ABB TPS44-H Series Assembly Instructions Manual Download Page 1

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Turbocharger / A100-M radial

Original assembly instructions – English

This document is valid for the TPS-H
series:

TPS44-H, TPS48-H, TPS52-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.

TPS-H turbocharger

—

ASSEMBLY INSTRUCTIONS

Turbocharger / TPS-H

Original assembly instructions – English

Summary of Contents for TPS44-H Series

Page 1: ...B 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 TPS H turbocharger ASSEMBLY INSTRUCTIONS Turbocharger TPS H Original assembly instructions English ...

Page 2: ......

Page 3: ...arning caution note 3 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 turbocharger 9 3 1 Swivel lifting eyes to be used 10 4 Installing the turbocharger 11 4 1 Inserting gaskets 11 4 2 Fitting threaded rods 12 4 3 Placing the turbocharger on the bracket and aligning 14 4 4 Connecting the turbochar...

Page 4: ...ngine 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 co...

Page 5: ...rging 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 op...

Page 6: ...Table 2 Personal protective equipment to be worn specific to the respective task 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 tight tighten wi...

Page 7: ...s 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 tur...

Page 8: ...o 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 suit...

Page 9: ...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 heigh...

Page 10: ...at 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 a...

Page 11: ...with a sufficient load limit must be used for transporting the turbocharger The weight specified below applies to the heaviest variant possible Depending on the specifica tion the weight specified on the rating plate may be lower than the standard value specified here Fig 3 Fitting lifting gear to turbocharger Produkt Gewicht Turbolader komplett kg TPS44 120 TPS48 180 TPS52 250 Table 4 Gesamtgewic...

Page 12: ... Rev A July 2020 3 1 Swivel lifting eyes to be used One swivel lifting eye S is required to safely lift this turbocharger This is not included in the ABB scope of delivery Fig 4 Swivel lifting eyes Product Thread M Length H mm Diameter D mm Minimum load limit kg TPS44 M8 12 25 300 TPS48 M8 12 25 300 TPS52 M10 15 25 400 Table 5 Swivel lifting eyes to be used Page 10 21 ...

Page 13: ...kets that are forgotten damaged or improperly inserted will lead to oil leaks u Always use new gaskets and insert them carefully into the slot The oil is supplied 02 and drained 03 through the bracket 01 The necessary sealing is provided by O rings The O rings are not included in the ABB scope of delivery Fig 5 Inserting O rings into bracket 01 Bracket 02 Oil supply 03 Oil drain 04 Slot for O ring...

Page 14: ...ed rods Product Diameter Threaded rod mm Material DIN ISO 898 Part 1 Thread length L1 mm Length of threaded rod L2 mm TPS44 Ø 16 M16 10 9 12 9 30 150 TPS48 Ø 16 M16 10 9 12 9 30 170 TPS52 Ø 20 M20 10 9 12 9 30 195 Table 6 Requirements for threaded rods Fastening material scope of delivery The threaded rods and nuts required for attaching the turbocharger to the bracket are not included in the ABB ...

Page 15: ...l rights reserved HZTL455311P0011_EN Rev A July 2020 4 2 2 Inserting the threaded rods Fig 7 Inserting threaded rods into the bracket 1 Lightly oil the surfaces of the threaded rods 02 to be screwed in 2 Screw the threaded rods into the bracket with the aid of locknuts 01 3 Remove nuts 01 again Page 13 21 ...

Page 16: ... sure that the covers of the oil and water connections are removed 2 Make sure that the gaskets are not damaged and are positioned correctly in the slots 3 Install the swivel lifting eye S and attach the lifting gear to it 4 Align the turbocharger over the threaded rods of the bracket 5 Place the turbocharger on the bracket 6 Lightly oil the hexagon nuts 7 Fit the hexagon nuts Observe tightening t...

Page 17: ...020 ABB All rights reserved HZTL455311P0011_EN Rev A July 2020 4 4 Connecting the turbocharger u Connect all gas and air lines according to the instructions of the enginebuilder Version with water cooled bearing casing u Fit the water pipes according to the instructions of the enginebuilder Page 15 21 ...

Page 18: ... 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 agains...

Page 19: ...bocharger 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 com...

Page 22: ... Operation Manual The Operation Manual for the turbocharger with the relevant serial number is available online on our website www abb com turbocharging Fig 11 Serial number of turbocharger on rating plate The rating plate 01 is attached at the top on the bearing casing of the turbocharger 1 Read the serial number 02 on the rating plate 01 of the turbocharger u The Operation Manual can be found on...

Page 24: ...product on our website see Operation Manuals Copyright 2020 ABB All rights reserved Operation Manual Contact information 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 HZTL455311P0011 ...

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ABB TPS44-H Series, Assembly Instructions Manual

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