Turbocharger / A200-L
20Pages

Assembly Instructions This document is valid for the A200-L series: A265-L, A270-L, A275-L, A280-L Purpose The assembly instructions explain how the ABB turbocharger is fitted to the engine correctly and without any health and safety risks. High performance turbocharger for two-stroke diesel engines The assembly instructions are intended for engineers and mechanics responsible for fitting the turbocharger on the engine. Power and productivity for a better world™

Assembly Instructions / A200-L Table of contents © Copyright 2016 ABB. All rights reserved.

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 directive 2006/42EC. The assembly instructions are a complement to and expansion of existing national regulations for occupational safety, accident prevention and environmental protection. 1.2 Definition of target group The assembly instructions are intended for engineers and mechanics responsible for fitting...

Accuracy of illustrations The illustrations in this document are general in nature and intended for ease of understanding. Differences in detail are therefore possible. ABB Turbo Systems ABB Turbo Systems Ltd is identified as ABB Turbo Systems in this document. Official service stations of ABB Turbo Systems Official service stations are identified in this document as ABB Turbocharging Service Stations. They are regularly audited and certified by ABB Turbo Systems. See "Contact Information" on our website at www.abb.com/turbocharging. Definition of warning, caution, note Definition of...

Table 3: Definition of pictograms © Copyright 2016 ABB. All rights reserved.

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. CE conformity information ABB turbochargers comply with the Machinery Directive 2006/42/EC and are partly completed machinery as defined by Article 2 g. Residual risks Nevertheless, there may be some residual risks during operation of and work on the turbocharger which: ■ Are caused by the turbocharger itself or its accessories. ■ Are caused by the...

Lifting of loads Suspended loads Loads that are not attached according to regulations can cause injury to personnel or fatal accidents.  Loads must always be fastened to properly functional lifting gear with a sufficient load limit.  Pay attention to the correct attachment of loads on the crane hook.  People must not stand beneath suspended loads. Wear safety gloves against mechanical risks. Wear safety helmet. Figure 1: Attachment of loads on the crane hook Figure 2: Attachment angle If there are two or more suspension points, the attachment angle of 45° must not be exceeded. This...

Occupational safety Injuries to persons WARNING Severe injuries to personnel or fatal accidents can be caused by mechanical influences as a consequence of hazardous and inadequate operational procedures or non-compliance with safety and health standards.  When working on the turbocharger always wear safety footwear and protective clothing to protect against mechanical hazards.  Keep personal protective equipment in perfect condition.  Obey mandatory signs.  Observe the general rules for occupational safety and prevention of accidents.  Only perform operations that are described in this...

 Cover all connections on the turbocharger so that no foreign objects can enter the turbo- Mechanical hazards when working on the turbocharger Physical hazards due to rotating parts WARNING The rotor can rotate due to the stack draught alone. Contact with rotating parts can cause severe injury.  Secure rotor against turning. Mechanical hazards WARNING Severe injuries to personnel or fatal accidents can be caused by mechanical influences as a consequence of hazardous and inadequate operational procedures.  Observe the general rules for occupational safety and prevention of accidents. ...

Assembly Instructions / A200-L 3 Weight and transportation of the turbocharger Page 9 / 17 3 Weight and transportation of the turbocharger Lifting gear with a sufficient load limit must be used for installing the turbocharger. The following weight specification applies to the heaviest variant possible. Depending on the specification, the weight specified on the rating plate may be lower than the standard value specified here. Weights of the complete turbocharger Table 4: Weights A200-L with filter silencer © Copyright 2016 ABB. All rights reserved.

Placing the turbocharger on the bracket Figure 4: Placing the turbocharger on the bracket  Remove covers from the oil connections.  Align turbocharger and place on engine bracket.  Tighten fixing screws (Steps for fastening the turbocharger [➙ 11]); while doing this, only slightly loosen the lifting gear.  Remove lifting gear from suspension eyes of the bearing casing.  Connect cable to speed sensor.  Connect all gas, air and oil pipes. © Copyright 2016 ABB. All rights reserved.

Assembly Instructions / A200-L 4 Installing the turbocharger Table 5: General information about fastening the turbocharger Property classes of screws Screws with a property class higher than 8.8 can also be used to install the turbocharger. Tightening torque and tightening angle remain identical to property class 8.8. ► Tighten the foot fixing screws or nuts diagonally according to the selected tightening method. Torque-controlled tightening (see Table 6) Angle-controlled tightening (see Table 7) © Copyright 2016 ABB. All rights reserved.

Assembly Instructions / A200-L 4 Installing the turbocharger ► Tighten the foot fixing screws or nuts according to the selected tightening method. Torque-controlled tightening Table 7: Tightening angle (foot screws) Pinning of turbocharger feet with positioning pins If the turbocharger is pinned at its feet, one pin hole per foot must be used. © Copyright 2016 ABB. All rights reserved.