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Assembly Instructions
Power2 800-M
Original assembly instructions – English
This document is valid for the Power2
series:
Power2 850-M
Purpose
The assembly instructions explain how the low- and high-
pressure stage of ABB Turbo Systems 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 low- and high-pressure
stage on the engine.
Power2 performance package
Two-stage turbocharging solution for highest turbocharging
efficiency
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Table of Contents
Related Manuals for ABB Power2 800-M
Summary of Contents for ABB Power2 800-M
- Page 1 Power2 performance package The assembly instructions explain how the low- and high- Two-stage turbocharging solution for highest turbocharging pressure stage of ABB Turbo Systems is fitted to the engine efficiency correctly and without any health and safety risks. Target group...
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Page 3: Table Of Contents
Installing the low-pressure stage ............. Gaskets ..................... Assembly procedure .................. Installing the high-pressure stage ............Gaskets ..................... Assembly procedure .................. Storage of new low-pressure and high-pressure stages ......Further information ................. © Copyright 2016 ABB. All rights reserved. HZTL455311P0010 Revision - March 2016... -
Page 4: Introduction
Introduction Purpose of the assembly instructions The assembly instructions explain how the low- and high-pressure stage of ABB Turbo Sys- tems 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 2006/42EC. - Page 5 Official service stations of ABB Turbo Systems Official service stations are identified in this document as ABB Turbocharging Service Sta- tions. They are regularly audited and certified by ABB Turbo Systems. See "Contact Infor- mation" on our website at www.abb.com/turbocharging.
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Page 6: Definition Of Warning, Caution, Note
- Mechanical hazards - Dusts - Chemical hazards - Gases - Heat hazards Safety helmet Ear protection Table 3: Personal protective equipment to be worn specific to the respective task © Copyright 2016 ABB. All rights reserved. HZTL455311P0010 Revision - March 2016... -
Page 7: Safety
Safety Introduction The two-stage turbocharging system (Power2) manufactured by ABB Turbo Systems is state of the art and complies with the respective health and safety standards in effect at the time the system was built. Thus Power2 is safe to operate. Nevertheless, there may be some residual... -
Page 8: Lifting Of 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 2016 ABB. All rights reserved. HZTL455311P0010 Revision - March 2016... -
Page 9: Occupational Safety
When performing welding work in the vicinity of the low-pressure stage, always cover the filter silencer to prevent the filter mat from being damaged. Keep flammable objects and substances out of the vicinity of flying sparks. © Copyright 2016 ABB. All rights reserved. HZTL455311P0010 Revision - March 2016... - Page 10 Observe the information in the material safety data sheet for the operating materials and supplies. Comply with local legislation. Wear safety goggles. Wear safety gloves against mechanical risks. Wear a respiratory mask to protect against gases. © Copyright 2016 ABB. All rights reserved. HZTL455311P0010 Revision - March 2016...
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Page 11: Weight And Transportation Of The Low-Pressure And The High-Pressure 3 Stages
Figure 3: Suspending the low-pressure and high-pressure stages Low-pressure stage High-pressure stage Power2 Product Weight [kg] 850 LP Low-pressure stage 1800 850 HP High-pressure stage Table 4: Weights of the low-pressure and high-pressure stages © Copyright 2016 ABB. All rights reserved. HZTL455311P0010 Revision - March 2016... - Page 12 Page 10 / 21 pressure stages Swivel lifting eyes to be used Two swivel lifting eyes (S) are required for the safe lifting of loads. These are not included in the ABB Turbo Systems scope of delivery. Swivel lifting eye (S) Power2 Thread...
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Page 13: Installing The Low-Pressure Stage
Installing the low-pressure stage Fixing elements and installation force The fixing screws for fastening the low-pressure stage are not included in the ABB Turbo Sys- tems scope of delivery and must be designed by the enginebuilder in accordance with the following details. -
Page 14: Gaskets
Gaskets are required in the bracket for sealing the interface of the oil pipes between the bracket and the low-pressure stage. These gaskets are not included in the ABB Turbo Sys- tems scope of delivery and must be provided by the enginebuilder. -
Page 15: Assembly Procedure
Installing the low-pressure stage Page 13 / 21 Gas and air lines The gas and air line gaskets are not included in the ABB Turbo Systems scope of delivery and must be provided by the enginebuilder. Assembly procedure Figure 6: Installing the low-pressure stage Attach lifting gear to the two suspension points of the bearing casing. -
Page 16: Installing The High-Pressure Stage
Fixing elements and installation force The fixing screws and sleeves for fastening the high-pressure stage are not included in the ABB Turbo Systems scope of delivery and must be designed by the enginebuilder in accord- ance with the following details. -
Page 17: Gaskets
Gaskets are required in the bracket for sealing the interface of the oil pipes between the bracket and the high-pressure stage. These gaskets are not included in the ABB Turbo Sys- tems scope of delivery and must be provided by the enginebuilder. - Page 18 Always use new gaskets and insert them carefully into the slot. CAUTION Gas and air lines The gas and air line gaskets are not included in the ABB Turbo Systems scope of delivery and must be provided by the enginebuilder. © Copyright 2016 ABB. All rights reserved. HZTL455311P0010...
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Page 19: Assembly Procedure
Tighten fixing elements at foot and support (see Table 11). Connect the cable connector to the speed sensor. Install air suction branch together with bellows. Secure all gas, air, water and oil pipes. © Copyright 2016 ABB. All rights reserved. HZTL455311P0010 Revision - March 2016... -
Page 20: Storage Of New Low-Pressure And High-Pressure Stages
Storage of new low-pressure and high-pressure stages and cartridge groups for up to 6 months New low-pressure and high-pressure stages and cartridge groups from ABB Turbo Systems can be stored in their closed packages for 6 months from the date of delivery without addition- al mothballing measures (indicated by VCI label on package). - Page 21 or the cartridge group must be checked and repackaged by an ABB Turbocharging Service Station. After every 3 years, the following steps must be carried out by an ABB Turbocharging Service Station: Checking the component Replacing the desiccant ...
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Page 22: Further Information
One rating plate each is attached on the left and the right side of the foot (bearing casing) and to the air suction branch of the high-pressure stage. 1. Read the serial number (02) on the rating plate (01) of the low-pressure and high-pressure stage. © Copyright 2016 ABB. All rights reserved. HZTL455311P0010 Revision - March 2016... - Page 23 Page 21 / 21 The Operation Manual can be found online in accordance with the details on the following page. Figure 14: Finding the Operation Manual online © Copyright 2016 ABB. All rights reserved. HZTL455311P0010 Revision - March 2016...
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Page 24: Contact Information
Operation Manual / Contact information ABB Turbo Systems Ltd Further information Bruggerstrasse 71 a Find your local service team on our website (see CH-5401 Baden/ Switzerland section “contact us“ / “Contact information”). Phone: +41 58 585 7777 Fax: +41 58 585 5144 Find and download the Operation Manual of your product on our website (see “Need product...