ABB A238-H Series User manual

Turbocharger / A100-M radial
Original assembly instructions – English
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.
A200-H turbocharger
More power, less fuel
—
ASSEMBLY INSTRUCTIONS
Turbocharger / A200-H
Original assembly instructions – English
This document is valid for:
A238-H.., A240-H..

Assembly Instructions / A200-H
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL455311P0042_EN Rev.A September 2021
Assembly Instructions / A200-H
1 Introduction............................................................................................................ 2
1.1 Purpose of the assembly instructions....................................................................... 2
1.2 Definition of target group ........................................................................................... 2
1.3 Symbols, definitions...................................................................................................... 2
1.4 Definition of warning, caution, note.......................................................................... 3
1.5 Definition of mandatory signs ................................................................................... 4
1.6 Definition of pictograms............................................................................................. 4
2 Safety ...................................................................................................................... 5
2.1 Introduction .................................................................................................................... 5
2.2 Lifting of loads .............................................................................................................. 6
2.3 Occupational safety ...................................................................................................... 7
3 Turbocharger weight and transportation .......................................................... 9
4 Installing the turbocharger................................................................................. 10
4.1 Inserting gaskets ......................................................................................................... 10
4.2 Fixing elements ............................................................................................................ 11
4.3 Placing and aligning the turbocharger on the bracket ........................................ 12
4.4 Fastening the turbocharger with a clamping nut ................................................. 14
4.5 Fastening the turbocharger with a standard nut ................................................. 16
4.6 Connecting the turbocharger.................................................................................... 17
5 Storage of new turbochargers and spare parts .............................................. 18
6 Further information............................................................................................. 20

Assembly Instructions / A200-H
1 Introduction / 1.1 Purpose of the assembly instructions
© Copyright 2021 ABB. All rights reserved. HZTL455311P0042_EN Rev.A September 2021
1 Introduction
1.1 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.
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 group
The assembly instructions are intended for engineers and mechanics responsible for fitting
the turbocharger on the engine. Basic mechanical training is a prerequisite.
All persons who are involved in the transportation and installation of the turbocharger have
read and understood the assembly instructions.
1.3 Symbols, definitions
Symbols
The following symbols are used in this document:
uIndicates an action step.
1. Indicates a numbered action step.
¡Indicates a list.
[➙ ] 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 sections
and descriptions of components that are not relevant for a specific turbocharger variant.
ABB Turbocharging Service Stations will be happy to provide information about questions
regarding a design variant (see "Contact Information" on our website www.abb.com/tur-
bocharging).
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.
Page 2 / 21

Assembly Instructions / A200-H
1 Introduction / 1.4 Definition of warning, caution, note
© Copyright 2021 ABB. All rights reserved. HZTL455311P0042_EN Rev.A September 2021
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 "Con-
tact Information" on our website at www.abb.com/turbocharging.
1.4 Definition of warning, caution, note
WARNING
Definition of Warning
Non-compliance or inaccurate compliance with working or operating in-
structions indicated by this symbol and the word WARNING can lead to seri-
ous injuries to personnel and even to fatal accidents.
uWarning signs must always be observed.
CAUTION
Definition of Caution
Non-compliance or inaccurate compliance with working or operating in-
structions indicated by this symbol and the word CAUTION can lead to seri-
ous damage to engine or property with grave consequences.
uCaution signs must always be observed.
NOTICE
Note
The note provides advice which facilitates the work.
Page 3 / 21

Assembly Instructions / A200-H
1 Introduction / 1.5 Definition of mandatory signs
© Copyright 2021 ABB. All rights reserved. HZTL455311P0042_EN Rev.A September 2021
1.5 Definition of mandatory signs
To be worn at all times
Protective clothing Safety footwear to protect
against mechanical hazard and
risk of falling
Table1: Personal protective equipment to be worn at all times
To be worn specific to the respective task
Safety glasses Safety goggles
Safety gloves to protect
against
- Mechanical hazard
- Chemical hazard
- Thermal hazard
Respiratory mask to protect
against
- Dusts
- Gases
Safety helmet Ear protection
Table2: Personal protective equipment to be worn specific to the respective task
1.6 Definition of pictograms
Definition of pictograms
The following pictograms can occur in this document. These point out actions that must be
taken in accordance with the meaning of the relevant pictogram.
Pictogram Meaning Pictogram Meaning
Tighten with specified torque Affix
Tighten over specified tight-
ening angle
Measure
Hand-tight, tighten without
tools
Note
Oil Visually inspect
Apply screw locking paste
(e.g. Loctite)
Please note text for numbered
work step.
Apply high-temperature
grease
See document
Apply other paste in accord-
ance with specifications
Dispose of in an environmentally
compatible, professional way
and in compliance with locally
applicable regulations.
Oil free, grease free and dry
Table3: Definition of pictograms
Page 4 / 21

Assembly Instructions / A200-H
2 Safety / 2.1 Introduction
© Copyright 2021 ABB. All rights reserved. HZTL455311P0042_EN Rev.A September 2021
2 Safety
2.1 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.
CE conformity information
ABB turbochargers comply with the Machinery Directive 2006/42/EC and are partly com-
pleted machinery as defined by Article 2 g.
Residual risks
Nevertheless, there may be some residual risks during operation of and work on the tur-
bocharger which:
¡are caused by the turbocharger itself or its accessories.
¡are caused by the operating equipment used or supplies and materials.
¡are a consequence of insufficient compliance with safety instructions.
All of the instructions contained within this chapter must be followed when working on the
turbocharger.
Responsibility of the operating company
In awareness of its responsibility, the operating company must ensure that only authorised
personnel 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 and
accident 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 instructions
must be checked periodically.
Suitable working materials and personal protective equipment must be kept in a perfect
condition.
Page 5 / 21

Assembly Instructions / A200-H
2 Safety / 2.2 Lifting of loads
© Copyright 2021 ABB. All rights reserved. HZTL455311P0042_EN Rev.A September 2021
2.2 Lifting of loads
WARNING
Suspended loads
Loads that are not attached according to regulations can cause injury to
personnel or fatal accidents.
uLoads must always be fastened to properly functional lifting gear with a
sufficient load limit.
uPay attention to the correct attachment of loads on the crane hook.
uPeople must not stand beneath suspended loads.
Wear safety gloves to protect against mechanical hazards.
Wear safety helmet.
Fig.1: Attachment of loads on the crane hook
Fig.2: Attachment angle
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.
uUse a suitable edge guard if there are sharp edges.
uThe assembly devices must be completely screwed in and must not unscrew during use.
uUse assembly devices only for the described applications.
Page 6 / 21

Assembly Instructions / A200-H
2 Safety / 2.3 Occupational safety
© Copyright 2021 ABB. All rights reserved. HZTL455311P0042_EN Rev.A September 2021
2.3 Occupational safety
General
WARNING
Injuries to persons
Severe injuries to personnel or fatal accidents can be caused by mechanical
influences as a consequence of hazardous and inadequate operational pro-
cedures or non-compliance with safety and health standards.
uWhen working on the turbocharger always wear safety footwear and pro-
tective clothing to protect against mechanical hazards.
uKeep personal protective equipment in perfect condition.
uObey mandatory signs.
uObserve the general rules for occupational safety and prevention of acci-
dents.
uOnly perform operations that are described in this document.
uOnly 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.
WARNING
Risk of falling
When working on the turbocharger, there is a risk of falling.
uDo not climb onto the turbocharger or onto attached parts and do not
use them as climbing aids.
uUse suitable climbing aids and working platforms for work above body
height.
uOnly perform work on the turbocharger when you are in a physically and psychologically
stable condition.
uOnly work with suitable tools, equipment and appliances that function properly.
uKeep the workplace clean; clear away any loose objects and obstacles on the floor.
uKeep the floor, equipment, and turbocharger clean.
uHave oil binding agents ready and provide or keep oil pans at hand.
Welding work in the vicinity of the turbocharger
uWhen performing welding work in the vicinity of the turbocharger, always cover the filter
silencer to prevent the filter mat from being damaged.
uKeep flammable objects and substances out of the vicinity of flying sparks.
Page 7 / 21

Assembly Instructions / A200-H
2 Safety / 2.3 Occupational safety
© Copyright 2021 ABB. All rights reserved. HZTL455311P0042_EN Rev.A September 2021
uCover all connections on the turbocharger so that no foreign objects can enter the tur-
bocharger.
uWear personal protective equipment (PPE) for welding operations.
Mechanical hazards when working on the turbocharger
WARNING
Mechanical hazard
Severe injuries to personnel or fatal accidents can be caused by mechanical
influences as a consequence of hazardous and inadequate operational pro-
cedures.
uObserve the general rules for occupational safety and prevention of acci-
dents.
uEnsure workplace safety.
uOnly perform operations that are described in this chapter.
uOnly 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 and
solvents, acids or similar substances.
WARNING
Handling operating materials and supplies
Swallowing 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 to
an explosion.
uDo not breathe in these substances and avoid contact with the skin.
uEnsure proper ventilation.
uObserve the information in the material safety data sheet for the operat-
ing materials and supplies.
uComply with local legislation.
Wear safety goggles.
Wear safety gloves to protect against mechanical hazards.
Wear a respiratory mask to protect against gases.
Page 8 / 21

Assembly Instructions / A200-H
3 Turbocharger weight and transportation / 
© Copyright 2021 ABB. All rights reserved. HZTL455311P0042_EN Rev.A September 2021
3 Turbocharger weight and
transportation
Lifting gear with a sufficient load limit must be used for removing, installing and transport-
ing the turbocharger. The weight specified below 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.
Swivel lifting eyes to be used
Swivel lifting eyes are required for the safe lifting of loads, which are not supplied by ABB.
Fig.3: Swivel lifting eye (example)
Product Thread M Length L Load limit Quantity
A238-H M10 ≤18mm ≥450kg 1
A240-H M12 ≤21mm ≥700kg 1
Table4: Swivel lifting eyes
Fig.4: Turbocharger suspension with swivel lifting eye (S)
Product Weights [kg]
A238-H 450
A240-H 700
Table5: Weight of the turbocharger
Page 9 / 21

Assembly Instructions / A200-H
4 Installing the turbocharger / 4.1 Inserting gaskets
© Copyright 2021 ABB. All rights reserved. HZTL455311P0042_EN Rev.A September 2021
4 Installing the turbocharger
4.1 Inserting gaskets
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 ABB scope of delivery
and must be provided by the enginebuilder.
uUse O-ring gaskets with a cord diameter of at least 3.5mm.
uIntegrate the slots in the contact surface of the bracket(01).
CAUTION
Oil leak
Damaged or improperly inserted gaskets lead to oil leaks.
uAlways use new gaskets and insert them carefully into the slot.
Fig.5: Inserting the gasket
01 Bracket 05 O-rings
02 Oil supply 06 Pin (optional)
03 Oil drain CE Compressor end
04 Slot for gasket
(suggestion)
Pin(06) as installation safety device
Turbochargers can have an oil inlet either on their right or left side; the oil inlet position can
be different for the turbocharger fitted on the left and on the right engine bank.
A pin can be installed in every support as an installation safety device to prevent inadvertent
incorrect fitting. This pin fits into the respective slot on the foot of the bearing casing. In-
structions of the enginebuilder must be observed.
Page 10 / 21

Assembly Instructions / A200-H
4 Installing the turbocharger / 4.2 Fixing elements
© Copyright 2021 ABB. All rights reserved. HZTL455311P0042_EN Rev.A September 2021
4.2 Fixing elements
The standard nuts(01), washers(02), threaded rods(03) and centering bushes(04) are not
supplied by ABB. The clamping nut (42201) can be ordered as an option. This enables the re-
quired pre-tension to be achieved with a commercially available torque spanner.
Variant with standard nut Variant with clamping nut
Table6: Overview of the fastening variants
Requirements for washers (02)
¡Use hardened washers
¡Thickness ≥ 15% of nominal thread diameter
Requirements for threaded rods(03)
Product Thread size Length [mm]
A238-H M20 ≥380mm
A240-H M24 ≥380mm
Table7
Requirements for centering bushes (04)
Strength class: 10.9 (DIN EN ISO 898-1)
Fig.6: Drawing of centering bush
Product External diameter daInternal diameter diLength H
A238-H 26 +0.0 / -0.02 mm
Chamfer: 1mm x 45°
M20 18mm
A240-H 30 +0.0 / -0.02 mm
Chamfer: 1mm x 45°
M24 20mm
Table8: Dimensions of the centering bushes (04)
Page 11 / 21

Assembly Instructions / A200-H
4 Installing the turbocharger / 4.3 Placing and aligning the turbochar-
ger on the bracket
© Copyright 2021 ABB. All rights reserved. HZTL455311P0042_EN Rev.A September 2021
4.3 Placing and aligning the turbocharger on the
bracket
Step A – Preparing the fixing screws
Fig.7: Placing and aligning the turbocharger
1. Place the turbocharger roughly over the bracket, but do not set it down yet.
2. Screw the clamping nut(42201) flush onto the threaded rod(03).
3. Insert the threaded rod through the washer(02) of the clamping nut.
4. Feed the threaded rod through the bearing casing.
Step B – Preparing the positioning
Fig.8: Screwing on the centering bush
uScrew the centering bush(04) flush onto the threaded rod from below.
uClean the surface of the bracket, the bearing casing, the centering bush and the centering
holes in the bracket.
Page 12 / 21

Assembly Instructions / A200-H
4 Installing the turbocharger / 4.3 Placing and aligning the turbochar-
ger on the bracket
© Copyright 2021 ABB. All rights reserved. HZTL455311P0042_EN Rev.A September 2021
uMake sure that the covers of the oil connections are removed.
uMake sure that the position of the oil inlet of the bracket matches the oil inlet hole in the
bearing casing.
uMake sure that the O-rings are placed correctly in the slots.
Step C - Placing the turbocharger
Fig.9: Placing the turbocharger on the bracket
1. Lightly lubricate the hole in the bracket, into which the centering bush(04) is inserted,
with screw grease.
2. Position threaded rod with centering bush into bracket and insert until stop.
3. Carefully lower turbocharger onto bracket and position using the centering bush(04)
located in the bracket.
4. Check dimension X. If dimension X is not reached, the turbocharger must be lifted up
from the bracket and realigned.
The values X and L depend on the length of the threaded rod and must be specified by
the user.
5. Using the hexagon, screw the threaded rod into the bracket up to dimension L. If dimen-
sion L is not reached or the threaded rod jams while being screwed in, the threaded rod
must be loosened by no more than ½ revolution (this will loosen the centering bush
which may have jammed the rod). Then continue screwing in. If dimension L is not
reached, loosen the screw connection, carefully take the turbocharger off the bracket
and repeat the procedure starting with Step 1.
uComply with the steps for fastening the turbocharger:
¡Fastening the turbocharger with a clamping nut →14
¡Fastening the turbocharger with a standard nut →16
Page 13 / 21

Assembly Instructions / A200-H
4 Installing the turbocharger / 4.4 Fastening the turbocharger with a
clamping nut
© Copyright 2021 ABB. All rights reserved. HZTL455311P0042_EN Rev.A September 2021
4.4 Fastening the turbocharger with a clamping nut
Preparations for tightening the clamping nut
CAUTION
Do not clean pressure screws (04)
The pressure screws are equipped with a permanent sliding layer that must
not be removed.
Do neither clean nor lubricate the pressure screws. In case of non-compli-
ance, it cannot be ensured that the necessary tension force is reached.
uDo not clean pressure screws.
uDo not lubricate pressure screws.
In order to correctly fit the clamping nuts, the pressure screws (04) must not protrude from
the clamping nuts (03) in the direction of the thrust washer (02).
uMake sure the pressure screws do not protrude in the direction of the thrust washer.
Fig.10: Preparing the clamping nut for the tightening procedure
1. Clean the thread of the bolt(01) and the contact surface.
2. Lightly oil the bolt thread.
3. Position the thrust washer(02) in place.
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.
Page 14 / 21

Assembly Instructions / A200-H
4 Installing the turbocharger / 4.4 Fastening the turbocharger with a
clamping nut
© Copyright 2021 ABB. All rights reserved. HZTL455311P0042_EN Rev.A September 2021
Tightening pressure screws
Fig.11: Tightening pressure screws
Product Fixing screw [mm] Tightening torque [Nm]
A238-H M20 38
A240-H M24 35
Table9: Pressure screw tightening torques
1. Screw in pressure screws crosswise by hand until reaching the stop.
2. Tighten pressure screws crosswise to 50% of the tightening torque specified in the
table.
3. Tighten pressure screws crosswise to 100% of the tightening torque specified in the
table.
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.
Page 15 / 21

Assembly Instructions / A200-H
4 Installing the turbocharger / 4.5 Fastening the turbocharger with a
standard nut
© Copyright 2021 ABB. All rights reserved. HZTL455311P0042_EN Rev.A September 2021
Loosening the clamping nut
It is imperative to proceed as follows if the clamping nut has to be loosened again:
CAUTION
Incorrect procedure can make loosening impossible
If individual pressure screws are fully relieved, the pressure screws can be-
come compressed, making it impossible to loosen them.
uComply with the following steps for loosening the pressure screws.
Fig.12: Loosening the clamping nut
uWorking in a circle, break loose all pressure screws of the clamping nut.
uWorking in a circle, loosen each of the pressure screws by about ¼ of a turn (90°).
uRepeat the previous step until all pressure screws are relieved of pressure.
uLoosen clamping nut by hand.
4.5 Fastening the turbocharger with a standard nut
uFit the nuts and tighten them according to variant 1 or 2 in the table below.
Product Through hole in
bearing casing
[mm]
Fixing screws
[mm]
Variant 1: Tightening
torques [Nm] **)
Variant 2: Hy-
draulic pre-ten-
sioning forces [kN]
A238-H Ø21 M20 560 175
A240-H Ø25 M24 900 235
Table10: Tightening torque for standard nuts
**) 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)
uRemove the lifting gear.
Page 16 / 21

Assembly Instructions / A200-H
4 Installing the turbocharger / 4.6 Connecting the turbocharger
© Copyright 2021 ABB. All rights reserved. HZTL455311P0042_EN Rev.A September 2021
4.6 Connecting the turbocharger
uConnect the cable to the speed sensor(86515).
uConnect all exhaust gas, water, blow-by and air lines according to the instructions of the
enginebuilder.
Version with compressor wheel cooling
CAUTION
Failure of compressor wheel cooling
Any prolonged failure of the compressor wheel cooling will shorten the re-
placement interval of the compressor wheel.
uMake sure there is an uninterrupted supply of cooling air during opera-
tion.
Fig.13: Connecting the compressor cooling air
uRemove the lock from the connection for the compressor wheel cooling (01) and fit the
cooling air line.
Page 17 / 21

Assembly Instructions / A200-H
5 Storage of new turbochargers and spare parts / 
© Copyright 2021 ABB. All rights reserved. HZTL455311P0042_EN Rev.A September 2021
5 Storage of new turbochargers and
spare parts
Storage of new turbochargers and spare parts up to 6 months
New turbochargers and spare parts can be stored in their closed packages for 6months
from the date of delivery without additional mothballing measures.
Only dry rooms in which the relative humidity is between 40…70% and no condensation can
form are suitable for storage.
Storage of new turbochargers and spare parts for more than 6 months
As the contents of the package are adapted as required, turbochargers may also be de-
livered without a VCI label.
For parts with a VCI label on the package, the following instructions must be observed.
Fig.14: Volatile Corrosion Inhibitor (VCI)
WARNING
Health protection when handling VCI
VCI products are not hazardous in terms of the Ordinance on Hazardous
Substances. Nevertheless, the following points must be observed when
handling VCI:
uObserve information in material safety data sheet
uEnsure proper space ventilation.
uDo not eat, drink or store food at the workplace while working with VCI.
uClean hands and face after working with VCI.
uFor more information, see www.branopac.com.
Wear safety gloves to protect against mechanical hazards.
Every 6months, the following mothballing measures are required:
uOpen package.
uRemove VCI corrosion protection emitter from package and replace with a new VCI corro-
sion protection emitter of the same kind. New VCI corrosion protection emitters can be
obtained from www.branopac.com.
uOld VCI corrosion protection emitters must be disposed of in an environmentally compat-
ible, professional way and in compliance with locally applicable regulations.
uClose package. The more tightly the package is sealed, the longer the protection dura-
tion.
Page 18 / 21