ABB Power2 800-M Assembly Instructions Manual Download Page 1

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Turbocharger / A100-M radial

Original assembly instructions – English

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

ASSEMBLY INSTRUCTIONS

Power2 800-M

Original assembly instructions – English

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Summary of Contents for Power2 800-M

Page 1: ...ngine 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 ASSEMBLY INSTRUCTIONS Power2 800 M Original assembly instructions English ...

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Page 3: ... 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 16 6 Sto...

Page 4: ... prevention 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 pres sure stage have read and understood the assembly instr...

Page 5: ... Turbo 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 Informa tion on our website at www abb com turbocharging Definition of pictograms The following pictograms can occur in this document These point out ...

Page 6: ...iance with working or operating in structions indicated by this symbol and the word CAUTION can lead to seri ous damage to engine or property with grave consequences u Caution signs must always be observed 1 5 Definition of mandatory signs To be worn at all times Protective clothing Safety footwear to protect against mechanical hazard and risk of falling Table 2 Personal protective equipment to be...

Page 7: ...ter must be observed for safe and trouble free opera tion of the Power2 and during all work on the Power2 components All further safety instructions contained and specifically identified in every chapter of this document 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 20...

Page 8: ...ntion 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...

Page 9: ...n the low pressure or high pressure stage there is a risk of falling u Do not climb onto the low pressure or high pressure stage or onto at tached 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 low pressure or high pressure stage when you are in a physic ally and psychologically stable condition u ...

Page 10: ...ribed 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 and supplies...

Page 11: ...sed for installing the low pressure and high pressure stages The following weight specifications apply to the heaviest variant pos sible Depending on the specification the weight specified on the rating plate may be lower than the standard values specified here Fig 3 Suspending the low pressure and high pressure stages A Low pressure stage B High pressure stage Power2 Product Weight kg 850 LP Low ...

Page 12: ...wo 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 Minimum load limit Lmin Lmax 850 LP M24 30 mm 40 mm 1900 kg Table 5 Swivel lifting eyes to be used Swivel lifting eye S Power2 Thread Length Minimum load limit Lmin Lmax 850 HP M12 15 mm 20 mm 700 kg Table 6 Swivel lifting e...

Page 13: ...thread diameter Table 7 Fixing elements The required installation pre tensioning force for the fixing elements of the low pressure stage are defined in table see Table 8 Fixing element requirements 11 An appropriate tightening method must be chosen for assembly Subject Power2 850 LP Thread size M20 Quantity 8 Low pressure stage foot clamping length a 70 mm Clearance in bracket diameter G n a Clear...

Page 14: ...he 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 Oil supply gaskets 12 Fig 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 72 mm 100 mm Table 9 Oil supply gaskets CAUTION Inserting the gaskets Gaskets tha...

Page 15: ...e bearing casing u Check that the orifices specified for the low pressure stage have been installed in both oil supply pipes u Check that the gaskets have been correctly fitted at the oil inlet and the oil outlet in the bracket u Align the low pressure stage on the engine u Tighten the fixing elements on the foot see Table 8 Fixing element requirements 11 u Secure all gas air water and oil pipes u...

Page 16: ... tension force for the fixing elements of the turbocharger are defined in table see Table 11 Fixing element requirements 14 An appropriate tighten ing 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 Fixing element requirements 14 in accordance with VDI2230 Power2 Subject Requirements Bearin...

Page 17: ...he bracket are recommended as seals The dimensions of the sealing surfaces provided at the high pressure stage are defined in the table see Table 12 Oil supply gas kets 15 Fig 7 Oil supply gaskets Power2 Oil supply Oil drain Inside diameter di Outside diameter da Inside diameter Di Outside diameter Da 850 HP 28 mm 50 mm 52 mm 65 mm Table 12 Oil supply gaskets CAUTION Inserting the gaskets Gaskets ...

Page 18: ...ch one lifting gear to the two suspension points of the bearing casing and one lifting gear to the support u Check that the orifices specified for the high pressure stage have been installed in both oil supply pipes u Check that the gaskets have been correctly fitted at the oil inlet and the oil outlet in the bracket u Check that the sleeves of the bearing casing fixing screws have been correctly ...

Page 19: ...s 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 u Ensure proper space ventilation u Do not eat drink or store food at the workplace while working with VCI u Wear safety gloves u Clean hands and face after working with VCI u F...

Page 20: ...ed 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 u 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 Station...

Page 22: ...serial number is available online on our website www abb com turbocharging Low pressure stage Fig 11 Serial number of low pressure stage on rating plate High pressure stage Fig 12 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 suction branch of the high pressure stage 1 Read the serial ...

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

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Summary of Contents for Power2 800-M

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ABB Power2 800-M, Assembly Instructions Manual, Page: 1 / 24

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Summary of Contents for Power2 800-M

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