ABB TPR56FV Series User manual

Turbocharger / A100-M radial
Original assembly instructions – English
This document is valid for the TPR..FV
series:
TPR56FV.., TPR61FV..
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.
TPR..FV turbocharger
The most power and efficiency for the long haul.
ASSEMBLY INSTRUCTIONS
Turbocharger / TPR..FV
Original assembly instructions – English
—

Assembly Instructions / TPR56FV.. - TPR61FV..
Table of contents
© Copyright 2018 ABB. All rights reserved. HZTL455311P0033_EN Revision B May 2018
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.................................................................................. 11
4.1 Installing the VTG control system ............................................................................ 12
4.2 Completion work, if required .................................................................................... 13
5 Storage of new turbochargers and spare parts .............................................. 14
6 Further information............................................................................................. 16

Assembly Instructions / TPR56FV.. - TPR61FV..
1 Introduction / 1.1 Purpose of the assembly instructions
© Copyright 2018 ABB. All rights reserved. HZTL455311P0033_EN Revision B May 2018
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).
Page 2 / 17

Assembly Instructions / TPR56FV.. - TPR61FV..
1 Introduction / 1.4 Definition of warning, caution, note
© Copyright 2018 ABB. All rights reserved. HZTL455311P0033_EN Revision B May 2018
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
In this document, ABB Turbo Systems Ltd is abbreviated to ABB Turbo Systems.
Official ABB Turbo Systems Service Stations
In this document, official service stations are referred to as ABB Turbocharging Service Sta-
tions. They are inspected and certified regularly by ABB Turbo Systems. 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 / TPR56FV.. - TPR61FV..
1 Introduction / 1.5 Definition of mandatory signs
© Copyright 2018 ABB. All rights reserved. HZTL455311P0033_EN Revision B May 2018
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
- Electrical 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
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 applic-
able regulations.
Table3: Pictograms
Page 4 / 17

Assembly Instructions / TPR56FV.. - TPR61FV..
2 Safety / 2.1 Introduction
© Copyright 2018 ABB. All rights reserved. HZTL455311P0033_EN Revision B May 2018
2 Safety
2.1 Introduction
State of the art
Turbochargers manufactured by ABB Turbo Systems 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 / 17

Assembly Instructions / TPR56FV.. - TPR61FV..
2 Safety / 2.2 Lifting loads
© Copyright 2018 ABB. All rights reserved. HZTL455311P0033_EN Revision B May 2018
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 / TPR56FV.. - TPR61FV..
2 Safety / 2.3 Occupational safety
© Copyright 2018 ABB. All rights reserved. HZTL455311P0033_EN Revision B May 2018
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 accidents.
uOnly perform operations that are described in this chapter.
uOnly perform operations for which you have received instruction or training.
Wear safety footwear to protect against mechanical hazard and risk of falling.
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.
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.
Page 7 / 17

Assembly Instructions / TPR56FV.. - TPR61FV..
2 Safety / 2.3 Occupational safety
© Copyright 2018 ABB. All rights reserved. HZTL455311P0033_EN Revision B May 2018
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 / TPR56FV.. - TPR61FV..
3 Weight and transportation of the turbocharger / 
© Copyright 2018 ABB. All rights reserved. HZTL455311P0033_EN Revision B May 2018
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.
Weights of the complete turbocharger
Product Weight [kg]
TPR56FV.. 400
TPR61FV.. 750
Table4: Weight complete
Page 9 / 17

Assembly Instructions / TPR56FV.. - TPR61FV..
3 Weight and transportation of the turbocharger / 
© Copyright 2018 ABB. All rights reserved. HZTL455311P0033_EN Revision B May 2018
Page 10 / 17

Assembly Instructions / TPR56FV.. - TPR61FV..
4 Installing the turbocharger / 
© Copyright 2018 ABB. All rights reserved. HZTL455311P0033_EN Revision B May 2018
4 Installing the turbocharger
uRemove the cover from the oil connection.
uCheck lifting gear.
uAttach one lifting gear each to the two fins of the bearing casing provided for this pur-
pose and to the gas inlet casing (Weight and transportation of the turbocharger →9).
NOTICE
Oil orifice
There is an orifice in each of the two oil inlet channels of the bearing casing.
The diameter of this orifice is individually adapted by the enginebuilder for
the purpose of adjusting the oil pressure.
uAlign turbocharger on bracket.
Tightening the foot fixing screws
Fig.2: Tightening foot fixing screws
Position TPR56FV.. TPR61FV..
B 135 Nm 205 Nm
Table5: Tightening torque for foot fixing screw (B)
uLightly oil the foot fixing screws (B).
uFit foot fixing screws (B) 1 to 4 with sliding block (S). Observe the tightening torque.
uFit foot fixing screws (B) 5 to 8. Observe the tightening torque.
uFit speed sensor and plug in cable connector (86515).
Page 11 / 17

Assembly Instructions / TPR56FV.. - TPR61FV..
4 Installing the turbocharger / 4.1 Installing the VTG control system
© Copyright 2018 ABB. All rights reserved. HZTL455311P0033_EN Revision B May 2018
4.1 Installing the VTG control system
WARNING
Installation location of the VTG control system
The control system is installed in a terminal box.
uIt is essential to follow the additional specifications and instructions of
the enginebuilder.
Fig.3: Installation of the VTG control system
uSecure the control system using the relevant screws in the terminal box.
uConnect plug XC2 to the control system and secure with the screw.
uSecure any other connection and grounding cables as per the specifications.
uConnect power supply plug XC1 to the control system.
Page 12 / 17

Assembly Instructions / TPR56FV.. - TPR61FV..
4 Installing the turbocharger / 4.2 Completion work, if required
© Copyright 2018 ABB. All rights reserved. HZTL455311P0033_EN Revision B May 2018
4.1.1 Connecting the VTG control system
WARNING
Crushing hazard
Unintentional adjustment of the VTG mechanics can lead to crushing injur-
ies.
uMake sure that the control system (B2) is disconnected from the power
supply before disassembly
Wear safety gloves to protect against mechanical hazards.
wIf the plugs are not inserted correctly or interchanged, the operation of the VTG mechan-
ics is not possible.
uConnect plug XA3 or XA4 to the actuator.
uConnect plug XA1 or XA2 to the actuator.
uFit the cooling water connections (CW) according to instructions of enginebuilder.
4.2 Completion work, if required
uAttach all gas, air and oil pipes according to the instructions of the enginebuilder.
Page 13 / 17

Assembly Instructions / TPR56FV.. - TPR61FV..
5 Storage of new turbochargers and spare parts / 
© Copyright 2018 ABB. All rights reserved. HZTL455311P0033_EN Revision B May 2018
5 Storage of new turbochargers and
spare parts
Storage of new turbochargers and spare parts for 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, indicated by the VCI la-
bel on the package.
Fig.5: Volatile Corrosion Inhibitor (VCI)
Only dry rooms with 40...70 % atmospheric humidity, in which no water condensation can
form, are suitable as storage locations.
Storage of new turbochargers and spare parts for more than 6 months
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 14 / 17

Assembly Instructions / TPR56FV.. - TPR61FV..
5 Storage of new turbochargers and spare parts / 
© Copyright 2018 ABB. All rights reserved. HZTL455311P0033_EN Revision B May 2018
Unpackaging replacement turbochargers or spare parts
Once the material has been unpackaged from the VCI package, the corrosion protection is
no longer effective.
To prevent condensation, the temperature of the package contents must be the same as the
ambient temperature.
Page 15 / 17

Assembly Instructions / TPR56FV.. - TPR61FV..
6 Further information / 
© Copyright 2018 ABB. All rights reserved. HZTL455311P0033_EN Revision B May 2018
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.
One rating plate(01) each is attached on the left and the right side of the turbocharger bear-
ing casing.
Fig.6: Location of the rating plates
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 / TPR56FV.. - TPR61FV..
6 Further information / 
© Copyright 2018 ABB. All rights reserved. HZTL455311P0033_EN Revision B May 2018
Page 17 / 17

Operation Manual /
Contact information
Further information
Find your local service team on our website
(see section “contact us“ / “Contact
information”).
Find and download the Operation Manual of
your product on our website (see “Need
product information” / “Operating
instructions“).
© Copyright 2017 ABB. All rights reserved.
ABB Turbo Systems Ltd
Bruggerstrasse 71 a
CH-5401 Baden/ Switzerland
Phone: [phone]
Fax: [phone]
E-mail: turbochar[email protected]
www.abb.com/turbocharging
Visit our website by
scanning the QR code.
HZTL455311P0033