Accelleron A100-H Series User manual

Purpose
The assembly instructions explain how
the turbocharger is fited to the engine
correctly and without any health and
safety risks.
Target group
The assembly instructions are intended
for engineers and mechanics responsi-
ble for fiting the turbocharger
on the engine.
Assembly Instructions
Turbocharger /
A100-H radial
Original assembly instructions – English
This document is valid for the
A100-H series:
A130-H, A135-H, A140-H

Assembly Instructions / Turbocharger A100-H
Table of contents
© Copyright 2023 Turbo Systems Switzerland Ltd. All rights reserved. HZTL455311P0004_EN Rev. D March 2023
Assembly Instructions / A100-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 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........................................................................ 21

Assembly Instructions / Turbocharger A100-H
1 Introduction / 1.1 Purpose of the assembly instructions
© Copyright 2023 Turbo Systems Switzerland Ltd. All rights reserved. HZTL455311P0004_EN Rev. D March 2023
1 Introduction
1.1 Purpose of the assembly instructions
The assembly instructions explain how the Accelleron 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 Directive
2006/42/EC.
The assembly instructions are a complement to and expansion of existing national regulations for oc-
cupational 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 tur-
bocharger 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 ® sym-
bol.
Design variants
This document is valid for different design variants of turbochargers. There may be sections and de-
scriptions of components that are not relevant for a specific turbocharger variant.
Accelleron service stations will be happy to provide information about questions regarding a design
variant (see "Contact Information" on the website www.accelleron-industries.com).
Accuracy of illustrations
The illustrations in this document are general in nature and intended for ease of understanding. Dif-
ferences in detail are therefore possible.
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Assembly Instructions / Turbocharger A100-H
1 Introduction / 1.4 Definition of warning, caution, note
© Copyright 2023 Turbo Systems Switzerland Ltd. All rights reserved. HZTL455311P0004_EN Rev. D March 2023
Accelleron
Accelleron Industries Ltd is referred to in this document as Accelleron.
Official Accelleron service stations
Accelleron service stations are regularly audited and certified by Accelleron Industries Ltd (see "Con-
tact Information" on the website www.accelleron-industries.com).
1.4 Definition of warning, caution, note
WARNING
Definition of Warning
Non-compliance or inaccurate compliance with working or operating instructions in-
dicated by this symbol and the word WARNING can lead to serious injuries to per-
sonnel and even to fatal accidents.
uWarning signs must always be observed.
CAUTION
Definition of Caution
Non-compliance or inaccurate compliance with working or operating instructions in-
dicated by this symbol and the word CAUTION can lead to serious damage to en-
gine 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 / Turbocharger A100-H
1 Introduction / 1.5 Definition of mandatory signs
© Copyright 2023 Turbo Systems Switzerland Ltd. All rights reserved. HZTL455311P0004_EN Rev. D March 2023
1.5 Definition of mandatory signs
To be worn at all times
Protective clothing Safety footwear to protect against
mechanical hazard and risk of fall-
ing
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 tighten-
ing 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 accordance
with specifications
Dispose of in an environmentally
compatible, professional way and
in compliance with locally applic-
able regulations.
Oil free, grease free and dry
Table3: Definition of pictograms
Page 4 / 21

Assembly Instructions / Turbocharger A100-H
2 Safety / 2.1 Introduction
© Copyright 2023 Turbo Systems Switzerland Ltd. All rights reserved. HZTL455311P0004_EN Rev. D March 2023
2 Safety
2.1 Introduction
State of the art
Turbochargers manufactured by Accelleron 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 opera-
tion of the turbocharger.
CE conformity information
Accelleron turbochargers comply with Machinery Directive 2006/42/EC and are partly completed ma-
chinery as defined by Article2g.
Residual risks
Nevertheless, there may be some residual risks during operation of and work on the turbocharger
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 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 / 21

Assembly Instructions / Turbocharger A100-H
2 Safety / 2.2 Lifting of loads
© Copyright 2023 Turbo Systems Switzerland Ltd. All rights reserved. HZTL455311P0004_EN Rev. D March 2023
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 suffi-
cient 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 exceeded. 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 / Turbocharger A100-H
2 Safety / 2.3 Occupational safety
© Copyright 2023 Turbo Systems Switzerland Ltd. All rights reserved. HZTL455311P0004_EN Rev. D March 2023
2.3 Occupational safety
General
WARNING
Injuries to persons
Severe injuries to personnel or fatal accidents can be caused by mechanical influ-
ences as a consequence of hazardous and inadequate operational procedures or
non-compliance with safety and health standards.
uWhen working on the turbocharger always wear safety footwear and protective
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 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 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 / Turbocharger A100-H
2 Safety / 2.3 Occupational safety
© Copyright 2023 Turbo Systems Switzerland Ltd. All rights reserved. HZTL455311P0004_EN Rev. D March 2023
Mechanical hazards when working on the turbocharger
WARNING
Mechanical hazard
Severe injuries to personnel or fatal accidents can be caused by mechanical influ-
ences as a consequence of hazardous and inadequate operational procedures.
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 instruction 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 contact with
them may be harmful to health. Flammable and combustible operating 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 operating ma-
terials 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