ABB A238-H 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.

A200-H turbocharger

More power, less fuel

—

ASSEMBLY INSTRUCTIONS

Turbocharger / A200-H

Original assembly instructions – English

This document is valid for:

A238-H.., A240-H..

Summary of Contents for A238-H Series

Page 1: ...ealth and safety risks Target group The assembly instructions are intended for engineers and mechanics responsible for fitting the turbocharger on the engine A200 H turbocharger More power less fuel ASSEMBLY INSTRUCTIONS Turbocharger A200 H Original assembly instructions English This document is valid for A238 H A240 H ...

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Page 3: ...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 10 4 2 Fixing elements 11 4 3 Placing and aligning the turbocharger on the bracket 12 4 4 Fastening the turbocharger with a clamping nut 14 4 5 Fastening the turbocharger ...

Page 4: ...e 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: ...charging 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 or...

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: ...ries 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: ...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: ...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 height u Only perform work on the turboc...

Page 10: ...nly 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 and supplies or con tact with them ma...

Page 11: ...ant possible 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 Swivel lifting eyes are required for the safe lifting of loads which are not supplied by ABB Fig 3 Swivel lifting eye example Product Thread M Length L Load limit Quantity A238 H M10 18 mm 450 kg 1 A240 H M12 21 mm 700 kg 1 Table 4 ...

Page 12: ... contact surface of the bracket 01 CAUTION Oil leak Damaged or improperly inserted gaskets lead to oil leaks u Always use new gaskets and insert them carefully into the slot Fig 5 Inserting the gasket 01 Bracket 05 O rings 02 Oil supply 06 Pin optional 03 Oil drain CECompressor end 04 Slot for gasket suggestion Pin 06 as installation safety device Turbochargers can have an oil inlet either on thei...

Page 13: ...panner Variant with standard nut Variant with clamping nut Table 6 Overview of the fastening variants Requirements for washers 02 Use hardened washers Thickness 15 of nominal thread diameter Requirements for threaded rods 03 Product Thread size Length mm A238 H M20 380 mm A240 H M24 380 mm Table 7 Requirements for centering bushes 04 Strength class 10 9 DIN EN ISO 898 1 Fig 6 Drawing of centering ...

Page 14: ...harger 1 Place the turbocharger roughly over the bracket but do not set it down yet 2 Screw the clamping nut 42201 flush onto the threaded rod 03 3 Insert the threaded rod through the washer 02 of the clamping nut 4 Feed the threaded rod through the bearing casing Step B Preparing the positioning Fig 8 Screwing on the centering bush u Screw the centering bush 04 flush onto the threaded rod from be...

Page 15: ...charger onto bracket and position using the centering bush 04 located in the bracket 4 Check dimension X If dimension X is not reached the turbocharger must be lifted up from the bracket and realigned The values X and L depend on the length of the threaded rod and must be specified by the user 5 Using the hexagon screw the threaded rod into the bracket up to dimension L If dimen sion L is not reac...

Page 16: ...ured 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 10 Preparing the clamping nut for the tight...

Page 17: ... 35 Table 9 Pressure screw tightening torques 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 the table...

Page 18: ...cle break loose all pressure screws of the clamping nut u Working in a circle loosen each of the pressure screws by about of a turn 90 u Repeat the previous step until all pressure screws are relieved of pressure u Loosen clamping nut by hand 4 5 Fastening the turbocharger with a standard nut u Fit the nuts and tighten them according to variant 1 or 2 in the table below Product Through hole in bea...

Page 19: ...ir lines according to the instructions of the enginebuilder Version with compressor 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 13 Connecting the compressor cooling air u Remove the lock ...

Page 20: ...NG 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 u Observe information in material safety data sheet u Ensure proper space ventilation u Do not eat drink or store food at the workplace while working with VCI u Clean hands and face after working with VCI u For ...

Page 21: ...ected 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 component Replace the desiccant agent Repackage the component NOTICE 70 field ...

Page 22: ... Manual The Operation Manual for the turbocharger with the relevant serial number is available online on our website www abb com turbocharging Fig 16 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 Manua...

Page 23: ...Assembly Instructions A200 H 6 Further information Copyright 2021 ABB All rights reserved HZTL455311P0042_EN Rev A September 2021 Fig 17 Finding the Operation Manual online Page 21 21 ...

Page 24: ...nd and download the Operation Manual of your product on our website see Operation Manuals Copyright 2019 ABB All rights reserved 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 ...

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