ABB TPL-C Series, Original Assembly Instructions

Page 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 TPL C turbocharger The reliable peak performer ASSEMBLY INSTRUCTIONS Turbocharger TPL C Original assembly instructions English ...

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Page 3: ... target group 2 1 3 Symbols and 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 Completion work if required 16 5 Storage of new turbochargers and spare parts 17 6 ...

Page 4: ...ger 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 outsi...

Page 5: ...nition 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 a...

Page 6: ...ty 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: ... 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 t...

Page 8: ...fficient 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 are ...

Page 9: ...ich 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 bo...

Page 10: ...s 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 materia...

Page 11: ...e prepared for installing the turbocharger The weight specified be low applies to the heaviest variant possible Depending on the specification the weight spe cified on the rating plate may be lower than the standard value specified here u Prepare the suspension unit in accordance with the values specified below TPL79 C dimension for suspending Distance mm A 1090 B 1500 C 960 Table 4 Weight kg TPL7...

Page 12: ...he foot at the compressor end CE is rigidly attached to the engine support whereas the foot at the turbine end TE is a sliding foot that is pressed onto the engine support to compensate for thermal expansion during operation u Lift the turbocharger as described in the chapter Weight and Transport place onto the bracket and align u Secure the turbocharger as described in steps 1 10 TE Foot on turbi...

Page 13: ...d screw lengths for the assembly using the table below NOTICE The screw in length of the thread c must be at least 1 5 times the nominal thread diameter Product Strength class TPL79 C 12 9 Foot M36 CE a 130 c 54 TE a 156 c 54 Number of cup springs X 5 Table 7 Step 2 u Insert the CE foot screws with one washer 01 each Take into account the thickness of the washers Page 11 21 ...

Page 14: ...A July 2020 Step 3 u Tighten the CE foot screws 3 4 5 6 with the pre tightening torque Table Pre tightening torque sequence Gas outlet branch position TPL79 C NB000 045 315 3 4 5 6 NB090 3 6 5 NB270 4 5 6 Table 8 Table Pre tightening torque Product Thread size mm Pre tightening torque Nm TPL79 C M 36 540 Table 9 Page 12 21 ...

Page 15: ...g the geometry of the bushes can cause serious damage to the en gine or property u Always leave bush B in its original condition u Insert bushes B into TE foot Make sure marking Top on bush face is upwards Step 5 u In order to determine the position of the bushes insert the TE foot screws into the bushes without the cup springs and screw them in by two turns Page 13 21 ...

Page 16: ...s reserved HZTL455311P0016_EN Rev A July 2020 Step 6 u Check position and clearance W of bushes B Table Minimum bush clearance Dimension mm TPL79 C Wmin 5 0 Table 10 Step 7 u Coat contact surface F at TE foot for the cup springs X with high temperature grease not surface of bush Page 14 21 ...

Page 17: ...X into foot at turbine end See table for 1st operation Step 9 u Insert the TE foot screws 1 2 7 8 and tighten them with the pre tightening torque Table Pre tightening torque sequence Gas outlet branch position TPL79 C NB000 045 315 1 2 7 8 NB090 NB270 Table 11 Table Pre tightening torque Product Thread size mm Pre tightening torque Nm TPL79 C M 36 540 Table 12 Page 15 21 ...

Page 18: ... 5 6 7 8 Table Tightening torque sequence Gas outlet branch position TPL79 C NB000 045 315 1 2 3 4 5 6 7 8 NB090 1 2 3 6 5 8 7 NB270 2 1 4 5 6 7 8 Table 13 Table Tightening torque Product Thread size mm Tightening torque Nm TPL79 C M 36 3300 Table 14 4 1 Completion work if required u Attach all gas air water and oil pipes in accordance with the enginebuilder s instructions u Fit insulation compone...

Page 19: ...e 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 against...

Page 20: ...n 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 21: ...Assembly Instructions TPL79 C 5 Storage of new turbochargers and spare parts Copyright 2020 ABB All rights reserved HZTL455311P0016_EN Rev A July 2020 Page 19 21 ...

Page 22: ...e turbocharger with the relevant serial number is available on line on our website www abb com turbocharging A rating plate is attached to the turbocharger foot one on the left and one on the right On turbochargers with insulation from ABB at least one additional rating plate is attached to the insulation of the gas outlet casing 1 Read the serial number 02 on the rating plate 01 of the turbocharg...

Page 23: ...Assembly Instructions TPL79 C 6 Further information Copyright 2020 ABB All rights reserved HZTL455311P0016_EN Rev A July 2020 Page 21 21 ...

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 HZTL455311P0016 ...