2.3 Special safety instructions

Safety when connecting
  • Work only on those connections for which you are qualified.
  • Before starting work, make a visual inspection of the working area.
  • Remove obstacles and any objects lying around from the work area.
  • Before commissioning check the turbocharger for damage and leaks.
  • Refrain from any activity which could compromise safety while working with the turbocharger.
  • Inspect the turbocharger after about 12 hours of operation or at least once a day for visible damage and defects.
  • Report any damage or changes in operational performance to the person/ department responsible immediately.
  • In the event of damage, shut down the turbocharger immediately and secure it against inadvertent or unauthorized use.

Safety when cleaning

When handling detergents, solvents, acids and alkalis be sure to observe the respective safety directions on the manufacturers' labels. Follow directions regarding the environmentally compatible collection, storage and disposal of these liquids.


Explosion hazard
Cleaning work should be carried out outdoors due to explosion hazard. If this is not possible, ensure that there is adequate ventilation and air circulation. Before beginning cleaning work in confined spaces, extinguish naked flames (including cigarettes!) due to the risk of explosion.

  • Before cleaning, protect the floor against unintended leaks of oil and operation materials.
  • You must wear protective clothing (see section General safety instructions).
  • Handle operation materials and detergents with utmost caution.

When handling solvents, wear protective clothing and observe the following rules:

  • Avoid skin contact with solvents.
  • Avoid inhaling vapours under all circumstances.
  • Do not allow solvents to soak protective clothing

  • After cleaning, check electric cables for signs of wear or damage.

Safety during disassembly, assembly, maintenance and troubleshooting

  • Follow the prescribed maintenance and inspection schedules for all adjustment, maintenance and inspection work.
  • Inform operating personnel about special work and repairs before starting.
  • Ensure that absorbent materials are available to clean up any operation materials that escape accidentally.
  • Ensure safe and environmentally-friendly drainage, collection and disposal of operating and auxiliary materials.
  • Before opening a cover or removing a protective component on the turbocharger, the engine must have been switched off and must not be started up again until all parts have been properly re-assembled.

Assembly and disassembly work must only be performed by trained personnel. Work on mechanical components, such as bearings or rotors, must only be performed by qualified fitters from an official service station of ABB Turbo Systems.

Safety when taking out of operation or putting into storage

  • Secure the rotor against turning.
  • Clean the turbocharger before mothballing.
  • Wear protective clothing when mothballing the turbocharger.
  • Keep the work area clean and free of oil and operating materials.
  • Remove any obstacles lying around on the floor.

          1. Purpose of the manual
          2. Layout and function
          3. Correct use of the turbocharger
          4. Essential information
          5. Abbreviations and symbols
          6. Turbocharger rating plate
          1. Basic safety instructions
          2. General safety instructions
          3. Special safety instructions
          4. Safety instructions and hazard protection
          5. Warnings on the turbocharger
          1. Oil supply
          2. Inspection work
          3. Putting into operation after laying up
          1. Servicing work
          2. Monitoring
          3. Emergency mode TPL..VA
          4. Surging of turbocharger
          5. Contact with rotating parts
          6. Shutting the engine down
          1. Foreword to MaintenanceServicing work
          2. Cleaning the filter silencer
          3. Cleaning the compressor during operation
          4. Cleaning turbines and guide blades in operation
          1. Possible remedies for failures
          1. Turbocharger weights
          2. Remove the turbocharger
          3. Installing the turbocharger
          1. Module weights
          2. Remove filter silencer/air suction branch and compressor casing
          3. Removing cartridge group
          4. Axial clearance
          5. Disassembling and assembling the turbine diffuser
          6. Dismantle the VTG unit together with the gas inlet casing
          7. Installing the VTG unit and gas inlet casing
          8. Installing the cartridge group
          9. Install filter silencer/air suction branch and compressor casing
          10. Table of tightening torques
          1. Possibilities for emergency repair
          2. Fitting the cover plate
          3. Blocking the inlets and outlets
          4. Bypass the turbocharger
          1. Taking out of operation for up to 12 months
          2. Taking out of operation for more than 12 months
          1. Ordering spare parts
          2. Directory of part numbers
          3. General view of turbocharger
          4. General view of cartridge group
          5. General view of VTG unit

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