Operation Manual A135-H66 HT601707 English Original Operation Manual Chapter Document-ID Introduction HZTL4005_EN_G Safety HZTL4022_EN_E Safety data sheet HT601707 Product description HZTL4030_EN_F ABB Switzerland Ltd, 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.
Definition of Caution / Warning Caution and warning signs are described in chapter Safety. ABB Turbocharging ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging or as ABB Turbo Sys- tems in this document. Official service stations of ABB Turbocharging Official service stations are regularly audited and certified by ABB Turbocharging.
Inspect the package for damage. If the package is damaged, the turbocharger must be in- spected by an ABB Turbocharging Service Station and repacked. After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station: ¡...
Operation Manual / 1 Introduction 1 Introduction / 1.4 Contact information Contact information Contact information for the ABB Turbocharging Service Stations is available online. Scan the QR code to access our website. ABB Switzerland Ltd, Turbocharging 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. Nevertheless, there may be some residual risks during operation of and work on the tur- bocharger which: ¡...
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 inspection.
The locations of the rating plates are defined in the Operation Manual, Chapter 4 Product description. 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". ¡...
Only operate the turbocharger with burst protection fitted and insulation fitted in one of the following, permitted variants. Fig. 5 Variant A Insulation (01) with integrated burst protection from ABB Turbo Systems. Variant B Burst protection (03) and insulation (02) from ABB Turbo Systems. Variant C Burst protection (03) from ABB Turbo Systems with appropriate insulation...
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. Please contact an ABB Turbocharging Service Station if you have any questions regarding a design variant (see Contact information at www.abb.com/turbocharging).
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. Clean and degrease the areas designated for the warning plates.
Always use new gaskets and insert them carefully into the slot. 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.
Oil pressure measuring point Oil temperature measuring point For monitoring the lubricating oil pressure, ABB Turbo Systems recommends installing a "P" manometer immediately upstream of the turbocharger oil inlet before the orifice. If the pressure is controlled electronically, the relevant signals should be triggered at the warning and alarm values.
Check the pressure loss of the alternative air inlet and compare it with normal 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...
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. Fig. 19: Replacing the speed sensor...
Agree on a specific service interval with ABB Turbo Systems. To prevent machine damage caused by ageing and downtime, we recommend having an in- spection carried out by an ABB Turbocharging Service Station no later than 5 years after the last service.
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 Operation and service / 5.2 Service work 5.2.5 Other service work If a protective grid is installed in the radial or axial gas outlet casing (61001) by ABB Turbo Systems: Fig. 21: Replacing the protective grid Remove the protective grid (61205) after 50000 hours and replace it with a new one.
ABB Turbo Systems therefore recommends having the components periodically inspected and replaced, if neces- sary, by an ABB Turbocharging Service Station based on the number of successful engine start cycles specified in the following table.
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 Fig. 22: Cleaning the filter silencer →42)
To prevent significant loss of efficiency, specific tolerances must be fulfilled. ¡ If there is any doubt about the extent of the rubbing, contact an ABB Tur- bocharging Service Station. ¡...
Turbochar- Turbine and/or nozzle ring severely con- Clean (see chapter Periodic mainten- taminated ance work →40) Rotor components or bearing damaged Contact ABB Turbocharging Service Station Engine Defects on the connected cylinders in Contact enginebuilder pulse charging Pipes Defects, such as leaks, in the exhaust...
Gradually reduce the engine load. Have the cause clarified and remedied immediately by an ABB Turbochar- ging Service Station. Have parts assessed for damage and, if necessary, replaced by an ABB Turbocharging Service Station. Possible causes Remedy...
→40) Bearing damaged Check clearances (see chapter Measuring clear- ance A and B). If clearances are outside the toler- ance or if in doubt, contact an ABB Turbocharging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station.
The specified tightening torques of the screw fittings must be observed (Table of tightening torques). Tightening torques for assembly devices Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB must be tightened so they are tight-fitting. WARNING...
Equipment for the lifting and transporting of loads (ropes, chain block, crane). Lifting gear is not supplied by ABB. Swivel lifting eyes to be used Swivel lifting eyes are required for the safe lifting of loads, which are not supplied by ABB. Fig. 26: Swivel lifting eyes Product...
≤ 65 Nm Table 32: 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 Turbocharging Service Station.
≤ 40 Nm Table 33: 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 tight- ening torque, contact an ABB Turbo Systems Service Station.
The repair of a cartridge group requires special tools and the expertise of an ABB Turbochar- ging Service Station. The rotating parts rotate extremely fast, and are sensitive to unbal- ance.
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 For the measures always necessary for preparing the turbocharger parts for mothballing, see section Taking the engine out of operation for up to 12 months, subsection Preparations...