ABB A100-H Series Original Assembly Instructions Download

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Turbocharger / A100-M radial

Original assembly instructions – English

This document is valid for the
A100-H series:

A130-H, A135-H, A140-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.

A100-H turbocharger

More power, less fuel

—

ASSEMBLY INSTRUCTIONS

Turbocharger / A100-H radial

Original assembly instructions – English

Summary of Contents for A100-H Series

Page 1: ...s 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 A100 H turbocharger More power less fuel ASSEMBLY INSTRUCTIONS Turbocharger A100 H radial Original assembly instructions English ...

Page 2: ......

Page 3: ...nition of pictograms 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 into the bracket 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 clamp...

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: ...al 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 Hand t...

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: ...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 sui...

Page 9: ...ar 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 turbocharger when you are in a physically and psychologically stable condition u Only work ...

Page 10: ...ng 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 may be harmful to health Flammable and combustible oper ating materials and supplies c...

Page 11: ... must be used for removing 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 Fig 3 Transportation of the turbocharger Product Weight of complete turbocharger unit kg A130 H 190 A135 H 270 A140 H 460 Table 4 Weigh...

Page 12: ...essary sealing is provided by O rings The O rings are not included in the ABB scope of delivery Fig 4 Inserting gaskets into the bracket 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 ...

Page 13: ... Remove nuts 01 again Requirements for the threaded rods Fig 6 Requirements for threaded rods Product Diameter Threaded rod mm Material DIN ISO 898 Part 1 Thread length L1 mm Length of threaded rod L2 mm A130 H Ø 16 M16 10 9 12 9 30 250 A135 H Ø 20 M20 10 9 12 9 30 325 A140 H Ø 24 M24 10 9 12 9 70 410 420 Table 5 Requirements for threaded rods Fastening material scope of delivery The threaded rods...

Page 14: ...on eye of the bearing casing 42001 and loop around the gas outlet casing 4 Position the turbocharger on the bracket 04 and align it If present pay attention to the positioning pin 05 in the bracket 5 When fixing with a standard nut C fit the expansion bushes in the correct position in the slot Safeguard against wrong fitting only for water cooled bearing casings Depending on the bracket version 04...

Page 15: ...riant 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 is mounted on the engine support the bolt threads and screw heads must be lightly oiled assumed fr...

Page 16: ...ws 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 8 Preparing the clamping nut for the tightening procedure 1 Check whether the expansion bushes 42190 with recess are cor...

Page 17: ...ontrolled 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 the table 5...

Page 18: ...eel 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 connection for the compressor wheel cooling 06 and fit the cooling...

Page 19: ...e 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 again...

Page 20: ...rbocharger 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 co...

Page 22: ...nual 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 Manual c...

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 HZTL455311P0004 ...

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ABB A100-H Series, Original Assembly Instructions

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