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ABB Power2 800-M, Original Assembly Instructions

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Power2 800-M

Original assembly instructions – English

Assembly Instructions

This document is valid for the Power2 

series:

Power2 850-M

Purpose

The assembly instructions explain how the low- and high-
pressure stage of ABB Turbo Systems 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 low- and high-pressure 
stage on the engine.

Power2

 

performance package

Two-stage turbocharging solution for highest turbocharging 
efficiency

Summary of Contents for Power2 800-M

Page 1: ...ow the low and high pressure stage of ABB Turbo Systems 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 low and high pressure stage on the engine Power2 performance package Two stage turbocharging solution for highest turbocharging efficiency ...

Page 2: ......

Page 3: ... 1 4 Definition of warning caution note 4 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 low pressure and the high pressure stages 9 4 Installing the low pressure stage 11 4 1 Gaskets 12 4 2 Assembly procedure 13 5 Installing the high pressure stage 14 5 1 Gaskets 15 5 2 Assembly procedure 17 6 S...

Page 4: ...and environmental protection 1 2 Definition of target group The assembly instructions are intended for engineers and mechanics responsible for fitting the low and high pressure stage on the engine Basic mechanical training is a prerequisite All persons who are involved in the transportation and installation of the low and high pressure stage have read and understood the assembly instructions 1 3 S...

Page 5: ...o 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 See Contact Infor mation on our website at www abb com turbocharging Definition of pictograms The following pictograms can occur in this document These point out actio...

Page 6: ...truc tions indicated by this symbol and the word CAUTION can lead to serious damage to engine or property with grave consequences Caution signs must always be observed NOTICE Note The note provides advice which facilitates the work 1 5 Definition of mandatory signs To be worn at all times Protective clothing Safety footwear to protect against mechanical hazards Table 2 Personal protective equipmen...

Page 7: ...r must be observed for safe and trouble free operation of the Power2 and during all work on the Power2 components All further safety instructions contained and specifically identified in every chapter of this doc ument see section Definition of safety instructions must also be observed Information Low pressure and high pressure stages from ABB Turbo Systems comply with the Machinery Directive 2006...

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

Page 9: ...twear against mechanical risks Wear protective clothing WARNING Risk of falling When work is performed on the low pressure or high pressure stage there is a risk of falling Do not climb onto the low pressure or high pressure stage or onto at tached parts and do not use them as climbing aids Use suitable climbing aids and working platforms for work above body height Only perform work on the low pre...

Page 10: ... of acci dents Ensure workplace safety Only perform operations that are described in this document 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 ...

Page 11: ...st be used for installing the low pressure and high pressure stages The following weight specifications apply to the heaviest variant possible Depending on the specification the weight specified on the rating plate may be lower than the standard values specified here Figure 3 Suspending the low pressure and high pressure stages A Low pressure stage B High pressure stage Power2 Product Weight kg 85...

Page 12: ...fting eyes to be used Two swivel lifting eyes S are required for the safe lifting of loads These are not included in the ABB Turbo Systems scope of delivery Swivel lifting eye S Power2 Thread Length L Minimum load limit 850 LP M24 30 mm 1800 kg Table 5 Swivel lifting eyes to be used Swivel lifting eye S Power2 Thread Length L Minimum load limit 850 HP M12 18 mm 700 kg Table 6 Swivel lifting eyes t...

Page 13: ...he screw head or nut Use hardened washers thickness 15 of the nominal thread diameter Table 7 Fixing elements The required installation pre tension force for the fixing elements of the low pressure stage are defined in table see Table 8 An appropriate tightening method must be chosen for as sembly Power2 Subject Requirements 850 LP Thread size M20 Quantity 8 Low pressure stage foot clamping length...

Page 14: ...d in the ABB Turbo Sys tems scope of delivery and must be provided by the enginebuilder O rings in the bracket are recommended as seals The dimensions of the sealing surfaces provided at the low pressure stage are defined in the table see Table 9 Figure 5 Oil supply gaskets Power2 Oil supply Oil drain Inside diameter di Outside diameter da Inside diameter Di Outside diameter Da 850 LP 46 mm 76 mm ...

Page 15: ...sembly procedure Figure 6 Installing the low pressure stage Attach lifting gear to the two suspension points of the bearing casing Check that the orifices specified for the low pressure stage have been installed in both oil supply pipes Check that the gaskets have been correctly fitted at the oil inlet and the oil outlet in the bracket Align the low pressure stage on the engine Tighten the fixing ...

Page 16: ...thread diameter Sleeves Strength class 10 9 DIN EN ISO 898 1 Table 10 Fixing elements The required installation pre tension force for the fixing elements of the turbocharger are de fined in table see Table 11 An appropriate tightening method must be chosen for assembly For the case of the torque controlled tightening method an appropriate tightening torque is defined in table see Table 11 in accor...

Page 17: ... through the bracket Gaskets are required in the bracket for sealing the interface of the oil pipes between the bracket and the high pressure stage These gaskets are not included in the ABB Turbo Sys tems scope of delivery and must be provided by the enginebuilder O rings in the bracket are recommended as seals The dimensions of the sealing surfaces provided at the high pressure stage are defined ...

Page 18: ...55311P0010 Revision March 2016 CAUTION Inserting the gaskets Damaged or improperly inserted gaskets lead to oil leaks Always use new gaskets and insert them carefully into the slot Gas and air lines The gas and air line gaskets are not included in the ABB Turbo Systems scope of delivery and must be provided by the enginebuilder ...

Page 19: ... pressure stage Attach one lifting gear to the two suspension points of the bearing casing and one lifting gear to the support Check that the orifices specified for the high pressure stage have been installed in both oil supply pipes Check that the gaskets have been correctly fitted at the oil inlet and the oil outlet in the bracket Check that the sleeves of the bearing casing fixing screws have b...

Page 20: ... and cartridge groups for more than 6 months VCI 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 Ensure proper space ventilation Do not eat drink or store food at the workplace while working with VCI Wear safety gloves Clean hands and face after working ...

Page 21: ...s changed colour the maximum admissible atmospheric humidity has been exceeded In this case the low pressure or high pressure stage or the cartridge group must be checked and repackaged by an ABB Turbocharging Service Station Check the package for damage If the package is damaged the low or high pressure stage or the cartridge group must be checked and repackaged by an ABB Turbocharging Service St...

Page 22: ...ow pressure and high pressure stage with the relevant serial number is available online on our website www abb com turbocharging Low pressure stage Figure 12 Serial number of low pressure stage on rating plate High pressure stage Figure 13 Serial number of high pressure stage on rating plate One rating plate each is attached on the left and the right side of the foot bearing casing and to the air ...

Page 23: ...ther information Page 21 21 Copyright 2016 ABB All rights reserved HZTL455311P0010 Revision March 2016 The Operation Manual can be found online in accordance with the details on the following page Figure 14 Finding the Operation Manual online ...

Page 24: ...he Operation Manual of your product on our website see Need product information Operating instructions Copyright 2016 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 HZTL455311P0010 ...

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