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ABB Turbocharger A130-M, Original Assembly Instructions, Page: 1 / 24

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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 
A100-M series:

A130-M, A135-M, A140-M, A145-M

A100-M turbocharger

More power, less fuel

ASSEMBLY INSTRUCTIONS

Turbocharger / A100-M radial

Original assembly instructions – English

Summary of Contents for Turbocharger A130-M

Page 1: ...ks 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 A100 M series A130 M A135 M A140 M A145 M A100 M turbocharger More power less fuel ASSEMBLY INSTRUCTIONS Turbocharger A100 M radial Original assembly instructions English ...

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Page 3: ... 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 Fitting threaded rods 11 4 3 Placing the turbocharger on the bracket 12 4 4 Fastening the turbocharger with a standard nut 13 4 5 Fastening the turbocharger with a clamping nut 14 4 6 Connec...

Page 4: ...he 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 outsid...

Page 5: ...ocharging 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 o...

Page 6: ...ion 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 tighte...

Page 7: ...ories 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: ...on 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 ...

Page 9: ...you 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 h...

Page 10: ...s 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 materia...

Page 11: ...ed 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 Suspension of complete turbocharger unit A Turbocharger with oil cooled bearing casing B Turbocharger with water cooled bearing casing C Complete turbocharger unit with gas outlet casing Product Weight of complete turbo...

Page 12: ...The necessary sealing is provided by O rings The O rings are not included in the ABB scope of delivery 01 Bracket 04 Slot for O ring 02 Oil supply 05 O rings 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 b...

Page 13: ...equirements for the threaded rods Fig 5 Requirements for threaded rods Product Diameter Threaded rod mm Material DIN ISO 898 Part 1 Thread length L1 mm Oil cooled L2 mm Water cooled L2 mm A130 Ø 16 M16 10 9 12 9 30 250 250 A135 Ø 20 M20 10 9 12 9 30 270 325 A140 Ø 24 M24 10 9 12 9 70 350 360 410 420 A145 Ø 30 M30 10 9 12 9 80 415 425 Table 5 Requirements for threaded rods Fastening material scope ...

Page 14: ...gear to the suspension eye of the bearing casing A B and loop around the gas outlet casing 61001 If the gas outlet casing is already fitted in the exhaust gas pipe the attachment of the lifting gear on the bearing casing is sufficient 5 Position the turbocharger on the bracket 04 and align it Pay attention to the position ing pins 05 in the bracket 6 When fixing with a standard nut D fit expansion...

Page 15: ...4 4 Fastening the turbocharger with a standard nut u Fit the nuts and tighten them according to variant 1 or 2 in the table below Product Through hole in bearing casing mm Fixing screws mm Variant 1 Tightening torques Nm Variant 2 Hy draulic pre ten sioning forces kN A130 Ø 17 M16 280 110 A135 Ø 21 M20 560 175 A140 Ø 25 M24 960 250 Table 6 Tightening torque for standard nuts When the turbocharger ...

Page 16: ...nsured that the necessary tension force is reached u Do not clean pressure screws u Do not lubricate pressure screws In order to correctly fit the clamping nuts the pressure screws 04 must not protrude from the clamping nuts 03 in the direction of the thrust washer 02 u Make sure the pressure screws do not protrude in the direction of the thrust washer Fig 7 Preparing the clamping nut for the tigh...

Page 17: ...pressure screws In order to correctly fit the clamping nuts the pressure screws 04 must not protrude from the clamping nuts 03 in the direction of the thrust washer 02 u Make sure the pressure screws do not protrude in the direction of the thrust washer Fig 8 Preparing the clamping nut for the tightening procedure 1 Check whether the expansion bushes 42190 with recess are correctly positioned and ...

Page 18: ...7 Torque controlled tightening of the pressure screws 1 Screw in pressure screws crosswise by hand until reaching the stop 2 Tighten pressure screws crosswise to 50 of the tightening torque specified in the table 3 Tighten pressure screws crosswise to 100 of the tightening torque specified in the table 4 Work in a circle to tighten all pressure screws to 100 of the tightening torque specified in t...

Page 19: ...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 screw plug on the connec...

Page 20: ...sense 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 a...

Page 21: ... 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 22: ...n Manual The Operation Manual for the turbocharger with the relevant serial number is available online on our website www abb com turbocharging Fig 14 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 Manu...

Page 23: ...Assembly Instructions A130 M A145 M 6 Further information Copyright 2020 ABB All rights reserved HZTL455311P0005_EN Rev B July 2020 Fig 15 Finding the Operation Manual online Page 21 21 ...

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 HZTL455311P0005 ...

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