ABB A100-M Series Original Assembly Instructions
Turbocharger
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ASSEMBLY INSTRUCTIONS
Turbocharger / A100-M radial
Original assembly instructions – English
This document is valid for the
A100-M series:
A150-M, A155-M
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-M turbocharger
More power, less fuel
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Table of Contents
Related Manuals for ABB A100-M Series
Summary of Contents for ABB A100-M Series
- Page 1 This document is valid for the A100-M series: A150-M, A155-M Purpose A100-M turbocharger The assembly instructions explain how the ABB More power, less fuel turbocharger is fitted to the engine correctly and without any health and safety risks. Target group...
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Page 3: Table Of Contents
Fastening the turbocharger with a clamping nut ..........14 Connecting the turbocharger..................16 Attaching the support ....................16 Storage of new turbochargers and spare parts ..........17 Further information..................... 20 © Copyright 2020 ABB. All rights reserved. HZTL455311P0006_EN Rev.B July 2020... -
Page 4: Introduction
Introduction Purpose of the assembly instructions The assembly instructions explain how the ABB 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 dir- ective 2006/42EC. -
Page 5: Definition Of Warning, Caution, Note
ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging in this document. Official service stations of ABB Turbocharging Official service stations are regularly audited and certified by ABB Turbocharging. See "Con- tact Information" on our website at www.abb.com/turbocharging. Definition of warning, caution, note... -
Page 6: Definition Of Mandatory Signs
Apply other paste in accord- Dispose of in an environmentally ance with specifications compatible, professional way and in compliance with locally Oil free, grease free and dry applicable regulations. Table 3: Definition of pictograms © Copyright 2020 ABB. All rights reserved. HZTL455311P0006_EN Rev.B July 2020... -
Page 7: Safety
Introduction State of the art Turbochargers manufactured by ABB Turbocharging are state of the art and comply with the respective health and safety standards in effect at the time the turbocharger was built. This ensures safe operation of the turbocharger. -
Page 8: Lifting Of Loads
Use a suitable edge guard if there are sharp edges. The assembly devices must be completely screwed in and must not unscrew during use. Use assembly devices only for the described applications. © Copyright 2020 ABB. All rights reserved. HZTL455311P0006_EN Rev.B... -
Page 9: Occupational Safety
Welding work in the vicinity of the turbocharger When performing welding work in the vicinity of the turbocharger, always cover the filter silencer to prevent the filter mat from being damaged. © Copyright 2020 ABB. All rights reserved. HZTL455311P0006_EN Rev.B... - Page 10 Observe the information in the material safety data sheet for the operat- ing materials and supplies. Comply with local legislation. Wear safety goggles. Wear safety gloves to protect against mechanical hazards. Wear a respiratory mask to protect against gases. © Copyright 2020 ABB. All rights reserved. HZTL455311P0006_EN Rev.B July 2020...
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Page 11: Weight And Transportation Of The Turbocharger
Complete turbocharger unit without gas outlet casing Complete turbocharger unit with gas outlet casing Product Weight of complete turbocharger unit [kg] A150-M 1200 A155-M 1800 Table 4: Weight of complete turbocharger unit © Copyright 2020 ABB. All rights reserved. HZTL455311P0006_EN Rev.B July 2020... - Page 12 Assembly Instructions / A150-M, A155-M 3 Weight and transportation of the turbocharger / © Copyright 2020 ABB. All rights reserved. HZTL455311P0006_EN Rev.B July 2020...
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Page 13: Installing The Turbocharger
Gaskets that are forgotten, damaged or improperly inserted will lead to oil leaks. Always use new gaskets and insert them carefully into the slot. Fig. 4: Inserting the gasket Oil supply Oil drain 42200 O-ring 42201 Bearing casing 42202 O-ring © Copyright 2020 ABB. All rights reserved. HZTL455311P0006_EN Rev.B July 2020... -
Page 14: Placing The Turbocharger On The Bracket
Make sure that the position of the oil inlet of the bracket matches the oil inlet hole in the bearing casing. Make sure that the O-rings are placed correctly in the slots. © Copyright 2020 ABB. All rights reserved. HZTL455311P0006_EN Rev.B... - Page 15 Step A. Observe the instructions for fastening the turbocharger with clamping nuts (see chapter Fastening the turbocharger with a clamping nut →14). © Copyright 2020 ABB. All rights reserved. HZTL455311P0006_EN Rev.B July 2020...
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Page 16: Fastening The Turbocharger With A Clamping Nut
4. Tighten clamping nut (03) by hand. 5. Unscrew clamping nut (03) by ¼ of a turn (90°). The distance between the thrust washer and the clamping nut is now about 1 mm. © Copyright 2020 ABB. All rights reserved. HZTL455311P0006_EN Rev.B... - Page 17 4. Work in a circle to tighten all pressure screws to 100 % of the tightening torque specified in the table. 5. Tighten pressure screws to 100 % in 5 … 7 rounds until the required residual tightening angle of < 20° is achieved. © Copyright 2020 ABB. All rights reserved. HZTL455311P0006_EN Rev.B July 2020...
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Page 18: Connecting The Turbocharger
Remove the screw plug on the connection for the compressor wheel cooling (06) and fit the cooling air line. Attaching the support Fig. 10: Attaching the support If present: Attach support (61301) to engine support or to a connecting piece. © Copyright 2020 ABB. All rights reserved. HZTL455311P0006_EN Rev.B July 2020... -
Page 19: Storage Of New Turbochargers And Spare Parts
Dispose of the old VCI corrosion protection emitter in an environmentally compatible manner, professionally and in accordance with local regulations. Seal the package. The better the external seal is designed, the more permanent the pro- tection. © Copyright 2020 ABB. All rights reserved. HZTL455311P0006_EN Rev.B July 2020... - Page 20 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: ¡...
- Page 21 Assembly Instructions / A150-M, A155-M 5 Storage of new turbochargers and spare parts / © Copyright 2020 ABB. All rights reserved. HZTL455311P0006_EN Rev.B July 2020...
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Page 22: Further Information
Operation Manual The Operation Manual for the turbocharger with the relevant serial number is available online on our website www.abb.com/turbocharging. Fig. 13: 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. - Page 23 Assembly Instructions / A150-M, A155-M 6 Further information / Fig. 14: Finding the Operation Manual online © Copyright 2020 ABB. All rights reserved. HZTL455311P0006_EN Rev.B July 2020...
- Page 24 Phone: +41 58 585 7777 Station”). Fax: +41 58 585 5144 Find and download the Operation Manual of E-mail: turbocharging@ch.abb.com your product on our website (see “Operation Manuals“). www.abb.com/turbocharging © Copyright 2020 ABB. All rights reserved. Visit our website by scanning the QR code.