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Assembly Instructions
Turbocharger /
A200-H
Original assembly instructions – English
This document is valid for:
A238-H.., A240-H..
Purpose
The assembly instructions explain how
the 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 responsi-
ble for fitting the turbocharger
on the engine.
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Table of Contents
Related Manuals for Accelleron A200-H
Summary of Contents for Accelleron A200-H
- Page 1 Assembly Instructions Turbocharger / A200-H Original assembly instructions – English This document is valid for: A238-H.., A240-H.. Purpose Target group The assembly instructions explain how The assembly instructions are intended the turbocharger is fitted to the engine for engineers and mechanics responsi-...
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Page 3: Table Of Contents
Fastening the turbocharger with a clamping nut ............ 14 Fastening the turbocharger with a standard nut ............ 16 Connecting the turbocharger................17 Storage of new turbochargers and spare parts ....... 18 Further information ................ 21 © Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0042_EN Rev. B May 2022... -
Page 4: Introduction
Introduction Purpose of the assembly instructions The assembly instructions explain how the Accelleron 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 Directive 2006/42/EC. -
Page 5: Definition Of Warning, Caution, Note
Accelleron Industries Ltd is referred to in this document as Accelleron. Official Accelleron service stations Accelleron service stations are regularly audited and certified by Accelleron Industries Ltd (see "Con- tact Information" on the website www.accelleron-industries.com). Definition of warning, caution, note... -
Page 6: Definition Of Mandatory Signs
Dispose of in an environmentally 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 2022 Accelleron Industries. All rights reserved. HZTL455311P0042_EN Rev. B May 2022... -
Page 7: Safety
Introduction State of the art Turbochargers manufactured by Accelleron 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 opera- tion 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 2022 Accelleron Industries. All rights reserved. HZTL455311P0042_EN Rev. B... -
Page 9: Occupational Safety
Keep flammable objects and substances out of the vicinity of flying sparks. Cover all connections on the turbocharger so that no foreign objects can enter the turbocharger. Wear personal protective equipment (PPE) for welding operations. © Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0042_EN Rev. B... - Page 10 Observe the information in the material safety data sheet for the operating ma- terials 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 2022 Accelleron Industries. All rights reserved. HZTL455311P0042_EN Rev. B May 2022...
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Page 11: Turbocharger Weight And Transportation
Swivel lifting eyes to be used Swivel lifting eyes are required for the safe lifting of loads, which are not supplied by Accelleron. Fig. 3: Swivel lifting eye (example) Product... -
Page 12: Installing The Turbocharger
The oil is supplied (02) and drained (03) through the bracket (01). The necessary gaskets (05) must be integrated in the support plate. A suggestion for the slot shape (04) is shown below. The gaskets are not included in the Accelleron scope of delivery and must be provided by the enginebuilder. -
Page 13: Fixing Elements
Fixing elements The standard nuts (01), washers (02), threaded rods (03) and centering bushes (04) are not supplied by Accelleron. The clamping nut (42201) can be ordered as an option. This enables the required pre- tension to be achieved with a commercially available torque spanner. -
Page 14: Placing And Aligning The Turbocharger On The Bracket
Clean the surface of the bracket, the bearing casing, the centering bush and the centering holes in the bracket. Make sure that the covers of the oil connections are removed. © Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0042_EN Rev. B... - Page 15 Step 1. Comply with the steps for fastening the turbocharger: ¡ Fastening the turbocharger with a clamping nut →14 ¡ Fastening the turbocharger with a standard nut →16 © Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0042_EN Rev. B May 2022...
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Page 16: Fastening The Turbocharger With A Clamping Nut
4. Tighten clamping nut (03) by hand. 5. Unscrew clamping nut (03) by ¼ of a turn (90°). The distance between the thrust washer and the clamping nut is now about 1 mm. © Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0042_EN Rev. B... - 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 2022 Accelleron Industries. All rights reserved. HZTL455311P0042_EN Rev. B May 2022...
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Page 18: Fastening The Turbocharger With A Standard Nut
**) 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 2022 Accelleron Industries. All rights reserved. HZTL455311P0042_EN Rev. B... -
Page 19: Connecting The Turbocharger
Make sure there is an uninterrupted supply of cooling air during operation. Fig. 13: Connecting the compressor cooling air Remove the lock from the connection for the compressor wheel cooling (01) and fit the cooling air line. © Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0042_EN Rev. B May 2022... -
Page 20: Storage Of New Turbochargers And Spare Parts
Long-term storage of turbochargers The turbochargers will be prepared for long-term storage if requested in the purchase order. The package is equipped with a hygrometer (see illustration). © Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0042_EN Rev. B May 2022... - Page 21 Inspect the package for damage. If the package is damaged, the turbocharger must be inspected by a Accelleron service station and repacked. After every 3 years the following work steps must be performed by a Accelleron service station: ¡ Inspect the component ¡...
- Page 22 Assembly Instructions / A238-H.. - A240-H.. 5 Storage of new turbochargers and spare parts / © Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0042_EN Rev. B May 2022...
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Page 23: Further Information
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. © Copyright 2022 Accelleron Industries. All rights reserved. HZTL455311P0042_EN Rev. B... - Page 24 Further information Find your nearest Service Station on the website. Find and download the Operation Manual of your product on the website (see “Operation Manuals“). Visit our website by scanning the QR code. © Copyright 2022 Accelleron Industries. All rights reserved.