ABB A100-M Series Original Assembly Instructions Download Page 1

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Turbocharger / A100-M radial

Original assembly instructions – English

Purpose

The assembly instructions explain how the ABB
turbocharger is fitted to the engine correctly and
without any health and safety risks.

Target group

The assembly instructions are intended for
engineers and mechanics responsible for fitting
the turbocharger on the engine.

—

This document is valid for the
A100-M series:

A150-M, A155-M

A100-M turbocharger

More power, less fuel

ASSEMBLY INSTRUCTIONS

Turbocharger / A100-M radial

Original assembly instructions – English

Summary of Contents for A100-M Series

Page 1: ...ety risks Target group The assembly instructions are intended for engineers and mechanics responsible for fitting the turbocharger on the engine This document is valid for the A100 M series A150 M A155 M A100 M turbocharger More power less fuel ASSEMBLY INSTRUCTIONS Turbocharger A100 M radial Original assembly instructions English ...

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Page 3: ...f warning caution note 3 1 5 Definition of mandatory signs 4 2 Safety 5 2 1 Introduction 5 2 2 Lifting of loads 6 2 3 Occupational safety 7 3 Weight and transportation of the turbocharger 9 4 Installing the turbocharger 11 4 1 Inserting gaskets 11 4 2 Placing the turbocharger on the bracket 12 4 3 Fastening the turbocharger with a clamping nut 14 4 4 Connecting the turbocharger 16 4 5 Attaching th...

Page 4: ...he engine Basic mechanical training is a prerequisite All persons who are involved in the transportation and installation of the turbocharger have read and understood the assembly instructions 1 3 Symbols definitions Symbols The following symbols are used in this document u Indicates an action step 1 Indicates a numbered action step Indicates a list Refers to a page number The trademarks of outsid...

Page 5: ...ocharging 1 4 Definition of warning caution note WARNING Definition of Warning Non compliance or inaccurate compliance with working or operating in structions indicated by this symbol and the word WARNING can lead to seri ous injuries to personnel and even to fatal accidents u Warning signs must always be observed CAUTION Definition of Caution Non compliance or inaccurate compliance with working o...

Page 6: ...ion Table 2 Personal protective equipment to be worn specific to the respective task 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 tight ening angle Measure Hand tight tighte...

Page 7: ...ories are caused by the operating equipment used or supplies and materials are a consequence of insufficient compliance with safety instructions All of the instructions contained within this chapter must be followed when working on the turbocharger Responsibility of the operating company In awareness of its responsibility the operating company must ensure that only authorised personnel work on the...

Page 8: ...on to the correct attachment of loads on the crane hook u People must not stand beneath suspended loads Wear safety gloves to protect against mechanical hazards Wear safety helmet Fig 1 Attachment of loads on the crane hook Fig 2 Attachment angle If there are two or more suspension points the attachment angle of 45 must not be ex ceeded This prevents excessive loading due to diagonal pull u Use a ...

Page 9: ...you have received instruction or train ing Wear safety footwear to protect against mechanical hazard and risk of fall ing Wear protective clothing WARNING Risk of falling When working on the turbocharger there is a risk of falling u Do not climb onto the turbocharger or onto attached parts and do not use them as climbing aids u Use suitable climbing aids and working platforms for work above body h...

Page 10: ...s that are described in this chapter u Only perform operations for which you have previously received instruc tion or training Hazards due to operating materials and supplies Operating materials and supplies can include Oils greases coolants cleaning agents and solvents acids or similar substances WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materia...

Page 11: ...urbocharger The weight specified below applies to the heaviest variant possible Depending on the specifica tion the weight specified on the rating plate may be lower than the standard value specified here Fig 3 Suspension of complete turbocharger unit A Complete turbocharger unit without gas outlet casing B Complete turbocharger unit with gas outlet casing Product Weight of complete turbocharger u...

Page 13: ...B July 2020 4 Installing the turbocharger 4 1 Inserting gaskets CAUTION Inserting the gaskets Gaskets that are forgotten damaged or improperly inserted will lead to oil leaks u Always use new gaskets and insert them carefully into the slot Fig 4 Inserting the gasket 01 Oil supply 02 Oil drain 42200 O ring 42201 Bearing casing 42202 O ring Page 11 21 ...

Page 14: ...p 3 Place the thrust washer 01 of the clamping nut on the expansion bush and with the clamping nut screwed on guide the threaded rod through the thrust washer expansion bush and bearing casing Step B Preparing the positioning u Screw the centering bush 42193 flush onto the threaded rod from below u Clean the surface of the bracket the bearing casing the centering bush and the centering holes in th...

Page 15: ...ition using the centering bushes 42193 located in the bracket 5 Check value x u If value x is not reached the turbocharger must be lifted up from the bracket and re aligned Step D Fixing the threaded rod in place in the bracket u Using the hexagon screw the threaded rod into the bracket up to value L u If value L is not reached or the threaded rod jams while being screwed in the threaded rod must ...

Page 16: ...nsured that the necessary tension force is reached u Do not clean pressure screws u Do not lubricate pressure screws In order to correctly fit the clamping nuts the pressure screws 04 must not protrude from the clamping nuts 03 in the direction of the thrust washer 02 u Make sure the pressure screws do not protrude in the direction of the thrust washer Fig 7 Preparing the clamping nut for the tigh...

Page 17: ...6 Torque controlled tightening of the pressure screws 1 Screw in pressure screws crosswise by hand until reaching the stop 2 Tighten pressure screws crosswise to 50 of the tightening torque specified in the table 3 Tighten pressure screws crosswise to 100 of the tightening torque specified in the table 4 Work in a circle to tighten all pressure screws to 100 of the tightening torque specified in t...

Page 18: ...r wheel cooling CAUTION Failure of compressor wheel cooling Any prolonged failure of the compressor wheel cooling will shorten the re placement interval of the compressor wheel u Make sure there is an uninterrupted supply of cooling air during opera tion Fig 9 Connecting the compressor cooling air intake u Remove the screw plug on the connection for the compressor wheel cooling 06 and fit the cool...

Page 19: ...sense of the Hazardous Substances Ordinance Nevertheless the following points are to be observed when handling VCIs u Observe specifications in the safety data sheet u Ensure good room ventilation u Do not eat drink or keep food at the workplace while working with VCIs u Clean hands and face after working with VCIs u For further information refer to www branopac com Wear safety gloves to protect a...

Page 20: ... turbocharger must be inspected by an ABB Turbocharging Service Station and repacked u 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 Inspect the components Replace the desiccant agent Repackage the...

Page 22: ...n Manual The Operation Manual for the turbocharger with the relevant serial number is available online on our website www abb com turbocharging Fig 13 Serial number of the turbocharger on the rating plate One rating plate 01 each is attached on the left and the right side of the turbocharger bear ing casing 1 Read the serial number 02 on the rating plate 01 of the turbocharger u The Operation Manu...

Page 23: ...Assembly Instructions A150 M A155 M 6 Further information Copyright 2020 ABB All rights reserved HZTL455311P0006_EN Rev B July 2020 Fig 14 Finding the Operation Manual online Page 21 21 ...

Page 24: ...product on our website see Operation Manuals Copyright 2020 ABB All rights reserved Operation Manual Contact information ABB Switzerland Ltd Turbocharging Bruggerstrasse 71 a CH 5401 Baden Switzerland Phone 41 58 585 7777 Fax 41 58 585 5144 E mail turbocharging ch abb com www abb com turbocharging Visit our website by scanning the QR code HZTL455311P0006 ...

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ABB A100-M Series, Original Assembly Instructions

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