case, the water injec- tion time for cleaning the compressor can be increased from ten to forty seconds. Page 52 / 133

5 Maintenance / 5.3 Cleaning the compressor during operation © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 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 which has been tested and is recommended by ABB Turbocharging, the following pre- requisites must be fulfilled: u Engine load 50 – 85% u Start cleaning cycle according to following description Wet cleaning operation with XC3. Operating procedure for compressor wet cleaning with XC3 Operating the water pres- sure vessel u The operating state prerequisites for compressor cleaning with XC3 must be fulfilled. u Remove sealing plug (X). u Fill vessel with required volume of clean water (see table Cleaning parameters). u Screw in sealing plug (X). u Push the valve activator (Y) against the spring and hold it for 10 ... 15 seconds until the entire volume of water has been injected. Page 53 / 133

5 Maintenance / 5.3 Cleaning the compressor during operation © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 u After cleaning, wait at least 5 minutes to allow turbocharger to dry. The cleaning process can be repeated up to two times. If the cleaning is still unsuccessful after three cleaning processes and the engine values are unsatisfactory, it is recommended to have the tur- bocharger checked and cleaned by an ABB Turbocharging Service Sta- tion. Cleaning parameters per turbocharger compressor Product Engine load Water temperature [°C] Contents of water ves- sel [dm3] TPL76-C 50 ... 85% 5 … 50 1 Surging of the compressor stage Should repeated surging of the compressor stage occur during com- pressor cleaning, first the cleaning parameters as well as the engine-side system must be checked with regard to deviations (e.g. an increased pressure loss in the charge air cooler) and corrected if necessary. If, despite correct settings, surging of the compressor stage occurs while cleaning the compressor, as a remedial measure the engine load can be reduced further while cleaning the compressor. The reduction of the engine load can lead to a reduction in the effectiveness of the com- pressor cleaning. u To avoid a decreased engine availability, the compressor stage can be cleaned at reduced engine load during the drying time after wet cleaning of the turbine has been completed. (see section Wet cleaning turbine and nozzle ring during operation). In this case, the water injec- tion time for cleaning the compressor can be increased from ten to forty seconds. Page 54 / 133

5 Maintenance / 5.4 Cleaning turbine blades and nozzle ring in opera- tion © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 5.4 Cleaning turbine blades and nozzle ring in operation The combustion of heavy fuel oil in diesel engines contaminates the tur- bine blades and nozzle rings of turbochargers. The deposits on the tur- bine components originate from the following combustion products: ¡ Soot ¡ Molten ash ¡ Cinder ¡ Incompletely burned fuel ¡ Sodium vanadyl vanadate It is advisable to use fuels with a low ash, sulphur, sodium and vanadium content. The fuel must also be correctly stored, prepared and handled. We recommend using fuels with a vanadium-to-sodium mass ratio of less than 3:1 so that the melting temperature of the sodium vanadyl vanadate is as high as possible. The amount of contamination increases over time, which is why regular and correctly performed cleaning is important in order to remove the de- posits that have formed. Contaminated turbine components can cause a slight increase in char- ging pressure because of narrowing of the turbine cross-section. The contamination causes a drop in turbine efficiency, and the engine tem- peratures downstream of the cylinder can increase. The engine perform- ance must therefore be reduced if necessary. The contamination of the turbine also causes rotor unbalance. Extremely heavy contamination can lead to non-permissibly high unbalance of the rotor. Operating experience has shown that, in spite of regular cleaning during operation, it is essential to carry out the overhauls during which the tur- bine and the nozzle ring are cleaned mechanically. However, if cleaning is carried out properly and the cleaning system is properly dimensioned, the intervals between overhauls can be increased. Wet cleaning interval The interval between periodic cleaning is very dependent on the operat- ing conditions. As a rule, cleaning should be carried out every 50 to 200 operating hours. Cleaning method When cleaning the turbine components during operation, use wet clean- ing. This cleaning method is tested and approved by ABB Turbocharging. Prerequisites for wet cleaning are that the enginebuilder approves the process and his instructions are followed. Principle of wet cleaning Wet cleaning makes use of various effects. Depending on the composi- tion of the contamination, the individual effects with their different levels of intensity have a varying influence on the cleaning result: Page 55 / 133

5 Maintenance / 5.4 Cleaning turbine blades and nozzle ring in opera- tion © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 ¡ Erosion The dirt is removed by the mechanical action of the impacting water droplets. ¡ Solubility Water solubility of the contamination deposits in water. ¡ Thermal shock Spalling of contamination due to temperature difference. CAUTION Corrosion and deposits when cleaning Damage and impairment of turbocharger parts due to salt water and cooling water additives u Don't use salt water for cleaning, but only clean fresh water. Components at the turbine end are not cleaned until the engine has been started or the engine load reduced. The exhaust gas temperature must not exceed the value specified in the respective cleaning instructions (see section PrerequisitesTPL-A/-C: Operating state prerequisites for wet cleaning turbine and nozzle ring →57). CAUTION Reduced service life of the components Failure to comply with the minimum stabilisation time before cleaning, the prescribed turbine inlet temperatures and the drying time after cleaning significantly reduces the expected service life of the compon- ents. u Comply with the cleaning parameters given in the tables. V-engines In the case of V-engines with several turbochargers on each engine, we recommend parallel cleaning of both turbochargers. This cleaning pro- cess is faster and the risk of turbocharger surging is reduced. We recom- mend finding the most suitable method by performing trials. Page 56 / 133

5 Maintenance / 5.4 Cleaning turbine blades and nozzle ring in opera- tion © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 5.4.1 Wet cleaning turbine and nozzle ring during operation Prerequisites for wet cleaning of turbine The following operating state and prerequisites have been tested and approved by ABB Turbocharging for the cleaning process: u The engine has just been started or the engine load has been reduced as far as possible (best cleaning is achieved at a load level of roughly 10 … 15%). u As soon as the turbine inlet temperature is stable and below 430 °C, wait at least another 10 minutes for the charger parts to cool down. u Start cleaning cycle according to following description Wet cleaning procedure. Page 57 / 133

5 Maintenance / 5.4 Cleaning turbine blades and nozzle ring in opera- tion © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Layout of cleaning pipes Wet cleaning procedure for turbine during operation u Meet prerequisites and operating state requirements without fail be- fore cleaning! u Make sure water supply (01) is connected, turned on and guaranteed. u Open drain pipe (08, 09), if provided. u Switch over 3-way valve (04) from scavenging air mode to water sup- ply. u Set the required volume of water on the flowmeter as shown in the table (see table Cleaning parameters). u Shut off the water supply again by switching the 3-way valve (04) to scavenging air mode after injecting the required volume of water. u The injection process has been completed. u Close drain hole (if provided) above drain pipe (08, 09). u After cleaning, wait with engine running for at least 10 minutes without changing load to allow turbocharger to dry. CAUTION Corrosion damage to bearing casing In order to avoid corrosion damage to the bearing casing, it is advisable to carry out an additional 30 minutes of operation with TTE > 500°C after the 10 minute drying time. Page 58 / 133

5 Maintenance / 5.4 Cleaning turbine blades and nozzle ring in opera- tion © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Recommendation for wa- ter pressure It is necessary to have the corresponding water pipe pressure in order to achieve the correct water flow rate (see table Cleaning parameters). If the water pressure is too low, the water flow rate specified in the table will not be obtained. In this case, the cleaning effect will be decreased. Repeating cleaning cycles immediately after each other must be avoided as this can lead to high mechanical loading and consequently to a reduc- tion in the service life of the components. If cleaning is unsatisfactory, the length of the process can be extended. If the injection time is extended, it must be ensured that no unaccept- able volume of water collects in the gas outlet casing. To avoid this, a drainage system for the gas outlet casing should be installed and open during the cleaning process. If a drainage system is not provided, the in- jected volume of water can be controlled by a flowmeter in the water supply. The maximum volume of water allowed in individual cases must be determined together with an ABB Turbocharging Service Station. The influence of the cleaning water on peripheral equipment, such as a boiler, must be clarified by the operator. Points to remember when cleaning The following points must be observed with regard to draining the gas outlet casing: ¡ The exhaust gas temperature behind the turbocharger drops signi- ficantly when cleaning (typical turbocharger outlet temperatures dur- ing cleaning: 60 ... 180 °C). ¡ Depending on the engine load, water might run out of the drain pipe. This outflow might not start for two or three minutes, or it might not occur at all. ¡ If the drainage of the gas outlet casing is omitted, the turbocharger speed and/or the gas inlet temperature must be monitored during the cleaning process. If the load is too low, water can collect in the gas outlet casing. Indicators for this are a sudden severe drop in the turbocharger speed or a very large increase in the gas inlet temperat- ure. In such cases, the cleaning operations must be stopped and the cleaning cycle restarted with reduced water pressure or higher en- gine load. Cleaning parameters for wet cleaning of turbine and nozzle ring Product Max. temperat- ure when starting cleaning TTI [°C] Injection time t i [min] Water flow rate per tur- bocharger at pWater = 3 bar MW [l/min] TPL76-C 430 10 37 Page 59 / 133

5 Maintenance / 5.5 Cleaning components mechanically © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 5.5 Cleaning components mechanically 5.5.1 Introduction Compressor wheels can be heavily contaminated by badly filtered intake air, as can turbines by heavy fuel oil operation or coked oil. Such contam- ination may possibly no longer be removed through cleaning during op- eration and must be cleaned mechanically during the standard service in- tervals (see chapter entitled Service work). Professional overhauling of the components by an ABB Turbocharging Service Station is required, preferably using the cleaning method de- scribed in the following. 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. u Only use soft tools such as scouring cloths, brushes or wire brushes. u In the event of heavy contamination, the cleaning methods de- scribed in this chapter such as soaking can be repeated until a satis- factory result has been achieved. The disassembly and assembly of the components is described in chapter Fitting and dismantling. u Dispose of contaminated water and cleaning agents in an environ- mentally compatible manner, professionally and in accordance with valid local regulations. Page 60 / 133

5 Maintenance / 5.5 Cleaning components mechanically © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 5.5.2 Turbine-end, non-rotating parts WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or contact with them may be harmful to health. u Do not breathe in these substances and avoid contact with the skin. u Ensure proper ventilation. u Observe the information in the material safety data sheet for the op- erating materials and supplies. u Wear personal protective equipment (PPE) according to the material safety data sheet. u Comply with local legislation. Wear safety goggles. Wear safety gloves to protect against chemical hazards. Wear a respiratory mask to protect against gases. CAUTION Damage to coated nozzle rings The coating of coated nozzle rings can be damaged if cleaned improp- erly. u Only insert the nozzle ring in water. u Only clean the nozzle ring with soft brushes. u Do not sandblast the nozzle ring. Baked-on layers of contamination, for example from heavy fuel oil or coked oil, occur at the turbine end. The following performance-relevant parts can be cleaned according to the following description. 56001 Nozzle ring 63000 Turbine diffuser u Place contaminated parts in hot water or in a liquid such as brake cleaner, so that the contamination softens. u Brush off the contamination or remove it with a steam cleaner. Page 61 / 133

5 Maintenance / 5.5 Cleaning components mechanically © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 u Repeat the soaking and brushing if necessary. u Completely remove any solvents from the parts in clean water. u Dry components completely. u Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the turbocharger. u Dispose of contaminated water and cleaning agent in accordance with the specifications in the safety data sheet. 5.5.3 Cartridge group – General CAUTION Corrosion If the cartridge group is not put into operation again immediately after cleaning, parts may corrode. u Re-install and use the cartridge group immediately after cleaning. u Remove turbocharger from the engine (see chapter Removal and in- stallation). u Remove cartridge group (see chapter Disassembly and assembly). First clean the compressor end and then the turbine end in accordance with the following description. 5.5.4 Cleaning the cartridge group on the compressor end CAUTION Selection of the cleaning agent Cleaning agents that contain chlorine corrode metals. u Only use pH-neutral cleaning agents that do not corrode metals. u Observe the material safety data sheet. u Observe country-specific regulations regarding banned and restric- ted substances. CAUTION Water and contamination in the cartridge group If water or contamination penetrates the cartridge group, this can im- pair the function of the turbocharger and damage parts inside the cart- ridge group. u Make sure that no water or contamination can enter into the cart- ridge group. u Clean compressor wheel with a scouring cloth or soft brush soaked in water with household cleaning agent. Do not use any wire brushes! Page 62 / 133

5 Maintenance / 5.5 Cleaning components mechanically © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 u Dry the compressor wheel and the gap between the compressor and the bearing casing with a weak jet of compressed air. u Lightly spray the gap between the compressor and the bearing casing with penetrating oil. u Dispose of contaminated water and cleaning agent in accordance with the safety data sheet. 5.5.5 Cleaning the cartridge group on the turbine end Soaking the contamination Baked layers of contamination from fuel residue or coked oil may occur at the turbine end. The contamination can be removed by soaking and brushing. The procedure for soaking the layers of contamination as well as for cleaning the turbine are described in the following. To soak the layers of contamination on the turbine, the cartridge group can be immersed vertically in a container with fluid. The cartridge group must be rotated to do this. u Two cranes (or chain blocks) must be used for the rotating operation. Suspending the chain block directly from the crane and rotating the cart- ridge group is not permitted because of the risk of damage to the com- pressor wheel. 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. u Choose appropriate lifting gear length. Page 63 / 133

5 Maintenance / 5.5 Cleaning components mechanically © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 1. Suspend cartridge group from normal suspension point and suspend from first crane. 2. Secure two lifting loops with swivel lifting eyes in the lower push-off threads and suspend from a second crane. 3. Rotate cartridge group horizontally by lifting the second crane. 4. When the cartridge group is horizontal, secure one chain block to one of the upper push-off threads using a swivel lifting eye and suspend from the second crane. 5. Tighten chain block until entire cartridge group is suspended from second crane. 6. Remove loop from first crane. Page 64 / 133

5 Maintenance / 5.5 Cleaning components mechanically © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 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. u Choose appropriate lifting gear length. 1. Suspend cartridge group from the two side suspension points on the crane using two lifting loops. or Attach two swivel lifting eyes to the side and suspend the cartridge group from the crane using two lifting loops. 2. Attach third lifting loop with swivel lifting eye to thread of oil outlet flange. 3. Rotate the cartridge group into a horizontal position by lifting. Page 65 / 133

5 Maintenance / 5.5 Cleaning components mechanically © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 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. 6. Remove loop from second crane. CAUTION Selection of the cleaning agent Cleaning agents that contain chlorine corrode metals. u Only use pH-neutral cleaning agents that do not corrode metals. u Observe the material safety data sheet. u Observe country-specific regulations regarding banned and restric- ted substances. u Fill the tank with soaking liquid. u Only immerse the cartridge group until all blades are covered with cleaning agent. Page 66 / 133

5 Maintenance / 5.5 Cleaning components mechanically © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 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. u Observe the information in the material safety data sheet. Wear a respiratory mask according to material safety data sheet. 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. u Place cartridge group on suitable wooden or metal supports. u Allow the layers of contamination on the turbine to soak for at least four hours. Removing contamination WARNING Health hazard due to soot particles If soot particles enter the eyes or respiratory tract, this can be harmful to health. u Avoid the formation of dust. u Vacuum up dust with a suitable vacuum cleaner. u Wear a respiratory mask to protect against particles (P1 or P2 mask). u Wear safety goggles. Wear safety goggles. Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against mechanical hazards. u Raise the cartridge group and align horizontally. Page 67 / 133

5 Maintenance / 5.5 Cleaning components mechanically © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 u 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. u Make sure that water or contamination does not get into the gap between the sealing cover and turbine. CAUTION Non-permissible rotor unbalance after cleaning Invisible and unevenly distributed residual contamination deposits lead to rotor unbalance. This can result in bearing or turbocharger damage. u Remove all traces of contamination from the turbine. u After brushing off the contamination, fill the tank with clean water, not salt water. u Submerge the turbine of the cartridge group in clean water, so that loose particles of contamination detach completely. u Lift the cartridge group. u Dry turbine and gap between turbine and sealing cover with a weak jet of compressed air. u Lightly spray turbine and gap between turbine and sealing cover with penetrating oil. u Rotate cartridge group back to horizontal position (described proced- ure in reverse order, see Cleaning the cartridge group on the turbine end →63). u Dispose of contaminated water and cleaning agent in accordance with the specifications in the safety data sheet. Page 68 / 133

6 Troubleshooting / 6.1 Malfunctions when starting © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 6 Troubleshooting 6.1 Malfunctions when starting Sluggish start-up Possible causes Elimination Turbochar- ger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Vibrations Possible causes Elimination Turbochar- ger 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 around the periphery of rotor components, caused by slight local rubbing of adjacent components, is per- missible. The compressor blades and turbine blades are then shortened somewhat. 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 Turbochar- ging Service Station. Page 69 / 133

6 Troubleshooting / 6.2 Surging of the turbocharger © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 6.2 Surging of the turbocharger Turbocharger surging Possible causes Elimination Engine Guard in front of the tur- bocharger is contaminated or damaged Clean / replace it Turbocharger Filter silencer or diffuser contaminated Clean it Heavy deposits of dirt in the turbine or nozzle ring Charge air cooler Cooler contaminated Clean it Charge air duct blocked CAUTION Prolonged or periodic 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 rectified. u Have components inspected for damage and, if necessary, replaced by an ABB Turbocharging service station. Sporadic surge blows Surging of the turbocharger can occur during certain operating condi- tions such as when reducing the engine performance quickly when man- oeuvring. At the same time, the flow direction in the compressor is mo- mentarily reversed. Such sporadic surge blows do not impair the safe operation of the turbocharger. ¡ A surge blow is accompanied by a loud bang and escape of hot air from the filter silencer. Page 70 / 133

6 Troubleshooting / 6.3 Malfunctions during operation © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 6.3 Malfunctions during operation Lubricating oil pressure too low Possible causes Elimination Engine Oil filter heavily contaminated Clean it Defective oil pump in lubricat- ing system Check / replace it Manometer display wrong Replace the manometer Turbochar- ger Rotor axial clearance too large Contact an ABB Turbocharging Service Station Reduction in speed Possible causes Elimination Engine Defects of connected cylinders when pulse charging Contact the enginebuilder Turbochar- ger Heavy contamination of the turbine Clean it Damaged rotor components or bearing Contact an ABB Turbocharging Service Station Pipes Defects such as leaks in the ex- haust gas pipes or charge air ducts Make repairs Increase in speed Possible causes Elimination Turbochar- ger Heavily contaminated nozzle ring (with 4-stroke application) Contact an ABB Turbocharging Service Station Page 71 / 133

6 Troubleshooting / 6.3 Malfunctions during operation © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Exhaust gas temperature too high Engine performance and engine speed unchanged Possible causes Elimination Engine Malfunctioning injection system Repair it or contact the manu- facturer Turbocharger Air starvation, 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-section of the nozzle ring due to de- formed blade trailing edges Contact an ABB Turbocharging Service Station Damaged or eroded turbine Charge air cooler Cooler contaminated Clean it Cooling water volume too low Top up the water Entry temperature of cool- ing water too high Inspect / clean the cooling sys- tem Inadequate ventilation Improve the ventilation Page 72 / 133

6 Troubleshooting / 6.3 Malfunctions during operation © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Charge air pressure too low Engine performance and engine speed unchanged, air intake condition normal Possible causes Elimination Engine Air receiver leaking Make repairs Gas piping between the engine and the turbine leaking Poorly adjusted injection sys- tem Correct it Poorly adjusted valve control Turbochar- ger Manometer display wrong Replace the 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 ABB Turbocharging Service Station Exhaust counterpressure too high Clean or repair the boiler or ex- haust silencer Charge air pressure too high Engine performance and engine speed unchanged, air intake condition normal Possible causes Elimination Engine Malfunctioning injection sys- tem Repair it or contact the manu- facturer Poorly adjusted injection sys- tem Correct it Engine performance higher than expected Check engine performance Turbochar- ger Manometer display wrong Replace the manometer Page 73 / 133

6 Troubleshooting / 6.4 Malfunctions when stopping © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 6.4 Malfunctions when stopping Noises during run-down 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 too short Possible causes Elimination Turbochar- ger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Page 74 / 133

6 Troubleshooting / 6.5 Speed measurement system © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 6.5 Speed measurement system Possible causes Elimination Signal amp- litude non ex- istent or poor Fitting error The screw plug for the sensor is fitted with a gasket. When fitting the speed sensor, this gasket must be removed. If it is fitted by mistake, the distance from the sensor tip to the sig- nal-generating sealing disc increases. As a result, the voltage amplitude of the speed signal decreases, which can cause prob- 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 tip is magnetic and can thus at- tract metal particles. As a result, the dis- tance to the auxiliary bearing decreases, which can lead to amplification of the noise component and consequently to faulty triggering. Remove the sensor, clean its tip and refit the sensor using the specified tightening torque. Measured speed too low - - Contact ABB Turbocharging service sta- tion. Other sources of errors - - If none of the above measures eliminates the problem, we recommend that you have the speed measuring system inspected by an official ABB Turbocharging service sta- tion. Page 75 / 133

7 Removal and installation / 7.1 Turbocharger weight © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 7 Removal and installation 7.1 Turbocharger weight 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. This standard value may deviate from the data on the rating plate depending on the specification. Weight [kg] TPL76-C 4070 Page 76 / 133

7 Removal and installation / 7.2 Removing the turbocharger © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 7.2 Removing the turbocharger u A suitable suspension device (as illustrated) must be used when re- moving and installing the turbocharger. The suspension device is not included in the scope of delivery of ABB. u Disconnect all gas, air and oil pipes in accordance with the engineb- uilder’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. When the cartridge group, the bear- ing casing or the turbocharger-is being fitted to the engine, it must be ensured that the orifices specified for the turbocharger are installed in both oil supply pipes. u Check that the oil orifices have been correctly installed. Suspension dimension Distance in [mm] A 860 B 1210 C 800 Use the two suspension eyes on the bearing casing (L1, L2) (observe the marking on the insulation). The two suspension eyes on the turbine-end foot (T1, T2) are used for horizontal alignment of the turbocharger. u Remove the insulation shell from the bearing casing and turbine-end foot. Leave the remaining insulation on the turbocharger. Page 77 / 133

7 Removal and installation / 7.2 Removing the turbocharger © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Version with compressor wheel cooling system u Dismantle air supply line. (See also chapter entitled Preliminary re- marks / Layout and functionality) u Inspect the lifting gear. u Secure lifting gear to the suspension eyes of the bearing casing and the turbine-end foot. u Unplug the cable connector on the speed sensor. u Loosen the fixing screws on the feet. u Lift the turbocharger off the engine and set it down to one side. WARNING If the turbocharger is not sufficiently supported or not supported at all during removal and installation, it may tip over and cause severe injury to personnel or accidents resulting in fatalities. u Support the turbocharger at a suitable point. u Cover the oil connection. Page 78 / 133

7 Removal and installation / 7.3 Installing the turbocharger © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 7.3 Installing the turbocharger u Remove cover from oil connection. u Inspect the lifting gear. u Secure lifting gear to the suspension eyes of the bearing casing and of the turbine-end foot. CAUTION Oil orifices There is an orifice for adjusting the oil pressure in each of the two oil supply pipes of the bearing casing. When the cartridge group, the bear- ing casing or the turbocharger-is being fitted to the engine, it must be ensured that the orifices specified for the turbocharger are installed in both oil supply pipes. u Check that the oil orifices have been correctly installed. u Adjust the turbocharger on the engine. u Tighten fixing screws in foot. NOTICE The fastening specifications for the foot screws are supplied to the en- ginebuilder by ABB Turbocharging and given in his manual. u Fasten all gas, air and oil lines in accordance with the enginebuilder’s instructions. Version with compressor wheel cooling system u Fit the air supply line. (See also chapter entitled Preliminary remarks / Layout and functionality) u Plug in cable connector on speed sensor. Page 79 / 133

8 Disassembly and assembly / 8.1 Introduction © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 8 Disassembly and assembly 8.1 Introduction CAUTION Working on the cartridge group 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. u Unqualified work on the cartridge group can lead to total system failure and void the warranty. 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 enclosed in the toolbox. WARNING Maintaining assembly devices Assembly devices must be checked for damage before and after use. u Check visually for corrosion, cracks, deformation and wear. u Don't use damaged assembly devices, but replace them. Customer spare part set Before beginning work, ensure that the required customer spare part sets are available. u See chapter Spare parts. Page 80 / 133

8 Disassembly and assembly / 8.1 Introduction © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Tightening torques for turbocharger components The specified tightening torques of screw connections for turbocharger components must be observed (see section Table of tightening torques). Tightening torques for assembly devices from ABB Unless otherwise described, the screws and nuts of the assembly devices must be secured so they are tight-fitting. WARNING Suspended loads Loads not suspended in compliance with regulations may lead to per- sonal injury or accidents with fatal consequences. u Attach turbochargers, assemblies or individual components only to lifting gear which is in technically perfect condition and has a suffi- cient load limit. u Make sure the load is suspended properly on the crane hook. u Do not let anyone stand beneath a suspended load. Wear safety gloves to protect against mechanical hazards. Wear safety helmet. Definition of terms ¡ Suspension point Defined load attachment point on a component or an assembly (blind hole thread, eye, lug). ¡ Assembly device Devices that are fitted on the turbocharger in order to obtain a sus- pension point. Assembly devices are specially constructed and de- signed for the defined use; they are not commercially available products. Use assembly devices only for the described applications. ¡ Lifting gear Equipment for lifting and transporting loads (lifting slings, chain block, crane). Lifting gear is not supplied by ABB. Page 81 / 133

8 Disassembly and assembly / 8.2 Module weights © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 8.2 Module weights The specified weights of individual parts or assemblies are guides roun- ded off to the next highest value. Assemblies Weights [kg] Item Description TPL76-C 1 Filter silencer 280 2 Axial air suction branch 70 3 Radial air suction branch 120 4 Compressor casing internal part 220 5 Wall insert 220 6 Diffuser 45 7 Compressor casing external part 310 8 Cartridge group 900 9 Turbine diffuser 80 10 Nozzle ring 23 11 Radial gas inlet casing with segment connection 250 12 Segment 18 13 Radial gas inlet casing with flange connection 190 Page 82 / 133

8 Disassembly and assembly / 8.2 Module weights © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Complete compressor casing internal part Weight [kg] TPL76-C 490 The total weight of the complete compressor casing internal part con- sists of the following parts: the compressor casing internal part, the dif- fuser and the wall insert. Page 83 / 133

8 Disassembly and assembly / 8.3 Removing and fitting filter silencer or air suction branch © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 8.3 Removing and fitting filter silencer or air suction branch u Disconnect all air lines / ducts in accordance with engine builder’s in- structions. u Remove the insulation where necessary. u Loop the lifting gear around the air suction branch. u Unscrew the nuts (74027) and remove them together with their wash- ers (74018). u Remove the air suction branch and set it down to one side. Installing the air suction branch u Install the air suction branch in reverse order. Page 84 / 133

8 Disassembly and assembly / 8.3 Removing and fitting filter silencer or air suction branch © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 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 (74027) and remove them together with washers (74018). u Remove filter silencer and it set down to one side. Fitting the filter silencer u Fit filter silencer in reverse order. Page 85 / 133

8 Disassembly and assembly / 8.4 Axial clearance © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 8.4 Axial clearance WARNING Physical hazards due to sharp edges on compressor wheel The compressor wheel has sharp edges which can result in injury. u Wear safety gloves. Wear safety gloves to protect against mechanical hazards. The axial clearance (A) must be measured before removing and after in- stalling the cartridge group. u Measure and note the axial clearance (A). Clearance A [mm] TPL76-C 0.43 … 0.69 CAUTION Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. u Have the components assessed and, if necessary, replaced by an ABB Turbocharging Service Station. Page 86 / 133

8 Disassembly and assembly / 8.5 Removing cartridge group © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 8.5 Removing cartridge group CAUTION Locked safety segments (76080) during disassembly Observe the maximum tightening torque for the nuts (90458) so as not to shear off the threaded studs of the safety segments (76080). u Fit four nuts (74027) complete with washers (74018), equally spaced around circumference, and tighten. u Remove insulation (from bearing casing). Removing safety segments / releasing casing u Take nuts (90458) out of toolbox and screw them onto threaded studs of safety segments (76080) on internal part of compressor cas- ing (76000). u Tighten nuts (90458) to a maximum torque of 30 Nm. The internal part of the compressor casing (76000) has now been separ- ated from the external part (74000) and can be removed. NOTICE Note the control dimension (u). Check dimension (u) [mm] Dimension TPL76-C u 21.8 Page 87 / 133

8 Disassembly and assembly / 8.5 Removing cartridge group © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Removing the compressor casing internal part u Remove two studs (74029 / 74026) at the point where the lifting device (90190) will be fitted later. u Using press-off screws (90900), push apart the compressor casing in- ternal part (76000) until the lifting device (90190/90195) can be at- tached. u Slightly lift and then withdraw the compressor casing internal part in- cluding the wall insert and diffuser. u Attach the support angle (90025) using screws (90021) and nuts (74027). u Put down the compressor casing internal part including the wall in- sert and diffuser on the support angle and an underlay. u Remove the O-ring (76040). Page 88 / 133

8 Disassembly and assembly / 8.5 Removing cartridge group © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Transporting / turning internal part of compressor casing u Carefully turn internal part of compressor casing complete with wall insert and diffuser about support angle (90025) and put onto under- lay. u Set down casing on flange (F). u Set down internal part of compressor casing in such a way that lifting device (90190/90195) can be removed. WARNING Ensure that the shim does not slip. u Rest the internal part of the compressor casing only on flange (F). u Check shim and adjust as necessary. Page 89 / 133

8 Disassembly and assembly / 8.5 Removing cartridge group © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Removing diffuser and wall insert u Remove screws (76002). u Remove diffuser (79000) using swivel lifting eyes (90235). u Press away wall insert (77000) using press-off screws (90230) and re- move from internal part of compressor casing (76000) using swivel lifting eyes (90235). Page 90 / 133

8 Disassembly and assembly / 8.5 Removing cartridge group © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Removing external part of compressor casing u Fasten lifting device (90190/90195) to external part of compressor casing (74000) using screws and secure to crane. u Remove screws (42280). u Uniformly press away external part of compressor casing (74000) us- ing press-off screws (90900) and remove. NOTICE Insulation on external part of compressor casing The insulation on the external part of the compressor casing does not need to be taken off when removing or fitting the casing. u Remove O-ring (42012). Page 91 / 133

8 Disassembly and assembly / 8.5 Removing cartridge group © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Removing the cartridge group u Unplug cable connector (86515) and unscrew speed sensor (86505) with O-ring (86506). u Disconnect oil inlet and oil outlet pipes. CAUTION Oil orifices There is an orifice for adjusting the oil pressure in each of the two oil supply pipes of the bearing casing. When the cartridge group, the bear- ing casing or the turbocharger-is being fitted to the engine, it must be ensured that the orifices specified for the turbocharger are installed in both oil supply pipes. u Check that the oil orifices have been correctly installed. Version with compressor wheel cooling system u Remove air supply line. (See also chapter entitled Preliminary re- marks / Layout and functionality) Page 92 / 133

8 Disassembly and assembly / 8.5 Removing cartridge group © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 * When pressing off, use diametrically opposite press-off threads. Other- wise the bearing casing can jam and damage the turbine blades. u Check lifting gear and attach to bearing casing (42001). u Loosen nuts (61037) and remove Verbus Ripp® washers (61051). u Screw guide rod (90490) onto threaded stud (X) to balance cartridge group. u Evenly press off cartridge group by screwing press-off screws (90900) into the designated holes. CAUTION If the blades have insufficient or no clearance between the rotor and the casing, the blades and the casing may be damaged. u Check that the blades do not rub on the turbine diffuser by rotating the rotor. u Withdraw cartridge group. u Remove screws (42064) together with flange (42044) and also remove possible contamination behind the flange. u Fit supports (90450) using screws (42280) and put down cartridge group. u Cover the oil connections. Page 93 / 133

8 Disassembly and assembly / 8.6 Dismantling and installing the tur- bine diffuser and nozzle ring © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 8.6 Dismantling and installing the turbine diffuser and nozzle ring Removing turbine diffuser u Put assembly plate (90020) over strain bolts (61036). u Insert extension (A) of torque spanner (B) through hole in assembly plate and loosen screws (61056) one after other. u Don't remove screws (61056) yet. Page 94 / 133

8 Disassembly and assembly / 8.6 Dismantling and installing the tur- bine diffuser and nozzle ring © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 u Replace two screws (61056) with guide studs (90320). u Fit assembly plate (90020) over studs (61036). u Screw nuts (61037) onto start of threads of studs (61036) to secure. u Remove remaining screws (61056). u Press away turbine diffuser (63000) using press-off screws (90901) and withdraw it until assembly plate (90020) touches nuts (61037). u Loop lifting gear around turbine diffuser (63000) and secure to crane. u Remove nuts (61037) and assembly plate (90020) from studs. u Fully withdraw turbine diffuser and remove. u Remove guide studs (90320). Page 95 / 133

8 Disassembly and assembly / 8.6 Dismantling and installing the tur- bine diffuser and nozzle ring © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Removing the nozzle ring u Bend up the locking plates (56018), undo nuts (56022) and remove. u Pull out nozzle ring (56001). u Remove threaded stud (56021). CAUTION Fastening the nozzle ring When fitting the nozzle ring, new threaded studs (56021), nuts (56022) and locking plates (56018) from the customer spare part set (97070) must be used. CAUTION Clogged areas on the nozzle ring If a nozzle ring is clogged in some areas or is covered by loose parts, it is recommended to appoint an ABB Turbocharging Service Station to inspect the turbine blades and carry out a crack inspection. Page 96 / 133

8 Disassembly and assembly / 8.6 Dismantling and installing the tur- bine diffuser and nozzle ring © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Installing the nozzle ring CAUTION Fastening the nozzle ring When fitting the nozzle ring, new threaded studs (56021), nuts (56022) and locking plates (56018) from the customer spare part set (97070) must be used. u Push in nozzle ring (56001) as far as it will go at the cover of the gas inlet casing. u Coat threads of threaded studs (56021) with high-temperature grease and fit threaded studs. Fit the locking plates (56018) and nuts (56022). u Tighten nuts (56022) and bend locking plates (56018) over. CAUTION Correct assembly The nozzle ring must be easily movable after assembly. Page 97 / 133

8 Disassembly and assembly / 8.6 Dismantling and installing the tur- bine diffuser and nozzle ring © Copyright 2020 . All rights reserved. HZTL2485_EN Rev.G March 2020 Fitting turbine diffuser u Coat all screw threads on and in the gas casings with high-temperat- ure grease. u Fasten turbine diffuser (63000) to lifting gear. u Align marking "TOP" with the position of the gas outlet flange and pay attention to where the positioning pin is in the gas outlet casing. u Fit turbine diffuser (63000) to guide studs (90320). u Put assembly plate (90020) over strain bolts (61036) and guide studs (90320). u Remove lifting gear and push in turbine diffuser. u Using three screws (61056), alternately and uniformly screw in turbine diffuser as far as it will go. u Insert torque spanner extension through hole in assembly plate and tighten screws (61056) one after another. (See illustration in section Removing turbine diffuser) Page 98 / 133