ABB TPX Series Assembly Instructions Manual Download

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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.

—

This document is valid for the
TPX series:

TPX44-H

TPX turbocharger

Turbo Power eXtra. Delivering uncompromising
reliability in the toughest environments.

ASSEMBLY INSTRUCTIONS

Turbocharger / TPX

Original assembly instructions – English

Summary of Contents for TPX Series

Page 1: ...p The assembly instructions are intended for engineers and mechanics responsible for fitting the turbocharger on the engine This document is valid for the TPX series TPX44 H TPX turbocharger Turbo Power eXtra Delivering uncompromising reliability in the toughest environments ASSEMBLY INSTRUCTIONS Turbocharger TPX Original assembly instructions English ...

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Page 3: ... 3 Symbols definitions 2 1 4 Definition of warning 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 4 Installing the turbocharger 10 4 1 Inserting gaskets 10 4 2 Turbocharger attachment 11 4 3 Attaching the turbocharger to the bracket 12 5 Storage of new turbochargers ...

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: ...our website at www abb com turbocharging 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 inacc...

Page 6: ...on 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...

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: ...ou 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 he...

Page 10: ... that 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 material...

Page 11: ...ing installing and transport ing the turbocharger The weight specified below applies to the heaviest variant 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 One swivel lifting eye S is required to safely lift this turbocharger This is not included in the ABB Turbo Systems scope of de...

Page 12: ... for dimensions The necessary gaskets 05 must be integrated in the support plate A suggestion for the slot shape 04 is shown below The gaskets are not included in the ABB Turbo Systems scope of delivery and must be provided by the enginebuilder u Use O ring gaskets with a cord diameter of at least 3 5 mm u Integrate the slots in the contact surface of the bracket 01 CAUTION Oil leak Damaged or imp...

Page 13: ...or threaded rods Product Diameter Threaded rod mm Material DIN ISO 898 Part 1 Thread length L1 mm Length of threaded rod L2 mm TPX44 Ø12 M12 10 9 12 9 30 170 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 Turbo Systems scope of delivery These parts depend on th...

Page 14: ...Make 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 the tigh...

Page 15: ...nse 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 aga...

Page 16: ...turbocharger 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 ...

Page 18: ...operation mainten ance and ordering spare parts NOTICE 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 Position of the rating plate 1 Read the serial number 02 on the rating plate 01 of the turbocharger u The Operation Manual can be found online in accordance with the details on the follo...

Page 19: ...Assembly Instructions TPX44 H 6 Further information Copyright 2019 ABB All rights reserved HZTL455311P0037_EN Rev A November 2019 Fig 12 Finding the Operation Manual online Page 17 17 ...

Page 20: ...ion Find and download the Operation Manual of your product on our website see Operation Manuals 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 ...

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