NR15-R Operating Manual

Technical Documentation
Exhaust Gas Turbocharger

Operating Manual
Exhaust gas turbocharger . . . . . . . . . . NR15/R

Works No. . . . . . . . . . . . . . . . . . . . . . . .
D36 5654-- 2 E
MAN B&W Diesel Aktiengesellschaft S 86224 Augsburg, Germany S Phone +49 821 322 0 S Fax +49 821 322 3382
5654 C--02 E 06.02 101/ 02

E 1989 MAN B&W Diesel AG
All rights reserved, including the reproduction in any form or by photomechanical means (photocopy/microcopy), in
whole or in part, and the translation.
5654 C--02 E 06.02 102/ 02

Table of contents
h 0 Introduction
S S S h 0.51 Preface
S S S h 0.52 Product Liability
S S h 0.53 Addresses/Telephone numbers
S S S h 0.54 Destination/suitability of the turbocharger
S S S h 0.55 Risks/dangers
S S S h 0.56 Safety regulations
S S S h 0.57 Safety instructions
h 1 Technical data
S h 1.51.1 Exhaust gas turbocharger Brief description, function

S S S h 1.51.2 Rating data
S S h 1.51.3 Operating data, temperatures, pressures
S S h 1.51.4 Weights
S S h 1.51.5 Pipe connections
S S h 1.52 Gaps and clearances
h 2 Systems
S S h 2.51 Lube oil system

S S h 2.54 Acceleration system -- Jet Assist
h 3 Operation
S S h 3.51 Starting, Operation, Stopping

S S h 3.52 Operating faults, Trouble shooting (Fault--finding chart)
Categories of information
Information
Description
Instruction
Data/formulas/symbols
Intended for ...
Experts
Middle management
Upper management
5654 09.07 NR15/R 101 /03

S S h 3.53 Emergency operation on failure of one turbocharger
h 4.1 Maintenance
S S h 4.51 Maintenance work

S S h 4.52 Cleaning
S S h 4.53 Checking the individual Components
S S S h 4.54 Maintenance schedule (explanations)
S S h 4.55 Maintenance schedule (signs/symbols)
S S h 4.56 Maintenance Schedule (Turbocharger)
S S h 4.57 Check list
S S h 4.58 Service Report
h 4.2 Work Cards
h 5 Spare parts catalogue
S S h 5.51 Organisation and Use of the Spare Parts Catalogue

S S h 5.52 Ordering Spare Parts
h 5.55 List of Assemblies
h 501.01 Gas--admission casing
h 506.01 Gas outlet casing
h 509.01 Gas outlet diffuser
h 513.01 Turbine nozzle ring
h 517.01 Bearing casing
h 520.01 Rotor complete
h 542.01 Diffuser
h 544.01 Silencer
h 544.02 Silencer
h 545.01 Air intake casing
h 546.01 Compressor casing
h 562.01 Speed measuring device
h 578.01 Cleaning device for turbine
h 579.01 Cleaning device for compressor
h 591.01 Coverings
Information
Description
Instruction
Intended for ...
Experts
Middle management
Upper management
5654 09.07 NR15/R 102 / 03

h 599.01 Cartridge
h 6 Reserve Parts, Tools
h 594 List of reserve parts

h 596 List of tools
Information
Description
Instruction
Intended for ...
Experts
Middle management
Upper management
5654 09.07 NR15/R 103 /03

Introduction
0 Introduction
1 Technical Data
2 Systems
3 Operation
4.1 Maintenance
4.2 Work Cards
5 Spare Parts Catalogue
6 Reserve Parts, Tools
5649 0--01 E 03.02 101/ 01

Table of contents
h 0 Introduction
S S S h 0.51 Preface
S S S h 0.52 Product Liability
S S h 0.53 Addresses/Telephone numbers
S S S h 0.54 Destination/suitability of the turbocharger
S S S h 0.55 Risks/dangers
S S S h 0.56 Safety regulations
S S S h 0.57 Safety instructions
Information
Description
Instruction
Intended for ...
Experts
Middle management
Upper management
5654 09.07 NR15/R 101 /01

Preface 0.51
Characteristics of turbochargers, Turbochargers produced by MAN B&W Diesel AG have evolved from
justified expectations, periods of continuous, successful research and development work. They
prerequisites satisfy high standards or performance and have ample redundancy of
withstanding adverse or detrimental influences. However, to meet all the
requirements of practical service, they have to be used to purpose and
serviced properly. Only with these prerequisites can unrestricted efficiency
and long useful life be expected.
Purpose of the The operating manual as well as the work cards are thought to assist you
operating manual in becoming familiar with the turbocharger and the equipment. They are
and also thought to provide answers to questions that may turn up later on,
work cards and to serve as a guidance in your activities of engine operation, checking
and servicing. Furthermore, we attach importance to familiarising you with
the functions, relations, causes and consequences, and to conveying the
empirical knowledge we have. Not the least, in providing the technical
documentation including the operating manual and work cards, we comply
with our legal duty of warning the user of the hazards which can be caused
by the turbocharger or its components - in spite of a high level of
development and much constructive efforts - or which an inappropriate or
wrong use of our products involve.
Turbocharger design The operating manual will be continually updated, and matched to the
design of the engine as ordered. There may nevertheless be deviations
between the sheets of a primiarily describing/illustrating content and the
definite design.
Condition 1 The technical management and also the persons in charge of servicing
works (possibly on order) have to be familiar with the operating manual
and work cards. These should all times be available.
▲▲ Caution! Missing information and disregard for information

can cause injury to persons, damage to property and the
environment.
Please read the operating manual and work cards.
Condition 2 The servicing and overhaul of turbochargers will in each case require
previous training of the personnel in charge. The level of knowledge that is
acquired during such training is a prerequisite to using the operating
manual and work cards. No warranty claims can be derived from the fact
that a corresponding note is missing in these.
▲▲ Caution! Untrained persons can cause injury to persons,

damage to property and the environment.
Never give orders which may exceed the level of knowledge and
experience. Access must be denied to unauthorised personnel.
5649 0.51--01 E 03.02 NR, NA 101/ 01

Product Liability 0.52
The reliable and economically efficient operation of a propulsion system

(inclusive turbocharger) requires that the operator has a comprehensive
knowledge. Similarly, proper performance can only then be restored by
maintenance or repair work if such work is done by qualified specialists
with the adequate expertise and skill. Rules of good workmanship have to
be observed, negligence is to be avoided.
This Technical Documentation complements these faculties by specific

information, and draws the attention to existing dangers and to the safety
regulations in force. MAN B&W Diesel AG asks you to observe the
following:
▲▲ Caution! Neglection of the Technical Documentation, and

especially of the Operating Instructions, Work Cards and Safety
Regulations, the use of the system for a purpose other than intended
by the supplier, or any other misuse or negligent application may
involve considerable damage to property, pecuniary damage and/or
personal injury, for which the supplier rejects any liability
whatsoever.
5649 0.52--01 E 03.02 NR, NA 101/ 01

Addresses/Telephone numbers 0.53
Addresses Table 1 contains the addresses of Works of the

MAN B&W Diesel Aktiengesellschaft.
The addresses of MAN B&W service centers, agencies and authorised

repair workshops can be looked up in the brochure
“Diesel and Turbocharger Service Worldwide”
from the MAN B&W Diesel Aktiengesellschaft.
MAN B&W Diesel AG Company Address

Work Augsburg MAN B&W Diesel Aktiengesellschaft
86224 Augsburg
Germany
Phone +49 821 322 0
Fax +49 821 322 3382
MAN B&W Diesel Aktiengesellschaft
86224 Augsburg
-- Engine Service
Germany
Phone +49 821 322 3930
Fax +49 821 322 3838
86224 Augsburg
-- Turbocharger Service
Germany
Phone +49 821 322 3994
Fax +49 821 322 3998
Work Hamburg MAN B&W Diesel Aktiengesellschaft
Service Center Werk Hamburg
Rossweg 6
20457 Hamburg
Germany
Phone +49 40 7409 0
Fax +49 40 7409 104
Technical Branch Office Hamburg MAN B&W Diesel Aktiengesellschaft
Vertriebsbüro Hamburg
Admiralitätstraße
20459 Hamburg
Germany
Phone +49 40 378515 0
Fax +49 40 378515 10
Table 1. Companies and addresses of the MAN B&W Diesel Aktiengesellschaft
5649 0.53--01 E 03.02 NR, NA 101/ 01

Destination/suitability
of the turbocharger 0.54
Use in accordance with the destination
The delivered turbocharger is destined for (firstly) operation under the

marginal conditions stipulated
D under Technical Data,
D in the scope of supply/technical specification and
D in the order confirmation.
Furthermore destined for (secondly)
D operation using the specified operating media,
D taking into consideration the design/layout of the supply, measuring,
control and regulating systems as well as laying down of the marginal
conditions (e.g. removal space/crane capacities) in accordance with the
recommendations of MAN B &W Diesel AG or according to the state of
the art.
Furthermore destined for (thirdly)
D start, operation and stopping of the engine in accordance with the usual
organisational rules, exclusively by authorised, qualified, trained
persons who are familiar with the plant.
With restrictions destined/suitable for
The turbocharger is with restrictions destined/suitable for:

D operation at operating values resulting in an alarm situation,
D operation in case of failure of supply equipments,
D operation at reduced maintenance expenditures,
D speeded-up acceleration/abrupt loading/unloading to a moderate
extent,
Not destined/suitable for
The Turbocharger is not destined/suitable for:

D operation at operating values due to which engine stop or load
reduction was effected,
D operation in case of failure of supply equipments,
D operation within barred speed ranges,
D operation without appropriate surveillance/supervision,
D operation without maintenance expenditures or if they have been
reduced to a great extent,
D unauthorised modifications,
D use of other than original spare parts,
D long-term shut-down without taking preservation measures.
5649 0.54--01 E 03.02 NR, NA 101/ 01

Risks/dangers 0.55
Dangers due to deficiencies concerning personnel/level of training
Expectations in case of vessel Propeller operation/generator operation (normal operation/operation in

plants road stead):
Chief engineer on board. Operational control by technical officer.
Maintenance work/repair work in the port:

To be carried out by engine operator, technical assistants or technicians
and helpers. For instructions and in difficult cases: technical officer or chief
engineer.
Generator operation (in port):

Operational control by technical officer.
Maintenance work/repair work in port:

As mentioned above.
Supplementary, the following Persons responsible for the operational control must be in possession of a
applies qualification certificate/patent which is in accordance with the national
requirements and international agreements (STCW). The number of
required persons and their minimum qualification are, as a rule, specified
by national requirements, otherwise by international agreements (STCW).
Expectations in case of During operation:

stationary plants (power plants) Plant manager (engineer) available. Operational control/supervision of the
engine and the belonging supply systems by trained and specially
instructed engine operator or technical assistant.
Maintenance work/repair work:

Execution by engine operator, technical assistants or technicians and
helpers. For instructions and in difficult cases: engineer or chief engineer.
Supplementary, the following For persons responsible for the operational control and for persons
applies carrying out/supervising maintenance and repair work, proof must be
furnished in Germany in accordance with the power economy law
(Energiewirtschaftsgesetz = EnWG) that, among other things, the
technical operation is ensured by a sufficient number of qualified
personnel. In other countries, comparable laws/guidelines are to be
observed. Deficiencies regarding personnel/level of training cannot be
compensated by other efforts.
Dangers due to components/systems
Certain dangers do of course originate from technical products and from

certain operating conditions or actions taken. This also applies to engines
and turbochargers in spite of all efforts in development, design and
manufacturing. They can be safely operated in normal operation and also
under some unfavourable conditions. Nevertheless, some dangers
remain, which cannot be avoided completely. Some of them are only
potential risks and some do only occur under certain conditions or in case
of unforeseen actions. Others do absolutely exist.
5649 0.55--01 E 03.02 NR, NA 101/ 02

Dangers due to emissions
Emission Danger Preventive/protective measure

Treated cooling water, lube oil, Harmful to skin and noxious, Use/dispose in accordance with the
hydraulic oil, fuel polluts water instructions of the
manufacturers/suppliers
Cleaning agents and aids According to the manufacturers’ Use/dispose in accordance with the
specification instructions of the
manufacturers/suppliers
Exhaust gas with the dangerous Noxious, has a negative effect on Carry out maintenance work
constituents NOx, SO2, CO, HC, soot the the environment in case the according to the maintenance
limit values are exceeded schedule, maintain danger--oriented
operational control, critically
observe operating results
Sound Noxious, has a negative effect on Wear ear protection, restrict
the environment in case the limit exposure to the necessary
values are exceeded minimum
Planned working places
Engines are usually operated under remote control. Regular rounds

according to the rules of “observation--free operation” are required. In this
connection, measurement, control and regulating devices as well as other
areas of the plant, which require special attention, are preferably checked.
A continuous stay in the immediate vicinity of the running engine/
turbocharger is not planned.
Personal protective measures
The regulations for prevention of accidents (Unfallverhütungsvorschriften =

UVV) and other regulations of the proper trade association or other
comparable institutions are to be observed without restriction.
This includes wearing of protective working clothing and safety shoes, the
use of a safety helmet, safety goggles, ear protection and gloves.
The relevant sections of the technical documentation must be read and

comprehended.
5649 0.55--01 E 03.02 NR, NA 102/ 02

Safety regulations 0.56
Preliminary remarks
Personell The engine and the systems required for its operation may only be started,
operated and stopped by authorised personell. The personell has to be
trained for this purpose, possess complete understanding of the plant and
should be aware of the existing potential risks.
Technical documentation The personnel must be familiar with the technical documentation of the
plant, in particular the operating manual of the engine, the turbocharger
and the accessories requiered for engine operation, particularly the safety
regulations contained therein.
Service log book It is advisable to keep a service log book into which all the essential jobs
and deadlines for their performance, the operating results and special
events can be entered. The purpose of this log book is that in the event of
a change in personnel the successors are in a position to duly continue
operation using this data log. Moreover, the log book permits to derive a
certain trend analysis and to trace back faults in operation.
Accident prevention regulations The accident prevention regulations applicable for the plant should be
observed during engine operation as well as during maintenance
operations and overhauls. It is advisable to post those regulations
conspicously in the engine room and to stress the danger of accidents
over and over again.
Warranty claims The given advices does not claim to be complete. Safety requirements
mentioned in other passages of the technical documentation are
supplementarily valid and are to be observed in the same way.
Please also note that incorrect behaviour might result in the loss of
warranty claims.
Precautions
Opening of pipes/pressure Before opening pipes, flanges, screwed connections or fittings, check if
vessels the system is depressurised respectively emptied.
▲ Attention! Disregarding this means: risk of burns when hot

fluids are involved, fire hazard in case of fuel, injuries caused by
flung-out screw plugs or similar objects when loosening same under
pressure.
Disassembling/assembling In case of disassembly, all pipes to be reinstalled, especially those for fuel
pipelines oil, lube oil and air, should be carefully locked. New pipes to be fitted
should be checked whether clean, and flushed if necessary. It should in
each case be avoided that any foreign matter gets into the system. All
parts involved have to be subjected to preservation treatment for
prolonged storage.
Removing/refitting of heavy When removing or detaching heavy engine components it is imperative to

engine components ensure that the transportation equipment is in perfect condition and has
the adequate capacity of carrying the load. The place selected for
5649 0.56--01 E 03.02 NR, NA 101/ 02

depositing must also have the appropriate carrying capacity. This is not
always the case with platforms, staircase landings or gratings.
Coverings Following assembly work, check whether all the coverings over moving
parts and laggings over hot parts have been mounted in place again.
Engine operation with coverings removed is only permissible in special
cases, e.g. if the valve rotator is to be checked for proper performance.
▲ Attention! Loose clothing and long hair might get entangled.

Spontaneous supporting against moving parts when loosing ones
balance may result in serious injury. In addition, there is the risk of
burning and/or fire.
Use of cleaning agents When using cleaning agents, observe the suppliers instructions with
respect to use, potential risks and disposal.
▲ Attention! Disreagarding this means: danger of caustic skin and

eye injury, and also of the respiratory tract if vapours are produced.
▲ Attention! Using Diesel fuel for cleaning purposes involves the

risk of fire or even explosion. Otto fuel (petrol) or chlorinated
hydrocarbons must not be used for cleaning purposes.
Use of high-pressure cleaning When using high-pressure cleaning equipment, be careful to apply this
equipment properly. Air filters, shaft ends including ones with lip seal rings,
controllers, splash water protected monitoring equipment, cable entries
and sound/heat insulating parts covered by water-permeable materials
have to be appropriately coverd or excluded from high-pressure cleaning.
Fire hazard The use of fuel and lube oils involves an inherent fire hazard in the engine
room. Fuel and lube oil pipes must not be installed in the vicinity of
unlagged, hot engine components (exhaust pipe, turbocharger). After
carrying out overhaul work on exhaust gas pipes and turbochargers, all
insulations and coverings must be carefully refitted completely. The
tightness of all fuel oil and oil pipes should be checked regularly. Leaks are
to be repaired immediately.
Fire extinguishing equipment must be available and is to be inspected

periodically.
In case of fire, the supply of fuel and lube oil must be stopped immediately
(stop the engine, stop the supply pumps, shut the valves), and the fire
must be attempted to be extinguished using the portable fire-fighting
equipment. Should these attempts be without success, or if the engine
room is no longer accessible, all openings are to be locked, thus cutting off
the admission of air to quench the fire. It is a prerequisite for success that
all openings are efficiently sealed (doors, skylights, ventilators, chimney as
far as possible). Fuel oil rquires much oxygen for combustion, and the
isolation from air is one of the most effective measures of fighting the fire.
▲▲▲ Danger! Carbon dioxide fire extinguishing equipment must

not be used until it has been definitely ensured that no one is in the
engine room. Ignoring this means danger of life!
5649 0.56--01 E 03.02 NR, NA 102/ 02

Safety instructions 0.57
Characterisation/danger scale
Characterisation According to the relevant laws, guidelines and standards, attention must
be drawn to dangers by means of safety instructions. This applies to the
marking used on the product and in the technical documentation. In this
connection, the following information is to be provided:
D type and source of danger,
D imminence/extent of danger,
D possible consequences,
D preventive measures.
Danger scale The imminence/extent of danger is characterised by a five--step scale as

follows:
▲▲▲ Danger! Imminent danger

Possible consequences:
Death or most severe injuries,
total damage to property
▲▲ Caution! Potentially dangerous situation

Possible consequences: Severe injuries
▲ Attention! Possibly dangerous situation

Possible consequences: Slight injuries,
possible damage to property
Important! For calling attention to error sources/handling errors
Tip! For tips regarding use and supplementary information
Remarks next to this sign are of special importance on the basis of service
experiences.
However, only the signs of the safety instructions indicate the importance.
5649 0.57--01 E 11.04 NR, NA 101/ 04

Warning instruction sign, danger spots on the turbocharger
With each MAN B&W turbocharger, warning instruction signs about

possible injury risks that can be caused through the turbocharger are
supplied.
Important!
The warning instruction signs are to be posted to the engine system
and to the entrances towards the engine room by the engine manu-
facturer or the system operator where they are well visible!
Figure 1. Warning instruction sign
Persons who have to proceed to the danger area of the engine for opera-
tional reasons are to be instructed with regard to the prevailing dangers.
Admittance to the danger area is permitted on condition that the engine is
in proper operating condition and only if a suitable safety outfit is worn.
An unnecessary stay within the danger area is prohibited.
5649 0.57--01 E 11.04 NR, NA 102/ 04

Explanations with regard to the warning instruction sign,
meaning of the symbols Warning notices
Attention!
Beware of a danger spot!
Inflammable material!
Beware of hand injuries

Danger of bruising!
Hot surface!

meaning of the symbols Prohibitions
Fire, open light and smoking are forbidden!
No admittance for unauthorised persons!
5649 0.57--01 E 11.04 NR, NA 103/ 04

meaning of the symbols Imperative
Use ear protection!
Wear a hard hat!
Use eye protection!
Wear protective clothing!
Wear safety shoes!
Wear protective gloves!
Observe the operating instructions/

working instructions!
5649 0.57--01 E 11.04 NR, NA 104/ 04

Technical data
0 Introduction
1 Technical Data
2 Systems
3 Operation
4.1 Maintenance
4.2 Work Cards
5649 1--01 E 03.02 101/ 01

Table of contents
h 1 Technical data
S h 1.51.1 Exhaust gas turbocharger Brief description, function

S S S h 1.51.2 Rating data
S S h 1.51.3 Operating data, temperatures, pressures
S S h 1.51.4 Weights
S S h 1.51.5 Pipe connections
S S h 1.52 Gaps and clearances
Information
Description
Instruction
Intended for ...
Experts
Middle management
Upper management
5654 09.07 NR15/R 101 /01

Exhaust gas turbocharger
Brief description, function 1.51.1
-
Figure 1. Exhaust gas turbocharger NR15/R
Brief description Turbocharger with one radial--flow turbine stage and one radial--flow compressor stage.
Rotor supported on 2 floating bearing bushes arranged inboard.
Turbine wheel (3) with shaft in one integral piece, compressor wheel (8) mounted on shaft.
Compressor (10) with one outlet socket.
Silencer (6a), or air intake casing (6b), if provided.
Bearing lubrication integrated in engine lube oil circuit.
No water cooling. Casings on turbine side with heat insulation.
Function In operation the engine exhaust gases drive the turbocharger rotor by converting the
exhaust gases into energy. The exhaust gases flow from the engine exhaust pipe
through the turbocharger via the gas--admission casing (1), turbine nozzle ring (2),
turbine wheel (3), gas outlet diffuser (4) and gas outlet casing (5).
Simultaneously, fresh air is drawn in via the silencer (6a) or air intake casing (6b) and
compressed via compressor wheel (8), diffuser (9) and compressor casing (10).
Via charge air cooler and charging air pipe the compressed air is pressed into the
engine cylinders. Generally this process achieves a tremendous increase in the
performance of the engine. Flow areas and directions of flow are adjusted to the
individual application.
The rotor of the turbocharger is guided through 2 floating bearing bushes arranged
between turbine wheel (3) and compressor wheel (8) in the bearing casing (11).
The turbocharger bearings are lubricated by the lube oil circuit of the engine via a
common feed pipe. The lube oil serves as well for the cooling of the bearings.
5654 1.51.1--01 E 08.02 NR15/R 101/ 01

Rating data 1.51.2
Relation of the Turbocharger/engine
Turbocharger Engine
Type Type Rating [kW] Speed [rpm]
NR15/R ......
Type plate of the turbocharger
Type NR15/R . . . . . . . . . . . . . . . refer to the type plate

(mounted at the pressure socket
of the compressor)
Works--No. . . . . . . . . . . . . . . . . . . . . . . . refer to the type plate

(mounted at the pressure socket
of the compressor)
Maximum admissible speed n max . . . . . . . . . . 57,000 [rpm]

(operating limit)
Maximum admissible exhaust t max . . . . . . . . . . . . . 650 [ °C ]

gas temperature before turbine
(operating limit)
Further data
Display range of the 0 ... 60,000 [rpm]

speed transmitter
Operating speed of the refer to the Acceptance Records of the turbocharger

turbocharger
Further operating data refer to the Acceptance Records and Operating Manual of the engine
5654 1.51.2--01 E 06.02 NR15/R 101/ 01

Operating data,
temperatures, pressures 1.51.3
Lube oil
Selection of lube oil SAE-class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 30 or SAE 40
Filtration of lube oil grade of filtration smaller than . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm
Operating temperature maximum permissible oil admission temperature . . . . . . . . . . . . . 75 °C
maximum permissible oil outlet temperature . . . . . . . . . . . . . . . . . 105 °C
Operating pressure using SAE 30 at 60° C or SAE 40 at 65° C

(reference measuring height on turbocharger centreline)
S normal operation and full engine load . . . . . . . . . . . . . . . 1.5 ± 0,2 bar
S alarm and reduction to engine half load (slow-down) . . . . . ≤ 1.0 bar
S engine stop (shut-down) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ≤ 0.8 bar
Flow rate of lube oil using SAE 30 at 60° C or SAE 40 at 65° C . . . . . . . . . . . . . . . . . 600 l/h
Further remarks refer also to the “Lube oil system”, sheet 2.51
5654 1.51.3--01 E 06.02 NR15/R 101/ 01

Weights
1.51.4
Weights assigned to assemblies/components (approximate values)
List of assemblies (500 ... 599), please refer to section 5, Spare Parts Catalogue
500 Exhaust gas turbocharger, complete (with 506 and 544) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 kg
501 Gas--admission casing, complete (with covering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 kg
506 Gas outlet casing, complete (with covering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 kg
509 Gas outlet diffuser, complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 kg
513 Turbine nozzle ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 kg
517 Bearing casing, complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 kg
520 Rotor complete (turbine rotor .... 4 kg, compressor wheel ... 1.5 kg) . . . . . . . . . . . . . . . . . . . . . . . 6 kg
542 Diffuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 kg
544 Silencer, complete (if provided) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 kg
545 Air intake casing, complete (if provided) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 kg
546 Compressor casing, complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 kg
599 Cartridge, complete (517 + 520) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 kg
5654 1.51.4--01 E 06.02 NR15/R 101/ 01

Pipe connections 1.51.5
Pipe connections
Exhaust gas Entry at the gas--admission casing (501) . . . . . . . . . . . . mm 1 x 205 dia.
or . . . . . . . . . . . . . mm 1 x 150 dia.
or . . . . . . . . . . . . . mm 2 x 85 dia.
Outlet at the gas outlet casing (506) . . . . . . . . . . . . . . . . mm 110 x 400
Charge air Outlet at the compressor casing (546) . . . . . . . . . . . . . . . mm 105 dia.
Lube oil Inlet at the top of bearing casing (517)

for pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 12.0 x 1.5
Drain at the bottom of bearing casing (517)

flange connection for pipe . . . . . . . . . . . mm 28.0 x 2.0
Additional lubrication Inlet laterally at the bearing casing (517)

(if provided) for pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 8.0 x 1.5
Jet assist Connection laterally at the compressor casing (546)

(if provided) flange connection for pipe . . . . . . . . . . . mm 25.0 x 2.0
5654 1.51.5--01 E 06.02 NR15/R 101/ 01

Gaps and clearances 1.52
-
Figure 1. Gaps and clearances
Item Designations Order No. When new Replace or

No. of parts remachine parts
min [mm] max [mm] min [mm] max [mm]
1 a) Compressor wheel (520.005)
Radial gap 0.50 0.60 0.40 0.70
Compressor casing (546.001)
2 b) Compressor wheel (520.005)
Axial gap 0.30 0.90 0.25 1.00
Compressor casing (546.001)
3 a) Turbine rotor (520.001)
Radial gap 0.50 0.57 0.40 0.70
Gas--admission casing (501.001)
4 d) Turbine rotor (520.001)
Axial gap 0.50 0.90 0.40 1.00
Gas--admission casing (501.001)
5 e) Bearing bush (517.002)
Axial clearance 0.20 0.27 ------ 0.33
Labyrinth ring (520.006)
6 admissible aberration from the plane of rotation
Compressor wheel (520.005)
(face runout) ................... 0.06 mm
Admissible transverse play of the rotor in bearings please refer to work card 500.06
a) Using feeler gauge, measure at 4 points on the circumference and calculate mean value.
b) Measure by means of soft metal imprint (lead wire) at 3 points on the circumference and calculate the
mean value. Deduct the measured axial clearance (5) from calculated mean value with the rotor pushed up
in direction (B).
d) Measure by means of soft metal imprint (lead wire) at 3 points on the circumference and calculate the
mean value. Deduct the measured axial clearance (5) from calculated mean value with the rotor pushed up
in direction (B).
e) Using the dial gauge, measure while vigorously moving the rotor in the directions (A) and (B). In case of
labyrinth seals already run in it might be possible that the measured value is smaller.
5654 1.52--01 E 06.02 NR15/R 101/ 01

Systems
0 Introduction
1 Technical Data
2 Systems
3 Operation
4.1 Maintenance
4.2 Work Cards
5649 2--01 E 03.02 101/ 01

Table of contents
h 2 Systems
S S h 2.51 Lube oil system

S S h 2.54 Acceleration system -- Jet Assist
Information
Description
Instruction
Intended for ...
Experts
Middle management
Upper management
5654 09.07 NR15/R 101 /01

Lube oil system 2.51
Lube oil system The turbocharger rotor is guided in radial direction through 2 floating bearing
(see figure 1) bushes (4) arranged between turbine wheel and compressor wheel in the bearing
casing.
The turbocharger bearings are lubricated by the lube oil circuit of the engine via a
common feed pipe (2). The lube oil serves as well for the cooling of the bearings.
Designs/possibilities The figure 1 shows several possibilities of lube oil supply. The scope required
for the installation of the respective engine system can be selected by the
following criteria:
D For engines ... that are primed immediately prior to start--up (standard design)
Feed pipe (2), throttle point (3), discharge pipe (6), sight glass/venting box (7),
venting pipe (8), connection for pressure monitoring (9, 10).
D For engines ... being primed at intervals or continuously (e.g. stand--by engines)
Feed pipe (2) with non--return valve (14), throttle point (3), additional feed
pipe (12), discharge pipe (6), sight glass/venting box (7), venting pipe (8),
connection for pressure monitoring (9, 10).
The non--return valve (14) is to be fitted as closely to the feed pipe (1) as
possible, and it should be in closed position during priming and after the lube oil
pumps have been switched off. Tis prevents overlubrication of the turbocharger
on priming on the one hand, and a draining of the feed pipe (2) causing air to
enter, on the other.
D For engines ... with retarded engine shut--down in case of dropping lube oil pressure (special design)
Further to the two possibilities mentioned above, a connection of the
hydro--pneumatic accumulator (15) is necessary. Moreover, engines being primed
immediately prior to start--up a non--return valve (14) which, however, is to open
at minimal priming pressure already.
Lube oil pressure The measuring connection at the entry to the bearing casing is to be used for
controlling and monitoring the lube oil pressure.
The lube oil pressure is to be so adjusted that a pressure of 1.5 ± 0.2 bar prevails at
this point at full engine load and with the lube oil at service temperature (inlet
temperature max. 75 °C).
On start--up and during heating up of the engine, when the lube oil temperature is
relatively low, a lube oil pressure of up to 2.0 bar is admissible for a short period of
time.
The necessary lube oil pressure is set by means of a throttle point (3, e.g. an orifice
≥
or pressure reducing valve) in the feed pipe (2).
In case of engine lube oil pressures 2.5 bar, we recommend the installation of a
pressure reducing valve with outlet control.
Differences in hight Differences in height between the indicating instrument and turbocharger
centreline must be made allowance for with ± 0.1 bar per 1.0 metres difference.
Example: If the pressure gauge (9) and/or the pressure controller (10) is located
3.0 metres lower, the pressure gauge must indicate a by 0.3 bar higher pressure
and/or the setting of the pressure controller must by 0.3 bar be higher than the
operating pressure specified above.
5649 2.51--02 E 02.01 NR 101/ 03

Alarm/engine shut--down The alarm point is to be adjusted to a value of 1.0. When an alarm is triggered,
the engine performance has to be reduced simultaneously (without delay) to half
load (engine slow--down).
If the oil pressure continues to drop, the engine is to be stopped and the causes
are to be remedied. The limit value for engine shut--down is at 0.8 bar lube oil
pressure.
If it is not allowed to stop the engine for an important reason, damages of the
turbocharger are to be expected.
Lube oil flow rate The required lube oil flow rate depends on the viscosity of the lube oil and may
differ from that stated in the Operating data (see sheet 1.51).
Lube oil quality The plain bearings are rated for use of standard engine lube oils SAE30 or
SAE40 and can therefore be directly connected to the lube oil system of the
engine.
Lube oil filtration The turbocharger does not require its own lube oil filter. The filtration which
nowadays is the standard for engines is adequate, provided that the fineness is
smaller than/equal to 0.05 mm. A precondition is that the engine lube oil is
permanently treated by separation and excessive concentrations of water of more
than 0.2 % portion by weight and solid residues larger than 0.02 mm are avoided.
Prior to initial operation of the engine or after major servicing work, the pipes
between the filter and turbocharger are to be cleaned, pickled and flushed
carefully.
Priming Prior to engine start--up, the bearings of the turbocharger must be primed, which,
depending on the lube oil system of the engine system, is done by priming
immediately prior to start--up, or by interval or continuous priming.
Post lubrication For cooling the plain bearings, the turbocharger has to be lubricated after engine
stop with a lube oil pressure of min. 0.3 bar. The engine lube oil pumps or the
auxiliary pumps must therefore continue running for 10 ... 30 minutes.
Lube oil drain The discharge pipe (6) should have a gradient as steep as possible, and it should
be amply dimensioned and free of resistances and back pressures. On ships, the
inclination of the line should be not less than 5° more than the maximum possible
inclination of the vessel.
The oil discharge pipe must have a venting facility from a sufficiently large
compartment permitting the oil to settle down, e.g. a sight glass/venting box (7).
The cross section of the venting pipe (8) should be approximately that of the oil
discharge pipe (6).
Shaft sealing The oil space is sealed on the turbine and compressor sides by labyrinths fitted
on the rotor shaft. The radial labyrinth clearance should be such that the rotating
labyrinth tips slightly dig into the softer sealing cover layer. At higher speeds, the
rotor is slightly lifted corresponding to the lubricating film, so that the labyrinth tips
come clear. The rotor will be lowered when the turbocharger stops. The labyrinth
tips will then come down into the grooves in the sealing covers, providing better
sealing during priming. Local running--in grooves in the bore of the sealing covers
are therefore desirable and no reason for replacement of parts.
Sealing air For the shaft sealing on turbine side, sealing air (compressed air) is additionally
required:
D against entry of exhaust gas into the oil space,
D against trickle of lube oil into the turbine (oil coke)
During operation, the sealing air (11) is withdrawn downstream of the compressor
wheel and led to the labyrinth seal on the turbine side via ducts drilled into the
bearing casing.
5649 2.51--02 E 02.01 NR 102/ 03

1 Feed pipe (engine) 7 Sight glass or 12 Feed pipe
2 Feed pipe (turbocharger) venting box (interval or
3 Throttle point (orifice or 8 Venting pipe continuous priming)
pressure reducing valve) 9 Pressure gauge 14 Non--return valve
4* Bearing bush 10 Pressure controller 15 * Hydro--pneumatic
6 Discharge pipe 11 * Sealing air accumulator
* Scope of supply of turbocharger
Figure 1. Lube oil system, Turbochargers NR
Retarded engine shut--down (special design)
Retarded engine shut--down In engine systems with lube oil pressure monitoring (alarm and/or engine stop
when the set points are fallen below), a retarded engine shut--down leaves a
moment to decide whether the engine should be stopped to avoid damage to the
engine and turbocharger, or whether a necessary manoeuvre should be continued
to avert major damage. An oil pressure accumulator providing for temporary
lubrication of the turbocharger is required for this purpose.
Pressure accumulator A hydro--pneumatic accumulator (15) with a nominal capacity of 10 litres permits
the decision of engine shut--down to be retarded by a maximum of 10 seconds. If
retarded longer, operational safety will be jeopardised, and the turbocharger must
be expected to suffer damage.The hydro--pneumatic accumulator (15) is to be
appropriately positioned max. 2.0 metres below the highest point of feed pipe (2),
between the throttle point (3) and the non--return valve (14).
The service temperature is max. +80°C.
5649 2.51--02 E 02.01 NR 103/ 03

Acceleration system - Jet Assist 2.54
-
A Starting-air bottle (30 bar) C Orifice E Compressor wheel

B 2/2 way solenoid valve D Insert F Turbocharger
Figure 1. Jet Assist diagram
Functional Description The Jet Assist acceleration system is used when special requirements are
made towards swift and possible soot-free acceleration, and/or towards
the load applications of the engine.
The engine control actuates the 2/2 way solenoid valve (B). Compressed
air of 30 bar now flows from the starting-air bottle (A) through the
orifice (C), where it is reduced to a maximum of 4 bar. The compressed air
is now blown onto the blades of the compressor wheel (E), which is done
via a ring duct and the inclined bores in the insert (D).
On the one hand, this provides additional air to the compressor while on
the other hand, the compressor wheel is accelerated, thus increasing the
charge-air pressure for the engine.
5649 2.54--01 E 07.05 NR, NA 101/ 01

Operation
0 Introduction
1 Technical Data
2 Systems
3 Operation
4.1 Maintenance
4.2 Work Cards
5649 3--01 E 03.02 101/ 01

Table of contents
h 3 Operation
S S h 3.51 Starting, Operation, Stopping

S S h 3.52 Operating faults, Trouble shooting (Fault--finding chart)
S S h 3.53 Emergency operation on failure of one turbocharger
Information
Description
Instruction
Intended for ...
Experts
Middle management
Upper management
5654 09.07 NR15/R 101 /01

Starting, Operation, Stopping 3.51
Preparations for start
Turbocharger Prior to engine start--up, the bearings of the turbocharger must be primed,
which, depending on the lube oil system of the engine system, is done by
priming immediately prior to start--up, or by interval or continuous priming.
Engine/Turbocharger Ensure that the shut--off elements of the systems have been set to
in--sevice position. Check the lube oil pressure upstream of the
turbocharger.
Starting
Turbocharger The turbocharger is driven by the exhaust gases and starts automatically
on engine start.
Operation
General State-of-the-art engine systems are operated automatically as a rule,

using intelligent control and regulation systems. Dangers and damage are
precluded to a large extent by internal testing routines and monitoring
equipment. Regular checks are necessary nevertheless so as to recognise
the cause of potential problems as early as possible, and to take remedial
action in due time. Moreover, the necessary maintenance work should be
done as and when required.
It is the operator’s duty to carry out the checks listed below. Results,
observations and actions taken in connection with such checks should be
entered in an engine log book. Reference values should be defined so as
to make an objective assessment of findings possible.
Regular checks The regular checks should include the following measures:
on the turbocharger D Turbine speed
D Lube oil pressure upstream of turbocharger
D Lube oil temperature upstream of turbocharger
D Lube oil temperature downstream of turbocharger
D Exhaust gas pressure upstream of turbine
D Exhaust gas temperature upstream of turbine
D Charge air pressure downstream of compressor
D Charge air temperature downstream of compressor
D Exhaust gas, charge--air and oil--carrying pipes and conduits for tightness
D Air filter mat on the silencer for dirt accumulation / saturation
D Turbocharger for quiet running
Quiet running Damage to the rotor and bearings is in most cases announced by irregular
running due to imbalance or contact of rotating parts. Listening to the
running noise of the turbocharger in many cases permits to recognise
irregular running at an early time.
5649 3.51--02 E 03.02 NR, NA 101/ 02

Speed Provided the air ducts of the compressor are properly clean, a specific
charge--air pressure is related to every turbine rotor speed. Therefore it is
possible to conclude the rotor speed from the charge--air pressure as a
rough method of speed control.
Stopping
Turbocharger The rotor of the turbocharger continues rotating for some more time on
engine shut--down, due to the flywheel effect. The run--down time of the
rotor is indicative of the mechanical condition of the turbocharger.
An early stop suggests mechanical damage to the bearings, a touching of
the compressor or turbine wheel, a solid object that has got caught
somewhere or the like.
Post lubrication
≥
Turbocharger For cooling the plain bearings, the turbocharger has to be lubricated after
engine stop with a lube oil pressure of 0.3 bar (on the hight of
turbocharger).
The engine lube oil pumps or the auxiliary pumps must therefore continue
running for 10 ... 30 minutes.
Also refer to the lube oil system, in section 2 of the Operating Manual.
5649 3.51--02 E 03.02 NR, NA 102/ 02

Operating faults, Trouble shooting
(Fault-- finding chart) 3.52
Preliminary conditions
Alarms, signals Alarm--, reduction-- and safety signals serve the purpose of warning
against dangers or of avoiding them. Their causes are to be traced with
the necessary care. The sources of malfunctions are to be eliminated
consistently. They must not be ignored or suppressed, except on instruc-
tions from the management or in cases of a more severe danger.
▲▲ Caution! Ignoring or suppressing of alarms, the cancellation of

reduction and stop signals is highly dangerous, both for persons
and for the technical equipment.
Liability claims for damages due to exceeded nominal values and

supressed or ignored alarm and safety signals respectively, can in no case
be accepted.
Operating faults
Indications Operating faults normally manifests itself by abnormal readings (exhaust

gas temperature, charge--air pressure and speed), by distinct running
noice or by leaks in the oil pipes.
Possible consequential Should anomalies turn up on the turbocharger on starting or during engine
damage operation, the cause is to be traced immediately, if possible, and the fault
is to be eliminated. Otherwise, there will be risk of minor initial faults
causing consequential damage to the turbocharger, and also to the
engine.
First preparations In case of faults, the engine load should be reduced, if possible, or the
engine should be shut down completely and not be restarted before the
cause of faults has been eliminated.
Important! Unsystematic trying out should be avoided because it

will lead to success in rare cases only.
Trouble shooting
Fault--finding chart The fault--finding chart (refer to page 2) is thought to contribute to reliably
recognising trouble that turns up and finding the cause it is due to, and to
taking prompt remedial action.
5649 3.52--02 E 03.02 NR, NA 101/ 02

Exhaust gas temperature before turbine too high
Charge air pressure too low TROUBLES
Charge air pressure too high EXPERIENCED
Speed too low
Speed too high
Lubricating oil pressure too low
Lubricating oil losses
Sluggish starting or short run--down time
Abnormally high noise level
Turbocharger developing vibrations
Compressor surging
POSSIBLE CAUSES
Silencer or air filter fouled
Compressor fouled
Turbine wheel heavily fouled
Turbine nozzle ring slightly fouled / narrowed
Turbine nozzle ring heavily fouled / narrowed
Trust ring, labyrinth ring or locating ring damaged
Labyrinth seals defective
Seals damaged, leaking connections
Defective bearings, imbalance of the rotor
Rotor rubbing
Foreign bodies before or in turbine
Foreign bodies before or in compressor
Turbine or compressor wheel damaged
Sealing air ineffective, oil coke behind turbine wheel
Large erosion on turbine wheel/shroud ring, nozzle ring
High air inlet temperature
Low air inlet temperature
Intercooler fouled
Leaking charge air pipe
Charge air temperature too high
Lubricating oil inlet temperature too high
Lubricating oil pressure too high
Dirty lubricating oil filter
Lubricating oil pressure gauge disturbed
Excessive pressure in oil discharge or crankcase
Deposits on inlet or exhaust valves / slots of engine
Leaking exhaust gas pipe
Exhaust gas backpressure after turbine too high
Fuel injection system on engine disturbed
5649 3.52--02 E 03.02 NR, NA 102/ 02

Emergency operation on failure
of one turbocharger 3.53
Preliminary remarks
Turbochargers are turbo machines subjected to high stresses which must

reliably ensure the entire gas renewal performance of the engine at very
high speeds and relatively high temperatures and pressures. Like the
engine, the turbocharger can also suffer disturbances, despite careful
system operation, and emergency operation is also possible in most cases
unless the damage can be repaired immediately.
Means available The following means are availabe for emergency operation of the engine
with the turbochargers defective:
NR turbochargers: refer to work card 500.05

D End cover to close the turbine rear side with the rotor and bearing
housing removed (cartidge)
NA turbochargers: refer to work cards 500.05
D Arresting key to block the rotor from the compressor side (the suction
cross-sectional opening remains unclosed) -- such a key is also
available for NR 34/S,
D end cover to close the compressor and turbine rear side with the rotor
dismantled.
All of these elements are so designed that the flow is not obstructed on the
air side and exhaust side of the turbocharger.
Means for use on the engine:

D Cover piece (protection grid) for the far end of the turbocharger
charge-air pipe (remove the charge-air bypass pipe before if required).
This cover piece serves to facilitate suction.
D Blind flange for the exhaust gas pipe at the end opposite the
turbocharger (if there is a charge-air bypass). The blind flange serves
to lock the exhaust pipe during suction, with the bypass removed.
D In the case of V-type engines, depending on the layout of charge-air
and exhaust pipes on the engine, blind flanges for the charge-air pipe
socket and exhaust pipe socket (charge air side: downstream of the
compressor, exhaust gas side: upstream of the turbine). These blind
flanges serve to prevent wrong switching/backflow/leakage in
emergency operation.
Emergency operation with one The following possibilities exist if the rotor of the turbocharger can no
or both turbochargers failing longer rotate freely, or must be prevented from rotating. Please refer to
Table 1.
5649 3.53--02 E 05.02 NR, NA 101/ 03

Emergency measures Supplementary measures/
provisiones
Code number
Engine stop not permitted for compulsory reasons
Nothing is changed on the turbocharger 1-3
Engine may be stopped (temporarily)
NR turbocharger
● Dismantle the rotor and bearing housing (cartridge), mount the end cover on 1-7
the rear of the turbine (see turbocharger operating manual and relevant work
cards). Gas renewal of the engine is through the partly stripped turbocharger
on the air side and exhaust side.
This possibility exists in case of failure of

1 turbocharger In-line engine
V-type engine
2 turbochargers V-type engine
NA turbocharger
● Measure A
Block the rotor from the compressor side using the arresting key (suction 1-4, 7
opening remains open). Subsequently re-assemble intake air silencer or intake (5-7 depending on
casing. Please refer to turbocharger operating manual and work card 500.05. situation and required)
Take measure A only if measure B cannot be taken for reasons of time.
Consequential damage possible.
● Measure B
Dismantle the rotor with bearings, block the bearing casing by mounting end
covers on the compressor and turbine sides. Reassemble the silencer/intake
casing and the turbine inlet casing, if applicable. Please refer to the 1-7
turbocharger operating manual and work card 500.05.
Possibilities in case of failure of

1 turbocharger In-line engine
V-type engine
2 turbochargers V-type engine
Table 1. Emergency operation with one or both turbochargers failing (continued from preceding page)
Explanations
Code number Supplementary measures/provisions
1 Reduce the engine output. The maximum exhaust gas temperatures

downstream of the cylinders and upstream of the turbocharger and (on
engines equipped with two turbochargers) the maximum admissible
turbocharger speed must not be exceeded. Observe the exhaust gas for
discolouration.
2 Use all the endeavours that appear appropriate to reduce consequential

damage.
3 With the rotor arrested or dismantled, cut off the lube oil supply to avoid
fouling and fire hazards.
4 The engine has to be operated in the naturally aspirated mode, (if

equipped with two turbochargers) with reduced super-charging.
5649 3.53--02 E 05.02 NR, NA 102/ 03

Code number Supplementary measures/provisions
5 In-line engines:
Cover pieces (protection girds) have to be mounted on the charge-air pipe.

On engines equipped with a charge-air bypass, it is also necessary to
mount the blind flange at the exhaust gas side connection.
6 V-type engines
On V-type engines having a common charge-air pipe, a blind flange is to

be mounted on the compressor outlet of the defective turbocharger so as
to avoid air losses.
7 V-type engines
Separate the exhaust gas inlet side of the defective turbocharger from the
gas flow of the second turbocharger by fitting a blind flange.
1 turbocharger failing In-line engine V-type engine

Fixed-pitch
p propeller
p p 15% up to 50%
of the rated output at the
corresponding speed
Controllable-pitch
p 20% up to 50%
propeller/generator
ll / t service
i of the rated output at the rated speed
Table 2. Output/speed that can be reached
5649 3.53--02 E 05.02 NR, NA 103/ 03

Maintenance
0 Introduction
1 Technical Data
2 Systems
3 Operation
4.1 Maintenance
4.2 Work Cards
5649 4.1--01 E 03.02 101/ 01

Table of contents
h 4.1 Maintenance
S S h 4.51 Maintenance work

S S h 4.52 Cleaning
S S h 4.53 Checking the individual Components
S S S h 4.54 Maintenance schedule (explanations)
S S h 4.55 Maintenance schedule (signs/symbols)
S S h 4.56 Maintenance Schedule (Turbocharger)
S S h 4.57 Check list
S S h 4.58 Service Report
Information
Description
Instruction
Intended for ...
Experts
Middle management
Upper management
5654 09.07 NR15/R 101 /01

Maintenance work 4.51
Maintenance Schedule Please refer to sheet 4.56.
General To keep the exhaust gas turbocharger in a good, reliable condition, it is to

be subjected to inspection and checking at various points and at specific
intervals as specified in the maintenance schedule.
Depending on the special conditions in the engine room, the best way of
disassembly has to be chosen. To perform maintenance and control jobs,
it will in most cases be sufficient to strip subassemblies of the
turbocharger. Dismounting the complete turbocharger from the engine
normally will only be required for basic overhaul.
For basic overhaul of the turbocharger, or for repair work involving

essential components, it is recommended to note down the condition of
the individual subassemblies and to include this information in the engine
operating records. A form sheet ”Check list” (4.57) has been enclosed
herein as a sample.
Spare parts Wear and damage suffered, specifically if affecting the strength or balance
precision and hence the running smoothness of rotating parts, require
replacement by original spare parts or repair in an authorised repair shop
or at the works. Rotor components sent out for repair have to be
appropriately packed and protected against corrosion to prevent further
damage in transit.
For ordering original spare parts, please refer to Spare Parts Catalogue.
Screwed connections Where screws and nuts cannot be loosened straight away because they
have seized, avoid applying excessive force because the components
might be destroyed in this way and would have to be replaced. It may also
become necessary to bore broken bolts out of casings and to retap the
bored--out threads. Seizures can in most cases be slackened by
lubricating the threads with Diesel fuel oil or low-viscosity special lubricants
(such as Caramba or Omnigliss) and by slightly tapping the bolt head with
a hammer. Such solvents should be applied liberally and allowed to act
upon the bolted or screwed joint for some time (1/2 hour or longer) so that
they will be able to penetrate right down into the threads. The
recommendations issued by the suppliers of such solvents should be
observed.
Screws, nuts and lockwashers used in joints on the turbine side and
exposed to elevated temperatures are made of non-scaling materials. In
order to prevent such non-scaling screws and nuts from being mixed up
with normal ones, they are identified by markings on their face (SM, VM or
4923, Z1 or 4828). During disassembly, such elements should therefore
be put down somewhere separately until being reassembled.
All the lockwasher pairs used on the turbocharger are of non-scaling
material but not marked.
To prevent screws and nuts from sticking, thereby facilitating later

disassembly, screwed connections and seats should be made sure to be
treated with a high-temperature lubricant (such as Molykote HSC) prior to
every reassembly. Before applying this lubricant, clean the threads
carefully. Threads of stud screws remain untreated.
5649 4.51--03 E 03.02 NR, NA 101/ 02

All the bolted and screwed connections of the turbocharger must be in an
unobjectionable condition on assembly, or replacement is necessary.
Inappropriately tightened and secured screws and nuts may come loose
by vibratory effects and be drawn into the turbocharger by the air or gas
flow, causing severe damage.
When assembling the lockwasher pairs (one pair consisting of 2 identical
washers), make sure that the long wedged surfaces (B) contact each other
(on the inside), otherwise the securing effect will be lost.
5649 4.51--03 E 03.02 NR, NA 102/ 02

Cleaning 4.52
Air filter
Air filter mat The air intake opening of the silencer is covered by a air filter mat of high
filtering effect. The silencer, compressor and charge-air cooler are therefore
effectively protected against fouling. To maintain this efficiency, timely
cleaning or replacement of the air filter mat is necessary and is definitely
due when the inside of the air filter mat starts getting dark, a reliable sign
that the absorbing capacity of the air filter mat is exhausted and dirt begins
to appear at the filter. Taking the pressure differential as an indicator is not
reliable because it depends on the rate of air flow as prevailing, which is to
say on the service point and the position in the map.
Cleaning intervals For recommended cleaning intervals, please refer to the maintenance
schedule (4.56) and work card (500.11).
Compressor
Cleaning during operation In the case of NR turbochargers, dirt depositing on the blades of the
by injecting water compressor wheel and on the nozzle ring vanes may cause a measurable
loss in efficiency, because of the relatively small dimensions.
We therefore recommend a compressor washing device, especially in cases
of extremely dirt-laden intake air. Freshwater is to be used exclusively. Sea
water and chemical additives and cleansers are not permitted. Cleaning
agents for the charge-air cooler have to be introduced downstream of the
compressor.
Cleaning should be carried out with the engine being at operating
temperature and under full load.
Cleaning intervals For recommended cleaning intervals, please refer to the maintenance
schedule (4.56) and work cards (500.08).
Versions available A portable water container with accumulator to be connected to the
cleaning opening on the compressor casing, silencer or air intake casing.
A syringe is provided for small frame sizes such as NR12.
As an alternative, a water tank can be installed at a fixed, easily
accessible point. The tank is to be located not less than 600 mm lower
than the point of injection to avoid that the water is prematurely extracted
by a vacuum in the compressor as the tank is topped up with water. The
air required to draw the water out of the tank should be withdrawn
downstream of the charge-air cooler.
Mechanical cleaning Dirt that has deposited on the compressor wheel, the air diffuser and
compressor volute can be removed during maintenance periods by means
of the steam jet. A further possibility is the soaking in Diesel fuel or other
liquid cleansers and the subsequent brushing off of the dirt deposits.
Chlorous cleaning agents may attack the aluminium alloy (of the
compressor wheel) and must therefore not be used.
It should in each case be avoided that some of the cleaning agent or

dissolved dirt gets into the lube oil system. It is not allowed to use
high-pressure cleaners.
5649 4.52--03 E 12.04 NR 101/ 02

Turbine
Cleaning during operation Depending on the fuel oil grade and the engine operating mode, residues
from combustion may accumulate on the vanes / blades of the nozzle ring
and turbine. The progressing build-up of dirt deposits and the considerable
deterioration of operating performance involved may lead to compressor
surging or to the excitation of dangerous vibrations of the turbine wheel
blades due to uneven fouling of the nozzle ring. Incipient fouling is indicated
by a rising charge-air pressure as a result of the narrower nozzle ring cross
section. The charge-air pressure will drop as fouling proceeds, and the
exhaust gas temperature will rise as a result.
Cleaning intervals For recommended intervals of cleaning, please refer to the maintenance
schedule (4.56) and work card (500.07). Depending on the fuel oil grade and
engine operating mode, other intervals may be appropriate.
Two methods are available for cleaning the turbine during operation:
Wet cleaning The engine has to be brought down to approx. 10 ... 15% output for this
purpose so as to avoid an overloading of the turbine blades (thermo shock).
The medium used for cleaning is freshwater introduced without any
chemical additives upstream of the turbine.
Dry cleaning Granulates of nut shells or activated charcoal (soft) of a grain size of
1 ... 1.5 mm are introduced upstream of the turbine, under normal engine
service load and using compressed air from the board mains.
The engine loading need not be reduced for this purpose.
The cleaning device is designed to introduce the necessary amount of
granulate over a period of 20 to 30 seconds rather than at a time. This will
prevent a sudden speed drop and surging of the compressor, especially
where several turbochargers are operated in parallel.
The required granulate can be ordered by:

Turbocharger Service Dept.
86224 Augsburg, Germany
Mechanical cleaning During maintenance work, severe fouling (such as heavy fuel oil deposits or
oil coke) accumulated on the nozzle ring and turbine wheel can be soaked in
water treated with standard domestic detergents and subsequently brushed
off. If necessary, the process has to be repeated several times. Soaking can
be done in an appropriate vessel over several hours.
It must be made absolutely sure that the water and dissolved dirt cannot
get into the lube oil system.
5649 4.52--03 E 12.04 NR 102/ 02

Checking the individual Components 4.53
The following notes and questions are intended for guidance, e.g. for
D judging the condition of the turbocharger

D recording engine operating data and preparing checklists
D checking, reusing, repairing and replacing components
Oil coke downstream of the Sealing air bore in the bearing casing clogged
turbine wheel Shaft seal on turbine side damaged
Priming pressure too high
Touching marks over the entire Check of the bearing bushes (refer to work card 500.18)
circumference (turbine rotor, Check of gaps and clearances (refer to sheet 1.52)
compressor wheel, inserts)
Touching marks in sections of Signs of imbalance

circumference (turbine rotor,
compressor wheel, inserts)
Crack detection tests on the By acoustic testing or fluorescent dye penetration method
blades (turbine rotor,
compressor wheel)
Gaps and clearances For admissible limits, refer to sheet 1.52.
Erosion in HFO operation Where heavy fuel oil is used, the exhaust gas contains solids of small size
(e.g. ”Cat fines”) which have an erosive effect especially at the outlet of
the turbine nozzle ring, where gas velocities and concentrations of these
particles are high. Moreover, there is a very pronounced deflection of the
flow in circumferential direction, and the particles are furthermore subject
to the centrifugal effect.
“Cat Fines” Where do these erosive solid particles come from?

As a result of the refining process, and depending on the quality, heavy
fuel oil contains ”Cat fines”, fine-grained and very hard powdered solids
(indicators are the Al and Si concentrations), and other impurities of
abrasive effect. Amply dimensioned, heated settling tanks and adequate
separation are means to reduce their concentration.
Admixtures Of a particularly negative effect is the admixing of used engine lube oil,
characterised by more-than-normal Ca and Fe concentrations. Used
engine lube oil not only contains wear residues but specifically ”detergent
dispersant additives”. Fine-grained solids are bound by these additives so
that ”Cat fines” and other impurities cannot be extracted by separating.
Much more severe erosion damage is the result of blending the fuel with
”Waste oil”.
Residues from incomplete combustion may also have an erosive effect.
Clean combustion should therefore be ensured.
5649 4.53--03 E 03.02 NR 101/ 02

Casings Which casings are heavily fouled by soot, oil or oil coke?
Were the casings tight, especially at the joints and connecting flanges?
Did the casings have cracks?
Had bolts broken off?
Had all the bolts and nuts been firmly tightened and secured?
Were any sealing air or oil ducts in the bearing casing clogged?
Are the seals in order?
Silencer, if provided What is the condition of the air filter mat?

What is the condition of the felt linings?
Have cracks formed on components?
Electronic speed measuring Was the speed transmitter or the speed indicator defective?
device Were the two pole plates on the speed transmitter deformed?
Compressor wheel Are blades affected by cracks or pronounced wear?

Do the blades show impact marks at the leading edge, caused by solid
objects drawn in?
Are traces of touching found?
What is the seat of the compressor wheel?
Is the seating surface bright, or does it show fretting corrosion?
Turbine rotor Have blades been damaged or are blades affected by pronounced wear or
erosion on the edges?
Are blades affected by cracks?
Are any traces of touching found on blades, on the wheel or shaft?
Concentricity of the shaft?
Condition of the bearing points?
Have the labyrinth tips of the locating ring been severly worn?
Are the seating faces bright or do they show fretting corrosion?
Inserts Are there any signs of touching?
Distance sleeve, labyrinth ring Are there traces of fretting or pronounced wear?
Are the seating faces bright or do they show fretting corrosion?
Bearing bushes Check the bearing bushes (refer to work card 500.18)
Wear diagonally across on both bearings suggests rotor imbalance.
Sealing cover/Bearing casing Does the pattern of labyrinth tip running-in appear normal?
Turbine nozzle ring Are there vanes that have been bent?
Have vanes suffered serious erosive wear?
Have foreign objects got jammed in the ducts?
Are there traces that are indicative of foreign objects?
Are cracks found on the vanes?
5649 4.53--03 E 03.02 NR 102/ 02

Maintenance schedule (explanations) 4.54
Binding character and adaptabilities
Validity of the maintenance The maintenance schedule (turbocharger) 4.56 is a summary of all the
schedule maintenance and inspektion works up to a major overhaul of the
turbocharger after an operating period of
D 12,000 --18,000 hours for NR--turbochargers,
D 12,000 --18,000 hours for NA--turbochargers

at four--stroke engines,
D 24,000 -- 30,000 hours for NA--turbochargers

at two--stroke engines.
Whenever major overhaul of the turbocharger has been carried out, for
practical considerations in common with an engine maintenance being
doe, the maintenance schedule is to be started anew.
A major overhaul comprises the disassembly of the complete turbocharger

for the inspection of the actual condition, careful cleaning and checking of
all parts.
▲ Attention! In consideration of the operational safety of the

turbocharger and engine, the maintenance works should be carried
out as timely as possible and not later than scheduled.
Adaption of the maintenance The maintenance schedule has been drawn up for standard operating
schedule conditions and an operation of 6,000 hours per year. After a critical
evaluation of the operating values and conditions shorter intervals may
become necessary provided external operating conditions as timetable/
timetable of ships/inspection time for plants allow it.
Favourable operating conditions are:

D constant load within the range of 60% to 90% nominal load,
D observing the specified temperature and pressure of the operating
media,
D using the specified lube oil and fuel quality,
D as well as a proper separation of the fuel and lube oil.
Adverse operating conditions are:
D long-term operation at maximum or minimum load; prolonged idling
times; frequent, drastic load changes,
D frequent engine starting and repeated warming-up phases without
adequate preheating,
D higher loading of the engine before the specified cooling water and lube
oil temperatures are reached,
D lube oil, cooling water and charge air temperatures that are too low,
D using inappropriate fuel qualities and insufficient separation,
D inadequate combustion air filtering (e.g. on stationary engines).
5649 4.54--03 E 03.02 NR, NA 101/ 02

Tools for turbochargers
Commercial tools are not included in the delivery scope of the

Inventory tools
turbocharger. It is expected that these tools are contained in the inventory
of the plant.
Standard tools If included in the delivery scope, the turbochargers are equipped with a set
of standard tools. For a plant with several turbochargers, 1 set of
standard tools is generally sufficient. These standard tools and the
inventory tools permit the usual maintenance work to be carried out.
The tools set intended for the turbocharger(s) is contained in one box (or
in several boxes), and a table of contents is also included.
A list specifying the extent and designations of these tools is also
contained in Section 6 of the Operating Manual.
Tools on customer’s request In particular case, such tools/devices are supplied on request.
MAN B&W Diesel AG will gladly submit an offer, if desired.
Special tools Certain jobs, which are rather repair jobs than maintenance jobs, require
special expert knowledge, experience and supplementary
equipment/auxiliary means. Further special tools are made available to our
service bases, and possibly also our authorised workshops, for such
purposes. We therefore recommend that you consult these partners, or
entrust them to do jobs for you whenever the own capacities in terms of
time, qualification or personnel are inadequate.
5649 4.54--03 E 03.02 NR, NA 102/ 02

Maintenance schedule (signs/symbols) 4.55
Explanation of signs and symbols
The heading of the maintenance schedule shows symbols instead of

entries in two languages. They have the following meaning:
Serial number of the maintenance work.

1, 2, 3 The series shows gaps for changes/up-dates which could become
necessary.
Brief description of the job
Related work cards.

The work cards listed contain detailed information on the work steps
required.
A No Work card required/available
Relation between working cards.

x These notes are of particular significance within the maintenance
system CoCoS. They give you information on the jobs with a temporal
y connection to the work in question.
Required personnel
Time required in hours per person
per Relational term to indicate the time required
Repetition intervals given in operating hours

24 ... 18,000 24 ... 18,000 (NR)
24 ... 18,000 (NA, at the four--stroke engine)
24 ... 30,000
24 ... 30,000 (NA, at the two--stroke engine)
Signs used in the columns of intervals.

Their meaning is repeated in each sheet.
X, 1, 2
We assume that the signs and symbols used in the head are sufficiently
pictorial and that it is not necessary to repeat them constantly.
Table 1. Explanation of signs and symbols of the maintenance schedule
5649 4.55--03 E 03.02 NR, NA 101/ 01

Wartungsplan (Turbolader)
Maintenance Schedule (Turbocharger) 4.56
1, x
12000
18000
per
1500
3000
6000
2,
150
250
y
24
50
3
Inspektion (während des Betriebes) Inspection (during operation)
•
901 Turbolader auf abnormale Geräusche Check turbocharger for unusual noise A 1 0.1 Turbo-- X
und Vibrationen kontrollieren and vibrations lader
Turbo--
charger
903 Turbolader und Systemleitungen auf Check turbocharger and system pipes A 1 0.2 Turbo-- X
Leckagen kontrollieren (Sperrluft, for leakages (sealing air, charge air, lader
Ladeluft, Abgas, Schmieröl) exhaust gas, lube oil) Turbo--
charger
905 Alle Befestigungsschrauben, Check all the fixing screws, casing 500.10 1 1 Turbo-- 2 X
Gehäuseschrauben und screws and pipe connections for tight fit lader
Rohrleitungsanschlüsse auf festen Sitz Turbo--
prüfen charger
Wartung (während des Betriebes) Maintenance (during operation)

•
911 Turbine reinigen Clean the turbine 500.07 1 0.3 Turbo-- 1

-- Trockenreinigung, falls vorhanden -- Dry cleaning, if provided lader
Turbo--
charger
913 Turbine reinigen Clean the turbine 500.07 1 0.6 Turbo-- 1
-- Naßreinigung, falls vorhanden -- Wet cleaning, if provided lader
Turbo--
charger
X Wartungsarbeit fällig X Maintenance work is necessary

1 Nach Bedarf/Zustand 1 As required/depending on condition
2 Kontrolle neuer oder überholter Teile erforderlich (einmal nach der angegebenen Zeit) 2 Check new or overhauled parts once after the time given in the column
5654 4.56--01 E 12.04 NR15/R 101 /02

Wartungsplan (Turbolader)
Maintenance Schedule (Turbocharger) 4.56
1, x
12000
18000
per
1500
3000
6000
2,
150
250
y
24
50
3
915 Verdichter reinigen Cleaning the compressor 500.08 1 0.3 Turbo-- 1
(im Betrieb) (in operation) lader
Turbo--
charger
917 Luftfilter reinigen Clean the air filter 500.11 1 0.4 Turbo-- 1
(falls vorhanden) (if provided) lader
Turbo--
charger
Wartung (gemeinsam mit einer Motorwartung) • Maintenance (in common with an engine maintenance)
931 Verdichtergehäuse, Einsatzstück, Clean and check (visually check) the 500.10 2 4 Turbo-- X
Nachleitapparat und Verdichterrad compressor casing, insert, diffuser and 500.14 lader
reinigen und kontrollieren compressor wheel. Turbo--
(Sichtkontrolle). Restore the turbocharger for operation charger
Betriebsbereitschaft des Turboladers
wieder herstellen
951 Grundüberholung Major overhaul 000.31 931 2 15 Turbo-- X
12 000 ...18 000 Betriebsstunden: 12,000 ... 18,000 operating hours: 500.04 lader
Alle Komponenten des Turboladers Remove, clean and check all 500.06 Turbo--
abbauen, reinigen und kontrollieren. components of the turbocharger. Check 500.10 charger
Spalte und Spiele beim Zusammenbau gaps and clearances on reassembly. 500.16
kontrollieren 500.17
500.18
500.19
500.20
X Wartungsarbeit fällig X Maintenance work is necessary

1 Nach Bedarf/Zustand 1 As required/depending on condition
2 Kontrolle neuer oder überholter Teile erforderlich (einmal nach der angegebenen Zeit) 2 Check new or overhauled parts once after the time given in the column
5654 4.56--01 E 12.04 NR15/R 102 /02

Check list 4.57
Relating to service report of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Date . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Name of customer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger . . . . . . . . . . . . . . . . . . . . .

Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Works No. . . . . . . . . . . . . . . . . . . . . . . .
Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine type . . . . . . . . . . . . . . . . . . . . . .
Ship’s name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Works No.. . . . . . . . . . . . . . . . . . . . . . .
Turbocharger inspected / overhauled on . . . . . . . . . . . . . . . . . . . . . . . . . . . . by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Last inspection / overhaul on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No. of operating hours since last inspection / overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . h
No. of operating hours since commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . h
Silencer (544.000), Compressor casing (546.001) Turbine rotor (520.001)

if provided
j fouled j fouled
air filter mat by . . . . . . . . . . . . . . . . . . . . . by . . . . . . . . . . . . . . . . . . . . .
j replaced
j cracks signs of touching
reason: . . . . . . . . . . . . . . . .
j damage by foreign object j radial
felt linings j over the entire circumference
j fouled j in section of the circumference
j wavy Diffuser (542.001)
j separated j used j replaced
blades
j bent
j j with cracks
Air intake casing (545.001), fouled
j erosion
if provided by . . . . . . . . . . . . . . . . . . . . .
j damage by foreign object
j j vanes bent
j
fouled
bearing points
by . . . . . . . . . . . . . . . . . . . . .
j
vanes with incipient cracks
j fretting marks
Speed transmitter (562.040),
damage by foreign object
j wear
if provided
seating faces
j defective Compressor wheel (520.005) j fretting corrosion
j pole plates deformed j fouled labyrinth tips
by . . . . . . . . . . . . . . . . . . . . . j oil coke
Speed indicator (562.100),
signs of touching j wear
if provided
j j axial
defective j radial Labyrinth ring (520.006)
j over the entire circumference j j
j
Insert (540.001) used replaced
j j in section of the circumference j fretting marks
j
used replaced
blades j wear
fouled
j bent j fretting corrosion
j
by . . . . . . . . . . . . . . . . . . . . .
with cracks
signs of touching
j radial
j damage by foreign object Distance sleeve (517.003)
j bore j used j replaced
j
over the entire circumference
j in section of the circumference fretting corrosion j fretting marks
5649 4.57--03 E 03.02 NR 101/ 02

Bearing casing (517.001) Sealing cover (517.087), Gas--admission casing
j fouled if provided (501.001)
by . . . . . . . . . . . . . . . . . . . . . j used replaced j j fouled
j cracks j by . . . . . . . . . . . . . . . . . . . . .
j
abnormal running--in pattern
j cracks
sealing air bores
j j j
wear
j erosion
clogged
oil bores
cleaned signs of touching
j damage by foreign object
j clogged jcleaned Sealing cover (517.017) screwed connections
if provided j slack
seals
j j used replaced j j torn off
replaced
j abnormal running--in pattern j replaced
Bearing bush compressor side
(517.002)
j wear
j used replaced j j oil coke j cleaned Gas outlet casing

(506.001)
j fretting marks
j
j wear Turbine nozzle ring (513.001)
fouled
j outside diameter j j replaced
by . . . . . . . . . . . . . . . . . . . . .
j used
j cracks
j
inside diameter
vanes bent j damage by foreign object
Bearing bush turbine side j vanes with incipient cracks
(517.002) j damage by foreign object screwed connections
j
j used replaced j j erosion
j
slack
j fretting marks
j
torn off
j wear Insert (541.001) replaced
j outside diameter j used j
replaced
j inside diameter j fouled
Gas outlet diffuser
(509.001)
j
Covering disk (517.009) by . . . . . . . . . . . . . . . . . . . . .
Intermediate ring (517.009) j erosion
fouled
j used replaced j by . . . . . . . . . . . . . . . . . . . . .
j
signs of touching
j wear j cracks
j
over the entire circumference
j oil coke cleaned j j in section of the circumference damage by foreign object
j
X please tick the appropriate box
Gaps and clearances, (for admissible values, please refer to sheet 1.52)
Item 1 Compressor wheel / insert (radial gap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Item 2 Compressor wheel / insert (axial gap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Item 3 Turbine rotor / insert (radial gap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Item 4 Turbine rotor / insert (axial gap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Item 5 Bearing bush / labyrinth ring (axial clearance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Item 6 Face runout, compressor wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Remarks: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
................................................................................................
................................................................................................
................................................................................................
................................................................................................
................................................................................................
................................................................................................
................................................................................................
5649 4.57--03 E 03.02 NR 102/ 02

Service Report 4.58
5649 4.58--01 E 07.02 NR 101/ 01

Work Cards
0 Introduction
1 Technical Data
2 Systems
3 Operation
4.1 Maintenance
4.2 Work Cards
5649 4.2--01 E 03.02 101/ 01

Table of contents
S S S h 4.60 How the work cards are organised, and how to use them
000.31 Tightening of screw connections
S S h General tightening torques
500.04 Turbine nozzle ring
S S h Checking
500.05 Emergency operation
S S h with closing device
500.06 Transverse movement of the rotor
S S h Checking
500.07 Cleaning the turbine
S S h Wet cleaning
500.07 Cleaning the turbine
S S h Dry cleaning
500.08 Cleaning the compressor (in operation)
S S h with syringe
500.08 Clean the compressor (in operation)
S S h with fitted tank
500.08 Cleaning the compressor (in operation)
S S h with pressure sprayer
500.10 Turbocharger or subassemblies
S S h Removing and refitting
500.11 Air filter
S S h Cleaning
500.12 Silencer
500.12 Silencer
500.13 Air intake casing
500.14 Insert, compressor casing, diffuser
500.16 Cartridge
500.17 Cartridge
S S h Checking and cleaning
500.18 Cartridge
S S h Checking the individual Components
Information
Description
Instruction
Intended for ...
Experts
Middle management
Upper management
5654 09.07 NR15/R 101 /02

500.19 Gas outlet casing, gas outlet diffuser
500.20 Turbine nozzle ring
S S h Removing, refitting, checking
Information
Description
Instruction
Intended for ...
Experts
Middle management
Upper management
5654 09.07 NR15/R 102 / 02

How the work cards are organised,
and how to use them 4.60
Numbering The ordinal number of the work cards - on top at the right - is composed of
the three-digit subassembly group number 500 (basic subassembly
number for turbochargers) and a two--digit counting number, or of a neutral
numerical combination (e.g. 000, for universally valid instructions) and a
two--digit counting number.
Example:
Turbocharger or subassemblies
Removing and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 . 10
Subassembly group number (500 for turbocharger)

Counting number (work card number 10)
How to find the work cards The work cards are contained in the list (Table of contents).
required
Structure Work cards contain the following information as a rule:

D Notes on the purpose of the jobs to be done,
D Personnel and time required
D on the relevant work cards, i.e. those work cards containing further
essential or useful information,
D on the necessary tools and appliances,
D any supplementary details/technical data and
D the individual operating sequences, starting in each case with the
original condition and followed by the individual working steps.
Parts and tools are marked with the order number in illustrations and texts.
Order numbers for tools are identical with the tool number punched into
the tool (as a rule).
Tools/appliances Remarks:
The number in the column Denomination are width across flats given in
mm, e.g. socket wrench 22 = socket wrench width across flats 22 mm.
The availability keys in the column Availability have following meaning:
Standard Standard tools (with tool numbers)
If included in the delivery scope, the turbochargers are equipped with a set
of standard tools.
Optional Tools on customer’s request (with tool numbers)
Inventory Commercial tools/appliances
These are not included in the delivery scope. It is expected that these
tools/appliances are contained in the inventory of the plant.
Extra Extra tools, e.g. for service bases
5649 4.60--03 E 03.02 NR, NA 101/ 02

Safety notes Text passages in italic type draw the attention to dangers sources of
failure, technical necessities, supplementary information. The following are
used:
▲▲▲ Danger! Imminent danger.
Possible consequences: Death or most severe injuries, total damage
to property.
▲▲ Caution! Potentially dangerous situation.
Possible consequences: Severe injuries.
▲ Attention! Possibly dangerous situation.
Possible consequences: Slight injuries, possible damage to
property.
Important! For calling attention to error sources/handling errors.
Tip! For tips regarding use and supplementary information.
Remarks next to this sign are of special importance on the basis of service
experiences.
However, only the signs of the safety instructions indicate the importance.
Personnel and time required The time required is given in hours, indicating the number and qualification
of the required personnel for a single job. The higher amount covers the
time for the entire extent of the particular work card. Personnel with a
smaller number of hours is required only temporarily, eg. for operating the
lifting tackle.
The time indicated applies only under the provision that the personnel
employed is familiar with the work involved and that all necessary tools are
at hand. It is also assumed that the turbocharger is readily accessible and
that a hoist is available for lifting off the heavy parts.
Furthermore, the times shown are based on a normal operating condition
of the parts when undergoing maintenance.
However, the man--hours given may be considerably exceeded where
parts have been affected by some accidents
Work cards and maintenace The work cards are closely related to the Maintenance Schedule of the
schedule turbocharger, please refer to sheet 4.56 of the Operating Manual.
The latter briefly specifies the maintenance work to be done, whereas this
volume gives a step-by-step description, with illustrations, of the operating
sequences required to maintain the operational reliability and efficiency of
the turbocharger. The work cards have an introductory part describing the
purpose of the work, and contain information also stating which tools and
appliances are required. For most of the jobs, several work cards have to
be consulted.
Gaps and clearances Please refer to Operating Manual, sheet 1.52.
Tightening torques for Screw connections should be tightened by means of torque wrenches as
screw connections far as possible.
For importent screw connections on the turbocharger, the tightening
torques are prescribed in the relevant work cards.
For all the other screw connections, which are tightened using a torque
wrench, guide values for the tightening torques are stated in
Work Card 000.31.
5649 4.60--03 E 03.02 NR, NA 102/ 02

Tightening of screw connections
Generally tightening torques 000.31
Purpose of jobs to be done
Indicating tightening torques for essential bolted connections.

Guaranteeing operating safety.
Brief description
Screw connections should be tightened by means of torque wrenches as

far as possible.
The work includes:
Refitting of components.
Generally tightening torques for screw connections
Tightening of screw Screw connections should be tightened by means of torque wrenches as

connections acc. to the torque far as possible.
For importent screw connections on the turbocharger, the tightening
torques are prescribed in the relevant work cards.
For all the other screw connections, which are tightened using a torque
wrench, guide values for the tightening torques are stated in table 2.
The following should be observed:
D The load acting on a screw connection depends on the tightening
torque applied, on the lubricant used, the finished condition of the
surfaces and threads, and on the materials paired. It is, therefore, of
great importance that all these conditions are met.
D Table 2 lists the tightening torques for various threads as a function of
the coefficient of friction, i.e. of the lubricant used. The torques are
based on bolt material of the strength class 8.8 with the bolts stressed
up to approximately 70 % of the elastic limit. For other strength
classes, the tightening torques listed in the table have to be multiplied
by the corresponding conversion factors. The strength class is stamped
on the bolt head.
Strength class 5.6 6.8 10.9 12.9

Conversion factor x 0.47 0.75 1.40 1.70
Table 1. Conversion factors for tightening torques as a function of the bolt strength
class
Approximate coefficient of friction µ :

µ
≤
= 0.08 with lubricants, for temperatures
200°C, e.g. Molykote G--n or Molykote P40
≥ 200°C, e.g. Molykote HSC
µ = 0.14 for surfaces that are not finish-treated, with a thin film of oil
6686 000.31--01 E 04.99 NR, NA 101/ 02

Tightening torque Tightening torque
Thread in Nm Thread in Nm
Nominal Coefficient of Nominal Coefficient of
size friction µ size friction µ
0.08 0.14 0.08 0.14
M5 4 6 M 24 475 690
M6 7 10 M 24x2 500 750
M8 17 25 M 27 700 1020
M 10 34 50 M 27x2 730 1100
M 12 60 85 M 30 950 1380
M 14 95 135 M 30x2 1015 1540
M 14x1.5 100 145 M 33 1270 1870
M 16 140 205 M 33x2 1350 2060
M 16x1.5 150 220 M 36 1640 2400
M 18 200 280 M 36x3 1710 2550
M 18x1.5 215 320 M 39 2115 3120
M 18x2 205 300 M 39x3 2190 3300
M 20 275 400 M 42 2630 3860
M 20x1.5 295 450 M 42x3 2760 4170
M 20x2 285 425 M 45 3260 4820
M 22 370 540 M 45x3 3415 5180
M 22x1.5 395 595 M 48 3950 5820
M 22x2 380 565 M 48x3 4185 6370
Table 2. Tightening torques for bolts of the strength class 8.8
6686 000.31--01 E 04.99 NR, NA 102/ 02

Turbine nozzle ring
Checking 500.04
Check state/wear condition of components,

ensure/restore operational reliability.
Brief description
Checking the turbine nozzle ring,

replace if necessary.
The work includes:
checking components.
A guide vane
B trailing edge
(original)
C contour of the reduction
Σ
D mean reduction
(area F areas E)
E negative areas
(on the left of D)
F positive area
(on the right of D)
G root of the guide vane
Figure 1. Erosion of the turbine nozzle ring
General The erosive wear of the guide vanes (A) is caused by the outlet flow mainly
in the area of the trailling edges (B). The original position of the trailling
edges (B) can be recognised at the roots (G) of the guide vanes (A).
Since the guide vanes do not wear evenly, the mean value of the reduction
from the guide vanes (Lm) is calculated as follows:
Lm = (L1 + L2 + L3n + + Ln)

n = number of the guide vanes (A)
Replacement Replace the turbine nozzle ring, if Lm ≥ as the indicated value of the
table:
Turbocharger Lm ≥ [mm] Turbocharger Lm ≥ [mm]

NR15/R 8 PTG 18 8
NR20/R 10 PTG 23 11
NR24/R 12 PTG 26 14
NR26/R 14 PTG 30 14
5649 500.04--01 E 03.02 NR 101/ 01

Emergency operation
with closing device 500.05
Enabling emergency operation.
Brief description
Emergency operation by removing the cartridge.

The work/steps include:
behaviour in case of problems,
removing components,
installing components.
Personnel and time required
Numb Qualification Time [h]

1 Qualified mechanic 1
1 Assistant 1
Tools/appliances required
Qty Designation No. Availability

1 Closing cover 596.027 Optional
1 Open--jaw wrench 13 -- Inventory
-- Lifting tackle, ropes, shackles -- Inventory
Related work cards
Work card Work card Work card

500.10 500.12 500.13
500.14 500.16
During emergency operation of the engine, the exhaust gas must continue
passing through the damaged turbocharger.
5654 500.05--01 E 06.02 NR15/R 101/ 02

Figure 1. Closing device
Operating sequence 1 -- Emergency operation with closing device
Steps 1. Undo all the connections to clear the cartridge for removal
(refer to work card 500.10).
2. Remove the silencer or air intake casing, compressor casing and
cartridge
(refer to work cards 500.12 up to 500.16).
The turbine nozzle ring (513.001) to remain in place.
3. Close the lube oil pipes.
4. Attach the closing cover (596.027) with clamping claws (501.005),
lock washer pairs (501.007) and hexagon nuts (501.008) to the
gas-admission casing (501.001).
5. For further notes on emergency operation, please refer to sheet 3.53
of the Operating Manual for Turbocharger, and to the Operating
Manual for Engine, Section Operating Faults.
5654 500.05--01 E 06.02 NR15/R 102/ 02

Transverse movement of the rotor
Checking 500.06
Check state/wear condition of components.
Brief description
Checking the rotor for transverse movement.

The work includes:

1 Qualified mechanic 0.3

1 Dial gauge with retainer -- Inventory
Related work cards

500.10 500.12 500.13
500.14
General Judgement on condition of bearing by measuring the transverse

movement is only possible in case of labyrinth seals already run in
(after approx. 500 operating hours).
Starting condition Silencer or air intake casing and compressor casing removed,
or cartridge removed.
5654 500.06--02 E 06.02 NR15/R 101/ 02

Figure 1. Checking of the transverse movement
Operating sequence 1 -- Checking of the transverse movement
Steps 1. Attach the dial gauge with retainer in such a way that the measuring
pin of the dial gauge contacts the magnetic nut (520.124) in radial
position.
2. Tilt the shaft of turbine rotor (520.001) by hand vigorously in direc-
tions A and B (transverse to the axle of turbine rotor).
Thereby read and note down the total swing of dial gauge.
3. Recommended measures, especially when close the upper limit:
please refer to the table.
Measuring range
Remarks
[mm]
Range of admissible transverse movement

to 0.85
(corresponds to the tolerances of the radial bearing clearance)
Inspection of single parts of the cartridge by specialized service personnel

0.85 to 1.10 during the next opportunity.
Checking : Quality and pressure of the lube oil.
Operating reliability endangered.

Replace the respective parts through specialized service personnel
above 1.10
or exchange the cartridge.
Checking : Quality and pressure of the lube oil.
Table 1. Measuring ranges of the transverse movement
5654 500.06--02 E 06.02 NR15/R 102/ 02

Cleaning the turbine
Wet cleaning 500.07
Carry out the work in time according to the maintenance schedule,

free components from fouling or residues,
Brief description
Clean the turbine

-- Wet cleaning, if provided
Maintenance (during operation)

General The number and location of exhaust gas pipes depends on the engine
type and may vary from the above schematic. Every individual exhaust
gas pipe has its own three--way cock (D) for turbine cleaning.
Cleaning agent Use freshwater for cleaning exclusively.
Cleaning interval Every 150 operating hours, with reduced engine load.
Tip! To save time, we recommend washing shortly after engine

start--up, when the parts to be washed are not very hot yet. In that way,
the step 2. of the operating sequence 1 can be omitted.
Brief information See also cleaning instructions given in plate (mounted to the engine).
6660 500.07--01 E 12.04 NR 101/ 02

1 Turbocharger
2 Exhaust gas pipe upstream
of turbine
3 Water admission (freshwater)
4 Dirt water discharge
downstream of turbine, if fitted
A Stop cock
B Pressure reducing valve
with pressure gauge
C Three--way cock:
ZERO POSITION
BLOW--OUT
WASHING
D Three--way cock:
● (= zero position)
● ● (= control position)
● ● ● (= washing position)
E Drain cock, if fitted
Figure 1. System: Wet cleaning of the turbine
Operating sequence 1 -- Wet cleaning of the turbine
Steps 1. Reduce engine load to 10 ... 15 %.

2. Following reduction of the engine load from a higher load, wait
approx. 10 minutes (for the temperature to reach steady--state
condition).
3. First check all the three--way cocks (D) one after the other in the
control position ●● (if no exhaust gas is blown out, the passage to the
exhaust gas pipe has got clogged and must be cleared using a
2.5--mm dia. piece of wire); then switch over to washing position ● ● ● .
4. Open the drain cock (E) if such a cock is fitted, check the blowing out
of exhaust gas; if necessary, clear the passage.
5. Switch the tree--way cock (C) to BLOW--OUT.
6. Open the stop cock (A) on the water admission (3); set the water
pressure to 2 bar on the pressure reducing valve (B), and check on
the pressure gauge.
7. Switch the three--way cock (C) to WASHING.
8. Washing for 10 minutes at 2 bar water pressure (check on the
pressure gauge).
9. Close the stop cock (A) on the water admission (3).
10. Temporarily switch the three--way cock (C) to BLOW--OUT, than to
ZERO POSITION.
11. Switch all the three--way cocks (D) to zero position ● .
12. Close the drain cock (E), if fitted.
13. Let the turbocharger run dry for 10 minutes at reduced engine load,
then slowly increase the load.
Tip! Should vibrations occur on the turbocharger that were not noticed
before, repeat the washing.
▲ Attention! If these vibrations, produced by irregular dirt

accumulations, cannot be eliminated by washing, the turbocharger
has to be dismounted and the parts involved have to be submitted to
mechanical cleaning.
6660 500.07--01 E 12.04 NR 102/ 02

Cleaning the turbine
Dry cleaning 500.07

Brief description
Clean the turbine

-- Dry cleaning, if provided


-- Granulates (grain size 1.0 ... 1.5 mm) -- Inventory
nut shells/activated charcoal -- soft
General Depending on the type of engine and turbocharger, the arrangement of

items may also differ somewhat from that shown in the schematic.
The tank (1) should be installed at an approximate place, not lower than
1.0 m below the connection point (4). The pipe (3) should not be longer
than 6.0 m and properly supported to preclude that it oscillates, permitting
≤
free flow.
The maximum service temperature of the stop cock (B): 300 ° C.
Connection point (4) is provided on the exhaust gas pipe, immediately
upstream of the turbine.
Cleaning agent Appropriate cleaning materials are granulates from nut shells or activated
charcoal (soft) of a grain size of 1.0 mm (max. 1.5 mm).
▲ Attention! Do not use water for cleaning with this facility, because
herewith the cleaning to be carried out with the engine operated at
normal service load.
Cleaning interval Every 24 operating hours, at normal service load of the engine.
6660 500.07--02 E 12.04 NR 101/ 02

1 Tank
2 Screw plug
3 Pipe
4 Connection point
5 Data plate
6 Exhaust gas pipe
7 Compressed air pipe
A Stop cock
(compressed air)
B Stop cock
(exhaust gas)
Figure 1. Arrangement: Dry cleaning of the turbine
Operating sequence 1 -- Dry cleaning of the turbine (during operation)
Steps 1. Stop cocks (A and B) must be closed.
2. Unscrew the screw plug (2). Fill the prescribed quantity of granulate into
the tank (1) and close it with the screw plug (2).
Quantities required: NR12, NR14, NR15, NR17, NR20 . . 0.3 litres

NR24, NR26 . . . . . . . . . . . . . . . . . . . . 0.4 litres
NR29, NR34 . . . . . . . . . . . . . . . . . . . . 0.5 litres
3. Open the stop cock (A). Slowly open the stop cock (B) until a
whistling sound is heard indicating the introduction of the granulate.
Granulate injection time approx. 30 seconds.
4. Close the stop cocks (A and B).
6660 500.07--02 E 12.04 NR 102/ 02

Cleaning the compressor
(in operation)
with syringe 500.08

Brief description

(in operation)

Cleaning agent Use only fresh water for cleaning.

When injecting, the water droplets, due to the high speed of the rotor, are
hitting of the compressor wheel and the diffuser at high velocity, thus
removing the dirt deposits mechanically.
Cleaning intervals We recommend the following cleaning intervals for

NR--Turbochargers: every 150 operating hours.
The cleaning intervals depend on the degree of contamination of the air
taken in, and are located between 100 and 200 operating hours.
In smaller turbocharger sizes (NR), the dirt deposits on blades of
compressor wheel and diffuser may lead to a considerable drop of
efficiency.
Important! Cleaning must only be made with the engine warm and
running at full load. Engine must not be shut down immediately after
completion of the cleaning process.
5654 500.08--01 E 07.02 NR15/R 101/ 02

Figure 1. Cleaning the compressor (with syringe)
Operating sequence 1 -- Cleaning the compressor (during operation)
Steps 1. Operate engine at full load.

2. Unscrew the screw plug (544.084 or 545.018) together with the seal-
ing ring (544.085 or 545.019).
3. Fill the syringe (579.119) with clean, fresh water, and insert it through
the screw--plug opening.
4. Inject the complete content of the syringe within a period of
4 ... 10 seconds.
5. Screw in the screw plug (544.084 or 545.018) together with the seal-
ing ring (544.085 or 545.019).
5654 500.08--01 E 07.02 NR15/R 102/ 02

Clean the compressor
(in operation)
with fitted tank 500.08

free components from contaminations/residues,
Brief description
Clean the compressor

(in operation)
Numb Qualification Time requ

1 Technical assistant 0.3
General Depending on type of engine and turbocharger, the arrangement of the

individual parts may not coincide completely with the ones shown in the
drawing.

hitting the blades of the compressor wheel and the final diffuser at high
velocity, thus removing the dirt deposits mechanically.
Cleaning interval We recommend the following cleaning intervals:
NR-Turbocharger: every 150 operating hours,
NA-Turbocharger: every 150 operating hours.
taken in and are between 100 and 200 operating hours. In the smaller
turbocharger sizes (NR, NA34, NA40), the dirt deposits on blades of
compressor wheel and final diffuser may lead to a considerable drop of
efficiency.
From turbocharger size NA48 onwards, compressor cleaning is not
necessary if the air filter mat is serviced as per instruction.
Brief information See also cleaning instructions given in plate (10), mounted to the engine.
5649 500.08--02 E 10.99 NR, NA 101/ 02

1 Screw--type cap
2 Tank
3 Hydrometer cock
4 Charge air line
5 Intercooler
7 Turbocharger (compressor)
10 Plate (cleaning instructions)
Figure 1. System: Cleaning of the compressor (with fitted tank)
Operating sequence 1 -- Cleaning of the compressor (during operation)
Steps 1. Operating engine at full load.

2. Open screw-type cap (1) and fill tank (2) with clean, fresh water.
3. Close tank by means of screw-type cap (1).
4. Depress pushbutton of hydrometer cock (3) for about 20 seconds.
5649 500.08--02 E 10.99 NR, NA 102/ 02

(in operation)
with pressure sprayer 500.08

Brief description

(in operation)

General Depending on type of engine and turbocharger, the arrangement of the

individual parts may not coincide completely with the ones shown in the
drawing.

hitting the blades of the compressor wheel and the final diffuser at high
velocity, thus removing the dirt deposits mechanically.
Cleaning interval We recommend the following cleaning intervals:
NR-Turbocharger: every 150 operating hours,
NA-Turbocharger: every 150 operating hours.
taken in and are between 100 and 200 operating hours. In the smaller
turbocharger sizes (NR, NA34, NA40), the dirt deposits on blades of
compressor wheel and final diffuser may lead to a considerable drop of
efficiency.
From turbocharger size NA48 onwards, compressor cleaning is not
necessary if the air filter mat is serviced as per instruction.
Brief information See also cleaning instructions given in plate (10), mounted to the pressure
sprayer (2).
5649 500.08--03 E 11.99 NR, NA 101/ 02

1 Handle
2 Pressure sprayer
3 Relief valve
4 Nipple
5 Coupling
6 Hand valve
7 Turbocharger (compressor)
10 Plate (cleaning instructions)
Figure 1. System: Cleaning of the compressor (with pressure sprayer)
Operating sequence 1 -- Cleaning of the compressor (during operation)
Steps 1. Operating the engine at full load.

2. Turn handle (1) on pressure sprayer tank (2) in counter-clockwise
direction and take out the pump.
3. Fill maximal 2.0 litres of fresh water into the tank
(up to the mark -- 2 L-- on the tank).
4. Screw in the pump and operate until the pressure relief valve (3)
blows off.
5. Connect hose with nipple (4) to the coupling (5).
6. Depress pushbutton (see big arrow in figure) on the hand valve (6)
until the water is completely injected into the compressor
(for approx. 30 seconds).
7. Release plug-in connection and vent the tank. For venting, pull
spindle on the relief valve (3) outwards (see small arrow in figure).
5649 500.08--03 E 11.99 NR, NA 102/ 02

Turbocharger or subassemblies
Removing and refitting 500.10
Brief description
Remove the turbocharger complete or in subassemblies.

dismounting components,
mounting components.


1 Open--jaw and ring wrenches (set) -- Inventory
1 Socket wrench (set) -- Inventory
1 Torque wrench -- Inventory
1 Screw driver -- Inventory
-- Wood (for placing underneath) -- Inventory
-- High--temperature lubricant -- Inventory
(e.g. Molykote HSC)
Technical details
Term Information
Turbocharger 210 kg
In general for maintenance work at the turbocharger individual subassemblies

are successively to be removed (see work cards 500.12 to 500.20).
5654 500.10--02 E 06.02 NR15/R 101/ 03

Figure 1. Connections at the turbocharger
Operating sequence 1 -- Separating or removing the connections
Steps 1. Compressor cleaning (1, if provided), cable to the speed indicator in

the terminal box (2, if provided), air entry (3) on the air intake casing
(545, if provided)
Removing of silencer (544, if provided)
or air intake casing (545, if provided) is possible
➨ Work card 500.12 or 500.13
2. Jet assist (4, if provided), air outlet (5)
Removing of insert, compressor casing and diffuser is possible
➨ Work card 500.14
3. Two-part plate (6), lube oil feed (7), interval or continuous priming (8),
lube oil drain (9), casing foot (10, if provided)
Removing of cartridge is possible
4. Dirty water or condensed water discharge (11, if provided), exhaust
gas outlet (12, if provided)
Removing of gas outlet casing (if provided) is possible
5. Exhaust gas admission (13)
Removing of the complete turbocharger is possible
➨ Work card 500.10, Operating sequence 2
5654 500.10--02 E 06.02 NR15/R 102/ 03

Operating sequence 2 -- Removing the complete turbocharger
Steps 1. For separating or removing the connections, refer to operating

sequence 1. Also separate or take off other special connections
(such as for pressure and temperature measuring, etc.).
2. Suspend the turbocharger from the lifting tackle with a rope of
appropriate strength slung around the bearing casing, and carefully
stretch the rope. Attach secondary ropes to appropriate points to
assist in balancing.
▲▲▲ Danger! Eye bolts serve the purpose of lifting off individual
subassemblies. They must not be used for suspending the main
load of the complete turbocharger. Make sure to observe safety
regulations for the lifting of loads.
3. Undo the screw connection on the casing foot (10, if provided).
4. Carefully lift off the turbocharger and put it down onto a wooden
support.
Important! For the time of storage and during assembly, openings
for air, exhaust gas and lube oil are to be appropriately sealed to prevent
that foreign objects or water can enter.
Operating sequence 3 -- Refitting
Refitting the complete turbocharger or its subassemblies, and restoring of

the connections is carried out in the reverse order of removing.
Important! Prior to reassembly, make sure to take off protective
caps from pipes.
Make sure to use unobjectionable gaskets/seals and screw securing
elements only. Apply high-temperature lubricant (such as Molykote HSC)
to the threads of heat-resistant screws and nuts on the turbine side.
Slightly tighten the screw connection on the casing foot (10, if provided)
initially, and finally tighten it on connection of the casing pipes/conduits.
For tightening torgue, see working instructions/work cards of engine.
5654 500.10--02 E 06.02 NR15/R 103/ 03

Air filter
Cleaning 500.11

Brief description
Clean or replace the air filter mat.


General The dirty air filter mat (544.201) can be cleaned several times or replaced
by a new one.
Replacement is required if the air filter mat is considerably dilated, plucked
or perforated.
Important! The increase of pressure loss by contamination of the air

filter mat is insignificant and does not serve as an indication of the time
cleaning is required
Cleaning intervals Every 250 operating hours.

taken in, and are located between 250 and 500 operating hours.
Tip! Cleaning is necessary when the inside of the air filter mat starts to
discolour grey. Then the air filter is saturated and the contamination starts
to advance towards the compressor and the intercooler. The inside of the
air filter mat may be inspected by loosening of one of the clamps (544.202).
Tip! In case of intense contamination, it may be necessary to immerse

the air filter mat in the cleanser and soak it for several hours. It is,
therefore, advisable to keep a second air filter mat available for exchange.
6660 500.11--01 E 09.99 NR 101/ 02

Figure 1. Air filter mat, mounted on the silencer
Operating sequence 1 -- Removing, cleaning/replacement, refitting
Steps 1. Loosen the clamps (544.202), remove cover sheet (544.205) and air
filter mat (544.201).
2. Air filter mat to be cleaned by flushing with warm water to which fine
cleanser has been added. Avoid intense mechanical stress
(e.g. wringing , sharp water jet). Subsequently, blow air filter mat
through with compressed air.
Tip! In case of intense contamination, it may be necessary to immerse
the air filter mat in the cleanser and soak it for several hours. It is,
therefore, advisable to keep a second air filter mat available for exchange.
3. Place air filter mat (544.201) over perforated plate of silencer and
cover sheet (544.205) over joint of air filter mat and fasten it by using
the clamps (544.202).
6660 500.11--01 E 09.99 NR 102/ 02

Silencer

check state/wear condition of the components.
Brief description
Remove and refit the silencer in complete condition.

Disassembling (e.g. for cleaning) only if necessary.

1 Assistant 0.2

1 Socket wrench 10 -- Inventory
1 Hexagon screw driver 6 -- Inventory
Related work cards

500.10 500.11
Technical details
Term Information
Silencer 16 kg
5654 500.12--01 E 07.02 NR15/R 101/ 03

Figure 1. Silencer, mounted on the compressor casing
General For air filter cleaning, please refer to work card 500.11.
For disassembling, cleaning and reassembling the silencer, refer to
operating sequence 3.
Important! Disassembling of the silencer (e.g. for cleaning) only if

necessary.
Starting condition Connecting pipe for compressor cleaning removed (if provided).
Operating sequence 1 -- Removing of the complete silencer
Steps 1. Suspend the silencer from the lifting tackle, using the rope.
2. Loosen the V-profile clamp (546.005) on both sides of the
circumference.
3. Remove the silencer in axial direction and place it on wooden pad
with the flange surface down.
Operating sequence 2 -- Refitting of the complete silencer
For refitting, proceed in the reverse order of removing.
▲ Attention! During refitting, the following tightening torques are to

be observerd. Apply oil to the threads and contact surfaces.
Tightening torque for V-profile clamp (546.005)
on both sides of the circumference: . . . . . . . . . . . 12 [Nm]
5654 500.12--01 E 07.02 NR15/R 102/ 03

Operating sequence 3 -- Disassembling, cleaning and reassembling the silencer
Steps 1. Remove the air filter mat (544.201) and clean it,
refer to work card 500.11.
2. Screw off the hexagon nuts (544.074) and take off the
washers (544.075).
3. Take off the front wall (544.041), protection grate (544.034), damping
plates (544.021) and spacer pipes (544.032) individually. This leaves
the rear wall (544.001) with the studs (544.069) screwed in.
4. Cleaning of the felt linings if the fouling matter is dry is best done with
compressed air or a brush which is not too hard.
▲ Attention! Diesel fuel can be used for removing smeary dirt. Sol-
vents containing acetone are not to be used; in particular, use no
trichlorethylene (or substitutes of it), because this will dissolve the
bonding.
5. For reassembly, proceed in the reverse order of disassembly.
5654 500.12--01 E 07.02 NR15/R 103/ 03

Silencer

Brief description
Remove and refit the silencer in complete condition.

Disassembling (e.g. for cleaning) only if necessary.

1 Assistant 0.2

Related work cards

500.10 500.11
Technical details
Term Information
Silencer 19 kg
5654 500.12--02 E 07.02 NR15/R 101/ 03

Figure 1. Silencer, mounted on the compressor casing
General For air filter cleaning, please refer to work card 500.11.
For disassembling, cleaning and reassembling the silencer, refer to
operating sequence 3.
Important! Disassembling of the silencer (e.g. for cleaning) only if
necessary.
Starting condition Connections for compressor cleaning and/or speed transmitter removed
(if provided).
Operating sequence 1 -- Removing of the complete silencer
Steps 1. Screw off the hexagon nuts (544.231), take off the washers (544.076)
and cover (544.222).
2. Screw off the hexagon nut (544.067), take off the holding
disk (562.004) and speed transmitter (562.040).
3. Suspend the silencer from the lifting tackle, using the rope.
circumference.
5. Remove the silencer in axial direction and place it on wooden pad
with the flange surface down.
Operating sequence 2 -- Refitting of the complete silencer

be observerd. Apply oil to the threads and contact surfaces.
on both sides of the circumference: . . . . . . . . . . . 12 [Nm].
The cable connection between speed transmitter (562.040) and speed
indicator is optional (alternating current).
5654 500.12--02 E 07.02 NR15/R 102/ 03

Operating sequence 3 -- Disassembling, cleaning and reassembling the silencer
Steps 1. Remove the air filter mat (544.201) and clean it,
refer to work card 500.11.
2. Loosen the hexagon nuts (544.074) and take off the
washers (544.075).
3. Take off the front wall (544.041), protection grate (544.034), damping
plates (544.021), spacer pipes (544.032) from outer graduated circle,
and centering bushes (544.033) from inner graduated circle
individually. This leaves the rear wall (544.001) with the
studs (544.069) screwed in.
4. Cleaning of the felt linings if the fouling matter is dry is best done with
compressed air or a brush which is not too hard.
▲ Attention! Diesel fuel can be used for removing smeary dirt.
Solvents containing acetone are not to be used; in particular, use no
trichlorethylene (or substitutes of it), because this will dissolve the
bonding.
5. For reassembly, proceed in the reverse order of disassembly.
5654 500.12--02 E 07.02 NR15/R 103/ 03

Air intake casing

Brief description
Remove air intake casing for inspection.


1 Assistant 0.2

Related work cards

500.10 500.11
Technical details
Term Information
Air intake casing 9 kg
5654 500.13--02 E 07.02 NR15/R 101/ 02

Figure 1. Air intake casing, mounted on the compressor casing
Operating sequence 1 -- Removing
Starting condition Pipe at the air intake released or removed.

Connections for compressor cleaning and/or speed transmitter released
(if provided).
Steps 1. Screw off the hexagon nuts (545.069), take off the holding
disk (562.004) and speed transmitter (562.004).
2. Suspend the air intake casing (545.001) from the lifting tackle, using
the rope. Carefully stretch the rope.
circumference.
4. Remove the air intake casing (545.001) in axial direction and place it
on wooden pad.

be observed. Apply oil to the threads and contact surfaces.
on both sides of the circumference: . . . . . . . . . . . . 12 [Nm]
5654 500.13--02 E 07.02 NR15/R 102/ 02

Insert, compressor casing,
diffuser

Brief description
Remove insert, compressor casing, diffuser for inspection, matching or

change.
removal of components,
checking of components,
installation of components.

1 Assistant 0.2

1 Screw driver -- Inventory
Spare parts required
Qty Designation No.

1 O--ring seal 517.063
1 O--ring seal 546.023
1 Sealing ring 546.051
5654 500.14--02 E 07.02 NR15/R 101/ 03

Related work cards

500.10 500.12 500.13
Technical details
Term Information
Compressor casing 31 kg
Figure 1. Insert, compressor casing, diffuser
Starting condition Connecting pipes, air intake casing or silencer removed.
Steps 1. If the insert (546.018) -- if provided -- is to be removed:

Screw off the hexagon nuts (546.024) and take off the
insert (546.018) in axial direction.
2. Attach the compressor casing (546.001) to rope and suspend from
lifting tackle, carefully tension the rope.
5654 500.14--02 E 07.02 NR15/R 102/ 03

3. Loosen the V--profile--clamp (546.005) on both sides of the
circumference, carefully take off the compressor casing in axial
direction and put it down on wooden pad.
▲ Attention! Take care not to damage blades of the compressor wheel.
4. If the diffuser (542.001) is to be removed:
Screw off the hexagon nut (546.021), and take off the lock
washer (546.022), countersunk bolt (546.008) and diffuser in axial
direction.

Make sure that the sealing rings (517.063, 546.023 and 546.051) are in
proper condition.
O--ring seal (546.023) and sealing ring (546.051) only if “Jet assist” is
provided.

be observed. Apply oil to the threads and contact surfaces.
Tightening torque for v--profile--clamp (546.005):
on both sides of the circumference ....... 12 [Nm].
For checking the gaps (positions 1 and 2), refer to Operating Manual,
Section 1, sheet 1.52.
5654 500.14--02 E 07.02 NR15/R 103/ 03

Cartridge

Brief description
Remove the cartridge for inspection or emergency operation.


1 Assistant 0.6

3 Segment 596.008 Standard
3 Spindle 596.009 Standard
6 Hexagon nut 596.010 Standard
(e.g. Molykote HSC)
Related work cards

500.10 500.12 500.13
500.14
5654 500.16--02 E 07.02 NR15/R 101/ 03

Technical details
Term Information
Cartridge 30 kg
Figure 1. Cartridge, removed from the gas--admission casing
Starting condition Connecting pipes, silencer or air intake casing and compressor casing
removed.
Steps 1. Take off the two--part plate (591.060), if provided.

2. Detach or remove the casing foot (if provided), depending on
attachment.
3. Attach the cartridge (599.000) to rope and suspend from lifting tackle,
carefully tension the rope.
4. Unscrew the hexagon nuts (501.008), take off the lock washer
pairs (501.007) and the clamping claws (501.005).
5. Evenly jack off the cartridge (599.000) at 3 points of the circumference,
using tools (596.008, 596.009, 596.010), see figure 2 , carefully move
it out in axial direction, and cautiously put it down on wooden pad.
▲ Attention! Take care not to damage blades of the turbine rotor.
5654 500.16--02 E 07.02 NR15/R 102/ 03

Figure 2. Jack off the cartridge
General For refitting, proceed in the reverse order of removing.
Screwed connections Apply high-temperature lubricant (such as Molykote HSC) to screws and
nuts but not to the screw thread when replacing studs.
Important! Lock washer pairs: Long wedged surfaces to contact

each other (on the inside), otherwise there will be no securing effect.

be observed. Apply high-temperature lubricant (such as Molykote HSC) to
the threads and contact surfaces.
Tightening torque for hexagon nuts (501.008) . . . . . . . . . 17 [Nm]
Checking For checking the gaps, refer to Operating Manual, Section 1, sheet 1.52.
5654 500.16--02 E 07.02 NR15/R 103/ 03

Cartridge
Checking and cleaning 500.17

Brief description
Check and clean the cartridge.

cleaning of components,
General
Checking and cleaning is restricted to the cartridge in assembled

condition.
▲ Attention! Disassembly or assembly of cartridge for cleaning or

replacing individual parts must be carried out by specialized service
personnel only.
Important! If a cartridge is to be sent to MAN B&W Diesel AG or

service point for overhaul, it must be packaged carefully to avoid additional
damage in transit.
Starting condition Cartridge removed from turbocharger.
Checking the cartridge
Check list The following check list includes data for evaluation and, if necessary,
measures to be taken for repairing the cartridge (please refer to table 1).
Possibilities Where several possibilities are marked off (a, b or c), the technical
optimum is to be selected (please, refer to table1).
5649 500.17--03 E 04.02 NR 101/ 03

Evaluation criteria Possibilities
on part or point a b c
condition
Transverse movement of rotor
please refer to work card 500.06
Measured value: permissible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a
Measured value: excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b c
Touch marks
Blad contour turbine wheel and/or compressor wheel:
one--sided on circumference: Signs of imbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b c
uniform on circumference: Check gaps and clearances (section 1, sheet 1.52) . . . . . a b c
Fouling
on axial gap between turbine rotor (turbine wheel) and bearing casing:
narrow oil trace: harmless, may be caused by post lubrication . . . . . . . . . . . . . . . . . . . . . . a
heavy fuel residues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a
thick cover of oil coke: indicates severe oil leakage,
leads mostly to sluggish running of rotor . . . . . . . . . . . . . . . . . . . b c
on turbine rotor (visible part of turbine wheel):
heavy fuel residues or other fouling cover ....................................... a
on compressor wheel (visible part of compressor wheel)):
dusty or oily cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a
Damage
Turbine rotor, compressor wheel, bearing casing:
turbocharging severely impaired, severe oil leakage, strength impaired . . . . . . . . . . . . . . b c
Sluggish running of rotor
very sluggish or blocked:
oil coke deposits after turbine wheel or in labyrinth seal, or bearing defect . . . . . . . . . . . . b c
Note Running--in labyrinths may cause some sluggishnes in rotation of new or

used turbochargers.
This is harmless because in operation the rotor floats and then runs free.
Test: Lift rotor to concentric position and rotate.
Table 1. Evaluations and possibilities
Possibilities: a Cartridge reuse, clean.

b Replace cartridge, or
c disassemble cartridge, check components, replace where necessary
(by specialized service personnel only).
5649 500.17--03 E 04.02 NR 102/ 03

Cleaning the cartridge
Burnt--in layers Burnt--in layers of dirt, particularly on the turbine side (e.g. heavy fuel
layers, oil coke), are to be removed by soaking in P3 water solution and
brushing. If necessary, repeat this process several times. Next neutralize
with soda water.
Oily layers Remove oily layers by means of fuel or some other liquid cleaning agent.
▲ Attention! The cleaning liquid and the dissolved dirt must not
enter the interior of the cartridge and thus the bearings or the lube
oil circuit. The gaps after the turbine wheel and the compressor
wheel should therefore be covered with suitable means.
Note For soaking layers of dirt on the turbine wheel, the cartridge can be placed
vertically, turbine side downwards, into a container with suitable seatings.
Fill the container with cleaning liquid only to a certain level which must not
be exceeded in order to prevent the liquid from entering the interior of the
cartridge (please refer to figure1).
Figure 1. Cleaning the cartridge
Dimensions Type D [mm] H [mm]

NR15/R 250 100
NR20/R 310 130
NR24/R 365 145
NR26/R 425 180
5649 500.17--03 E 04.02 NR 103/ 03

Cartridge
Checking the individual Components 500.18

Brief description
Checking the individual Components

cleaning components,

1 Assistant 1

1 Dial gauge with retainer -- Inventory
-- Special protective agent -- Inventory
(Molykote P40)
Related work cards

500.10 500.12 500.13
500.14 500.16 500.17
General
Starting condition Cartridge removed. Disassembly of cartridge required, please refer to work
card 500.17.
▲ Attention! Disassembly or assembly of cartridge for cleaning or
replacing individual parts must be carried out by specialized service
personnel only.
5654 500.18--01 E 07.04 NR15/R 101/ 04

Figure 1. Disassembly of the cartridge
Operating sequence 1 -- Disassembly of the cartridge
Steps 1. Unscrew the magnetic nut (520.124, right--hand tread), while holding the turbine rotor fast.
2. Pull off the carrier (520.009).
3. Pull off the compressor wheel (520.005) by hand in axial direction.
Tip! If the compressor wheel seizes: Heat the hub of compressor wheel (not the blades)
uniformly over entire circumference (not only locally), but quickly and carefully by means of a soft
flame up to but not exceeding 80° C. Then immediately pull the compressor wheel off swiftly.
▲ Attention! Overheating of the compressor wheel will lead to structural changes of
the aluminium alloy, rendering the compressor wheel unserviceable.
4. Slightly lift the turbine rotor (520.001) and pull it out as concentrically as possible.
Tip! Adhesion of labyrinths (from running--in) or coke deposits may impede the process. If so,
use pounding log. By removing the rotor, the labyrinth ring (520.006) is being stripped up. The
feather keys (520.018) are not stripped normally, they must not get lost, however.
5. Take out the labyrinth ring (520.006) and both bearing bushes (517.002) from bearing
casing (517.001).
Tip! In case the labyrinth ring sticks in the bearing casing, it may be pressed out together with
the distance sleeve (517.003) and the compressor side bearing bush after having removed the
turbine side bearing bush, as described in items 7. und 8.
6. Take off the intermediate ring (517.009).
7. Unscrew the holding screw (517.004, right--hand tread).
8. Press out the distance sleeve (517.003) in direction of compressor side.
Tip! In the event of the distance sleeve seizing, it may be loosened and forced out by light
hammer blows or using a press together with a wooden bolt or one of cooper .
5654 500.18--01 E 07.04 NR15/R 102/ 04

Cleaning and checking the individual parts, please refer to Operating sequence 3.
Figure 2. Assembly of the cartridge
Operating sequence 2 -- Assembly of the cartridge
General When assembly the cartridge, particular attention must be paid to the cleanliness of the individual
parts. Sliding surfaces of bearing points must be slightly moistened with clean lube oil.
Steps 1. Insert distance sleeve (517.003) into the bearing casing, paying attention to correct position.
Axial distance of bore hole for holding screw (517.004) is smaller towards compressor side.
2. Screw in the holding screw (517.004) up to stop position. Only tighten slightly.
3. Place the intermediate ring (517.009) on centering of bearing casing (517.001).
4. Insert bearing bushes (517.002) into bearing casing on turbine and compressor side. Bearing
bushes are symetric, thus, mounting position at discretion.
5. Apply a thin protective film of Molykote P40 to the fitting surfaces of the turbine shaft (for
labyrinth ring, compressor wheel and carrier). Cautiously insert turbine rotor in axial direction.
6. Move in the labyrinth ring (520.006) and insert feather keys (520.018). Push the compressor
wheel (520.005) and carrier (520.009) over turbine shaft up to the end position.
Important! The balancing marks (W) of the turbine rotor (520.001), labyrinth ring (520.006),
comressor wheel (520.005) and carrier (520.009) must coincide radially.
Tip! If necessary, heat the compressor wheel by suitable means (e.g. in a water bath or on
hot plate) up to but not exceeding 80° C.
▲ Attention! Overheating of the compressor wheel will lead to structural changes of
the aluminium alloy, rendering the compressor wheel unserviceable.
7. Apply Molykote P40 to the threads and contact surfaces of the magnetic nut (520.124) and
tighten the magnetic nut with tightening torque:
D 60 [Nm] in case of magnetic nut made of steel (across flats 19 mm)
D 21 [Nm] in case of magnetic nut made of aluminium (across flats 30 mm)
8. After cooling down the compressor wheel, loosen the magnetic nut (520.124) and thighten it
again with the thightening torque according to point 7.
9. Check the axial clearance of the complete rotor and the face runout of compressor wheel
using the dial gauge. For admissible values, please refer to Section 1, sheet 1.52, items (5)
and (6).
5654 500.18--01 E 07.04 NR15/R 103/ 04

Operating sequence 3 -- Cleaning and checking the individual parts
Cleaning Burnt--ine dirt layers, particularly on turbine side (e.g. residues of heavy fuel, oil coke) to be soaked
with P3--water solvent and brushed off. If required, this process is to be repeated several times.
Subsequently, neutralize with soda water.
Layers of oily dirt to be removed with fuel oil or any liquid cleansing agent.
Bores for sealing air and lube oil to be flushed with fuel oil and then to be blow through with
compressed air jet.
Checking The following check list includes data for evaluation and measures to be taken for repairing the cartridge.
Posibilities Where several possibilities are marked off (a or b), the technical optimum is to be selected:
a = Individual part to be replaced. b = Individual part to be sent in for repair.
Part No. Designation of individual part Possibilities

Order No. Condition a b
Dimensions of Replacement: D = External dia., d = Internal dia., b = Width
517.001 Bearing casing
Damage or incipient cracks, if stability or oil--proof condition imperiled . . . . . . . . . a
Traces of seizure or wear in bearing bore: d ≥
42.03 mm dia. . . . . . . . . . . . . . . . a
Running--in pattern abnormal by tips of labyrinth rings . . . . . . . . . . . . . . . . . . . . . . . a
Note The labyrinth clearance is smaller than the bearing clearance. Terefore,
the labyrinth tips are running into the bore of the bearing casing. The running--
in grooves are, depending on position of rotor, somewhat one--sided on the
circumference.
517.002 Bearing bush (2 units, identical for turbine and compressor side)
Traces of seizure in contact pattern of axial surfaces . . . . . . . . . . . . . . . . . . . . . . . . a
Wear: D ≤41.85 mm dia., d ≥
24.04 mm dia., b ≤
23.95 mm . . . . . . . . . . . . . . a
Note Uniform layer of lacquering is no cause of concern, internal and exter-
nal diameters cannot be evaluated by visual inspection.
517.003 Distance sleeve
Traces of seizure on axial surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a
517.009 Intermediate ring
Damage, if function or stability imperiled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a
520.001 Turbine rotor
Damage to blades, e.g. by foreign matter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a
Incipient cracks (Test: e.g. sound test, fluorescent dye check) . . . . . . . . . . . . . . . . a
Traces of touching on blade contur:
one--sided on circumference, are indication of imbalance . . . . . . . . . . . . . . . . . a b
over entire circumference, if permissible gap exceeded, please refer to
Operating Manual, section 1, sheet 1.52, items (3) and (4) . . . . . . . . . . . . . a
Labyrinth tips damaged or worn: D ≤
49.85 mm dia. . . . . . . . . . . . . . . . . . . . . . . . a b
Bearing points damaged or worn: D ≤
23.94 mm dia. . . . . . . . . . . . . . . . . . . . . . . a
Concentring running test: Clean centering points, allocate in points for centering,
measure concentric running at both bearing points and at seat of compressor
wheel (3 locations), if run--out exceeds 0,01 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . a b
Note If eccentricity at those 3 locations is in same position on the
circumference and runs linear, the centering points are damaged and the real
run--out from concentric running is smaller (max. permissible 0.01 mm)
520.005 Compressor wheel
Damage to blades, e.g. by foreign matter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a
Incipient cracks (Test: e.g. sound test, fluorescent dye check) . . . . . . . . . . . . . . . . a
Traces of touching on blade contur:
one--sided on circumference, are indication of imbalance . . . . . . . . . . . . . . . . . a b
over entire circumference, if permissible gap exceeded, please refer to
Operating Manual, section 1, sheet 1.52, items (1) und (2) . . . . . . . . . . . . . a
520.006 Labyrinth ring
Labyrinth tips damaged or worn: D ≤
49.85 mm dia. . . . . . . . . . . . . . . . . . . . . . . . a
5654 500.18--01 E 07.04 NR15/R 104/ 04

Gas outlet casing,
gas outlet diffuser
Brief description
Remove gas outlet casing and gas outlet diffuser for inspection.

1 Assistant 1

(e.g. Molykote HSC)
Related work cards

500.10
Technical details
Term Information
Gas outlet diffuser 15 kg
Gas outlet casing 50 kg
5654 500.19--02 E 07.02 NR15/R 101/ 02

Figure 1. Removing and refitting the gas outlet casing and gas outlet diffuser
Starting condition Connecting pipes and exhaust gas pipe disconnected, or complete
turbocharger removed from engine.
Steps 1. Take off the annular lagging (591.160).

2. Attach the gas outlet casing (506.001) to rope and suspend from
lifting tackle, carefully tension the rope.
3. Unscrew the hexagon nuts (506.103) and take off the lockwasher
pairs (506.107). Carefully detach the gas outlet casing in axial
direction and put it down on wooden pad. Take care of the covering.
4. Unscrew the hexagon nuts (509.103), take off the lockwasher
pairs (509.107) and gas outlet diffuser (509.001) in axial direction.
General For refitting, proceed in the reverse order of removing.
Screwed connections Apply high--temperature lubricant (such as Molykote HSC) to screws and
nuts but not to the screw thread when replacing studs.
Important! Lock washer pairs: Long wedged surfaces to contact

each other (on inside), otherwise there will be no securing effect.

be observed. Apply high--temperature lubricant (such as Molykote HSC) to
the threads and contact surfaces.
Tightening torque for hexagon nuts (509.103) . . . . . . . . . 17 [Nm]
5654 500.19--02 E 07.02 NR15/R 102/ 02

Turbine nozzle ring
Removing, refitting, checking 500.20
Brief description
Remove turbine nozzle ring for inspection.

removal of components,
checking of components,
installation of components.


1 Punch -- Inventory
1 Hammer -- Inventory
Related work cards

500.04 500.16 500.19
Preliminary remarks
General Removing of the turbine nozzle ring is only necessary in case of

replacement.
Starting condition Gas outlet casing, gas outlet diffuser and cartridge removed.
5654 500.20--01 E 07.02 NR15/R 101/ 02

Figure 1. Removing and refitting the turbine nozzle ring
Steps 1. For cecking the turbine nozzle ring (513.001),

please refer to Work card 500.04.
2. Remove the turbine nozzle ring (513.001) by means of pounding with
invariable force in direction “A”, with a hammer and a piercer onto 4
collar pins (501.009).
Steps 1. Press the 4 collar pins (501.009) with their longer, tapered portion
into the gas--admission casing (501.001) up to the stop.
2. Place the turbine nozzle ring (513.001) onto collar pins in a manner
so that the corner--shaped nozzle vanes are in congruence with the
separating walls of the gas--admission casing (marks “Z”, refer to
figure 1).
3. Press in the turbine nozzle ring uniformly and evenly, do not tilt and
do not apply pressure on nozzle vanes.
Important! The number of separating walls is depending on design
of gas--admission casing.
5654 500.20--01 E 07.02 NR15/R 102/ 02

Spare parts catalogue
0 Introduction
1 Technical Data
2 Systems
3 Operation
4.1 Maintenance
4.2 Work Cards
5649 5--01 E 03.02 101/ 01

Table of contents
h 5 Spare parts catalogue
S S h 5.51 Organisation and Use of the Spare Parts Catalogue

S S h 5.52 Ordering Spare Parts
h 5.55 List of Assemblies
h 501.01 Gas--admission casing
h 506.01 Gas outlet casing
h 509.01 Gas outlet diffuser
h 513.01 Turbine nozzle ring
h 517.01 Bearing casing
h 520.01 Rotor complete
h 542.01 Diffuser
h 544.01 Silencer
h 544.02 Silencer
h 545.01 Air intake casing
h 562.01 Speed measuring device
h 591.01 Coverings
h 599.01 Cartridge
Information
Description
Instruction
Intended for ...
Experts
Middle management
Upper management
5654 09.07 NR15/R 101 /01

Organisation and Use
of the Spare Parts Catalogue 5.51
Spare parts for turbochargers
Spare parts, Maintenance and repair work can only be carried out properly if the
spare parts catalougue necessary spare parts are available. They are to be kept on stock or
ordered in time. The order numbers required for the ordering of spare
parts can be looked up in the Spare Parts Catalogue.
Spare parts Spare parts for the turbocharger can be identified by means of the Spare
Parts Catalogue. For this purpose, illustration and text sheets with order
numbers are available. An order number consists of a three--digit
subassembly number and a three--digit item number, which are separated
by a dot. The Spare Parts Catalogue is arranged in the order of the
subassemblies.
The order numbers, however, can also be looked up in the respective work
cards contained in Section 4.2 of the Operating Manual.
Reserve parts, If ordered separatly a basic provision of spare parts will be delivered as so
refer also to Section 6 called “Reserve parts”, the range of which is listed in the table. The
of the Operating Manual numbers in the list should be quoted in your order and coincide with the
numbers with which the parts are marked. All parts, unless packed in
plastic bags should be kept well greased during storage. Any parts
showing rust deposits should be cleaned and coated with grease.
It is recommended that any reserve parts installed should be re--ordered at
once, seeing that transport (and customs clearance) may cause
considerable delays in the delivery of the parts. Prompt repairs depend on
any necessary parts being at hand when needed.
Tools, Complete or individual tools for turbochargers can be ordered with the aid
refer also to Section 6 of the list of contents for tools, stating the respective order numbers. This
of the Operating Manual list of contents is included in the tool box for the turbocharger. An order
number is composed of a three--digit subassembly number 596 (=
subassembly for tools) and a three--digit item number, which are separated
by a dot.
The order numbers, however, can also be looked up in the respective work
cards contained in Section 4.2 of the Operating Manual.
Instructions for use
What does the spare parts The spare parts catalogue covers all essential components of the
catalogue contain/what not? turbocharger. The spare parts catalogue does not contain subordinate or
plant--specific insulations/coverings and subordinate cabling, or cabling
leading away from the turbocharger/cabling and pipes carried out by other
parties.
What can be done if parts are If parts have to be ordered which the spare parts catalogue does not
not found? contain or that are not found, the component and the place where it is
installed should be described as precisely as possible with instant photos
possibly attached. Where parts from subsuppliers are concerned, that
cannot be found in their documentation, the information given on the
relevant technical data plate should be stated.
5649 5.51--01 E 04.02 NR, NA 101/ 02

Sources of fault If a turbocharger undergoes modifications in the course of operating time
and MAN B&W Diesel AG does not execute new drawings reflecting such
modifications and if therefore a new spare parts sheet is not drawn up
either, the engine operator himself should enter a warning in his spare
parts catalogue to avoid that wrong equipment is ordered.
Supply of modified components Since our turbochargers undergo upgrading development, it may happen
that when spare parts are ordered later on the parts supplied differ from
the ones supplied originally, which, however, serve the same purpose as
the latter. In such cases, the identity card of the part supplied will contain
a corresponding reference.
Organisation and characteristic features
Organisational pattern The order of the sheets in the spare parts catalogue follows the
subassembly group system of the turbocharger.
The subassembly group list is part of the Spare Parts Catalogue.
It consists of an illustration sheets and a table. The table is arranged in the
order of the subassembly group numbers.
Subassembly groups The subassembly group column is characterised by the symbol shown at
the left. Subassembly groups of which the numbers are put in
parentheses, are not available on all turbochargers. Subassembly groups
of which the numbers are marked with *, are not shown in the
subassembly group list.
Ordinal number The ordinal number at the right--hand top of the spare parts sheets
consists of the three--digit subassembly group number and a variant
number corresponding to the constructional variant.
Sheet number The sheet number consists of the four--digit print number (e.g. 6661) at the
bottom left, and the ordinal number (e.g. 520.01 D) right of it.
Item number The item numbers can be found in the text sheet underneath the symbol
1 2 shown at the left. They are mentioned here for the turbocharger for
3
technical reasons only.
Order number The order numbers in the second column of the text sheet -- underneath
✍ the symbol of a writing hand shown at the left -- consist of a three--digit

subassembly group number and a three--digit item number. Subassembly
group number and item number are structured by a dot.
520 . 001 Order number (e.g. turbine rotor)
Item number
Subassembly group number
Spare parts designation The spare parts designation can be found under the respective language
symbol in the columns 3 to 6.
D E F Sp
5649 5.51--01 E 04.02 NR, NA 102/ 02

Ordering Spare Parts 5.52
Information required To avoid queries, the following information should be provided when
ordering spare parts:
Type of the turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . xxxxxxxxx

Works number of the turbocharger . . . . . . . . . . . . . . . . . . x xxx xxx
(Type of the engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxxxxxxxx

(Works number of the engine) . . . . . . . . . . . . . . . . . . . . . . x xxx xxx
Designation of part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxxxxxxxx

Order number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxx . xxx
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx
Shipping address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxxxxxxxx

Mode of shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxxxxxxxx
Address Please address your order to:

86224 Augsburg
Germany
Phone +49 821 322 3994

Fax +49 821 322 3998
5649 5.52--01 E 04.02 NR, NA 101/ 01

Baugruppenübersicht
List of Assemblies
Aperçu des sous- ensembles
Lista de todos los grupos 5.55
5654 5.55--01 E 06.02 NR15/R 101/ 03

List of Assemblies
D GB F E
500 Abgasturbolader Exhaust gas turbocharger Turbocompresseur à gaz Turbosobrealimentador de gas de

d’ échappement escape
501 Turbinen--Zuströmgehäuse Gas--admission casing Corps d’admission de turbine Carcasa de afluencia de la turbina
(506) Turbinen--Abströmgehäuse Gas outlet casing Corps d’échappement de turbine Carcasa de evacuación de la turbina
509 Turbinen--Abströmdiffusor Gas outlet diffuser Diffuseur d’échappement de Difusor de evacuación de la turbina
turbine
513 Turbinenleitapparat Turbine nozzle ring Distributeur de turbine Distribuidor de gases de la turbina
517 Lagergehäuse Bearing casing Boîte de paliers Carcasa de cojinetes

520 Läufer komplett Rotor complete Rotor complet Rotor completo
542 Nachleitapparat Diffuser Diffuseur Difusor
(544) Schalldämpfer Silencer Silencieux Silenciador
(545) Ansauggehäuse Air intake casing Corps d’aspiration Caja de aspiración
546 Verdichtergehäuse Compressor casing Corps de compresseur Caja del compresor

(562) Drehzahlmeßeinrichtung Speed measuring device Dispositif de mesure de régime Instalación para la medición del
número de revoluciones
(578) Reinigungseinrichtung für Turbine Cleaning device for turbine Dispositif de nettoyage pour Dispositivo de lavado para turbina
turbine
(579) Reinigungseinrichtung für Cleaning device for compressor Dispositif de nettoyage pour Dispositivo de lavado para compresor
Verdichter compresseur
(591) Verschalungen Coverings Revêtements Revestimientos
5654 5.55--01 E 06.02 NR15/R 102/ 03

List of Assemblies
D GB F E
599 Rumpfgruppe (517 + 520) Cartridge (517 + 520) Groupe base (517 + 520) Grupo base (517 + 520)
* Diese Baugruppen sind in den Bildern nicht sichtbar
These assemblies are not shown in the figures
Ces sous--groupes ne sont pas illustrés sur les figures
Estos grupos constructivos no están visibles en las figuras
(...) falls vorhanden
if provided
s’il existe
si existe
5654 5.55--01 E 06.02 NR15/R 103/ 03

Turbinen- Zuströmgehäuse
Gas- admission casing
Corps d’admission de turbine
Carcasa de afluencia de la turbina 501.01
5654 501.01 E 06.02 NR15/R 101/ 02

Turbinen- Zuströmgehäuse
Gas- admission casing
Corps d’admission de turbine
Carcasa de afluencia de la turbina 501.01
1 2
3
✍ D GB F E
000 501.000 Turbinen--Zuströmgehäuse, Gas--admission casing, Corps d’admission de turbine, Carcasa de afluencia de la
komplett compl. compl. turbina,
compl.
001 501.001 Turbinen--Zuströmgehäuse Gas--admission casing Corps d’admission de turbine Carcasa de afluencia de la
turbina
005 501.005 Spannpratze Clamping claw Patte de serrage Garra tensora
006 501.006 Stiftschraube Stud Goujon Espárrago
007 501.007 Sicherungsscheibenpaar Lock washer pair Paire de rondelles d’arrêt Par de arandelas de seguridad
008 501.008 Sechskantmutter Hexagon nut Ecrou hexagonal Tuerca hexagonal

009 501.009 Bundbolzen Collar pin Boulon à collet Perno con collar
5654 501.01 E 06.02 NR15/R 102/ 02

Turbinen- Abströmgehäuse
Gas outlet casing
Corps d’échappement de turbine
Carcasa de evacuación de la turbina 506.01
5654 506.01 E 06.02 NR15/R 101/ 02

Turbinen- Abströmgehäuse
Gas outlet casing
Corps d’échappement de turbine
Carcasa de evacuación de la turbina 506.01
1 2
3
✍ D GB F E
000 506.000 Turbinen--Abströmgehäuse, Gas outlet casing, complete Corps d’échappement de Carcasa de evacuación de la
komplett turbine, compl. turbina, compl.
001 506.001 Turbinen--Abströmgehäuse Gas outlet casing Corps d’échappement de turbine Carcasa de evacuación de la
turbina
074 506.074 Verschlußschraube Screw plug Bouchon fileté Tapón roscado
075 506.075 Dichtring Sealing ring Anneau--joint Anillo--junta

5654 506.01 E 06.02 NR15/R 102/ 02

Turbinen- Abströmdiffusor
Gas outlet diffuser
Diffuseur d’échappement de turbine
Difusor de evacuación de la turbina 509.01
5654 509.01 E 06.02 NR15/R 101/ 02

Turbinen- Abströmdiffusor
Gas outlet diffuser
Diffuseur d’échappement de turbine
Difusor de evacuación de la turbina 509.01
1 2
3
✍ D GB F E
000 509.000 Turbinen--Abströmdiffusor, Gas outlet diffuser, complete Diffuseur d’échappement de Difusor de evacuación de la
komplett turbine, compl. turbina, compl.
001 509.001 Turbinen--Abströmdiffusor Gas outlet diffuser Diffuseur d’échappement de Difusor de evacuación de la
turbine turbina
5654 509.01 E 06.02 NR15/R 102/ 02

Turbinenleitapparat
Turbine nozzle ring
Distributeur de turbine
Distribuidor de gases de la turbina 513.01
5654 513.01 E 06.02 NR15/R 101/ 02

Turbinenleitapparat
Turbine nozzle ring
Distributeur de turbine
Distribuidor de gases de la turbina 513.01
1 2
3
✍ D GB F E
001 513.001 Turbinenleitapparat Turbine nozzle ring Distributeur de turbine Distribuidor de gases de la
turbina
5654 513.01 E 06.02 NR15/R 102/ 02

Lagergehäuse
Bearing casing
Boîte de paliers
Carcasa de cojinetes 517.01
5654 517.01 E 06.02 NR15/R 101/ 02

Lagergehäuse
Bearing casing
Boîte de paliers
Carcasa de cojinetes 517.01
1 2
3
✍ D GB F E
000 517.000 Lagergehäuse, komplett Bearing casing, compl. Boîte de paliers, compl. Carcasa de cojinetes, compl.
001 517.001 Lagergehäuse Bearing casing Boîte de paliers Carcasa de cojinetes
002 517.002 Lagerbuchse Bearing bush Coussinet de palier Casquillo de cojinete
003 517.003 Abstandshülse Distance sleeve Douille d’écartement Manguito distanciador
004 517.004 Halteschraube Holding screw Vis de support Tornillo de soporte
009 517.009 Zwischenring Intermediate ring Bague intermédiaire Anillo intermedio


063 517.063 Runddichtring O--ring seal Joint torique d’étanchéité Junta tórica
122 517.122 Einspritzrohr Injection pipe Tuyau d’injection Tubo de inyeccion
5654 517.01 E 06.02 NR15/R 102/ 02

Läufer komplett
Rotor complete
Rotor complet
Rotor completo 520.01
5654 520.01 E 06.02 NR15/R 101/ 02

Läufer komplett
Rotor complete
Rotor complet
Rotor completo 520.01
1 2
3
✍ D GB F E
000 520.000 Läufer komplett Rotor complete Rotor complet Rotor completo
001 520.001 Turbinenläufer Turbine rotor Rotor de turbine Rotor de la turbina
005 520.005 Verdichterrad Compressor wheel Roue de compresseur Rodete compresor
006 520.006 Labyrinthring Labyrinth ring Bague à labyrinthe Anillo de laberinto
009 520.009 Mitnehmer Carrier Entraîneur Arrastrador
018 520.018 Paßfeder Feather key Clavette Chaveta de ajuste

124 520.124 Magnetmutter Magnetic nut Ecrou magnétique Tuerca magnética
5654 520.01 E 06.02 NR15/R 102/ 02

Nachleitapparat
Diffuser
Diffuseur
Difusor 542.01
5654 542.01 E 06.02 NR15/R 101/ 02

Nachleitapparat
Diffuser
Diffuseur
Difusor 542.01
1 2
3
✍ D GB F E
001 542.001 Nachleitapparat Diffuser Diffuseur Difusor
5654 542.01 E 06.02 NR15/R 102/ 02

Schalldämpfer
Silencer
Silencieux
Silenciador 544.01
5654 544.01 E 06.02 NR15/R 101/ 02

Schalldämpfer
Silencer
Silencieux
Silenciador 544.01
1 2
3
✍ D GB F E
000 544.000 Schalldämpfer, komplett Silencer, complete Silencieux, complet Silenciador, completo
001 544.001 Rückwand Rear wall Paroi arrière Pared trasera
021 544.021 Dämpfungsplatte Damping plate Plaque d’ amortissement Placa de amortiguación
032 544.032 Distanzrohr Spacer pipe Tuyau d’écartement Tubo distanciador
034 544.034 Schutzgitter Protection grate Grill protectrice Rejilla protectora
041 544.041 Vorderwand Front wall Paroi en avant Pared delantera

075 544.075 Scheibe Washer Rondelle Arandela
084 * 544.084 Verschlußschraube Screw plug Bouchon fileté Tapón roscado

090 * 544.090 Einspritzrohr Injection pipe Tuyau d’injection Tubo de inyeccion
201 544.201 Luftfiltermatte Air filter mat Natte de filtre à air Estera de filtro de aire
202 544.202 Spannschelle Clamp Agrafe de serrage Abrazadera de sujeción
205 544.205 Abdeckblech Cover sheet Tôle de recouvrement Chapa de revestimiento
* falls vorhanden
if provided
si présent
si existe
5654 544.01 E 06.02 NR15/R 102/ 02

Schalldämpfer
Silencer
Silencieux
Silenciador 544.02
5654 544.02 E 06.02 NR15/R 101/ 03

Schalldämpfer
Silencer
Silencieux
Silenciador 544.02
1 2
3
✍ D GB F E
000 544.000 Schalldämpfer, komplett Silencer, complete Silencieux, complet Silenciador, completo
001 544.001 Rückwand Rear wall Paroi arrière Pared trasera
021 544.021 Dämpfungsplatte Damping plate Plaque d’ amortissement Placa de amortiguación
032 544.032 Distanzrohr Spacer pipe Tuyau d’écartement Tubo distanciador
033 544.033 Zentrierbuchse Centering bush Douille de centrage Casquillo de centraje
034 544.034 Schutzgitter Protection grate Grill protectrice Rejilla protectora

041 544.041 Vorderwand Front wall Paroi en avant Pared delantera


201 544.201 Luftfiltermatte Air filter mat Natte de filtre à air Estera de filtro de aire
202 544.202 Spannschelle Clamp Agrafe de serrage Abrazadera de sujeción
205 544.205 Abdeckblech Cover sheet Tôle de recouvrement Chapa de revestimiento
222 544.222 Deckel Cover Couvercle Tapa

5654 544.02 E 06.02 NR15/R 102/ 03

Schalldämpfer
Silencer
Silencieux
Silenciador 544.02
1 2
3
✍ D GB F E
* falls vorhanden
if provided
si présent
si existe
5654 544.02 E 06.02 NR15/R 103/ 03

Ansauggehäuse
Air intake casing
Corps d’aspiration
Caja de aspiración 545.01
5654 545.01 E 06.02 NR15/R 101/ 02

Ansauggehäuse
Air intake casing
Corps d’aspiration
Caja de aspiración 545.01
1 2
3
✍ D GB F E
000 545.000 Ansauggehäuse, komplett Air intake casing, complete Corps d’aspiration, complet Caja de aspiración, completa
001 545.001 Ansauggehäuse Air intake casing Corps d’aspiration Caja de aspiración
014 545.014 Sechskantschraube Hexagon bolt Boulon à tête hexagonale Tornillo de cabeza hexagonal

* falls vorhanden
if provided
si présent
si existe
5654 545.01 E 06.02 NR15/R 102/ 02

Verdichtergehäuse
Compressor casing
Corps de compresseur
Caja del compresor 546.01
5654 546.01 E 06.02 NR15/R 101/ 02

Verdichtergehäuse
Compressor casing
1 2
3
✍ D GB F E
000 546.000 Verdichtergehäuse, komplett Compressor casing, compl. Corps de compresseur, compl. Caja del compresor, compl.
001 546.001 Verdichtergehäuse Compressor casing Corps de compresseur Caja del compresor
005 546.005 V--Profil--Spannschelle V--profile clamp Agrafe de serrage profile en V Abrazadera de sujeción perfil
en V
008 546.008 Senkschraube Countersunk bolt Vis à tête fraisée Tornillo de cabeza avellanada
022 546.022 Sicherungsscheibe Lock washer Rondelle d’arrêt Arandela de seguridad

025 546.025 Typenschild Type plate Plaque de type Placa de tipo
026 546.026 Kerbnagel Notched nail Clou à rainures Clavo entallado
5654 546.01 E 06.02 NR15/R 102/ 02

Verdichtergehäuse
Compressor casing
5654 546.02 E 06.02 NR15/R 101/ 02

Verdichtergehäuse
Compressor casing
1 2
3
✍ D GB F E
000 546.000 Verdichtergehäuse, komplett Compressor casing, compl. Corps de compresseur, compl. Caja del compresor, compl.
001 546.001 Verdichtergehäuse Compressor casing Corps de compresseur Caja del compresor
005 546.005 V--Profil--Spannschelle V--profile clamp Agrafe de serrage profile en V Abrazadera de sujeción perfil
en V
008 546.008 Senkschraube Countersunk bolt Vis à tête fraisée Tornillo de cabeza avellanada
018 546.018 Einsatzstück Insert Insert Pieza de inserción

022 546.022 Sicherungsscheibe Lock washer Rondelle d’arrêt Arandela de seguridad
023 546.023 Runddichtring O--ring seal Joint torique d’étanchéité Junta tórica
025 546.025 Typenschild Type plate Plaque de type Placa de tipo

026 546.026 Kerbnagel Notched nail Clou à rainures Clavo entallado
050 546.050 Flansch Flange Bride Brida
5654 546.02 E 06.02 NR15/R 102/ 02

Drehzahlmeßeinrichtung
Speed measuring device
Dispositif de mesure de régime
Instalación para la medición del número de revoluciones 562.01
5654 562.01 E 06.02 NR15/R 101/ 02

Drehzahlmeßeinrichtung
Speed measuring device
Dispositif de mesure de régime
Instalación para la medición del número de revoluciones 562.01
1 2
3
✍ D GB F E
000 562.000 Drehzahlmeßeinrichtung, Speed measuring device, Dispositif de mesure de régime, Instalación para la medición del
komplett compl. compl. número de revoluciones, compl.
004 562.004 Haltescheibe Holding disk Disque de support Disco de soporte
040 562.040 Drehzahlgeber Speed transmitter Transmetteur de vitesse Transmisor de velocidad
083 * 562.083 Klemmenkasten Terminal box Boîte à bornes Caja de bornes
100 * 562.100 Drehzahlanzeiger Speed indicator Indicateur de vitesse Indicador de revoluciones
135 * 562.135 Teflon--Panzerleitung Teflon--armoured cable Conduite armee teflonee Tubería blindada de teflon
* falls vorhanden
if provided
si présent
si existe
5654 562.01 E 06.02 NR15/R 102/ 02

Reinigungseinrichtung für Turbine
Cleaning device for turbine
Dispositif de nettoyage pour turbine
Dispositivo de lavado para turbina 578.01
6661 578.01 E 03.01 NR 101/ 02

1 2
3
✍ D GB F E
000 578.01.000 Reinigungseinrichtung Cleaning device Dispositif de nettoyage Dispositivo de lavado

für Turbine, komplett for turbine, complete pour turbine, complet para turbina, completo
(Naßreinigung) (wet cleaning) (nettoyage par voie humide) (limpieza por vía húmeda)
002 578.01.002 Verschraubung Screwed connection Raccord Racor
003 578.01.003 Dichtring Sealing ring Anneau--joint Anillo--junta
005 578.01.005 Dichtring Sealing ring Anneau--joint Anillo--junta
006 578.01.006 Druckminderstation Pressure reducing station Station de réduction de pression Equipo de reducción de presión
010 578.01.010 Schild Plate Plaque Placa

(mit Reinigungsvorschrift) (with cleaning instructions) (avec cahier de nettoyage) (con instrucciones de limpieza)
020 578.01.020 Dreiwegehahn Three--way cock Robinet à trois voies Grifo de tres pasos
6661 578.01 E 03.01 NR 102/ 02

6661 578.02 E 11.01 NR 101/ 02

1 2
3
✍ D GB F E
000 578.02.000 Reinigungseinrichtung Cleaning device Dispositif de nettoyage Dispositivo de lavado

für Turbine, komplett for turbine, complete pour turbine, complet para turbina, completo
(Trockenreinigung) (dry cleaning) (nettoyage à sec) (limpieza en seco)
001 578.02.001 Behälter Tank Réservoir Recipiente
020 578.02.020 Verschlußschraube Screw plug Bouchon fileté Tapón roscado

029 578.02.029 Bügelschraube U--bolt Etrier fileté Horquilla roscada
030 578.02.030 Kugelhahn Ball cock Robinet sphérique Grifo esférico
031 578.02.031 Absperrhahn Stop cock Robinet à boisseau Llave de cierre
035 578.02.035 Schild Plate Plaque Placa

6661 578.02 E 11.01 NR 102/ 02

Reinigungseinrichtung für Verdichter
Cleaning device for compressor
Dispositif de nettoyage pour compresseur
Dispositivo de lavado para compresor 579.01
5654 579.01 E 06.02 NR15/R 101/ 02

1 2
3
✍ D GB F E
119 579.119 Handspritze Syringe Seringue à main Jeringa a mano
5654 579.01 E 06.02 NR15/R 102/ 02

6661 579.01 E 09.99 NR, NA 101/ 02

1 2
3
✍ D GB F E
000 579.000 Reinigungseinrichtung Cleaning device Dispositif de nettoyage Dispositivo de lavado

für Verdichter, komplett for compressor, complete pour compresseur, compl. para compresor, compl.
(abgesetzter Behälter) (separate tank) (réservoir séparé) (recipiente separado)
029 579.029 Behälter Tank Réservoir Recipiente
030 579.030 Schraubverschluß Screw plug Vis de fermeture Tapón roscado
080 579.080 Saugrohr Suction pipe Tuyau d’aspiration Tubería de aspiración
090 579.090 Schlauch Hose Tuyau flexible Tubo flexible

091 579.091 Schlauchschelle Hose clamp Agrafe flexible Abrazadera de manguera
103 579.103 Verschraubung Screwed connection Raccord Racor
104 579.104 Reduzierverschraubung Reducing connection Raccord à vis pour réduction Racor de reducción
120 579.120 Anschlußstück Connecting piece Pièce de raccordement Pieza de racor
122 579.122 Hydrometerhahn Hydrometer cock Robinet hydromètre Llave del hidrómetro
130 579.130 Halterung Support Support Soporte

178 579.178 Schild Plate Plaque Placa
6661 579.01 E 09.99 NR, NA 102/ 02

6661 579.02 E 09.99 NR, NA 101/ 02

1 2
3
✍ D GB F E
000 579.000 Reinigungseinrichtung Cleaning device Dispositif de nettoyage Dispositivo de lavado

für Verdichter, komplett for compressor, complete pour compresseur, compl. para compresor, compl.
(Druckspritze) (pressure sprayer) (dispositif d’aspersion à (dispositivo de chorrear a
pression) presión)
029 579.029 Druckspritze Pressure sprayer Dispositif d’aspersion à pression Dispositivo de chorrear a presión
095 579.095 Kupplung Coupling Accouplement Acoplamiento
096 579.096 Nippel Nipple Raccord Boquilla

100 579.100 Einschraubstutzen Screwed socket Tubulure filetée Unión roscada
102 579.102 Winkelverschraubung Angular screw connection Raccord à vis coudé Racor angular
130 579.130 Halter Retainer Support Soporte

179 579.179 Schild Plate Plaque Placa
6661 579.02 E 09.99 NR, NA 102/ 02

Verschalungen
Coverings
Revêtements
Revestimientos 591.01
5654 591.01 E 06.02 NR15/R 101/ 02

Verschalungen
Coverings
Revêtements
Revestimientos 591.01
1 2
3
✍ D GB F E
001 * 591.001 Verschalung mit Isolierung Covering with insulation Revêtement avec calorifugeage Revestimiento con aislamiento
am Turbinen--Zuströmgehäuse on gas--admission casing sur corps d’admission de turbine en la caja de afluencia de la
turbina
060 * 591.060 Schild zweiteilig Two--part plate Plaque en deux pièces Placa de dos piezas
066 * 591.066 Dichtring Sealing ring Anneau--joint Anillo--junta
085 * 591.085 Verbindungsstück Joining piece Pièce de jonction Pieza de conexión
101 * 591.101 Verschalung mit Isolierung Covering with insulation Revêtement avec calorifugeage Revestimiento con aislamiento
am Turbinen--Abströmgehäuse on gas outlet casing sur corps d’échappement de en la caja de evacuación de la
turbine turbina
160 * 591.160 Ringverschalung Annular lagging Revêtement annulaire Revestimiento anular

* falls vorhanden
if provided
si présent
si existe
5654 591.01 E 06.02 NR15/R 102/ 02

Rumpfgruppe
Cartridge
Groupe base
Grupo base 599.01
5654 599.01 E 06.02 NR15/R 101/ 02

Rumpfgruppe
Cartridge
Groupe base
Grupo base 599.01
1 2
3
✍ D GB F E
000 * 599.000 Rumpfgruppe Cartridge Groupe base Grupo base

* 599.000 = (517.000) und (520.000) zusammengebaut
599.000 = (517.000) and (520.000) assembled
599.000 = (517.000) et (520.000) assemblés
599.000 = (517.000) y (520.000) ensamblados
5654 599.01 E 06.02 NR15/R 102/ 02

Reserve Parts, Tools
0 Introduction
1 Technical Data
2 Systems
3 Operation
4.1 Maintenance
4.2 Work Cards
5649 6--01 E 03.02 101/ 01

Table of contents
h 6 Reserve Parts, Tools
h 594 List of reserve parts

h 596 List of tools
Information
Description
Instruction
Intended for ...
Experts
Middle management
Upper management
5654 09.07 NR15/R 101 /01

List of reserve parts 594
S11.59400--0086, X11.59400--0087 (X11.59500--0114)
Order No. Designation Sketch [mm] Quantity
501.006 Stud D = 8.0 6

L = 29.8
( 24 )*
501.007 Lock washer pair D =13.5 24

S = 2.2
( 24 )*
501.008 Hexagon nut W = 13.0 6

B = 6.5
( 24 )*
517.002 Bearing bush D = 42 2

B = 24
( 2 )*
517.063 O--ring seal D = 340 1

S = 4
( 1 )*
5654 594--01 E 06.02 NR15/R 101/ 01

List of tools 596
E11.59600--0124, X11.59600--0125 (X11.59700--0117)
Order No. Designation Sketch [mm] Quantity
596.008 Segment L = 70 3
B = 40
*)
(0.300 kg)
596.009 Spindle D = 12 3
L = 70
*)
(0.051 kg)
596.010 Hexagon nut W= 19 6

B = 10
*)
(0.017 kg)
*) = For removing the cartridge (Work card 500.16)
5654 596--01 E 06.02 NR15/R 101/ 01

NR15-R Operating Manual

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Technical Documentation

Exhaust Gas Turbocharger

Exhaust gas turbocharger . . . . . . . . . . NR15/R

5654 C--02 E 06.02 101/ 02

5654 C--02 E 06.02 102/ 02

S h 1.51.1 Exhaust gas turbocharger Brief description, function

S S h 2.51 Lube oil system

S S h 3.51 Starting, Operation, Stopping

5654 09.07 NR15/R 101 /03

S S h 4.51 Maintenance work

h 4.2 Work Cards

h 5 Spare parts catalogue

S S h 5.51 Organisation and Use of the Spare Parts Catalogue

5654 09.07 NR15/R 102 / 03

h 6 Reserve Parts, Tools

h 594 List of reserve parts

5654 09.07 NR15/R 103 /03

4.2 Work Cards

5 Spare Parts Catalogue

6 Reserve Parts, Tools

5649 0--01 E 03.02 101/ 01

5654 09.07 NR15/R 101 /01

▲▲ Caution! Missing information and disregard for information

▲▲ Caution! Untrained persons can cause injury to persons,

5649 0.51--01 E 03.02 NR, NA 101/ 01

The reliable and economically efficient operation of a propulsion system

This Technical Documentation complements these faculties by specific

▲▲ Caution! Neglection of the Technical Documentation, and

5649 0.52--01 E 03.02 NR, NA 101/ 01

Addresses Table 1 contains the addresses of Works of the

The addresses of MAN B&W service centers, agencies and authorised

MAN B&W Diesel AG Company Address

5649 0.53--01 E 03.02 NR, NA 101/ 01

Use in accordance with the destination

The delivered turbocharger is destined for (firstly) operation under the

With restrictions destined/suitable for

The turbocharger is with restrictions destined/suitable for:

Not destined/suitable for

The Turbocharger is not destined/suitable for:

5649 0.54--01 E 03.02 NR, NA 101/ 01

Dangers due to deficiencies concerning personnel/level of training

Expectations in case of vessel Propeller operation/generator operation (normal operation/operation in

Maintenance work/repair work in the port:

Generator operation (in port):

Maintenance work/repair work in port:

Expectations in case of During operation:

Maintenance work/repair work:

Dangers due to components/systems

Certain dangers do of course originate from technical products and from

5649 0.55--01 E 03.02 NR, NA 101/ 02

Emission Danger Preventive/protective measure

Planned working places

Engines are usually operated under remote control. Regular rounds

Personal protective measures

The regulations for prevention of accidents (Unfallverhütungsvorschriften =

The relevant sections of the technical documentation must be read and

5649 0.55--01 E 03.02 NR, NA 102/ 02

▲ Attention! Disregarding this means: risk of burns when hot

Removing/refitting of heavy When removing or detaching heavy engine components it is imperative to

5649 0.56--01 E 03.02 NR, NA 101/ 02

▲ Attention! Loose clothing and long hair might get entangled.

▲ Attention! Disreagarding this means: danger of caustic skin and

▲ Attention! Using Diesel fuel for cleaning purposes involves the