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TMS-02187

Filing System: Turbo Manuals Service Documentation and Software Systems

Engine Type: NR 20 Installation: Engine Numbers:

TURBOCHARGER
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OPERATING MANUAL FOR


EXHAUS~GASTURBOCHARGERS

TYPE

Nr;t ;~O
SERIAL NO.

to,)

TURBO CHARGER UNION, Post Office Box 100080 0-8900 Augsburg W. Germany
1 l
TURBO CHARGER UNION B.V.

Request to operators

In order to render our servIces as quIck and complete as possible


we requIre the specific datas of your turbocharger beforehand.

Please be so kInd and return the completed postcard to the given


address.

We apprecIate your cooperatIon and thank you In advance,

Your Turbocharger Service·

Please cut out


r - '- -- - ---: - - - - - - - - - - - - - - - -- -
I Type of turbo: .
I Postcard
I Serial No.: ••••••••••••••
I Turbo Charger Union
I CommIssIoning date: . B.V.
N I Branch Office
I
ol(") I Name of plant: Department SL
o I . Postfach 10 00 80
I
I Installed englne type: D-8900 Augsburg
I ..... , ....••. I • • • , • I •• I • • • • West Germany
I
I Address of owner:
I
J
NR 20
TABLE OF CONTENTS
036 55 L.9-20E
Sheet
TECHNICAL DATA
Section 1
Brief description .............•........••...... 51
1
Operating data •.•.•....•...•......•......•...... 51
Pi pe connect; ons ...••....•......•..•..........•. 51
Weights 51
Longitudinal section ......•........•............ 51
Gaps and clearances .....••............•..•...... 52

Section 2 DESCRIPTION OF SYSTEMS


Lubricating system •.......•.•••.•.•.•.•....•••.. 51 2

Section 3 OPERATION AND OPERATING DIFFICULTIES


Starting ..•..............•....•................. 51
3
Operating ......•...•....•...•..........•........ 51
Shutti ng down •.••...•....•.•....•.....•...••..•. 51
Operating difficulties ..•......•..........•..... 52
Cartridge ..•...........•....•..••......•...•.... 52
Emergency operation with inoperative
turbocharger •.•....•....••..•................... 53
Fault-finding chart ..............•..•........•.. 54

Section 4 MAINTENANCE 4
Maintenance schedule .•................•......... 51
Maintenance work ..........•..•............•..... 52
Form IlInspection Findings" .......•.............. 53
Work cards (description) 54
Hints 55
Work cards ..•...•............................... 500.01 -

Section 5 SPARE PARTS LIST 5


Ordering spare parts .....................•....•. 500.01/2
Spare parts .....00 ••• 0 ••• 0 500.01/ .•.
••••••••••••••••••••••

\0
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co 036 5649- 20 E
ABGASTURB :>lADER
1
=heu EXHAUST TURBOCHARGER
TURBO-COMPRESSEUR
TURBOSOBREAllMENTADOR
SOBREAl IMENTADORES
TURBOSOFFIANTI A GAS DI
50

SCARICO

TECHNISCHE DATEN I
TECHNICAL DATA

CARACTERISTIQUES TECHNIQUES

DATOS TECNICOS

DADOS TECNICOS

DATI TECNICI
-

D365650 1 .50 - 1
TECHNICAL DATA 1
Brief Description, Operating Data, NR 20
Pipe Connections, Weights 51

Brief Description
Exhaust gas turbocharger with a single-stage radial-flow turbine and a single-
stage radial-flow compressor.
Rotor supported in 2 centrally located floatingly seated plain bearings with
the impeller (compressor wheel) and the turbine wheel overhung.
Turbine wheel integral with shaft, impeller (compressor wheel) mounted.
Gas inlet divided to suit exhaust manifold.
Compressor with 1 outlet socket.
Air intake casing or silencer.
Bearing lubrication connected to engine forced-feed lubricating system.
No water cooling.
Operating Data :

Admissible maximum operating speed, see type plate -


:
,
Exhaust temperature before turbine, see engine operating manual
Lubricating oil pressure at inlet of bearing casing ......•.. bar 1. 1 - 1 .3
--
Lubricating oil flow rate SAE 30/60°C or SAE 40/70°C
at turbocharger speed of 10,000 rpm ..••.••. lit/HR 750 - 850
at turbocharger speed of 40,000 rpm .•..•.•. lit/HR 450 - 550
Lubricating oil filtered to particle size of less than mm 0.05
Admissible maximum oil temperature atinlet of bearing casing °C 85
Admissible maximum oil temperature at outlet of bearing casing °C 105 0-

For further operating data, refer to engine acceptance record


-
Pipe Connections
Lubricating Oil Inlet on bearing casing, top Thread M14xl.5
for screw connection
of oil supply pipe
Outlet on bearing casing, bottom Oval flange connec-
tion for tube 30 x 2
or for tube 28 x 2
-
We; ghts (approximations) -
Turbocharger complete with silencer ...•..................... kg 131
Turbocharger complete with air intake casing . kg 115
Replacement type cartridge •................................. kg 36
Silencer with air filter (air filter 5 kg) . kg 25
Air intake casing ...................•....................... kg 9
Compressor cas i ng ...................•....................... kg 30
Gas admission casing . kg 40 -
-

036 5649 E 1.51-2 P.T.D.


50' --+--t.-l

545-~

562 ~~--+--51 7

544 546 591-......


~l
N.

~1
~~----1r-----~--j

501 Gas admission casing


513 Turbine nozzle ring
517 Bearing
520 Rotor
542 Final diffusor
544 Silencer
545 Air intake casing
546 Compressor casing
591 Lagging on gas admission casing

D 36 5649 E 1.51-2
1
TECHNICAL DATA NR 20
Gaps and Clearances 52

Measure radio I gaps <Dand


@ using feeler (thickness)
gauge,
~nd axial gaps ® and @ by
means of soft meta I imprint
(lead wire). Always measure
at 3 points on the circvm-
ference and calculate mean
~_s-t-+--G) value.
....1.--++--+---f-+--"~,@

Apply dial gauge to suitable


axia I surface and measure
axial play@of rotor by
vigorously moving the rotor in -
®---+--+-~ the directions A and B.

Posn. When new Replace or


in Designation of Parts Part No. Gap Clearance re-machine parts
Fig. min max min max min max
Compressor wheel - Com- 520.005 0.65 0.75 0.55 0.85
ressor casin , radial 546.001
2 Compressor wheel - Com- 520.005 0.50 1.15 0.40 1.25
pressor casin , axial * 546.001
3 Rotor - Gas admission 520.001 0.50 0.57 0.40 0.70
casin , radial 501.001
4 Rotor - Gas admission 520.001 0.50 0.90 0.40 1.00
cas;n , axial ** 501.001
5 Bearing bush - Labyrinth 0.20 0.27 0.33
ring

Admissible aberration from the plane of rotation bf the compressor


wheel (impeller)
(measured with dial gauge at largest radial distance) 0.06 mm
Admissible transverse movement of rotor in bearings ••• See VVork Card 500.06

* measured with rotor pushed up in the direction A} *


** measured with rotor pushed up in the direction B
S3 • with the rotor pushed up in opposite direction, withdraw measured axial play ®
o 36 5649 E 1 .52 - 2
ABGAS TURBOLAOER
2
~u
EXHAUST TURBOCHARGER
TURBD-COMPRESSEUR
TURBOSOBREALtMENTADOR 50
SOBREALIMENTAOORES
TURBOSOFFIANTI A GAS 01
SCARICD

SCHEMABESCHREI BUNGEN
I
DESCRIPTIONS OF SYSTEMS

DESCRIPTIONS DES CIRCUITS

DESCRI PCI ONES ESQUEMATleAS

DESCR Ic;OES DE ESQUEMAS

DESCRIZIONE SCHEMI

D365650 2.50 -1
DESCRIPTION OF SYSTEMS 2
NR 20
51
Lubricating Oil System

Primi ng ri ght before start-up Interval type primi ng

2 2
t t
7
t
====1 =====1
3642263

LECE{)
1 SI.4>Ply pi pe (eng; ne ) 5 Exhaust turbocharger
2 SI.4>P1y pi pe (turbocharger) (bearing hwsing)
3 Thrott1e poi nt 6 Di scharge pi pe (turbocharger)
4 Pressure check JX>i nt 7 tb1-retum (check) va1ve
(pressure gauge) 8 SI.4>Ply pi pe (primi ng of turbocharger)

_F~r priming and during'operation~ the turbocharger is connected to the lu~e


oil circuit of the engine. The oil serves for bearing lubrication and also
for dissipation of heat.
Lube oil supply scheme:
Engines being primed immediately before start-up
Supply line (2) with throttle point (3), connection at top of bearing
housi ng (5).
Engines with interval type priming system
Supply line (2) with throttle point (3) and non-return valve (7), connection
at top of bearing housing (5). Additional supply line (8) for turbocharger
priming, connection to supply line at pierced retaining screw located
laterally at bearing casing (5).
In compliance with plant layout, non-return valve (7) must be closed during
priming and with the lube oil pumps at rest and open during operation,
thus preventing the turbocharger from being flooded during priming and
from being emptied after shut-down of lube oil pumps.
For oil quantities required, grade of filtration, pressure and temperature,
refer to Technical Data, Section 1, Sheet 51.
The required lube oil pressure is adjusted by a throttle point (3) connected
in the supply line (2) (e.g. by an orifice plate).
Tap-off for pressure checks (connection for pressure gauge) is to take place
immediately before the supply pipe is connected to the bearing casing.
Lube oil discharge: To be unrestrained, at maximum possible drop (slope).
In case of marine plants: At least 5° over maximum possible inclination of
ship.

036 5649 E 2.51- 2


ABGAS TURBOLADER
EXHAUST TURBOCHARGER
TURBO-COMPRF.SSEUR
3
TURBOSOBREALIMENTADOR 50
SOBREALIMENTADORES
TURBOSOFFIANTI A GAS 01
SCARleo

BETRIEB UND BETRIEBSSTORUNGEN I


OPERATION AND OPERATING DIFFICULTIES

FONCTIONNEMENT ET INCIDENTS
DE FONCTIONNEMENT

SERVICIO E IRREGULARIDADES EN EL
FUNCIONAMIENTO

OPERA<;AO E ANOMALIAS DURANTE A OPERA~AO

ESERCIZIO ED AVARIE 01 FUNZIONAMENTO


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~ D365650 3.50 -1
OPERATION -3
Starting, Operation, Shutting, Down NR
51

Preparations for Operation


The bearing points of the turbocharger need be primed (pre lubricated) prior to start-up of the
engine. Depeding on plant layout, two types of priming systems are available: Priming right -
before start-up, or interval type priming with breaks not exeeding a duration of 2 hours.
For lube oi I system, refer to section 2, sheet 51.

Starting
The turbocharger being driven by the exhaust gases of the engine wi II start up automatically
as the engi ne ;s started.

Operation
Instrument readings should be taken at regular intervals during operation to the extent
instrumentation is provided:
1. Exhaust temperature at inlet of turbine
2. Charge air pressure at outlet of ccmpressor
3. Lubricating oi J pressure at in let of turbocharger
Furthermore, the following checks should .be made at regular intervals:
4. Exhaust I charge air and oi I pipes for tightness
5. Air filter and silencer for fouling (if fitted)
6. Turbine rotor whether it is running freely
7. Turbocharger whether it is running smoothly

Incipient rotor or bearing damage is usually indicated by erratic operation caused by


imbalance cr contact of rotating parts with stationary components. Erratic operation can
often. be determined at an early stage by listening for unusual operating noises. In such
cases the engine should be stopped immediately, if possible, and the turbocharger inspected.
Seri ous damage can thus usua Ity be prevented.

Rotor speed and charge air pressure are interdependent, i. e. the roter turns at a certain speed
at a given charge air preS$ure provided the air ducts of the compressC'" are in-clean condition.
The charge air pressure can thus be used to approximate the rotor speed. -
Shutting Down
After shut-down of engine, the rotor of the turbocharger continues running for some period
of time due to its flywheel effect. Sudden stoppage is indicative of mechanical defects
(defective bearings, compressor or turbine wheel making contact with stationary parts,
obstructions caused by foreign matter etc.).

On stopping the engine, the turbocharger requires no additional measures for lubrication as
it is connected to the force-feed lubricating system of the engine.

Measures for Loying Up


For preserving the turbocharger, if it is to be laid up for a long period of time, proceed in
accordance with the instructions, as applicable, given for the Diesel engine (See Engine
Operating Manual).

D365649 E 3.51-1
OPERATION 3
Q:>erating Difficulties NR 52

Operating Difficulties -
As a rule, faults developing in the turbocharger are accompanied by abnormal instrument
readings (exhaust gas temperature, charge air pressure and speed), high noise level or leaking -
lubricating oil pipes. If any irregularities should be noticed in a turbocharger during start-up
or operation of the engine, the couse should be determined at once and remedial action taken.
Failure to attend to what may be a minor defect initially is liable to give rise to serious conse-
quential damage to the turbocharger and even to the engine. If there are any irregularities,
reduce the engine load or shut-down the engine, if possible, and do not restart it until after
the cause of the trouble has been removed.
Hit-and-miss tadics in attending to trouble should be avoided as they are rarel y successful.
The instructions given hereunder a~d the fault-finding chart are intended to assist in diagnosing
the cause of irregularities experienced accurately and suggest how the problem can be overcome
quickly.

Cartridge
Repair of a defective rotor in general requires the skill and the tools of specialised shops, as
the parts rotating at very high speeds are sensitive to any unbalance. However, with a spare
cartridge kept on stock the operator of a plant wi II be able to bring a defective turbocharger
back irto operating condition within a short time and with a minimum of assembly work.
The cartridge, comprising the complete bearing casing with the 2 bearings and the balanced
rotor, is ready for installation. Effective, on the spot overhaul of the turbocharger is thus
quite simple as the casings on the compressor side and on the turbine side can be removed from
the cartridge with the use of standard tools only.
,
We would therefore recommend that a cartridge be included in your spare parts stock so as to
have it avai lable when needed. The cartridge can be ordered under the order no. 599.001
either from the manufacturer's works or one of our representatives. The defective cartridge
CDn then be sent in for repair either to us or one of our representatives.

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D36 5642 E 3.52-1
3
OPERATION NR
Operating Difficulties 53

Emergency Operation with Inoperative Turbocharger I-

If, for the time being, there ;s no possibility to repair the in- I-

operative turbocharger(s), the engine can, in absolute emergencies,


be further run with reduced load.
In such a case, fuel admission and thus the engine output must be reduced
so far that the maximum admissible exhaust gas temperatures and, on
engines with 2 turbochargers, the maximum permissible speed of the one
turbocharger still in operation are not exceeded.

In addition, the following applies to the inoperative turbocharger:


1. Interruption of engine operation not possible: -
The inoperative turbocharger remains in place.
This emergency situation should be confined to an absolute m1n1mum of
time as additional damage to the turbocharger cannot be excluded.
In the event of rotor being stationary, lube oil supply to the faulty
turbocharger must at any rate be cut off due to risk of fire.
2. Interruption of engine operation possible for ash 0 r t period of time
For measures to be taken on the engine, refer to Operating Instructions
concerning the engine.
In case that further conduction of the exhaust gases through the faulty
turbocharger is compulsory:
,
Remove cartridge of faulty turbocharger and replace by sealing cover
(refer to section 4, work card 500.05).

If, in case of engine with 2 turbochargers, close-off of the charge air


and/or exhaust line on the faulty turbocharger ;s required:
Remove faulty turbocharger complete (cf section 4, work card 500.10).
Depending on engine version, close off (seal) or reconnect the lines
concerned.

036 5642 E 3.53-2


FAULT-FINDING CHART
NA 3
NR
54

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Silencer resp. air filter clogged

Compressor dirty

Nozzle ring dirty


Air cooler dirty

High intake air temperature

LOW intake air temperature


hir manifold leaking

Exhaust pipe leaking

High gas backpressure after turbine


Faulty fuel injection on engine
Bearing damage

Turbine or impeller damaged


Rotor contact

Foreign matter in turbine or impeller

L~byrinth ring or locating ring damaged


Seals damaged, connections leaking

lube oil passages, filter clogged


Excessive pressure in oil discharge or in crankcase
Inlet and/or exhaust valves dirty

Lock-air ineffective
Oil pressure gauge defective
High oil admission temperature
~t----------------------""'_--I_-"""-"""'--"""'---"'-_.&:.:.-':lI:.o:.I._-"""--~
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.- D36 5642 E 3.54 -1
ABGAS TURBOLAD ER
4
b:.u
EXHAUST TURBOCHARGER
TURBO-COMPRESSEUR
TURBOSOBREAL IMENTADOR 50
SOBREALIMENTADORES
TURBOSOFFIANTI A GAS Dl
SCARICO

WARTUNG I
fv\A INTENANCE

ENTRETIEN

ENTRETENIMIENTO

fv\A NUT EN C;Aa

MANUTENZ lONE

D365650 4.50 -1 1
MAINTENANCE NR 4
Maintenance Schedule 51

The MAINTENANCE SCHEDULE is a summary of all maintenance work up to a major -


overhaul of the turbocharger every 15,000 ± 500 operating hours.
Always when a major overhaul of the turbocharger has been carried out - for -
practical considerations in common with an engine maintenance being due -
the maintenance schedule is to be started anew.
In consideration of the operational safety of turbocharger and engine, the
maintenance work should be carried out as timely as possible and not later
than scheduled.
Cross-sections of the compressor being reduced by layers of dirt will adversely
effect the performance of the engine. Therefore, if operating ;n areas of
heavy dust concentrations in the air, shortening of the cleaning intervals
for the compressor components may be required.
-
For checks to be carri'ed out during operation ;n regular intervals, refer
to section 3, sheet 51 .
. . --
Posn. MAINTENANCE WORK Service Work
Interval Card
in Hours No.

501 COMPRESSOR CLEANING during operation: every 24 500.08


Actuate compressor washing apparatus

502 *) TURBINE CLEANING (dry cleaning) during ~ every 24 500.07


operation: Actuate turbine cleaning
apparatus

503 *} TURBINE CLEANING (wet cleaning) during every 100 500.07


operation: Actuate turbine washing device

504 +) AIR FILTER CLEANING: every 250 500.11


Air filter removed from silencer

505 INSPECTION: with new or 500.10


Check all mounting screws, casing screws overhauled
and pipe line connections for tight fit turbocharger
by tapping, retighten if necessary once after
1000

506 COMPRESSOR CLEANING in dismantled condition: every 5,000 500.14


Compressor inner components, final diffusor, -: 250
compressor wheel

507 +} SILENCER CLEANING in dismantled condition: every 5,000 500.12


Silencer felt linings + 250

508 MAJOR (GENERAL) OVERHAUL: every 15, 000 500.06


Dismantling, cleaning, inspection, ~ 500 500.10
cheking and cleaning cartridge, checking etc.
bearing clearances, checking gaps and
clearances on reassembly
*) If operated on heavy oil: Either POSe
502 or 503 depending on version
D36 5649 E 4.51-2 +) Version with silencer only
4
MAINTENANCE NR
Maintenance Work 52

Maintenance Work 10-


In order to ensure continued safe and reliable operation, and to keep the turbo-
charger in good condition, it is necessary that the inspections and checks to _
be made at certain intervals are carried out in accordance with the Maintenance:
Schedule (sheet 4.51). Careful observation of the turbocharger performance w,ll
enable the personnel to detect any deficiencies in good time.
Dismantling or partial disassembly of the turbocharger should, however, be lim-
ited to the work to be carried out within the scope of the Maintenance Schedula~
Minor deficiencies can normally be repaired by the engine room personnel. But
any investigations or work beyond this scope or the repair of major damage -
should only be carried out in the manufacturer's works or by one of the service
stations because they are equipped with the necessary balancing machines for
determining any rotor imbalance, as these high-speed rotating parts are sensi-
tive to any rotor-mass eccentricity. -
It is recommended that a cartridge be kept on stock or be ordered in the event
of rotor or bearing damage as this is the quickest way of repair and resuming
engine operation. This cartridge comprises the bearing casing with bearings and
the fitted and balanced rotor and thus all wear parts. The seals and gaskets
necessary for installation of a new cartridge are supplied with it.
The work to be performed on the turbocharger ;s exactly described on the work
cards step by step in sequential order. The question whether it will be easier
to disassemble the turbocharger in place or after removing it, depends on the
space conditions in the engine room. In most cases it will be sufficient for the
purpose of carrying out maintenance and inspection work to remove only sections
of the unit. Dismounting the complete turbocharger from the engine is normally
necessary only for a general overhaul.
If, during disassembly, any bolt or nut should resist removal because it has
seized, avoid using excessive force which is liable to destroy the part and
necessitate replacement. Also, this may result in the need to recut threads or
to drill out fractured bolts that are stuck in the casing. The best method to
start with is to try to free the threads by turning the bolts or nuts carefully
back and forth, using Diesel fuel or a highly fluid special agent (e.g. Caramba
or Omnigliss). These solvents should be applied liberally and allow to act upon
the bolted or screwed joint for some time (1/2 hour or more) so that they will
be able to penetrate right down into the threads. The recommendations-issued by
the makers of such solvents should be observed.
Bolts and nuts used in joints exposed to elevated temperatures are made of non-
scaling materials. In order to prevent normal bolts and nuts being substituted
by mistake, non-scaling nuts are identified by a small collar at their end face~
and non-scaling bolts are marked by identification letters on their head. Bolts
and nuts made of normal material are unsuitable for assembly of these ~omponents
During disassembly, care should be taken to see that these non-scaling bolts and
nuts are not mixed up with normal ones; if necessary, they should be kept sep-
arate until reassembly. In order to prevent bolts and nuts from carboning in
place and to facilitate futur dismantling, such screwed connections and the
seating areas should be coated with special lubricants every time they are as-
sembled. This applies especially to all bolts and nuts on the turbine end. Suit-
able lubricants are, for instance, MoS2-based lubricants which are available in
form of pastes (e.g. Molykote HSC) for this purpose. Before applying these lu-
bricants, the threads should be thoroughly cleaned from a'l foreign matter.
Threads of stud bolts remain untreated.

036 5649 E 4.52-2 P.T.D.


Cleaning Air Filter and Silencer
The air filter and the silencer must be cleaned as necessary, the intervals
between cleaning being dependent on the contamination of the air drawn in.
Cleaning Compressor
Fouling of the air passages in the compressor will reduce the amount of air
delivered. This is indicated by a decrease in charge air pressure at a given
operating point of the engine and, as a result, exhaust gas temperatures and
fuel consumption will go up. The intervals at which cleaning is required vary
according to specific operating conditions and the relative purity of the air
drawn in. It is recommended that the compressor be cleaned or washed when the
charge air pressure at a given operating point and a given temperature of the
a1r entering the compressor has dropped more than 4% though the air filter is
in a clean condition.
There are two methods of cleaning:
1. Mechanical Cleaning
In order to clean out dirt deposits mechanically, it is necessary to remove
the silencer and the complete compressor casing. The compressor wheel (impeller
is left on the rotor shaft (turbine shaft) during the cleaning operation.
Fuel or another liquid solvent is used to wash off the deposits. Great care
must be taken to keep the liquid out of the bearing bush and the charge air
pipe.
2. Cleaning of Compressor during Operation by Washing System
A washing system is available to clean the compressor also during operation as
long as deposit build-up is not too far advanced (cf work card 500.08).

Cleaning of Turbine
It is possible that a washing device for cleaning the turbine during operation
is mounted (optional equipment) - (cf work card 500.07).
Inspecting/Checking Component Parts
On occasion of a general (major) overhaul of the turbocharoer, or when under-
going repairs, and when essential components are concerned, we recommend to
make notes on the condition of the individual parts and to enter them into
the log book.
A blank form "Test Results" ;s attached as a sample.
For judgement of wear, refer to table "Gaps and Clearances" in section 1.

D36 5649 E / 4.52-2


CHECK LIST Date t
f ••••••••• t,' I, ,: ft.,

Turbocharger: NR f t.

With Engineer's Report dtd ....••.•.....


~------.;..._---L_---------------t Ser i al No. : ...•.........,...'
Name of cus tomer .........•...............•..................•.•....
Address ." , I
Engine type:
•••• ,. ••• t • I , •••••••••• t

Sit e / sh i piS name ••••••.•.••••••••••••••••••••••.•..••••••••.••••• Sar i aL No. :

Turbocharger inspected - overhauled on ..•..•..•....•. by ••••••••.•••••••••••••••.••••••••.•.••••


Reason • t 11 •••••••••••••••••••••••••••••••••••••••••••••• t •••

Last inspection - overhaul on •.........•............. by •..•••••••.•.••.•..•••••..•••••••••.••••


Service hours since the lost inspection - overhaul t to.h
Serv i ce hours s j nce COIllIl iss i on i ng .. . •. . •. . . . . . . . . . . •. . . •. . •. . . •. . . •. . . . ••. •. •••. . .. . . . . . . . .. . •• h
CONDITION OF COMPONENTS
Silencer + <:)
Ai r- i ntoke cos i ng + 0 8
(:) cleon
dus t y
Gas-admission casing,
I"sar t piece +

cond j t ion
of felt plates..........
§
oily
soo t y
satisfactory
Gas exit diffusor + 0 clean
0 rus t y
c:> sooty
bod c:> scaled
-- - - - - - - - - - - - - - 0 cracked
Comp~essor casing. <=) clean
Insert piece + <:) dusty Stud scre.s ...•......... <=) satisfactory
o
0 ily traces 0 broken
traces 0 sooty of rotor contact. .... to. 0 no 0 yes
0 local [clock)
of ro t or con t ac t .•.....• 0 no 0 yes 0 total circumference
o
local ........ (clock)
(:) total circumference
0 radial 0 axial
<:) reused
8
~:~~~~ 0 axial >- O_re_ploc_ed _
(:) replaced Cartridge in assembled state
~--------------
Diffusor <:) satisfactory turbine side .••...•.•.. (:) clean
o bent 0 0i l traces
o cracked
<=) loose
<=) reused turbine rotor...........
8
0 ca~bon residue or oil
heavy fuel coating
satisfactory
o replaced 0
~Turb i-n~ nozz-le ring - -O-sa-ti sf ac to-ry -
o bent
(blades)
- - damaged by fore j gn
matter.......
bent
cracked 8
on leading edges
o(:) scaled
cracked 0 on blades
traces of contact ..... <=) no 0 yes
<=) eroded <:) local
(:) loose 0 total circumference
o damaged by foreign 0 radial 0 Qxial
matter compressor side <=> clean
o reused <=) dusty
- - - - - -
+ if provided
- _O_re_placed - - - - 8:il;Y
co
: D365649E 4.53-2 PTO
r-----------------~---------------.....,
Compressor wheel .......• (:)
(blades)
damaged by foreign
8 satisfactory
bent
cracked
Gaps cnd clearances(section 1, sheet 52)
Transverse play of rotor Wlm
matter O on leading edges Axial runout
o
to . .

on blades of compressor .heel ........•........•..... mrn


traces of contQ~t ..... O no <:) yes Radial gap •. (1)
o local
11 11m

o total circumference Axial gap •••..••••.••.•• ~ .••.•...••.... 11m


o radial <=) axial
Cartridge (599.001) .... 8 reused
replaced
Radial gap ••..•.•••.•••• Q)
Ax i at gap .. , .•• ®
t • t ••••••

Axial clearance ......... (5)


,
,.
Rim
mm

o d, sossembled to ••••••• 1m

CONDITION OF SiNGLE PARTS OF CARTRIDGE


<:) reused
Bearing casing(517.001J Sealing cover, compressor side reused 8
replaced
8
(517.017) or (517.087) + replaced

lock-air passages ~
oil passages 8 cleon
b

c eon.
d reason: ..•....••............••.•.••.•........•..
c~r on covere -T;bi~ ~orl520.001i - - -Oreused - -
0 replaced
O restricted
0 Clogge d r . o
i' l 'd t'
rlC,lono OXI 0 'on.......... 0 no
<:) yes
reason: 11 , ••• " • , •••• , , , , ••

.... - - _ - - - - - - - - - - - reason: ., , .
Bearing bush[517,OO2) o reused 1-- - - -
Compressor ,heel(520.005l
- - - -
<:) reused
- - - - --

Oturbine side
8o
(:) replaced
replaced
(:)compressor side
Quality of fit ••............. satisfactory
reason: .. , ..... medium
r--------------- o poor
I ••••••••••••••••••••••••••••••••

Spacer sleeve(517.003) 0 reused


o rep l aced reason: ......•..•...............................
reason:
~B~j; ~e;(517.008)-:; -
It

<:) ~used - - -
~--------------
Labyrinth ring(520.006)
replaced
8 reused

o rep laced reason: .•.....•...•...•..........•..............


1---------------
reason: •...•...........••.........•..•.....•.••. R t (520 000)
~ - - - - - - - - - - - - - - 0 or .
Coverf517.009)+ (:) reused --;;balanced (:) no
(:) replaced <:) yes
condition before
reos on: , , .
---------------- rebalancing O satisfactory
Sealing cover. turbine side <:) reused , 0 bad
0
(517.017) +
reason: I ••••••••••••• 41 ••••••••• _
replaced
••••••••••••••
~--------------

Seals. · · · · •· · · ·· · · · ·· · ·· ·· · · · · · · 8~:~l~~ed
+ if provided
Remarks:

036 5649 E / 4.53-2 signature


tAA1NTENANCE 4
NR
Work Cards
54

Work Cords -
The Work Cords supplied with the Q:>erating Manual are consecutively numbered and arranged ,....
in the order of operations required for maintenance and inspection as well as the replacement
of the cartridge (cf List of Work Cards 500.01). The instructions given on the individual cards
relate only to the job stated in the heading. Depending on the scope of overhaul or repair
work, one or several Work Cards may be required (see Reference Table).

The numbering of the Work Cards is based on a five-digit code, the first 3 digits of which are
the component code which is 500 for turbochargers, the lost 2 digits being a consecutive num-
ber. ---
Example:
500 12
T
1 Consecutive Number (12 Card)
_ _ _ _ _ _ _ Code Number for Turbocharger

lhe Work Cards include guiding information on the amount of time and manpower required
(manhours). The time indicated applies only to the set of operations for the job described
(1. for disassembly or removal and 2. fer assembly or installation) on the card concerned.
The information given is on the uriderstanding that the personnel employed is familiar with the
work involved and that a II necessary tools are at hand. It is also assumed that the turbocharger
is readi Iy accessible and that a hoist is available for lifting off the heavy ports. Furthermore, _
the times shown ore based on a normal condition of maintenance. The nomed times maybe
considerably exceeded when ports have suffered damage. f-

D36 5642 E 4.54-3


MAINTENANCE 4
NR 20
Brief Hints 55

-
Brief Hints
The table below lists those work cards which are required for recurring work.

Maintenance Job Work Cards required

CLEANING COMPRESSOR
during operation . 500.8
in disassembled condition . 500.10 through 500.14
CLEANING TURBINE
during operation ..•............ 500.07
in disassembled condition .•.... 500.10 through 500.17
CLEANING AIR FILTER
in disassembled condition 500.11
CLEANING SILENCER
in disassembled condition 500.11 through 500.12 -
CHECKING CARTRIDGE (check of bearing
clearances)
with cartridge removed . 500.10 through 500.17 and 500.06
in disassembled condition . 500.10 through 500.18
REMOVAL AND MOUNTING OF COMPLETE
TURBOCHARGER 500.10
GAPS AND CLEARANCES see Section 1, Sheet 52

,..... 036 5649 E 4.55-2


=b...cu LIST OF WORK CARDS
NR 20
Arbeilskorle·Nr
Work card No
Corle trol/oil No
Tor,elo lrobojo No.
1500
500.01

Work Card Designation

500.05 PUTTING EXHAUST TURBOCHARGER OUT OF OPERATION


(emergency operation of engine)
500.06 CHECKING ROTOR FOR TRANSVERSE MOVEMENT (bearing clearance)
500.07 * CLEANING TURBINE (wet cleaning) during operation
500.07 * CLEANING TURBINE (mechanical/dry cleaning) during operation
500.08 CLEANING COMPRESSOR during operation
500.10 REMOVING AND MOUNTING TURBOCHARGER
Separating and reconnecting the connections
500.11 * REMOVING AND REFITTING AIR FILTER
Cleaning
500. 12 * REMOVING AND REFITTING SILENCER
* Removing revolution transmitter
Dismantling an~ cleaning
500. 13 * REMOVING AND REFITTING AIR-INTAKE CASING
* Removing revolution transmitter
500. 14 REMOVING AND REFITTING COMPRESSOR CASING
Removing final diffusor
Cleaning
500.15 REMOVING AND REFITTING GAS-ADMISSION CASING t
TURBINE NOZZLE RING
500.16 REMOVING AND INSTALLING CARTRIDGE
500.17 CHECKING AND CLEANING CARTRIDGE

* These work cards are required only if they apply


to the turbocharger version in question

036 5649 E
500.01-2
PUTTING TURBOCHARGER NR 20 500
OUT OF OPERATION Arbeitskarle·Nr
Work cord No.
Carte tra"ail No 500.05
(Engine Emergency Operation) Tarjeta trabojo No.

associated work cards 500.16


'j through 500.16

+ \\ TOOLS REQUIRED
Open e~d wrench A/F 13
t
.---.....t-.~ Open end wrench A/F 17
596.027-.......J .-L- Open end wrench A/F 19
.J Socket wrench A/F 17
Lifting gear with rope
SPECIAL TOOL
501.008
(available on special order)
501.007
501.005 596.027 Cover
SOL 001 -i-----1~~~~___<')1
LEGEND
501.001 Gas admission casing
501.005 Clamping shoe, 2-part
501.007 Lockwasher
501.008 Hexagon nut

+1'- +---1"
+-.- +J
L.- --i

GENERAL
For given possibilities and instructions with regard to engine emergency operation, refer
to section 3, sheet 53.

STARTING POSITION
Full downflow of the exhaust gases through the defective turbocharger must be maintained.

SEQUENCE OF OPERATIONS
1. Disconnect all connections until the cartridge can be removed (cf work card 500.10).
2. Remove individually or in common: silencer or air-intake casing, compressor casing, and
cartridge (cf work cards 500.12 through 500.16).
3. Using clamping shoes (501.005), lockwashers (501.007) and hexagon nuts (501.008), mount
cover (596.027) to the gas admission casing (501.001).
4. Seal up lube oil supply line and lube oil discharge line.
5. Seal up line for jet assist (if fitted).
Note: Dependent upon engine version, it might be necessary to also seal up the charge air
line (refer to Operating Instructions for the engine).
In case of emergency operation of the engine, its performance has to be limited to
such a degree that the maximum permissible exhaust temperatures are not exceeded.

036 5649 Poe!' ,ebSSIUnde- n


ArDc,ISZt" - ~Iv"'cler, Aile
500.05-1
as 'req U1• re d
Wor'"nQ "me - HOlJrs Every OperOl,ng hours
Our~ at troveil - HelJr.es Toules les Heures de morcne
T.empo oe lrcbolo - Horos Codo Horo< de lCrlr.(.O
CHECKING ROTOR FOR NR 20 500
TRANSVERSE PLAY
(Bea~ing Clearance)

520.005 517.002 520.001

TOOLS REOUIRED
1 Dial gouge
1 Dial gauge holder
LEGEND
517.002 Bearing bush
520.001 Turbine rotor
520.005 Compressor wheel

36 35 634

to 1.00 Range of admissible transverse play (corresponds to the tolerances


of the radial bearing clearance for new turbochargers)
1.00 to 1.30 Inspection of single parts of the cartridge by specialized service
personneL during the next opportunity.
Checking: Qual ity and pressure of the lube oil.
above 1.30 Operating reliability endangered.
Replace the respective ports through specialized service personnel
or exchange cartridge.
Checking: Qual ity and pressure of the lube oil.

~ 036 5649 E Ar-b. i h;u i 'T


Work i ng t i ••
- Stund.n
- Houri ~~~~y Be darf B.tr i .b.. tundln
Op.ra t j no houri
C> 500.06-2 eL,... d. t rOYel i l - Heu,..•• Tout •• l •• H.u,.•• d. r.Q,..ch.
T i ..po d. lrabojo - HorOI Coda Horae d. '.,..Y i c i 0
NR, NA 500
CLEANING TURBINE Arbeillkorle·Nr

Wet Cleaning (Washing)


Work c;ard No.
Corle Iral/oil No
500.07
TorjelQ lrobojo No

LEGEND
1 Exhaust gas turbocharger
2 Exhaust manifold
3 Water supply (fresh water)
4 Water drain after turbine (if installed)
A Stop cock
B Pressure reducing valve with pressure gauge
C Three-way-cock with plate: ZERO-BLOWING OUT-WASHING
o Three-way-cock with plate:" (-Zero position)
4 •• (=Check position)
• • • (a::Washing position)
E Drainage cock (if installed)
y 3642260

Note Number and arrangement of exhaust manifolds depend on engine type and may not coincide with
illustration. For washing the turbocharger, each individual exhaust gas line is equipped
with a separate three-way-cock (0).
Use only fresh water for washing.
To avoid danger of burns, use protective gloves.

GENERAL
Cleaning interval: Refer Maintenance Schedule Section 4, Sheet 51
In order to save time, washing is recommended briefly after starting the engine, as at that time,
the parts to be washed are not yet too hot. Thus, operation as per step 2 of sequence becomes obsolete

SEQUENCE OF OPERATIONS
Also refer to plate on the engine with cleaning instructions.
1. Reduce engine load to 10 - 15 %.
2. Following reduction of engine load from a higher range, wait for approx. 15 minutes
(status of inertia).
3. Examine all three-way-cocks (0) consecutively, first in Check position • • • (if exhaust gas
does not blowout, the aperture to the exhaust gas line is blocked and must be freed with a
2.5 mm dia. piece of wire),
then set to Washing position -4t4ttt .
4. Open drainage cock (E) of water drain (4), check if exhaust gas blows out, if necessary, free
opening (if provided).
5. Set three-way cock (C) to Blowout position.
6. Open stop cock (A) of water supply (3), set water pressure to 2 bar at pressure reduction valve (B)
check pressure gauge.
7. Set three-way cock (C) to Washing position.
8. Washing period is 10 minutes at 2 bar water pressure (check at pressure gauge).
9. Close stop cock (A) of water supply (3).
10. Set three-way-cock (C) briefly to position Blowing out, then to position Zero.
11. Set all three-way-cocks (0) to position Zero . . .
12. Close drainage cock (E) (if provided).
13. Run the exhaust gas turbocharger at reduced engine load for 10 minutes to allow turbine to dry.
then gradually increase load. If vibrations of turbocharger are observed that did not exist be-
fore cleaning, repeat washing process.
Note If vibrations cannot be eliminated by washing on account of extreme deposits of dirt, the
turbocharger must be dismantled and the respective parts must be cleaned mechanically.

036 5649 "'rOellne,' - ~tunQer. (1.('1' ,eO\~lunOl'n


Won..,nQ I,me - Hovr~
Alit
EIfe' l NR: 1DO, NA:250 ODtrOllne; nOv'!
500.07-1 Dur~e Ot t'OlfQil - Hturel 1.0 Toutel leI Hcvrco\ Cl n.':;"~"t:
T,tmpo Ot ,rot-OIO - HorOI CoDe As required Moro(. Ot· ir'..,HtC.
CLEANING TURBINE NR, NR/R 500
(Or'y Cleaning) Arb.ihkal"'t.-Nr. 5 00 07
Wor-k eor-d No.
COl't. travail No. •
Tor-jet!' tl"'obojo No.

LEGEND
1 Exhaust gas turbocharger
2 Exhaust gas line bofore turbine
3 Container
4 Cover
5 Hose for compressed air
A Stop cock
B stop cock
C S10p cock
3642283 D Coupl ing
E Coupl ing

GENERAL
Number and arrangement of exhaust manifolds depend on engine type and may not coincide with
illustration. For cleanin~ the turbine, each individual exhaust gas line is equipped with a separate
connection with stop cock(A) and plugging nipple ot short distance before turbine, so that the
container(3) may be coupled on.
For cleaning the turbine, granulated nut shells, activated carbon or rice of 1 rom (max. 1.5 mm) groin
size can be used.
Fill-in Quantities per exhaust gas line for turbocharger type
NR20, NR15/R, NR20/R : 0,2 bis 0,3 Liter
NR26 , NR24/R, NR26/R : 0,3 bis 0,4 Liter
Cleaning interval: Refer Maintenance Schedule Section 4, Sheet 51.
Cleaning 10 be carried out at normal load of operation of engine. Therefore for cleaning the turbine
with this device no water is to be used.
To avoid danger of burns. use protective gloves.
During the cleaning process it is possible that dirty particles may be emitted through the chimney.
SEOUENCE OF OPERATIONS
Also refer to plate on the engine with cleaning instructions.
1. Check all exhaust gas lines as to whether exhaust gas blows out by opening the respective stop
cocks(A) , if need be, free opening with a piece of wire. Close stop cock(A) ,
2. Compressed air hose[5) to be coupled on at location(D). Air pressure approx. 4 - 7 bar.
3. Open container(3) by unscrewing cover(4), filL in granulated substance, close again and coupte
on at location(E).
4. Open stop COCKS in sequence A- B- C. Granulated substance is being blown in. Duration of
blowing-in process depends on compressed air pressure and exhaust gas pressure.
5. Close stop cocks in sequence A- B- C. Container to be de-coupled at location(EJ.
6. Repeat operations 3 through 5 for remaining exhaust gas lines.
7. If operation ratings not improved, repead operations 3 through 6 after 15 minutes.
~ote Ligh surging of compressor or temporary drop of turbocharger speed during cleaning process
is no couse of concern.

r-
co
D36 5649 E
500.07-2
Arb.itu.it
i..
Wo",k i ng 1 - - Stund.n
HoUI"I
Dur•• d. t rovo Il - Keur ••
All.
Ev.",,,
Tou1 •• l ••
24 B.tr iebu1unden
Op.N1t i ng houri
HeUI"•• d• • ol"e~.
0-- T i .rape d. traboj Cl - Hor-a. Codo Bedarf Hor-a. d. ..,. ... i c i 0
NR 500
ClEANING COMPRESSOR Arbeilskorte·Nr
Work card No.
Carle lravail No 500.08
Ta,.,eto troboio No.

TOOLS REQUIRED Tool No.


1 Open-end wrench, size 17
1 Syringe •••••••••••••••• 579.119

LEGEND
544.084 Screw plug
544.085 Seal ring
579 119----<
545.018 Screw plug
545.019 Seal ring

36£1$137

SEQUENCE OF OPERATIONS
1. Run the engine with as high a load as possible (80 - 100%).
2. Unscrew the screw plug (544.084) together with seal ring (544.085) from silencer, or
unscrew the screw plug (545.018) together with seal ring (545.019) from the air-intake
casing.
3. Fill the syringe (579.119) with clean, fresh water, and insert it through the screw-plug
opening.
4. Inject the to~plete content of the syringe within a period of 4 - 10 seconds.
5. Run the engine for another about 10 minutes at the same load.
6. Make comparative ~easurements of the operating data (engine power and charge-air pressure).

• 7.
These measurements will indicate the success or not of the washing procedure.
If necessary, carry out the washing again.
Screw in the screw plug (544.084) together with the seal ring (544.085) at the silencer,
or screw the screw plug (545.018) together with the seal ring (545.019) into the air-intake
casing.
Note The cleaning process is only to be carried out when the engine is at operating
temperature and when it is loaded as far as possible at full foad. After cleaning,
the engine must not be shut off immediately.
Compressor cleaning using the syringe is only suitable when a high degree of
dirt is not present. If there is too much dirt deposited in the compressor,
the compressor components must be dismantled and cleaned mechanically (refer
to Work Card 500.14).

ArpellH(:" - SlunOtn
035 5649 E Nor~·\f'I9 lime - HOvrs
Aile: Bel' iep5SI ..moen
hery
500.08-1 Durt(: C1e I rcyoi' -
T,t:rr.pc oe IrCt-OIO -
HeL'r~,
Horc:
0.3 Toules ies as required Ooerallng nours
Hevres ae more he
eace Horo~ Cle sc-rv,C.c
RE'M QVING AND M aJNTING
NR 20 500
THE COv\PLETE TURBOCHARGER Arbeilskarte-N r
Work cord No
Carle travail No 500. 10
Tarjela Irabo;o No.

,
4
TOOLS REQUIRED
1 Set open-end wrenches

,
1 2
+
1 Lifting gear with rope

LEGEND
1 Air inl et
2 Air outl et
3 Lubricating oil inlet
4 Exhaust gas inlet
5 Exhaust gas outlet
6 Lubricating oil discharge

~ of turbocharger
with air intake casing 115kg
with silencer •••••••• 127kg
5
Note:
It depends on the free space avail-
able in the engine rOom whether it
Hill be simpler to dismantle the

,
6
turbocharger while installed on the
engine or to remove the whole unit.
For performing maintenance work or
inspections, it l'Iill usual 1y suffice
to remove sections only. Removal of
the complete turbocharger from the
engine \lil1 onl y be necessary in the
case of general overhaul.

SE~UENCE OF OPERATIONS 1, Removing


1. Separate or remove duct to air intake casing (1) (if provided).
2. Disconnect pipes on suction socket (if provided).
3. Disconnect pipe bend on air outlet (2) of compressor, paying attention to the se~.
4. Unscre~ lubricating oil supply pipe (3).
5. Disconnect lubricating oil discharge pipe (6) at flange.
6. Disconnect pipe on exhaust gas outlet (5)) remove if necessar~/) paying attention to the seal.
7. Hang complete turbocharger on lifting gear, with rope slung round the bearing casing, paying attention to centre of
gravity.
8. Unscrew fixing screws in exhaust gas inlet (4) of gas admission casing, pa~/ing attention to the seal.
9. Cautiously lift turbocharger up and set it down on wooden supports.
Note: The inlet and outlet openings for air, exhaust gas and oil must be carefully sealed to prevent foreign
matters and water from entering during storage and assembly.

SEQUENCE OF OPERATIONS 2, Mounting


1. Hang complete turbocharger on lifting gear, with a rope slung around the bearing casing (pay at'~ention to centre of
gravity) and fasten exhaust gas inlet (4) to exhaust gas pipe.
2. Mount pipe on exhaust outlet (5), insert seal.
3. Connect lubricating oil discharge pipe (6).
4. Fasten lubricating oil supply pipe (3).
5. Bolt down pipe bend to air outlet (2) of compressor, insert sea1.

P. T. O.
Aroellsze,' - Siunoer Ai,e BelrieoSSlunoe r
g 036 5549 E VVOrlonc lime - HOU~S Ever' ODerOlln~ hov,,"

~. 500."1 G--'; Duree oe lrc,fci -


Itel""")DC oe ~rc:>a!c -
He\J~e;
""",:orc~
3.0 TOUI~~ Jes
ecce.
As ~~ ecessary "'1eu r es oe mo~rne
"'10rc\ oe serviclc
G. Connect duct to air intake casing (1) (if provided).
7. Connect pipes to suction socket (if provided).
8. Tighten all bolts in connecting piping.
~: All seals between pipe joints must be in good condition and the pipes must be free from stress at the
points of connection. The connecting bolts in the exhaust gas manifolds must be coated with MoSZ-based
lubricant.

C3E 5549 E / 500.10-1


REMOVING AND REFITTING NR 20 500
Arbeilskorte-Nr.
AIR FILTER Work cord No 500. 11
Corte travail No
Tarjeto trobo;o No

--
544 .20' -11- --_.." ,
!'Wo"'----
~~
~.M

~
TOOLS REQUIRED
~~ x :~~~ Open end wrench A/F 13
~~ xX~~

~
~

:x: ....
x
x:)l(

"1IIl!>e X >e>e
~~~
~
~
~
)
(
Cleaning trough
Cleanser fluid
544.067 ~;K:JIl:X:~""

~~~ ) Compressed air tap


~ ~>?<x~~
~ >< >C x.. ~..~<. I
't: xx~-".,.~x.
)
~ ~~~~ ....
'~'~-::JIIt:.-....-.. ~ LEGEND
~ ;X~'X-.,c~~~"X

( 544.067 Hexagon nut


544.201 Air filter
)
WEIGHT of air filter ••••••••• 5 kg

\D
ex)
N
N
-.:
'"
M I
- - \

SEQUENCE OF OPERATIONS 1: Removal


1. Unscrew both hexagop nuts (544.067) from the fastening straps of the air filter
(544.201).
2. Lift off the air filter (544.201) axially over the silencer.

SEQUENCE OF OPERATIONS 2: Refitting


1. Place air filter (544.201) axially over the silencer.
2. Using 2 hexagon nuts (544.067), mount air filter to the silencer.

SEQUENCE OF OPERATIONS 3: Cleaning


For cleaning intervals, refer to Maintenance Schedule, section 4, sheet 51, and hint on
sheet 4.52.
For removal of greasy and sticky dirt, Diesel fuel or commercial household cleansers may be
used. Next blowout the filter with an air hose.
In case of high-degree fouling, it may be necessary to submerge the filter in the cleanser
and to leave it there for a number of hours.

Arbe,'uelt - S'unOtn Alit fl,cl,;ebSSI",nd('1\


D36 5649 E Wor~,n9 I,me - Hours 1.: 0.1 E"ery 250 Ooerclln9 I'IOurS
Dure-e de trovoil - Heur.es Toutu Ie,
500.11-1 T,empo de 'rabato - Horos 2.: 0.1 Code as required Heures de marcnt
Horo, de 5C'v,CIO
NR 20 500

=tLau REMOVING AND REFITTING


SILENCER
Arbei',korle-Nr
Work cord No
Corle travail No
Terlclo lrobolO No

associated work card •••••.•••• 500.11


500. 12

544 034-JI!!~~~!~~~
544.041-~
TOOLS REQUIRED
Open end wrench AIF 13
544.067 Liquid cleanser
544.066 Compressed air tap

LEGEND
544.066
544.067 544.001 Rear wall
544.032 544.021 Damping plate
544.033 544.032 Spacer tube
~.-l--t!!R~~ '-----544.021 544.033 Spacer ring
)(

i+--tJitl~m 544.034 Protection grate


544.041 Front wall
544.084 544.066 Stud bolt
544.085 544.067 Hexagon nut
544.201 Air filter
546.001 Volute casing

WEIGHT of silencer ••••••••••• 25 kg

SEQUENCE OF OPERATIONS 1: Removing


1. Remove air filter (544.201),
544.066 refer work card 500.11.
2. Loosen 2 hexagon nuts (544.067) on
outer hole circle.
544.067=-. 3. Pullout silencer assembly axially
3642289 over stud bolts (544.067) on outer
hole circle.
544.201

Note Removal of electronic revolution counting device (if installed) is described on reverse.

SEQUENCE OF OPERATIONS 2: Refitting


Refitting is effected in reverse sequence as described for removal.
SEQUENCE OF OPERATIONS 3: Dismantling, cleaning and reassembling
For cleaning intervals, refer to Maintenance Schedule, Section 4, Sheet 51 and instruction contained
in sheet 4.52.
1. loosen hexagon nuts (544.067) on inner hole circle.
2. Take out individually front wall (544.041), protection grate (544.034), damping plates (544.021)~
spacer rings (544.033), spacer tubes (544.032) and rear wall (544.001).
3. Clean all component parts of the silencer.
Note: If the fouling matter is dry, the felt lining is best cleaned using an air hose or a brush
which is not too hard. In case of 11smear type ll contar,o,ination or dirt, Diesel fuel or
conventional household cleansers can be used. Solvents containing acetone are not to be
used though, especially "Tri" (trichlorethylene), because this will dissolve the adhesive
joints. If felt linings have becom~ extremely wavy or corrugated (with the result that the
cross-section for incoming air is reduced), these are to be replaced.
4. Reassembly is a reversal of the dismantling procedure.

~('1rleO~~lvno{'"~
~~;rr 5 ~ 000 + 250
Aroe,lHel' - 5lunde"
D 36 5649 E Wo·~,nQ limp - Hours 2.0 Oo~rOI,n<;; hours
DoJree Cle Irovo,: - Hevr/!\ TOUlel
eaoe
leI as requ; red P'1eur~s OC mo":h~
oe
50C.12-2 T,eP'T\po dp Irooo,o - Horos .....,orc~ i(" wI': I':'
REMOVING AND REFITTING ELECTRONIC SPEED MEASURING DEVICE
(if fitted)

TOOLS REQUIRED
544.067 1 Open end wrench AIr 17
544.066 1 Open end wrench A/r 15
1 Open end wrench A/r 13
1 Socket wrench A/r 10

562.040 LEGEND
562.002
562.004 520.124 Magnetic nut
562.005 544.001/1 Rear wall (to be
562.061 finally aachined)
544.066 Stud bolt
544.067 Hexagon nut
544.201 Air filter
546.001/1 Volute casing (to be
finally machined)
562.002 Insert
562.004 Retaining disk
562.005 Hexagon nut
562.040 Revolution transmitte
544.067 562.061 Stud bolt
562.396
562.396 Stud bolt
562.586 Screw connection

544.201~"""-

SEQUENCE OF OPERATIONS 1. Removal


1. Remove air filter (544.201), refer work card 500.11.
2. loosen two hexagon nuts (544.067) on outer hole circle.
3. Pullout silencer assembly axially over stud bolts (544.066 and 562.396) on outer hole circle.
4. Disconnect cable of revolution transmitter (562.040) from revolution indicator instrument.
5. loosen thrust screw from screw connection (562.586).
6. Carefully move out insert (562.002) axially, in doing so, grasp cable of revolution transmitter
from inside of volute casing (546.001/1 as soon as possible and pullout through opened screw
connection (562.586).
7. If revolution transmitter (562.040) is intended to be removed:
Screw off hexagon nut (562.005) and remove retaining disk (562.004).
Carefully withdraw revolution transmitter (562.040) axially from insert (562.002), watch cable.
Attention: Do not bend the two pole tips of revolution transmitter (562.040).

SEQUENCE OF OPERATIONS 2, Refitting


Refitting is a reversal of the removal procedure.

036 5649 E / 500.12-2


REMOVING AND REFITTING NR 20 500
AIR-INTAKE CASING
associated work card •••..... 500.10

TOOLS REQUIRED
Open end wrench A/F 13
Socket wrench A/F 10

LEGEND
520.124 Magnetic nut
562.005 545.001_ Air-intake casing
562.004 545.067 Hexagon nut
562.061
546.001 Volute casing
562.040
562.004 Retaining disk
562.005 Hexagon nut
562.040 Revolution transmitter

520.124
WEIGHT of air-intake casing ••• 9 kg

STARTING POSITION
Air line has been removed from inlet port of air-intake casing.
Cable of revolution transmitter (if installed) is disconnected.

SEQUENCE OF OPERATIONS 1: Removal


1. If revolution transmitter (562.040) is installed, screw off hexagon nut (562.005).
Remove retaining disk (562.004) und carefully withdraw revolution transmitter (562.040)
in an axial direction.
Attention: Do not bend the two pole tips of the revolution transmitter (562.040).

2. Screw off hexagon nuts (545.067), take off air-intake casing (545.001) in an axial
direction and deposit it on wooden supports.

SEQUENCE OF OPERATIONS 2: Refitting


Refitting is a reversal of the removing procedure.

D36 5649 E Arbeilsze;t


Working lime
-
-
Stunden
Hours
1 • : a• 2 Aile
Every
Bel r ieb~ SI unden
Opera! ing hours
500.13-2 Duree de travail - Heur.es 2.; 0 . 2 Toules les as required Heurts de morc~
Tlempo de Irabolo - Ho"o~ Code Horo~ de servicio
REMOVING AND REFITTING
NR 20 500
Arbritsl(orle·Nr
COMPRESSOR CASING Worl( cord No
Code Irovo;1 No 500. 14
Tarjeto trobaio No.

associated work cards ••• 500.10 through


500.13

TOOLS REQUIRED
1 Open end wrench A/ F 13
1 Socket wrench A/F 10
1 Screw driver
1 Brush
1 Cleansing fluid
1 Vat
I Compressed air tap

LEGEND
542.001 Final diffuser
546.001 Volute casing
546.005 Stud bolt
546.006 Hexagon nut
546.008 Countersunk screw
546.021 Hexagon nut
599.001 Cartridge (.517.000 and 520.000)

WEIGHT of compressor casing •••••• 30 kg


f'oo.
ClO
N

~&----- STARTING POSITION Silencer or air-intake


casing removed.
~~~~~

SEQUENCE OF OPERATIONS 1, Dismantling


1. Loosen hexagon nuts (546.006) and take off compressor casing cautiously, if necessary, separate
same with 3 forcing bolts over bearing casing flange.
2. If final diffuser (542.001) is also to be dismantled, screw off hexagon nut (546.021) from
counter sunk screw (546.008).
SEQUENCE OF OPERATIONS 2, Remounting
1. Insert volute casing (546.001) with fina1 diffuser (542.001) mounted, in direction of cartridge
over compressor wheel, in doing so, watch compressor wheel.
2. Screw on hexagon nuts (546.006) and tighten.
SEQUENCE OF OPERATIONS 3, Cleaning
Cleaning interval: Refer Maintenance Schedule Section 4, Sheet 51 and instructions of Sheet 4.52.
1. Clean volute casing (546.001) and final diffuser (542.001) with fuel or another liquid cleanser
and a brush until all dirt, especially in the air ducts, has been removed.
2. Clean compressor wheel in the same way.
The compressor wheel is to be left installed in the basic assembly (599.001).
Note The cleaning fluid and thus the dissolved dirt must not be allowed to penetrate inside the
basic assembly and to enter the bearings or the lube oil circuit. The gap behind the
compressor wheel should, therefore, be covered with suitable means.
3. Dry all cleaned parts with compressed air.
4. Check whether rotor rotates freely and easily.

Poe I r ,etlnlvndC''"'
036 5649 £
Arbel'ue,'
WorkIng lime
-
-
Shmden
Hours
1. a
Aile
Every 5,000 f 250 ODerQlln9 hours

500.14-2
Our~ de Irovoil -
1',empo c:le Irc.bOIO -
Hevr,rs
Horos
joules les
Codc
as required Heures de morc"'e
Horo< cie ~C'rv'(IO
REMOVING AND REFITTING NR 20 500
GAS ADMISSION CASING AND Arbeitskorle-Nr

TURBINE NOZZLE RING Work cord No


Corte travail No
500. 15
Tar,eta lroboJo No

associated work cards •••• 500.10 through


500.14, 500.16

TOOLS REQUIRED
1 Open end wrench A/F 17
1 flat chisel
1 Piercer
1 Hammer
501. 001_J.l._j(;;2~2ZZZ:Z~
LEGEND
501.006---
501.007 SOL 001 Gas admission casing
501.009 Collared bolt
501.008
501.005 513.001 Turbine nozzle ring

599.00' WEIGHT of Gas admission casing ••••• 40 kg

STARTING POSITION
line at exhaust gas outlet of gas admission
casing is removed, or complete turbocharger
is removed from ~ngine.
Basic assembly is removed, refer work card
500.16.
513 .001 ---1---+0---_ A
501.009~,-4---+-"'.~J _ +- GENERAL
i ---"
Removal of turbine nozzle ring or gas
i """"
\ i -""- I admission casing is, under normal circum-
\ i ~~ stances, only necessary in case of exchange
\\ i If complete turbocharger was removed,
-1- II: sequence of operations "Removal of gas
~
,L ._.~~1?9j
I admission casing" and "Remounting of gas
admission casing"

SEQUENCE OF OPERATIONS 1, Removal turbine nozzle ring


1. Remove turbine nozzle ring (513.001) by means of pounding with invariable force in direction A,
with a hammer and a piercer onto 4 collared bolts (501.009).
SEQUENCE OF OPERATIONS 2, Remounting turbine nozzle ring
1. Press in collared bolts (501.009) with their longer, tapered portion into ~as admission casing
up to stop position.
2. Place turbine nozzle ring (513.001) onto collared bolts (501.009) in a manner so that the corner
shaped nozzle vanes are congruent with the separating walls of the gas admission casing (refer
to liZ" marks of ilL). Depending on execution, there are 1, 2, 3 or 4 separating walls.
3. Press i~ turbine nozzle ring evenly, do not tilt and do not apply pressure on nozzle vanes.
SEQUENCE OF OPERATIONS 3, .Removal gas admission casing
1. Loosen fastening screws at exhaust gas inlet and take off gas admission casing (501.001),
watch seal (and lagging, if provided).
SEQUENCE OF OPERATIONS 4, Remounting gas admission casing
1. Screw on gas admission casing to exhaust line of engine with seal and fastening screws, watch
seal (and lagging, if provided).
Note Apply MoSz-based high-temperature lubricant (e.g.Molykote HSC) to bolts and nuts, however,
do not apply this lubricant to screw-in threads if studs are replaced.
Arbe,lne,' - Sluf"Idef"l All!.' P.clr leb\~1 unOe"

as requl• re d
Wor~lnQ l,me - Hours Every Oppralong hovr S
036 5649 E Durk de trovoil - Hevr.e~ levlfs le~ Heures Oe mor~"e
HorO~ df H~' vl(lO
500.15-2 T ,empo de lroba,o - Horos Coao
NR 20 500
REMOVING AND INSTALLING Arbeit5korte-Nr.
CARTRIDGE ~oO~: ~~~~C1~~o 500. , 6
Tor;eto troboio No.

associated work cards 500.05


500.10
501. 0 0 1 - - - -....... through 500.14
591.060---",",
501.005--~
TOOLS REQUIRED
501.007 Open-end wrench A/F 13
SOt008 ..---~ Open-end wrench A/F 17
Open-end wrench A/F 19
Box (socket) wrench A/F 17
Lifting gear with rope (if available)

LEGEND
501.001 Gas admission casing
501.005 Tightening (locking)ring, 2-part
501.007 Lockwasher
501.008 Hexagon nut
517.099 Sealing putty, heat-proof (Epple 3~
591.060 Shield, 2-part (if fitted)
599.001 Cartridge
(comprises 517.000 and 520.000)

WEIGHT of cartridge........... 36 kg

517.09 9 ---'lJ~~~;;;:s:s~'X

GENERAL
Removal of cartridge for inspection and, where necessary, replacement is only required in the
following cases:
1. If admissible transverse movability is exceeded (cf work card 500.06).
2. For major overhaul of turbocharger (cf Maintenance Schedule, section 4, sheet 51).
3. If there are signs of irregularities in service which might lead to subsequent damage on
turbocharger, e.g. unusual running noise, turbine or compressor-side oil leakage, previously
not experienced turbocharger vibrations or abnormal readings (exhaust gas temperature, charge-
air pressure, turbocharger speed) - if compressor or turbine cleaning during operation is
unsuccessful.
4. In case of damage to turbocharger, e.g. bearing damage (owing to oil starvation or contaminat~d
oil), damage caused by foreign matter or vibration failure on turbine wheel (rotor) or
compressor wheel, casing cracks.

STARTING POSITION
Tacho-generator (if fitted), air-intake casing or silencer and compressor casing removed.
The gas admission casing is not normally removed and remains connected to the exhaust gas pipe.

SEQUENCE OF OPERATIONS 1: Removal


1. Detach 2-part shield (591.060), if fitted.
2. Remove oil supply and drain pipes from bearing casing.
3. Using the rope, secure cartridge to lifting gear and tension rope ~ith caution.
4. Unscrew hexagon nuts (501.008), remove lockwashers (501.007) and 2-part tightening ring
(501.005).
Note: If no lifting gear is available, support cartridge before loosening of upper hexagon
nuts (501.008) to avoid tilting out.

F. I.e.
D36 5649 Arbe1l52eil - 51unden
1• :
Workm9 lime - Hours
Aile
Every 15,000 ! 500 Bel r lebsSI unoer
Operating no .... rs
500.16-2 Duree oe trovoi, -
T,empo oe IrabOlO -
Heur.es
horos 2. : Toutes les
Code
as required Heures oe me"en"
nor-o( oe se"Vlc,c
5. Extract cartridge carefully in axial direction from gas admission casing (do not damage
turbine wheel) and lower it onto wooden support with caution.

CHECKING AND CLEANING CARTRIDGE: See work card 500.17.

SEQUENCE OF OPERATIONS 2: Installing


1. Check the gaps (see Gaps and Clearances, section 1, sheet 52).
_ Screw cartridge (temporarily for measurement only) to compressor casing while measuring
axial gap (point 2) by lead print and radial gap (point 1) by thickness (feeler) gauge
three times on circumference.
Insert cartridge (temporarily for measurement only) carefully into gas admission casing
and screw together. Measure axial gap (point 4) by lead print and radial gap (point 3)
by thickness (feeler) gauge (only if gas outlet side is accessible) three times on
circumference.
2. Apply sealing putty (517.099) to one of the contact faces of bearing casing flange and
gas admission casing and insert cartridge carefully into gas admission casing in axial
direction (do not damage turbine wheel).
3. Fix cartridge with 2-part tightening ring (501.005), lockwashers (501.007) and hexagon nuts
(501.008) to gas admission casing.
4. Connect oil drain and supply pipes making sure that any protective plugs used are removed
before fitting.
5. Fix 2-part shield (591.060) if applicable.
Note: Use faultless lockwashers for fitting.
Apply MoSZ-based high-temperature lubricant (e.g. Molykote HSC) to bolts and nuts but
not to screw-in threads if studs are replaced.

036 5649 E / 500.16-2


CHECKING AND CLEANING NR 20
Arbeitskor1e·Nr
I 500
CARTRIDGE Work cord No
Carte travail No. 500. 17
Torjete trebajo No

GENERAL associated work cards •••• 500.06 and 500.16


Checking and cleaning is restricted to the cartridge in the assembled condition.
Disassembly of cartridge for cleaning or replacing individual parts must be carried out by
specialized service personnel only (see notes in section 3 sheet 52 - Cartridge, section 4
sheet 52 - Maintenance, and work card 500.06).
Note: If a cartridge is to be sent to manufacturer or service point for overhaul, it must
be packaged carefully to avoid additional damage in transit.
STARTING POSITION
Cartridge removed from turbocharger.
CHECKING THE CARTRIDGE
The following CHECK LIST includes data for evaluation and, if necessary, measures to be taken
for repairing the cartridge.
Note: Where several possibilities are marked off, the technical optimum is to be selected.

EVALUATION CRITERIA CARTRIDGE


on part or point - disassemble, check components, replace where
condition necessary (by specialized service personnel only)
- replace
- reuse, clean 1
TRANSVERSE MOVABILITY OF ROTOR
cf work card 500.06
Measured value: permissible ..................................................... x
Measured value: excessive ...•...••..•..•.•....•.....•........................... x X
TOUCH MARKS
Blade contour turbine wheel (rotor) and/or compressor wheel
one-sided on circumference: Signs of imbalance •••••••••••••••••••••••••••••••••• x X
uniform on circumference: Check gaps and clearances (section 1, sheet 52) ••••••• X X X
FOULING
on gap after turbine wheel (rotor) disc
narrow oil trace: harmless, may be caused by run down lubrication ••••••••••••••• x
heavy fuel residues ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• X
thick cover of oil coke distributed over entire circumference: indicates severe
oil leakage, leads mostly to sluggish running of turbine wheel (rotor) X X
Turbine wheel (rotor) - (visible part of bladed wheel)
heavy fuel residues or other fouling cover ••••••••••••••••.••••••••••••••••••••• X
Compressor wheel (visible part of bladed wheel)
dusty, oily cover •••••.••••••••••••••••••••••••••••••••••••••••••••.••••••••••.. x
DAMAGE
Turbine wheel (rotor), compressor wheel, bearing casing
turbocharging severely impaired, severe oil leakage, strength impaired x x
SLUGGISH RUNNING OF ROTOR
very sluggish or blocked: oil coke deposits after turbine wheel (rotor) or in
labyrinth seal, or bearing defect •••••••••••••••.•••.••••••••••.••••••• X X
Note: Running-in labyrinths may cause some sluggishness in rotation of new or
used turbochargers. This is harmless because in operation the rotor floats
and then runs free.
Test: Lift rotor to concentric position and rotate.

P. T.0.

~
<::;
036 5549 E
500.17-1
Arbe,lszel '
Working lime
Dvree de trovai'
-
-
Tlemoo de lrabolo -
SlunOen
Hovrs
Heur,e~
Hora~
!I ~~) 15,000! 500
~~~~es 1115 requi red
Belrtebsslunoen
Ooeratmg hours
I-Ieures oe marcne
Horae oe s.e . . 'ICJ=
CLEANING THE CARTRIDGE

Burnt-in layers of dirt, particularly on the turbine side (e.g. heavy fuel layers, oil coke),
are removed by soaking in P3 water solution and brushing. If necessary, repeat this process
several times. Next neutralize with soda water.

Remove oily layers by means of fuel or some other liquid cleaning agent.

Note: The cleaning liquid and the dissolved dirt must not enter the interior of the cartridge
and thus the bearings or the lube oil circuit. The gaps after the turbine wheel (rotor)
disc and the compressor wheel should therefore be covered with suitable means.

for soaking layers of dirt on the turbine wheel (rotor) disc, the cartridge can be
placed vertically, turbine side downwards, into a container with suitable seatings.
Fill the container with cleaning liquid only to a certain level which must not be
exceeded in order to prevent liquid from entering the interior of the cartridge (see
illustration) •

599.001

·ca. ~.280

036 5549 E I 500.17-1


ABGASTURBOLADER NR 20 500.01

1;Lou EXHAUST TURBOCHARGER


TURBO-COMPRESSEUR
TURBOSOBREALIMENTADOR
1

ERSATZTE ILLIST E
fUr
ABGASTURBOLADER

SPARE PARTS LIST


for
EXHAUST TURBOCHARGER

LISTE DE PIECES DE RECHANGE


pour
TURBO-COMPRESSEUR A GAZ
D'ECHAPPEMENT

llSTA DE REPUESTOS
para
TURBOSOBR EALIMENTADOR
DE GAS DE ESCAPE

o
CO

- D365649 500.01/1
ERSATZTEIL8ESTELLUNG

~u
ORDERING SPARE PARTS NR 500.02
COMMANDE DE PIECES DE RECHANGE
PEDIDOS DE REPUESTOS 2
E r sat z t e i 1 b est ell u n 9
rur die Bestellung von Ersatzteilen 1st das Verzeichnis der Einzelteile mit den dazugehorenden Sildern zu
verwenden. Die ersten 3 Stellen der Teilnummern bezcichnen die Baugruppe und die restlichen Zahlen sind eine
Z~hlnummer. Urn RUckfragen und Unklarheiten zu vermeiden, sind bei Bestelluno folqende Anaaben erfurderlich.

1. AAschfift MAN B&W Diesel GmbH *


StadtbachstraBe 1, D-8900 Augsburg 1, re pt. SL

fernsprecher: (0821) 322 - 3994


fernschreiber: 53796-0
Drahtanschrift: MANBW AUGSBURG
2. Typ des Turboladers xxx
3. Werk-Nr. des Turboladers xxx xxx
(~. Typ des Motors) xxx * zustandig fUr die Be-
(5. Werk-Nr. des Motors) xxx xxx arbeitung von Turbo-
6. Bestell-Nr. xxx. xxx
7. Benennung xxx lader-Ersatzteilbe-
B. StUckzahl xxx stellungen von allen
9. Versandadresse xxx TCU-Kunden.
[ r sat z t e i 1 e
Das in der Ersatzteilkiste befindliche Verzeichnis fUhrt die Ersatzteile an, die dem Turbolader mitgegeben werden.
Die Nummern der Liste sind gleich den Bestell-Nr. und stimmen mit oenen an den Ersatzteilen angebrachten Nummern
uberein. Alle Ersatzteile, soweit nicht in Plastikbeutel verpackt, sind stets gut gefettet aufzubewahren. Rostig ge-
wordene leile sind zu reinigen und einzufetten.
Es ~ird empfohlen, verbrauchte Ersatzteile sofort nachzubestellen, da Transport (und Zollabfertigung) die Anliefe-
rung der Teile sehr verztigern konnen. rUr Reparaturarbeiten ist es jedoch wesentlich, die erforderlichen Ersatzteile
moglichst sofort greifbar zu haben.
We r k z e u 9 e
Die dem Turbolader mitgegebenen Werkzeuge sind in einer Kiste verpackt und in einer liste am Deckel der WerkzeuQ-
kiste aufgefUhrt. fur die Behandlung und Nachbestellung von Werkzeugen gelten die gleichen Anweisungen wie fOr Er-
satzteile. Die Baugruppe fOr Werkzeuge ist 596•••••
o r d e r i n 9 Spa reP art s
Reference should be made to the list of single parts and the relevant drawings in preparing orders 'for spare
parts. The first three digits of the part numbers designate the equipment group and the last digits represent
a consecutive number.
In order to avoid confusion and queries, make it a point to include the followino information in your orders.
1. Our full name and address MAN B&W Diesel GmbH *
StadtbachstraBe 1, 0-8900 Augsburg 1, De pt. SL

Telephone: (0821) 322 - 3994


Telex: 53796-0
Cables: MANBW AUGSBURG
2. Type of turbocharger xxx
3. Work No. of tucbocharger
(4. Type of engine)
xxx xxx
xxx
* re spO nsib 1e for pro ce ssin 9
(~. Work No. of engine) xxx xxx turbocharger spare part
o. Ordering No. xxx. xxx orders of all leu
7. Description xxx custOm? rs.
8. Quantity xxx
9. Shipping address xxx
Spare Parts
The list included in the spare parts case shows the spare parts supplied with the turbocharger. The numbers in the
list should be quoted in your order and coincide with the numbers with which the sp'are parts are markec. :.Ql SDare
parts, unless packed in plastic bags, Should be kept well greased during storage. kny parts showi~g rust depcslts
should be cleaned and coated with grease.
It is recQrnmended that any spare parts installed should be re-ordered at once, seeing that transport (and customs
cl€arance) may cause conslderable delays in the delivery of the parts. Prompt repairs depend on any necessary spares
being at hand when needed.
Tools
lh~ tools supplied with the turbochargers are packed in a cas€ and tabulated in a list attached to the lid of the
tool box. In handling and re-ordering tools, the same instructions as given for spare parts should be followed. The
. code number for tools is 596 •••••
~ D365642 500.02;2 sigue 21 dorsa
cc [ rn n d e d e D i ice s d ere c h 2 nee
2
PGu~ 1, com~anoe Of pieces O~ rechano~. il convient d'utiliser 1, liste des pieces ccnstitutives avec les figures
c~rreSDOnGantes. Les 5 premiers chifrres de numeros de pieces designent Ie sous-9foupe, tandi$ que les autres
~niffre£ cons~ituent un numerc compteur.
hfin c'eviter oes oemandes de renseionements et oes imprecions, il s'imocse tie donner les renseianements suivants.
lo~~ c'unE com~ande: -
1. Aciresse MAN B&W Diesel GmbH *
StadtbachstraBe 1, 0-8900 Augsburg 1,oept. SL

Telephone: (0821) 322 - 3994


Telex: 53796-0
Calble: MANBW AUGSBURG
z. Type du turbo-compresseur xxx
3. No. d'usine du turbo-compresseur xxx xxx * competent pour l'exe-
(4. Type du moteur) xxx cution des commandes
(5. No. d'usine du moteur) xxx xxx de pieces de rechange
6. No. de commande xxx. xxx pour turbocompresseurs
7. Designation xxx de tous les clients de
8. Nombre xxx TeD.
9. Adresse d'espedition xxx
P i ice s d ere c han 0 e
La liste se trouvant dans }a caisse des pieces de rechange ~numere les pieces de rechanoe Qui Dnt ~te fDurni avec Ie
turbc-compresseur. Les numeros indiques sur 1a liste sont en meme temRs les numeros de commande et correspondent a
ceux appliques aux pieces de rechange memes. Dans la mesure ou les pieces no sont pas emballees dans des sacs en
m2tiere plcstique, i1 convient de les stocker bien oraissees. Des pieces devenues rouillees doivent etre nettoyees et
gr2issees. -
11 est recommande de commander de nQuvequ des pieces de rechange tout de suite apres leur consommation, parce que Ie
transport (et les formalites douanieres) peuvent beaucoup retarder Ie livraison des piices. Or, pour des travaux de
reparation, il est essentiel d'avoir les pieces de rechange necessaires sur place.
Outils
Les outils fournis avec Ie turbo-compresseur sont emballes dans une caisse et enumeres sur une liste appose au
couvercle de 12 Ceisse a outils. Pour Ie traitement et 1a commande des outils s'appliQuent les memes instructions
que celles donnees pour les pieces de rechange. Le sous-groupe pour les outils est 596•••••

P e did 0 S d ere p u est 0 S


Para pedir repuestos, se debe utilizar el indice de las piezas individuales con sus figuras correspondientes.
las primeras 3 cifras de los numeros de referencia indican el grupo parcial componente del turbosobrealimentador,
las cifras restantes son de enumeracion.
P2ra evitar demanda~ de aclaracion y confusiones, es necesario indicar los siauientes datos en los pedidos:

1. Senas
MAN B&W Diesel GmbH *
StadtbachstraBe 1, D-8900 Augsburg 1, Dept. SL

Telefono: (0821) 322- 3994


Teletipo: 53796-0
Direccion telegrafrica: MANBW AUGSBURG
2. ripo del turbosobrealimentador xxx
3. NUmero de fabrica del turbosobreali- * competente para ejecu-
mentador xxx xxx
(4. ripo del motor) xxx tar pedidos cubriendo
(5. Numero del motor) xxx xxx repuestos para turbo-
6. NUmero de referencia xxx. xxx sobrealimentadores de
7. Denominacion xxx todos los clientes de
8. Cantidad xxx TeD.
9. Senas c donde mandar e1 pedido xxx
P~rue~ cs
-~:2 Que se encuentrc en 1a caja de repuestos indica las piezas de recambio que Se entregan junto con el tvrbc-
-£2limentador. Los numeros de Ie liste son cl mismo tiempc lcs de referencic y coinciden cor. lcs numeros marcadc5
l~S piezas. 10dos los repuestos, menos aquellos que vienen en bolsGS tie pl~sticc, deben clmacencfse siempre bien
engrasacios. Las piezas que se hayan oxidaoo, deben limpiarse y lubricarse.
~e recomiend, pedir los repuestos utilizados en seguida de nuevo, ya que el transporte (y el despacho en 12 aduana)
~ueden r€~ra~ar ,mucho el suministro de hs piezas. Sin embargc, pare poder efectuar trabajos de reparacion, es de
Imp~rtanclc Tunoamental tener las piezas necesarias en seguida 0 mano 0 10 antes posible.
~ t r r E rr, i e n t a s
Las herrar.ie~Ta$ Que se entregan junto con e1 turbosobrealimentador vienen embaladas en un? cajc y estan enumer&-
~2S e~ un: ~l~~c a~e est~ pegaca en lc tapa de dichc ccja. Parc el trataffiiento y los pedido$ de herraffiientas valen
~2~ mlS~2~ InOlcaClones Que pare los repuestos. [1 grupo de herramientas lleva el n~mero 596 •••••

D36 5642 /500.02;'2


VERZEICHNIS OER EINZELTEILE NR 20 500 ..02
LIST or SINGLE PARTS
LISTE DES PIECES CONSTITUTIVES
INDICE DE LAS PIEZAS INDIVIDUALES
Bestell-Nr. NOClm Nr.
Order No. Benennung Designation Standard No.
No. de commande Designation Designacion No. standard
No de oedido No de norma

500.000 Turbolader, komplett Turbocharger, complete


Bild 1 Figure 1
Turbocompresseur, compl. Turbosobrealimentador, campI.
Fi gure 1 Figura 1

501.000 Turbinen-Zustromgehause Gas-admission casing ..{)4Z6


Bild 2 figure 2 -0466
Corps d'admission de turbine Caja de afluencia de turbina
Figure 2 Figura 2

501.001 Turbinen-Zustromgehause Gas-admission casing


Cprps d'admission de turbine Caja de afluencia de turbina
501.005 Spannring, zweiteilig Locking ring, twopart
Anneau de serrage, deux pieces Anillo de tension, dos piezas
501.006 Stiftschraube Stud screw ~M 1701-M10x35
Goujon Prisionero
501.007 Sicherungsblech lockw~sher
Tole d'arret Chapa de seguridad
501.008 Sechskantmutter Hexagon nut AM 1702--M10
[crou a six pans Tuerca hexagonal
501.009 Bundbolzen Collar bolt
Boulon a collet Perno con collar

513.001 Turbinenleitapparat Turbine nozzle ring -0900


Bild 2 figure 2
Distributeur de turbine Distribuidor de gases de turbina
Figure 2 Figura 2

517.000 Lagerung Bearing -0321


Bild 1+3 Figure 1+3
Logement Alojamiento
Figure 1+3 Figura 1+3

517.001 Lagergergehause Bearing casing


Boitier de paliers Caja de cojinetes
517.002 Lagerbuchse Bearing bush
Douille de palier Casquillo de cojinete
517.003 AbstandshUlse Spacer sleeve
Douille d'ecartement Manguito distanciador
517.004 Halteschraube Holding screw
Vis de retenue Tornillo fiador
517.008 LagerhUlse Bearing sleeve
Douille de palier Casquillo de cojinete
AbschluBdeckel, turbinenseitig End cover, turbine side
Couvercle de fermeture, cote turbine Tapa de cierre, lade de turbina
517.017 Dichtdeckel Sealing cover
Couvercle d'etancheite Tapa de cierre hermetico
517.022 Dichtring Seal ring DIN 7603-A14x20-Cu
Anneau-joint Anillo de junta
517.029 Stiftschraube
Goujon
Stud screw
Prisionero
AM 1701~6x18

I
-.0 siehe Ruckseite - PTO
co t.s.\.p. - sigue cl dorsa
co D36 5649 500.02/3
Bestell-Nr. Norm i\ •
Order No. Benennung Designation Standard No.
No. de commande Designation Designacion No. standard
No de pedido No de norma

517.030 Sti ftschraube Stud screw DIN 939~6x12-8.8


Goujon Prisionero
517.031 Dichtung Gasket
Joint Junta
517.032 Sechskantmutter Hexagon nut AM 1702~6
Ecrou a six pans Tuerca hexagonal
517.033 Sicherungsblech Lockwasher
Tole d'arret Chapa de seguridad
517.034 Metallkleber Metal adhesive
Adhesif de metal Adhesivo de metal
517.099 Dichtungskitt, hitzefest Sealing cement, heat-resistant Epple 35
ciment d'etancheite, resistant Mastico para juntas, resistente
a 1a chaleur a1 calor

520.000 ~ Rotor -0571


BUd 3 Figure 3
Rotor Rotor
rigure 3 figura 3

520.001 TurbinenHiufer Turbine rotor


Rotor Rotor
520.005 Verdichterrad Compressor wheel
Roue de compresseur Rodete compresor
520.006 Labyrinthring Labyrinth ring
Anneau labyrinthe Junta laberintica
520.009. Mitnehmer Carrier
Entrarneur Arrastrador
520.011 AbschluBmutter Closing nut
Ecrou Tuerca
520.017 Runddichtring O-ring MAN 356-24x5~V02-55
Joint toripue Anil10 circular de junta
520.018 PaBfeder Feather key
Clavette Cheveta de ajuste
520.124 + Magnetmutter Magnetic nut
Ecrou a aimant Tuerca con iman

+ Nur bei AusfUhrung mit Drehzahlmesseinrichtung, anstelle von 520.011


Only for design with speed measuring device, instead of 520.011
Unipuement pour l'~xecution avec compte-tours, an lien de 520.011
Solo en 1a ejecucion con contador de revoluciones, en lugar de
520.011

D36 5649 / 500. 02/3


VERZEICHNIS OER EINZELTEILE

t..::&u
Bestell-Nr.
LIST Of SINGLE PARTS
LISTE DES PIECES CONSTITUTIVES
INDICE DE LAS PIEZAS INDIVIDUALES
NR 20

NOClm Nr.
500.02

Order No. Benennung Designation Standard No.


No. de commande Designation Designacion No. standard
No de norma
--
No de oedido
'--

542.001 Nachleitapparat Oi ffuser


Bild 1 Figure 1
Oi ffuseur final Di fusor final
rigure 1 Figura 1

544.000 + Schalld~mpfer Silencer -0.238


Bild 4 Figure 4
Silencieux Silenciador
Figure 4 Figur~ 4 f-

544.001 ++ RUckwand
Paroi arriere
Rear wall
Pared posterior
--
544.021 Dampfungsplatte Damping plate
Plaque amortisseur Plaea amortiguadora
544.032 Distanzrohr Spacer: tube
Tuyau d'ecartement Tuba distanciador
544.033 Distanzring Spacer ring
Anneau d'ecartement Anillo distanciador
544.034 Schutzgitter Protection grate
Grille pr~ectrice Rejilla protectors
544.041 Vorden.;and Front board
ParDi en avant Pared delan1era -
544.066 Stiftschraube Stud screw DIN 835-M8x185-8.8
Goujon Prisionero .;.....

544.067 Sechskantmutter Hexagon nut M1536-AM8


[erou a six pans Tuerca hexagonal
544.084 VerschluBschraube Screw plug DIN 910-M16x1,5-5.8
Bouchon filete Tornillo de cierre
544.085 Dichtring Sealing ring DIN 7603-A16x20-Vf grau
Anneau-joint Anillo de junta
544.201 Luftfilter Air filter
riltre d'air FiItro de aire

:-

-
+ falls vorhanden
if provided
s'il existe
si existe

++ Bei AusfUhrung mit Drehzahlmesseinrichtung siehe auch unter 562.000~


For design featuring speed measuring device, see 562.000/1
Pour l'execution avec compte-tours, cf. egalement 562.000/1
En la ejecucion con contador de revoluciones vease tambien 562.000/1

I
Siehe Ruckseite - PTO
-.0
00 T.s.\.p. - Sigue 21 dorsG
00 D365649 500.02/4
Bestell-Nr. Norm Nr.
Order No. Benennung Designation Standard No.
No. de commande Designation Designacion No. standard
No de pedido No de norma

5~5.000 + Ansaugaeh~use Air-intake casing -0116


Bild 5 figure 5
Corps d'aSDiration Caja de aspiracion
Figure 5 Figura 5

5~5.001 Ansauggeh~use Air-intake casing


Corps d' aspiration Caja de aspiracion
545.004 Sti ftschraube Stud screw DIN 939-M8x25-8.8
Goujon Prisionero
545.014 Sechskantschraube Hexagon screw DIN 933-M10x40-10.9
Boulen a six pans Tornillo hexagonal
545.018 VerschluBschraube Screw plug DIN 7604-M16x1,5-S.8
Bouchon fi lete Tornillo de cierre
545.019 Dichtring Sealing ring DIN 7603-A16x20-CU
Anneau-joint Anillo de junta
545.067 Sechskantmutter Hexagon nut M1536-AM8
Ecrou a six pans Tuerca hexagonal

546.000 Verdichtergeh~use Compressor casing -0363


Bild 1 Figure 1
Corps de compresseur Caja del compresor
Figure 1 Figura 1

~
546.001 ++ Spiralgehause Volute casing
Corps a volute Caja espiral
546.005 Sti ftschraube Stud screw DIN 939-M8x2S-8.8
Goujon Prisionero
546.006 Sechskantmutter Hexagon nut M1536-AM8
Ecrou a six pans Tuerca hexagonal
546.008 Senkschraube Countersunk screw DIN 963-M6x35-4.8
Vis a tete noyee lornillo avellanado
546.021 Sechskantmutter Hexagon nut M1536-AM6-6
Ecrou a six pans Tuerca hexagonal
5~6.025 Firmenschild Name plate M1055-D37x74
Plaque d' usine Placa de fabrica
546.026 Halbrundkerbnagel Splined pin DIN 1476-3x8-St
Clou cannelea tete ronde Pasador redondo estriado

+ falls vorhanden
if provided
s'il existe
si existe

++ Bei AusfUhrung mit Drehzahlmesseinrichtung und Schalldampfer siehe


auch unter 562.000/1
For design with speed measuring device and silencer, see 562.000/1
Pour l'execution avec compte-tours et silencieux, cf. egalement
562.000/1
En 1a ejecucion con contador de revoluciones y silenciador vease
tambien 562.009/1

D36 5649 / 500. 02/4


,
VERZEICHNIS OER EINZELTEILE
LIST or SINGLE PARTS NR 20 500.02
LISlE DES PIECES CONSTITUTIVES
INDICE DE LAS PIEZAS INDIVIDUALES 5
Bestell-Nr. NOClm Nr.
Order No. Benennung Designation Standard No.
No. de commande Designation Designacion No. standard
No de oedido No de norma

562.000/1 + Drehzahlgeber Speed transmitter


Bild 4 Figure 4
Transmetteur de regime Dinamo-tacometro
Figure 4 Figura 4

544.001/1 ++ RUckwand mit Restbearbeitung Rear wall with residual machining


Paroi arriere avec usinage Pared posterior can mecanizado
restant restante
546~001/1 ++ Spiralgehause mit Restbearbeitung Volute casing with residual machining
Corps a volute avec usinage Caja espiral con mecanizado
restant restante
562.002 ++ [insatz Insert
lnsert Insercion
562.004 Haltescheibe Holding disc
Disque de retenue Disco de sujecion
562.005 Sechskantmutter Hexagon nut M 1536-AM6-6
[erou a six pans Tuerca hexagonal
562.040 Drehzahlgeber Speed transmitter
Transmetteur du nombre de tours [misor del numero de revoluciones
562.061 Stiftschraube Stud screw DIN 835-M6x16-5.6
Goujon Prisionero
562.396 ++ Stiftschraube Stud screw
Goujon Prisionero
562.586 ++ Verschraubung Screw connection DIN 46320-C5Pg 9x6-7
Vissage Racor
-
562.000/2 + Drehzahlanzeioer Indicating instrument
ohne Bild wi thout figure
Indicateur de regime Indicador de revoluciones
sans figure sin figura

562.100 Drehzahlanzeiger Indicating instrument


Indieateur de regime Indicador de revoluciones
562.135 +++ Teflon-Panzerleitung Teflon-armoured cable
Conduite armee teflonnee Tuberia blindada de Teflon

+ falls vorhanden
if provided
s'il existe
si existe

++ Diese Teile entfallen bei TurboladerausfUhrung mit Ansauggehause.


These parts are not required for turbocharger design with air intake casing.
Ces pieces fie sont pas necessaires pour turbocompresseur avec bati d'admission dTair.
Estas piezas no son requeridas en los turbocompresores con caja de admision de aire.

+++ Bei Bestellung Lange angeben


State length when ordering
En cas de commande, indiquer 1a longueur
Indicar la longitud en e1 pedido

'0
co siehe Ruckseite - PTO
co D365649 500.02/5 1.s.\.s. - 5iQU~ 2: o~rs:
Bestell-Nr. Norm
Order No. Benennung Designation Standa itO.
No. de commande Designation Designacion No. standard
No de pedido No de norma

578.000/1 + Reinigungseinrichtunq fUr Turbine Washing device for turbine -0012


(Nassreinigung) (Water washing)
Bild 6 Figure 6
Dispositif de nettoyaqe pour Dispositivo de lavado para turbina
turbine
(nettoyage a l'eau) (Limpieza por via humeda)
Figure 6 Figura 6

578.002 Verschraubung Screw connection DIN 2353-CL15-St


Vissage Racor
578.003 Dichtring Seal ring DIN 7603-A18x24-Cu
Anneau-joint Ani110 de junta
578.005 Dichtring Seal ring DIN 7603-A14x18-Cu
Anneau-joint Anillo de junta
578.006 Druckminderstation Pressure-reducing station
Station de reduction de pression Equipo de reduccion de presion
578.010 Schild Metal plate
Plaque Chapita
578.020 Dreiwegehahn Three-way cock
Robinet a trois voies Grifo de tres pasos

578.000/2 + Reinigungseinrichtung fUr lurbine Washing device fer turbine


(Trockenreinigung) (Dry cleaning)
Bild 7 Figure 7
Dispositif de nettoyage pour Dispositivo de lavado para turbins
turbine
(nettoyage a sec) (Limpieza en seco)
Figure 7 Figura 7

578.001 Beh~lter Tank


Reservoir Recipiente
578.002 Deckel Cover
Couvercle Tapa
578.003 Runddichtring O-ring
Joint torique Anillo circular de junta
578.004 Stiftschraube Stud screw
Goujon Prisionero
578.005 flUgelmutter Winged nut
Ecrou a creilles Tuerca de oreja
578.007 Doppelnippel Double nipple
Raccord filete double Racor doble
578.010 Absperrhahn Shut-off cock
Robinet d'ar.ret Gri fo de cierre
578.020 Nippel mit Gewinde Nipple with thread
Raccord filete Boquilla roscada
578.021 Kupplung fUr Schlauch Coupling for hose
Connecteur pour flexible ~coplamiento para manga
578.025 Kupplung mit Gewinde Coupling with thread
Connecteur filete Acoplamiento roscado
578.026 Nippel mit Gewinde Nipple with thread
Raccord filete Boqui 11a roscada
578.030 Absperrhahn Shut-off cock
Robinet d'arret Gri fo de cierre
578.035 Schild Metal plate
Plaque Chapita
+ falls vorhanden + if provided
s'il existe si existe
g + +

0 D 36 5649 / 500.02/5
VERZEICHNIS DER EINZELTEILE

~-u LIST or SINGLE PARTS NR 20 500.02


LISTE DES PIECES CONSTITUTIVES
INDICE DE LAS PIE1AS INDIVIDUALES 6
8estell-Nr. Noom Nr.
Order No. Benennung Designation Standard Ho.
No. de commande Designation Designacion No. standard ~

Ho de oedido No de nonna
~

579.119 Handspritze (Verdichterreinigung) Syringe (for cleaning the compressor


Seringue a main (nettoyage du Jeringa (limpieza del compresor)
compresseur)

591.060 + Schild, 2weiteilig Metal plate, two-part


Plaque, deux pieces Chapita, dos piezas

- ~
591.952 + Isolierung am Turbinen-Zustr5m- Insulation on gas-admission
geh~use casing
"Bild1 figure 1 i-

Isolation de corps d'admission Aislamiento de caja de afluencia


de turbine de turbina
rigure 1 Figura 1

599.001 Rumpf gruppe CartridQe


Bild 3 Figure 3
Groupe base Grupo base
figure 3 figura 3
l-

t-

I-

+ falls vorhanden
if provided
..
s'il existe
si existe
. D36 5649 500.02/6
8.86

546.001 51.6005 520.006 517001 517.0)1 501008 5011100


5Ll. OU 5L1.[03L 5".001
SLL 021 5{,6.006 520.017 tiL
S(L OJJ 501102
""" , 501001
SI.L 032
t1l SL4061 501003
o S01OOl.
o SI.L 066
o 511.009 co
tv .....
I--'
Cl.
~ SLL 066/ 511001
~

--4 ---4---4_
--., c:: c:: c:: c::
;:0 ;:0 ::'0 ::'0
.....
(0
co co co
CJ <::) CJ CJ
=
517017 V)
.,c:
(1)
CJ
co
hg~
~:J::>Ot::1
::'0 ("Tl
517.008 ::'0
~
,..,
:J::>O
"
::'0 G"J
,.., ::'0
r- M ::'0
517003 l-i t/)
...., V)
..... ~ M
(0 c::
511002 c: = :::u
.,
(1)
~
C7
CJ
520001 -:.
-
::'0

511033
--.,
517032 .....
to
"----. ~ S17 029 .,c::
OJ
_OJ~~ll1_ ---51703'
-:.
I 517022· 517030
517001. 50UJ09
Schnitl 11.-8
517032
517.099

501005
./////////////
591952
520011 520009 51.6008

520018 51.6021 51.2001 520005 r-


Z
l11 ~

0 t-..>
-..A 0
00

-H---------SL6025
546026

01
o
o
o
'"
TURBINEN-ZUSTROMGEHAUSE, TURBINENLEITAPPARAT
GAS-ADMISSION CASING, TURBINE NOZZLE RING NR 20 500.02
CORPS D'ADMISSION Dr TURBINE, DISTRIBUT£UR DE TURBINE
CAJA DE AFLUENCIA Dr TURBINA, DISTRIBUIDOR Dr GASES DE L 15 206 8
10----------4 TURBIN~ ~ --s._ _- I

Bild 2 - Figure 2 - Figure 2 - Figura 2

SOt. 0 Ot _';';"'_ieZ::::ZZ::2:ZZz:zz:~

SO'.006--r-~
50t.007
501.008 ~I~~~~~
501.005

599.001

513.001--+--+---- "//-L...L..~
501 .009-......--......,~~I~~_ A
\ -~+-
j '"
\ i "'-"'_ I
\ i ,,~
. I
\ '
I'

.1 I'

-r-
~

I
i
i
'- 364~~9.i

co D 36 5649 500.02/ 8
RUMprGRUPPE, (l~GERUNG+lAUrER)
CARTRIDGE, (BEARING+ROTOR) NR 20 500.02
GROUPE BAS~ (lONGEMENT+ROTOR)
GRUPO BAS£, (ALOJAMIENTO+ROTOR) 9

Bild 3 - rigure 3 - Figure 3 - Figura 3

599.001

517.022 517.001
517.004

517.009
517.031-_
517.D17 ~___

520.005

520.001

-.0
co
co D36 5649 500.02 9
8.86
o

544.034==-I~~~~~~!~
544.041
01 544.067
o
a 544.066
o
tv

562.040--t+----
562.002--t+---
562.004-...&...1
562.00S-.IL..L
562 .061---t+--......oqI~

546.001-.LJI

544.067
544 066 562.396
544 067 r r
.-J
I ..... tl1
Z
;0
l'J
I 0 t-.>
544.201 W 0
544.201 -~~IIIIIII I

.. Go]~O
ANSAUGGEHAUSE
AIR-INTAKE CASING NR 20 500.02
CORPS 0' ASPJRAfION
CAJA DE ASPIRACJON L 15 230 11

Bild 5 - rigure 5 - rigure 5 - Figura 5

5"5.014
"'---545.001

562.005
562.004
562.061
562.040

520.124


00
00 D365649 500.02/ 11
REINIGUNGSEINRICHTUNG FUR TURBINE (NASSREINIGUNG)
WASHING DEVIC£ FOR TURBINE (WATER WASHING) ~ NR 20 1500.02

=\;Leu DISPOSITIF DE NETTOYAGE POUR TURBINE (NETTOYAGE ~ L'[AU·


DISPOSITIVO DE LAVADO PARA TURBINA (LIMPIEZ~ POR VIA L 15 201 12
I

Bild 6 - Figure 6 - Figure 6 - Figura 6

+ +

co
~
N
~

+ I +
--'

0 CO
0
5 0
a:) cD
l"'- I"'-
LI') LI')

, N
C"")
Ln 0
0 N 0 0
~ ~ 0 ~
cO
I U)
I"'-
LI')
U)
I"'-
Ln
r---
LI')
U)
r-
LI')

I
-_.-t--
-.0
co
cOl D36 5649 500.02/12
REINIGUNGSEINRICHTUNG rUR TURBINE (TROCK£NREINIGUNG)

=tL.QUJ WASHING DEVICE FOR TURBINE (DRY CLEANING)


DISPOSITIF DE NETTDYAG£ POUR TURBINE (N£TTOYAGE ASEC)
DISPOSITIVO DE LAVADO PARA TURBINA (LIMPIEZA DEN SEeD)
NR 20

L 15 234
500.02
13

Bild 7 - Figure 7 - Figure 7 - Figura 7

_ . !« xu .-L.~~.-L. 14 >< >

-.0
co
c:> I D36 5649 500.02/13
SUPPLEMENT TO
TURBOCHARGER TYPE NR 20
Dismantling and Reassembling
Cartridge

Contents Sheet No.

Sequence of Operations Dismantling of Cartridge 1, 2


Sequence of Operations 2 Inspection of Individual Parts 3
Sequence of Operations 3 Reassembling Cartridge 4

List of Contents: Set of Spare Parts 5

List of Contents: Set of Tools 6

D36 5655-1 E

9.86
599.001

517.022 517.001
517.00'

S1k009
517.031-~
517..017 - - ~

517.030--
517.032
517.033
520.001

fig, 1
LEGEND
599.001 Cartridge complete, consisting of:
517.001 Bearing casing 520.001 520.001 Rotor
517.002 Bearing bush 520.005 Compressor wheel
517.003 Spacer sleeve 520.006 Labyrinth ring
517.004 Holding screw 520.009 Carrier
517.008 Bearing sleeve 520.011 Closing nut
517.009 Closing cover. turbine side 520.017 O-ring
517.017 Sealing cover 520.018 Feather key
517.022 Sealing ring
517.029 Stud screw 520.124 Magnetic nut
517.030 Stud screw ( only for version with revolution
517.031 Gasket counting, instead of 520.011 )
517.032 Hexagon nut
517.033 Lockwasher
517.034 Adh€sive
D35 5E55/C E
DISMANTLING A~D Rlh~~~MBLING NR 20
CARTRIDGE Arbe;tskorle·Nr
Sheet 1
Work cord No
INSPECTION OF COMPONENT PARTS Corle travail No
Tor,elo trobn,O No of 4
associated work cards •••• 500.06
500.10 through
500.16

a
" --~
ll

TOOLS REQUIRED •••...••• Tool No.


Jacking device ••••••••• 596.002
consisting of:
1 Oil injector ••••••••• (596.003)
1 Intermediate piece •.• (596.00~)
2 Sealing rings •..•.••. (596.005)
10-ring •••••••••• , •..• (596.006)

1 Open end wrench SW 41


1 Open end wrench SW 24
I 1 Open end wrench SW 19

~B • _ _e
C
.. . . - - . _
1 Socket wrench SW 22
1 Socket wrench SW 10

c'19.
I
2

STARTING POSITION
Cartridge (599.001) is detached from turbocharger

SEQUENCE OF OPERATIONS 1, Disassembly

1. Removal of compressor wheel (520.005) - Ill. 1 and 2

1.1 Measure distance "a" and record. - Ill. 2


1.2 Unscrew closing nut (520.011) or, for version with revolution counting, magnetic nut (520.124)
- right-hand thread -
1.3 Withdraw carrier (520.009).
1.4 Fill up jacking device (596.002) and screw onto shaft end of rotor (520.001), while doing so,
watch position of sealing rings (596.005). - Ill. 2 -
Note Filling up of jacking device:
Screw off oil injector (596.003) from intermediate piece (596.004)
- Screw sleeve (A) of oil injector back as far as possible
- Press piston (8) back to end position with suitable object
- Fill up cylinder (8) with clean lube oil (Viscosity SAE 30 - SAE 50)
Screw on oil injector (596.003) - with sealing ring (596.005) - to intermediate piece
(596.004).

P. T. .
Aroe"sze,· - S'v"ae" Alit ~CII P:::;'~:' u,..=,.. . .
036 5655 'lYo" '''Q I ,me - MOvrs t"er'r O:>~~~ I"'; rOV f )

D"ree ae !rC.O' - Heure~ lOJtes It~ ..··'H....... res GC -C":"'~


T,e"'DO ae ,rot-o.c - ,",oros Cooc. ~O~Ct oe)(' ,: 1:-
Fig. 3
1.5 Extraction of compressor wheel (520.005) - Ill. 2 and 3 -
By turning sleeve (A) at oil injector (596.003) , oil is pumped into the shaft pin until it has
reached the groove between turbine shaft (520.001) and compressor wheel (520.005) and the
compressor wheel can be moved freely on the shaft.
Now, the com~ressor wheel (520.005) must be extracted by hand immediately and steadily,
employing constant axial force.

Note Uneven force in extracting the compressor wheel may result in disruption of the oil
pressure in the groove between turbine shaft and compressor wheel.
The compressor wheel then seizes.

If that happens, the remedy is described hereunder:

Remove jacking device (596.002)


Heat compressor wheel hub (not the blades) uniformly and carefully, but quick by
means of a soft flame up to but not exceeding 80° C (over entire circumference,
not only locally) then pull off compressor wheel with steady force immediately.

Attention: Overheating of the compressor wheel will lead to structural changes of


the aluminium alloy, rendering the compressor wheel unserviceable.

1.6 Dismount jacking device (596.002), clean and place into tool kit again.

2. Removal of rotor (520.001)

2.1 Lift rotor (520.001) slightly and move out centrically as far as possible in direction of turbine

Note Run-in labyrinths or deposits of coke residue may impair the process of removal, if so,
use wooden pounding block.

In the process of removing the rotor, the labyrinth rings (520.006) and the O-ring
(520.017) are being stripped off.

C3E 5555
Sheet 2
3. Removal of bearing bushes (517.002)

3.1 Take off O~ring (520.017) or, if stripped off, collect, resp.
3.2 Take off labyrinth ring (520.006).

Note If the labyrinth ring with its tips sticks to the sealing cover (517.017), loosen first
lockwashers (517.033) on compressor side, unscrew hexagon nuts (517.032) and dismount
sealing cover together with labyrinth ring.

3.3 Take out both bearing bushes (517.002).

Only in case of damage of sealing cover (51l.017), bearing sleeve (517.008) or spacer sleeve
(517.003), the following operations are required:

4. Removal of sealing covers (517.017)

4.1 on compressor side - loosen lockwashers (517.033), unscrew hexagon nuts (517.008), take off
sealing cover (517.017) and gasket (517.031).
4.2 on turbine side - loosen lockwashers (517.033), unscrew hexagon nuts (517.032), take off
end cover (517.009), sealing cover (517.017) and gasket (517.031).

Fig. 4

5. Removal of bearing sleeve (517.008) and spacer sleeve (517.003) - Ill. 4 -

5.1 Screw out holding screw (517.004) and take off sealing ring (517.022).
5.2 Press out bearing sleeve (517.008) and spacer sleeve (517.003).

Note If, in case of remedying da~age, the sleeves should be shrunk on or seize, they can easily
be loosened or pressed through by slight pounding with a ham~~r or by means of a press,
using a wooden or a copper bolt.

C3E 56:: 2 P. T• C.
599.0()1

517.022 517.001
517.004

512009
517.031 ----.
51'7.017 ------.

520.005

517.030-~
517.032
517.033
520.001

364 22~3

Fig. 1
LEGEND
599.001 Cartridge complete, consisting of:
517.001 Bearing casing 520.001 Rotor
517.002 Bearing bush 520.005 Compressor wheel
517.003 Spacer sleeve 520.006 Labyrinth ring
517.004 Holding screw 520.009 Carrier
517.008 Bearing sleeve 520.011 End nut
517.009 End cover, turbine side 520.017 a-ring
51"1.017 Sealing cover 520.018 Feather key
517.022 Sea1inq ring
517.029 Stud bolt 520.124 Magnetic nut
517.030 Stud bolt ( only for version with
517.031 GasKet revolution counting. instead
517.032 Hexago r nut of 520.011 )
517.033 Lockwasher
517.034 Adhesive

· ",;Jt
D ,..~­
2
SEQUENCE OF OPERATIONS 2, Inspection of individual parts Sheet 3
For inspection, clean individual parts as described hereunder.
Burnt-in dirt layers, particularly on turbine side (such as residues of heavy fuel, oil coke)
to be soaked in P3-water solvent and brushed off. If required, repeat process several times.
Subsequently, neutralize with soda water.
Layers of oily dirt to be removed with fuel oil or any other liquid cleansing agent.
Bores for sealing air and lube oil to be flushed with fuel oil and then to be blown through with
compressed air jet.
The following CHECKLIST comprises details on evaluation and required measures for repaIrIng the
cartridge (basic assembly). If more than one column is marked "X", the alternative more favourable
with respect to the situation under consideration may be chosen.
Part No. Individual Part
Order Condition Part to be sent in for repair
No. Dimension of (0 = External 0, d = Internal 0, b = Width)
rejection Part to be replaced
517.001 Bearing casing
Damage or incipient cracks, if stability or oil-leak-proof condition imperiled .••••••• X
517.002 Bearing bush (2 units: identical for turbine and compressor side)
Traces of seizure in touching pattern of axial surfaces ••••••••••••••••••••••••••••••• X
Wear: 0 ~ 0 49.82, d L 0 30.04, b ~ 23.94 •••••••••••••••••••••••••••••••••••••••••• X
Note Uniform layer of lacquering is no cause of concern, internal and external
diameters cannot be evaluated by visual inspection.
517.003 Spacer sleeve
Traces of seizure on axial surfaces................................................... X
517.008 Bearing sleeve
Traces of seizure in the bore, or wear: d L ~ 50.03 ........•.............•..•........ X
517.009 Closing cover - turbine side
In case of damage, if function or stability imperiled •••••••.•.••••.....•••••••••••••• X
517.017 Sealing cover (2 units: identical for turbine and compressor side)
Running-in pattern abnormal........................................................... X
Note The labyrinth clearance is smaller than the bearing play. Thus, the tips of
the labyrinths are touching the sealing covers, causing wear. The scores,
depending on the positioning of the rotor are, at the circumference, some-
what one-sided.
If sealing covers are replaced, the gaskets (517.031) are also to be re-
newed.
520.001 Rotor
Damage to blades, for instance by foreign matter ..••.••.••..••••.•••.•....•••.•••..••• X
Incipient cracks, (Crack test: e.g. sound test, fluorescent dye check) ••••••••.•••.••• X
Traces of touching at blade outline. unilateral at circumference, are indication of
imbalance •••.•••••••••.••••••••••.•••••••••••••••.•••••.•••••.•••.••..•.••.•.•..•..••• X X
Traces of touching at blade outline, over entire circumference; If permissible gap ex-
ceeded. (Refer Operating Manual: Gaps and clearances, points 3 and 4) ••••••••••••••••• X
Labyrinth tips damaged or worn: 0 ~ ~ 55.85 X
Bearing points damaged or worn: D ~ 0 29.94 X
Concentric running test: Clean centering points, mount for centering, measure for con-
centric running at both bearing points and at seat of compressor wheel (3 locations),
if deviation exceeding 0.01 mm .••...•.•••••.••.•...•..••••.....•..••....•..•••.•••.•••. X x
Note If eeccentricity at those 3 locations is in same circumferential positl0n and
runs linear, the centering points are damaged and the real deviation from
concentric running is smaller (max. permissible 0.01 mm).
520.005 Compressor wheel
Damage to blades, for instance by foreign matter .•....••••.........•.•••..••...•..••..• X
Incipient cracks, (Crack test: e.g. sound test, fluorescent dye check) ..•..••••.•..•••• X
Traces of touching at blade outline, unilateral at circumference, are indication of
imbalance .••.••.••••.•...••••••••.•••.•••..••••.•..•..•.•..••••.•••••..••.•••.•.•••.•.• X x
Traces of touching at blade outline, over entire circumference: If permissible gap ex-
ceeded (Refer Operating Manual: Gaps and clearances, points 3 and 4) •••..••.•••.••.••• X
520.005 labyrinth ring
Labyrinth tips damaged or worn: D ~ 0 55.85 X

t3t SESS .. F. T.0


599.001

511.022 517.001
517.004

51IO09
517.031
517.017

520.005

520.. 001

LEGEND
599.001 Cartridge complete, consisting of:
517.001 Bearing casing 520.001 Rotor
517.002 Bearing bush 520.005 Compresor wheel
517.003 Spacer sleeve 520.006 Labyrinth ring
S17.004 Holding screw 520.009 Carrier
517.008 Bearing sleeve 520.011 End nut
517.009 End cover, turbine side 520.017 O-ring
517.017 Sealing cover 520.018 feather key
5J7.022 Se31jng ring
517.029 Stud bolt 520.124 Magnetic nut
517.030 Stud bolt ( only for version with
517.031 Gasket revolution counting, instead
517.032 Hex~gon nut of 520.011 )
517.033 Lockwasher
517.034 Ad~esive
SEQUENCE OF OPERATIONS 3, Reassembly
Sheet 4
The reassembly of the cartridge is a reversal of the process of dismantling.
Watch out particularly for cleanliness of the individual parts. Slightly moisten sliding surfaces
with clean lube oil.
If a new rotor and/or a new compressor wheel is installed, check for identity of blade outline
with component originally installed.

1. Inserting Bearing sleeve (517.008) and spacer sleeve (5l7.003)

1.1 Insert bearing sleeve and spacer sleeve in a manner ensuring that the bores for holding screw
(517.004) and for oil supply coincide. - Ill. 4 -
1.2 Screw in completely holding screw (517.004) with sealing ring (517.022).

2. Mounting sealing cover (51l.017)

2.1 on turbine side - Put on gasket (517.031), sealing cover (517.017) and end cover (517.009)
and tighten with hexagon nuts (517.032), secure with lockwashers (517.033)~

2.2 on compressor side - Put on gasket (517.031) and sealing cover (517.017), tighten with hexagon
nuts (517.032) and secure with lockwashers (517.033).

3. Fitting of bearing bushes (517.002)

3.1 Insert bearing bushes into bearing sleeve (517.008) on turbine as well as on compressor side.

Note The bearing bushes are completely symmetrical installation, therefore, at discretio~.

4. Fitting rotor (520.001), labyrinth ring (520.006) and a-ring (520.017)

4.1 Carefully insert rotor in axial direction, do not damage labyrinth tips.
4.2 Place labyrinth ring (520.006) on turbine shaft, balancing marks on labyrinth ring and on rotor
must coincide.
4.3 Shove on a-ring (520.017).

5. Fitting of compressor wheel (520.005)

Note Tight fit of the compressor wheel on the turbine shaft is secured by employing the heat
shrink process. Therefore, the following operations must be performed in quick succession.
Fix rotor in end position towards compressor side and secure against turning either by
hand or with other suitable means.

Ensure that balancing marks of rotor (520.001), labyrinth ring (520.006), compressor wheel
(520.005) and carrier (520.009) correspond radially regarding angle position.

Claws of labyrinth ring (520.006) and compressor wheel) 520.005) must mesh.

For putting on the heated compressor wheel, wear protective gloves.

5.1 Clean seats from oil, grease or lubricants containing M52 carefully. Apply thin gliding film
of Mo1ykote G Rapid, Molkote G-n or Molykote 0 on cylingrical seat of turbine shaft.
5.2 Heat compressor wheel (520.005) to approx. 80 0 C in water.
5.3 Insert feather keys (520.018) in turbine shaft, if they had been removed.
5.4 Shove compressor wheel (520.005) and carrier (520.009) on turbine shaft and tighter at once with
closing nut (520.011) or magnetic nut (520.124) resp., in case of version with revolution counting

6. Inspection

6.1 Measure distance "a ll - refer Ill. 2 - and compare with readings taken prior to disassel1'~ly.
If ~xcessive, claws of compressor wheel and labyrinth ring do not mesh. In that case, remove
compressor wheel once more and refit correctly.

D3E 565: L F. T.0.


INHAlTSVERZEfCHNfS: WERKZEUG-SATZ NR20 6
=b...C\UI INDEX; SET OF TOOLS
SOMMAfRE: JEU O'OUTrLS
RELACION DEL JUEGO DE HERRAMIENTAS S11.59600-0031

Bestell·Nr. Menge
Order No 8enennung Designation Quantity
No de (de O'signation Designaci6n Quantit'
Node pedido Cantidad

Abbau Verdichtergehause Removing Compressor casing -


Demontage du corps de compresseur Para desmontaje de la caja del compresor -
596.001 Sechskantschraube (AbdrOckschraube) Hexagon screw (puller screw) 3
Vis a t!te a six pans (Vis a chasser) Tornillo cabeza exagonal (Tornillo extrac-
tor por compresi6n)

Abbau Verdichterrad Removing Compressor wheel -


Demontage de la roue de compresseur Para desmontaje del rodete -
596.003 Olinjektor Oi I-i njektor 1
Injecteur d'huile Inyettor del aceite
596.004 Zwischenstuck Intermediate piece 1
Pi~ce intermediaire Elemento intermedio
596.005 Dichtung Seal ring 2
Joint Junta
596.006 Runddichtring O-ring 1
Joint torique Anillo circular de junta

0365655/6 986