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Turbocharger / A100-M radial

Original assembly instructions – English

This document is valid for the
A200-L series:

A255-L, A260-L,

A265-L,

A270-L, A275-L, A280-L

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.

A200-L turbocharger

High performance turbocharger for two-stroke
diesel engines

—

ASSEMBLY INSTRUCTIONS

Turbocharger / A200-L

Original assembly instructions – English

Содержание A200-L

Страница 1: ...ed 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 A200 L turbocharger High performance turbocharger for two stroke diesel engines ASSEMBLY INSTRUCTIONS Turbocharger A200 L Original assembly instructions English ...

Страница 2: ......

Страница 3: ... 2 1 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 10 4 Installing the turbocharger 11 4 1 Placing the turbocharger on the bracket 11 4 2 Steps for fastening the turbocharger 12 5 Storage of new turbochargers and spare...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 heig...

Страница 10: ...aught alone Contact with rotating parts can cause severe injury u Secure rotor against turning WARNING Mechanical hazard Severe injuries to personnel or fatal accidents can be caused by mechanical influences as a consequence of hazardous and inadequate operational pro cedures u Observe the general rules for occupational safety and prevention of acci dents u Ensure workplace safety u Only perform o...

Страница 11: ...health Flammable and combustible oper ating materials and supplies can catch fire or resulting vapours can lead to an explosion u Do not breathe in these substances and avoid contact with the skin u Ensure proper ventilation u Observe the information in the material safety data sheet for the operat ing materials and supplies u Comply with local legislation Wear safety goggles Wear safety gloves to...

Страница 12: ... 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 Fastening of the turbocharger Product Weight of complete turbocharger unit kg A255 L 1350 A260 L 1550 A265 L 2600 A270 L 3800 A275 L 6...

Страница 13: ...harger 4 1 Placing the turbocharger on the bracket Fig 4 Placing the turbocharger u Remove covers from the oil connections u Align turbocharger and place on engine bracket u Tighten the fixing screws Steps for fastening the turbocharger while only slightly loosening the lifting gear u Remove lifting gear from turbocharger u Connect cable to speed sensor u Connect all gas air and oil pipes Page 11 ...

Страница 14: ...a compressor end a height of turbocharger foot a Dimension a turbine end a height of turbocharger foot F spacer sleeve D Dimension b Hole in bracket Dimension c Thread length 1 5 x nominal thread diameter Coefficient of friction 0 12 lightly oiled Table 5 General information about fastening the turbocharger Compressor end foot Fig 5 Compressor end foot u Tighten the foot fixing screws or nuts diag...

Страница 15: ...6 1500 Table 6 Tightening torques foot screws Angle controlled tightening Product Thread size Height a foot mm Pre tightening torque Nm Tightening angle height a DEG Additional tightening angle for every 10 mm of ad ditional screw length b DEG A255 L M27 60 220 30 3 1 A260 L M27 60 220 30 3 1 A265 L M22 86 120 30 3 7 A270 L M27 100 220 30 3 1 A275 L M30 120 300 30 2 6 A280 L M33 136 400 35 2 6 Tab...

Страница 16: ...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...

Страница 17: ...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...

Страница 18: ...anual The Operation Manual for the turbocharger with the relevant serial number is available online on our website www abb com turbocharging Fig 9 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...

Страница 19: ...Assembly Instructions A200 L 6 Further information Copyright 2020 ABB All rights reserved HZTL455311P0001_EN Rev A July 2020 Fig 10 Finding the Operation Manual online Page 17 17 ...

Страница 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 HZTL455311P0001 ...

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