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Turbocharging Operation Manual / A135-H65 HT609937 Document identification Document number HZTL4030 Revision Language English Original Operation Manual Product identification Serial number HT609937 Customer part number X00074674 Delivery date (yyyy-mm-dd) 2022-07-15 Weight Operating limits according to rating plate Speed limit in test rig operation only...
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).
Caution and warning signs are described in 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 Turbocharging. See also chapter Contact information →5.
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: ¡...
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: ¡...
The use of the turbocharger is limited to the specific application released at the time of de- livery. ABB accepts no liability and rejects all warranty claims for any non-intended uses. WARNING Unapproved operation Any operation of the turbocharger outside of its operating limits can be haz- ardous to personnel.
An ABB Turbocharging Service Station should be instructed to carry out this inspection. 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". ¡...
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.
Operation above the indicated values n can considerably shorten the recommended Bmax Bmax replacement intervals. In such cases, we recommend contacting the nearest ABB Turbochar- ging Service Station. normally apply only when running at overload (110 %) during trials on the engine Mmax Mmax test bed.
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 scope of delivery. Fig. 15: Inserting gaskets into the bracket...
Oil pressure measuring point Oil temperature measuring point For monitoring the lubricating oil pressure, ABB Turbocharging 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.
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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. 5.3.4 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. 25: Replacing the speed sensor...
Agree on a specific service interval with ABB Turbocharging. 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.
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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.
6 Operation and service / 6.2 Service work 6.2.5 Other service work If a protective grid is installed in the radial or axial gas outlet casing (61001) by ABB: Fig. 27: Replacing the protective grid Remove the protective grid (61205) after 50000 hours and replace it with a new one.
ABB Turbocharging 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.
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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. 28: Cleaning the filter silencer →62)
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 →60) 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...
→60) 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.
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The specified tightening torques of the screw fittings must be observed (Table of tightening torques). Tightening torques for assembly devices Unless otherwise described, the screws and nuts of the assembly devices supplied by ABB must be tightened in such a way that 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. 32: Swivel lifting eyes Product...
≤ 65 Nm Table 34: 3 press-off screws * not included in the ABB 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 35: 6 press-off screws * not included in the ABB 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 Turbocharging 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 quickly, 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...
(RoHS2). Products and related accessories manufac- tured by ABB Switzerland Ltd, Turbocharging do not fall within the Scope of RoHS2 due to their application in large scale fixed installations, means of transports for persons or goods, non-road mobile machinery (Directive 2011/65/EC Article 2, 4.(e), (f), (g)).
90042 Press-off tool 90070 Extraction device Table 55: Customer tool set 90000 Tool sets can be ordered from any ABB Turbocharging Service Station. The following spe- cifications must be included in the order: ¡ Turbocharger type ¡ Designation and part number of the tool set.