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ASSEMBLY INSTRUCTIONS
Turbocharger / TPS-R
Original assembly instructions – English
This document is valid for the TPS-R
series:
TPS61-R..
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.
TPS..-R turbocharger
Powerful and compact.
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Table of Contents
Related Manuals for ABB TPS61-R Series
Summary of Contents for ABB TPS61-R Series
- Page 1 This document is valid for the TPS-R series: TPS61-R.. Purpose TPS..-R turbocharger The assembly instructions explain how the ABB Powerful and compact. 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.
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Page 3: Table Of Contents
Installing the turbocharger.................. 11 Connecting ABB gas pipes ..................11 Attaching the turbocharger to the bracket ............12 Storage of new turbochargers and spare parts ..........13 Further information..................... 16 © Copyright 2018 ABB. All rights reserved. HZTL455311P0036_EN Revision A August 2018... -
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
Official service stations of ABB Turbo Systems Official service stations are identified in this document as ABB Turbocharging Service Sta- tions. They are regularly audited and certified by ABB Turbo Systems. See "Contact Informa- tion" on our website at www.abb.com/turbocharging. -
Page 6: Definition Of Mandatory Signs
Dispose of in an environmentally ance with specifications compatible, professional way and in compliance with locally applic- Oil free, grease free and dry able regulations Table 3: Definition of pictograms © Copyright 2018 ABB. All rights reserved. HZTL455311P0036_EN Revision A August 2018... -
Page 7: Safety
Introduction State of the art Turbochargers manufactured by ABB Turbo Systems 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 2018 ABB. All rights reserved. HZTL455311P0036_EN Revision A... -
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 2018 ABB. All rights reserved. HZTL455311P0036_EN Revision A... - Page 10 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. © Copyright 2018 ABB. All rights reserved. HZTL455311P0036_EN Revision A August 2018...
- Page 11 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 2018 ABB. All rights reserved. HZTL455311P0036_EN Revision A August 2018...
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Page 12: Turbocharger Weight And Transportation
The parts are delivered separately, because they can be damaged or des- troyed during turbocharger transport if they are fitted. Never transport turbocharger with bellows fitted. Fig. 3: Turbocharger transport Product Weights [kg] TPS61-R Table 4: Weight of the turbocharger © Copyright 2018 ABB. All rights reserved. HZTL455311P0036_EN Revision A August 2018... -
Page 13: Installing The Turbocharger
Table 5: Requirements for fixing screws Connecting ABB gas pipes Fig. 5: ABB gas pipes 1. Connect the ABB gas pipes (01) to the gas pipes of the engine. Observe the instructions of the engine builder. © Copyright 2018 ABB. All rights reserved. -
Page 14: Attaching The Turbocharger To The Bracket
5. Connect the oil supply. Ensure that the connection is tight. 6. Connect cable to speed sensor (86505). 7. Remove the lifting gear. Connect all the gas pipes and air lines according to the enginebuilder's instructions. © Copyright 2018 ABB. All rights reserved. HZTL455311P0036_EN Revision A August 2018... -
Page 15: 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 2018 ABB. All rights reserved. HZTL455311P0036_EN Revision A August 2018... - Page 16 Inspect the package for damage. If the package is damaged, the turbocharger or cart- ridge group must be inspected 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 17 Assembly Instructions / TPS61-R 5 Storage of new turbochargers and spare parts / © Copyright 2018 ABB. All rights reserved. HZTL455311P0036_EN Revision A August 2018...
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Page 18: 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. 1. Read the serial number (02) on the rating plate (01) of the turbocharger. The Operation Manual can be found online in accordance with the details on the following page. -
Page 19: Copyright 2018 Abb. All Rights Reserved. Hztl455311P0036_En Revision A August
Assembly Instructions / TPS61-R 6 Further information / Fig. 9: Finding the Operation Manual online © Copyright 2018 ABB. All rights reserved. HZTL455311P0036_EN Revision A August 2018... - Page 20 +41 58 585 5144 Find and download the Operation Manual of E-mail: turbocharging@ch.abb.com your product on our website (see “Need product information” / “Operating www.abb.com/turbocharging instructions“). © Copyright 2018 ABB. All rights reserved. Visit our website by scanning the QR code.