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Assembly Instructions / A238-H.. - A240-H..

1 Introduction / 1.1 Purpose of the assembly instructions

© Copyright 2022 Accelleron Industries. All rights reserved.

HZTL455311P0042_EN

Rev. B

May 2022

1

Introduction

1.1

Purpose of the assembly instructions

The assembly instructions explain how the Accelleron turbocharger is fitted to the engine correctly
and without any health and safety risks. This element of the documentation is supplied with the
product, as is required for partly completed machinery in accordance with Machinery Directive
2006/42/EC.

The assembly instructions are a complement to and expansion of existing national regulations for oc-
cupational safety, accident prevention and environmental protection.

1.2

Definition of target group

The assembly instructions are intended for engineers and mechanics responsible for fitting the tur-
bocharger 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, 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 companies are used in this document. These are marked with the ® sym-
bol.

Design variants

This document is valid for different design variants of turbochargers. There may be sections and de-
scriptions of components that are not relevant for a specific turbocharger variant.

Accelleron service stations will be happy to provide information about questions regarding a design
variant (see "Contact Information" on the website 

www.accelleron-industries.com

).

Accuracy of illustrations

The illustrations in this document are general in nature and intended for ease of understanding. Dif-
ferences in detail are therefore possible.

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Содержание A200-H

Страница 1: ...and without any health and safety risks Target group The assembly instructions are intended for engineers and mechanics responsi ble for fitting the turbocharger on the engine Assembly Instructions Tu...

Страница 2: ......

Страница 3: ...Definition of mandatory signs 4 1 6 Definition of pictograms 4 2 Safety 5 2 1 Introduction 5 2 2 Lifting of loads 6 2 3 Occupational safety 7 3 Turbocharger weight and transportation 9 4 Installing t...

Страница 4: ...charger 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 instruct...

Страница 5: ...es com 1 4 Definition of warning caution note WARNING Definition of Warning Non compliance or inaccurate compliance with working or operating instructions in dicated by this symbol and the word WARNIN...

Страница 6: ...le 2 Personal 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...

Страница 7: ...ccessories 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 chap...

Страница 8: ...y attention 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 Attac...

Страница 9: ...falling 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...

Страница 10: ...n 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 Handli...

Страница 11: ...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 Swivel lifting eyes are req...

Страница 12: ...lots in the contact surface of the bracket 01 CAUTION Oil leak Damaged or improperly inserted gaskets lead to oil leaks u Always use new gaskets and insert them carefully into the slot Fig 5 Inserting...

Страница 13: ...le torque spanner Variant with standard nut Variant with clamping nut Table 6 Overview of the fastening variants Requirements for washers 02 Use hardened washers Thickness 15 of nominal thread diamete...

Страница 14: ...ocharger roughly over the bracket but do not set it down yet 2 Screw the clamping nut 42201 flush onto the threaded rod 03 3 Insert the threaded rod through the washer 02 of the clamping nut 4 Feed th...

Страница 15: ...d position using the centering bush 04 located in the bracket 4 Check dimension X If dimension X is not reached the turbocharger must be lifted up from the bracket and realigned The values X and L dep...

Страница 16: ...t be ensured 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 p...

Страница 17: ...40 H M24 35 Table 9 Pressure screw tightening torques 1 Screw in pressure screws crosswise by hand until reaching the stop 2 Tighten pressure screws crosswise to 50 of the tightening torque specified...

Страница 18: ...ing in a circle break loose all pressure screws of the clamping nut u Working in a circle loosen each of the pressure screws by about of a turn 90 u Repeat the previous step until all pressure screws...

Страница 19: ...by and air lines according to the instructions of the engineb uilder Version with compressor wheel cooling CAUTION Failure of compressor wheel cooling Any prolonged failure of the compressor wheel co...

Страница 20: ...Ordinance on Hazardous Sub stances Nevertheless the following points must be observed when handling VCI u Observe information in material safety data sheet u Ensure proper space ventilation u Do not...

Страница 21: ...ckage for damage If the package is damaged the turbocharger must be inspected by a Accelleron service station and repacked After every 3 years the following work steps must be performed by a Accellero...

Страница 22: ...Assembly Instructions A238 H A240 H 5 Storage of new turbochargers and spare parts Copyright 2022 Accelleron Industries All rights reserved HZTL455311P0042_EN Rev B May 2022 Page 20 21...

Страница 23: ...ation Manual The Operation Manual for the turbocharger with the relevant serial number is avail able online on our website www accelleron industries com Fig 16 Serial number of the turbocharger on the...

Страница 24: ...and download the Operation Manual of your product on the website see Operation Manuals Accelleron Industries Ltd Bruggerstrasse 71a 5400 Baden Switzerland 41 58 585 7777 accelleron industries com Visi...

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