ABB RR 1 Series User manual

Turbocharger / A100-M radial
Original assembly instructions – English
This document is valid for the RR..1
and RR..3 series:
RR131, RR151, RR181, RR221, RR153
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.
RR turbocharger
Reliability in traction
—
ASSEMBLY INSTRUCTIONS
Turbocharger / RR..1, RR..3
Original assembly instructions – English

Assembly Instructions / RR.. 1, RR153
Table of contents
© Copyright 2020 ABB. All rights reserved. HZTL455311P0022_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 and 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 loads ................................................................................................................... 6
2.3 Occupational safety ...................................................................................................... 7
3 Weight and transportation of the turbocharger ............................................... 9
4 Installing the turbocharger................................................................................. 10
4.1 Fastening RR turbocharger to exhaust gas pipes................................................. 10
4.2 Fastening RR turbocharger to bracket.................................................................... 11
5 Storage of new turbochargers and spare parts .............................................. 12
6 Further information............................................................................................. 16

Assembly Instructions / RR.. 1, RR153
1 Introduction / 1.1 Purpose of the assembly instructions
© Copyright 2020 ABB. All rights reserved. HZTL455311P0022_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 and definitions
The following symbols are used in the documents:
wPrerequisite
uWork step
¡Enumeration, first level
- Enumeration, second level
→ 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 on questions re-
garding a design variant (see Contact information at 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.
Page 2 / 17

Assembly Instructions / RR.. 1, RR153
1 Introduction / 1.4 Definition of warning, caution, note
© Copyright 2020 ABB. All rights reserved. HZTL455311P0022_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 also
chapter Contact address and after-sales service.
1.4 Definition of warning, caution, note
WARNING
Definition of warning
Serious personal injuries and even accidents with fatal consequences may
occur if work and operating instructions marked with this symbol and the
word WARNING are either not followed or not followed precisely.
uWarning signs must be observed at all times.
CAUTION
Definition of caution
Serious machine or property damage may occur if work and operating in-
structions marked with this symbol and the word CAUTION are either not
followed or not followed precisely.
uCaution signs must be observed at all times.
NOTICE
Note
A note provides suggestions which facilitate the work on the product.
Page 3 / 17

Assembly Instructions / RR.. 1, RR153
1 Introduction / 1.5 Definition of mandatory signs
© Copyright 2020 ABB. All rights reserved. HZTL455311P0022_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
To be worn according to the specific work
Safety glasses Safety goggles
Safety gloves against
- Mechanical hazard
- Chemical hazard
- Thermal hazard
Respiratory mask against
- Dusts
- Gases
Safety helmet Ear protection
Table2
1.6 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
applicable regulations.
Table3: Pictograms
Page 4 / 17

Assembly Instructions / RR.. 1, RR153
2 Safety / 2.1 Introduction
© Copyright 2020 ABB. All rights reserved. HZTL455311P0022_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
pertinent safety and health-protection requirements that applied when the turbocharger
was manufactured. Consequently, the turbocharger is safe to operate.
CE conformity information
ABB turbochargers fulfil machinery directive 2006/42/EC and are considered partly com-
pleted machinery as defined by Article2g.
Residual risks
Nevertheless, during turbocharger operation and when working on the turbocharger, resid-
ual risks can exist which:
¡Are caused by the turbocharger itself or its accessories.
¡Are caused by the operating and auxiliary materials used.
¡Are a consequence of insufficient compliance with safety instructions.
All instructions contained in this chapter must be observed during all work on the turbochar-
ger.
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 / 17

Assembly Instructions / RR.. 1, RR153
2 Safety / 2.2 Lifting loads
© Copyright 2020 ABB. All rights reserved. HZTL455311P0022_EN Rev.B July 2020
2.2 Lifting loads
WARNING
Suspended loads
Loads not suspended in compliance with regulations may lead to personal
injury or accidents with fatal consequences.
uLoads must always be fastened to technically perfect lifting gear with
sufficient loading capacity.
uMake sure the load is suspended properly on the crane hook.
uDo not let anyone stand beneath a suspended load.
Wear safety gloves to protect against mechanical hazards.
Wear safety helmet.
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 / 17

Assembly Instructions / RR.. 1, RR153
2 Safety / 2.3 Occupational safety
© Copyright 2020 ABB. All rights reserved. HZTL455311P0022_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 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 chapter.
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 close to the turbocharger
uIf welding work is being carried out in the vicinity of the turbocharger, cover the filter si-
lencer so that the filter mat is not damaged.
Page 7 / 17

Assembly Instructions / RR.. 1, RR153
2 Safety / 2.3 Occupational safety
© Copyright 2020 ABB. All rights reserved. HZTL455311P0022_EN Rev.B July 2020
uRemove combustible objects and substances out of the range of flying sparks.
uCover all connections on the turbocharger so that no foreign objects can get into 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 chemical hazards.
Wear a respiratory mask to protect against gases.
Page 8 / 17

Assembly Instructions / RR.. 1, RR153
3 Weight and transportation of the turbocharger / 
© Copyright 2020 ABB. All rights reserved. HZTL455311P0022_EN Rev.B July 2020
3 Weight and transportation of the
turbocharger
Lifting gear with a sufficient load limit must be used for installing the turbocharger. The fol-
lowing weight specification applies to the heaviest variant possible. Depending on the spe-
cification, the weight specified on the rating plate may be lower than the standard value
specified here.
Fig.1: Transport of RR turbocharger
Product Weight [kg]
Complete turbocharger, without cool-
ing water, with filter silencer
Weight [kg]
Complete turbocharger, without cool-
ing water, with air suction branch
RR153 63 58
RR131 70 65
RR151 112 106
RR181 198 190
RR221 359 344
Table4: RR Turbocharger weights
Page 9 / 17

Assembly Instructions / RR.. 1, RR153
4 Installing the turbocharger / 4.1 Fastening RR turbocharger to ex-
haust gas pipes
© Copyright 2020 ABB. All rights reserved. HZTL455311P0022_EN Rev.B July 2020
4 Installing the turbocharger
4.1 Fastening RR turbocharger to exhaust gas pipes
RR turbochargers are fastened directly to the exhaust gas pipe of the engine. The turbochar-
ger is fastened to the gas inlet flange or gas outlet flange of the turbine casing (see follow-
ing illustration).
¡Use heat resistant screws the strength of which is sufficient to withstand the temperat-
ures that can occur (Rp02 > 590 N/mm2, for example Nimonic 90).
¡Apply heat resistant grease to the threads.
Fig.2: Fastening the RR turbocharger to the exhaust gas pipe
Product Fastening to gas inlet flange (01) Fastening to gas outlet flange (02)
RR131, RR151,
RR153
4 x M16
MA = 160 Nm ±35 Nm
8 x M10
MA = 37.5 Nm ±8.5 Nm
RR181 *) Not admissible 12 x M10
MA = 37.5 Nm ±8.5 Nm
RR221 *) Not admissible 12 x M12
MA = 65 Nm ±15 Nm
Table5: Fastening the RR turbocharger to the exhaust gas pipe
*) Has to be fastened additionally to a bracket in accordance with the following chapter.
uFit all pipes in accordance with the enginebuilder's instructions.
Page 10 / 17

Assembly Instructions / RR.. 1, RR153
4 Installing the turbocharger / 4.2 Fastening RR turbocharger to
bracket
© Copyright 2020 ABB. All rights reserved. HZTL455311P0022_EN Rev.B July 2020
4.2 Fastening RR turbocharger to bracket
The following turbochargers have to be fastened to a bracket:
¡RR151 with bearing casing NA2
¡RR131 with bearing casing NA4
¡RR181
¡RR221.
The turbocharger is fastened on one side or on both sides to a bracket with tightening
torques (01) shown in the table. If present for RR151 and RR131 (in the case of high vibration),
the support(02) must be fastened additionally using screws(03).
Fig.3: Fastening the RR..1 turbocharger to a bracket
Product Fastening to bracket (01) *)
RR151 with bearing casing NA2 2x M16
MA = 230 Nm ±50 Nm
RR151 with bearing casing NA4 2x M20
MA = 455 Nm ±105 Nm
RR181 2x M20
MA = 455 Nm ±105 Nm
RR221 2x M24
MA = 780 Nm ±180 Nm
Table6: Fastening the RR..1 turbocharger to a bracket
*) 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).
uFit all pipes in accordance with the enginebuilder's instructions.
Page 11 / 17

Assembly Instructions / RR.. 1, RR153
5 Storage of new turbochargers and spare parts / 
© Copyright 2020 ABB. All rights reserved. HZTL455311P0022_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 from ABB Turbocharging can be stored in sealed pack-
aging without additional mothballing measures for up to 6months from the date of delivery
(marked by the VCI label on the package).
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 (VCI)
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:
uEnsure good room ventilation.
uDo not eat, drink or keep food at the workplace while working with VCIs.
uWear safety gloves.
uClean hands and face after working with VCIs.
uFor further information refer to www.branopac.com.
Wear safety gloves to protect against chemical 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 12 / 17

Assembly Instructions / RR.. 1, RR153
5 Storage of new turbochargers and spare parts / 
© Copyright 2020 ABB. All rights reserved. HZTL455311P0022_EN Rev.B July 2020
Long-term storage of turbochargers
The turbochargers will be prepared for prolonged storage by ABB Turbocharging on request.
The package is equipped with a hygrometer (see illustration).
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 component
¡Replace the desiccant agent
¡Repackage the component.
NOTICE
Turbocharger ready for operation
If the 70% field of the hygrometer(02) has not changed colour and the pack-
age is undamaged, the turbocharger can be put into operation without any
prior inspection by an ABB Turbocharging Service Station.
Unpacking the 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 13 / 17

Assembly Instructions / RR.. 1, RR153
5 Storage of new turbochargers and spare parts / 
© Copyright 2020 ABB. All rights reserved. HZTL455311P0022_EN Rev.B July 2020
Page 14 / 17

Assembly Instructions / RR.. 1, RR153
5 Storage of new turbochargers and spare parts / 
© Copyright 2020 ABB. All rights reserved. HZTL455311P0022_EN Rev.B July 2020
Page 15 / 17

Assembly Instructions / RR.. 1, RR153
6 Further information / 
© Copyright 2020 ABB. All rights reserved. HZTL455311P0022_EN Rev.B July 2020
6 Further information
The Operation Manual must be observed with regard to commissioning, operation, mainten-
ance and ordering spare parts.
Operation Manual
The Operation Manual for the turbocharger with the relevant serial number is available on-
line on our website www.abb.com/turbocharging.
Fig.4: Rating plate on turbocharger
One rating plate(01) each is attached on the left and the right side of the turbocharger bear-
ing casing.
1. Read the serial number (02) on the rating plate (01) of the turbocharger.
uThe Operation Manual can be found online in accordance with the details on the following
page.
Page 16 / 17

Assembly Instructions / RR.. 1, RR153
6 Further information / 
© Copyright 2020 ABB. All rights reserved. HZTL455311P0022_EN Rev.B July 2020
Page 17 / 17

Further information
Find your nearest Service Station on our
website (see “Find your nearest Service
Station”).
Find and download the Operation Manual of
your product on our website (see “Operation
Manuals“).
© Copyright 2020 ABB. All rights reserved.
Operation Manual /
Contact information
ABB Switzerland Ltd, Turbocharging
Bruggerstrasse 71 a
CH-5401 Baden/ Switzerland
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
www.abb.com/turbocharging
Visit our website by
scanning the QR code.
HZTL455311P0022