ABB TPL-C Series Assembly Instructions Manual

Turbocharger

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Assembly instructions manual (24 pages)

Original assembly instructions (24 pages)

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ASSEMBLY INSTRUCTIONS

Turbocharger / TPL-C, TPLVC

Original assembly instructions – English

This document is valid for the TPL-C

series:

TPL67-C, TPL67VC, TPL71-C

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.

TPL-C turbocharger

The reliable peak performer

Table of Contents

Summary of Contents for ABB TPL-C Series

Page 1 This document is valid for the TPL-C series: TPL67-C, TPL67VC, TPL71-C Purpose TPL-C turbocharger The assembly instructions explain how the ABB The reliable peak performer turbocharger is fitted to the engine correctly and without any health and safety risks. Target group...
Page 3: Table Of Contents
Weight and transportation of the turbocharger ..........9 Installing the turbocharger................. 10 Completion work, if required ..................17 Storage of new turbochargers and spare parts ..........18 Further information..................... 20 © Copyright 2020 ABB. All rights reserved. HZTL455311P0014_EN Rev.A July 2020...
Page 4: Introduction
Introduction 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.
Page 5: Definition Of Warning, Caution, Note
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. Definition of warning, caution, note...
Page 6: Definition Of Mandatory Signs
Apply high-temperature grease See document Apply other paste in accordance Dispose of in an environmentally with specifications compatible, professional way and in compliance with locally applicable regulations. Table 3: Pictograms © Copyright 2020 ABB. All rights reserved. HZTL455311P0014_EN Rev.A July 2020...
Page 7: Safety
Safety 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.
Page 8: Lifting Loads
Use a suitable edge guard if there are sharp edges. The assembly devices must be completely screwed in and must not unscrew during use. Use assembly devices only for the described applications. © Copyright 2020 ABB. All rights reserved. HZTL455311P0014_EN Rev.A...
Page 9: Occupational Safety
Welding work close to the turbocharger If 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. © Copyright 2020 ABB. All rights reserved. HZTL455311P0014_EN Rev.A...
Page 10 Observe the information in the material safety data sheet for the operat- ing materials and supplies. Comply with local legislation. Wear safety goggles. Wear safety gloves to protect against chemical hazards. Wear a respiratory mask to protect against gases. © Copyright 2020 ABB. All rights reserved. HZTL455311P0014_EN Rev.A July 2020...
Page 11: Weight And Transportation Of The Turbocharger
Remove insulation jacket and insulation at gas inlet casing. Weights [kg] TPL67-C TPL71-C 1330 2040 Table 4 Weights [kg] TPL67VC32 1330 Table 5 © Copyright 2020 ABB. All rights reserved. HZTL455311P0014_EN Rev.A July 2020...
Page 12: Installing The Turbocharger
Lift the turbocharger as described in the chapter Weight and Transport, place onto the bracket and align. Secure the turbocharger as described in steps 1-10. Foot on turbine end Foot on compressor end Foot contact surface Centre axis Table 6 © Copyright 2020 ABB. All rights reserved. HZTL455311P0014_EN Rev.A July 2020...
Page 13 75/62 Number of cup springs (X) Table 7 -------------------------------------------------------------------------------------------------- Step 2: Insert the CE foot screws with one washer (01) each. Take into account the thickness of the washers. -------------------------------------------------------------------------------------------------- © Copyright 2020 ABB. All rights reserved. HZTL455311P0014_EN Rev.A July 2020...
Page 14 3, 6, 5 NB270 4, 5, 6 Table 8 Table: Pre-tightening torque Product Thread size [mm] Pre-tightening torque [Nm] TPL67-C M 24 TPL67VC32 M 24 TPL71-C M 24 Table 9 -------------------------------------------------------------------------------------------------- © Copyright 2020 ABB. All rights reserved. HZTL455311P0014_EN Rev.A July 2020...
Page 15 In order to determine the position of the bushes, insert the TE foot screws into the bushes without the cup springs and screw them in by two turns. -------------------------------------------------------------------------------------------------- © Copyright 2020 ABB. All rights reserved. HZTL455311P0014_EN Rev.A July 2020...
Page 16 Remove TE foot screws. Grease the contact surface (F) for the cup springs (X) on the foot at the turbine end with high-temperature grease (do not grease bush surfaces). -------------------------------------------------------------------------------------------------- © Copyright 2020 ABB. All rights reserved. HZTL455311P0014_EN Rev.A July 2020...
Page 17 1, 8, 7 NB270 2, 7, 8 Table 11 Table: Pre-tightening torque Product Thread size [mm] Pre-tightening torque [Nm] TPL67-C M 24 TPL67VC32 M 24 TPL71-C M 24 Table 12 -------------------------------------------------------------------------------------------------- © Copyright 2020 ABB. All rights reserved. HZTL455311P0014_EN Rev.A July 2020...
Page 18 NB270 2, 5, 4, 6, 7, 8 Table 13 Table: Tightening torque Product Thread size [mm] Tightening torque [Nm] TPL67-C M 24 TPL67VC32 M 24 TPL71-C M 24 Table 14 -------------------------------------------------------------------------------------------------- © Copyright 2020 ABB. All rights reserved. HZTL455311P0014_EN Rev.A July 2020...
Page 19: Completion Work, If Required
Completion work, if required Attach all gas, air, water and oil pipes in accordance with the enginebuilder's instructions. Fit insulation components. Fit speed sensor and plug in cable connector. © Copyright 2020 ABB. All rights reserved. HZTL455311P0014_EN Rev.A July 2020...
Page 20: 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).
Page 21 Inspect 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: ¡...
Page 22: Further Information
A rating plate is attached to the turbocharger foot, one on the left and one on the right. On turbochargers with insulation from ABB, at least one additional rating plate is attached to the insulation of the gas outlet casing.
Page 24 Phone: +41 58 585 7777 Station”). Fax: +41 58 585 5144 Find and download the Operation Manual of E-mail: turbocharging@ch.abb.com your product on our website (see “Operation Manuals“). www.abb.com/turbocharging © Copyright 2020 ABB. All rights reserved. Visit our website by scanning the QR code.

This manual is also suitable for:

Tplvc series Tpl67-c Tpl67vc Tpl71-c

ABB TPL-C Series Assembly Instructions Manual

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