ABB RR 1 Series, Original Assembly Instructions

Page 1: ...ocharger 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 RR turbocharger Reliability in traction ASSEMBLY INSTRUCTIONS Turbocharger RR 1 RR 3 Original assembly instructions English ...

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Page 3: ...d 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 Fastening RR turbocharger to exhaust gas pipes 10 4 2 Fastening RR turbocharger to bracket 11 5 Storage of new tu...

Page 4: ...rger 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 of outs...

Page 5: ...finition 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 if work...

Page 6: ...ety 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 Measure Oil...

Page 7: ...r 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 work on ...

Page 8: ...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 there ar...

Page 9: ...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 above ...

Page 10: ...ns 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 materi...

Page 11: ...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 Fig 1 Transport of RR turbocharger Product Weight kg Complete turbocharger without cool ing water with filter silencer Weight kg Complete turbocharger without cool ing water with air suction branch RR153 63...

Page 12: ...screws the strength of which is sufficient to withstand the temperat ures that can occur Rp02 590 N mm2 for example Nimonic 90 Apply heat resistant grease to the threads Fig 2 Fastening the RR turbocharger to the exhaust gas pipe Product Fastening to gas inlet flange 01 Fastening to gas outlet flange 02 RR131 RR151 RR153 4 x M16 MA 160 Nm 35 Nm 8 x M10 MA 37 5 Nm 8 5 Nm RR181 Not admissible 12 x M...

Page 13: ...If present for RR151 and RR131 in the case of high vibration the support 02 must be fastened additionally using screws 03 Fig 3 Fastening the RR 1 turbocharger to a bracket Product Fastening to bracket 01 RR151 with bearing casing NA2 2x M16 MA 230 Nm 50 Nm RR151 with bearing casing NA4 2x M20 MA 455 Nm 105 Nm RR181 2x M20 MA 455 Nm 105 Nm RR221 2x M24 MA 780 Nm 180 Nm Table 6 Fastening the RR 1 t...

Page 14: ...re 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 agains...

Page 15: ...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 Turbocharger ready...

Page 16: ...Assembly Instructions RR 1 RR153 5 Storage of new turbochargers and spare parts Copyright 2020 ABB All rights reserved HZTL455311P0022_EN Rev B July 2020 Page 14 17 ...

Page 17: ...Assembly Instructions RR 1 RR153 5 Storage of new turbochargers and spare parts Copyright 2020 ABB All rights reserved HZTL455311P0022_EN Rev B July 2020 Page 15 17 ...

Page 18: ...peration Manual The Operation Manual for the turbocharger with the relevant serial number is available on line on our website www abb com turbocharging Fig 4 Rating plate on turbocharger 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 can be found on...

Page 19: ...Assembly Instructions RR 1 RR153 6 Further information Copyright 2020 ABB All rights reserved HZTL455311P0022_EN Rev B July 2020 Page 17 17 ...

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 HZTL455311P0022 ...