ABB A135-M56 Bedienungsanleitung

ABB Turbocharging

Operation Manual

A135-M56

HT563939 English

Original Operation Manual

Chapter Document-ID

1 Introduction HZTL4005_EN_E

2 Safety HZTL4022_EN_C

3 Safety data sheet HT563939

4 Product description HZTL4031_EN_D

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.

Operation Manual / 1 Introduction

able of contents Page 1 /

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July 2016

Introduction

Introduction ............................................................................................

1.1

Purpose of the manual...............................................................................

1.2

Symbols, definitions ...................................................................................

1.3

Storage of new turbochargers and spare parts ..........................................

1.4

Contact information....................................................................................

Operation Manual / 1 Introduction

Introduction

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1 Introduction

1.1 Purpose of the manual

Figure 1: Serial number (01) on the rating plate

This Operation Manual belongs to the turbocharger with the identical serial number (01), see

chapter 3 (Safety data sheet) and the rating plate on the turbocharger.

Operation Manual

The Operation Manual explains the turbocharger and contains instructions for safe operation.

The Operation Manual is a complement to and expansion of existing national regulations for

occupational safety, accident prevention and environmental protection.

Target group

The Operation Manual is aimed at engineers and trained mechanics responsible for the proper

operation of the engine and for the turbocharger connected to it.

Availability of the Operation Manual

The Operation Manual must be available where the turbocharger is used.

All persons operating or working on the turbocharger must have read and fully understood the

Operation Manual.

Operation Manual / 1 Introduction

Introduction

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1.2 Symbols, definitions

Symbols

The following symbols are used in this document:

Shows an action.

1. Shows a numbered action.

Enumeration, first level

– Enumeration, second level

[➙ ] Refers to a page number

Definition of Note

NOTICE

Note

The note provides advice which facilitates the work.

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 complied with.

Definition of Caution / Warning

Caution and warning signs are described in chapter Safety.

ABB Turbo Systems

ABB Turbo Systems Ltd is identified as ABB Turbo Systems in this document.

Official service stations of ABB Turbo Systems

Official service stations are identified in this document as ABB Turbocharging Service Sta-

tions. They are regularly audited and certified by ABB Turbo Systems. Also see chapter Con-

tact information [➙ 8].

Operation Manual / 1 Introduction

Introduction

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Definition of pictograms

The following pictograms can occur in this document. These point out actions that must be

taken in accordance with the meaning of the relevant pictogram.

Pictogram

Meaning

Pictogram

Meaning

Tighten with specified torque

Affix

Tighten over specified tightening

angle

Measure

Hand-tight, tighten without tools

Note

Oil

Visually inspect

Apply screw locking paste (e.g.

Loctite)

Please note text for numbered

work step.

Apply high-temperature grease

See document

Apply other paste in accordance

with specifications

Dispose of in an environmentally

compatible, professional way and

in compliance with locally applica-

ble regulations.

Oil free, grease free and dry

Table 1: Definition of pictograms

Operation Manual / 1 Introduction

Introduction

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1.3 Storage of new turbochargers and spare parts

Storage of new turbochargers and spare parts for up to 6 months

New turbochargers and spare parts can be stored in their closed packages for 6 months from

the date of delivery without additional mothballing measures, indicated by VCI label on package.

Figure 2:

olatile

orrosion

nhibitor (VCI)

Only dry rooms with 40...70 % atmospheric humidity, in which no water condensation can

form, are suitable as storage locations.

Storage of new turbochargers and spare parts for more than 6 months

WARNING

Health protection when handling VCI

VCI products are not hazardous in terms of the Ordinance on Hazardous

Substances. Nevertheless, the following points must be observed when

handling VCI:

Observe the information in the material safety data sheet.

Ensure proper space ventilation.

Do not eat, drink or store food at the workplace while working with VCI.

Clean hands and face after working with VCI.

For more information, see www.branopac.com.

Wear safety gloves to protect against mechanical hazards.

Every 6 months, the following mothballing measures are required:

Open package.

Remove VCI corrosion protection emitter from package and replace with a new VCI corro-

sion protection emitter of the same kind. New VCI corrosion protection emitters can be ob-

tained from www.branopac.com.

Old VCI corrosion protection emitters must be disposed of in an environmentally compati-

ble, professional way and in compliance with locally applicable regulations.

Close package. The more tightly the package is sealed, the longer the protection duration.

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Introduction

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Long-term storage of replacement turbochargers or spare parts

If requested in the purchase order, the turbochargers or cartridge groups will be prepared for

long-term storage. The package is equipped with a hygrometer (see illustration).

Figure 3: Package with hygrometer

Every 6 months, the following measures are required:

Check the hygrometer (02) in the sight-glass. There is an opening (01) in the wooden crate

to enable you to perform this check. If the 70% indicator field has changed colour, the

maximum admissible atmospheric humidity has been exceeded. In this case, the turbo-

charger or cartridge group must be checked and repackaged by an ABB Turbocharging

Service Station.

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

Replacing the desiccant

Repackaging the component.

NOTICE

Replacement components which are ready for operation

If the 70% field of the hygrometer (02) has not changed colour and the

package is not damaged, the replacement turbocharger or replacement car-

tridge group can be put into operation without previously having been

checked by an ABB Turbocharging Service Station.

Unpackaging replacement turbochargers or spare parts

Once the material has been unpackaged from the VCI package, the corrosion protection is no

longer effective.

To prevent condensation, the temperature of the package contents must be the same as the

ambient temperature.

Operation Manual / 1 Introduction

Introduction

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1.4 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

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