ABB axial A100-M Series Original Assembly Instructions

ABB axial A100-M Series Original Assembly Instructions

Turbocharger
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ASSEMBLY INSTRUCTIONS
Turbocharger / A100-M axial
Original assembly instructions – English
This document is valid for the
A100-M series:
A170-M, A175-M
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.
A100-M turbocharger
More power, more options

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Table of Contents
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Summary of Contents for ABB axial A100-M Series

  • Page 1 This document is valid for the A100-M series: A170-M, A175-M Purpose A100-M turbocharger The assembly instructions explain how the ABB More power, more options turbocharger is fitted to the engine correctly and without any health and safety risks. Target group...
  • Page 3: Table Of Contents

    Weight and transportation of the turbocharger ..........9 Installing the turbocharger................. 10 Tightening the clamping nut ..................14 Storage of new turbochargers and spare parts ..........16 Further information..................... 20 © Copyright 2020 ABB. All rights reserved. HZTL455311P0007_EN Rev.A July 2020...
  • 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

    ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging in this document. Official service stations of ABB Turbocharging Official service stations are regularly audited and certified by ABB Turbocharging. See "Con- tact Information" on our website at www.abb.com/turbocharging. Definition of warning, caution, note...
  • Page 6: Definition Of Mandatory Signs

    Apply other paste in accord- Dispose of in an environmentally ance with specifications compatible, professional way and in compliance with locally Oil free, grease free and dry applicable regulations. Table 3: Definition of pictograms © Copyright 2020 ABB. All rights reserved. HZTL455311P0007_EN Rev.A July 2020...
  • Page 7: Safety

    Introduction State of the art Turbochargers manufactured by ABB Turbocharging 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 2020 ABB. All rights reserved. HZTL455311P0007_EN Rev.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 2020 ABB. All rights reserved. HZTL455311P0007_EN Rev.A...
  • Page 10 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 2020 ABB. All rights reserved. HZTL455311P0007_EN Rev.A July 2020...
  • Page 11: Weight And Transportation Of The Turbocharger

    Fig. 3: Turbocharger suspension points Weight of the entire turbocharger Product Weight [kg] A170-M 3100 A175-M 4600 Table 4: Weight of the turbocharger © Copyright 2020 ABB. All rights reserved. HZTL455311P0007_EN Rev.A July 2020...
  • Page 12: Installing The Turbocharger

    If present: Remove insulation segment on the bearing casing. Attach lifting gear to the suspension lug of the bearing casing and the turbine-end foot. Remove the covers from the oil connections. Align turbocharger and place on bracket. © Copyright 2020 ABB. All rights reserved. HZTL455311P0007_EN Rev.A July 2020...
  • Page 13 Tighten clamping nuts as described in the following sections. Connect all gas, air and oil pipes. If present: Re-fit the insulation segments. If present: Connect cable to speed sensor. Compressor-end (CE) foot Fig. 6: Compressor-end foot © Copyright 2020 ABB. All rights reserved. HZTL455311P0007_EN Rev.A July 2020...
  • Page 14 Table 8: Foot screws, number of cup springs Holes b1/b2 are needed to achieve the required clamping length. An additional drill hole is not needed at the higher turbine-end foot side (01). © Copyright 2020 ABB. All rights reserved. HZTL455311P0007_EN Rev.A...
  • Page 15 (see Table 5: Foot screws, dimen- sion and strength class →12) on the foot of the turbine end (TE) with high-temperature grease. Tighten clamping nuts on turbine end (TE) (see Tightening the clamping nut). © Copyright 2020 ABB. All rights reserved. HZTL455311P0007_EN Rev.A July 2020...
  • Page 16: Tightening The Clamping Nut

    3. Tighten clamping nut (c) by hand. 4. Screw back clamping nut by ¼ of a turn (90°). The distance between the thrust washer and the clamping nut is now about 1 mm. © Copyright 2020 ABB. All rights reserved. HZTL455311P0007_EN Rev.A...
  • Page 17 4. Work in a circle to tighten all pressure screws to 100 % of the tightening torque specified in the table. 5. Tighten pressure screws to 100 % in 5 … 7 rounds until the required residual tightening angle of < 20° is achieved. © Copyright 2020 ABB. All rights reserved. HZTL455311P0007_EN Rev.A July 2020...
  • Page 18: 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 2020 ABB. All rights reserved. HZTL455311P0007_EN Rev.A July 2020...
  • Page 19 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: ¡...
  • Page 20 Assembly Instructions / A170-M, A175-M 5 Storage of new turbochargers and spare parts / ​ © Copyright 2020 ABB. All rights reserved. HZTL455311P0007_EN Rev.A July 2020...
  • Page 21 Assembly Instructions / A170-M, A175-M 5 Storage of new turbochargers and spare parts / ​ © Copyright 2020 ABB. All rights reserved. HZTL455311P0007_EN Rev.A July 2020...
  • Page 22: 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. Fig. 14: Serial number of the turbocharger on the rating plate One rating plate each is attached on the left and the right side of the foot of the turbochar- ger.
  • Page 23 Assembly Instructions / A170-M, A175-M 6 Further information / ​ Fig. 15: Finding the Operation Manual online © Copyright 2020 ABB. All rights reserved. HZTL455311P0007_EN Rev.A July 2020...
  • Page 24 Phone: +41 58 585 7777 Station”). Fax: +41 58 585 5144 Find and download the Operation Manual of E-mail: turbocharging@ch.abb.com your product on our website (see “Operation Manuals“). www.abb.com/turbocharging © Copyright 2020 ABB. All rights reserved. Visit our website by scanning the QR code.

This manual is also suitable for:

Axial a170-mAxial a175-m

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