Professional Documents
Culture Documents
ST5
Operating instructions
for exhaust-gas turbocharger
ST5
1 General ..................................................................................................... 5
1.1 Definitions.......................................................................................................................... 5
1.2 Product description .......................................................................................................... 7
1.2.1 Brief description .................................................................................................................. 7
1.2.2 Design ................................................................................................................................. 7
1.2.3 Function .............................................................................................................................. 7
1.2.4 Intended use ....................................................................................................................... 7
1.3 Product identification ....................................................................................................... 8
1.3.1 Marking of the exhaust-gas turbocharger ........................................................................... 8
1.3.2 Marking of parts and subassemblies .................................................................................. 9
1.4 Safety ............................................................................................................................... 10
1.4.1 Introduction ....................................................................................................................... 10
1.4.2 Definition of safety instructions and mandatory signs....................................................... 10
1.4.3 Hazards during operation and when working on the exhaust-gas turbocharger .............. 12
1.4.4 Warning signs on the exhaust-gas turbocharger .............................................................. 14
1.4.5 Prerequisites for operation ................................................................................................ 15
1.4.6 Operating and maintenance staff ...................................................................................... 16
1.4.7 Mounting spare and wearing parts.................................................................................... 16
1.4.8 Declaration of incorporation .............................................................................................. 17
1.4.9 Lifting loads ....................................................................................................................... 18
3 Operation ................................................................................................ 26
3.1 Removal of temporary corrosion protection ................................................................ 26
3.2 Commissioning ............................................................................................................... 27
3.3 Putting into operation ..................................................................................................... 27
3.4 Malfunctions .................................................................................................................... 28
3.5 Troubleshooting .............................................................................................................. 29
3.6 Replacement intervals for components ....................................................................... 35
3.7 Emergency operation of the exhaust-gas turbocharger ............................................. 36
3.8 Shutdown (short-term) ................................................................................................... 37
3.9 Extended shutdown (preservation) ............................................................................... 38
3.10 Disposal ........................................................................................................................... 39
3.11 Maintenance .................................................................................................................... 40
3.11.1 General ............................................................................................................................. 40
3.11.2 Maintenance work and intervals ....................................................................................... 40
3.11.3 Scope of inspections ......................................................................................................... 42
3.11.4 Spare parts required for inspections ................................................................................. 43
3.11.5 Maintenance of the turbine nozzle ring ............................................................................. 44
3.12 Cleaning ........................................................................................................................... 45
3.12.1 Cleaning the compressor .................................................................................................. 45
3.12.2 Turbine cleaning................................................................................................................ 47
3.12.3 Cleaning the silencer ........................................................................................................ 52
1 General
1.1 Definitions
Abbreviations
The following abbreviations may be used in this document:
TC Exhaust-gas turbocharger
RG Cartridge
TGA Turbine outlet casing
TGE Turbine inlet casing
TLG Turbine nozzle ring
VLG Compressor diffuser
KBB Kompressorenbau Bannewitz GmbH
Pictograms
The following pictograms may be used in this document:
Pictogram Meaning
Apply oil.
Apply threadlock.
Figures
All figures in this document are schematic and of a general nature. The figures can be based on different
design versions and differences in detail may occur.
1.2.2 Design
The main subassemblies of the exhaust-gas turbocharger (TC) are a one-stage radial-flow turbine and
a one-stage radial-flow compressor.
The turbine wheel and shaft consist of one part and the compressor wheel is mounted on the shaft. Two
plain bearings support the rotor in the bearing casing. The compressor casing and turbine inlet casing
are flanged to the bearing casing. Alternatively, an air intake bend, a silencer or an air intake flange can
be mounted on the inlet side of the compressor casing.
The lubricating oil system of the engine supplies the plain bearings with lubricating oil. The lubricating
oil flow rate depends on the oil temperature, oil pressure and speed of the exhaust-gas turbocharger.
1.2.3 Function
The exhaust-gas energy of the combustion engine drives the rotor. The exhaust gases reach the turbine
wheel via the turbine inlet casing and turbine nozzle ring.
The compressor wheel that is located on the same shaft takes in the air required for combustion,
compresses it to a higher pressure and feeds the compressed air to the engine via a charge air cooler.
The exhaust-gas turbocharger has no special control unit. The exhaust-gas turbocharger speed
depends on the engine output.
In addition, the exhaust-gas turbocharger's serial number and the year and month of construction are
stamped into the bearing casing (e.g.: 00014 / 13 = serial number: 00014 / year of construction: 2013).
Please quote the:
• Type (Type)
• Specification number (Spec.)
• Serial number (Serial)
in all correspondence, spare part inquiries and orders. Requests and orders can only be handled
properly and promptly if this data is known.
1.3.1.1 Type and serial number
The type of the exhaust-gas turbocharger is identified by the code for the turbocharger generation (here
ST ) and the size (here 5).
Example: Type ST 5
↓ ↓
Design Size
The serial number consists of a 5-digit number beginning with 00001 for each type and a code for the
year of construction.
Example: Serial 00014 / 13
↓ ↓
↓ Year of construction
Serial number
1.3.1.2 Specification number
The specification number of the exhaust-gas turbocharger is a 7-digit number.
Example: Spec 75 00 002
↓ ↓
Type consecutive 3-digit number
The following characteristics of the exhaust-gas turbocharger are encoded in the specification number:
• Thermodynamic specification of the rotor
• Thermodynamic specification of the compressor diffuser
• Thermodynamic specification of the turbine nozzle ring
• Design and position of the casings
Example of a component:
1 pc. (7010) turbine nozzle ring for 7500002 can be supplied separately.
Example for spare part:
5 pc. (5230) stud bolts for 7500002 cannot be supplied separately!
9 The "Spare parts (9951)" set has to be ordered instead.
9 1 pc. (9951) spare parts for 7500002
1.3.2.2 Identification of a spare cartridge
Spare cartridges have a cartridge nameplate with the following details:
• Type: ST5
• Spec: Specification number of the cartridge, e.g. 7507002
• Serial: C and 5-digit continuous number of the cartridge and the year of construction
e.g.: C 00001/14
The installed rotor is also identified by the cartridge serial number.
An exchange protocol is supplied with each spare cartridge. This protocol has to be
completed and returned to Kompressorenbau Bannewitz GmbH.
1.4 Safety
1.4.1 Introduction
KBB exhaust-gas turbochargers comply with the safety and health protection requirements valid at the
time of manufacture. Despite the operational safety ensured by KBB, residual risks may arise during
operation of or while working on the exhaust-gas turbocharger and its components. These may:
• arise from the exhaust-gas turbocharger itself or its accessories.
• arise from operating resources and auxiliary means.
• arise from an ignorance of safety instructions.
• arise from the improper execution of maintenance and service work.
The operator has to define measures to ensure safe access to and handling of KBB turbochargers.
The exhaust-gas turbocharger is a partly completed machine and has been designed on the basis of
the following standards and regulations:
• Machinery directive 2006/42/EC
• Risk assessment pursuant to ISO 12100
Caution
Caution indicates a hazard with a low level of risk which, if not avoided, could result
in minor or moderate injury.
CAUTION
– Warnings and orders must be followed.
Wear gloves!
Fire risk
Operating and auxiliary materials may be highly flammable.
This may lead to fire and severe injuries.
WARNING
– Observe the safety data sheets for the operating and auxiliary materials.
– Observe the safety data sheets for the operating and auxiliary materials.
– Make sure that these materials are disposed of properly.
New warning signs must be attached if the old ones are lost or no longer legible.
Proceed as follows:
1. Order new warning signs from Kompressorenbau Bannewitz GmbH.
2. Remove illegible warning signs.
3. Degrease and thoroughly clean the surfaces.
4. Attach the new warning signs.
1. The exhaust-gas turbocharger may only be maintained by duly qualified and authorized
persons.
2. The responsibilities must be clearly defined and observed to avoid uncertain competences
with respect to safety during maintenance of the exhaust-gas turbocharger.
3. The instructions contained in these operating instructions must be followed irrespective of the
type of work (operation, maintenance, etc.) concerned.
4. The exhaust-gas turbocharger may only be operated according to the technical data so as to
ensure its long service life.
5. The operating staff is not allowed to interfere with the unit in a way that would affect the
exhaust-gas turbocharger's safety.
6. It is also the operating staff's responsibility to help ensure that no unauthorized persons work
on the exhaust-gas turbocharger.
7. The operating staff must inform the owner without delay of any changes to the exhaust-gas
turbocharger that affect its safety.
8. The cleaning, maintenance and repair work described in these operating instructions are easy
to understand by persons skilled in mechanical, cleaning and maintenance work. The
necessary tools and testing/inspection equipment must be placed at their disposal.
Ingolf Ulbricht
QM Officer
Please refer to the Annex for a description of the basic safety and health requirements according to
2006/42/EC, Annex 1, that have been used and complied with.
A tilted position may not be corrected on the silencer if the entire TC is lifted!
WARNING
Improperly attached loads may lead to accidents resulting in severe injuries or even
death.
Furthermore, there is a crushing hazard.
WARNING Observe the following accident prevention regulations:
– Winches, lifting and drawing gear (BGV D 8)
– Load handling devices for lifting operations (BGR 500, Chapter 2.8)
Wear gloves!
2 Technical data
2.1 Operating data
General
Types of lubricating oil: engine oil with a kinematic viscosity 110 – 140 mm²/s
at 40 °C, e.g. SAE30, SAE40
Nominal oil filter fineness before TC Max. 25 µm
* Lubricating oil temperatures before the TC up to 105 °C are permissible after consulting KBB.
*An orifice has to be used to ensure the indicated range if a higher lubricating oil pressure is expected
on the engine side.
The aforementioned values may not be exceeded, or must at least be reached with
respect to the lubricating oil pressure, if the alarm values are adjusted to the engine
data!
CAUTION Please refer to the nameplate and/or acceptance certificate for the maximum speed
and the maximum exhaust-gas temperature before the turbine!
* The indicated dimensions depend on the exhaust-gas turbocharger specification and the casing
design. They are the maximum values for the variant shown.
B* T* H*
1318 mm 622 mm 705 mm
2.4 Connections
Bearing casings with water cooling have the additional connections M and N.
The connections M and N should only be used diagonally to ensure their optimum
usage (M1 together with N1 or M2 together with N2). The respective free connections
must be closed with the screw plugs and gaskets.
3 Operation
3.1 Removal of temporary corrosion protection
KBB exhaust-gas turbochargers and their spare parts and tools are protected against corrosion before
delivery. Corrosion protection for six months is provided as standard. Corrosion protection for three
years can be provided on request. The anti-corrosion materials (films, anti-corrosion paper) have to be
removed and the respective surfaces cleaned.
KBB uses the following anti-corrosion materials to protect parts against corrosion:
Anti-corrosion spray
The anti-corrosion spray is extremely flammable. It may be harmful to health if
brought in contact with the skin frequently or if inhaled.
Ensure the following precautions when removing the temporary corrosion
CAUTION protection from the exhaust-gas turbocharger (removing the protective films from
the openings of the casings):
– Keep away from sources of ignition
– Do not smoke
– Do not inhale
– Avoid skin contact
– Ensure good ventilation of the room
CAUTION
– Do not inhale
– Avoid skin contact
– Ensure good ventilation of the room
Cling film
Dispose of this film according to the local regulations.
3.2 Commissioning
It has to be ensured that the exhaust-gas turbocharger's plain bearings are supplied with oil before
commissioning. The lubricating oil system of the engine supplies the plain bearings with lubricating oil.
The lubricating oil flow rate depends on the oil temperature, oil pressure and speed of the exhaust-gas
turbocharger.
The permissible lubricating oil pressures for special operating states are listed in the Technical Data
chapter.
The free return flow of the lubricating oil has to be ensured and checked.
The following has to be checked:
1. oil inlet pressure before the exhaust-gas turbocharger
2. lubricating oil temperature before exhaust-gas turbocharger
The lubricating oil supply to the plain bearings has to be ensured in all operating
conditions.
Always pre-lubricate before start-up operations.
CAUTION
Make sure that the oil supply and return lines do not leak so as to prevent oil from
escaping onto the hot, gas-carrying casings. This rules out the possibility of the
development of oil vapours which are detrimental to health and can cause fire.
3.4 Malfunctions
Malfunctions are indicated by abnormal measurement values (exhaust-gas temperature, charge air
pressure, speed), loud running noise or leaks.
The engine load has to be reduced or the engine stopped in the event of irregularities on the exhaust-
gas turbocharger.
Faults on the exhaust-gas turbocharger can also be due to engine-side trouble.
Since even minor malfunctions may cause severe consequential damage, the cause
of the malfunctions has to be determined and eliminated immediately.
CAUTION
Avoid any unsystematic search for possible causes; this seldom leads to success
and often has an adverse effect.
3.5 Troubleshooting
Exhaust-gas temperatures too high
Immediate measure:
Do not exceed the maximum permissible temperature after the cylinder. Reduce the
output if necessary.
Cause Remedy
Exhaust-gas turbocharger:
• Silencer / intake filter dirty • Clean the silencer / intake filter
• Compressor dirty • Clean the compressor
• Compressor damaged • Repair the compressor
• Turbine damaged • Repair the turbine
• Turbine nozzle ring worn • Replace the turbine nozzle ring
• Rotor sluggish • Check for score marks
• Bearing damaged • Replace the bearing
Engine:
• Charge air cooler dirty • Clean the charge air cooler
• Exhaust-gas or charge air piping leaky • Repair the leaks
• Exhaust-gas counter-pressure after turbine • Measure the exhaust-gas pressure, check the
too high exhaust-gas piping
• Vacuum pressure in the engine room • Improve the engine room ventilation
• Faulty fuel injection • Refer to engine instruction manual
• Cylinder valves dirty • Refer to engine instruction manual
• High intake temperatures • Make sure the intake air is not too warm,
improve the engine room ventilation
Always balance the rotor following any repair work on the rotor or replacement of
rotor parts!
Cause Remedy
Exhaust-gas turbocharger :
• Silencer / intake filter dirty • Clean the silencer / intake filter
• Compressor dirty • Clean the compressor
• Compressor damaged • Repair the compressor
• Turbine damaged • Repair the turbine
• Turbine nozzle ring worn • Replace the turbine nozzle ring
• Rotor sluggish • Check for score marks
• Bearing damaged • Replace the bearing
Engine:
• Faulty indication, measuring line to pressure • Replace the pressure gauge, repair the leaks
gauge leaky
• Charge air cooler dirty • Clean the charge air cooler
• Exhaust-gas piping leaky • Repair the leaks
• Vacuum pressure in the engine room • Improve the engine room ventilation
• Injection time maladjusted • Refer to engine instruction manual
• Exhaust-gas counterpressure after turbine • Measure the exhaust-gas pressure, check the
too high exhaust-gas piping
• High intake temperatures • Make sure that the intake air is not too warm
Always balance the rotor following any repair work on the rotor or replacement of
rotor parts!
Thick deposits lead to reduced clearances and to the rotor making contact with the
casing in extreme cases. These deposits must be removed mechanically.
Regular cleaning of the compressor and turbine (with heavy fuel oil operation) from
the very beginning prevents the formation of thick deposits (refer to the Maintenance
Schedule chapter).
Cause Remedy
Exhaust-gas turbocharger:
• Turbine dirty • Clean the turbine
• Turbine nozzle ring partly clogged or • Clean the turbine nozzle ring, replace if
deformed necessary
• Wrong specification • Contact the manufacturer
Engine:
• Faulty indication • Replace the pressure gauge
• Faulty fuel injection • Refer to engine instruction manual
• Cylinder valves leaky • Refer to engine instruction manual
• Low intake temperature • Avoid intake of cold air
If the charge air pressure is too high, this will lead to high combustion pressures!
Cause Remedy
Exhaust-gas turbocharger :
• Silencer / intake filter dirty • Clean the silencer / intake filter
• Compressor diffuser damaged • Replace the compressor diffuser
• Turbine dirty • Clean the turbine
• Turbine nozzle ring damaged • Replace the turbine nozzle ring
• Wrong specification • Contact the manufacturer
• With several TCs per engine: different • Overhaul the TC (likelihood of surging higher in
conditions in the TCs the poorer TC)
Engine:
• Charge air cooler dirty • Clean the charge air cooler
• Charge air temperature too high, cooling • Clean the water cooler
water temperature before cooler too high
• Exhaust-gas counter-pressure after turbine • Measure the exhaust-gas pressure, check the
too high exhaust-gas piping
• Cylinder valves dirty • Refer to engine instruction manual
• Faulty fuel injection • Refer to engine instruction manual
• Low intake temperatures • Avoid intake of cold air
• Engine overloaded • Refer to the information below
Frequent or permanent surging leads to damage of the compressor, rotor parts and
bearings!
Surging may also be caused by an engine overload, e.g. due to high resistance of
the vessel (heavy sea, deep draft, propeller pitch too high or propeller too heavy).
Cause Remedy
Exhaust-gas turbocharger:
• Compressor dirty • Clean the compressor
• Turbine dirty • Clean the turbine
• Rotor is rubbing against parts • Check the clearances
• Bearing damaged • Replace the bearing
• Compressor damaged • Repair the compressor
• Turbine damaged • Repair the turbine
Engine:
• Forces exerted by piping on the exhaust-gas • Loosen the piping, align and fit without
turbocharger casings are too high stresses; pay attention to heat expansion
Always balance the rotor following any repair work on the rotor or replacement of
rotor parts!
Cause Remedy
Exhaust-gas turbocharger:
• Imbalanced rotor due to heavy soiling • Clean the rotor mechanically and balance
• Compressor damaged • Repair the compressor
• Turbine damaged • Repair the turbine
• Bearing damaged • Replace the bearing
Engine:
• Unfavourable mounting position • Measure vibrations, perform an FFT analysis
Always balance the rotor following any repair work on the rotor or replacement of
rotor parts!
Cause Remedy
Exhaust-gas turbocharger:
• Piston rings damaged • Replace the piston rings
Engine:
• Overpressure in the oil return • Crankcase ventilation ineffective
• Gaskets damaged, connections leaky • Remedy the fault
• If operated with lubricating oil separator: oil • Contact the manufacturer
leak rate is too high
*) Shorter replacement intervals apply to special applications (e.g. application for dredger or crane)!
The following influences / operating conditions may shorten the replacement intervals:
• Applications with special operating regimes and/or frequent load cycles
• Frequent start – stop processes / emergency shut-offs
• Frequent or longer part load operation with heavy fuel oil applications
• Low fuel quality / poor fuel treatment
• Low lubricating oil quality and/or inappropriate lubricating oil filtering
• High intake temperatures, high gas inlet temperatures
• High degree of contamination on the rotor
If the exhaust-gas turbocharger, in particular the rotor or the bearing, has been
damaged, the TC has to be shut down and may only continue running in the
emergency operating mode to prevent any further damage.
Please also observe the operating instructions of the engine manufacturer in this
respect.
When operating the engine with a defective exhaust-gas turbocharger, reduce the
engine power to such an extent that the permissible exhaust-gas temperature after
the cylinder is not exceeded.
2. Then close the turbine casing with the sealing device (9704) to prevent exhaust gas from
escaping.
Make sure that the exhaust-gas turbocharger is stored safely and securely.
The state of the preserved parts and exhaust-gas turbochargers has to be checked every twelve months.
The exhaust-gas turbocharger has to be cleaned of the anticorrosive agent before re-starting.
The anti-corrosion spray is extremely flammable. It may be harmful to health if
brought in contact with the skin frequently or if inhaled.
Ensure the following precautions when removing the temporary corrosion
CAUTION protection from the exhaust-gas turbocharger (removing the protective films from
the openings of the casings):
– Keep away from sources of ignition
– Do not smoke
– Do not inhale
– Avoid skin contact
– Ensure good ventilation of the room
Wear gloves!
3.10 Disposal
Dispose of all waste in an environmentally responsible manner and in compliance with the valid local
regulations.
The exhaust-gas turbocharger is made of the materials listed in the table below. These materials have
to be disposed of as described below:
3.11 Maintenance
3.11.1 General
Proper maintenance work allows faults to be detected in due time. It also indicates necessary overhauls
as well as work to be scheduled during yard or harbour times as well as interruptions.
The operating hours specified in the maintenance schedule should be seen as average values. They
can be shortened according to prevalent operating conditions and adjusted to the maintenance intervals
of the engine.
It is important to eliminate even minor, apparently insignificant defects immediately and to determine
and remedy their causes so as to prevent consequential damage to the engine or exhaust-gas
turbocharger.
If the engine is not equipped with an automatic monitoring system with data recording, entries must be
made in the engine log at least once every 24 operating hours. This helps you detect deviations in due
time.
The operating hours given in the table are guidelines which can be reduced for
adjustment to the maintenance intervals of the engine.
The interval of inspection 0 depends on the fuel quality.
Inspections at the main intervals I to III may only be carried out by KBB or their
authorised service stations, either on site or in their workshops.
Maintenance interval
Maintenance work
in operating hours
Every 24 h Check for strange noises
Every 24 – 48 h Wash the compressor during operation, actuate the
compressor washing system
Approx. every 300 h and only with HFO Wash the turbine during operation,
and/or as required depending on the actuate the turbine washing system,
heavy fuel oil quality clean with water
Approx. every 500 h Change the filter mat at the silencer
or as required
Once after commissioning, then every Check the fastening bolts at the feet, tighten all casing
1,000 hours bolts and piping joints
Every 6,000 h max. and only with HFO Inspection 0
Every 12,500 h max. Inspection I
Every 25,000 h max. Inspection II
Every 50,000 h max. Inspection III
Inspections at the main intervals I to III may only be carried out by KBB or their
authorised service stations, either on site or in their workshops.
The components' potential service life depends on different factors and conditions which may require a
premature replacement of a component.
A shorter service life is to be expected under the following conditions:
• Applications with a special operating regime and/or frequent load changes
• Frequent start – stop processes
• Poor quality of the lubricating oil and/or inappropriate lubricating oil filtering
• Poor quality of the fuel (HFO)
• Frequent or longer partial load operation with heavy fuel oil applications
a) Minimum scope
• Disassembly of the exhaust-gas turbocharger including:
o Removal of the silencer
o Removal of the compressor casing
o Removal of the cartridge
• Cleaning the silencer and replacing the filter mats
• Cleaning the turbine side and compressor side
• Visual inspection of all parts
• Check of the S15 bearing clearance
• Replacement of the turbine nozzle ring with heavy fuel oil applications depending on the wear
• Assembly with new gaskets, O-rings and locking elements
b) Complete inspection (as under "a" but also including the following work)
• Disassembly of the rotor
• Check of important operational dimensions (diameter of shaft seats, compressor wheel
diameter), surface finish and concentricity
• Check of the turbine and compressor blades for cracks
• Check of the bearings
• Check of the balance
• Assembly with new gaskets, O-rings and locking elements
• Check of the clearances
Inspection II (25,000 hours max.)
• As inspection I (scope as b)
• Replacement of the bearings
Inspection III (50,000 hours max.)
• As inspection I and II
• Replacement of the rotor
Spare parts and tools are only supplied in complete sets (refer to "Parts catalogue"
annex). Spare parts cannot be ordered separately!
Components (e.g. casings, diffusers/nozzle rings) and subassemblies (e.g.
cartridges), however, can be supplied separately.
Sets of spare parts are offered for the inspections 0 - III (refer to "Parts catalogue"
annex).
* Turbine nozzle ring (7010) under heavy fuel oil operation conditions:
With heavy fuel oil operation, the turbine nozzle ring is subject to higher wear and
should thus be considered a wearing part.
The turbine nozzle ring has a service life of at least 12,500 hours under heavy fuel
oil operation conditions.
The turbine nozzle ring has to be replaced if the parameters (charge air pressure,
exhaust-gas temperatures) deviate significantly.
Changes in the exhaust-gas temperature and charge air pressure can also be caused
by other factors!
Notwithstanding this, the exhaust-gas limit values (after the cylinder) specified by the engine
manufacturer may not be exceeded.
Wear mostly affects the guide blades and can progress as follows.
Wear pattern 1
• The guide blades have a slit alongside one of the disks.
• The nozzle ring can still be used if the slit length is < 25 mm and the slit width < 6 mm.
Under the afore-mentioned conditions, the nozzle ring is not considered to be worn to such an extent
that it needs replacement and can thus continue to be used.
Wear pattern 2
• The guide blades have a slit alongside both disks.
• The nozzle ring can still be used if the slit length is < 25 mm and the slit width < 4 mm.
Under the afore-mentioned conditions, the nozzle ring is not considered to be worn to such an extent
that it needs replacement and can thus continue to be used.
Wear pattern 3
• The guide blades show deep slits alongside both disks and the outlet edge of more than two
of the guide blades is completely worn.
• The turbine nozzle ring must be replaced.
3.12 Cleaning
1 Union piece
2 Air piping
Stainless steel pipe 12 x 1
3 Ball valve
4 Water tank
5 Water piping
Stainless steel pipe 12 x 1
6 Ball valve
7 Union piece
6010 Compressor casing
9010 Silencer
Never lead the water directly from the water piping into the compressor. This may
cause damage to the exhaust-gas turbocharger or engine.
Do not use any chemical cleaning additives.
– Risk of corrosion!
Only clean the compressor with a warm engine at 50 to 85 % of the rated output.
The engine output has to be further reduced if the compressor surges during or after
injection of the water.
Continue to operate the engine for at least 10 to 15 minutes after cleaning!
Do not wash the compressor before a pause in operation. Risk of corrosion!
Washing is ineffective for caked deposits. You should thus wash the compressor
and/or clean the compressor mechanically at regular intervals!
Do not use any chemical additives!
If the vacuum pressure before the compressor is too high, the water will already be
taken in while the water tank is being filled and the cleaning effect is reduced. As a
remedy:
– arrange the water tank in a lower position (at least 1,000 mm below the centre of
the exhaust-gas turbocharger )
or
– install a second shut-off valve in the water piping and open this after closing the
water tank.
The cleaning effect may not be as expected if the washing process used in operation
deviates from KBB's recommended turbine washing process!
The exhaust-gas turbocharger speed may drop during the washing process.
After the washing process, the cleaning effect can be verified by checking the
changes in the charge air pressure and exhaust-gas temperatures!
The water pressure and washing duration can be increased, if necessary, to improve
the cleaning effect!
Draining instructions
Hot exhaust gas may escape from the drain connection –> risk of burns!
Depending on the pre-set engine load and the washing water quantity, draining of
the washing water may be delayed by several minutes or may not start at all!
Washing is ineffective once a dirt layer has hardened; washing should therefore be
performed regularly from the very beginning.
Clean the turbine mechanically if washing is ineffective. The turbine casing must be
dismantled for this purpose.
Observe the instructions of the engine manufacturer!
If insufficient cleaning effect has been found during inspections the parameter of
turbine washing needs to be checked.
A modification of injection nozzle diameter is possible after analysis and
consultation with KBB.
Mode of operation
There are two ways to wash the turbine:
• Interval washing during reduced engine output
• 10 minutes washing with the engine idling
Work sequence for interval washing
1. Connect the removable hose section (4) to the fresh water line (3).
2. Reduce the engine output until the temperature before the turbine drops to its specified value
(see table).
3. Wait for approx. 10 minutes!
4. Open the valve (10) (if present) for drainage (9).
5. Open the valve (2) and set the water pressure (see table).
6. Open the 3-way valve (6) for approx. 30 seconds and adjust the water pressure again if
necessary with the valve (2).
7. Close the 3-way valve (6).
8. Wait for approx. 3 minutes to allow the injected water to evaporate.
9. Repeat steps 6 to 8 two or three times.
10. Close the valve (2) and valve (10) for drain!
11. Run the exhaust-gas turbocharger dry for approx. 10 min. and gradually increase the engine
output!
12. Repeat the washing if vibrations are noticed at the exhaust-gas turbocharger that did not
occur before washing.
13. Remove the hose section (4)!
The cleaning effect can be monitored on the basis of the changes in the charge air
pressure and exhaust-gas temperatures!
The water pressure and washing duration can be increased to improve the cleaning
results if necessary!
1. Connect the removable hose section (4) to the fresh water line (3).
2. Reduce the engine output (see table) or run the engine in the idling mode.
Allow the engine to warm up if washing is planned after starting the engine!
The exhaust-gas temperature before the turbine may rise during turbine washing but
may not exceed the maximum value of 350 °C!
The cleaning effect can be monitored on the basis of the changes in the charge
pressure and exhaust-gas temperatures!
The water pressure and washing duration can be increased to improve the cleaning
results if necessary!
Never clean to such an extent that the coating comes off, e.g. with a hammer and
chisel.
Sand blasting is not permissible!
Crack tests may provide false results after sand blasting.
Observe the safety instructions in the Safety chapter during all dismantling and
assembling work!
Pay attention to the indicated weights and respective lifting instructions!
All illustrations in this document are schematic and general. They can be based on
different design variants. Differences in details are thus possible.
Casings
1. Are the casings heavily contaminated by oil, dust or soot?
2. Are there any leaks at the casings? (primarily: connection flanges, charge air, exhaust gas
and oil connections)
3. Are all bolts/screws and nuts screwed tight?
A1 = 35 Nm A2 = 50 Nm B1 = 70 Nm B2 = 70 Nm
A3 = 16 Nm C1 =270 (+10) Nm C2 = 36 Nm C3 = 36 Nm C4 = 36 Nm
Spare parts and tools are only supplied in complete sets (refer to "Parts catalogue"
annex). Spare parts cannot be ordered separately!
Components (e.g. casings, diffusers/nozzle rings) and subassemblies (e.g.
cartridges), however, can be supplied separately.
Sets of spare parts are offered for the inspections 0 - III (refer to "Parts catalogue"
annex).
Optional tools are available for each exhaust-gas turbocharger type (please refer to
the Parts Catalogue annex).
The tool set (9700) contains accessories and devices that are indispensable for
installing and removing the cartridge.
The tool set (9720) contains special devices that are required for dismantling and
assembling the rotor. We recommend that service workshops use the tool set (9720)
in addition to the tool set (9700)!
Standard tools
Furthermore, other standard tools in various sizes and designs are required for assembling and
dismantling KBB turbochargers (in general).
• Torque spanner
• Flat nose pliers
• Hammer
• Hexagon key with T handle
• Open-end / Ring spanner
• Mallet
• Socket
• Extension
• The exhaust-gas turbocharger has been unpacked and the temporary anti-corrosion materials
removed.
• The contact surfaces on the engine bracket (D) and exhaust-gas turbocharger have been
cleaned.
• Suitable lifting gear is available.
Work sequence:
1. Insert the O-rings for the oil inlet (B) and oil outlet (C) into the engine bracket (D).
The O-rings (B, C) are included in the engine manufacturer's scope of delivery.
We recommend that the O-rings be replaced during each assembly!
2. Place the assembly protecting sheet (9712) on the engine bracket (D) to protect the O-rings (B,
C).
3. Suspend the exhaust-gas turbocharger in suitable lifting gear according to the lifting instructions
and lower it onto the engine bracket (D).
4. Pull the assembly protecting sheet (9712) out from between the exhaust-gas turbocharger and
engine bracket (D).
5. Screw the exhaust-gas turbocharger to the engine bracket (D) with the corresponding
connection elements (A) depending on the variant.
The connecting elements for attaching the ATL to the motor are supplied by the
engine manufacturer.
Information on strength class and mounting preload from the engine manufacturer
is to be preferred.
• The exhaust-gas turbocharger has been attached to suitable lifting gear according to the lifting
instructions.
• Suitable lifting gear is available.
Work sequence:
1. Loosen the connection elements (A) and carefully lift the exhaust-gas turbocharger from the
engine bracket (D).
2. Remove and dispose of the O-rings (B, C) from the engine bracket.
The O-rings (B, C) are included in the engine manufacturer's scope of delivery.
We recommend that the O-rings be replaced during each assembly!
Make sure that the compressor wheel is not damaged when removing and mounting
the compressor casing!
• All connection piping has been disconnected from the compressor casing.
• The air intake bend / silencer / air inlet flange have been removed.
• The radial clearance (S1) between the compressor wheel and compressor casing insert has
been measured and recorded in the service report (see Annex) before the compressor casing
is removed.
Dimensions of the support (F) for ST5: H = min. 80mm D = 325 - 385mm
Installing the compressor casing insert
1. Place the compressor casing insert on the support (F) as shown in the figure.
2. Fit new O-rings.
3. Set the compressor casing down as shown in the figure and fix with plates, locking washers
and hexagon socket screws (MA = 16 Nm).
Determine dimension "h" according to the figure before dismantling when replacing
the compressor diffuser.
Make sure that the sealing air bore "Z" is free when mounting the compressor
diffuser.
• All connection piping has been disconnected from the exhaust-gas elbow.
• The insulation of the exhaust elbow has been removed.
1. Attach the exhaust-gas elbow to suitable lifting gear according to the lifting instructions.
2. Unscrew the nuts and remove the locking washers.
3. Carefully remove the support (if present) and the exhaust-gas elbow from the exhaust-gas
turbocharger in the axial direction.
1. Carefully mount the exhaust-gas elbow and support in the axial direction.
2. Fit the locking washers and tighten the nuts (MA = 70 Nm).
Make sure that the turbine wheel is not damaged when removing and installing the
cartridge!
Caution: The turbine nozzle ring may fall out of the turbine casing!
1. Loosen the connecting elements between the cartridge and engine bracket.
2. Loosen the nuts and remove the locking washers.
The turbine casing can be forced off with the forcing screws (9707). Remove the
hexagon head bolts (5140) for this purpose.
Use diesel fuel or penetrating oil to separate seized joints!
4. Carefully pull the cartridge out of the turbine casing in the axial direction.
The O-rings (B, C) are included in the engine manufacturer's scope of delivery.
We recommend that the O-rings be replaced during each assembly.
2. Place the assembly protecting sheet (9712) on the engine bracket (D) to protect the O-rings
(B, C).
Make sure that the turbine wheel is not damaged when removing and mounting the
turbine casing!
Caution: The turbine nozzle ring may fall out of the turbine casing!
The turbine casing can be forced off with the forcing screws (9707). Remove the
hexagon head bolts (5140) for this purpose.
Use diesel fuel or penetrating oil to separate seized joints!
1. Carefully mount the turbine casing in the axial direction and align to the mark.
2. Fit the locking washers and tighten the nuts (MA = 70 Nm).
Only one position allows a positive fit of the turbine nozzle ring.
Make sure that the turbine wheel is not damaged when removing and installing the
turbine casing insert!
2. Force off the turbine casing insert with the forcing screws (52099) (thread A) and carefully
remove the turbine casing insert from the exhaust-gas turbocharger in the axial direction.
Caution: The containment ring may fall out of the turbine casing!
Correct the tilted position to prevent damage to the turbine wheel when pulling out
the turbine casing insert!
Correct the tilted position to prevent damage to the turbine wheel when installing
the turbine casing insert!
Fit new locking washers (5072) with the mounting sleeve (9855).
Warranty claims are excluded if the rotor is removed and mounted by unauthorised
staff!
Disassembly and assembly of the turbocharger should only be carried out by trained
staff!
Initial situation:
There are two different initial situations from which you can proceed to remove the cartridge. We
recommend that initial situation A be used:
A B
• The cartridge has been removed. • The cartridge has been mounted firmly on the
engine bracket.
• The cartridge has been mounted on the rack
(9722). • All compressor-side components have been
removed.
• The rack (9722) has been screwed to an
assembly trestle or screwed firmly to the • The exhaust-gas elbow has been removed.
ground.
• The speed sensor has been removed.
• The speed sensor has been removed.
The axial clearance S15 has to be measured and recorded in the service report
before dismantling.
1. Important: Use the respective locking device to fix the shaft on the turbine side before
removing the cartridge.
Use the protective cap (9856) as shown in the figure when setting the compressor
wheel down.
Use the magnetic centre protector (9723) to protect the shaft centring device.
The bearing disk (4030) may adhere to the compressor bearing (4020) and fall off!
Pay attention to the shims (3071 / 3072) under the compressor bearing (4020)!
If the compressor bearing jams, use the threaded bores (C) to force it off.
The bearing disk (4030) may adhere to the thrust ring (2020) and fall off!
9. Remove the locking device before carrying out the next operations. Furthermore, the turbine
casing insert has to be removed in case B.
Push the shaft towards the turbine up and attach to suitable lifting gear as shown in the figures
for case A or B.
The rotor is removed. Dismantling of the cartridge is now complete. All parts can be checked and
cleaned.
Warranty claims are excluded if the rotor is removed and mounted by unauthorised
staff!
Disassembly and assembly of the turbocharger should only be carried out by trained
staff!
Initial situation:
All parts have been checked and cleaned according to the KBB requirements.
There are two different initial situations from which you can proceed to install the cartridge. We
recommend that initial situation A be used:
A B
• The bearing casing has been mounted on the • The bearing casing has been mounted firmly
rack (9722). on the engine bracket.
• The rack (9722) has been screwed to an • The turbine casing has been mounted to the
assembly trestle or screwed firmly to the bearing casing.
ground.
• The heat shield has been mounted and
secured.
4. Attach the shaft to suitable lifting gear and carefully insert it into the bearing casing.
All assembly marks (to be found on the shaft (2010), thrust ring (2020), spacer (2030))
must be in alignment after mounting.
The shaft (2010) should be mounted with the assembly mark (M) pointing up to
facilitate the following operations!
5. The locking device has to be fitted but not fastened tight to carry out the following operations.
The turbine casing insert has to be installed beforehand in case B.
7. Moisten the thrust ring and shaft with lubricating oil and slide onto the shaft up to the chamfer
of the shaft using the extractor (9703).
The assembly mark on the thrust ring (2020) and the assembly mark on the shaft
must be in alignment.
The clearance S18 has to be measured and corrected with shims (3071, 3072) as
required.
The compressor bearing has to be fastened with only two hexagon socket bolts for
this purpose!
9. Clean the compressor bearing (4020), moisten with lubricating oil and slide onto the shaft
(2010) with the mounting sleeve (9708). Screw in place with the hexagon socket bolts
(MA = 36 Nm).
Adjust clearance S18 with the shims (3071, 3072) behind the compressor bearing.
Increase the shim thickness to reduce clearance S18.
Reduce the shim thickness to increase clearance S18.
Then fasten the compressor bearing with all hexagon socket screws (MA = 36 Nm)!
10. The following operations require that the shaft has been fixed with the corresponding locking
device and is thus pushed towards the compressor.
The clearance S19 has to be measured and corrected with gaskets (3065, 3066, 3067)
as required.
The compressor-side piston ring may not be fitted when the clearance is measured!
11. Mount the compressor bearing cover with three hexagon socket screws and without the piston
ring as shown in the figure.
Measure dimension L1 from the bearing casing wall (reference plane X) to the shoulder of the
compressor bearing cover. Use the ruler and depth gauge for this purpose.
The assembly mark on the spacer and the assembly mark on the shaft (2010) must
be in alignment!
Measure dimension L2 from the bearing casing wall (reference plane X) to the shoulder of the
spacer. Use the ruler and depth gauge for this purpose.
Clearance S19 can be corrected by changing the gaskets (3065, 3066, 3067) behind
the compressor bearing cover.
Fit at least one gasket!
Increase the gasket thickness to reduce clearance S19.
Reduce the gasket thickness to increase clearance S19.
The axial bearing clearance has now to be measured to check the correct assembly
of the cartridge!
Place the dial gauge on the compressor-side shaft end in the axial direction. Push the rotor
towards the turbine side and set the dial gauge to "0".
Slowly pull the rotor towards the compressor side and read clearance S15 on the dial gauge.
Admissible clearance S15 = 0.21 (+0.14)
4.5.1 General
The clearances have to be observed to ensure a safe exhaust-gas turbocharger operation and achieve
the required efficiency.
The clearances have to be checked and adjusted if:
• components have been replaced (turbine casing or turbine casing insert, compressor casing
or compressor casing insert, cartridge)
• the engine or exhaust-gas turbocharger operating parameters deviate from the standard
• there are score marks on the rotor parts or casings
• checks and inspections are performed
Clearances:
Proceed in the following sequence when checking and correcting the clearances:
1. Adjust the clearances:
a. S18 (clearance of the turbine-side piston ring) (see Installing the rotor)
b. S19 (clearance of the compressor-side piston ring) (see Installing the rotor)
c. S2 (compressor-side axial clearing)
2. Check the clearances:
a. S15 (axial bearing clearance)
b. S12 (turbine-side radial clearance)
c. S1 (compressor-side radial clearance)
3. Record the clearances in the service report (see Annex)
Shims and gaskets:
The clearances are adjusted by inserting shims or gaskets with different thicknesses at the locations
"A“, "B“ und "C“.
A Shims (8011, 8013)
B Gaskets (3065, 3066, 3067) Install at least one gasket!
C Shims (3071, 3072)
Piston rings:
The turbine-side and compressor-side compression rings wear in the axial direction
when running in.
This wear is normal and can be up to 0.5 mm.
The compression rings should be replaced during each inspection!
New Run-in
Centre the insert as exactly as possible so that the radial clearance is uniform over
the circumference.
2. Determine the dimension L1 between the reference plane "Y" and the compressor wheel with
a ruler and depth gauge as shown in the figure.
Centre the insert as exactly as possible so that the radial clearance is uniform over
the circumference.
6. Determine the dimension L2 between the reference plane "Y" and the compressor wheel with
a ruler and depth gauge.
Work sequence:
Determine clearance S1 in the opposite positions C1 and C2 (horizontal and vertical) between the
compressor wheel and compressor casing insert simultaneously with two feeler gauges (measuring
range of 0.05 to 1.0 mm).
Determine clearance S12 in the opposite positions T1 and T2 (horizontal and vertical) between the
turbine wheel and turbine casing insert simultaneously with two feeler gauges (measuring range of 0.05
to 1.0 mm).
Work sequence:
1. Carefully push the shaft towards the turbine in the axial direction and set the dial gauge to
zero.
2. Carefully pull the shaft towards the compressor and read off S14 on the dial gauge.
Work sequence:
Determine clearance S15 on the shaft end on the compressor side. Push the rotor towards the turbine
side and set the dial gauge (measuring range of 0 to 1 mm, precision of ±0.01) to "0". Now pull the rotor
towards the compressor side and read off the clearance S15 on the dial gauge.
Appendix
Parts catalogue
Overview Service Stations
Attachment of the declaration of incorporation
Service report
Teilekatalog
Parts catalogue
ST5
Seite 1 von 26
Prepared: J. Scholze Page 1 of 26 Released: K. Buchmann
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
Seite 2 von 26
Page 2 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
Hinweise
Bei der Demontage und Montage des Rotors durch unautorisiertes Personal erlischt
jeglicher Gewährleistungsanspruch!
Im Vorfeld einer Demontage und Montage ist der Zustand des Abgasturboladers zu begutachten um
eventuell den Umfang der benötigten Ersatzteile besser einschätzen zu können. Anschließend ist nach
Rücksprache mit KBB der Umfang der zu bestellenden Ersatzteile abzustimmen.
Für die Durchsichten 0 - III werden Ersatzteilsätze angeboten. Jeder Satz enthält alle für die
Durchführung der entsprechenden Durchsicht notwendigen Ersatzteile (Verbindungselemente,
Dichtungen, Beilagen).
Die Anzahl der Ersatzteile ist entsprechend der Notwendigkeit entweder im kompletten oder im
reduzierten Umfang enthalten.
Bei bestimmten Ersatzteilen ist ein Austausch während der Demontage und Montage notwendig (z.B.
Dichtungen und Sicherungsscheiben). Diese werden im entsprechendem Satz im kompletten Umfang
geliefert.
Bei einigen Ersatzteilen, ist ein Bereitstellen für die Demontage und Montage (für den Fall des Verlustes
oder Defektes) nur in reduziertem Umfang notwendig (z.B. Stiftschrauben). Diese werden im
entsprechendem Satz auch nur im reduzierten Umfang geliefert.
Ersatzteile werden nur in Sätzen geliefert. Das Bestellen von einzelnen Ersatzteilen
ist nicht möglich!
Bauteile (z. B. Gehäuse, Leitgitter) und Baugruppen (z. B. Rumpfgruppe) können
jedoch einzeln geliefert werden.
Für die Durchsichten 0 - III werden Ersatzteile in Sätzen angeboten.
Seite 3 von 26
Page 3 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
a) Mindestumfang
• Demontage des Abgasturboladers mit:
o Abbau des Schalldämpfers
o Abbau des Verdichtergehäuses
o Ausbau der Rumpfgruppe
• Schalldämpferreinigung und Austausch der Filtermatten
• Reinigen der Turbinen- und Verdichterseite
• Sichtkontrolle aller Teile
• Kontrolle des Lagerspiels S15
• Wechsel des Turbinenleitgitters bei Schwerölanwendung in Abhängigkeit vom Verschleiß
• Montage mit neuen Dichtungen, O-Ringen und Sicherungselementen
Seite 4 von 26
Page 4 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
Instructions
Check the state of the exhaust-gas turbocharger before carrying out any dismantling and assembly work
so that you can better assess the spare parts required. The scope of spare parts to be ordered should
then be agreed after consulting KBB.
Sets of spare parts are offered for inspections 0 – III. Every set contains all of the spare parts that are
required for carrying out the corresponding inspection (connection elements, gaskets, shims).
The sets contain either the complete or a reduced number of spare parts depending on the
requirements.
Certain spare parts have to be replaced when dismantling and assembling the exhaust-gas turbocharger
(e.g. gaskets and locking washers). The relevant set contains the complete number of spare parts in
this case.
Only a reduced number of spare parts (e.g. stud bolts) is required for dismantling and assembly work
(in case a part is lost or damaged). The relevant set contains only a reduced number of spare parts.
Spare parts and tools are only supplied in complete sets. Spare parts cannot be
ordered separately!
Components (e.g. casings, diffusers/nozzle rings) and subassemblies (e.g.
cartridges), however, can be supplied separately.
Sets of spare parts are offered for the inspections 0 - III.
Seite 5 von 26
Page 5 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
a) Minimum scope
• Disassembly of the exhaust-gas turbocharger including:
o Removal of the silencer
o Removal of the compressor casing
o Removal of the cartridge
• Cleaning the silencer and replacing the filter mats
• Cleaning the turbine side and compressor side
• Visual inspection of all parts
• Check of the S15 bearing clearance
• Replacement of the turbine nozzle ring with heavy fuel oil applications depending on the wear
• Assembly with new gaskets, O-rings and locking elements
b) Complete inspection (as under "a" but also including the following work)
• Disassembly of the rotor
• Check of important operational dimensions (diameter of shaft seats, compressor wheel
diameter), surface finish and concentricity
• Check of the turbine and compressor blades for cracks
• Check of the bearings and bearing clearances
• Check of the balance
• Assembly with new gaskets, O-rings and locking elements
• Check of the clearances
Inspection II (every 25,000 hours max.)
• As inspection I (scope as b)
• Replacement of the bearings
Inspection III (every 50,000 hours max.)
• As inspection II
• Replacement of the rotor
Seite 6 von 26
Page 6 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
Inhalt Teil-Nr.
Content Part-no.
Bauteile Abgasturbolader komplett (1000)
Components Exhaust-gas turbocharger complete
Basisturbolader (1100)
Exhaust-gas turbocharger, basic unit
Rumpfgruppe (1200)
Cartridge
Rotor (2000)
Rotor
Schalldämpfer (9010)
Silencer
Ansauggehäuse (9020)
Air intake bend
Luftanschlussflansch (9025)
Air inlet flange
Verdichtergehäuse (6010)
Compressor casing
Lagergehäuse (3010)
Bearing casing
Turbinengehäuse (5010)
Turbine casing
Abgaskrümmer (9100)
Exhaust elbow
Weiteres Zubehör (optional)
Further accessoirs
Werkzeuge Für den Ein- und Ausbau der Rumpfgruppe notwendig. (9700)
Tools Required for removing and installing the cartridge.
Für die Demontage und Montage des Rotors notwendig. (9720)
Required for disassembly and assembly the rotor.
Seite 7 von 26
Page 7 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
Seite 8 von 26
Page 8 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
Basisturbolader (1100)
Exhaust-gas turbocharger, basic unit (1100)
Seite 9 von 26
Page 9 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
Rumpfgruppe (1200)
Cartridge (1200)
Seite 10 von 26
Page 10 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
Seite 11 von 26
Page 11 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
Seite 12 von 26
Page 12 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
Seite 13 von 26
Page 13 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
Rotor (2000)
Rotor (2000)
Seite 14 von 26
Page 14 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
Schalldämpfer (9010)
Silencer (9010)
Ansauggehäuse (9020)
Air intake bend (9020)
Seite 15 von 26
Page 15 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
Luftanschlussflansch (9025)
Air inlet flange (9025)
Seite 16 von 26
Page 16 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
Verdichtergehäuse (6010)
Compressor casing (6010)
Seite 17 von 26
Page 17 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
Lagergehäuse (3010)
Bearing casing (3010)
Seite 18 von 26
Page 18 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
Seite 19 von 26
Page 19 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
Turbinengehäuse (5010)
Turbine casing (5010)
Seite 20 von 26
Page 20 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
Seite 21 von 26
Page 21 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
Abgaskrümmer (9100)
Exhaust elbow (9100)
Seite 22 von 26
Page 22 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
Weiteres Zubehör
Further accessories
Seite 23 von 26
Page 23 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
Werkzeuge Für den Ein- und Ausbau der Rumpfgruppe notwendig. (9700)
Tools Required for removing and installing the cartridge.
Für die Demontage und Montage des Rotors notwendig. (9720)
Required for disassembly and assembly the rotor.
Seite 24 von 26
Page 24 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
Teil-Nr. Ersatzteil
Part-no. Spare part
Dichtungen
9911
Gaskets
Verbindungselemente Verdichterseite inklusive Rumpfgruppe
9922
Connection elements compressor side with cartridge
Verbindungselemente Turbinengehäuse - Lagergehäuse
9931
Connection elements turbine casing - bearing casing
Verbindungselemente Turbinengehäuse - Abgaskrümmer
9950
Connection elements turbine casing – exhaust elbow
Teil-Nr. Ersatzteil
Part-no. Spare part
Dichtungen
9911
Gaskets
Beilagen
9915
Shims
Verbindungselemente Verdichterseite inklusive Rumpfgruppe
9922
Connection elements compressor side with cartridge
Verbindungselemente Turbinengehäuse - Lagergehäuse
9931
Connection elements turbine casing - bearing casing
Verbindungselemente Turbinengehäuse - Abgaskrümmer
9950
Connection elements turbine casing – exhaust elbow
Teil-Nr. Ersatzteil
Part-no. Spare part
Lagerung
4000
Bearings
Dichtungen
9911
Gaskets
Beilagen
9915
Shims
Verbindungselemente Verdichterseite inklusive Rumpfgruppe
9922
Connection elements compressor side with cartridge
Verbindungselemente Turbinengehäuse - Lagergehäuse
9931
Connection elements turbine casing - bearing casing
Verbindungselemente Turbinengehäuse - Abgaskrümmer
9950
Connection elements turbine casing – exhaust elbow
Seite 25 von 26
Page 25 of 26
Teilekatalog ST5
Parts catalogue ST5 ST5_D_00
Seite 26 von 26
Page 26 of 26
Ersatzteile ST5 (9911) 7592002
Spare parts ST5 (9911) 03-17-121
Seite 1 von 2
Page 1 of 2
Ersatzteile ST5 (9911) 7592002
Spare parts ST5 (9911) 03-17-121
Dichtungen
Gaskets
Seite 2 von 2
Page 2 of 2
Ersatzteile ST5 (9915) 7592023
Spare parts ST5 (9915) 02-18-224
Seite 1 von 2
Page 1 of 2
Ersatzteile ST5 (9915) 7592023
Spare parts ST5 (9915) 02-18-224
Beilagen
Shims
Seite 2 von 2
Page 2 of 2
Ersatzteile ST5 (9922) 7591011
Spare parts ST5 (9922) 01-18-196
Seite 1 von 2
Page 1 of 2
Ersatzteile ST5 (9922) 7591011
Spare parts ST5 (9922) 01-18-196
Verbindungselemente
Connection elements
Seite 2 von 2
Page 2 of 2
Ersatzteile ST5 (9931) 7591003
Spare parts ST5 (9931) 00-17-121
Seite 1 von 2
Page 1 of 2
Ersatzteile ST5 (9931) 7591003
Spare parts ST5 (9931) 00-17-121
Verbindungselemente
Connection elements
Seite 2 von 2
Page 2 of 2
Ersatzteile ST5 (9950) 7591012
Spare parts ST5 (9950) 01-18-196
Seite 1 von 2
Page 1 of 2
Ersatzteile ST5 (9950) 7591012
Spare parts ST5 (9950) 01-18-196
Verbindungselemente
Connection elements
Seite 2 von 2
Page 2 of 2
Ersatzteile ST5/ST5-EP/LPR5 (4000) 7530980
Spare parts ST5/ST5-EP/LPR5 (4000) 01-17-205
Lagerung
Bearings
Seite 1 von 1
Page 1 of 1
Werkzeuge LPR5, ST5 (9700) 8597001
Tools LPR5, ST5 (9700) 02-18-029
Seite 1 von 2
Page 1 of 2
Werkzeuge LPR5, ST5 (9700) 8597001
Tools LPR5, ST5 (9700) 02-18-029
Werkzeuge
Tools
Seite 2 von 2
Page 2 of 2
Werkzeuge LPR5, ST5 (9720) 8597020
Tools LPR5, ST5 (9720) 03-18-029
Seite 1 von 3
Page 1 of 3
Werkzeuge LPR5, ST5 (9720) 8597020
Tools LPR5, ST5 (9720) 03-18-029
Werkzeuge
Tools
Seite 2 von 3
Page 2 of 3
Werkzeuge LPR5, ST5 (9720) 8597020
Tools LPR5, ST5 (9720) 03-18-029
Vorrichtungen
Devices
Seite 3 von 3
Page 3 of 3
Service Stations
Argentina China
Turbogen de Pascual Mario Ruffa Tru-Marine Machinery
Lugones 1851 / 55 Engineering Shanghai Co., Ltd.
1430 Buenos Aires No. 318 Cheng Yin Road
Phone: +54 11 4521 5667/ 1914 Baoshan Urban Industrial Park
Fax: +54 11 4521 8283 Baoshan, Shanghai 200444
Mobile: +54 911 4440 7867 Phone: +86 21 65204 220
E-mail: turbogeninfo@turbogen.com Fax: +86 21 6520 6639
Web: www.turbogen.com E-mail: turbo@trumarineshanghai.cn
Web: www.trumarine.com
Australia Tru-Marine Cosco (Tianjin) Engineering Co., Ltd.
MTQ Engine Systems (Aust) P/L No. 26 Lu Shan Road
111 Beenleigh Road Bin Hai New Area
Acacia Ridge Tianjin P.C. 300451
Queensland 4110 Phone: +86 22 2521 2086
Phone: +61 7 3723 4400 Fax: +86 22 2521 2300
Fax: +61 2 8788 2520 E-mail: turbo@trumarinetianjin.cn
Mobile: +61 488 238 393 Web: www.trumarine.com
E-mail: steve.douglas@mtqes.com.au
powermarine@mtqes.com.au Tru-Marine Machinery Engineering Guangzhou Co. Ltd.
Web: www.mtqes.com.au No. 1168 Kangnan Road
Yunpu Industrial Park
Bangladesh Huangpu District, Guangzhou
P.R. China, P.C. 510760
Dalwin Marine Bangladesh Ltd.
Phone: +86 20 8222 7678
Fouzderhat Station Fax: +86 20 8222 7578
CDA Road Bhatiary
E-mail: turbo@trumarineguangzhou.cn
Sitakund, Chittagong, 4315
Phone: +880 3 12780222 Chunhua Turbocharger Services Ltd.
Fax: +880 3 12780200 Guangzhou City Huang Pu Qu Miao Tou Si Gong YeQu
Mobile: +880 18193 18410
Di 15 Dong Chang Fang
E-mail: dalwinbd@dalwin.com
Phone: +86 13602750755
Web: www.dalwin.com
Fax: +86 20 82050616
Nordroy Ltd.
E-Mail: service@gzchunhua.com
Holding No 113. Chondalvogue (Diabari) Web: www.gzchunhua.com
P.S. Turag, Uttara
Dhaka Hongkong
Phone: +880 1771110341
Kemklen Technical Services Ltd.
E-Mail: info@nordroy.com
Shop No. 8, G/F., Block B, Vigor Industrial Bldg.,
14-20 Cheung Tat Road, Tsing Yi, N.T. Hong Kong
Brazil
Phone: +852 2861 2812
American Turbo I.C. Ltda. Fax: +852 2861 1168
Rua Gibraltar Nº 280 E-mail: service@turbokts.com
Sao Paulo – SP (04755-070) Web: www.turbokts.com
Phone: +55 11 5641 3600
K&C Global Ltd.
Fax: +55 11 5641 5550
Block M, Yiu Lian Dockyards
E-mail: kbb@americanturbo.com.br
No 1-7, Sai Tso Wan Road
Web: www.americanturbo.com.br
Tsing Yi Island, New Territories
Hong Kong
Canada
24 Hours: +852 9449 4281
Allied Marine & Industrial Inc. Phone: +852 2435 7880
Fax: +852 2432 1001
1 Lake Road, Port Colborne
Ontario, L3K 1A2 E-mail: service@kc-global.com
Web: www.kc-global.com
Phone: +1 905 834 8275
Fax: +1 905 834 5645
Denmark
E-mail: sales@allmind.com
Web: www.allmind.com PJ Diesel Engineering A/S
Skudehavnsvej 14
Chile DK-2150 Nordhavn Copenhagen
Maestranza Diesel Ltda. Phone: +45 3929 1553
Fax: +45 3927 1054
Santa Elena 1433
Santiago E-mail: pjdiesel@pjdiesel.dk
Web: www.pjdiesel.dk
Phone: +56 2 5502000
Fax: +56 2 5550938
E-mail: hadriazola@md.cl
Web: www.md.cl
Ecuador Hungary
Turbomotores Ecuatorianos S.A. Ferryker Turbo Kft.
Grupo TME Janos Apostol u. 186799 hrsz.
Av. Pedro Vicente Maldonado S23-175 1239 Budapest
Quito 170605 Phone: +361 2870 256
Fax: +361 2870 514
Phone: +593 2 267 5605
Fax: +593 2 268 2097 E-mail: ferrykerturbo@t-online.hu
Web: www.ferrykerturbo.hu
E-mail: turbokralj@grupotme.com
Web: www.grupotme.com
Iceland
Germany Framtak Blossi EHF
Blohm + Voss GmbH Dvergshöfda 27
110 Reykjavik
Norderelbstraße 15
20457 Hamburg Phone: +354 535 5850
Fax: +354 535 5851
Phone: +49 40 311 88 126
Fax: +49 40 311 88 155 E-mail: jon@blossi.is
Web: www.blossi.is
E-mail: service@barthels-lueders.com
Web: www.barthels-lueders.com
India
Scan Turbo Handels- und Service GmbH
Dalwin Marine Turbo Engg Pvt Ltd.
Kleiner Westring 15
27572 Bremerhaven R-307, Rabale
TTC Industrial Area
Phone: +49 471 969 165 0 Navi Mumbai, Maharashtra
Fax: +49 471 969 165 20 India – 400701
E-mail: info@scan-turbo.com Phone: +91-22-27602239
Web: www.scan-turbo.com Fax: +91-22-27602931
Turbinen & Motoren – Service GmbH E-mail: power@dalwin.com
Kleiner Westring 7 Web: www.dalwin.com
27572 Bremerhaven Dalwin Marine Turbo Engg Pvt Ltd.
Phone: +49 471 97 202 0 Plot-50A, AIE
Fax: +49 471 97 202 39 Pedagantyada Road No. 10
E-mail: info@turbinen-motoren.de Visakhapatnam, Andhra Pradesh
Web: www.turbinen-motoren.de India – 530044
Treckel Schiffsservice GmbH & Co. KG Phone: +91-891-2707053
Fax: +91-891-2707053
Reusenweg 1 Mobile: +91 932 4265196
18069 Rostock
E-mail: power@dalwin.com
Phone: +49 381 20260 – 420 Web: www.dalwin.com
Fax: +49 381 20260 – 423
E-mail: mail@treckel.com RAS-TEK Group
R-53, T.T.C. Industrial Area,
Greece Rabale, M.I.D.C.,
Navi Mumbai-400701
Turbomed Yiannis Paraskevopoulos S.A. Phone: +91 22 7101 2021
Schisto Industrial Park (VIPAS), Block 2 Str. 1, No. 2 Fax: +91 22 7101 2119
18863 Perama, Piraeus E-Mail: marine@ras-tek.com
Phone: +30 210 4000111 Web: www.ras-tek.com
Fax: +30 210 4000225
Helpline: +30 6932210060 Indonesia
E-mail: turbomed@otenet.gr
Web: www.turbomed.gr PT. Trimanunggal Perkasindo
Bizpark Commercial Estate Block A7#21.
Guatemala Jalan Raya Bekasi Km.21.5, Jakarta 13920
Phone: +62 21 2936 8722
Elliott Turbocharger Guatemala, S.A. Fax: +62 21 2936 8724
4 Av. 4-44 Z.8 San Cristobal, Sector A-5 E-mail: tpturbo@cbn.net.id
Mixco
Phone: +502 2427 9696 Iran
Fax: +502 2427 9608 Ikad Turbo Internacional
E-mail: ventas@elliott-guatemala.com No. 34, 307 street, South Pajoohesh Square,
Web: www.elliott-guatemala.com Shiraz Industrial Town, Shiraz, Iran
Phone: +98 713 2233538-40
Cell: +98 917 104 8096
E-Mail: info@ikadturbointernacional.com
Netherlands
Tru-Marine Rotterdam
Nieuwe Waterwegstraat 17
3115 HE Schiedam
Phone: +31 10 426 7383
Fax: +31 10 473 3050
E-mail: turbo@trumarine.nl
Web: www.trumarine.com
Turkey
Istanbul Marine Turbine Service Ind. & Trd. Co. Ltd.
Istanbul Deri Organize Sanayi Sitesi
1. Yol X5-A Parsel Aydinli-Orhanli Mevkii
34953 Tuzla / Istanbul
Phone: +90 216 394 04 73
Fax: +90 216 394 04 75
E-mail: info@istmarin.com
Web: www.istmarin.com
UAE
Tru Marine Turbocharger Services LLC
P.O. Box 125837, WS#120-B
Dubai Maritime City, Dubai
Phone: +971 4 874 7785
Fax: +971 4 874 7802
E-mail: turbo@trumarinedubai.ae
Web: www.trumarine.com
Gulf Turbo W.L.L
P.O. Box 50917
Hidd, Kingdom of Bahrain
Phone: +973 1746 4134
Fax: +973 1767 1259
E-Mail: gt.sales@gulfturbo.com
Web: www.gulfturbo.com
UK
Marine Turbo Engineering Ltd.
Abbey House
Priory Trading Estate
Birkenhead, Merseyside
CH 415 JU
Phone: +44 151 647 8141
Fax: +44 151 666 2143
E-mail: info@marineturbo.co.uk
Web: www.marineturbo.co.uk
USA
Motor-Services Hugo Stamp Inc.
3190 S.W. 4th Avenue
Ft. Lauderdale, Florida 33315
Phone: +1 954 763 3660
Fax: +1 954 713 0440
E-mail: turbo@mshs.com
Web: www.mshs.com
Motor-Services Hugo Stamp Inc.
1509 Sams Avenue
Harahan, Louisiana 70123
Phone: +1 504 265 8800
Fax: +1 504 265 8838
E-mail: turbo@mshs.com
Web: www.mshs.com
st
Attachment_Declaration_20140112 Page 1 of 2 1 Edition (11/2013)
Declaration of incoporation
st
Attachment_Declaration_20140112 Page 2 of 2 1 Edition (11/2013)
Service report
for radial exhaust gas turbocharger
Please send the completed service report to the following contact details!
If you have any questions, please contact us.
E-mail: service-24/7@kbb-turbo.com
Telefax: +49 351 40 85 648 (service)
The condition of the turbocharger components should be documented with photos if possible!
Service specifications
Reason of Inspection:
Turbocharger specifications:
Engine specifications:
Application:
Name of customer:
Address of customer:
Shaft
Serial No. (old): (new): IMO-No.:
Turbine blades: ☐ well ☐ cracked ☐ blade parts missing
Compressor impeller
IMO-No.: Serial No. (old): (new):
Compressor blades: ☐ well ☐ cracked ☐ blade parts missing
Thrust ring
will be: ☐ used ☐ replaced → Cause:
Spacer
will be: ☐ used ☐ replaced → Cause:
Compressor diffusor
IMO-Nr.: C
will be: ☐ used ☐ replaced → Cause:
Damages: ☐ no ☐ yes
Notes:
Turbine casing
will be: ☐ used ☐ replaced → Cause:
Compressor casing
will be: ☐ used ☐ replaced → Cause:
Bearing casing
will be: ☐ used ☐ replaced → Cause:
Compressor bearing
will be: ☐ used ☐ replaced → Cause:
Turbine bearing
will be: ☐ used ☐ replaced → Cause:
Other defects: