ABB A101-H Series Original Assembly Instructions Download

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Turbocharger / A100-M radial

Original assembly instructions – English

This document is valid for the A101-H

series:

A131-H, A136-H

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.

A101-H turbocharger

More power, less fuel

—

ASSEMBLY INSTRUCTIONS

Turbocharger / A101-H radial

Original assembly instructions – English

Summary of Contents for A101-H Series

Page 1: ...tted 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 A101 H turbocharger More power less fuel ASSEMBLY INSTRUCTIONS Turbocharger A101 H radial Original assembly instructions English ...

Page 2: ......

Page 3: ... 3 1 5 Definition of mandatory signs 4 1 6 Definition of pictograms 4 2 Safety 5 2 1 Introduction 5 2 2 Lifting of loads 6 2 3 Occupational safety 7 3 Turbocharger weight and transportation 9 4 Installing the turbocharger 10 4 1 Inserting gaskets into the bracket 10 4 2 Fitting threaded rods 11 4 3 Placing the turbocharger on the bracket 12 4 4 Fastening the turbocharger with a standard nut 13 4 5...

Page 4: ... 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 outside ...

Page 5: ...ur website at www abb com turbocharging 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 inaccu...

Page 6: ...onal protective equipment to be worn specific to the respective task 1 6 Definition of pictograms 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...

Page 7: ...ies 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 t...

Page 8: ...n 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 s...

Page 9: ...ou 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 he...

Page 10: ...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 materials...

Page 11: ...e Depending on the specification the weight specified on the rating plate may be lower than the standard value specified here Swivel lifting eyes to be used Two swivel lifting eyes are required for the safe lifting of loads these are not supplied by ABB Turbo Systems Fig 3 Swivel lifting eyes Product Thread M Length L mm Minimum load limit kg Quantity A131 H M8 13 mm 300 kg 2 A136 H M10 17 mm 450 ...

Page 12: ...y sealing is provided by O rings The O rings are not included in the ABB Turbo Systems scope of delivery Fig 5 Inserting gaskets into the bracket 01 Bracket 04 Slot for O ring 02 Oil supply 05 O rings 03 Oil drain 06 Pin optional Pin 06 as installation safety device Turbochargers can have an oil inlet either on their right or left side the oil inlet position can be different for the turbocharger f...

Page 13: ... Systems scope of delivery Requirements for the threaded rods Fig 6 Requirements for threaded rods Product Diameter Threaded rod mm Material DIN ISO 898 Part 1 Thread length L1 mm Free length over bracket L2 mm A131 H Ø 16 M16 10 9 12 9 30 195 A136 H Ø 20 M20 10 9 12 9 30 225 Table 6 Requirements for threaded rods Fig 7 Fitting threaded rods onto the bracket 1 Lightly oil the surfaces of the threa...

Page 14: ... the bracket Fig 8 Placing the turbocharger on the bracket A Standard nut u Make sure that covers of the oil and water connections are removed 1 Make sure that the O rings 03 are undamaged and positioned correctly in the slots 2 Attach lifting gear to the swivel lifting eyes S 3 Position the turbocharger on the bracket 04 and align it If present pay attention to the positioning pin 05 in the brack...

Page 15: ...d on the engine support the bolt threads and screw heads must be lightly oiled assumed friction coefficient µ 0 12 for tightening torque u Remove the lifting gear 4 5 Connecting the turbocharger u Connect the cable to the speed sensor 86515 u Connect all exhaust gas water and air lines according to the instructions of the engineb uilder Version with compressor wheel cooling CAUTION Failure of comp...

Page 16: ...nse 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 aga...

Page 17: ...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 18: ...Manual The Operation Manual for the turbocharger with the relevant serial number is available online on our website www abb com turbocharging Fig 12 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 Manual...

Page 19: ...Assembly Instructions A101 H 6 Further information Copyright 2019 ABB All rights reserved HZTL455311P0038_EN Rev A December 2019 Fig 13 Finding the Operation Manual online Page 17 17 ...

Page 20: ...ion Find and download the Operation Manual of your product on our website see Operation Manuals Copyright 2019 ABB All rights reserved ABB Turbo Systems Ltd 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 ...

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ABB A101-H Series, Original Assembly Instructions

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