ABB TPR48-F Series Assembly Instructions Manual Download

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Turbocharger / A100-M radial

Original assembly instructions – English

This document is valid for:

TPR48-F.. - TPR52-F..

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.

TPR48-F.. - TPR52-F.. turbocharger

Powerful and compact

—

ASSEMBLY INSTRUCTIONS

Turbocharger / TPR48-F.. - TPR52-F..

Original assembly instructions – English

Summary of Contents for TPR48-F Series

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 turbocharger on the engine TPR48 F TPR52 F turbocharger Powerful and compact ASSEMBLY INSTRUCTIONS Turbocharger TPR48 F TPR52 F Original assembly instructions English ...

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Page 3: ...ory 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 the turbocharger with threaded rods 11 4 3 Fitting the turbocharger with screws 12 4 4 Placing the turbocharger on the bracket 13 4 5 Securing the t...

Page 4: ... the 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 outs...

Page 5: ...rbocharging 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...

Page 6: ...ersonal 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 H...

Page 7: ...ssories 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 t...

Page 8: ...tion 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: ...in 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 tur...

Page 10: ...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 or con tact with them...

Page 11: ...ssible 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 which are not supplied by ABB Turbocharging Fig 3 Swivel lifting eyes Product Thread M Length L mm Minimum load limit kg Quantity TPR48 F M8 13 mm 300 kg 2 TPR52 F M10 17 ...

Page 12: ...05 O rings CE Compressor end 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 fitted on the left and on the right engine bank A pin can be installed in every support as an installation safety device to prevent inadvertent incorrect fitting This pin fi...

Page 13: ...rger to the bracket are not supplied by ABB Requirements for threaded rods Fig 6 Threaded rod requirements Product Threaded rod diameter mm Material DIN ISO 898 part 1 Thread length L1 mm Free length above bracket L2 mm TPR48 F Ø 16 M16 10 9 12 9 30 195 TPR52 F Ø 20 M20 10 9 12 9 30 225 Table 6 Threaded rod requirements Fig 7 Fitting threaded rods on the bracket 1 Lightly oil the surfaces of the t...

Page 14: ...ting the turbocharger with screws Scope of delivery of fastening material The screws and positioning sleeves for securing the turbocharger to the bracket are not supplied by ABB Requirements for screws Fig 8 Screw requirement Product Screw size Material DIN ISO 898 part 1 Free length above bracket L1 mm TPR48 F M16 10 9 12 9 195 TPR52 F M20 10 9 12 9 225 Table 7 Screw requirements Page 12 21 ...

Page 15: ...ioned opposite the bracket and that the oil supply is ensured during operation 1 Make sure that the O rings 03 are undamaged and positioned correctly in the slots 2 Attach the lifting gear to the swivel lifting eyes S and loop around the gas outlet casing 3 Position the turbocharger on the bracket 04 and align it If present pay attention to the positioning pin 05 in the bracket Safeguard against w...

Page 16: ...ng mm Fixing screws mm Variant 1 Tightening torques Nm Variant 2 Hy draulic pre ten sioning forces kN TPR48 F Ø 17 M16 280 110 TPR52 F Ø 21 M20 560 175 Table 8 Tightening torque for standard nuts Securing the turbocharger with screws Product Through hole in bearing cas ing mm Fixing screws mm Tightening torques Nm TPR48 F Ø 17 M16 280 TPR52 F Ø 21 M20 560 Table 9 Screw tightening torque When the t...

Page 17: ...r 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 10 Connecting the compressor cooling air intake u Remove the...

Page 18: ...Assembly Instructions TPR48 F TPR52 F 4 Installing the turbocharger 4 6 Connecting the turbocharger Copyright 2021 ABB All rights reserved HZTL455311P0040_EN Rev A August 2021 Page 16 21 ...

Page 19: ...RNING 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 F...

Page 20: ...nspected 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 fie...

Page 22: ...ion 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 Ma...

Page 23: ...Assembly Instructions TPR48 F TPR52 F 6 Further information Copyright 2021 ABB All rights reserved HZTL455311P0040_EN Rev A August 2021 Fig 14 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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ABB TPR48-F Series, Assembly Instructions Manual

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