ABB Power2 800-M User manual

Power2 800-M
Original assembly instructions – English
Assembly Instructions
This document is valid for the Power2
series:
Power2 850-M
Purpose
The assembly instructions explain how the low- and high-
pressure stage of ABB Turbo Systems 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 low- and high-pressure
stage on the engine.
Power2 performance package
Two-stage turbocharging solution for highest turbocharging
efficiency

Assembly Instructions / Power2 800-M
Table of contents
Page 1 /
21
© Copyright 2016 ABB. All rights reserved.
HZTL455311P0010
Revision -
March 2016
Assembly Instructions
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 ............................................................
4
1.5
Definition of mandatory signs .....................................................................
4
2
Safety.....................................................................................................
5
2.1
Introduction ................................................................................................
5
2.2
Lifting of loads............................................................................................
6
2.3
Occupational safety ...................................................................................
7
3
Weight and transportation of the low-pressure and the high-pressure
stages ....................................................................................................
9
4
Installing the low-pressure stage .............................................................
11
4.1
Gaskets .....................................................................................................
12
4.2
Assembly procedure ..................................................................................
13
5
Installing the high-pressure stage ............................................................
14
5.1
Gaskets .....................................................................................................
15
5.2
Assembly procedure ..................................................................................
17
6
Storage of new low-pressure and high-pressure stages............................
18
7
Further information .................................................................................
20

Assembly Instructions / Power2 800-M
1
Introduction
Page 2 /
21
© Copyright 2016 ABB. All rights reserved.
HZTL455311P0010
Revision -
March 2016
1 Introduction
1.1 Purpose of the assembly instructions
The assembly instructions explain how the low- and high-pressure stage of ABB Turbo Sys-
tems 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 the
low- and high-pressure stage on the engine. Basic mechanical training is a prerequisite.
All persons who are involved in the transportation and installation of the low and high-pressure
stage have read and understood the assembly instructions.
1.3 Symbols, definitions
Symbols
The following symbols are used in this document:
Indicates an action step.
1. Indicates a numbered action step.
Indicates a list.
[➙ ] Refers to a page number
Terms used
The following terms are used in this document:
Two-stage turbocharging (Power2)
Low-pressure stage (Power2 LP)
High-pressure stage (Power2 HP)
Low-pressure and high-pressure stage
The trademarks of outside companies are used in this document. These are marked with the
® symbol.

Assembly Instructions / Power2 800-M
1
Introduction
Page 3 /
21
© Copyright 2016 ABB. All rights reserved.
HZTL455311P0010
Revision -
March 2016
Design variants
This document is valid for different design variants of low and high-pressure stages. There
may be sections and descriptions of components that are not relevant for a specific low or
high-pressure stage.
ABB Turbocharging Service Stations will be happy to provide information about questions re-
garding a design variant (see "Contact Information" on our website
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.
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 Sta-
tions. They are regularly audited and certified by ABB Turbo Systems. See "Contact Infor-
mation" on our website at www.abb.com/turbocharging.
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
Oil free, grease free and dry
Tighten over specified tightening
angle
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 accordance
with specifications
Dispose of in an environmentally
compatible, professional way and
in compliance with locally applica-
ble regulations.
Table 1: Definition of pictograms