ABB TPR48-F Series Assembly Instructions Manual

Turbocharger

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ASSEMBLY INSTRUCTIONS
Turbocharger / TPR48-F.. - TPR52-F..
Original assembly instructions – English
This document is valid for:
TPR48-F.. - TPR52-F..
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.
TPR48-F.. - TPR52-F.. turbocharger
Powerful and compact

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Summary of Contents for ABB TPR48-F Series

  • Page 1 Original assembly instructions – English This document is valid for: TPR48-F.. - TPR52-F.. Purpose TPR48-F.. - TPR52-F.. 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...
  • Page 3: Table Of Contents

    Placing the turbocharger on the bracket ..............13 Securing the turbocharger to the bracket.............. 14 Connecting the turbocharger..................15 Storage of new turbochargers and spare parts ..........17 Further information..................... 20 © Copyright 2021 ABB. All rights reserved. HZTL455311P0040_EN Rev.A August 2021...
  • 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 2021 ABB. All rights reserved. HZTL455311P0040_EN Rev.A August 2021...
  • 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 2021 ABB. All rights reserved. HZTL455311P0040_EN Rev.A...
  • Page 9: Occupational Safety

    When performing welding work in the vicinity of the turbocharger, always cover the filter silencer to prevent the filter mat from being damaged. Keep flammable objects and substances out of the vicinity of flying sparks. © Copyright 2021 ABB. All rights reserved. HZTL455311P0040_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 2021 ABB. All rights reserved. HZTL455311P0040_EN Rev.A August 2021...
  • Page 11: Turbocharger Weight And Transportation

    TPR48-F 13 mm 300 kg TPR52-F 17 mm 450 kg Table 4: Swivel lifting eyes Fig. 4: Suspension of complete turbocharger unit Product Weights [kg] TPR48-F TPR52-F Table 5: Weights of turbochargers © Copyright 2021 ABB. All rights reserved. HZTL455311P0040_EN Rev.A August 2021...
  • Page 12: Installing The Turbocharger

    Always use new gaskets and insert them carefully into the slot. The oil is supplied (02) and drained (03) through the bracket (01). The necessary sealing is provided by O-rings. The O-rings are not included in the ABB scope of delivery. Fig. 5: Insert gaskets into the bracket...
  • Page 13: Fitting The Turbocharger With Threaded Rods

    1. Lightly oil the surfaces of the threaded rods (02) to be screwed in. 2. Screw the threaded rods into the bracket using locked nuts (01). 3. Remove the nuts (01) again. © Copyright 2021 ABB. All rights reserved. HZTL455311P0040_EN Rev.A August 2021...
  • Page 14: Fitting The Turbocharger With Screws

    Fig. 8: Screw requirement Product Screw size Material Free length above DIN / ISO 898 bracket (part 1) L1 [mm] TPR48-F 10.9 / 12.9 TPR52-F 10.9 / 12.9 Table 7: Screw requirements © Copyright 2021 ABB. All rights reserved. HZTL455311P0040_EN Rev.A August 2021...
  • Page 15: Placing The Turbocharger On The Bracket

    Depending on the bracket version (04), two positioning pins (05) can be used for positioning and safeguarding against wrong fitting of the turbocharger. Therefore the turbocharger must always be removed from and installed on the bracket vertically. © Copyright 2021 ABB. All rights reserved. HZTL455311P0040_EN Rev.A...
  • Page 16: Securing The Turbocharger To The Bracket

    **) When the turbocharger is mounted on the engine support, the bolt threads and screw heads must be lightly oiled (assumed friction coefficient µ = 0.12 for tightening torque) Remove the lifting gear. © Copyright 2021 ABB. All rights reserved. HZTL455311P0040_EN Rev.A...
  • Page 17: Connecting The Turbocharger

    Make sure there is an uninterrupted supply of cooling air during opera- tion. Fig. 10: Connecting the compressor cooling air intake Remove the lock from the connection for the compressor wheel cooling (01) and fit the cooling air line. © Copyright 2021 ABB. All rights reserved. HZTL455311P0040_EN Rev.A August 2021...
  • Page 18 Assembly Instructions / TPR48-F.. - TPR52-F.. 4 Installing the turbocharger / 4.6 Connecting the turbocharger © Copyright 2021 ABB. All rights reserved. HZTL455311P0040_EN Rev.A August 2021...
  • Page 19: Storage Of New Turbochargers And Spare Parts

    Old VCI corrosion protection emitters must be disposed of in an environmentally compat- ible, professional way and in compliance with locally applicable regulations. Close package. The more tightly the package is sealed, the longer the protection dura- tion. © Copyright 2021 ABB. All rights reserved. HZTL455311P0040_EN Rev.A August 2021...
  • Page 20 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 21 Assembly Instructions / TPR48-F.. - TPR52-F.. 5 Storage of new turbochargers and spare parts / ​ © Copyright 2021 ABB. All rights reserved. HZTL455311P0040_EN Rev.A August 2021...
  • 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. 13: Serial number of the turbocharger on the rating plate One rating plate (01) each is attached on the left and the right side of the turbocharger bear- ing casing.
  • Page 23 Assembly Instructions / TPR48-F.. - TPR52-F.. 6 Further information / ​ Fig. 14: Finding the Operation Manual online © Copyright 2021 ABB. All rights reserved. HZTL455311P0040_EN Rev.A August 2021...
  • 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 2019 ABB. All rights reserved. Visit our website by scanning the QR code.

This manual is also suitable for:

Tpr52-f series

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