ABB Turbocharger TPL-65A Assembly Instructions Manual Download

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Turbocharger / A100-M radial

Original assembly instructions – English

This document is valid for the TPL-A
series:

TPL-65A, TPL65VA, TPL69-A,
TPL73-A, TPL77-A

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.

TPL-A turbocharger

High on efficiency, low on running costs

—

ASSEMBLY INSTRUCTIONS

Turbocharger / TPL-A

Original assembly instructions – English

Summary of Contents for Turbocharger TPL-65A

Page 1: ...er 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 TPL A turbocharger High on efficiency low on running costs ASSEMBLY INSTRUCTIONS Turbocharger TPL A Original assembly instructions English ...

Page 2: ......

Page 3: ...s and definitions 2 1 4 Definition of warning caution note 3 1 5 Definition of mandatory signs 4 1 6 Definition of pictograms 4 2 Safety 5 2 1 Introduction 5 2 2 Lifting loads 6 2 3 Occupational safety 7 3 Weight and transportation of the turbocharger 9 4 Installing the turbocharger 10 4 1 Steps for fastening the turbocharger 10 4 2 Version with VTG 13 4 3 Completion work if required 13 5 Storage ...

Page 4: ...urbocharger on 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 and definitions The following symbols are used in the documents w Prerequisite u Work step Enumeration first level Enumeration second level Refers to a page number The trademarks ...

Page 5: ...1 4 Definition of warning caution note WARNING Definition of warning Serious personal injuries and even accidents with fatal consequences may occur if work and operating instructions marked with this symbol and the word WARNING are either not followed or not followed precisely u Warning signs must be observed at all times CAUTION Definition of caution Serious machine or property damage may occur i...

Page 6: ...ses Safety helmet Ear protection Table 2 1 6 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 Oil free grease free and dry Tighten over specified tightening angle Affix Hand tight tighten without tools Meas...

Page 7: ...ocharger itself or its accessories Are caused by the operating and auxiliary materials used Are a consequence of insufficient compliance with safety instructions All instructions contained in this chapter must be observed during all work on the turbochar ger Responsibility of the operating company In awareness of its responsibility the operating company must ensure that only authorised personnel w...

Page 8: ... with sufficient loading capacity u Make sure the load is suspended properly on the crane hook u Do not let anyone stand beneath a suspended load Wear safety gloves to protect against mechanical hazards Wear safety helmet 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 suitable edge guard if th...

Page 9: ...s for which 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 ...

Page 10: ...perations 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...

Page 11: ...ent load limit must be used for installing the turbocharger The fol lowing weight specification applies to the heaviest variant possible Depending on the spe cification the weight specified on the rating plate may be lower than the standard value specified here u Remove the insulation at the suspension ribs u Fit lifting gear to turbocharger Product Weight kg TPL65 A 1230 TPL65VA 1210 TPL69 A 1780...

Page 12: ...ed to the engine it must be ensured that the orifices specified for the turbocharger are installed in both oil supply pipes u Check that the oil orifices have been correctly installed u Adjust the turbocharger on the engine u Tighten the fixing screws Steps for fastening the turbocharger 10 4 1 Steps for fastening the turbocharger General information Subject Requirement Information Turbocharger fi...

Page 13: ...lled tightening Product Thread size Tightening torque Nm Height a of tensioned tur bocharger foot mm TPL65 A M20 560 64 TPL65VA M20 560 64 TPL69 A M24 960 75 5 TPL73 A M24 960 88 TPL77 A M30 1900 104 Table 6 1 In Z configuration hand tighten without tools 2 In Z configuration tighten to 50 of tightening torque 3 In Z configuration tighten to 100 of tightening torque Angle controlled tightening Pag...

Page 14: ... pre tensioning force Due to the special foot design of this turbocharger the foot is not in contact with the bracket in the area of the screw holes as long as the screws have not been tightened Ini tially the foot only touches the bracket at the centre of the foot 1 In Z configuration hand tighten without tools 2 In Z configuration tighten to 50 of pre tightening torque 3 In Z configuration tight...

Page 15: ... These turbocharger types have adjustable guide vanes at the turbine end instead of a nozzle ring u The VTG drive must be connected to the operating lever in accordance with the engineb uilder s instructions 4 3 Completion work if required u Attach all gas air water and oil pipes in accordance with the enginebuilder s instructions u Fit insulation components u Fit speed sensor and plug in cable co...

Page 16: ...ducts are not hazardous in the sense of the Hazardous Substances Ordinance Nevertheless the following points are to be observed when handling VCIs u Ensure good room ventilation u Do not eat drink or keep food at the workplace while working with VCIs u Wear safety gloves u Clean hands and face after working with VCIs u For further information refer to www branopac com Wear safety gloves to protect...

Page 17: ...ted 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 Turbocharge...

Page 18: ...l for the turbocharger with the relevant serial number is available on line on our website www abb com turbocharging A rating plate is attached to the turbocharger foot one on the left and one on the right On turbochargers with insulation from ABB at least one additional rating plate is attached to the insulation of the gas outlet casing 1 Read the serial number 02 on the rating plate 01 of the tu...

Page 20: ...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 HZTL455311P0017 ...

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ABB Turbocharger TPL-65A, Assembly Instructions Manual

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