Operation Manual A145-M56 HT538538 English Original Operation Manual Chapter Document-ID Introduction HZTL4005_EN_E Safety HZTL4022_EN_D Safety data sheet HT538538 Product description HZTL4031_EN_E ABB Turbocharging...
Operating limits and replacement intervals The recommended replacement intervals and the corresponding operating limits in chapter 3 are jointly defined with the enginebuilder. This information is specific to the product. Non-observance of the recommended replacement intervals and the operating limits increases the risk of unpre- dictable component failures.
Check the package for damage. If the package is damaged, the turbocharger or cartridge group must be checked and repackaged by an ABB Turbocharging Service Station. After every 3 years, the following steps must be carried out by an ABB Turbocharging Service Station: Checking the component ...
Operation Manual / 1 Introduction Introduction Page 8 / 8 Contact information Contact information of the ABB Turbocharging Service Stations is available online. Scan the QR code to access our website. ABB Turbo Systems Ltd Bruggerstrasse 71a CH-5401 Baden Switzerland www.abb.com/turbocharging...
Safety Introduction Turbochargers manufactured by ABB reflect the state of the art. The respective safety and health protection requirements are met. This ensures safe operation of the turbocharger. Nev- ertheless, there may be some residual risks during operation of and work on the turbocharger which: ...
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 accepts no liability and rejects all warranty claims for any non-intended uses.  Euromot = The European Association of Internal Combustion Engine Manufacturers...
If during external inspection anomalies are found or if a particularly strong deflagration event has taken place, it is also recommended to check the bearings of the turbochargers before the next start. An ABB Turbocharging Service Station should be instructed to carry out this inspec- tion.
Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging, 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.
This document is valid for different design variants of turbochargers. There may be sections and descriptions of components that are not relevant for a specific turbocharger variant. ABB Turbocharging Service Stations will be happy to provide information on questions regard- ing a design variant (see Contact information at www.abb.com/turbocharging).
Figure 3: Warning plate locations If warning plates are not present in the designated locations or not readable, proceed as fol- lows: Order new warning plates from ABB Turbocharging Service Stations. Remove any warning plates that have become unreadable.
The oil is supplied (02) and drained (03) through the bracket (01). The necessary sealing is provided by O-rings. The O-rings are not included in the ABB Turbo Systems scope of delivery. Figure 9: Inserting gaskets into the bracket...
Oil pressure measuring point Oil temperature measuring point For monitoring the lubricating oil pressure, ABB Turbo Systems recommends installing an "M" manometer immediately before the turbocharger. If the pressure is controlled electronically, the appropriate signals are to be triggered at the warning and alarm values.
If the engine can be stopped temporarily: Inspect air lines, gas piping and the turbochargers and remedy any malfunctions. In any case, contacting the nearest ABB Turbocharging Service Station is recommended. 4.3.4 Malfunctions on the speed measurement system In the case of malfunctions of the speed measurement system, refer to the chapter entitled Troubleshooting/Speed measurement system [➙...
Wear safety gloves when disassembling the speed sensor. Wear safety gloves to protect against thermal hazards. The speed sensor supplied by ABB is equipped with a sealing lip and an O-ring. No additional gasket is required during assembly. Figure 19: Replacing the speed sensor...
Service work according to data on the rating plate (Usually after 8000 … 12000 operating hours) The rotor and bearing parts must be checked and assessed by an ABB Turbocharging Service Station. The following work can be carried out as preparation.
5.2.5 Other service work If a protective grid is installed in the gas outlet casing (61001) by ABB Turbo Systems: Figure 21: Replacing the protective grid Remove the protective grid (61205) after 50000 hours and replace it with a new protective ...
– 600 °C with non-insulated casing At temperatures below the specified values, post-lubrication must be ensured until the ro- tors come to a standstill. ABB Turbo Systems recommends post-lubrication for 10 minutes. Observe the oil pressure specified for post-lubrication (see Table 6).
To allow you to observe the standard service intervals and to maintain a high turbocharger efficiency, ABB Turbo Systems recommends that the cleaning procedure be carried out during operation. This allows the thermal load of the engine to be kept low while ensuring maximum fuel efficiency.
Very heavily contami- nated components can no longer be cleaned using this method. In this case, ABB Turbo Sys- tems recommends having the contaminated components cleaned mechanically by an ABB Turbocharging Service Station.
The compressor is cleaned during operation using the wet cleaning method. It is carried out at an engine load of 50 ... 85 %. This cleaning method has been tested and approved by ABB Turbo Systems. V-engines On V-engines with several turbochargers per engine, parallel cleaning of both turbochargers is recommended.
Very heavily contami- nated components can no longer be cleaned using this method. In this case, ABB Turbo Systems recommends having the contaminated components cleaned mechanically by an ABB Turbocharging Service Station.
Cleaning method The turbine components are cleaned during operation using the wet cleaning method. This cleaning method is tested and approved by ABB Turbo Systems. The precondition for wet cleaning is that the enginebuilder approves the process and these regulations are observed.
Close the stop valve (02) after 10 minutes. Wait for 10 minutes; do not change the load during this stabilisation phase. If the cleaning result is unsatisfactory or there is water leakage, contact an ABB Turbocharg- ing Service Station. Product Temperature before...
When cleaning, note that the absorption segments (81136) must only be cleaned lightly with compressed air, a soft brush or a moist cleaning cloth. Have any heavily contaminated absorption segments replaced by an ABB Turbocharging Service Station. Fitting the filter silencer (see Figure 24) Insert the absorption segments (81136) into the sheet-metal coverings (81137).
To prevent significant loss of effi- ciency, specific tolerances must be fulfilled. If there is any doubt about the extent of the rubbing, contact an ABB Turbocharging Service Station. Have a dimension check carried out by an ABB Turbocharging Service Station.
Increased speed due to contamination of Clean (see chapter Periodic maintenance nozzle ring work [➙ 45]) or contact an ABB Turbo- charging Service Station Table 24: Malfunctions during operation – Charge air pressure too high Reduced compressor performance/efficiency, hence engine performance losses...
Gradually reduce the engine load. Have the cause clarified and remedied immediately by an ABB Turbo- charging Service Station. Have parts assessed for damage and, if necessary, replaced by an ABB Turbocharging Service Station. Possible causes Remedy...
Bearing damaged Check clearances (see chapter Axial clearance A and radial clearance B [➙ 91]). If clearances are outside the tolerance or if in doubt, contact an ABB Turbo- charging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R [➙...
≤ 65 Nm Table 36: 3 press-off screws * not included in the ABB Turbo Systems scope of delivery. 1. Press off and remove the gas outlet flange (57002) with screws (01) according to the table. If it is not possible to press off the gas outlet flange with the maximum tightening torque, contact an ABB Turbo Systems Service Station.
≤ 65 Nm Table 37: 6 press-off screws * not included in the ABB Turbo Systems scope of delivery. 1. Evenly press off and remove the gas outlet flange (57002) with screws (01) according to the table. If it is not possible to press off the gas outlet flange with the maximum tightening torque, contact an ABB Turbo Systems Service Station.
(02), a separate burst pro- tection (03) is fitted. If the insulation from ABB Turbo Systems (01) is not installed, the separate burst protection (03) plus either the insulation (02) or an appropriate insula- tion supplied by the enginebuilder must be installed for operation.
If present: Installing a replacement cartridge group [➙ 108]. If a replacement turbocharger or cartridge group is not available: Fit cover plate [➙ 109] and contact an ABB Turbocharging Service Station. Observe the following sections in connection with the emergency repairs mentioned.
A replacement cartridge group is ready for use immediately and includes the complete bearing casing with bearing and a balanced rotor. The repair of a cartridge group requires special tools and the expertise of an ABB Turbocharg- ing Service Station. The rotating parts turn very fast and are very sensitive to unbalance.
Page 110 / 121 Cover plate drawing The cover plate is not included in the ABB Turbo Systems scope of delivery and must be manufactured by the operating company according to the following drawing. Material: General structural steel, in compliance with DIN EN 10025-2.
If the acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking the engine out of operation: Dismantle the turbocharger. The rotor and bearing parts must be dismantled and subsequently refitted by an ABB Tur- bocharging Service Station. Clean all parts.
The casings of the turbocharger remain attached to the engine, the rotor and bearing parts are dismantled by an ABB Turbocharging Service Station and stored separately The turbocharger is completely removed, either as a whole unit or in individual parts...