Original assembly instructions – English Turbocharger ...

Turbocharger / A100-M radialOriginal assembly instructions – English

This document is valid for the TPL-C series:

TPL67-C, TPL67VC, TPL71-C

PurposeThe assembly instructions explain how the ABB turbocharger is fitted to the engine correctly and without any health and safety risks.

Target groupThe assembly instructions are intended for engineers and mechanics responsible for fitting the turbocharger on the engine.

TPL-C turbochargerThe reliable peak performer

—ASSEMBLY INSTRUCTIONS

Turbocharger / TPL-C, TPLVCOriginal assembly instructions – English

Assembly Instructions / TPL67-C ... TPL71-C, TPL67VCTable of contents

© Copyright 2020 ABB. All rights reserved. HZTL455311P0014_EN Rev.A July 2020

Assembly Instructions1 Introduction............................................................................................................ 21.1 Purpose of the assembly instructions....................................................................... 21.2 Definition of target group ........................................................................................... 21.3 Symbols and definitions............................................................................................... 21.4 Definition of warning, caution, note.......................................................................... 31.5 Definition of mandatory signs ................................................................................... 41.6 Definition of pictograms............................................................................................. 4

2 Safety ...................................................................................................................... 52.1 Introduction .................................................................................................................... 52.2 Lifting loads ................................................................................................................... 62.3 Occupational safety ...................................................................................................... 7

3 Weight and transportation of the turbocharger ............................................... 9

4 Installing the turbocharger................................................................................. 104.1 Completion work, if required .................................................................................... 17

5 Storage of new turbochargers and spare parts .............................................. 18

6 Further information............................................................................................. 20

Assembly Instructions / TPL67-C ... TPL71-C, TPL67VC1 Introduction / 1.1 Purpose of the assembly instructions


1 Introduction

1.1 Purpose of the assembly instructionsThe assembly instructions explain how the ABB turbocharger is fitted to the engine correctlyand without any health and safety risks. This element of the documentation is supplied withthe product, as is required for partly completed machinery in accordance with machinery dir-ective 2006/42EC.

The assembly instructions are a complement to and expansion of existing national regula-tions for occupational safety, accident prevention and environmental protection.

1.2 Definition of target groupThe assembly instructions are intended for engineers and mechanics responsible for fittingthe turbocharger on the engine. Basic mechanical training is a prerequisite.

All persons who are involved in the transportation and installation of the turbocharger haveread and understood the assembly instructions.

1.3 Symbols and definitionsThe following symbols are used in the documents:

w Prerequisite

u Work step

¡ Enumeration, first level

- Enumeration, second level

→ Refers to a page number

The trademarks of outside companies are used in this document. These are marked with the® symbol.

Design variants

This document is valid for different design variants of turbochargers. There may be sectionsand descriptions of components that are not relevant for a specific turbocharger variant.

ABB Turbocharging Service Stations will be happy to provide information on questions re-garding a design variant (see Contact information at www.abb.com/turbocharging).

Accuracy of illustrations

The illustrations in this document are general in nature and intended for ease of understand-ing. Differences in detail are therefore possible.

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http://www.abb.com/turbocharging

Assembly Instructions / TPL67-C ... TPL71-C, TPL67VC1 Introduction / 1.4 Definition of warning, caution, note


ABB Turbocharging

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 alsochapter Contact address and after-sales service.

1.4 Definition of warning, caution, note

WARNINGDefinition of warningSerious personal injuries and even accidents with fatal consequences mayoccur if work and operating instructions marked with this symbol and theword WARNING are either not followed or not followed precisely.

u Warning signs must be observed at all times.

CAUTIONDefinition of cautionSerious machine or property damage may occur if work and operating in-structions marked with this symbol and the word CAUTION are either notfollowed or not followed precisely.

u Caution signs must be observed at all times.

NOTICENoteA note provides suggestions which facilitate the work on the product.

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Assembly Instructions / TPL67-C ... TPL71-C, TPL67VC1 Introduction / 1.5 Definition of mandatory signs


1.5 Definition of mandatory signs

To be worn at all timesProtective clothing Safety footwear to protect

against mechanical hazardand risk of falling

Table 1

To be worn according to the specific workSafety glasses Safety goggles

Safety gloves against- Mechanical hazard- Chemical hazard- Thermal hazard

Respiratory mask against- Dusts- Gases

Safety helmet Ear protection

Table 2

1.6 Definition of pictogramsThe following pictograms can occur in this document. These point out actions that must betaken in accordance with the meaning of the relevant pictogram.

Pictogram Meaning Pictogram MeaningTighten with specified torque Oil free, grease free and dry

Tighten over specified tighteningangle

Affix

Hand-tight, tighten without tools Measure

Oil Note

Apply screw locking paste (e.g.Loctite)

Visually inspect

Apply high-temperature grease See document

Apply other paste in accordancewith specifications

Dispose of in an environmentallycompatible, professional wayand in compliance with locallyapplicable regulations.

Table 3: Pictograms

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Assembly Instructions / TPL67-C ... TPL71-C, TPL67VC2 Safety / 2.1 Introduction


2 Safety

2.1 Introduction

State of the art

Turbochargers manufactured by ABB Turbocharging are state of the art and comply with thepertinent safety and health-protection requirements that applied when the turbochargerwas manufactured. Consequently, the turbocharger is safe to operate.

CE conformity information

ABB turbochargers fulfil machinery directive 2006/42/EC and are considered partly com-pleted machinery as defined by Article 2 g.

Residual risks

Nevertheless, during turbocharger operation and when working on the turbocharger, resid-ual risks can exist which:

¡ Are caused by the turbocharger itself or its accessories.

¡ Are caused by the operating and auxiliary materials used.

¡ Are a consequence of insufficient compliance with safety instructions.

All instructions contained in this chapter must be observed during all work on the turbochar-ger.

Responsibility of the operating company

In awareness of its responsibility, the operating company must ensure that only authorisedpersonnel work on the turbocharger, who:

¡ Correspond to the target group (see Definition of target group →2).

¡ Are versed in the general and locally applicable regulations for occupational safety andaccident prevention

¡ Are equipped with the prescribed personal protective equipment

¡ Have been instructed in the use of the turbocharger.

The safety-conscious work of the personnel and adherence to the assembly instructionsmust be checked periodically.

Suitable working materials and personal protective equipment must be kept in a perfectcondition.

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Assembly Instructions / TPL67-C ... TPL71-C, TPL67VC2 Safety / 2.2 Lifting loads


2.2 Lifting loads

WARNINGSuspended loadsLoads not suspended in compliance with regulations may lead to personalinjury or accidents with fatal consequences.

u Loads must always be fastened to technically perfect lifting gear withsufficient loading capacity.

u Make sure the load is suspended properly on the crane hook.

u Do not let anyone stand beneath a suspended load.

Wear safety gloves to protect against mechanical hazards.

Wear safety helmet.

If there are two or more suspension points, the attachment angle of 45° must not be ex-ceeded. This prevents excessive loading due to diagonal pull.

u Use a suitable edge guard if there are sharp edges.

u The assembly devices must be completely screwed in and must not unscrew during use.

u Use assembly devices only for the described applications.

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Assembly Instructions / TPL67-C ... TPL71-C, TPL67VC2 Safety / 2.3 Occupational safety


2.3 Occupational safety

General

WARNINGInjuries to personsSevere injuries to personnel or fatal accidents can be caused by mechanicalinfluences as a consequence of hazardous and inadequate operational pro-cedures or non-compliance with safety and health standards.

u When working on the turbocharger always wear safety footwear and pro-tective clothing to protect against mechanical hazards.

u Keep personal protective equipment in perfect condition.

u Obey mandatory signs.

u Observe the general rules for occupational safety and prevention of acci-dents.

u Only perform operations that are described in this chapter.

u Only perform operations for which you have received instruction or train-ing.

Wear safety footwear to protect against mechanical hazard and risk of fall-ing.

Wear protective clothing.

WARNINGRisk of fallingWhen working on the turbocharger, there is a risk of falling.

u Do not climb onto the turbocharger or onto attached parts and do notuse them as climbing aids.

u Use suitable climbing aids and working platforms for work above bodyheight.

u Only perform work on the turbocharger when you are in a physically and psychologicallystable condition.

u Only work with suitable tools, equipment and appliances that function properly.

u Keep the workplace clean; clear away any loose objects and obstacles on the floor.

u Keep the floor, equipment, and turbocharger clean.

u Have oil binding agents ready and provide or keep oil pans at hand.

Welding work close to the turbocharger

u If welding work is being carried out in the vicinity of the turbocharger, cover the filter si-lencer so that the filter mat is not damaged.

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Assembly Instructions / TPL67-C ... TPL71-C, TPL67VC2 Safety / 2.3 Occupational safety


u Remove combustible objects and substances out of the range of flying sparks.

u Cover all connections on the turbocharger so that no foreign objects can get into the tur-bocharger.

u Wear personal protective equipment (PPE) for welding operations.

Mechanical hazards when working on the turbocharger

WARNINGMechanical hazardSevere injuries to personnel or fatal accidents can be caused by mechanicalinfluences as a consequence of hazardous and inadequate operational pro-cedures.

u Observe the general rules for occupational safety and prevention of acci-dents.

u Ensure workplace safety.

u Only perform operations that are described in this chapter.

u 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 andsolvents, acids or similar substances.

WARNINGHandling operating materials and suppliesSwallowing or inhaling vapours of operating materials and supplies or con-tact with them may be harmful to health. Flammable and combustible oper-ating materials and supplies can catch fire or resulting vapours can lead toan explosion.

u Do not breathe in these substances and avoid contact with the skin.

u Ensure proper ventilation.

u Observe the information in the material safety data sheet for the operat-ing materials and supplies.

u Comply with local legislation.

Wear safety goggles.

Wear safety gloves to protect against chemical hazards.

Wear a respiratory mask to protect against gases.

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Assembly Instructions / TPL67-C ... TPL71-C, TPL67VC3 Weight and transportation of the turbocharger /


3 Weight and transportation of theturbocharger

Lifting gear with a sufficient load limit must be used for installing the turbocharger. The fol-lowing weight specification applies to the heaviest variant possible. Depending on the spe-cification, the weight specified on the rating plate may be lower than the standard valuespecified here.

u Remove insulation jacket and insulation at gas inlet casing.

Weights [kg]

TPL67-C TPL71-C1330 2040

Table 4

Weights [kg]

TPL67VC321330

Table 5

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Assembly Instructions / TPL67-C ... TPL71-C, TPL67VC4 Installing the turbocharger /


4 Installing the turbochargerThe TPL-C turbocharger has a two-part foot, consisting of a foot at the turbine end (TE) anda foot at the compressor end (CE). The foot at the compressor end (CE) is rigidly attached tothe engine support, whereas the foot at the turbine end (TE) is a sliding foot that is pressedonto the engine support to compensate for thermal expansion during operation.

u Lift the turbocharger as described in the chapter Weight and Transport, place onto thebracket and align.

u Secure the turbocharger as described in steps 1-10.

TE Foot on turbine endCE Foot on compressor endA Foot contact surfaceM Centre axisTable 6

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Step 1

u Determine the screw strength and screw lengths for the assembly using the table below.

NOTICEThe screw-in length of the thread (c) must be at least 1.5 times the nominalthread diameter.

Productstrength class

TPL67-C 10.9

TPL67VC3210.9

TPL71-C10.9

Foot M24 M24 M24CE a 75/62 75/62 75

c 36 36 36TE a 92 92 95

c 36 36 36Number of cup springs (X) 5 5 6Table 7

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Step 2:

u Insert the CE foot screws with one washer (01) each. Take into account the thickness ofthe washers.

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Step 3:

u Tighten the CE foot screws (3, 4, 5, 6) with the pre-tightening torque.

Table: Pre-tightening torque sequence

Gas outlet branch position TPL67-C / TPL67VC32 / TPL71-CNB000 (045 / 315) 3, 4, 5, 6NB090 3, 6, 5NB270 4, 5, 6Table 8

Table: Pre-tightening torque

Product Thread size [mm] Pre-tightening torque [Nm]TPL67-C M 24 160TPL67VC32 M 24 160TPL71-C M 24 160Table 9

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Step 4:

CAUTIONBush geometryChanging the geometry of the bushes can cause serious damage to the en-gine or property.

u Always leave bush (B) in its original condition.

u Insert bushes (B) into TE foot. Make sure marking Top on bush face is upwards.

Step 5:

u In order to determine the position of the bushes, insert the TE foot screws into thebushes without the cup springs and screw them in by two turns.

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Step 6:

u Check position and clearance (W) of bushes (B).

Table: Minimum bush clearance

Dimension [mm] TPL67-C TPL67VC32 TPL71-CWmin 3.0 3.0 3.5

Table 10

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Step 7:

u Remove TE foot screws.

u Grease the contact surface (F) for the cup springs (X) on the foot at the turbine end withhigh-temperature grease (do not grease bush surfaces).

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8th operation:

u Insert number of cup springs (X) into foot at turbine end. (See table for 1st operation.)

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Step 9:

u Insert the TE foot screws (1, 2, 7, 8) and tighten them with the pre-tightening torque.

Table: Pre-tightening torque sequence

Gas outlet branch position TPL67-C / TPL67VC32 / TPL71-CNB000 (045 / 315) 1, 2, 7, 8NB090 1, 8, 7NB270 2, 7, 8Table 11

Table: Pre-tightening torque

Product Thread size [mm] Pre-tightening torque [Nm]TPL67-C M 24 160TPL67VC32 M 24 160TPL71-C M 24 160Table 12

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Step 10:

u Now tighten all TE and CE foot screws with the tightening torque in sequence (1, 2, 3, 4, 5,6, 7, 8).

Table: Tightening torque sequence

Gas outlet branch position TPL67-C / TPL67VC32 / TPL71-CNB000 (045 / 315) 1, 2, 3, 4, 5, 6, 7, 8NB090 1, 6, 3, 5, 8, 7NB270 2, 5, 4, 6, 7, 8Table 13

Table: Tightening torque

Product Thread size [mm] Tightening torque [Nm]TPL67-C M 24 800TPL67VC32 M 24 800TPL71-C M 24 800Table 14

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Assembly Instructions / TPL67-C ... TPL71-C, TPL67VC4 Installing the turbocharger / 4.1 Completion work, if required


Additional function TPL..V.

These turbocharger types have adjustable guide vanes at the turbine end instead of a nozzlering.

u The VTG drive must be connected to the operating lever in accordance with the engineb-uilder's instructions.

4.1 Completion work, if requiredu Attach all gas, air, water and oil pipes in accordance with the enginebuilder's instructions.

u Fit insulation components.

u Fit speed sensor and plug in cable connector.

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Assembly Instructions / TPL67-C ... TPL71-C, TPL67VC5 Storage of new turbochargers and spare parts /


5 Storage of new turbochargers andspare parts

Storage of new turbochargers and spare parts up to 6 months

New turbochargers and spare parts from ABB Turbocharging can be stored in sealed pack-aging without additional mothballing measures for up to 6 months from the date of delivery(marked by the VCI label on the package).

Volatile Corrosion Inhibitor (VCI)

Only dry rooms in which the relative humidity is between 40…70 % and no condensation canform are suitable for storage.

Storage of new turbochargers and spare parts for more than 6 months (VCI)

WARNINGProtection of health when handling VCIsVCI products are not hazardous in the sense of the Hazardous SubstancesOrdinance. Nevertheless, the following points are to be observed whenhandling VCIs:

u Ensure good room ventilation.

u Do not eat, drink or keep food at the workplace while working with VCIs.

u Wear safety gloves.

u Clean hands and face after working with VCIs.

u For further information refer to www.branopac.com.

Wear safety gloves to protect against chemical hazards.

The following mothballing measures are required every 6 months:

u Open the package.

u Remove the VCI corrosion protection emitter from the package and replace it with a new,identical VCI corrosion protection emitter. New VCI corrosion protection emitters can beobtained at www.branopac.com.

u Dispose of the old VCI corrosion protection emitter in an environmentally compatiblemanner, professionally and in accordance with local regulations.

u Seal the package. The better the external seal is designed, the more permanent the pro-tection.

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http://www.branopac.com

http://www.branopac.com

Assembly Instructions / TPL67-C ... TPL71-C, TPL67VC5 Storage of new turbochargers and spare parts /


Long-term storage of turbochargers

The turbochargers will be prepared for prolonged storage by ABB Turbocharging on request.The package is equipped with a hygrometer (see illustration).

The following measures are required every 6 months:

u Check the hygrometer (02) in the sight-glass. There is an opening (01) in the woodencrate which allows this check to be carried out. When the display field has changed colourat the 70% level, the maximum permissible humidity has been exceeded. In this case, theturbocharger must be inspected by an ABB Turbocharging Service Station and repacked.

u 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 TurbochargingService Station:

¡ Inspect the component

¡ Replace the desiccant agent

¡ Repackage the component.

NOTICETurbocharger ready for operationIf the 70% field of the hygrometer (02) has not changed colour and the pack-age is undamaged, the turbocharger can be put into operation without anyprior inspection by an ABB Turbocharging Service Station.

Unpacking the turbochargers

The corrosion protection effect ends after the material is unpacked from the VCI package.

To avoid the formation of condensation, the surroundings and the content of the packagemust have the same temperature during unpacking.

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Assembly Instructions / TPL67-C ... TPL71-C, TPL67VC6 Further information /


6 Further informationThe Operation Manual must be observed with regard to commissioning, operation, mainten-ance and ordering spare parts.

Operation Manual

The Operation Manual for the turbocharger with the relevant serial number is available on-line on our website www.abb.com/turbocharging.

A rating plate is attached to the turbocharger foot, one on the left and one on the right. Onturbochargers with insulation from ABB, at least one additional rating plate is attached tothe insulation of the gas outlet casing.

1. Read the serial number (02) on the rating plate (01) of the turbocharger.

u The Operation Manual can be found online in accordance with the details on the followingpage.

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Assembly Instructions / TPL67-C ... TPL71-C, TPL67VC6 Further information /


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Further information

Find your nearest Service Station on our website (see “Find your nearest Service Station”).

Find and download the Operation Manual of your product on our website (see “Operation Manuals“).

© Copyright 2020 ABB. All rights reserved.

Operation Manual / Contact information

ABB Switzerland Ltd, Turbocharging Bruggerstrasse 71 aCH-5401 Baden/ SwitzerlandPhone: +41 58 585 7777Fax: +41 58 585 5144E-mail: [email protected]

www.abb.com/turbocharging

Visit our website by scanning the QR code.

HZT

L455

311P

0014

Original assembly instructions – English Turbocharger ...

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