ABB A100-H Series User manual

Turbocharger / A100-M radial
Original assembly instructions – English
This document is valid for the
A100-H series:
A130-H, A135-H, A140-H
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.
A100-H turbocharger
More power, less fuel
—
ASSEMBLY INSTRUCTIONS
Turbocharger / A100-H radial
Original assembly instructions – English

Assembly Instructions / A100-H
Table of contents
© Copyright 2020 ABB. All rights reserved. HZTL455311P0004_EN Rev.B July 2020
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.......................................................................... 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 Weight and transportation of the turbocharger ............................................... 9
4 Installing the turbocharger................................................................................. 10
4.1 Inserting gaskets into the bracket........................................................................... 10
4.2 Fitting threaded rods.................................................................................................. 11
4.3 Placing the turbocharger on the bracket................................................................ 12
4.4 Fastening the turbocharger with a standard nut ................................................. 13
4.5 Fastening the turbocharger with a clamping nut ................................................. 14
4.6 Connecting the turbocharger.................................................................................... 16
4.7 Attaching the support ................................................................................................ 16
5 Storage of new turbochargers and spare parts .............................................. 17
6 Further information............................................................................................. 20

Assembly Instructions / A100-H
1 Introduction / 1.1 Purpose of the assembly instructions
© Copyright 2020 ABB. All rights reserved. HZTL455311P0004_EN Rev.B July 2020
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 / A100-H
1 Introduction / 1.4 Definition of warning, caution, note
© Copyright 2020 ABB. All rights reserved. HZTL455311P0004_EN Rev.B July 2020
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 / A100-H
1 Introduction / 1.5 Definition of mandatory signs
© Copyright 2020 ABB. All rights reserved. HZTL455311P0004_EN Rev.B July 2020
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 / A100-H
2 Safety / 2.1 Introduction
© Copyright 2020 ABB. All rights reserved. HZTL455311P0004_EN Rev.B July 2020
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 / A100-H
2 Safety / 2.2 Lifting of loads
© Copyright 2020 ABB. All rights reserved. HZTL455311P0004_EN Rev.B July 2020
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 / A100-H
2 Safety / 2.3 Occupational safety
© Copyright 2020 ABB. All rights reserved. HZTL455311P0004_EN Rev.B July 2020
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 protect-
ive 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 accidents.
uOnly perform operations that are described in this document.
uOnly perform operations for which you have received instruction or training.
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.
uCover all connections on the turbocharger so that no foreign objects can enter the turbocharger.
uWear personal protective equipment (PPE) for welding operations.
Page 7 / 21

Assembly Instructions / A100-H
2 Safety / 2.3 Occupational safety
© Copyright 2020 ABB. All rights reserved. HZTL455311P0004_EN Rev.B July 2020
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 accidents.
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 / A100-H
3 Weight and transportation of the turbocharger / 
© Copyright 2020 ABB. All rights reserved. HZTL455311P0004_EN Rev.B July 2020
3 Weight and transportation of the
turbocharger
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.
Fig.3: Transportation of the turbocharger
Product Weight of complete turbocharger unit [kg]
A130-H 190
A135-H 270
A140-H 460
Table4: Weight of complete turbocharger unit
Page 9 / 21

Assembly Instructions / A100-H
4 Installing the turbocharger / 4.1 Inserting gaskets into the bracket
© Copyright 2020 ABB. All rights reserved. HZTL455311P0004_EN Rev.B July 2020
4 Installing the turbocharger
4.1 Inserting gaskets into the bracket
CAUTION
Inserting the gaskets
Gaskets that are forgotten, damaged or improperly inserted will lead to oil
leaks.
uAlways 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.4: Inserting gaskets into the bracket
01 Bracket 04 Slot for O-ring
02 Oil supply 05 O-rings
03 Oil drain 06 Pin (optional)
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 / A100-H
4 Installing the turbocharger / 4.2 Fitting threaded rods
© Copyright 2020 ABB. All rights reserved. HZTL455311P0004_EN Rev.B July 2020
4.2 Fitting threaded rods
Fig.5: Fitting threaded rods onto the bracket
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.
Requirements for the threaded rods
Fig.6: Requirements for threaded rods
Product Diameter
Threaded rod
[mm]
Material
DIN / ISO 898
(Part 1)
Thread length
L1[mm]
Length of
threaded rod
L2 [mm]
A130-H Ø 16 / M16 10.9 / 12.9 ≥ 30 250
A135-H Ø 20 / M20 10.9 / 12.9 ≥ 30 325
A140-H Ø 24 / M24 10.9 / 12.9 ≥ 70 410 … 420
Table5: Requirements for threaded rods
Fastening material, scope of delivery
The threaded rods and nuts for fastening the turbocharger on the bracket are not included
in the ABB scope of delivery.
The clamping nuts are included in the ABB scope of delivery.
Page 11 / 21

Assembly Instructions / A100-H
4 Installing the turbocharger / 4.3 Placing the turbocharger on the
bracket
© Copyright 2020 ABB. All rights reserved. HZTL455311P0004_EN Rev.B July 2020
4.3 Placing the turbocharger on the bracket
Fig.7: Placing the turbocharger on the bracket
B Clamping nut
C Standard nut
uMake sure that covers of the oil and water connections are removed.
1. Make sure that the O-rings(03) are undamaged and positioned correctly in the slots.
2. Clean the expansion bushes(42190) and the contact surfaces of the expansion bushes in
the bearing casing.
3. Attach the lifting gear to the suspension eye of the bearing casing(42001) and loop
around the gas outlet casing.
4. Position the turbocharger on the bracket(04) and align it. If present, pay attention to the
positioning pin(05) in the bracket.
5. When fixing with a standard nut (C), fit the expansion bushes in the correct position in
the slot.
Safeguard against wrong fitting (only for water-cooled bearing casings)
Depending on the bracket version(04), two positioning pins(05) can be used for positioning
and safeguarding against wrong fitting of the turbocharger. Therefore the turbocharger
must always be removed from and installed on the bracket vertically.
uObserve the instructions for the fastening variant at hand.
¡Fastening the turbocharger with a standard nut →13 (A130-A140)
¡Fastening the turbocharger with a clamping nut →14 (only A140)
Page 12 / 21

Assembly Instructions / A100-H
4 Installing the turbocharger / 4.4 Fastening the turbocharger with a
standard nut
© Copyright 2020 ABB. All rights reserved. HZTL455311P0004_EN Rev.B July 2020
4.4 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]
A130 Ø17 M16 280 110
A135 Ø 21 M20 560 175
A140 Ø 25 M24 960 250
Table6: 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 13 / 21

Assembly Instructions / A100-H
4 Installing the turbocharger / 4.5 Fastening the turbocharger with a
clamping nut
© Copyright 2020 ABB. All rights reserved. HZTL455311P0004_EN Rev.B July 2020
4.5 Fastening the turbocharger with a clamping nut
Preparation for tightening
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.8: Preparing the clamping nut for the tightening procedure
1. Check whether the expansion bushes (42190) with recess are correctly positioned and do
not touch the flange of the core hole cover (A).
2. Clean the thread of the bolt (01) and the contact surface.
3. Lightly oil the bolt thread.
4. Position the thrust washer (02) in place.
5. Tighten clamping nut (03) by hand.
6. 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 / A100-H
4 Installing the turbocharger / 4.5 Fastening the turbocharger with a
clamping nut
© Copyright 2020 ABB. All rights reserved. HZTL455311P0004_EN Rev.B July 2020
Tightening pressure screws
Fig.9: Tightening pressure screws
Product Fixing screw [mm] Tightening torques [Nm]
A140 M24 35
Table7: Torque-controlled tightening of the pressure screws
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 / A100-H
4 Installing the turbocharger / 4.6 Connecting the turbocharger
© Copyright 2020 ABB. All rights reserved. HZTL455311P0004_EN Rev.B July 2020
4.6 Connecting the turbocharger
uConnect cable to speed sensor(86515).
uConnect all gas, water 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.10: Connecting the compressor cooling air intake
uRemove the screw plug on the connection for the compressor wheel cooling (06) and fit
the cooling air line.
4.7 Attaching the support
Fig.11: Attaching the support
uIf present: Attach support (61301) to engine support or to a connecting piece.
Page 16 / 21

Assembly Instructions / A100-H
5 Storage of new turbochargers and spare parts / 
© Copyright 2020 ABB. All rights reserved. HZTL455311P0004_EN Rev.B July 2020
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 sealed packaging without additional
mothballing measures for up to 6months from the date of delivery (marked by the VCI label
on the package).
Fig.12: Volatile Corrosion Inhibitor (VCI)
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
WARNING
Protection of health when handling VCIs
VCI products are not hazardous in the sense of the Hazardous Substances
Ordinance. Nevertheless, the following points are to be observed when
handling VCIs:
uObserve specifications in the safety data sheet
uEnsure good room ventilation.
uDo not eat, drink or keep food at the workplace while working with VCIs.
uClean hands and face after working with VCIs.
uFor further information refer to www.branopac.com.
Wear safety gloves to protect against mechanical hazards.
The following mothballing measures are required every 6months:
uOpen the package.
uRemove 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 be
obtained at www.branopac.com.
uDispose of the old VCI corrosion protection emitter in an environmentally compatible
manner, professionally and in accordance with local regulations.
uSeal the package. The better the external seal is designed, the more permanent the pro-
tection.
Page 17 / 21

Assembly Instructions / A100-H
5 Storage of new turbochargers and spare parts / 
© Copyright 2020 ABB. All rights reserved. HZTL455311P0004_EN Rev.B July 2020
Long-term storage of turbochargers
The turbochargers will be prepared for prolonged storage by ABB Turbocharging on re-
quest. The package is equipped with a hygrometer (see illustration).
Fig.13: Package with hygrometer
The following measures are required every 6months:
uCheck the hygrometer(02) in the sight-glass. There is an opening(01) in the wooden
crate which allows this check to be carried out. When the display field has changed colour
at the 70% level, the maximum permissible humidity has been exceeded. In this case the
turbocharger must be inspected by an ABB Turbocharging Service Station and repacked.
uInspect 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:
¡Inspect the components
¡Replace the desiccant agent
¡Repackage the components.
If the 70% display field of the hygrometer(02) has not changed colour and the package is
undamaged, the turbocharger can be placed into operation without any prior testing by an
ABB Turbocharging Service Station.
Unpacking 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 package
must have the same temperature during unpacking.
Page 18 / 21