Accelleron A100-H Series, Assembly Instructions Manual

Page 1: ...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 Turbocharger A100...

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Page 3: ...atory 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 Weight and transportation of the turbocharger 9 4 Installing the turbochar...

Page 4: ...e 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...

Page 5: ...industries 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 wor...

Page 6: ...tion Table 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 po...

Page 7: ...or its accessories 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 t...

Page 8: ...mit u Pay 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...

Page 9: ...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...

Page 10: ...struction 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 WARNIN...

Page 11: ...fficient load limit must be used for removing installing and transporting the tur bocharger The weight specified below applies to the heaviest variant possible Depending on the specification the weigh...

Page 12: ...cket 01 The necessary sealing is provided by O rings The O rings are not included in the Accelleron scope of delivery Fig 4 Inserting gaskets into the bracket 01 Bracket 04 Slot for O ring 02 Oil supp...

Page 13: ...ket with the aid of locknuts 01 3 Remove nuts 01 again Requirements for the threaded rods Fig 6 Requirements for threaded rods Product Diameter Threaded rod mm Material DIN ISO 898 Part 1 Thread lengt...

Page 14: ...ear to the suspension eye of the bearing casing 42001 and loop around the gas outlet casing 4 Position the turbocharger on the bracket 04 and align it If present pay attention to the posi tioning pin...

Page 15: ...ten them according to variant 1 or 2 in the table below Product Through hole in bearing casing mm Fixing screws mm Variant 1 Tightening torques Nm Variant 2 Hydraulic pre tensioning forces kN A130 17...

Page 16: ...lean pressure screws u Do not lubricate pressure screws In order to correctly fit the clamping nuts the pressure screws 04 must not protrude from the clamping nuts 03 in the direction of the thrust wa...

Page 17: ...35 Table 7 Torque controlled tightening of the pressure screws 1 Screw in pressure screws crosswise by hand until reaching the stop 2 Tighten pressure screws crosswise to 50 of the tightening torque s...

Page 18: ...with compressor wheel cooling CAUTION Failure of compressor wheel cooling Any prolonged failure of the compressor wheel cooling will shorten the replacement interval of the compressor wheel u Make su...

Page 19: ...Health protection when handling VCI VCI products are not hazardous in terms of the Ordinance on Hazardous Sub stances Nevertheless the following points must be observed when handling VCI u Observe th...

Page 20: ...case the turbocharger must be in spected by an Accelleron service station and repacked u Inspect the package for damage If the package is damaged the turbocharger must be inspected by an Accelleron se...

Page 21: ...Assembly Instructions Turbocharger A100 H 5 Storage of new turbochargers and spare parts Copyright 2023 Turbo Systems Switzerland Ltd All rights reserved HZTL455311P0004_EN Rev D March 2023 Page 19 21...

Page 22: ...Assembly Instructions Turbocharger A100 H 5 Storage of new turbochargers and spare parts Copyright 2023 Turbo Systems Switzerland Ltd All rights reserved HZTL455311P0004_EN Rev D March 2023 Page 20 21...

Page 23: ...at relates to the turbocharger with the identical serial number 02 can be accessed via the website https loreka accelleron indus tries com library The Operation Manual that is valid at the time of del...

Page 24: ...eron Industries Ltd Bruggerstrasse 71a 5400 Baden Switzerland 41 58 585 7777 accelleron industries com Visit our website by scanning the QR code Copyright 2023 Turbo Systems Switzerland Ltd All rights...