ABB TPS-H Series Assembly Instructions Manual

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ASSEMBLY INSTRUCTIONS

Turbocharger / TPS-H

Original assembly instructions – English

This document is valid for the TPS-H

series:

TPS44-H, TPS48-H, TPS52-H

Purpose

TPS-H turbocharger

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.

Table of Contents

Summary of Contents for ABB TPS-H Series

Page 1 This document is valid for the TPS-H series: TPS44-H, TPS48-H, TPS52-H Purpose TPS-H turbocharger 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.
Page 3: Table Of Contents
Fitting threaded rods....................12 Placing the turbocharger on the bracket and aligning ........14 Connecting the turbocharger..................15 Storage of new turbochargers and spare parts ..........16 Further information..................... 20 © Copyright 2020 ABB. All rights reserved. HZTL455311P0011_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. HZTL455311P0011_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. HZTL455311P0011_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. HZTL455311P0011_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. HZTL455311P0011_EN Rev.A July 2020...
Page 11: Weight And Transportation Of The Turbocharger
Fig. 3: Fitting lifting gear to turbocharger Produkt Gewicht Turbolader komplett [kg] TPS44 TPS48 TPS52 Table 4: Gesamtgewicht © Copyright 2020 ABB. All rights reserved. HZTL455311P0011_EN Rev.A July 2020...
Page 12: Swivel Lifting Eyes To Be Used
Product Thread M Length H Diameter D Minimum load limit [mm] [mm] [kg] TPS44 ≤ 12 ≤ 25 TPS48 ≤ 12 ≤ 25 TPS52 ≤ 15 ≤ 25 Table 5: Swivel lifting eyes to be used © Copyright 2020 ABB. All rights reserved. HZTL455311P0011_EN Rev.A July 2020...
Page 13: 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: Inserting O-rings into bracket...
Page 14: Fitting Threaded Rods
Fastening material, scope of delivery The threaded rods and nuts required for attaching the turbocharger to the bracket are not included in the ABB scope of delivery. These parts depend on the version of the engine-side bracket. © Copyright 2020 ABB. All rights reserved.
Page 15 1. Lightly oil the surfaces of the threaded rods (02) to be screwed in. 2. Screw the threaded rods into the bracket with the aid of locknuts (01). 3. Remove nuts (01) again. © Copyright 2020 ABB. All rights reserved. HZTL455311P0011_EN Rev.A...
Page 16: Placing The Turbocharger On The Bracket And Aligning
Remove the lifting gear. Connect all gas and air lines according to the instructions of the enginebuilder. If the gas outlet casing from ABB has not been dismantled with the turbocharger, refer to chapter Removing the gas outlet casing. Fit the water pipes according to the instructions of the enginebuilder.
Page 17: Connecting The Turbocharger
Connect all gas and air lines according to the instructions of the enginebuilder. Version with water-cooled bearing casing Fit the water pipes according to the instructions of the enginebuilder. © Copyright 2020 ABB. All rights reserved. HZTL455311P0011_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. HZTL455311P0011_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 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. 11: Serial number of turbocharger on rating plate The rating plate (01) is attached at the top on the bearing casing of the turbocharger.
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:

Tps44-h Tps48-h Tps52-h

ABB TPS-H Series Assembly Instructions Manual

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