This document provides assembly instructions for the ABB TPX series turbocharger, specifically the TPX44-H model. These are the original assembly instructions in English, valid for the TPX series.
Function Description
The ABB TPX turbocharger, standing for Turbo Power eXtra, is designed to deliver uncompromising reliability in the toughest environments. Its primary function is to be fitted to an engine, enhancing its performance. The assembly instructions detail the correct and safe installation of the turbocharger onto the engine, ensuring proper integration and operation. The document emphasizes that the turbochargers are state-of-the-art and comply with health and safety standards, ensuring safe operation.
The turbocharger's operation involves the supply and drainage of oil, as well as connections for gas, air, and water lines. Oil is drained through a bracket (01) and supplied separately via a connection at the top side of the bearing casing (02). Gaskets (05) are crucial for preventing oil leaks and must be properly inserted into the support plate's slots (04). A speed sensor (86505) is also connected as part of the installation process.
Important Technical Specifications
- Model: TPX44-H
- Weight: 130 kg (for the complete turbocharger, heaviest variant possible)
- Lifting Eye Requirements:
- Thread M: M18x1.5
- Length H: 30 mm
- Diameter D: 56 mm
- Minimum Load Limit: 130 kg
- Only one swivel lifting eye (S) is required for safe lifting.
- Threaded Rod Requirements for Attachment:
- Diameter Threaded Rod: Ø12/M12
- Material (DIN / ISO 898 Part 1): 10.9/12.9
- Thread Length L1: ≥ 30 mm
- Length of Threaded Rod L2: 170 mm
- Tightening Torque for Turbocharger Fixing Screws:
- Through hole in bearing casing: Ø 14 mm
- Fixing screws: M12
- Tightening torque (assumed friction coefficient μ = 0.12): 100 Nm
- Gaskets: O-ring gaskets with a cord diameter of at least 3.5 mm are required. These are not included in the ABB Turbo Systems scope of delivery and must be provided by the engine builder.
Usage Features
The assembly instructions are designed for engineers and mechanics with basic mechanical training. Key usage features include:
- Clear, Step-by-Step Installation: The document outlines a detailed process for installing the turbocharger, including inserting gaskets, attaching the turbocharger to the bracket, and connecting various lines (gas, air, oil, water).
- Safety Guidelines: Extensive safety information is provided, covering lifting of loads, occupational safety, and hazards related to operating materials and supplies. This includes warnings about suspended loads, risks of falling, mechanical hazards, and handling of operating materials.
- Personal Protective Equipment (PPE): Specific PPE is mandated for various tasks, including protective clothing, safety glasses, safety goggles, safety gloves (for mechanical, chemical, and thermal hazards), respiratory masks (for dusts and gases), safety helmets, and ear protection.
- Pictograms: A comprehensive set of pictograms is used to indicate specific actions such as tightening with specified torque, affixing, measuring, noting, visual inspection, applying pastes, and proper disposal.
- Design Variants: The document acknowledges that it is valid for different design variants of turbochargers, and some sections may not be relevant for all variants. Users are advised to contact ABB Turbocharging Service Stations for specific information.
- Accuracy of Illustrations: Illustrations are general and for ease of understanding, with possible differences in detail.
- CE Conformity: ABB turbochargers comply with the Machinery Directive 2006/42/EC.
Maintenance Features
The manual also provides guidance on storage and long-term maintenance:
- Storage of New Turbochargers and Spare Parts (up to 6 months): New turbochargers and spare parts can be stored in sealed packaging with a VCI (Volatile Corrosion Inhibitor) label for up to 6 months from delivery. Storage requires dry rooms with 40-70% relative humidity and no condensation.
- Storage of New Turbochargers and Spare Parts (more than 6 months): For longer storage, mothballing measures are required every 6 months. This involves opening the package, replacing the VCI corrosion protection emitter with a new one, and resealing the package. Old emitters must be disposed of environmentally.
- Health Protection when Handling VCIs: Warnings are provided regarding VCI products, emphasizing the need to observe safety data sheets, ensure good ventilation, avoid ingestion, and clean hands and face after handling.
- Long-term Storage of Turbochargers: For prolonged storage, ABB Turbo Systems can prepare turbochargers on request. These packages are equipped with a hygrometer.
- Hygrometer Check: Every 6 months, the hygrometer (02) in the sight-glass (01) must be checked. If the display field changes color at the 70% level, indicating excessive humidity, the turbocharger must be inspected and repacked by an ABB Turbocharging Service Station.
- Package Inspection: The package must be inspected for damage. A damaged package necessitates inspection and repacking by an ABB Turbocharging Service Station.
- Periodic Inspection (every 3 years): After every 3 years, an ABB Turbocharging Service Station must inspect components, replace the desiccant agent, and repackage the components.
- Unpacking Turbochargers: The corrosion protection effect ends upon unpacking. To prevent condensation, the turbocharger and its surroundings must be at the same temperature during unpacking.
- Operation Manual Access: The Operation Manual for the turbocharger, specific to its serial number, is available online at www.abb.com/turbocharging. Users can find the serial number on the rating plate (01, 02) of the turbocharger.
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