MaK M20 - Инстр. по экспл.ГТН R4-3

 



  

OPERATING
and
MOUNTING INSTRUCTION
for
EXHAUST GAS
TURBOCHARGER
TYPE R4-3
Kompressorenbau Bannewitz GmbH

Windbergstra?e 45
01728 Bannewitz
Federal Republic of Germany
Phone: +49 (351) 40 85 50

+49 (172) 35 16 045 (24 Hours Phone)
Fax: +49 (351) 40 85 840
en 3 rd Edition (07/99)
Exhaust gas turbocharger R4-3
Type plate
Type/Works - No.
Variants - No.
o
max. rpm max. C
Speed Temp
Weight kg Year of
Manuf.
Made in Germany
The data given in the operating instructions apply only to the exhaust gas turbochargers of the works
number mentioned above. This number is also given on the type plate affixed to the compressor housing
of the exhaust gas turbocharger.
In case you have questions regarding the exhaust gas turbocharger, it is important to give the correct
 type
 variant number
 works number.
Only if these data are known the request can be handled properly and promptly.
Direct your requests to the following addresses:
Kompressorenbau Bannewitz GmbH

Windbergstr. 45
01728 Bannewitz
Federal Republic of Germany
Fax: +49 (351) 40 85 840

Phone: +49 (351) 40 85 50
+49 (172) 35 16 045 (24 Hours Phone)
Page 2 of 51 3 rd Edition (07/99) en

Table of Contents
Chapter Title Page
1 SAFETY.............................................................................................5
1.1 Built-in safety systems............................................................................................5
1.2 Safety measures (to be taken by operator) .......................................................5
2 GENERAL INFORMATION ABOUT DANGERS............................6

2.1 Danger zone...............................................................................................................6
2.2 Operators and maintenance personnel..............................................................6
2.3 Use of spare parts and wearing parts .................................................................7
3 DESIGN AND SPECIFICATIONS....................................................8

3.1 Brief description .......................................................................................................8
3.2 Operating data ...........................................................................................................9
3.3 Pipe connections................................................................................................... 10
3.4 Test connections ................................................................................................... 11
3.5 Dimensions of important subassemblies ....................................................... 12
4 INSTRUCTIONS FOR MOUNTING TURBOCHARGER..............13

4.1 General requirements........................................................................................... 13
4.2 Console for the TC ................................................................................................ 13
4.3 Gas and air pipings ............................................................................................... 13
4.4 Loads of housings of the exhaust gas turbocharger .................................. 14
4.5 Vibrations................................................................................................................. 14
5 OPERATION...................................................................................15
5.1 Preparation for operation .................................................................................... 15
5.1.1 Lubricating oil supply............................................................................................... 15
5.1.2 Cooling water............................................................................................................ 15
5.2 Engine operation ................................................................................................... 16
5.3 Putting out of operation....................................................................................... 16
5.4 Failures..................................................................................................................... 17
6 MAINTENANCE..............................................................................18
6.1 General ..................................................................................................................... 18
6.2 Maintenance work ................................................................................................. 18
6.3 Cleaning ................................................................................................................... 19
6.4 Maintenance schedule ......................................................................................... 20
6.5 Troubleshooting table .......................................................................................... 21
en 3rd Edition (07/99) Page 3 of 51

Chapter Title Page
7 DISASSEMBLY AND ASSEMBLY ...............................................22

7.1 Introduction............................................................................................................. 22
7.2 Checking the components.................................................................................. 22
7.3 Test results.............................................................................................................. 24
7.4 Clearance sheet ..................................................................................................... 26
7.5 Process of maintenance ...................................................................................... 27
7.5.1 Compressor washing ............................................................................................... 27
7.5.2 Turbine washing ....................................................................................................... 28
7.5.3 Stoppage the exhaust gas turbocharger .............................................................. 29
7.5.4 Bearing check........................................................................................................... 30
7.5.5 Disassembly of the complete turbocharger ......................................................... 31
7.5.6 Assembly of the complete turbocharger............................................................... 32
7.5.7 Assembly and disassembly of silencer or air-intake housing ........................... 33
7.5.8 Cleaning the silencer ............................................................................................... 34
7.5.9 Assembly and disassembly of the compressor housing .................................... 35
7.5.10 Assembly and disassembly of the bearing housing with rotor.......................... 36
7.5.11 Disassembly of rotor complete .............................................................................. 37
7.5.12 Installation of rotor complete .................................................................................. 39
7.5.13 Disassembly turbine outlet housing ...................................................................... 42
8 SPARE PARTS AND T OOLS........................................................43

8.1 General ..................................................................................................................... 43
8.2 Spare parts .............................................................................................................. 44
8.2.1 Bearings .................................................................................................................... 44
8.2.2 Gaskets ..................................................................................................................... 45
8.2.3 Locking elements ..................................................................................................... 46
8.3 Tools ......................................................................................................................... 47
9 SECTIONAL DRAWING.................................................................48
10 LIST OF COMPONENTS ...............................................................49

1 SAFETY
The exhaust gas turbocharger has been designed on the basis of the following standards and
regulations:
 EC machinery directive (89/392/EEC, 91/368/EEC, 93/44/EEC, 93/68/EEC)
 EN 292 Parts 1 and 2: Safety of machines (fundamentals)
 EN 294 : Safety of machines; Safety distances to be kept to prevent the upper limbs from
reaching dangerous zones.
1.1 Built-in safety systems

 A safety system for the turbocharger is not necessary as its design and connection with
the engine to which it is attached require an inherent safety.
 Because of the high temperatures occurring, the turbine housing is provided with a
protective cover.
 For general speed monitoring, i.e. without a turn -off function being included, a tachometer
can be mounted on the exhaust gas turbocharger.
Maintenance work must not be done during operation. See Chapter 7.5.1
and 7.5.2 "Maintenance" for maintenance jobs to be done while the
engine is running.
1.2 Safety measures (to be taken by operator)

 These operating instructions are part of the exhaust gas turbocharger and shall be always
accessible for the operators and maintenance personnel.
 The operating instructions should be read before mounting the turbocharger. Part icular
attention should be paid to directions and information relating to dangers.
The user is required
 to instruct his operators and maintenance personnel on the safety equipment of the
turbocharger
 makes them familiar with safe working methods
 supervises observance of the safety regulations.
The individual jobs in these instructions are described such that they can be understood by
skilled workers.
The necessary tools and testing/inspection means must be available to these workers.
The user must obtain permission to operate the unit from the local authorities and observe
the following:
 labour safety
 cleaning and maintenance of the machines
 product disposal
 environmental protection.
en 3 nd Edition (07/99) Page 5 of 51

2 GENERAL INFORMATION ABOUT DANGERS
2.1 Danger zone

The danger zone is defined by the engine as the turbocharger is an integral part of the
engine.
 During turbocharger operation, the user must keep the danger zone free
of any objects so to ensure unhindered access to the unit.
Ear muffs should be worn as the sound level is high. Care should also
be taken when approaching the hot housings!
The exhaust gas turbocharger is mounted on the engine. It may not be interfered with when
the engine is running.
 Make sure the exhaust gas pipes on the turbine side cannot come loose during operation
since exhaust gas might escape at this point.
 As the exhaust gas turbocharger is an integral part of the engine, its operation is
described in connection with the engine. However, its maintenance is described
separately.
2.2 Operators and maintenance personnel

Operators and maintenance personnel are persons who are responsible for transport,
assembly, installation, operation, setting, maintenance, cleaning and troubleshooting.
 Adhere to the following accident prevention regulations:

- winches, hoisting and drawing gear (VBG 8)
- load take-up devices for hoisting operations (VBG 9a).
If these regulations are not observed, your life and limb may be endangered!
1. The turbocharger may only be maintained by duly qualified and authorised persons.
2. In operating the turbocharger, the responsibilities shall be clearly defined and must be
adhered to so as to prevent confusing competences with respect to the safety aspect.
3. The operating instructions shall be followed irrespective of what kind of work (operation,
maintenance, repair etc.) is concerned.
4. The cleaning, maintenance and repair work described in these instructions are easy to
understand by persons skilled in mechanical, cleaning and maintenance work.
The necessary tools and testing/inspection means must be available to these persons.
5. Operators are not allowed to interfere with the unit in a way that would affect machine
safety.

6. It is also within the responsibility of the operator to see to it that no unauthorised person
works on the turbocharger.
7. The operator must inform the user without delay of any safety-affecting changes to the
turbocharger.
8. The user must not operate the turbocharger when it is not in proper condition.
2.3 Use of spare parts and wearing parts

It is emphasised that spare and wearing parts not supplied by us are not tested/ inspected
and approved by us. The use of such products may negatively affect the performance of your
turbocharger. We assume no liability for damage caused by the use of components and
accessories not made by us.
For ordering spare parts and tools, please refer to the
 parts list
 sectional drawings
 spare parts list
 tools list.
The spare parts lists attached contain all spare parts for the turbocharger. DIN (standard)
parts may be bought from specialised dealers.
For the assembly, disassembly and commissioning of the turbocharger, refer to the
respective sections in these operating instructions.
Before doing any maintenance, cleaning or repair work, turn the engine
off and secure it against unintentional starting. See chapter 7.5.1 and
7.5.2 "Maintenance" for maintenance jobs to be done during engine
operation.
Please observe the following accident prevention regulations:
If these regulations are not observed, your life and limb may be
endangered!
 See the inspection schedule (see Chapter 6.4) for the maintenance
intervals.

3 DESIGN AND SPECIFICATIONS
3.1 Brief description

Exhaust gas turbocharger (TC): R4-3
Variant number : 2.448-. . . . .
Mass : 450 kg
The R4-3 TC is equipped with a single- stage radial flow turbine and a single- stage radial
flow compressor.
The turbine wheel is welded to the shaft, whereas the compressor impeller is shrunk to the
shaft. The complete rotor has a bearing consisting of two plain bearings in a water-cooled
bearing housing. The turbine and compressor housing is flanged to the bearing housing. The
turbine outet housing is mounted on the turbine inlet housing. You can use a silencer or an
intake housing on the entrance of the compressor housing.
The bearing lubrication is connected to the lubricating oil system of the engine.
The TC is not equipped with a special control device. The TC speed obtained depends on the
engine output.
The TC variant attached to the engine is thermodynamically adjusted and is binding for this
engine variant, i. e. if the TC has to be replaced, use the same TC variant.
Modifications and additional attachments to the TC are subject to a written consent of the TC
manufacturer.

3.2 Operating data

Variants refer to type plate (Page 2)
Max. speed (rpm) refer to type plate (Page 2)
Max. exhaust gas temperature upstream of turbine (°C) refer to type plate (Page 2)
2
Types of lubricating oil: Engine oil with a kinematic viscosity 60...115 mm /s
o
of at 50 C e.g. SAE 30, SAE 40
Nominal oil filter fineness upstream of TC : max. 25 µm

Lubricating oil pressure upstream of TC : 300 + 150 kPa
Admissible lubricating oil pressure for special operating
conditions
At start-up : min. 50 kPa
From start-up to idle running : min. 50 kPa
At standstill (Prelubrication or relubrication/ Standby see diagram down
operation)
Lubricating oil flow : 25 ... 30 l/min
Lubricating oil temperature at inlet : 40 ... 80 °C
Lubricating oil temperature at outlet : max. 100 °C
Cooling water pressure: max. 300 kPa
Cooling water temperature at inlet: 50 ... 85 °C
Max. temperature difference between inlet and outlet cooling 10 K
water :
3
Cooling water flow : min. 1,5 m /h
Counter - pressure downstream of turbine : max. 2.5 kPa(g)
Vacuum upstream of compressor : max. 1.5 kPa(g)
Sound power level (measured on silencer at 100 mm 108 dB at 36,000 rpm
distance from compressor housing):
POil
(kPa)
o
t Oil ( C)
Admissible lubricating oil pressure for prelubrication or relubrication
(Standby operation)

3.3 Pipe connections
 Dimensions are specified in mm!
Exhaust gas Inlet single - nozzle housing (1x) O 150 mm
Inlet double - nozzle housing (2x) O 110 mm
Inlet triple - nozzle housing (3x) O 100 mm
Outlet 185 x 500 mm
Charge air Outlet O 175 mm
Lubricating oil Inlet at bearing housing M27x2
Outlet at bearing housing Pipe 45 x 2
Cooling water Inlet at bearing housing Pipe 35 x 2
Compressor washing Air piping Pipe 12 x 1 St
Water piping Pipe 12 x 1,5 Cu
Turbine washing Water piping Pipe 12 x 2
Drainage Pipe 35 x 2
Further connection dimensions can be taken from the assembly drawing. This can be
requested from the TC manufacturer.
 The piping for the pipe connections listed is not included in the scope
of supply of Kompressorenbau Bannewitz GmbH.
Pipes have to be laid free of stress in any case.

3.4 Test connections

On request, the TC can be equipped with a speed measuring device consisting of magnetic
screw (9001) and an inductive speed sensor (9002).
The magnetic screw (9001) is screwed into the shaft centring hole. The inductive speed
sensor (9002) is screwed into the silencer/ air intake housing to the limit and then unscrewed
by half turns (distance 1 - 1,5 mm). After disassembly inductive speed sensor (9002) is
secured with the lock nut (A).
Legend
2500 Compressor housing
2517 Tension tape
2800 Silencer
2900 Intake housing
9001 Magnetic screw
9002 Inductive speed sensor
A Lock nut

3.5 Dimensions of important subassemblies
Exhaust gas turbocharger, cpl. 450 kg

Silencer 45 kg
Air-intake housing 20 kg
Compressor housing, cpl. 75 kg
Turbine inlet housing, cpl. 86 kg
Turbine outlet housing, cpl. 65 kg
Bearing housing, cpl. 70 kg
Rotor cpl. 18 kg
Shaft 13 kg
Compressor impeller 5 kg

4 INSTRUCTIONS FOR MOUNTING TURBOCHARGER
4.1 General requirements

The TC is to be connected to the engine without deflection or torsion. Thermal expansions
and relative motions are to be compensated by flexible or movable elements in the pipings.
4.2 Console for the TC

The console is to be designed resistant to
deflection and torsion in order to prevent any
additional forces from acting on the fastening bolts.
Use bolts of property classes 10.9 or 12.9
according to DIN 276. If the foot is not in horizontal
position (angle of inclination > 25°), it is to be
supported additionally (refer to figure).
4.3 Gas and air pipings

Gas and air pipes must not be supported at the exhaust gas turbocharger housings, but only
on the engine. They are to be fastened in a way avoiding free oscillations.
Thermal expansions are to be absorbed by expansion joints (compensators) to be arranged
as closed to the exhaust gas turbocharger as possible.
Compensators are to be prestressed in cold condition in order to ensure an optimum relief
during the operation.
Thick flexible gaskets must not be used instead of compensators or sliding seals.
Soft compensators are to be installed in the piping downstream of the air outlet, upstrea m of
the gas inlet as well as upstream of the air-intake housing.
Exhaust gas outlet of an exhaust gas turbocharger is connected via diffuser and compensator
to the exhaust gas piping. This exhaust gas piping has to be fixed to the building or ship
directly downstream of the compensator (refer to figure). The remaining forces acting on the
turbine housing are composed of the weight of the diffuser and of the compensator pressure.
Legend
1 - fastening point in
building or ship
2 - compensator
3 - diffuser
23 - diffuser housing

4.4 Loads of housings of the exhaust gas turbocharger

The air and gas piping may transfer inadmissible high forces and moments onto the TC
caused by deformation or thermal expansion.
This may caused distortion at TC housing components perhaps resulting in damages at the
TC; e. g. elimination of mounting clearances resulting in a rotor contact with the housings,
damaged bearings, TC failure.
The pipings attached may apply the following forces and moments to the TC
Maximum admissible forces and moments

F1 900 N
M1 400 Nm
M2 350 Nm
While dimensioning the compensator and the diffuser, make sure to

select their masses and the rigidity of the compensator in order to
prevent the forces mentioned from being exceeded in cold as well as
warm ope rating conditions as well as during start-up and stopping.
Recommended compensator rigidity : < 300 N/mm

Mass of diffuser firmly screwed to TC including half of the mass of the compensator
(max. admissible) : 90 kg
4.5 Vibrations
Maximum admissible vibration load at engine for 2 - 300 Hz :
Effective vibration speed at TC 30 mm/s
at silencer 50 mm/s
Amplitude 1 mm
2
Effective acceleration 15 m/s
(measured at TC at shaft level longitudinal and transverse to the Rotor)

5 OPERATION
5.1 Preparation for operation
5.1.1 Lubricating oil supply
The lubricating oil supply of the TC plain bearing is taken from the engine oil circuit. The lubri-
cating oil flow depends on the oil temperature, the oil pressure and the TC speed.
A nominal oil filter fineness of 25 µm is specified for the lubricating oil upstream of the TC. If
the lubricating oil filter of the engine does not meet this requirement, a correspondingly
switchable filter is to be inserted upstream of the TC. This lubricating oil filter has to permit a
lubricating oil flow of not less than 35 l/min.
The lubricating oil supply have an open width of not less than 15 mm and the lubricating oil
return line shall have an open width of not less than 35 mm. The lubricating oil return line is to
be designed as short inclined piping.
Prior to putting into operation, ensure that the bearings of the TC are supplied with oil in any
case.
The lubricating oil pressures required for special operating conditions are listed under chapter
3.2. Ensure and check the free return flow of the lubricating oil.
The following has to be checked :
 Lubricating oil temperature upstream of TC
 Lubricating oil pressure upstream of TC
During installation, make sure to provide sufficient space for maintenance and repair work.
 Ensure the lubricating oil supply of the plain bearings (refer to chapter
3.2).
 Lubrication has to be started prior to start-up processes.
 The engine has to be stopped immediately when the oil pressure falls
below the minimum value.
 Pay special attention to prevent leakage's in the oil supply and return
pipes to prevent oil from flowing under the sheathing of hot, gas-
carrying housings in order to prevent the formation of hazardous oil
vapours (and fire risks).
5.1.2 Cooling water
The cooling of the bearing housing is taken from the engine cooling water circuit (Connection
dimension see chapter 3.3). Prior to putting into operation or maintenance, ensure that the
connections of cooling circuit are tightly.
Ensure the cooling-water flow adjust, that you have not more then 10 K between the entrance
of cooling-water and outlet (see chapter 3.2.

5.2 Engine operation

The exhaust gas turbocharger is driven by the exhaust gases of the engine and is started
together with the engine. The TC speed is adjusted depending on the operating conditions of
the engine.
The charge air pressure required for the engine is fixed by adjusting the turbine nozzle ring
and the compressor diffuser during the TC approval.
If the corresponding meters are available, enter the following measured values into the
engine log during engine operation (at least once every 24 operating hours) :
 Speed of exhaust gas turbocharger
 Exhaust gas temperature upstream of turbine or downstream of cylinder
 Charge air temperature downstream of compressor or downstream of charge air cooler
 Charge air pressure downstream of compressor
 Lubricating oil temperature upstream of TC
 Lubricating oil pressure upstream of TC
 At the same time, perform the following checks at regular intervals:
 Tightness of the exhaust gas, charge air, cooling water and oil pipings
 Smooth running of the exhaust gas turbocharger
The charge air pressure is utilised as parameter for the exhaust gas turbocharger speed.
Unsteady operation (vibration of TC) indicates an unbalance of rotating parts possibly
resulting in the damaged rotor or bearing (refer to chapter 6.5).
5.3 Putting out of operation

After the engine has been stopped, the exhaust gas turbocharger continues to run for some
time. The run out period depends on the installation.
If the rotor comes to an immediate standstill, this can be caused by one of the following
reasons:
 damaged bearings
 contact of compressor or turbine blades by thermal distortion (refer to chapter 4.3 and
4.4.)
 clamed foreign matters
Measures for extended period without operation
Drain the cooling water from the cooling water compartments. Preserve cooling water
compart ments, oil compartments and all machined surfaces of the exhaust gas turbocharger
by slushing oil.
Protect the exhaust gas turbocharger against continuous vibration possibly damaging the
bearing during standstill.
Remove the preservation of the exhaust gas turbocharger prior to restoring it.
Perform an inspection according to the maintenance schedule, chapter 6.4.
Instruction for extended preservation and removing the preservation are available on request.

5.4 Failures
Failures can be detected by abnormal measured values (exhaust gas temperature, charge air
pressure, speed), heavy noise or leakage's of lubricating oil and cooling water pipes.
In case of irregularities, reduce the engine load or stop the engine.
Since even minor failures may cause heavy consequential damages, determine the cause of
failure and eliminate it immediately (refer to chapter 6.5).
Stoppage the exhaust gas turbocharger
If the exhaust gas turbocharger has to be stopped due to a defect and if the engine has to run
in emergency operation, perform the work according to the chapter 7.5.3.
During stopping the exhaust ga s turbocharger, limit the engine power in

order to prevent the exhaust gas temperature from exceeding admissible
values downstream of outlet valves. Pay attention to the operating
instruction of the engine manufacturer.

6 MAINTENANCE
6.1 General
Maintenance and monitoring work is summarised in the maintenance schedule, chapter 6.4.
Proper maintenance work enables failures to be detected in time. The maintenance work also
indicates necessary overhauls as well as work to be scheduled during yard or harbour times
on interruptions.
The operating hours specified in the maintenance schedule are to be considered as
averages. They can be extended or shortened according to existing operating conditions as
well as to be adjusted to the maintenance intervals of the engin e.
It is important to eliminate even minor, apparently insignificant defect immediately and to
determine and eliminate their causes in order to prevent consequential damages at engine or
exhaust gas turbocharger.
If the engine is not equipped with an automatic monitoring system with data recording, entries
into the engine log are required at least once every 24 operating hours. Thereby, you can
detect deviations in time.
6.2 Maintenance work

In order to keep the exhaust gas turbocharger in the safe conditions, perform the inspection
and check of various subassemblies and components according to maintenance schedule,
chapter 6.4.
The chapter 7.5 include detailed instructions on the work sequence for maintenance and
overhaul work.
Make sure to observe the following accident prevention regulations:

 winches, hoisting and towing equipment (VBG 8)
 load take -ups in hoisting gear operation (VBG 9a)
If bolts or nuts cannot be loosened immediately, do not apply excessive forces in order to
avoid damages of threads causing retouching work. Apply diesel fuel and wait for half an
hour. In this way, "Seizing" of threads can be avoided in most cases.
For bolted connections under heavy thermal load, bolts and nuts are made of high-
temperature material. Make sure that you do not confuse these bolts and nuts with
commercial ones during assembly work. In order to prevent burning and to facilitate
subsequent disassembly, apply a suitable bolt paste (e.g. molybdenum sulphide paste,
graphite) prior to assembly. Contamination's have to be removed from the threads previously.
During assembly, all bolted connection equipped with locking elements (lock nut, locking
plate) have to be properly locked.
 For a basic overhaul or repairs effecting essential parts of the exhaust

gas turbocharger, it is recommended to document their condition. The
"Test results" form can be used as sample (refer to chapter 7.3).

6.3 Cleaning
Cleaning the silencer

 refer to chapter 7.5.8
Cleaning the compressor

 Cleaning during operation: refer to chapter 7.5.1
 Mechanical Cleaning: refer to chapter 7.5.7 and 7.5.9
Remove the silencer and compressor housing. (The compressor impeller remains of the
shaft.). Deposits are removed by diesel fuel or another admissible liquid cleansing agent.
 Pay attention to accident prevention regulations !

 While washing, make sure to prevent the cleansing agent from
penetrating into the charge air piping or into the interior of the
turbocharger.
Cleaning the turbine

 cleaning during operation : refer to chapter 7.5.2
(for heavy fuel oil operation only)
Cleaning the cooling water compartments

The contamination of cooling water compartments in the bearing support depends on the
cooling water care and the cooling water at mixture in the engine circuit. It is recommended to
clean engine cooling compartments and cooling compartments of the bearing support
simultaneously.
Heavy deposits in the cooling water compartments of the exhaust gas

turbocharger result in a reduced life of the housing and of the bearing.

6.4 Maintenance schedule
Item Chapter Maintenance work Maintenance interval

(operating hours)
1. Check for abnormal noise 24
2. 7.5.1 Compressor washing during operation, actuate 25 - 50

compressor washing system or on demand
3. Turbine washing during operation, actuate

turbine washing system (for heavy fuel oil
operation only)
7.5.2 Cleaning with water approx. 300 - 500
4. 7.5.8 Clean air filter at silencer approx. 250

or on demand
5. Check fastening bolts at feet, tighten all housing after first starting up than
bolts and piping joints every 1000
6. 7.5.9 Cleaning : internal compressor parts, 8000

compressor
impeller and diffuser
7. 7.5.8 Cleaning : silencer and felt coat 10000
8. 7.5.4 - Inspection : disassemble, clean, check all parts, 20000

7.5.13 replace bearing
The operating hours given in the table above are guidelines which can be extended or
reduced depending on the operating conditions or for adjustment to the maintenance
intervals of the engine.

6.5 Troubleshooting table

A Temperature upstream of turbine too high
B Charge air pressure too low
C Charge air pressure too high
D Heavy noise
E Delayed start, short coasting
F Lubricating oil leakage
G Lubricating oil pressure too low
H Turbocharger pumps
I Turbocharger vibrates
Chapter A B C D E F G H I
Silencer or air filter contaminated 7.5.8
Compressor contaminated 7.5.9
Charge air cooler contaminated
Leaking exhaust gas piping
Exhaust gas counter pressure too high
downstream of turbine
Turbine or compressor impeller damaged 7.5.10
(unbalanced) 7.5.11
Defective bearing 7.5.4,
7.5.11
Rotor contact with housings 7.5.11
Foreign matter in turbine or compressor 7.5.9,
(unbalanced) 7.5.10
Turbine contaminated 7.5.2
Turbine nozzle ring contaminated 7.5.2
Failure of fuel injection at engine
Leaking charge air piping
High air intake temperature
Inlet or outlet valve contaminated
Low air intake temperature
Lubricating oil filter cont aminated
Lubricating oil pressure gauge defective
Lubricating oil inlet temperature too high
Excessive pressure in oil return
Sealing air ineffective
Gaskets damaged, connection le aking
Plain compression ring damaged 7.5.11

7 DISASSEMBLY AND ASSEMBLY
7.1 Introduction
The chapter 7.5 shall enable the user to perform certain repair and maintenance work by
himself.
Work sheets are sorted according to the sequence required to disassemble the exhaust gas
turbocharger. The instructions on the work sheet always refer to the working sequence
mentioned in the heading.
In case of complicated repair and overhaul work, it is required to prepare an exact working
sequence by compiling the respective work sheets.
It is assumed that the staff is familiar with the work and that the tools required are ready at
hand. Furthermore, the exhaust gas turbocharger has to be accessible and corresponding
hoists have to be available.
If change are caused by damages at certain components or if the exhaust gas turbocharger
is in a poor maintenance condition, the working time required may be extended.

 load take -ups in hoisting gear operation (VBG 9a)
7.2 Checking the components

The check list shown below can be used as instructions for the check of the condition of the
exhaust gas turbocharger and its major components. As a rule, the user is able to eliminate
minor damages. Major damages effecting rigidity, balance and smooth running of rotation
components should be eliminated by the manufacturer or an authorised workshop. If
damaged parts are returned for repair, ensure a good protection against transportation
damages.
After having disassembled the exhaust gas turbocharger, perform the following checks at
cleaned parts. The condition is to be recorded in the "Test results" form, chapter 7.3.
The valuation is made by means of the "Clearance sheet", chapter 7.4.

Rotor
 Are the turbine blades damaged or did they touch the housing ?
 Are contact traces visible at the housing ?
 Are contact traces visible at the rotor ?
 Does the shaft run smoothly ?
 How is the condition of bearings ?
 Are the plain compression rings heavily worn ?
If retouching work is performed or if rotor parts are replaced, rebalancing

has to be executed ! (for admissible residual unbalance, refer to
clearance sheet, chapter 7.4)
 Wear occurs at the plain compression rings in axial direction during

running-in, which his intended and could be max. 0.5 mm.
Compressor impeller
 Can you detect sliding traces or cracks at the compressor impeller ?
 Are the bore and the axial surface OK ?
Bearing
 Is the axial clearance of the rotor inadmissible high ?
 Are the bores of bearings irregularly worn ?
 Is there heavy wear at the bearing faces at thrust bearing plates, compressor or turbine
bearing ?
 For evaluation of bearings, refer to chapter 7.5.4 .
Turbine nozzle ring

 Are the guide vanes twisted ?
 Is foreign matter clamped into the ducts ?
 Can you detect traces of foreign matter ?
Housing
 Are the housings heavily contaminated by oil, dust or soot ?
 Is there any leakage at housings ? (Main items: connection flanges, joints, oil and water
connections)
 Are all bolts and nuts tight ?
 After extended standstill periods, boiler scale may occur in cooling water
compart ments. It is to be removed by suitable solvents.

7.3 Test results

Exhaust gas turbocharger : Works No. :
Variant No. :
Type of engine : Engine No. :
Customer name :
Address :
(Location, ship's name)
Latest inspection/ overhaul at : by :
Inspected/ overhauled at : by :
Number of operating hours since commissioning :
since latest inspection/ overhaul :
Results of inspection of components
Rotor/ Shaft
Turbine blades O no
damaged O yes
O blade parts missing
O traces of foreign matter
Contamination/ O no
deficits of O slight Plain compression O no
rotor blades O heavy rings damaged O yes
O uni-lateral
O uniform Radial deviation of rotor
(acc. to Clearance sheet) ............. m m
Blades tarnished O no Blade cracks O no
O yes O yes
Location : ..............
Gap between turbine impeller and housing Gap between compressor impeller and housing
(acc. to Clearance sheet) Clear. S12 : ........ mm (acc. to Clearance sheet) Clear. S1 : .......... mm
Clear. S14 : ........ mm Clear. S2 : .......... mm
Sliding traces O no Rotor rebalanced O no
at shaft O yes O yes
Bearing seats O no Condition prior O good
damaged O yes to rebalancing O poor
Compressor impeller
Sliding traces O no Blade cracks O no
O yes O yes
Location : ............... Location : ...............
Contamination O clean Quality of O good
O contaminated Bore O average
O oily O poor
Turbine nozzle ring
Guide vanes O good O Part turn out
O twisted O Traces of foreign matter
O scaled

Bearing housing
O clean Sealing air bores O clean
O coked O narrowed
O corroded O clogged
Compressor diffuser
Guide vanes O little Damage O no
contamination O heavy O yes
Location : ...............
Compressor bearing
O used Stop surface of radial bearing
O replaced B(rad) : ................ mm
Reason ................
Marks O no
O yes Location : ............... Depth : ................. mm
Thrust bearing
O used Stop surface of thrust bearing
O replaced B(ax) : ................. mm
Reason ................
Marks O no
O yes Location : ................ Depth : ................... mm
Turbine bearing
O used Stop surface
Reason ................
Marks O no
Silencer
Contamination O oil Condition of O good
O dust felt layer O poor
O soot
Filter mat O yes
cleaned O no
Other defects/ component/ type :

7.4 Clearance sheet

Clearance/ Value
(mm)
New condition Limit
clear.
Clear. Parts designation Parts No. min max
max.
*)
S1 Compressor impeller- compressor housing 1002/ 2500 0.6 0.7 1.0
(radial)
(axial)
S6 Rotor- compressor bearing (radial/ d7-d6) **) 1000/ 3200 0.09 0.12
S8 Rotor- turbine bearing (radial/ d11-d10) **) 1000/ 3100 0.1 0.13
S12 Turbine imp. - turbine housing (radial) 1000/ 2100 0.5 0.6 0.8
S13 Turbine imp. - radiation protection 1000/ 2009 0.6 0.9 1.1
S14 Turbine imp. - turbine housing (axial) 1000/ 2100 0.5 0.7 0.9
S15 Rotor- compressor bearing (axial) 1000/ 3200 0.1 0.2
S18 Compression ring- bearing cover turbine 1009/ 2004 0.20 0.30 0.5
S19 Compression ring- bearing cover compressor 1008/ 2003 0.20 0.30 0.5
*) by stepping over according work or spare part used
**) Measuring of bearing bore help a plug gauge( three points)
Admissible residual unbalance of rotor: 5.25 gmm per bearing
Admissible radial deviation of rotor: 0.020 mm (point E)
Admissible tightening torque of rotor nut: 260 (+5) Nm
Rotor pushed to the left for measuring the clearance S2, S15

7.5 Process of maintenance
7.5.1 Compressor washing
(Every 25 - 50 operating hours)
L
e
g
e
n
d
1
B
a
ll valve
2 Water tank
3 Water piping
4 Air piping
5 Pipe union
6 Design with Silencer
7 Design with air intake housing
8 Pipe union
Work sequence:
1. Operate engine close to full load.
2. Open water tank (2), fill with clean water (no seawater), close water tank.
3. Open valve (1), wait for approx. 20 sec., close valve (1). The compressed air flows
through the air piping (4) via valve (1) into the water tank. The water is pressed through
the water piping (3) into the injection pipe, atomised by the air taken in and hits the
compressor blade with high speed.
 Perform cleaning with warm engine close to full load operation only.
 Continue to operate the engine for at least 10 minutes after cleaning.
 Do not wash before a pause of operation. Corrosion attach!
 Washing is ineffective in case of hardened deposits, thus perform
washing at regular intervals.

7.5.2 Turbine washing
(For heavy fuel oil operation only, every 300 - 500 operating hours if available)
Legend:
1 Sanitary fresh-water 6 Wash-water piping 11 Draining
2 Regulating valve 7 Needle valve 12 Valve
3 Fresh-water piping 8 Exhaust gas inlet 13 Collecting hopper or inspection glass
4 Removable flexible tube 9 Exhaust gas outlet 14 Sewage
5 Stop valve 10 Diffuser housing
Work sequence:
1. Reduce the engine output to approx. 20 % of its rating until the temperature downstream
of the cylinder has come down to its specified value (see table).
2. Connect flexible tube (4) to fresh-water piping (3).
3. Wait for approx. 10 minutes!
4. Check draining piping (12) for passage. Blow through!
5. Open valve (2).
6. Completely open needle valve (7). Slowly open stop valve (5). Check water pressure at
pressure gauge. (For water pressure, washing period refer to table)
7. Close stop valve (5), needle valve (7) and draining valve (12)!
8. Run dry exhaust gas turbocharger at constant load for approx. 10 minutes. Subsequently
increase engine load slowly!
9. Repeat washing, if new vibrations occur at the exhaust gas turbocharger.
Operating values for turbine washing
Engine load Exhaust gas temperature Water pressure Washing period
downstream of cylinder (gauge)
max. 20% 280 - 300 °C 120 - 150 kPa 5 min
Do not wash before a pause of operation. Corrosion attack!

7.5.3 Stoppage the exhaust gas turbocharger
 In case of damages at the TC especially at the rotor or at the bearings it

is recommended to put out of operation to avoid any further damages.
Pay attention to the operating instruction of the engine manufacturer.
During locking the exhaust gas turbocharger, limit the engine power in
values downstream of outlet valves.
Related chapter 7.5.7, 7.5.9, 7.5.10

Legend
2100 Turbine inlet housing, cpl.
2105 Hexagon-head nut
2106 Spring washer
Tools required
1 Open-jawed spanner A/F 18/19
1 Sealing disk (9709)
Initial condition: The turbocharger is

mounted on the engine.
Mass of the silencer approx. 45 kg

Mass of the air intake bend approx. 20 kg
Mass of the compressor housing approx. 75 kg
Mass of bearing housing with rotor approx. 90 kg
Work sequence:
1. Disassembly of the silencer (2800) /Intake housing complete (2900) according to chapter
7.5.7.
2. Loosen the charge air pipe at the compressor housing (2500).
3. Loosen water and air pipes for compressor washing.
4. Disassembly of the compressor housing (2500) according to the chapter 7.5.9.
5. Drain lubricating oil and cooling water, loosen the connections.
6. Disassembly of the bearing housing (2000) with rotor according to the chapter 7.5.10.
Use hoisting gear!
 Be careful for dismounting work to avoid damage to the turbine blades.
7. Mount the sealing disk (9709) on the turbine housing (2100) and tighten with hexagonal
nuts.

7.5.4 Bearing check

Sliding surface
Related chapter 7.5.7 to 7.5.11
Radial bearing (3100/3200)
New bearing
Wedge-shaped
Load- sector
carrying
sector
Legend
D Bearing diameter
R Radius at wedge face
Bearing after
B(ax) Load-carrying sector
longer
width of thrust bearing
operation
B(rad) Load-carrying sector
Sliding surface
width of radial bearing
Tools required Thrust bearings (3200)

1 Micrometer screw
1 Caliper gauge
Initial condition: Compressor bearing (3200) and turbine bearing (3100) removed. (For
clearances, refer to chapter 7.4.)
Work sequence 1: Load-carrying sector of radial bearings
1. Clean bearings carefully!
2. Determine stop face width B(rad)!
3. Visual inspection!
Replace bearing, if :
  The load-carrying sector width B(rad) of the radial bearing has

reached 12 mm.
 Heavy dirt marks can be seen.
Determine the causes !
Work sequence 2: Load-carrying sector of axial bearings
1. Carefully clean the stop faces at both sides of theaxial bearings.
2. Determine the bearing stop face width B(ax).
3. Determine axial clearance S15.

Replace bearings, if :
 B(ax) is larger than 2/3 of the sliding face.
 The sliding faces reveal heavy dirt marks.
If material is deposited on the bearing faces of the shaft, a repair is

required in an authorised workshop.

7.5.5 Disassembly of the complete turbocharger
Legend
2000 Bearing housing, cpl.
2201 Foot, compressor
2202 Foot, turbine
2500 Compressor housing, cpl.
2800 Silencer
2900 Intake housing complete
Tools required
1 Socket spanner A/F 13
1 Open-jawed spanner A/F 22
1 Hoist / 2 Ropes
Mass of exhaust gas turbocharger is approx. 450 kg
Make sure to observe the following accident prevention regulations :
 load take-ups in hoisting gear operation (VBG9a)
Pay attention the pipings and sheathings!
General
Under normal conditions, the complete exhaust gas turbocharger has to be removed from the
engine for an inspection only. It is sufficient to dismantle individual subassemblies for
maintenance and checks. While removing the exhaust gas turbocharger, pay attention to
space conditions in the engine room.
Work sequence:
1. Loosen sheathings from turbine housing (2100).
2. Loosen exhaust gas pipings from compressor inlet and outlet housings (2100/2300). Pay
attention of gaskets.
3. Loosen the pipings from compressor housing (2500), remove them, if required.
4. Drain lubricating oil and cooling water from TC, loosen cooling water inlet and outlet and
lubricating oil inlet and outlet.
6. Round a rope around the flange between the silencer (2800) and compressor housing
(2500).
7. Round the second rope around the flange between turbine inlet housing (2100) and
turbine outlet housing (2300). Hang both ropes on the hoist.
8. Loosen and remove the bolts on the feets (2201/2202).
9. Lift TC and put down on a wooden plate. Save for tipping!

7.5.6 Assembly of the complete turbocharger
Legend
2202 Foot, turbine
2800 Silencer
Tools required
1 Hoist / 2 Ropes
Molybdenum sulphide lubricant

 load take -ups in hoisting gear operation (VBG9a)
Pay attention the pipings and sheathings!
Work sequence :
1. Lift complete TC (refer to chapter 7.5.5) with 2 ropes by hoist and put it onto the engine
console. Pay attention to pipe connection !
2. Insert and tighten bolts at the foot.
3. Connect exhaust gas pipes to turbine inlet and outlet housing (2100/2300).
4. Attach sheathing.
5. Connect charge air piping.
6. Connect cooling water inlet and outlet as well as lubricating oil inlet and outlet.
7. Connect water and air pipes for compressor washing.
8. Tighten bolts at foot of TC and all connection pipes.
After having installed the TC, check that the assembly is free of stresses
and forces. Retouch pipings, if required.
9. Supply lubricating oil and cooling water to TC and check all fl anged connections for
leakage's.
 Use proper gaskets for pipe joints only. Apply molybdenum sulphide
lubricant to connecting bolts of exhaust gas pipes prior to installation.

7.5.7 Assembly and disassembly of silencer or air-intake housing
Legend
2517 Tension tape
2800 Silencer
2900 Air-intake housing
9001 Magnetic screw
A Lock nut
Tools required
1 rope
2 shackles
Mass of silencer approx. 45 kg

Mass of air-intake housing approx. 20 kg
Work sequence 1 : Disassembly of silencer/ air-intake housing

1. Loosen the cabel of the inductive speed sensor (9002)
2. Hang the silencer (2800) with a rope and two shackles on the hoist or the rope around the
intake housing (2900)
3. Loosen hexagon nuts of the tension tape (2517), remove from one side the hexagon nuts.
4. Remove the tension tape from the flange.
5. Pull-off silencer/ air-intake housing in axial direction from compressor housing (2500) and
put it onto a wooden base.
Work sequence 2: Assembly of silencer/ air-intake housing
2. Slide on silencer/ air-intake housing in axial direction onto the compressor housing.
3. Round the tension tape (2517) around the flange, assembly hexagon nuts and ttighten with
25-30 Nm.
4. The inductive speed sensor (9002) is screwed to the limit and then unscrewed by half turns
(distance 1 - 1,5 mm). After disassembly inductive speed sensor (9002) is secured with
the lock nut (A). Connect the cabel.

7.5.8 Cleaning the silencer
(Every 250 operating hours)

Related chapter 7.5.7
Legend:
2800 Silencer
2813 Filter mat
2816 Punched plate
A Possible connection for maintenance
indicator
B Felt coat
General
In most of the cases, merely the filter mats have to be cleaned. For this purpose, the silencer
may stay at the exhaust gas turbocharger.
The given maintenance interval of 250 running hours is just a mean guide value, since the
accumulation of dirt in the filters and the pressure drop resulting therefrom are largely
dependent on the environment. For operation under extreme conditions, it is recommended
to add a maintenance indicator (water gauge) signalling the right moment for cleaning.
This indicator shall be adjusted so as to give the cleaning signal when a vacuum of
app. 100 mm w.g. is reached at point A intended for mounting (e.g. a MANN maintenance
indicator for air filters, max. 200 mm w.g. = 20 mbar).
Work sequence : Cleaning the filter mats and felt coat

1. Pull the filter mat (2813) over the silencer (2800) against the flange. The punched plate
(2816) stays by the silencer
2. Lay filter mat (2813) into clean liquid (diesel fuel, perchlorethylene) for approx. 10 hours.
Subsequently, rinse in the liquid and externally clean by a soft brush, stub out and dry the
filter mat.
3. Take off the punched plate (2816) means of loosen from three bolt (M6 ). (Only after
heavy soiling of the felt coat.(B)).
4. Clean the dry contaminated felt coat with a brush or oily contamination with diesel fuel
wipe up. Do not use water!
5. Install filter punched plate (2816) and dryed filter mat (2813) in reverse order. Before
screw the punched plate press it at the sides of egde.
Pay attention to applicable accident prevention regulations (handling of
hazardous, volatile, combustible solvents) and fire protection regulations
(DIN 14096). Cleaning by a P3-solution or trichlorethylene is prohibited. If
other solvents are use d, check the compatibility with the filter material.
In case of ship operation, pay attention to the regulations of
classification societies with regard to washing liquids.
 If the felt coatings of the silencer are heavily contaminated, they have to
be replaced. For this purpose, disassemble the silencer according to
chapter 7.5.7. The silencer has to be overhauled by an authorised
workshop.

7.5.9 Assembly and disassembly of the compressor housing

Legend
1002 Compressor impeller
2000 Bearing housing
2030 O-Ring
2507 Stud bolt
2508 Hexagon nut
2509 Spring washer
2518 Stud bolt
5001 Compressor diffuser
5002 Silicon cord
5003 Cylindrical screw
Tools required
2 ropes /4 shackles
Mass of Compressor
housing
approx. 75 kg
Work sequence 1: Disassembly of the compressor housing

1. Remove air and water piping for compressor washing.
2. Hang compressor housing (2500) with a rope and shackles on the hoist.
3. Mark the position of compressor housing. Loosen the hexagon nuts (2508), hexagon -head
bolts (2808) and spring washer (2809).
4. Pull off the compressor housing (2500) and the compressor diffuser (5001). Do not tilt !
5. Remove compressor diffuser (5001).
Work sequence 2: Assembly of the compressor housing
1. Change silicone cord (5002) at the rear of the compressor diffuser (5001).
2. Insert compressor diffuser (5001) and screw the cylindrical screw (5003).
3. Put the O-ring (2030) on the centring of bearing house (2000). Hang compressor housing
(2500) with a rope and shackles on the hoist.
4. Carefully attach compressor housing (2500) in axial direction to the bearing housing. Pay
attention to housing position !
5. Fasten by hexagon nuts (2808) and spring washers (2509). Check the clearance S1!
6. Connect water and air piping for compressor washing to compressor housing (2500).
Make sure not to damage the compressor impeller (1002) during

disa ssembly and assembly of the compressor housing.

7.5.10 Assembly and disassembly of the bearing housing with rotor
Related chapter 7.5.7, 7.5.9

Legend
1000 Rotor cpl.
2000 Bearing housing cpl.
2100 Turbine inlet housing cpl.
2104 Stud bolt
2105 Hexagon nut
2106 Spring washer
2201 Foot, turbine side
2300 Turbine outlet housing
Tools required
1 Hoist
1 Rope with Shackle
2 Eye bolts
Initial condition: Compressor housing, silencer and all pipings are removed.
Mass of turbine inlet housing approx. 86 kg
Mass of turbine outlet housing approx. 65 kg

Work sequence 1: Disassembly of bearing housing with rotor
1. Assemble two blank flange with eye bolt on side of the bearing housing.
2. Join the bearing housing (2000) on the hoist.
3. Loosen the hexagon nuts M10 (2105) of the spring washers (2106).
4. Loosen the screws from the foot (2201) from the motor support.
5. Forcing-off uniformly the bearing housing (2000) with forcing screw. Are the connection
with carbon glued, net with diesel fuel and wait a minute.
6. Move careful the bearing housing (2000) out of the turbine housing (2100) in axial
direction. Put it on a wooden plate.
 Be careful for mounting and dismounting work to avoid damage to the

turbine blades.
Work sequence 2 : Assembly of bearing housing with rotor

1. Clean the connecting flange between bearing housing and turbine housing from
combustion residues by fine abrasive cloth. Subsequently apply molybdenum sulphide
lubricant to flange.
2. Fasten bearing housing by the rope to the hoist and lift it to the turbine housing.
3. Carefully insert the bearing housing under consideration of the housing position into the
turbine housing; tighten bolts.
4. Tighten the screws from the foot (2201) to the motor support.
5. Check rotor for contact by slightly rotating it !

7.5.11 Disassembly of rotor complete
 For the disassembly of the rotor mount the bearing housing on a rack or
clamp it in a vice (with soft-material jaws).
Mass of bearing housing with rotor approx. 90 kg.
Mass of rotor cpl. 18 kg
Legend Tools required

1000 Rotor cpl. 1001 Shaft 1 Socket spanner A/F10
1002 Compressor impeller 1003 Spacer 1 Open-jawed spanner A/F10
1004 Thrust ring 1005 Rotor nut 1 Open-jawed spanner A/F13
1007 Conical spring washer 1007 Feather key 1 Open-jawed spanner A/F18/19
1008 Plain compression ring, 1009 Plain compression 1 Open-jawed spanner A/F24
turbine ring, compresssor
2003 Bearing plate, comp. 2004 Bearing plate, turb.r 1 Locking device (9705)
2005 Gasket, turbine 2007 Gasket, compr. 1 Extractor for thrust ring (9707)
2009 Labyrinth cover 2010 Stud bolt 2 Eye bolts (9708)
2011 Hexagon-head bolt 2012 Locking plate 1 Torque spanner 300 Nm A/F32
2013 Hexagon nut. 2014 Locking plate.
3101 Gasket, turbine 3102 Stud bolt
3201 Hexagon-head bolt 3203 Hexagon nut
3204 Locking plate 4000 Turbine nozzle ring
cpl

Work sequence 1: Disassembly of the compressor impeller (1002)

1. Mount on the locking device (9705) of rotor and connec t on the flange of bearing housing.
Loosen rotor nut (1005) with torque spanner A/F 32.
2. Loosen the rotor nut (1005) and remove it with the spring washer (1006).
3. Heat the hub of the compressor impeller (1002).
Temperature 150 °C max.
 Use burner flame with excessive gas.
 Uniformly heat the impeller hub range.
 Protect shaft thread by pipe against heat.
4. Pull off the compressor impeller (1002) from the shaft.
The installation position of the compressor impeller is marked with

regard to the shaft.
Work sequence 2: Disassembly of the compressor bearing (3201)

1. Unlock and loosen the hexagon head bolts (2011) and remove the bearing cover of
compressor (2003). The plain compression rings of compressor are located in the bearing
cover (1009). Pay attention to the gasket (2005) !
2. After cooling the shaft (1001) pull off spacer (1003).
3. Unlock and loosen the hexagon head bolts (3203) and remove the compressor bearing
(3201) with the aid of forcing screws.
4. Move the extractor for thrust ring (9707) on the shaft (1001) and turn it in the thrust ring
(1004).
5. Pull thrust ring (1004) from the shaft (1001).
Work sequence 3: Disassembly of the turbine bearing (3101)
1. Pull shaft (1012) carefully out of bearing housing.
2. Remove turbine nozzle ring (4000) and the labyrinth cover (2009) after having loosened
the four hexagon nut (2013).
3. Screw off bearing cover of turbine (2004). Pay attention to the gasket (2007) !
4. Remove the turbine bearing (3101) from the bearing housing. Close openings at bearing
housing in order to prevent dirt from reaching the bearing compart ment and the oil bores.
5. Remove the plain compression ring of the turbine (1008) from the shaft.
 Now, the turbocharger is disassembled. Check, evaluate and clean parts

according to chapter 7.2 and 7.3.

7.5.12 Installation of rotor complete
Related chapter 7.5.5 - 7.5.11
 For installing the rotor mount the bearing housing on a mounting rack.
Mass of rotor complete 18 kg.

1007 Conical spring washer 1007 Teather key 1 Open-jawed spanner A/F18/19
2005 Gasket, turbine 2007 Gasket, compr. 2 Eye bolts (9708)
2009 Labyrinth cover 2010 Stud bolt 1 Torque spanner 300 Nm A/F32
2011 Hexagon-head bolt 2012 Locking plate 1 Feeler gauge
cpl

 Prior to the assembly, check the cleanliness of the bearing housing, of

oil conducting ducts and of the sealing air piping. Pay attention to the
specifications of chapter 7.4 (Clearance sheet) during assembly.
Work sequence 1: Installation of the turbine bearing and shaft into the bearing ho using
1. Insert turbine bearing (3101) with the flattened flange side at the bottom; tighten and lock.
Pay attention on the assembly position. The stud bolt (3102) goes upper
in the groove (twisting securing)!
Always assembly turbine bearing with stud bolt!
2. Insert and tighten turbine side bearing cover (2004) with original gasket (2007). If the
gasket was damaged during disassembly, insert a gasket of the same thickness, since
otherwise the clearance S18 is changed and has to be reset. The clearance is measured
after installation of the compressor bearing.
3. Attach labyrinth cover (2009) onto the centring of the bearing housing.
4. Insert the plain compression ring of the turbine (1008) into the shaft groove.
5. Apply clean oil onto turbine bearing and slight the shaft carefully into the bearing. Be
especially careful while introducing the plain compression rings into the bearing cover.
Work sequence 2: Installation of the compressor bearing and completing the rotor
1. Apply oil to the thrust ring (1004) and slide it according onto the shaft. Pay attention on the
assemly position.
2. Wet the compressor bearing (3200) with oil. Move it onto the shaft with its flat flange side
pointing downward and fasten it with hexagon-head bolts (3203) and locking plates
(3204).
3. Check clearance S18 : (if components are replaced)

Press shaft from the turbine side to the bearing housing. Put dial gauge onto the shaft end
and adjust it to zero. Loosen fastening bolts (3203) of the compressor bearing and force
compressor bearing (32019) by approx. 1 mm. Press shaft towards compressor side. The
shaft is moved by the clearance S18; correct by changing the thickness of the bearing
cover gasket (2007), if required.
4. Check clearance S13 : by means of feeler gauge.
5. Mount the locking device (9705) to the turbine wheel and fasten it to the flange of the
bearing housing.
6. Slide spacer (1003) onto the shaft up to the shoulder. Pay attention the assembly position!
7. Check clearance S19 : Determine the distance between external face of compressor side
bearing cover and the colour of the suppo rted plain compression ring by a caliper gauge.
After having attached the bearing cover of the compressor (2003), measure the distance
between external face of bearing cover to the spacer by caliper gauge, while pressing the
shaft towards the compressor. The difference of the two dimensions is the clearance S19.
The correction is made by changing the thickness of the gasket at the bearing cover
(2005).

8. Install bearing cover, compressor (2003) and insert the plain compression rings,
compressor (1009) with staggered joints.
9. Heat compressor impeller (1002) (max. 150 °C) and slide it onto shaft.
The mounting marks at shaft (1001) and compressor impeller (1002) have
to match.
10. Grease slightly the thread by molybdenum lubricate. Mount spring washer (1012) and
rotor nut (1005).
11. When the compressor impeller has cooled down, tighten the rotor nut (1005) by torque
spanner with 50 Nm. Mark the position of rotor nut.

12
Lock rotor by means of locking device (9705). Use universal joint in any
case !
Tighten again the rotor nut (1005) with 260 Nm. The reached turning angle of the rotor
nut (1005) should be 75 to 90 degree otherwise dismantle rotor nut (1005) and spring
washer and repeat point 10 to 12.
13. Bolt turbine nozzle ring (4000) with labyrinth cover (2009) to bearing housing.
3
14. Check rotor for smooth running : Apply 40 cm oil into the oil guide bore in the
bearing housing and slowly turn rotor. The rot or has to be turned easily without sensible
resistance and has to make some rotations after having been pushed.
15. Check truth of rotor running : Apply dial gauge to shaft end at compressor side and
measure the radial run-out of the rotor while slowly turning the rotor. The radial run-out is
specified in the clearance sheet, chapter 7.4
Now the bearing housing with rotor is assembled and can be completed according to chapter
7.5.5 to 7.5.10.

7.5.13 Disassembly turbine outlet housing
Legend
2101 Turbine inlet housing
2302 Outer diffuser
2304 Inner diffuser
2306 Countersunk screw
2307 Stud bolt
2308 Stud bolt
2309Hexagon nut
2310 Spring washer
2313 Hexagon-head bolt
2314 Spring lock washe
Tools required
1 Socket spanner A/F 18/19
1 Hoist with ropes
Initial condition: Exhaust gas manifold and drain pipe for turbine washing are diassembled
from the turbine outlet housing.
Work sequence :
1. Removed the sheathing.
2. Hang the turbine outlet housing (2303) with a rope on the hoist.
3. Loosen hexagon-head nut (2309) with the curved spring washer (2310).
4. Forcing-off uniformly the turbine outlet housing (2303) with forcing screws.
5. Move careful axial the turbine outlet housing (2303) from turbine inlet housing (2101) and
put it on a wooden plate.
6. Loosen the hexagon-head bolt (2313) and removal the inner diffuser (2304).
7. Loosen the 2 hexagon-head bolt (2306) and removal the outer diffuser (2302) from the
turbine outlet housing (2102).

8 SPARE PARTS AND TOOLS
8.1 General
The following specification required for the order :
1. address of orderer
2. type of turbocharger
3. variant number (refer to to type plate on Page 2)
4. works number (refer to type plate on Page 2)
5. part number and designation
6. shipment address
The optionally supplied spare parts books contain the selection of the most important ware
parts as well as a corresponding list.
A certain selection of tools can be ordered, too. These are tools required to maintain and
repair the exhaust gas turbocharger and not included in the basic equipment of every
workshop.

8.2 Spare parts
8.2.1 Bearings
Part Quantity Designation

number
3100 1 Turbine bearing
3200 1 Compressor bearing

8.2.2 Gaskets

number
1008 1 Plain compression ring, turbine
1009 1 Plain compression ring, compressor
2005 1x2 Gasket , compressor (S=0,5/0,2)
2007 1x2 Gasket , turbine (S=0,5/0,2)
2020, 2312 1 Gasket
2021 1 Gasket
2022 3 Gasket A27x32 DIN 7603
2511 2 Gasket A17x21 DIN 7603
2513 3 Gasket A10x14 DIN 7603
5002 1 Silicon cord

8.2.3 Locking elements
Part number Quantity Designation
2012, 3204 18 Locking plate 6,4 DIN 463
2014 4 Locking plate 8,4 DIN 463
2106, 2310 24 Curved spring washer 12 DIN 137
2314 3 Spring lock washer B12 DIN 127
2106 2012
2310 2014
2316 2314 3204
2509

8.3 Tools
9705 1 Locking device
9706 1 Plug screw with gasket for oil supply
9707 1 Extractor for thrust ring complete
9709 1 Cover plate – not in the toolbox, optional order

9 SECTIONAL DRAWING

10 LIST OF COMPONENTS
1000 1 Rotor, cpl.
1001 1 Shaft
1002 1 Compressor impeller
1005 1 Rotor nut
1003 1 Spacer
1004 1 Thrust ring
1006 1 Conical spring washer
1007 2 Teather key A4x4x10 DIN 6885
2000 1 Bearing housing, complete
2001 1 Bearing housing
2003 1 Bearing plate, compressor
2004 1 Bearing plate, turbine
2005 1 Gasket , compressor 0,2 mm
2007 1 Gasket , turbine 0,2 mm
2009 1 Labyrinth cover
2010 4 Stud bolt (for 4001)
2011 12 Hexagon-head bolt M6x16 DIN 933
2013 4 Hexagon-head screw M8 DIN 934
2020 1 Gasket
2021 1 Gasket
2022 3 Gasket A27x32 DIN 7603
2030 1 O-ring
2100 1 Turbine inlet housing, cpl.
2101 1 Turbine inlet housing
2104 12 Stud bolt M12x25 grapite. DIN 939
2105 12 Hexagon-head nut M12 DIN 934
2106 12 Curved spring washer 12 DIN 137
2107 *) Screw plug G1/2 DIN 910
2108 *) Gasket 21x26 DIN 7603
*) 1 x per gas intake casing


2200 1 Foot, complete
2201 1 Foot, compressor
2202 1 Foot, turbine
2300 1 Turbine outlet housing, complete
2302 1 Outer diffuser
2303 1 Turbine outlet housing
2304 1 Inner diffuser
2306 2 Countersunk screw
2307 8 Stud bolt M12x35 graphite DIN 939
2309 12 Hexagon nut M12 DIN EN 24032
2312 1 Gasket
2313 3 Hexagon-head bolt M12x25 graph. DIN EN
24017
2315 4 Hexagon-head bolt M10x25 DIN EN 24017
2500 1 Compressor housing, complete
2501 1 Compressor housing
2507 7 Stud bolt M12x25 DIN 939
2508 12 Hexagon nut M12 DIN 934
2510 2 Screw plug G3/8 DIN 910
2511 2 Gasket A17x21 DIN 7603
2513 3 Gasket A10x14 DIN 7603
2516 1 Cylindrical grooved pin 8x16 DIN 1473
2517 1 Tension tape
2800 1 Silencer complete
2813 1 Filter mat 20x265x1950 mm
2816 1 Punched plate


2900 1 Intake housing complete
3100 1 Turbine bearing complete
3102 1 Cylindrical pin 5m6x10 DIN 7
3200 1 Compressor bearing complete
4000 1 Turbine nozzle ring complete
4001 1 Turbine nozzle ring
5000 1 Compressor diffuser complete
5001 1 Compressor diffuser
5002 1 Silicon cord
5003 1 Cylindrical screw
8000 1 Sheathing
8001 1 Sheathing , turbine inlet housing
8002 1 Sheathing , turbine outlet housing
9000 Components parts
9001 1 Magnetic screw
9002 1 Inductive speed sensor
9003 1 Speed indicator

 



  

Table of Contents
Chapter Title Page
1 SAFETY ......................................................................................... 5
1.1 Built-in safety systems ................................................................................. 5
1.2 Safety measures (to be taken by operator) ................................................. 5
2 GENERAL INFORMATION ABOUT DANGERS........................... 6
2.1 Danger zone ................................................................................................... 6
2.2 Operators and maintenance personnel ....................................................... 6
2.3 Use of spare parts and wearing parts.......................................................... 7
3 DESIGN AND SPECIFICATIONS.................................................. 8
3.1 Brief description ............................................................................................ 8
3.2 Operating data ............................................................................................... 9
3.3 Pipe connections......................................................................................... 10
3.4 Test connections ......................................................................................... 11
3.5 Dimensions of important subassemblies.................................................. 12
4 INSTRUCTIONS FOR MOUNTING TURBOCHARGER ............. 13
4.1 General requirements ................................................................................. 13
4.2 Console for the TC ...................................................................................... 13
4.3 Gas and air piping ....................................................................................... 13
4.4 Loads of housings of the exhaust gas turbocharger ............................... 14
4.5 Vibrations ..................................................................................................... 14
5 OPERATION................................................................................ 15
5.1 Preparation for operation ........................................................................... 15
5.1.1 Lubricating oil supply ..................................................................................... 15
5.1.2 Cooling water ................................................................................................ 1 5
5.2 Engine operation ......................................................................................... 16
5.3 Putting out of operation.............................................................................. 16
5.4 Failures................................................................................................... ...... 17
6 MAINTENANCE........................................................................... 18
6.1 General ................................................................................................... ...... 18
6.2 Maintenance work ....................................................................................... 18
6.3 Cleaning ................................................................................................... .... 19
6.4 Maintenance schedule ................................................................................ 20
6.4.1 Maintenance for Marine Diesel Oil (MDO) application................................... 20
6.4.2 Maintenance for Heavy Fuel Oil (HFO) application ....................................... 21
6.5 Troubleshooting table................................................................................. 22
en 4 th Edition (03/04) Page 3 of 53

Chapter Title Page
7 DISASSEMBLY AND ASSEMBLY ............................................. 23

7.1 Introduction ................................................................................................. 2 3
7.2 Checking the components ......................................................................... 23
7.3 Test results.................................................................................................. 25
7.4 Clearance sheet .......................................................................................... 27
7.5 Process of maintenance............................................................................. 28
7.5.1 Compressor washing .................................................................................... 28
7.5.2 Turbine washing............................................................................................ 29
7.5.3 Stoppage the exhaust gas turbocharger ....................................................... 31
7.5.4 Bearing check ............................................................................................... 32
7.5.5 Disassembly of the complete turbocharger ................................................... 33
7.5.6 Assembly of the complete turbocharger........................................................ 34
7.5.7 Assembly and disassembly of silencer or air-intake housing ........................ 35
7.5.8 Cleaning the silencer .................................................................................... 36
7.5.9 Assembly and disassembly of the compressor housing................................ 37
7.5.10 Assembly and disassembly of the bearing housing with rotor....................... 38
7.5.11 Disassembly of rotor complete...................................................................... 39
7.5.12 Installation of rotor complete ......................................................................... 41
7.5.13 Disassembly turbine outlet housing .............................................................. 44
8 SPARE PARTS AND TOOLS ..................................................... 45
8.1 General................................................................................................... ...... 45
8.2 Spare parts .................................................................................................. 46
8.2.1 Bearings................................................................................................. ....... 46
8.2.2 Gaskets.................................................................................................... ..... 47
8.2.3 Locking elements .......................................................................................... 48
8.3 Tools ............................................................................................................ 49
9 SECTIONAL DRAWING ............................................................. 50
10 LIST OF COMPONENTS ............................................................ 51
Page 4 of 53 4 th Edition (03/04) en

1 SAFETY
The exhaust gas turbocharger has been designed on the basis of the following standards and
regulations:
EC machinery directive (89/392/EEC, 91/368/EEC, 93/44/EEC, 93/68/EEC)
EN 292 Parts 1 and 2: Safety of machines (fundamentals)
EN 294 : Safety of machines; Safety distances to be kept to prevent the upper limbs from
reaching dangerous zones.
1.1 Built-in safety systems

A safety system for the turbocharger is not necessary as its design and connection with
the engine to which it is attached require an inherent safety.
Because of the high temperatures occurring, the turbine housing is provided with a
protective cover.
For general speed monitoring, i.e. without a turn-off function being included, a tachometer
can be mounted on the exhaust gas turbocharger.
Maintenance work must not be done during operation. See Chapter 7.5.1
and 7.5.2 "Maintenance" for maintenance jobs to be done while the
engine is running.
1.2 Safety measures (to be taken by operator)

These operating instructions are part of the exhaust gas turbocharger and shall be always
accessible for the operators and maintenance personnel.
The operating instructions should be read before mounting the turbocharger. Particular
attention should be paid to directions and information relating to dangers.
The user is required
to instruct his operators and maintenance personnel on the safety equipment of the
turbocharger
makes them familiar with safe working methods
supervises observance of the safety regulations.
The individual jobs in these instructions are described such that skilled workers can
understand them.
The necessary tools and testing/inspection means must be available to these workers.
The user must obtain permission to operate the unit from the local authorities and observe
the following:
labour safety
cleaning and maintenance of the machines
product disposal
environmental protection.

2 GENERAL INFORMATION ABOUT DANGERS
2.1 Danger zone

The engine defines the danger zone as the turbocharger is an integral part of the engine.
During turbocharger operation, the user must keep the danger zone free
of any objects so to ensure unhindered access to the unit.
Earmuffs should be worn as the sound level is high. Care should also
be taken when approaching the hot housings!
The exhaust gas turbocharger is mounted on the engine. It may not be interfered with when
the engine is running.
Make sure the exhaust gas pipes on the turbine side cannot come loose during operation
since exhaust gas might escape at this point.
As the exhaust gas turbocharger is an integral part of the engine, its operation is
described in connection with the engine. However, its maintenance is described
separately.
2.2 Operators and maintenance personnel

Operators and maintenance personnel are persons who are responsible for transport,
assembly, installation, operation, setting, maintenance, cleaning and troubleshooting.
Adhere to the following accident prevention regulations:

If these regulations are not observed, your life and limb may be endangered!
1. The turbocharger may only be maintained by duly qualified and authorised persons.
2. In operating the turbocharger, the responsibilities shall be clearly defined and must be
adhered to so as to prevent confusing competences with respect to the safety aspect.
3. The operating instructions shall be followed irrespective of what kind of work (operation,
maintenance, repair etc.) is concerned.
4. The cleaning, maintenance and repair work described in these instructions are easy to
understand by persons skilled in mechanical, cleaning and maintenance work.
The necessary tools and testing/inspection means must be available to these persons.
5. Operators are not allowed to interfere with the unit in a way that would affect machine
safety.

6. It is also within the responsibility of the operator to see to it that no unauthorised person
works on the turbocharger.
7. The operator must inform the user without delay of any safety-affecting changes to the
turbocharger.
8. The user must not operate the turbocharger when it is not in proper condition.
2.3 Use of spare parts and wearing parts

It is emphasised that spare and wearing parts not supplied by us are not tested/ inspected
and approved by us. The use of such products may negatively affect the performance of your
turbocharger. We assume no liability for damage caused by the use of components and
accessories not made by us.
For ordering spare parts and tools, please refer to the
parts list
sectional drawings
spare parts list
tools list.
The spare parts lists attached contain all spare parts for the turbocharger. DIN (standard)
parts may be bought from specialised dealers.
For the assembly, disassembly and commissioning of the turbocharger, refer to the
respective sections in these operating instructions.
Before doing any maintenance, cleaning or repair work, turn the engine
off and secure it against unintentional starting. See chapter 7.5.1 and
7.5.2 "Maintenance" for maintenance jobs to be done during engine
operation.
Please observe the following accident prevention regulations:
If these regulations are not observed, your life and limb may be
endangered!
See the inspection schedule (see Chapter 6.4) for the maintenance
intervals.

3 DESIGN AND SPECIFICATIONS
3.1 Brief description

Exhaust gas turbocharger (TC): R4-3
Variant number : 2.448-. . . . .
Mass : 450 kg
The R4-3 TC is equipped with a single- stage radial flow turbine and a single- stage radial
flow compressor.
The turbine wheel is welded to the shaft, whereas the compressor impeller is shrunk to the
shaft. The complete rotor has a bearing consisting of two plain bearings in a water-cooled
bearing housing. The turbine and compressor housing is flanged to the bearing housing. The
turbine outlet housing is mounted on the turbine inlet housing. You can use a silencer or an
intake housing on the entrance of the compressor housing.
The bearing lubrication is connected to the lubricating oil system of the engine.
The TC is not equipped with a special control device. The TC speed obtained depends on the
engine output.
The TC variant attached to the engine is thermodynamically adjusted and is binding for this
engine variant, i. e. if the TC has to be replaced, use the same TC variant.
Modifications and additional attachments to the TC are subject to a written consent of the TC
manufacturer.

3.2 Operating data

Variants refer to type plate (Page 2)
Max. speed (rpm) refer to type plate (Page 2)
Max. exhaust gas temperature upstream of turbine (°C) refer to type plate (Page 2)
2
Types of lubricating oil: Engine oil with a kinematics 60...115 mm /s
viscosity of at 50oC e.g. SAE 30, SAE 40
Nominal oil filter fineness upstream of TC : max. 25 µm

Lubricating oil pressure upstream of TC : 300 + 150 kPa
Admissible lubricating oil pressure for special operating
conditions
At start-up : min. 50 kPa
From start-up to idle running : min. 50 kPa
At standstill (Prelubrication or relubrication/ Standby see diagram down
operation)
Lubricating oil flow : 25 ... 30 l/min
Lubricating oil temperature at inlet : 40 ... 80 °C
Lubricating oil temperature at outlet : max. 100 °C
Cooling water pressure: max. 300 kPa
Cooling water temperature at inlet: 50 ... 85 °C
Max. temperature difference between inlet and outlet cooling 10 K
water :
Cooling water flow : min. 1,5 m3/h
Counter - pressure downstream of turbine : max. 2.5 kPa(g)
Vacuum upstream of compressor : max. 1.5 kPa(g)
Sound power level (measured on silencer at 100 mm 108 dB at 36,000 rpm
distance from compressor housing):
POil
(kPa)
tOil (oC)
Admissible lubricating oil pressure for prelubrication or relubrication
(Standby operation)

3.3 Pipe connections

Dimensions are specified in mm!
Exhaust gas Inlet single - nozzle housing (1x) O 150 mm
Inlet double - nozzle housing (2x) O 110 mm
Inlet triple - nozzle housing (3x) O 100 mm
Outlet 185 x 500 mm
Charge air Outlet O 175 mm
Lubricating oil Inlet at bearing housing M27x2
Cooling water Inlet at bearing housing Pipe 35 x 2
Compressor washing Air piping Pipe 12 x 1 St
Water piping Pipe 12 x 1,5 Cu
Turbine washing Water piping Pipe 12 x 2
Drainage Pipe 35 x 2
Further connection dimensions can be taken from the assembly drawing. This can be
requested from the TC manufacturer.
The piping for the pipe connections listed is not included in the scope
of supply of Kompressorenbau Bannewitz GmbH.
Pipes have to be laid free of stress in any case.

3.4 Test connections

On request, the TC can be equipped with a speed measuring device consisting of magnetic
screw (9001) and an inductive speed sensor (9002).
The magnetic screw (9001) is screwed into the shaft centring hole. The inductive speed
sensor (9002) is screwed into the silencer/ air intake housing to the limit and then unscrewed
by half turns (distance 1 - 1,5 mm). After disassembly inductive speed sensor (9002) is
secured with the lock nut (A).
Legend
2517 V-profile clamp
2800 Silencer
2900 Intake housing
9001 Magnetic screw
A Lock nut

3.5 Dimensions of important subassemblies
Exhaust gas turbocharger, cpl. 450 kg

Silencer 45 kg
Air-intake housing 20 kg
Compressor housing, cpl. 75 kg
Turbine inlet housing, cpl. 86 kg
Turbine outlet housing, cpl. 65 kg
Bearing housing, cpl. 70 kg
Rotor cpl. 18 kg
Shaft 13 kg
Compressor impeller 5 kg

4 INSTRUCTIONS FOR MOUNTING TURBOCHARGER
4.1 General requirements

The TC is to be connected to the engine without deflection or torsion. Thermal expansions
and relative motions are to be compensated by flexible or movable elements in the piping.
4.2 Console for the TC

The console is to be designed resistant to
deflection and torsion in order to prevent any
additional forces from acting on the fastening bolts.
Use bolts of property classes 10.9 or 12.9
according to DIN 276. If the foot is not in horizontal
position (angle of inclination > 25°), it is to be
supported additionally (refer to figure).
4.3 Gas and air piping

Gas and air pipes must not be supported at the exhaust gas turbocharger housings, but only
on the engine. They are to be fastened in a way avoiding free oscillations.
Thermal expansions are to be absorbed by expansion joints (compensators) to be arranged
as closed to the exhaust gas turbocharger as possible.
Compensators are to be prestressed in cold condition in order to ensure an optimum relief
during the operation.
Thick flexible gaskets must not be used instead of compensators or sliding seals.
Soft compensators are to be installed in the piping downstream of the air outlet, upstream of
the gas inlet as well as upstream of the air-intake housing.
Exhaust gas outlet of an exhaust gas turbocharger is connected via diffuser and compensator
to the exhaust gas piping. This exhaust gas piping has to be fixed to the building or ship
directly downstream of the compensator (refer to figure). The remaining forces acting on the
turbine housing are composed of the weight of the diffuser and of the compensator pressure.
Legend
1 - fastening point in
building or ship
2 - compensator
3 - diffuser
23 - diffuser housing

4.4 Loads of housings of the exhaust gas turbocharger

The air and gas piping may transfer inadmissible high forces and moments onto the TC
caused by deformation or thermal expansion.
This may caused distortion at TC housing components perhaps resulting in damages at the
TC; e. g. elimination of mounting clearances resulting in a rotor contact with the housings,
damaged bearings, TC failure.
The piping attached may apply the following forces and moments to the TC
Maximum admissible forces and moments

F1 900 N
M1 400 Nm
M2 350 Nm
While dimensioning the compensator and the diffuser, make sure to

select their masses and the rigidity of the compensator in order to
prevent the forces mentioned from being exceeded in cold as well as
warm operating conditions as well as during start-up and stopping.
Recommended compensator rigidity : < 300 N/mm

Mass of diffuser firmly screwed to TC including half of the mass of the compensator
(max. admissible) : 90 kg
4.5 Vibrations
Maximum admissible vibration load at engine for 2 - 300 Hz :
Effective vibration speed at TC 30 mm/s
at silencer 50 mm/s
Amplitude 1 mm
2
Effective acceleration 15 m/s
(measured at TC at shaft level longitudinal and transverse to the Rotor)

5 OPERATION
5.1 Preparation for operation
5.1.1 Lubricating oil supply
The lubricating oil supply of the TC plain bearing is taken from the engine oil circuit. The lubri-
cating oil flow depends on the oil temperature, the oil pressure and the TC speed.
A nominal oil filter fineness of 25 µm is specified for the lubricating oil upstream of the TC. If
the lubricating oil filter of the engine does not meet this requirement, a correspondingly
switchable filter is to be inserted upstream of the TC. This lubricating oil filter has to permit a
lubricating oil flow of not less than 35 l/min.
The lubricating oil supply have an open width of not less than 15 mm and the lubricating oil
return line shall have an open width of not less than 35 mm. The lubricating oil return line is to
be designed as short inclined piping.
Prior to putting into operation, ensure that the bearings of the TC are supplied with oil in any
case.
The lubricating oil pressures required for special operating conditions are listed under chapter
3.2. Ensure and check the free return flow of the lubricating oil.
The following has to be checked :
Lubricating oil temperature upstream of TC
Lubricating oil pressure upstream of TC
During installation, make sure to provide sufficient space for maintenance and repair work.
Ensure the lubricating oil supply of the plain bearings (refer to chapter
3.2).
Lubrication has to be started prior to start-up processes.
The engine has to be stopped immediately when the oil pressure falls
below the minimum value.
Pay special attention to prevent leakage's in the oil supply and return
pipes to prevent oil from flowing under the sheathing of hot, gas-
carrying housings in order to prevent the formation of hazardous oil
vapours (and fire risks).
5.1.2 Cooling water
The cooling of the bearing housing is taken from the engine cooling water circuit (Connection
dimension see chapter 3.3). Prior to putting into operation or maintenance, ensure that the
connections of cooling circuit are tightly.
Ensure the cooling-water flow adjust, that you have not more then 10 K between the entrance
of cooling-water and outlet (see chapter 3.2.

5.2 Engine operation

The exhaust gas turbocharger is driven by the exhaust gases of the engine and is started
together with the engine. The TC speed is adjusted depending on the operating conditions of
the engine.
The charge air pressure required for the engine is fixed by adjusting the turbine nozzle ring
and the compressor diffuser during the TC approval.
If the corresponding meters are available, enter the following measured values into the
engine log during engine operation (at least once every 24 operating hours) :
Speed of exhaust gas turbocharger
Exhaust gas temperature upstream of turbine or downstream of cylinder
Charge air temperature downstream of compressor or downstream of charge air cooler
Charge air pressure downstream of compressor
Lubricating oil temperature upstream of TC
Lubricating oil pressure upstream of TC
At the same time, perform the following checks at regular intervals:
Tightness of the exhaust gas, charge air, cooling water and oil piping
Smooth running of the exhaust gas turbocharger
The charge air pressure is utilised as parameter for the exhaust gas turbocharger speed.
Unsteady operation (vibration of TC) indicates an unbalance of rotating parts possibly
resulting in the damaged rotor or bearing (refer to chapter 6.5).
5.3 Putting out of operation

After the engine has been stopped, the exhaust gas turbocharger continues to run for some
time. The run out period depends on the installation.
If the rotor comes to an immediate standstill, this can be caused by one of the following
reasons:
damaged bearings
contact of compressor or turbine blades by thermal distortion (refer to chapter 4.3 and
4.4.)
clamed foreign matters
Measures for extended period without operation
Drain the cooling water from the cooling water compartments. Preserve cooling water
compartments, oil compartments and all machined surfaces of the exhaust gas turbocharger
by anti-corrosion oil.
Protect the exhaust gas turbocharger against continuous vibration possibly damaging the
bearing during standstill.
Remove the preservation of the exhaust gas turbocharger prior to restoring it.
Perform an inspection according to the maintenance schedule, chapter 6.4.
Instruction for extended preservation and removing the preservation are available on request.

5.4 Failures
Failures can be detected by abnormal measured values (exhaust gas temperature, charge air
pressure, speed), heavy noise or leakages of lubricating oil and cooling water pipes.
In case of irregularities, reduce the engine load or stop the engine.
Since even minor failures may cause heavy consequential damages, determine the cause of
failure and eliminate it immediately (refer to chapter 6.5).
Stoppage the exhaust gas turbocharger
If the exhaust gas turbocharger has to be stopped due to a defect and if the engine has to run
in emergency operation, perform the work according to the chapter 7.5.3.
During stopping the exhaust gas turbocharger, limit the engine power in
values downstream of outlet valves. Pay attention to the operating
instruction of the engine manufacturer.

6 MAINTENANCE
6.1 General
Maintenance and monitoring work is summarised in the maintenance schedule, chapter 6.4.
Proper maintenance work enables failures to be detected in time. The maintenance work also
indicates necessary overhauls as well as work to be scheduled during yard or harbour times
on interruptions.
The operating hours specified in the maintenance schedule are to be considered as
averages. They can be extended or shortened according to existing operating conditions as
well as to be adjusted to the maintenance intervals of the engine.
It is important to eliminate even minor, apparently insignificant defect immediately and to
determine and eliminate their causes in order to prevent consequential damages at engine or
exhaust gas turbocharger.
If the engine is not equipped with an automatic monitoring system with data recording, entries
into the engine log are required at least once every 24 operating hours. Thereby, you can
detect deviations in time.
6.2 Maintenance work

In order to keep the exhaust gas turbocharger in the safe conditions, perform the inspection
and check of various subassemblies and components according to maintenance schedule,
chapter 6.4.
The chapter 7.5 include detailed instructions on the work sequence for maintenance and
overhaul work.

Winches, hoisting and towing equipment (VBG 8)
Load take-ups in hoisting gear operation (VBG 9a)
If bolts or nuts cannot be loosened immediately, do not apply excessive forces in order to
avoid damages of threads causing retouching work. Apply diesel fuel and wait for half an
hour. In this way, "Seizing" of threads can be avoided in most cases.
For bolted connections under heavy thermal load, bolts and nuts are made of high-
temperature material. Make sure that you do not confuse these bolts and nuts with
commercial ones during assembly work. In order to prevent burning and to facilitate
subsequent disassembly, apply a suitable bolt paste (e.g. molybdenum sulphide paste,
graphite) prior to assembly. Contaminations have to be removed from the threads previously.
During assembly, all bolted connection equipped with locking elements (lock nut, locking
plate) have to be properly locked.
For a basic overhaul or repairs effecting essential parts of the exhaust

gas turbocharger, it is recommended to document their condition. The
"Test results" form can be used as sample (refer to chapter 7.3).

6.3 Cleaning
Cleaning the silencer

refer to chapter 7.5.8
Cleaning the compressor

Cleaning during operation: refer to chapter 7.5.1
Mechanical Cleaning: refer to chapter 7.5.7 and 7.5.9
Remove the silencer and compressor housing. (The compressor impeller remains of the
shaft.). Deposits are removed by diesel fuel or another admissible liquid cleansing agent.
Pay attention to accident prevention regulations!

While washing, make sure to prevent the cleansing agent from
penetrating into the charge air piping or into the interior of the
turbocharger.
Cleaning the turbine

cleaning during operation: refer to chapter 7.5.2
(for heavy fuel oil operation only)
Cleaning the cooling water compartments

The contamination of cooling water compartments in the bearing support depends on the
cooling water care and the cooling water at mixture in the engine circuit. It is recommended to
clean engine cooling compartments and cooling compartments of the bearing support
simultaneously.
Heavy deposits in the cooling water compartments of the exhaust gas

turbocharger result in a reduced life of the housing and of the bearing.

6.4 Maintenance schedule
6.4.1 Maintenance for Marine Diesel Oil (MDO) application
The operating hours given in the table below are guidelines which can be
reduced for adjustment to the maintenance intervals of the engine.
Item Chapter Maintenance work Maintenance interval

(operating hours)
compressor washing system
or on demand
4. Check fastening bolts at the feet, tighten all once after
housing bolts and piping joints commissioning, then
every 1,000 hours
5. 7.5.5 to Inspection I max. 10,000
7.5.13 disassembly
cleaning
checking of rotor and bearings
checking of housings
assembly
6. 7.5.5 to Inspection II max. 20,000
7.5.13 like inspection I
replacement of the bearings
7. 7.5.5 to Inspection III max. 40,000
7.5.13 like inspection II
replacement of the rotor

6.4.2 Maintenance for Heavy Fuel Oil (HFO) application
The operating hours given in the table below are guidelines which can be
reduced for adjustment to the maintenance intervals of the engine.
Item Chapter Maintenance work Maintenance

interval
(operating hours)
compressor washing system
3. 7.5.2 Turbine washing during operation, actuate approx. 300
turbine washing system depending on HFO
Cleaning with water quality
or on demand
5. Check fastening bolts at the feet, tighten all once after
housing bolts and piping joints commissioning, then
every 1,000 hours
6. 7.5.5 to Inspection I max. 10,000
7.5.13 disassembly
cleaning
checking rotor and bearings
checking housings
assembly
7. 7.5.5 to Inspection II max. 20,000
7.5.13 as inspection I
replacement of bearings
8. 7.5.5 to Inspection III max. 40,000
7.5.13
as inspection II
replacement of rotor
The nozzle ring is subject to an increased wear for heavy fuel oil
operation. Therefore it is a wear part.
The lifetime of the nozzle ring is approximately 12,000 hours, but it

depends on HFO quality and operating conditions.
After exceeding the lifetime the nozzle ring should be replaced in case of
fundamental change of performance data as charge air pressure and
exhaust temperature.

6.5 Troubleshooting table
Causes Chapter
Silencer or air filter contaminated 7.5.8
Compressor contaminated 7.5.9
Charge air cooler contaminated Engine
Leaking exhaust gas piping Engine
Exhaust gas counter pressure too high Engine
downstream of turbine
Turbine wheel or compressor impeller 7.5.10,
damaged (unbalanced) 7.5.11
Defective bearing 7.5.4 ,
7.5.10
Rotor in contact with housing 7.5.11
Foreign matter in turbine or compressor 7.5.9 ,
(unbalanced) 7.5.10
Turbine contaminated 7.5.2
Turbine nozzle ring contaminated 7.5.2
Failure of fuel injection at engine Engine
Leaking charge air piping Engine
High air intake temperature Engine
Inlet or outlet valves of the engine Engine
contaminated
Low air intake temperature Engine
Lubricating oil filter contaminated Engine
Lubricating oil pressure gauge defective Engine
Lubricating oil inlet temperature too high Engine
Excessive pressure in oil return Engine
Sealing air ineffective
Gaskets damaged, connections leaking
Plain compression rings damaged 7.5.11

7 DISASSEMBLY AND ASSEMBLY
7.1 Introduction
The chapter 7.5 shall enable the user to perform certain repair and maintenance work by
himself.
Work sheets are sorted according to the sequence required to disassemble the exhaust gas
turbocharger. The instructions on the work sheet always refer to the working sequence
mentioned in the heading.
In case of complicated repair and overhaul work, it is required to prepare an exact working
sequence by compiling the respective work sheets.
It is assumed that the staff is familiar with the work and that the tools required are ready at
hand. Furthermore, the exhaust gas turbocharger has to be accessible and corresponding
hoists have to be available.
If change is caused by damages at certain components or if the exhaust gas turbocharger is
in a poor maintenance condition, the working time required may be extended.

winches, hoisting and towing equipment (VBG 8)
load take-ups in hoisting gear operation (VBG 9a)
7.2 Checking the components

The check list shown below can be used as instructions for the check of the condition of the
exhaust gas turbocharger and its major components. As a rule, the user is able to eliminate
minor damages. Major damages effecting rigidity, balance and smooth running of rotation
components should be eliminated by the manufacturer or an authorised workshop. If
damaged parts are returned for repair, ensure a good protection against transportation
damages.
After having disassembled the exhaust gas turbocharger, perform the following checks at
cleaned parts. The condition is to be recorded in the "Test results" form, chapter 7.3.
The valuation is made by means of the "Clearance sheet", chapter 7.4.

Rotor
Are the turbine blades damaged or did they touch the housing?
Are contact traces visible at the housing?
Are contact traces visible at the rotor?
Does the shaft run smoothly?
How is the condition of bearings?
Are the plain compression rings heavily worn?
If retouching work is performed or if rotor parts are replaced, rebalancing

has to be executed! (for admissible residual unbalance, refer to
clearance sheet, chapter 7.4)
Wear occurs at the plain compression rings in axial direction during

running-in, which his intended and could be max. 0.5 mm.
Compressor impeller
Can you detect sliding traces or cracks at the compressor impeller?
Are the bore and the axial surface OK?
Bearing
Is the axial clearance of the rotor inadmissible high?
Are the bores of bearings irregularly worn?
Is there heavy wear at the bearing faces at thrust bearing plates, compressor or turbine
bearing?
For evaluation of bearings, refer to chapter 7.5.4.
Turbine nozzle ring

Are the guide vanes twisted?
Is foreign matter clamped into the ducts?
Can you detect traces of foreign matter?
Housing
Are the housings heavily contaminated by oil, dust or soot?
Is there any leakage at housings? (Main items: connection flanges, joints, oil and water
connections)
Are all bolts and nuts tight?
After extended standstill periods, boiler scale may occur in cooling water
compartments. It is to be removed by suitable solvents.

7.3 Test results

Exhaust gas turbocharger : Works No. :
Variant No. :
Type of engine : Engine No. :
Customer name :
Address :
(Location, ship's name)
Latest inspection/ overhaul at : by :
Inspected/ overhauled at : by :
Number of operating hours since commissioning :
since latest inspection/ overhaul :
Results of inspection of components
Rotor/ Shaft
Turbine blades O no
damaged O yes
O blade parts missing
O traces of foreign matter
Contamination/ O no
deficits of O slight Plain compression O no
rotor blades O heavy rings damaged O yes
O uni-lateral
O uniform Radial deviation of rotor
(acc. to Clearance sheet) ............. mm
Blades tarnished O no Blade cracks O no
O yes O yes
Location : ..............
Gap between turbine impeller and housing Gap between compressor impeller and housing
(acc. to Clearance sheet) Clear. S12 : ........ mm (acc. to Clearance sheet) Clear. S1 : .......... mm
Clear. S14 : ........ mm Clear. S2 : .......... mm
Sliding traces O no Rotor rebalanced O no
at shaft O yes O yes
Bearing seats O no Condition prior O good
damaged O yes to rebalancing O poor
Compressor impeller
Sliding traces O no Blade cracks O no
O yes O yes
Location : ............... Location : ...............
Contamination O clean Quality of O good
O contaminated Bore O average
O oily O poor
Turbine nozzle ring
Guide vanes O good O Part turn out
O twisted O Traces of foreign matter
O scaled

Bearing housing
O clean Sealing air bores O clean
O coked O narrowed
O corroded O clogged
Compressor diffuser
Guide vanes O little Damage O no
contamination O heavy O yes
Location : ...............
Compressor bearing
O used Stop surface of radial bearing
Reason ................
Marks O no
Thrust bearing
O used Stop surface of thrust bearing
O replaced B(ax) : ................. mm
Reason ................
Marks O no
O yes Location : ................ Depth : ................... mm
Turbine bearing
O used Stop surface
Reason ................
Marks O no
Silencer
Contamination O oil Condition of O good
O dust felt layer O poor
O soot
Filter mat O yes
cleaned O no
Other defects/ component/ type :

7.4 Clearance sheet

Clearance/ Value
(mm)
New condition Limit
clear.
Clear. Parts designation Parts No. min max
max.
*)
(radial)
(axial)
S6 Rotor- compressor bearing (radial/ d7-d6) **) 1000/ 3200 0.09 0.12
S8 Rotor- turbine bearing (radial/ d11-d10) **) 1000/ 3100 0.1 0.13
S12 Turbine imp.- turbine housing (radial) 1000/ 2100 0.5 0.6 0.8
S13 Turbine imp.- radiation protection 1000/ 2009 0.6 0.9 1.1
S14 Turbine imp.- turbine housing (axial) 1000/ 2100 0.5 0.7 0.9
S15 Rotor- compressor bearing (axial) 1000/ 3200 0.1 0.2
S18 Compression ring- bearing cover turbine 1009/ 2004 0.20 0.30 0.5
S19 Compression ring- bearing cover compressor 1008/ 2003 0.20 0.30 0.5
*) by stepping over according work or spare part used
**) Measuring of bearing bore help a plug gauge( three points)
Admissible residual unbalance of rotor: 5.25 gmm per bearing
Admissible radial deviation of rotor: 0.020 mm (point E)
Admissible tightening torque of rotor nut: 260 (+5) Nm
Rotor pushed to the left for measuring the clearance S2, S15

7.5 Process of maintenance
7.5.1 Compressor washing
(Every 25 - 50 operating hours)
Legend
1 Ball valve
2 Water tank
3 Water piping
4 Air piping
5 Pipe union
6 Design with Silencer
7 Design with air intake housing
8 Pipe union
Work sequence:
1. Operate engine close to full load.
2. Open water tank (2), fill with clean water (no seawater), close water tank.
3. Open valve (1), wait for approx. 20 sec., close valve (1). The compressed air flows
through the air piping (4) via valve (1) into the water tank. The water is pressed through
the water piping (3) into the injection pipe, atomised by the air taken in and hits the
compressor blade with high speed.
Perform cleaning with warm engine close to full load operation only.
Continue to operate the engine for at least 10 minutes after cleaning.
Do not wash before a pause of operation. Corrosion attach!
Washing is ineffective in case of hardened deposits, thus perform

7.5.2 Turbine washing
Heavy fuel oil operation results in contamination and deposits on nozzle

ring and turbine wheel reducing the efficiency. Due to these deposits the
charge air pressure will be increased.
The washing intervals depend on the fuel quality and operating
conditions. That's why they must be adjusted based on the experience
gained during engine operation if necessary later on. The washing
interval could be adjusted from 50 to 600 hours.
The increase of charge air pressure could be used for adjusting the
washing interval, which could adjusted within 50 to 600 hours.
Read and take down the charge air pressure and exhaust gas
temperatures at a reference point (at 75 % or 100 % of the output) before
and after washing to check the washing effect.
Legend (Example, could vary depending on engine installation)
1 Sanitary fresh water 5 Stop valve 9 Valve

2 Regulating valve 6 Wash-water piping 10 Escape funnel or sight glass
3 Fresh-water piping 7 Injector 11 Turbine outlet housing
4 Removable flexible tube 8 Connection for drain

Work sequence:
1. Connect the flexible tube (4) to fresh-water piping (3).
2. Reduce the engine output to approx. 15 % of its rating until the temperature after cylinder
has come down to its specified value. (see table)
3. Wait for approx. 10 minutes!
4. Open the valve (9) of the drain (8) (if present).
5. Open valve (2) and adjust the water pressure (see table).
6. Open stop valve (5) for approx. 30 seconds and close again.
7. Wait for approx. 3 minutes so that the injected water can evaporate.
8. Repeat steps 6. and 7. twice or three times.
9. Close the stop valve (5), valve (2) and the valve (9) of the drain.
10. Run dry the exhaust gas turbocharger at constant load for approx. 30 minutes, increase
engine load slowly!
11. Repeat the washing process if the exhaust gas turbocharger is affected by vibrations
which did not occur before.
12. Remove the flexible tube (4).
Operating values for turbine washing
Engine Exhaust gas Exhaust gas Water pressure Total

output temperature after temperature (gauge) washing
cylinder before / after the period
turbine
max. 15% 300 330 °C 400 420 / <330 °C 150 200 kPa 3-4x 30 sec
Hot exhaust gas can escape from the drain - Risk of burning!
Continue to operate the engine for at least 30 minutes after cleaning.
Do not wash before a stop of operation. Corrosion risk!
Washing is ineffective in case of hardened deposits, thus perform

Pay attention also to instruction of the engines operating manual!

7.5.3 Stoppage the exhaust gas turbocharger
In case of damages at the TC especially at the rotor or at the bearings it

is recommended to put out of operation to avoid any further damages.
Pay attention to the operating instruction of the engine manufacturer.
During locking the exhaust gas turbocharger, limit the engine power in
values downstream of outlet valves.
Related chapter 7.5.7, 7.5.9, 7.5.10
Legend
2105 Hexagon-head nut
2106 Spring washer
Tools required
1 Sealing disk (9709)
Initial condition: The turbocharger is

mounted on the engine.
Mass of the silencer approx. 45 kg

Mass of the air intake bend approx. 20 kg
Mass of the compressor housing approx. 75 kg
Work sequence:
1. Disassembly of the silencer (2800) /Intake housing complete (2900) according to chapter
7.5.7.
2. Loosen the charge air pipe at the compressor housing (2500).
4. Disassembly of the compressor housing (2500) according to the chapter 7.5.9.
5. Drain lubricating oil and cooling water, loosen the connections.
6. Disassembly of the bearing housing (2000) with rotor according to the chapter 7.5.10.
Use hoisting gear!
Be careful for dismounting work to avoid damage to the turbine blades.
7. Mount the sealing disk (9709) on the turbine housing (2100) and tighten with hexagonal
nuts.

7.5.4 Bearing check

Sliding surface
Radial bearing (3100/3200)
New bearing
Wedge-shaped
Load- sector
carrying
sector
Legend
D Bearing diameter
R Radius at wedge face
Bearing after
B(ax) Load-carrying sector
longer
width of thrust bearing
operation
B(rad) Load-carrying sector
Sliding surface
width of radial bearing
Tools required Thrust bearings (3200)

1 Micrometer screw
1 Caliper gauge
Initial condition: Compressor bearing (3200) and turbine bearing (3100) removed. (For
clearances, refer to chapter 7.4.)
Work sequence 1: Load-carrying sector of radial bearings
1. Clean bearings carefully!
2. Determine stop face width B(rad)!
Replace bearing, if :
The load-carrying sector width B(rad) of the radial bearing has
reached 12 mm.
Heavy dirt marks can be seen.
Determine the causes !
Work sequence 2: Load-carrying sector of axial bearings
1. Carefully clean the stop faces at both sides of the axial bearings.
2. Determine the bearing stop face width B(ax).
3. Determine axial clearance S15.
Replace bearings, if :
B(ax) is larger than 2/3 of the sliding face.
The sliding faces reveal heavy dirt marks.
If material is deposited on the bearing faces of the shaft, a repair is

required in an authorised workshop.

7.5.5 Disassembly of the complete turbocharger
Legend
2202 Foot, turbine
2800 Silencer
Tools required
1 Hoist / 2 Ropes
load take-ups in hoisting gear operation (VBG9a)
Pay attention the piping and sheathings!
General
Under normal conditions, the complete exhaust gas turbocharger has to be removed from the
engine for an inspection only. It is sufficient to dismantle individual subassemblies for
maintenance and checks. While removing the exhaust gas turbocharger, pay attention to
space conditions in the engine room.
Work sequence:
1. Loosen sheathings from turbine housing (2100).
2. Loosen exhaust gas piping from compressor inlet and outlet housings (2100/2300). Pay
attention of gaskets.
3. Loosen the piping from compressor housing (2500), remove them, if required.
4. Drain lubricating oil and cooling water from TC, loosen cooling water inlet and outlet and
lubricating oil inlet and outlet.
6. Round a rope around the flange between the silencer (2800) and compressor housing
(2500).
7. Round the second rope around the flange between turbine inlet housing (2100) and
turbine outlet housing (2300). Hang both ropes on the hoist.
8. Loosen and remove the bolts on the feet (2201/2202).
9. Lift TC and put down on a wooden plate. Save for tipping!

7.5.6 Assembly of the complete turbocharger
Legend
2202 Foot, turbine
2800 Silencer
Tools required
1 Hoist / 2 Ropes
Molybdenum sulphide lubricant

load take-ups in hoisting gear operation (VBG9a)
Pay attention the piping and sheathings!
Work sequence :
1. Lift complete TC (refer to chapter 7.5.5) with 2 ropes by hoist and put it onto the engine
console. Pay attention to pipe connection !
2. Insert and tighten bolts at the foot.
3. Connect exhaust gas pipes to turbine inlet and outlet housing (2100/2300).
4. Attach sheathing.
5. Connect charge air piping.
6. Connect cooling water inlet and outlet as well as lubricating oil inlet and outlet.
7. Connect water and air pipes for compressor washing.
8. Tighten bolts at foot of TC and all connection pipes.
After having installed the TC, check that the assembly is free of stresses
and forces. Retouch piping, if required.
9. Supply lubricating oil and cooling water to TC and check all flanged connections for
leakage's.
Use proper gaskets for pipe joints only. Apply molybdenum sulphide
lubricant to connecting bolts of exhaust gas pipes prior to installation.

7.5.7 Assembly and disassembly of silencer or air-intake housing
Legend
2517 V-profil clamp
2800 Silencer
2900 Air-intake housing
9001 Magnetic screw
A Lock nut
Tools required
1 rope
2 shackles
Mass of silencer approx. 45 kg

Mass of air-intake housing approx. 20 kg
Work sequence 1 : Disassembly of silencer/ air-intake housing

1. Loosen the cable of the inductive speed sensor (9002)
3. Loosen hexagon nuts of the V-profile clamp (2517), remove from one side the hexagon
nuts.
4. Remove the tension tape from the flange.
5. Pull-off silencer/ air-intake housing in axial direction from compressor housing (2500) and
put it onto a wooden base.
Work sequence 2: Assembly of silencer/ air-intake housing
2. Slide on silencer/ air-intake housing in axial direction onto the compressor housing.
3. Round the V-profile clamp (2517) around the flange, assembly hexagon nuts and tighten
with 25-30 Nm.
4. The inductive speed sensor (9002) is screwed to the limit and then unscrewed by half turns
(distance 1 - 1,5 mm). After disassembly inductive speed sensor (9002) is secured with
the lock nut (A). Connect the cable.

7.5.8 Cleaning the silencer
(Every 250 operating hours)

Legend:
2800 Silencer
2813 Filter mat
2815 Tension tape
2816 Punched plate
A Possible connection for maintenance
indicator
B Felt coat
General
In most of the cases, merely the filter mats have to be cleaned. For this purpose, the silencer
may stay at the exhaust gas turbocharger.
The given maintenance interval of 250 running hours is just a mean guide value, since the
accumulation of dirt in the filters and the pressure drop resulting therefrom are largely
dependent on the environment. For operation under extreme conditions, it is recommended
to add a maintenance indicator (water gauge) signalling the right moment for cleaning.
This indicator shall be adjusted so as to give the cleaning signal when a vacuum of
app. 100 mm w.g. is reached at point A intended for mounting (e.g. a MANN maintenance
indicator for air filters, max. 200 mm w.g. = 20 mbar).
Work sequence : Cleaning the filter mats and felt coat

1. Open the tension tape (2815) and pull the filter mat (2813) over the silencer (2800)
against the flange. The punched plate (2816) stays by the silencer
2. Lay filter mat (2813) into clean liquid (diesel fuel, perchlorethylene) for approx. 10 hours.
Subsequently, rinse in the liquid and externally clean by a soft brush, stub out and dry the
filter mat.
3. Take off the punched plate (2816) means of loosen from three bolt (M6). (Only after
heavy soiling of the felt coat.(B)).
4. Clean the dry contaminated felt coat with a brush or oily contamination with diesel fuel
wipe up. Do not use water!
5. Install filter punched plate (2816) and dried filter mat (2813) in reverse order. Before screw
the punched plate press it at the sides of edge.
Pay attention to applicable accident prevention regulations (handling of
hazardous, volatile, combustible solvents) and fire protection regulations
(DIN 14096). Cleaning by a P3-solution or trichlorethylene is prohibited. If
other solvents are used, check the compatibility with the filter material.
In case of ship operation, pay attention to the regulations of
classification societies with regard to washing liquids.
If the felt coatings of the silencer are heavily contaminated, they have to
be replaced. For this purpose, disassemble the silencer according to
chapter 7.5.7. The silencer has to be overhauled by an authorised
workshop.

7.5.9 Assembly and disassembly of the compressor housing

Legend
1002 Compressor impeller
2000 Bearing housing
2030 O-Ring
2507 Stud bolt
2508 Hexagon nut
2509 Spring washer
2518 Stud bolt
5001 Compressor diffuser
5002 Silicon cord
5003 Cylindrical screw
Tools required
2 ropes /4 shackles
Mass of Compressor
housing
approx. 75 kg
Work sequence 1: Disassembly of the compressor housing
1. Remove air and water piping for compressor washing.
2. Hang compressor housing (2500) with a rope and shackles on the hoist.
3. Mark the position of compressor housing. Loosen the hexagon nuts (2508), hexagon-head
bolts (2808) and spring washer (2809).
4. Pull off the compressor housing (2500) and the compressor diffuser (5001). Do not tilt !
5. Remove compressor diffuser (5001).
Work sequence 2: Assembly of the compressor housing
1. Change silicone cord (5002) at the rear of the compressor diffuser (5001).
2. Insert compressor diffuser (5001) and screw the cylindrical screw (5003).
3. Put the O-ring (2030) on the centring of bearing house (2000). Hang compressor housing
(2500) with a rope and shackles on the hoist.
4. Carefully attach compressor housing (2500) in axial direction to the bearing housing. Pay
attention to housing position !
5. Fasten by hexagon nuts (2808) and spring washers (2509). Check the clearance S1!
6. Connect water and air piping for compressor washing to compressor housing (2500).
Make sure not to damage the compressor impeller (1002) during

disassembly and assembly of the compressor housing.

7.5.10 Assembly and disassembly of the bearing housing with rotor
Related chapter 7.5.7, 7.5.9

Legend
1000 Rotor cpl.
2000 Bearing housing cpl.
2100 Turbine inlet housing cpl.
2104 Stud bolt
2105 Hexagon nut
2106 Spring washer
2201 Foot, turbine side
Tools required
1 Hoist
1 Rope with Shackle
2 Eye bolts
Initial condition: Compressor housing, silencer and all pipings are removed.
Mass of turbine inlet housing approx. 86 kg

Mass of turbine outlet housing approx. 65 kg
Work sequence 1: Disassembly of bearing housing with rotor
1. Assemble two blank flange with eye bolt on side of the bearing housing.
2. Join the bearing housing (2000) on the hoist.
3. Loosen the hexagon nuts M10 (2105) of the spring washers (2106).
4. Loosen the screws from the foot (2201) from the motor support.
5. Forcing-off uniformly the bearing housing (2000) with forcing screw. Are the connection
with carbon glued, net with diesel fuel and wait a minute.
6. Move careful the bearing housing (2000) out of the turbine housing (2100) in axial
direction. Put it on a wooden plate.
Be careful for mounting and dismounting work to avoid damage to the

turbine blades.
Work sequence 2 : Assembly of bearing housing with rotor

1. Clean the connecting flange between bearing housing and turbine housing from
combustion residues by fine abrasive cloth. Subsequently apply molybdenum sulphide
lubricant to flange.
2. Fasten bearing housing by the rope to the hoist and lift it to the turbine housing.
3. Carefully insert the bearing housing under consideration of the housing position into the
turbine housing; tighten bolts.
4. Tighten the screws from the foot (2201) to the motor support.
5. Check rotor for contact by slightly rotating it !

7.5.11 Disassembly of rotor complete
For the disassembly of the rotor mount the bearing housing on a rack or
clamp it in a vice (with soft-material jaws).
Mass of rotor cpl. 18 kg

1007 Conical spring washer 1007 Feather key 1 Open-jawed spanner A/F18/19
turbine ring, compressor
2005 Gasket, turbine 2007 Gasket, compr. 1 Extractor for thrust ring (9707)
2009 Labyrinth cover 2010 Stud bolt 2 Eye bolts (9708)
2011 Hexagon-head bolt 2012 Locking plate 1 Torque spanner 300 Nm A/F32
cpl

Work sequence 1: Disassembly of the compressor impeller (1002)

1. Mount on the locking device (9705) of rotor and connect on the flange of bearing housing.
Loosen rotor nut (1005) with torque spanner A/F 32.
2. Loosen the rotor nut (1005) and remove it with the spring washer (1006).
3. Heat the hub of the compressor impeller (1002).
Temperature 150 °C max.
Use burner flame with excessive gas.
Uniformly heat the impeller hub range.
Protect shaft thread by pipe against heat.
4. Pull off the compressor impeller (1002) from the shaft.
The installation position of the compressor impeller is marked with

regard to the shaft.
Work sequence 2: Disassembly of the compressor bearing (3201)

1. Unlock and loosen the hexagon head bolts (2011) and remove the bearing cover of
compressor (2003). The plain compression rings of compressor are located in the bearing
cover (1009). Pay attention to the gasket (2005) !
2. After cooling the shaft (1001) pull off spacer (1003).
3. Unlock and loosen the hexagon head bolts (3203) and remove the compressor bearing
(3201) with the aid of forcing screws.
4. Move the extractor for thrust ring (9707) on the shaft (1001) and turn it in the thrust ring
(1004).
5. Pull thrust ring (1004) from the shaft (1001).
Work sequence 3: Disassembly of the turbine bearing (3101)
1. Pull shaft (1012) carefully out of bearing housing.
2. Remove turbine nozzle ring (4000) and the labyrinth cover (2009) after having loosened
the four hexagon nut (2013).
3. Screw off bearing cover of turbine (2004). Pay attention to the gasket (2007) !
4. Remove the turbine bearing (3101) from the bearing housing. Close openings at bearing
housing in order to prevent dirt from reaching the bearing compartment and the oil bores.
5. Remove the plain compression ring of the turbine (1008) from the shaft.
Now, the turbocharger is disassembled. Check, evaluate and clean parts

according to chapter 7.2 and 7.3.

7.5.12 Installation of rotor complete
Related chapter 7.5.5 - 7.5.11
For installing the rotor mount the bearing housing on a mounting rack.
Mass of rotor complete 18 kg.

1007 Conical spring washer 1007 Teather key 1 Open-jawed spanner A/F18/19
2005 Gasket, turbine 2007 Gasket, compr. 2 Eye bolts (9708)
2009 Labyrinth cover 2010 Stud bolt 1 Torque spanner 300 Nm A/F32
2011 Hexagon-head bolt 2012 Locking plate 1 Feeler gauge
cpl

Prior to the assembly, check the cleanliness of the bearing housing, of

oil conducting ducts and of the sealing air piping. Pay attention to the
specifications of chapter 7.4 (Clearance sheet) during assembly.
Work sequence 1: Installation of the turbine bearing and shaft into the bearing housing
1. Insert turbine bearing (3101) with the flattened flange side at the bottom; tighten and lock.
Pay attention on the assembly position. The stud bolt (3102) goes upper
in the groove (twisting securing)!
Always assembly turbine bearing with stud bolt!
2. Insert and tighten turbine side bearing cover (2004) with original gasket (2007). If the
gasket was damaged during disassembly, insert a gasket of the same thickness, since
otherwise the clearance S18 is changed and has to be reset. The clearance is measured
after installation of the compressor bearing.
3. Attach labyrinth cover (2009) onto the centring of the bearing housing.
4. Insert the plain compression ring of the turbine (1008) into the shaft groove.
5. Apply clean oil onto turbine bearing and slight the shaft carefully into the bearing. Be
especially careful while introducing the plain compression rings into the bearing cover.
Work sequence 2: Installation of the compressor bearing and completing the rotor
1. Apply oil to the thrust ring (1004) and slide it according onto the shaft. Pay attention on the
assembly position.
2. Wet the compressor bearing (3200) with oil. Move it onto the shaft with its flat flange side
pointing downward and fasten it with hexagon-head bolts (3203) and locking plates
(3204).
3. Check clearance S18 : (if components are replaced)

Press shaft from the turbine side to the bearing housing. Put dial gauge onto the shaft end
and adjust it to zero. Loosen fastening bolts (3203) of the compressor bearing and force
compressor bearing (32019) by approx. 1 mm. Press shaft towards compressor side. The
shaft is moved by the clearance S18; correct by changing the thickness of the bearing
cover gasket (2007), if required.
4. Check clearance S13 : by means of feeler gauge.
5. Mount the locking device (9705) to the turbine wheel and fasten it to the flange of the
bearing housing.
6. Slide spacer (1003) onto the shaft up to the shoulder. Pay attention the assembly position!
7. Check clearance S19 : Determine the distance between external face of compressor side
bearing cover and the colour of the supported plain compression ring by a caliper gauge.
After having attached the bearing cover of the compressor (2003), measure the distance
between external face of bearing cover to the spacer by caliper gauge, while pressing the
shaft towards the compressor. The difference of the two dimensions is the clearance S19.
The correction is made by changing the thickness of the gasket at the bearing cover
(2005).

8. Install bearing cover, compressor (2003) and insert the plain compression rings,
compressor (1009) with staggered joints.
9. Heat compressor impeller (1002) (max. 150 °C) and slide it onto shaft.
The mounting marks at shaft (1001) and compressor impeller (1002) have
to match.
10. Grease slightly the thread by molybdenum lubricate. Mount spring washer (1012) and
rotor nut (1005).
11. When the compressor impeller has cooled down, tighten the rotor nut (1005) by torque
spanner with 50 Nm. Mark the position of rotor nut.
Lock rotor by means of locking device (9705). Use universal joint in any
case !
12 Tighten again the rotor nut (1005) with 260 Nm. The reached turning angle of the rotor
nut (1005) should be 75 to 90 degree otherwise dismantle rotor nut (1005) and spring
washer and repeat point 10 to 12.
13. Bolt turbine nozzle ring (4000) with labyrinth cover (2009) to bearing housing.
14. Check rotor for smooth running : Apply 40 cm3 oil into the oil guide bore in the
bearing housing and slowly turn rotor. The rotor has to be turned easily without sensible
resistance and has to make some rotations after having been pushed.
15. Check truth of rotor running : Apply dial gauge to shaft end at compressor side and
measure the radial run-out of the rotor while slowly turning the rotor. The radial run-out is
specified in the clearance sheet, chapter 7.4
Now the bearing housing with rotor is assembled and can be completed according to chapter
7.5.5 to 7.5.10.

7.5.13 Disassembly turbine outlet housing
Legend
2302 Outer diffuser
2304 Inner diffuser
2306 Countersunk screw
2307 Stud bolt
2308 Stud bolt
2309Hexagon nut
2310 Spring washer
2313 Hexagon-head bolt
2314 Spring lock washe
Tools required
1 Socket spanner A/F 18/19
1 Hoist with ropes
Initial condition: Exhaust gas manifold and drain pipe for turbine washing are diassembled
from the turbine outlet housing.
Work sequence :
1. Removed the sheathing.
2. Hang the turbine outlet housing (2303) with a rope on the hoist.
3. Loosen hexagon-head nut (2309) with the curved spring washer (2310).
4. Forcing-off uniformly the turbine outlet housing (2303) with forcing screws.
5. Move careful axial the turbine outlet housing (2303) from turbine inlet housing (2101) and
put it on a wooden plate.
6. Loosen the hexagon-head bolt (2313) and removal the inner diffuser (2304).
7. Loosen the 2 hexagon-head bolt (2306) and removal the outer diffuser (2302) from the
turbine outlet housing (2102).

8 SPARE PARTS AND TOOLS
8.1 General
The following specification required for the order :
1. address of orderer
2. type of turbocharger
3. variant number (refer to to type plate on Page 2)
4. works number (refer to type plate on Page 2)
5. part number and designation
6. shipment address
The optionally supplied spare parts books contain the selection of the most important ware
parts as well as a corresponding list.
A certain selection of tools can be ordered, too. These are tools required to maintain and
repair the exhaust gas turbocharger and not included in the basic equipment of every
workshop.

8.2 Spare parts
8.2.1 Bearings

number

8.2.2 Gaskets

number
2005 1x2 Gasket , compressor (S=0,5/0,2)
2007 1x2 Gasket , turbine (S=0,5/0,2)
2020, 2312 1 Gasket
2021 1 Gasket
2022 1 Gasket A27x32 DIN 7603
2030 1 O-ring
2511 2 Gasket A17x21 DIN 7603
2513 3 Gasket A10x14 DIN 7603
5002 1 Silicon cord

8.2.3 Locking elements
2012, 3204 18 Locking plate 6,4 DIN 463
2106 2012
2310 2014
2316 2314 3204
2509

8.3 Tools
9705 1 Locking device
9706 1 Plug screw with gasket for oil supply
9707 1 Extractor for thrust ring complete
9709 1 Cover plate not in the toolbox, optional order

9 SECTIONAL DRAWING

10 LIST OF COMPONENTS
1000 1 Rotor, cpl.
1001 1 Shaft
1002 1 Compressor impeller
1005 1 Rotor nut
1003 1 Spacer
1004 1 Thrust ring
1006 1 Conical spring washer
1007 2 Feather key A4x4x10 DIN 6885
2000 1 Bearing housing, complete
2001 1 Bearing housing
2003 1 Bearing plate, compressor
2004 1 Bearing plate, turbine
2009 1 Labyrinth cover
2010 4 Stud bolt (for 4001)
2013 4 Hexagon-head screw M8 DIN 934
2020 1 Gasket
2021 1 Gasket
2022 1 Gasket A27x32 DIN 7603
2030 1 O-ring
2100 1 Turbine inlet housing, cpl.
2101 1 Turbine inlet housing
2104 12 Stud bolt M12x25 graphite. DIN 939
2105 12 Hexagon-head nut M12 DIN 934
2107 *) Screw plug G1/2 DIN 910
2108 *) Gasket 21x26 DIN 7603
*) 1 x per gas intake casing


2200 1 Foot, complete
2201 1 Foot, compressor
2202 1 Foot, turbine
2300 1 Turbine outlet housing, complete
2302 1 Outer diffuser
2303 1 Turbine outlet housing
2304 1 Inner diffuser
2306 2 Countersunk screw
2309 12 Hexagon nut M12 DIN EN 24032
2312 1 Gasket
2313 3 Hexagon-head bolt M12x25 graph. DIN EN
24017
2315 4 Hexagon-head bolt M10x25 DIN EN 24017
2500 1 Compressor housing, complete
2501 1 Compressor housing
2510 2 Screw plug G3/8 DIN 910
2511 2 Gasket A17x21 DIN 7603
2513 3 Gasket A10x14 DIN 7603
2516 1 Cylindrical grooved pin 8x16 DIN 1473
2517 1 V-profile clamp
2800 1 Silencer complete
2813 1 Filter mat 20x265x1950 mm
2815 2 Tension tape
2816 1 Punched plate


2900 1 Intake housing complete
3100 1 Turbine bearing complete
3102 1 Cylindrical pin 5m6x10 DIN 7
3200 1 Compressor bearing complete
4000 1 Turbine nozzle ring complete
4001 1 Turbine nozzle ring
5000 1 Compressor diffuser complete
5001 1 Compressor diffuser
5002 1 Silicon cord
5003 1 Cylindrical screw
8000 1 Sheathing
8001 1 Sheathing , turbine inlet housing
8002 1 Sheathing , turbine outlet housing
9000 Components parts
9001 1 Magnetic screw
9002 1 Inductive speed sensor
9003 1 Speed indicator

MaK M20 - Инстр. по экспл.ГТН R4-3

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MaK M20 - Инстр. по экспл.ГТН R4-3

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 

  

Kompressorenbau Bannewitz GmbH

Phone: +49 (351) 40 85 50

Direct your requests to the following addresses:

Kompressorenbau Bannewitz GmbH

Fax: +49 (351) 40 85 840

Page 2 of 51 3 rd Edition (07/99) en

2 GENERAL INFORMATION ABOUT DANGERS............................6

3 DESIGN AND SPECIFICATIONS....................................................8

4 INSTRUCTIONS FOR MOUNTING TURBOCHARGER..............13

en 3rd Edition (07/99) Page 3 of 51

Chapter Title Page

7 DISASSEMBLY AND ASSEMBLY ...............................................22

8 SPARE PARTS AND T OOLS........................................................43

10 LIST OF COMPONENTS ...............................................................49

Page 4 of 51 3 rd Edition (07/99) en

1.1 Built-in safety systems

1.2 Safety measures (to be taken by operator)

en 3 nd Edition (07/99) Page 5 of 51

2 GENERAL INFORMATION ABOUT DANGERS

2.1 Danger zone

2.2 Operators and maintenance personnel

 Adhere to the following accident prevention regulations:

Page 6 of 51 3 rd Edition (07/99) en

2.3 Use of spare parts and wearing parts

en 3 nd Edition (07/99) Page 7 of 51

3 DESIGN AND SPECIFICATIONS

3.1 Brief description

Page 8 of 51 3 rd Edition (07/99) en

3.2 Operating data

Nominal oil filter fineness upstream of TC : max. 25 µm

en 3 nd Edition (07/99) Page 9 of 51

3.3 Pipe connections

 Dimensions are specified in mm!

Exhaust gas Inlet single - nozzle housing (1x) O 150 mm

Inlet double - nozzle housing (2x) O 110 mm

Inlet triple - nozzle housing (3x) O 100 mm

Outlet 185 x 500 mm

Charge air Outlet O 175 mm

Lubricating oil Inlet at bearing housing M27x2

Outlet at bearing housing Pipe 45 x 2

Cooling water Inlet at bearing housing Pipe 35 x 2

Outlet at bearing housing Pipe 35 x 2

Compressor washing Air piping Pipe 12 x 1 St

Water piping Pipe 12 x 1,5 Cu

Turbine washing Water piping Pipe 12 x 2

Pipes have to be laid free of stress in any case.

Page 10 of 51 3 rd Edition (07/99) en

3.4 Test connections

en 3 nd Edition (07/99) Page 11 of 51

3.5 Dimensions of important subassemblies

Exhaust gas turbocharger, cpl. 450 kg

Page 12 of 51 3 rd Edition (07/99) en

4 INSTRUCTIONS FOR MOUNTING TURBOCHARGER

4.1 General requirements

4.2 Console for the TC

4.3 Gas and air pipings

en 3 nd Edition (07/99) Page 13 of 51

4.4 Loads of housings of the exhaust gas turbocharger

Maximum admissible forces and moments

While dimensioning the compensator and the diffuser, make sure to

Recommended compensator rigidity : < 300 N/mm

Page 14 of 51 3 rd Edition (07/99) en