ABB TPR FV Series, Assembly Instructions Manual

Page 1: ...he 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 TPR FV turbocharger The most power and efficiency for the long haul ASSEMBLY INSTRUCTIONS Turbocharger TPR FV Original assembly instructions English ...

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Page 3: ...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 11 4 1 Installing the VTG control system 12 4 2 Completion work if required 13 5 Storage of new turbocha...

Page 4: ...nstructions are intended for engineers and mechanics responsible for fitting the turbocharger 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 Enumer...

Page 5: ...re inspected and certified regularly by ABB Turbo Systems See also chapter Contact address and after sales service 1 4 Definition 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 Warni...

Page 6: ...Dusts Gases Safety helmet Ear protection Table 2 Personal protective equipment to be worn specific to the respective task 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 Ti...

Page 7: ...essories 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 ...

Page 8: ...ith 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 ther...

Page 9: ...st mechanical hazard and risk of 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 climbing aids u Use suitable climbing aids and working platforms for work above body height u Only perform work on the turbocharger when you are in a physically and ps...

Page 10: ...eviously 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 materials and supplies or con tact with them may be harmful to health Flammable and combust...

Page 11: ...arger Lifting gear with a sufficient load limit must be used for installing the turbocharger The fol 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 Weights of the complete turbocharger Product Weight kg TPR56FV 400 TPR61FV 750 Table 4 Weight complete Pa...

Page 12: ...Assembly Instructions TPR56FV TPR61FV 3 Weight and transportation of the turbocharger Copyright 2018 ABB All rights reserved HZTL455311P0033_EN Revision B May 2018 Page 10 17 ...

Page 13: ...is an orifice in each of the two oil inlet channels of the bearing casing The diameter of this orifice is individually adapted by the enginebuilder for the purpose of adjusting the oil pressure u Align turbocharger on bracket Tightening the foot fixing screws Fig 2 Tightening foot fixing screws Position TPR56FV TPR61FV B 135 Nm 205 Nm Table 5 Tightening torque for foot fixing screw B u Lightly oil...

Page 14: ...em The control system is installed in a terminal box u It is essential to follow the additional specifications and instructions of the enginebuilder Fig 3 Installation of the VTG control system u Secure the control system using the relevant screws in the terminal box u Connect plug XC2 to the control system and secure with the screw u Secure any other connection and grounding cables as per the spe...

Page 15: ...he control system B2 is disconnected from the power supply before disassembly Wear safety gloves to protect against mechanical hazards w If the plugs are not inserted correctly or interchanged the operation of the VTG mechan ics is not possible u Connect plug XA3 or XA4 to the actuator u Connect plug XA1 or XA2 to the actuator u Fit the cooling water connections CW according to instructions of eng...

Page 16: ...in terms of the Ordinance on Hazardous Substances 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 eat drink or store food at the workplace while working with VCI u Clean hands and face after working with VCI u For more information see www branopac com Wear safety gloves to protect ag...

Page 17: ...ved HZTL455311P0033_EN Revision B May 2018 Unpackaging replacement turbochargers or spare parts Once the material has been unpackaged from the VCI package the corrosion protection is no longer effective To prevent condensation the temperature of the package contents must be the same as the ambient temperature Page 15 17 ...

Page 18: ...ts Operation Manual The Operation Manual for the turbocharger with the relevant serial number is available on line on our website www abb com turbocharging One rating plate 01 each is attached on the left and the right side of the turbocharger bear ing casing Fig 6 Location of the rating plates 1 Read the serial number 02 on the rating plate 01 of the turbocharger u The Operation Manual can be fou...

Page 19: ...Assembly Instructions TPR56FV TPR61FV 6 Further information Copyright 2018 ABB All rights reserved HZTL455311P0033_EN Revision B May 2018 Page 17 17 ...

Page 20: ...he Operation Manual of your product on our website see Need product information Operating instructions Copyright 2017 ABB All rights reserved ABB Turbo Systems Ltd 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 HZTL455311P0033 ...