Operating Instructions For Exhaust-Gas Turbocharger

Operating instructions
ST4
for exhaust-gas turbocharger
ST4
Kompressorenbau Bannewitz GmbH

Windbergstraße 45
01728 Bannewitz
Germany
Telephone: +49 351 40 85 603 (sales)
+49 351 40 85 669 (service)
+49 172 35 16 045 (24-hour-service)
Telefax: +49 351 40 85 648 (service)
E-mail: service-24/7@kbb-turbo.com
Website: www.kbb-turbo.com
Edition 10 01/2019 Page 1 of 108

Prepared: J. Scholze Approved: S.Käseberg Released: K. Buchmann
ST4

Operating instructions Content
ST4
Content
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
2 Technical data ........................................................................................ 19

2.1 Operating data ................................................................................................................. 19
2.2 Alarm values .................................................................................................................... 20
2.3 Main dimensions ............................................................................................................. 21
2.4 Connections .................................................................................................................... 22
2.5 Weights of important components................................................................................ 24
2.6 Permissible vibrations .................................................................................................... 25
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

Operating instructions Content
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4 Dismantling and assembly the exhaust-gas turbocharger ................ 53
4.1 Introduction ..................................................................................................................... 53
4.2 Important tightening torques ......................................................................................... 54
4.3 Spare parts, tools, measuring devices, auxiliary materials and lubricants .............. 55
4.3.1 Spare parts ........................................................................................................................ 55
4.3.2 Tools ................................................................................................................................. 56
4.3.3 Measuring devices ............................................................................................................ 56
4.3.4 Auxiliary materials and lubricants ..................................................................................... 56
4.4 Work steps ....................................................................................................................... 57
4.4.1 Mounting the complete exhaust-gas turbocharger ........................................................... 57
4.4.2 Removing the complete exhaust-gas turbocharger .......................................................... 58
4.4.3 Removing and mounting the air intake bend / silencer / air inlet flange ........................... 59
4.4.4 Removing and mounting the compressor casing.............................................................. 60
4.4.5 Removing and installing the compressor casing insert..................................................... 62
4.4.6 Removing and mounting the compressor diffuser ............................................................ 64
4.4.7 Removing and mounting the exhaust-gas elbow .............................................................. 66
4.4.8 Removing and installing the cartridge ............................................................................... 68
4.4.9 Removing and mounting the turbine casing ..................................................................... 72
4.4.10 Removing and installing the turbine nozzle ring ............................................................... 74
4.4.11 Removing and installing the turbine casing insert ............................................................ 75
4.4.12 Removing the rotor ........................................................................................................... 78
4.4.13 Installing the rotor.............................................................................................................. 87
4.5 Adjusting and checking the clearances ....................................................................... 99
4.5.1 General ............................................................................................................................. 99
4.5.2 Admissible clearances .................................................................................................... 100
4.5.3 Adjusting the clearance S2 ............................................................................................. 101
4.5.4 Checking the clearances S1 and S12 ............................................................................. 104
4.5.5 Checking the clearance S14 ........................................................................................... 105
4.5.6 Checking the clearance S15 ........................................................................................... 106
Appendix ........................................................................................................................ 107

Parts catalogue
Overview Service Stations
Attachment of the declaration of incorporation
Service report

Operating instructions Chapter 1
ST4
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
Tighten with the indicated torque.
Tighten hand-tight without tools.
Apply oil.
Apply high-temperature grease / ceramic paste.
Apply threadlock.
Free from grease, free from oil, dry.
Measure the value.
Record the value.
Carry out a visual inspection.
Observe the information in the documentation.
Dispose of all waste in a correct and environmentally responsible manner and in

compliance with the valid local regulations.

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Symbols
The following symbols may be used in this document:
1. Defines a numbered operation step. The sequence of the steps is important.
a. Defines a subordinate operation step.
• Defines a first-level enumeration
o Defines a second-level enumeration
[ ] Defines a reference to page / chapter
Defines a note
Work becomes more effective and easier if you follow the work and operating
instructions marked with this symbol.
Notes facilitate your work.
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.

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1.2 Product description
1.2.1 Brief description

Exhaust-gas turbocharger type: ST4
Specification number: 7400xxx
Weight (maximum value): 293 kg
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.
1.2.4 Intended use

The exhaust-gas turbocharger is used to charge combustion engines. Any other use is not permitted
and has to be agreed with Kompressorenbau Bannewitz GmbH (KBB) in advance.
The exhaust-gas turbocharger specification is based on the engine, adjusted to its thermodynamics and
binding for this engine variant, i.e. the same exhaust-gas turbocharger specification has to be used if
the exhaust-gas turbocharger is replaced.
Modifications and the attachment of additional parts to the exhaust-gas turbocharger are subject to the
written approval of Kompressorenbau Bannewitz GmbH, otherwise all warranty claims will be forfeited.
The intended use also includes compliance with the prescribed maintenance and inspection work and
its performance at regular intervals.

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1.3 Product identification
1.3.1 Marking of the exhaust-gas turbocharger

Each exhaust-gas turbocharger can be clearly identified by two markings:
• Type (Type)
• Serial number (Serial)
These markings are located on the nameplate which is attached to the bearing casing.
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 4).
Example: Type ST 4
↓ ↓
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 74 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

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1.3.2 Marking of parts and subassemblies
1.3.2.1 Part numbers in the documentation
Four- or five-digit "part numbers" are used to identify spare parts, components, subassemblies and tools
in the documentation. These "part numbers" are independent of the respective specification and
exhaust-gas turbocharger type.
Please quote the specification number of the exhaust-gas turbocharger in addition to the part number
when ordering parts.
Spare parts (connection elements, gaskets, shims) 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).
Example of a component:
1 pc. (7010) turbine nozzle ring for 7400002 can be supplied separately.
Example for spare part:
5 pc. (5230) stud bolts for 7400002 cannot be supplied separately!
 The "Spare parts (9951)" set has to be ordered instead.
 1 pc. (9951) spare parts for 7400002
1.3.2.2 Identification of a spare cartridge
Spare cartridges have a cartridge nameplate with the following details:
• Type: ST4
• Spec: Specification number of the cartridge, e.g. 7407002
• 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.
1.3.2.3 Identification of components

Some parts are marked with a 7-digit variant number. Some parts are also marked with an additional
IMO no.

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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
1.4.2 Definition of safety instructions and mandatory signs

Safety instructions
Warning
Warning indicates a hazard with a medium level of risk which, if not avoided, could
result in death or serious injury.
WARNING
 Warnings and orders must be followed.
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.
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Mandatory signs
Wear ear protectors!
Use protective equipment as required!
Wear gloves!
Wear head protection!
Wear breathing protection!
Use skin protection!
Wash your hands!
Wear protective clothing!
Protective equipment that must be worn when working on the exhaust-gas

turbocharger!
Wear foot protection!
Protective equipment that must be worn when working on the exhaust-gas

turbocharger!
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1.4.3 Hazards during operation and when working on the exhaust-gas
turbocharger
Danger due to hot surfaces
The exhaust-gas turbochargers surfaces may be hot. Operating materials may also
be hot.
WARNING
Direct contact may result in severe burns.
 Allow the exhaust-gas turbocharger to cool down before starting any work.
 Do not touch hot surfaces without protective equipment.
Wear heat-resistant gloves!
Danger due to rotating parts

The exhaust-gas turbocharger's rotor is a rotating part. The rotor may rotate due to
draughts even when the engine is at a standstill!
WARNING
Direct contact with rotating parts may result in severe injuries.
 Always block the rotor when working on the exhaust-gas turbocharger.
 Check that the rotor is blocked before starting work on the exhaust-gas
turbocharger.
Wear protective gloves!
Danger due to noise

Engines and exhaust-gas turbochargers may produce loud noise.
Noise exposure may affect your health, mental state and attention and may even lead
WARNING
to permanent hearing damage.
 Keep the time you spend in places with a high noise exposure to a minimum.
Wear ear protectors!
Danger due to tipping over

The exhaust-gas turbocharger or its components may tip over during storage and
transport.
WARNUNG
Tipping-over may result in contusions and serious injuries. It may even lead to
permanent health damage.
 Only store and transport the exhaust-gas turbocharger and its components on a
suitable base.
 Only store and transport the exhaust-gas turbocharger and its components after
fitting suitable protection against tipping over.
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Danger due to operating and auxiliary materials

Handling operating and auxiliary materials may cause hazards.
Contact with, swallowing and inhaling the vapours of such operating and auxiliary
WARNING
materials may lead to severe health conditions.
 Avoid inhaling vapours.
 Avoid contact without protective equipment.
 Observe the safety data sheets for the operating and auxiliary materials.
Wear protective gloves!
Wear protective clothing!
Use skin protection!
Wash your hands at the end of work!
Fire risk
Operating and auxiliary materials may be highly flammable.
This may lead to fire and severe injuries.
WARNING
Danger to the environment

Operating and auxiliary materials can cause permanent damage to the environment.
 Make sure that these materials are disposed of properly.
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1.4.4 Warning signs on the exhaust-gas turbocharger
All silencers and V-bands bear warning signs to increase safety. These warning signs must be clearly
visible and legible while the exhaust-gas turbocharger is in operation.
Warnings on the silencers
Warnings on the V-band (2 piece, every 180°)
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.
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1.4.5 Prerequisites for operation
Responsibility of the operator
These operating instructions are an integral part of the exhaust-gas turbocharger. It must be accessible
to the operating and maintenance staff at all times.
The operating instructions should be read before commissioning the exhaust-gas turbocharger.
Particular attention should be paid to the hazard warnings and information.
It is the operator's responsibility:
• to familiarize his operating and maintenance staff with safe working methods.
• to ensure that his operating and maintenance staff observes the safety instructions.
The work described in this manual is presented in such a way that it can be understood by anyone who
has undergone technical training.
The operator has to provide the staff with appropriate tools and test equipment.
The operator must obtain permission to operate the unit from the local authorities and observe the
pertinent regulations:
• Labour safety
• Cleaning and maintenance of the machines
• Product disposal
• Environmental regulations
Exclusion of warranty claims
Any damage due to
• poor maintenance,
• improper handling and/or failure to comply with the operating instructions in this instruction
manual,
• the attachment of additional parts to the exhaust-gas turbocharger by third parties or
• the use of non-original spare parts
is excluded from the warranty and liability.
Warranty and liability claims are also excluded in the event of interventions by unauthorised persons
during the warranty period.
This especially includes:
• the dismantling of any exhaust-gas turbocharger components,
• repair and maintenance work which requires the dismantling of exhaust-gas turbocharger
components,
• the replacement of parts which requires the dismantling of exhaust-gas turbocharger
components.
Exceptions:
Exceptions apply to the replacement / removal of the entire exhaust-gas turbocharger, the speed sensor,
silencer filter mats, the entire silencer and the turbine inlet casing.
The manufacturer of the exhaust-gas turbocharger may consent to other exceptions on request but
these are always subject to the written approval of Kompressorenbau Bannewitz GmbH.
Authorised persons
Authorised persons are employees of Kompressorenbau Bannewitz GmbH as well as employees of
authorised service workshops who have been trained by Kompressorenbau Bannewitz GmbH.
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1.4.6 Operating and maintenance staff
Operating and maintenance staff are persons who are responsible for the transport, installation,
operation, maintenance and cleaning as well as troubleshooting.
Observe the following accident prevention regulations:

 Winches, lifting and drawing gear (BGV D 8)
 Lifting accessories for lifting operations (BGR 500, Chapter 2.8)
WARNING You risk your life and limb if you do not observe these regulations!
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.
1.4.7 Mounting spare and wearing parts

We herewith emphasize that spare parts and accessories that are not supplied by our company have
not been tested and released by us. The use of such products may have a negative effect on the
properties specified by the design of the exhaust-gas turbocharger. Kompressorenbau Bannewitz
GmbH can assume no liability for damage caused by the use of non-original parts and accessories.
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1.4.8 Declaration of incorporation
Within the meaning of the EC directive 2006/42/EC on machinery, Annex II, no. 1 B
Manufacturer: Kompressorenbau Bannewitz GmbH,
Windbergstraße 45,
01728 Bannewitz,
Federal Republic of Germany
Product: Exhaust-gas turbocharger
Please refer to the nameplate for type, specification number and serial number.
The head of the Technology Division, Mr Klaus Buchmann, Windbergstraße 45, 01728 Bannewitz, is
authorized to compile the relevant technical documentation according to Annex VII B.
The exhaust-gas turbocharger is a partly completed piece of machinery according to Article 2g and
exclusively intended to be fitted to a combustion engine. The relevant technical documentation
according to Annex VII B has been drawn up and can be transmitted to the competent national
authorities in an electronic form on request.
The exhaust-gas turbocharger may not be put into service until it has been established that the final
machine or system into which the exhaust-gas turbocharger is to be incorporated conforms to the
provisions of the Directive on Machinery.
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.
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1.4.9 Lifting loads
The exhaust-gas turbocharger and its components must be attached to the lifting gear in one of the
ways shown in the respective chapters. The complete exhaust-gas turbocharger must always be lifted
by the eye bolts on the bearing casing. In addition, eye bolts can also be screwed into individual
components in different places to correct a tilted position. All necessary eye bolts are included in the
tools (9700).
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:
 Load handling devices for lifting operations (BGR 500, Chapter 2.8)
Wear head protection!
Wear gloves!
Lifting instructions for eye bolts
1 Lifting-eye nut α = max. 45°

2 Lifting-eye bolt β=0
3 Washer h=0
4 Hexagon head screw F Direction of force
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2 Technical data
2.1 Operating data
General
Specification Refer to nameplate (Spec)

Max. speed ( overload / short-term) Refer to nameplate (nmax)
Max. speed (continuous operation) 0.95 * nmax
Max. exhaust-gas temperature before turbine Refer to nameplate (tmax)
Counter-pressure after turbine Max. 2.5 kPa
(above atmospheric)
Vacuum pressure before compressor Max. 1.5 kPa
(below atmospheric)
Sound pressure level
Measured on the silencer / compressor casing, at a distance of 1 m, at 106 dB(A)

92% of the max. speed or 100% engine output
Cooling water (only for bearing casings with water cooling)
Cooling water temperature at inlet Max. 50 – 85 °C

Max. cooling water temperature difference between inlet and outlet 10 K
Cooling water pressure Max. 400 kPa
Lubricating oil (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
Lubricating oil temperature before TC 40 – 80°C*

Lubricating oil temperature after TC Max. 120°C
* Lubricating oil temperatures before the TC up to 105 °C are permissible after consulting KBB.
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Lubricating oil pressures
Lubricating oil pressure before TC in operation* 300 ± 150 kPa

Lubricating oil pressure at start-up to idle running of the engine Min. 50 kPa
"Low oil pressure" limit value before TC Min. 125 kPa
"Oil pressure too low" limit value before TC  EMERGENCY STOP Min. 50 kPa
At standstill for pre-lubrication or post-lubrication (standby mode) Refer to diagram
*An orifice has to be used to ensure the indicated range if a higher lubricating oil pressure is expected
on the engine side.
Lubricating oil flow
Lubricating oil flow at 60°C / 300kPa max. 38 l/min

Lubricating oil flow at 80°C / 450kPa max. 52 l/min
2.2 Alarm values

The following alarm values have to be set for automatic monitoring to ensure operational safety.
Measured variable Alarm value

Speed 0.97 * nmax
Exhaust-gas temperature before turbine tmax -15 K
Lubricating oil temperature after TC ≤ 120 °C
Lubricating oil pressure before TC ≥ 125 kPa (1.25 bar)
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!
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2.3 Main dimensions
* 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*
1080 mm 527 mm 574 mm
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2.4 Connections
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Quantity Status Size Use
Temperature / pressure measurement
A 2 Optional M18x1.5
(before compressor)
B 1 Standard M16x1.5 Compressor washing
C 3 Optional Wastegate connection or drain
M18x1.5 Temperature / pressure measurement
D1 1 Optional
or G3/4“ (after turbine)
D2 1 Optional M18x1.5
(after turbine)
E 2x per entry Optional M18x1.5
(before turbine)
Temperature / pressure measuring (after
F 2 Optional M18x1.5
compressor)
G 1x per entry Optional M18x1.5 Turbine washing
ST3/4 M 26x1.5
H 2 Optional Compressor air drive (Jet Assist)
ST5/6 M33x1.5
ST3 M16x1.5
I 2 Standard ST4/5/6 M18x1.5 Speed sensor
ST7 M20x1.5
ST3-6 M18x1.5
J 2 Standard Compressor cooling
ST7 M33x1.5
Pressure differential
K 1 Standard M18x1.5
“Silencer dirty” alarm
L 1 Standard M8 Vibration measurement
Bearing casings with water cooling have the additional connections M and N.
Quantity Status Size Use

ST4 M26x1.5
M 2 Standard Water cooling inlet
ST5 M33x2
ST4 M26x1.5
N 2 Standard Water cooling outlet
ST5 M33x2
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.
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2.5 Weights of important components

The weights shown in this document vary according to the turbocharger
specification and serve as a reference for any installation tools that may be required.
The given weights represent maximum values.
Part-No. Designation ST4

(1000) Exhaust-gas turbocharger, complete 293 kg
(1100) Exhaust-gas turbocharger, basic unit 230 kg
(1200) Cartridge 57 kg
(2010) Shaft 8.6 kg
(2040) Compressor wheel 2.5 kg
(3020) Bearing guide sleeve 3.8 kg
(3030) Heat shield 3.3 kg
(5010) Turbine casing 43 kg
(5020) Turbine casing insert 9 kg
(5210) Containment shield 15 kg
(5220) Containment ring 3 kg
(6010) Compressor casing 33 kg
(6040) Compressor casing insert 12 kg
(7010) Turbine nozzle ring 4 kg
(8010) Compressor diffuser 3 kg
(9010) Silencer 25 kg
(9020) Air intake bend 11 kg
(9025) Air intake flange 5 kg
(9100) Exhaust gas elbow 25 kg
(9704) Sealing device 12 kg
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2.6 Permissible vibrations

Maximum permissible vibrations on the engine at 10 … 250 Hz
At the exhaust-gas turbocharger At the silencer

(measured at bearing casing LG) (measured at SD)
Vibration speed vRMS max. 45 mm/s max. 71 mm/s
Vibration amplitude sRMS max. 0.7 mm max. 1.1 mm
Acceleration aRMS max. 70 m/s² max. 111 m/s²
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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
Anti-corrosion paper (VCI), anti-corrosion film (VCI)

Volatile corrosion inhibitor agents may be harmful to health if brought in contact
with the skin frequently or if inhaled.
CAUTION
 Do not inhale
Cling film
Dispose of this film according to the local regulations.
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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.
3.3 Putting into operation

The exhaust-gas turbocharger is driven by the engine's exhaust gases and is put into operation with the
engine.
The exhaust-gas turbocharger speed depends on the engine's operating condition. The charge air
pressure that is required for the engine is defined by matching the turbine nozzle ring and the
compressor diffuser when adjusting the exhaust-gas turbocharger.
The following measurement values should be entered into the engine log during engine operation (at
least every 24 operating hours) if the corresponding meters are available:
1. Speed of the exhaust-gas turbocharger
2. Exhaust-gas temperature before turbine and/or after cylinder
3. Charge air temperature after compressor and/or after charge air cooler
4. Charge air pressure after compressor
5. Lubricating oil temperature before exhaust-gas turbocharger
6. Lubricating oil pressure before exhaust-gas turbocharger
Stop the engine immediately if the oil pressure falls below the minimum pressure.
Always pre-lubricate before start-up operations.
Make sure that the oil supply and return lines do not leak so as to prevent oil from
CAUTION
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.
Furthermore, the following checks have to be carried out at regular intervals:

1. Tightness of the exhaust gas, charge air and oil lines
2. Smooth running of the exhaust-gas turbocharger
The charge air pressure can serve as a parameter for the speed of the exhaust-gas turbocharger.
Uneven running (vibration of the exhaust-gas turbocharger) indicates a major imbalance of rotating parts
which may result in damage to the rotor and bearing.
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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.
Regular maintenance work according to the schedule helps prevent malfunctions

and unplanned standstills.
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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!
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Charge air pressure and/or speed too low
Immediate measure:
Do not exceed the maximum permissible temperature after the cylinder. Reduce the
output if necessary.
Check for abnormal noise or increased vibration.
Cause Remedy
Exhaust-gas turbocharger :
• Turbine nozzle ring worn • Replace the turbine nozzle ring
• Rotor sluggish • Check for score marks
Engine:
• Faulty indication, measuring line to pressure • Replace the pressure gauge, repair the leaks
gauge leaky
• 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
• High intake temperatures • Make sure that the intake air is not too warm
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).
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Charge air pressure and/or speed too high
Immediate measure:
Do not exceed the maximum speed, reduce the engine output if necessary.
Cause Remedy
• 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
• 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!
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Compressor is surging
Immediate measure:
Reduce the output until operation without surging is possible.
Cause Remedy
Exhaust-gas turbocharger :
• Compressor diffuser damaged • Replace the compressor diffuser
• 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 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
• Cylinder valves dirty • 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).
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Delayed start / short run-down time
Immediate measure:
Pay attention to any strange noises.
Reduce the engine output or stop the engine if abnormal noise occurs suddenly.
Cause Remedy
• Rotor is rubbing against parts • Check the clearances
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
rotor parts!
Vibrations or loud noises
Cause Remedy
• Imbalanced rotor due to heavy soiling • Clean the rotor mechanically and balance
Engine:
• Unfavourable mounting position • Measure vibrations, perform an FFT analysis
rotor parts!
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Lubricating oil loss
Immediate measure:
Refill lubricating oil.
Cause Remedy
• 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
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3.6 Replacement intervals for components

The stress to which the individual components are subjected depends on the individual application, the
operating regime and the ambient conditions.
KBB usually recommends the following component replacement intervals. These are guideline values,
which may vary and depend on the operating conditions. These values constitute neither a guarantee
nor liability for the component's replacement free of charge.
Expected replacement intervals (in operating hours [h])
The following components have to be checked during each inspection according to the maintenance
schedule.
Components HFO MDO GAS

Bearing (radial bearing, bearing disk) 12500 - 25000 25000 - 36000 25000 - 36000
Rotor (compressor wheel, shaft) *) 50000 50000 50000
Turbine nozzle ring 12500 - 25000 50000 50000
Silencer (except filter mat) 25000 25000 25000
Turbine housing, turbine housing insert 25000 - 50000 25000 - 50000 25000 - 50000
Other housings, compressor diffuser 50000 50000 50000
*) 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
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3.7 Emergency operation of the exhaust-gas turbocharger
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.
Shutting the exhaust-gas turbocharger down

1. To shut down the TC, remove the compressor-side components so that the cartridge (1200)
and the turbine nozzle ring (7010) with the metal gasket (7040) can be removed from the turbine
casing (5010).
2. Then close the turbine casing with the sealing device (9704) to prevent exhaust gas from
escaping.
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3.8 Shutdown (short-term)

The exhaust-gas turbocharger continues to run for some time after the engine has been stopped.
The run-down time depends on the installation.
If the rotor stops immediately or the run-down time is much shorter than usual, this may be due to the
following reasons:
• damaged bearings
• the compressor wheel or turbine blades are rubbing against parts due to too low clearances
caused by exceptionally high forces resulting from thermal distortion
• jammed foreign matter
Exhaust-gas turbocharger without water-cooled bearing casing:

Continue lubricating the exhaust-gas turbocharger for at least 15 minutes after the
engine has been stopped.
Prolong the post-lubricating time for engines with a turbine inlet temperature
>580 °C (at full load) or oil inlet temperature >80 °C.
Observe the operating instructions of the engine manufacturer.
Exhaust-gas turbocharger with water-cooled bearing casing:

Postlubrication is not required!
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3.9 Extended shutdown (preservation)

If an exhaust-gas turbocharger that has been operated with an engine is shut down for longer than
twelve months, it has to be removed from the engine and preserved.
An inspection has to be carried out by an authorized service workshop in accordance with the
maintenance schedule.
The complete exhaust-gas turbocharger has to be dismantled. All components have to be cleaned and
oiled slightly. The exhaust-gas turbocharger can then be reassembled. All machined surfaces and
flanges have to be evenly coated with an anticorrosive agent (e.g. Tectyl). All openings have to be
sealed. Additionally, a hygroscopic drying agent can be placed into the interior spaces of the compressor
casing and the turbine inlet.
The preserved exhaust-gas turbocharger and spare parts have to be kept in a dry room (max. humidity
of 60 %) and protected against moisture, aggressive gases and vapours. When at rest, the exhaust-gas
turbocharger has to be protected against constant vibration which may damage the bearings.
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
Volatile corrosion inhibitor agents may be harmful to health if brought in contact

with the skin frequently or if inhaled.
 Do not inhale
CAUTION
Wear gloves!
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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:
Type Material Disposal

Cast-iron materials, aluminium, steel,
Metals as scrap metal for recycling
nickel-steel alloys, brass, copper
Non-metallic materials Rubber gaskets (O-rings), filter mat as waste
Lubricants Engine oil residues as used oil
Electronic components Speed sensor and cables as electrical scrap
Insulation material Thermal insulation of the casings as waste
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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.
3.11.2 Maintenance work and intervals

In order to keep the exhaust gas turbocharger in a safe condition, it is necessary to inspect and check
various subassemblies and components according to the maintenance schedule.
This includes detailed instructions on the procedure for assembly and dismantling work which may be
carried out by the operating and maintenance staff. Inspections may only be carried out by service
workshops authorised by KBB.
Observe the following accident prevention regulations:

 Lifting accessories for lifting operations (BGR 500, Chapter 2.8)
During a major overhaul or repairs to essential parts of the exhaust-gas

turbocharger, we recommend that their condition be documented.
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.
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The intervals between the individual exhaust-gas turbocharger inspections can be adjusted to the engine
inspection intervals but must not exceed the limits indicated below.
The bearing and rotor replacement intervals must not be exceeded!
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
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3.11.3 Scope of inspections
Inspection 0
Inspection 0 should be carried out before the interval time is reached, either as
required or after a performance loss, depending on the quality of the heavy fuel oil,
operating regimes and turbine washing.
• 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
• Assembly of the exhaust-gas turbocharger
Inspection I
The scope of the inspection should be extended or reduced between options "a" and
"b" depending on the place of inspection (on site or in the service workshop) and on
the available standstill times.
a) Minimum scope
• 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
• 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
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3.11.4 Spare parts required for inspections
Spare parts and tools are only supplied in complete sets (refer to "Parts catalogue"
annex). Spare parts cannot be ordered separately!
annex).
Spare parts and tools required for inspections
Inspections Components Spare parts Tools

0* (every 6,000 h max.) (9980) (9700)
I (every 12,500 h max.) (7010)* (9981) (9700), (9720)
II (every 25,000 h max.) (7010)* (9971) (9700), (9720)
III (every 50,000 h max.) (7010)*, (2000) (9971) (9700), (9720)
* with HFO operation
* 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.
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3.11.5 Maintenance of the turbine nozzle ring
The turbine nozzle ring is subject to increased wear during heavy fuel oil operation and is thus a wearing
part.
The life time of the turbine nozzle ring is at least 12,500 hours and depends on the quality of the heavy
fuel oil and the operating conditions.
The turbine nozzle ring should be replaced after this time if the parameters (charge air pressure,
exhaust-gas temperatures) vary significantly due to corresponding wear.
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.
Can still be used Replace

Wear pattern 1 Wear pattern 2 Wear pattern 3
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 < 15 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 2
• The guide blades have a slit alongside both disks.
• The nozzle ring can still be used if the slit length is < 15 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.
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3.12 Cleaning
3.12.1 Cleaning the compressor

3.12.1.1 Cleaning the compressor during operation
General
Deposits can form on the compressor components during operation of the exhaust-gas turbocharger.
These deposits may have an adverse effect on the operating parameters of the exhaust-gas
turbocharger and the engine.
The degree of soiling largely depends on the ambient conditions since the intake air may contain dust,
soot or oil vapours.
Regular cleaning of the compressor is necessary during operation to prevent or delay the formation of
such deposits.
Cleaning is performed by injecting water during high output.
The cleaning action is essentially due to the kinetic energy of the atomized drops of water.
Design (example with a silencer)
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
The compressor cleaning device is only delivered when ordered separately.

KBB's scope of delivery includes the items 1, 3, 4, 6 and 7.
The piping is not included in KBB's scope of delivery.
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!
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Work sequence (every 24 – 48 operating hours):
1. Operate the engine at 50 to 85% of its rated output.
2. Open the water tank (4) by unscrewing the wing nut and removing the cover and fill with clean
water (approx. 0.5 l) (No sea water! No additives!). Close the water tank.
3. Open the ball valve (3). Compressed air flows through the air pipe (2) into the water tank (4)
via the ball valve (3).
4. Open the ball valve (6), wait for approx. 20 sec., close the valve. The water is pressed
through the water pipe (5) into the injection pipe, atomized by the intake air and hits the
compressor blades at high speed in the compressor casing.
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.
3.12.1.2 Mechanical cleaning of the compressor

Work sequence
1. Remove the air intake bend/silencer, air connection casing and compressor casing (the
compressor wheel remains on the shaft).
2. Remove all deposits with diesel fuel or another permissible liquid cleansing agent.
Make sure to observe the following accident prevention regulations!

While washing, make sure to prevent the cleansing agent from entering the charge
air piping or the interior of the exhaust-gas turbocharger.
Do not use any caustic liquids to clean the compressor wheel!
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3.12.2 Turbine cleaning
3.12.2.1 Cleaning the turbine during operation
General
Deposits accumulate on the turbine nozzle ring and turbine wheel during operation with heavy fuel oil,
leading to a drop in efficiency. They also cause the charge air pressure to rise.
Inspections also showed that exhaust gas residues from operation with heavy fuel oil may block the
bores of the washing nozzles (8), making turbine washing impossible. A purging air line should be
installed to prevent the washing nozzles from clogging.
The washing intervals depend on the fuel quality and the operating conditions and therefore may have
to be adjusted subsequently based on experience with engine operation.
A rise in the charge air pressure of more than 0.1 bar (at identical engine output), for example, can be
used to determine the washing time.
The recommended standard washing interval for heavy fuel oil operation is approx. 300 hours but can
be altered to between 25 and 600 hours depending on the quality of the heavy fuel oil.
The charge air pressure and the exhaust-gas temperatures must be read and recorded at a reference
point (at an output of 75% or 100%) before and after washing to monitor the cleaning effect.
Turbine cleaning instructions

KBB recommends that the processes and operating states described below be used when washing the
turbine by wet cleaning.
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!
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Design
1 Sanitary fresh water

Do not use any additives or sea water!
2 Valve
Regulating valve to adjust the correct water pressure
3 Fresh water line
4 Hose section
The connection to the fresh water line should be made using a removable hose section,
preferably with a quick-disconnect coupling.
5 Pressure gauge
6 3-way valve
A 3-way valve is to be provided before the washing nozzles.
Media: either fresh water (1) for turbine cleaning or purging air (12) (optional)
7 Washing water line
8 Washing nozzles
The place of installation depends on the turbine casing variant
9 Drain connection (optional)
Provide an inner diameter of 18 mm.
10 Valve (optional)
11 Receiving funnel for wastewater / inspection glass (optional)
12 Purging air / charge air (optional)
5010 Turbine casing
9100 Exhaust-gas elbow
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Nozzles
Each inlet port of the turbine inlet housing is equipped with an injection nozzle for water injection. The
nozzle diameters specified in the table must be observed.
Turbine casing ST3 ST4 ST5 ST6 ST7

1-entry Ø 2.4 Ø 2.8 Ø 3.5 Ø 4.0 2 x Ø 4.0
2-entry Ø 1.7 Ø 2.0 Ø 2.4 Ø 2.8 Ø 4.0
3-entry – Ø 1.7 Ø 2.0 Ø 2.4 Ø 3.5
4-entry – – Ø 1.7 Ø 2.0 –
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!
Operating values for interval washing
Exhaust-gas temperature before Water pressure (above

Washing time
turbine atmospheric)
350 – 430 °C 2.5 – 4.5 bar 3-4 x 30 sec
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Work sequence for washing with the engine idling
Washing with the engine idling is only permitted if a drain is present!

The drain must be opened since otherwise the turbine may be flooded!
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!
3. Wait for approx. 10 minutes!

4. Open the valve (10) for drain (9).
5. Open the 3-way valve (6).
6. Open the valve (2) and set the water pressure (see table).
7. Check that the water runs off at the drain.
8. Close the 3-way valve (6) after 10 minutes.
9. Close the valve (2) and valve (10) for drain!
10. Run the exhaust-gas turbocharger dry for approx. 10 min. and gradually increase the engine
output!
11. Repeat the washing if vibrations are noticed at the exhaust-gas turbocharger that did not
occur before washing.
12. Remove the hose section (4).
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!
Operating values for washing with the engine idling
Exhaust-gas temperature Water pressure

Engine output Washing time
before turbine (above atmospheric)
< 10% Max. 350°C 2.5 – 4.5 bar 3-4 x 30 sec
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3.12.2.2 Mechanical cleaning of the turbine
The following methods are permitted:
1. Remove the cartridge from the turbine casing. Clean the turbine wheel, turbine nozzle ring and
turbine casing mechanically.
2. Clean the components with alkaline aqueous suds and dry thereafter.
3. Clean the turbine with diesel (if slightly soiled).
4. If heavily soiled, place the components in diesel or alkaline aqueous suds and then clean with
a wire brush.
Not permitted:
• Cleaning the turbine nozzle rings may not affect the dimensions of the functional surfaces.
• The surfaces may not be roughened up.
• The blades may not be bent.
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.
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3.12.3 Cleaning the silencer
General
In most cases merely the filter mat has to be cleaned. The silencer can remain on the exhaust-gas
turbocharger during this work.
The given maintenance interval of 500 operating hours is simply a mean guide value since the
accumulation of dirt in the filter mat and the resulting pressure drop are largely dependent on the
environment.
A maintenance indicator (vacuum gauge) which signals the correct replacement time should be installed
under extreme conditions. The maintenance indicator should be designed such that the replacement
signal is sent when a vacuum of approx. 100 mm water column is measured at the specified point of
installation “K“ (e.g. MANN maintenance indicator for air filters, max. vacuum pressure of 200 mm WG
= 20 mbar).
Work sequence for replacing the filter mat

1. Open and remove the tension tapes (9014).
2. Pull the filter mat (9012) from the silencer (9010).
3. Insert a new filter mat (9012) and reinstall the tension tapes (9014).
Work sequence for cleaning the silencer
The silencer has to be cleaned completely if heavily soiled or during an inspection.
1. Remove the silencer (9010).

2. Clean with a soft brush on the outside.
3. Mount the silencer (9010).
Operation of the exhaust gas turbocharger without a filter mat is not permitted!
The valid accident prevention regulations (handling of harmful, volatile, flammable
solvents) and the fire protection regulations (DIN14096) must be observed during
cleaning. Cleaning with P3 solution or trichloroethylene is prohibited. The
compatibility with the filter material has to be checked when using other solvents.
The regulations of the classification societies with respect to washing liquids have
to be observed if used on a vessel.
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4 Dismantling and assembly the exhaust-gas

turbocharger
4.1 Introduction
This chapter should enable the operator to perform easy dismantling and assembling work on the
exhaust-gas turbocharger by himself.
It is assumed that the staff is familiar with the work and that the tools required are at hand. Furthermore,
the exhaust gas turbocharger has to be accessible and corresponding lifting gear has to be available.
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.
Checks during dismantling

The questions listed below can be used to check the condition of the exhaust-gas turbocharger and its
major components. Damage affecting the rigidity, balance and smooth running of rotating components
has to be remedied by the manufacturer or an authorized workshop. If damaged parts are returned for
repair, ensure an appropriate protection against damage during transportation.
After dismantling the casings, perform the following checks on the cleaned parts.
Rotor, complete
1. Are contact traces visible on the casing?
2. Are contact traces visible on the rotor?
If reworking is performed or if rotor parts are replaced, the rotor has to be
rebalanced!
Compressor wheel / turbine wheel

1. Can you see any traces of sliding or cracks on the compressor wheel / turbine wheel?
Compressor diffuser/turbine nozzle ring

1. Are the guide vanes twisted or worn?
2. Is foreign matter stuck in the ducts?
3. Can you see traces of foreign matter?
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?
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4.2 Important tightening torques
A1 = 35 Nm A2 = 35 Nm B1 = 40 Nm B2 = 40 Nm
A3 = 16 Nm C1 =155 (+10) Nm C2 = 16 Nm C3 = 16 Nm C4 = 16 Nm
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4.3 Spare parts, tools, measuring devices, auxiliary materials

and lubricants
The following range of spare parts, tools, measuring devices, auxiliary materials and lubricants are
required for inspections and repairs on KBB exhaust-gas turbochargers.
4.3.1 Spare parts

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. A differentiation is made between various
connection points have to be distinguished (example: compressor casing – bearing casing connection
point). Every set contains all of the spare parts that are required for assembly at the relevant connection
point (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 (refer to "Parts catalogue"
annex). Spare parts cannot be ordered separately!
annex).
Inspections Components Spare parts Tools

0* (every 6,000 h max.) (9980) (9700)
I (every 12,500 h max.) (7010)* (9981) (9700), (9720)
II (every 25,000 h max.) (7010)* (9971) (9700), (9720)
III (every 50,000 h max.) (7010)*, (2000) (9971) (9700), (9720)
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4.3.2 Tools
KBB tools
Various KBB tools and devices that are marked with part numbers are shown in the documentation.
Please refer to the "Parts Catalogue" annex for a list of all tools and information on how to assemble
individual devices.
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
4.3.3 Measuring devices

The following measuring devices are required for a correct assembly:
• Feeler gauge (set)
• Vernier
• Depth gauge (digital) with extended legs
• Protractor (digital)
• Dial gauge
• Stand with magnetic foot (for dial gauge)
4.3.4 Auxiliary materials and lubricants

The following auxiliary materials and lubricants are required for easy and safe dismantling and assembly
work:
• Wire brush
• Lifting gear
• Lifting strap
• Ropes / chains
• Ceramic paste
• Penetrating oil
• Lubricating oil
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4.4 Work steps
4.4.1 Mounting the complete exhaust-gas turbocharger

Initial situation:
• 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.
Weight ST3 ST4 ST5 ST6 ST7

TC 161 kg 293 kg 384 kg 582 kg 1270 kg
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.
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4.4.2 Removing the complete exhaust-gas turbocharger
Initial situation:
• The exhaust-gas turbocharger has been attached to suitable lifting gear according to the lifting
instructions.
• Suitable lifting gear is available.
Weight ST3 ST4 ST5 ST6 ST7

TC 161 kg 293 kg 384 kg 582 kg 1270 kg
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.
We recommend that the O-rings be replaced during each assembly!
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4.4.3 Removing and mounting the air intake bend / silencer / air inlet flange
ST4
Persons required: 1
Time required: 0.25 h
Tools required: (9700)
Spare parts offered: (9922)
Weight of silencer (9010): 25 kg

Weight of air intake bend (9020): 11 kg
Weight of air inlet flange (9025): 12 kg
Removing the silencer / air intake bend / air inlet flange

• Piping has been removed from the air intake bend / air inlet flange.
• Compressor washing system supply line has been removed from the air intake bend / silencer
/ air inlet flange.
1. Attach the air intake bend / silencer to suitable lifting gear according to the lifting instructions.
2. Loosen the V-band.
3. Pull the air intake bend / silencer / air inlet flange off the compressor casing.
Mounting the silencer / air intake bend / air inlet flange

1. Attach the air intake bend / silencer to suitable lifting gear according to the lifting instructions.
2. Slide the air intake bend / silencer / air inlet flange onto the compressor casing.
3. Fit the V-band and tighten the screws (MA = 35 Nm).
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4.4.4 Removing and mounting the compressor casing
ST4
Persons required: 2
Spare parts required: (9911) (9922)
Weight of compressor casing (6010): 33 kg

Weight of compressor casing insert (6040): 12 kg
Make sure that the compressor wheel is not damaged when removing and mounting
the compressor casing!
Removing 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.
1. Mark the position of the compressor casing on the bearing casing!

2. Attach the compressor casing to suitable lifting gear according to the lifting instructions.
3. Loosen the nuts and remove the locking washers and clamping pieces.
4. Carefully dismantle the compressor casing from the exhaust-gas turbocharger in the axial
direction.
5. Remove and dispose of the O-ring.
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Mounting the compressor casing
Replace the O-rings during each assembly.

Replace the locking elements during each assembly.
1. Fit a new O-ring.

2. Slightly moisten the contact surface between the compressor casing and bearing casing with
oil.
3. Carefully mount the compressor casing in the axial direction and align to the mark.
4. Fit the clamping pieces and locking washers and tighten the nuts (MA = 35 Nm).
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4.4.5 Removing and installing the compressor casing insert
ST4
Persons required: 1
Spare parts required: (9911) (9922)
Weight of compressor casing (6010): 33 kg

Weight of compressor casing insert (6040): 12 kg
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Removing the compressor casing insert
1. Place the compressor casing on its side as shown in the figure and attach to suitable lifting
gear by the eye bolts.
2. Set the compressor casing down on a suitable support (F) so that only the compressor casing
insert rests on this on at least three points in the area (E).
3. Loosen the hexagon socket screws and locking washers and remove the plates.
4. Carefully raise the compressor casing.
5. Remove and dispose of the O-rings.
Dimensions of the support (F) for ST4: H = min. 60mm D = 275 - 325mm
Installing the compressor casing insert
Replace the O-rings during each assembly.

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).
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4.4.6 Removing and mounting the compressor diffuser
ST4
Persons required: 1
Spare parts offered: (9915)
Weight of compressor diffuser (8010): 3 kg
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.
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Removing the compressor diffuser:
1. Loosen the hexagon socket screws.
2. Remove the compressor diffuser and shims.
Mounting the compressor diffuser:

1. Fit the shims and the compressor diffuser in the correct position and fasten with hexagon
socket screws. (MA = 16 Nm)
2. Measure dimension "h" again after changing the compressor diffuser.
3. Correct with shims if the measured value deviates by > 0.05 mm.
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4.4.7 Removing and mounting the exhaust-gas elbow
ST4
Persons required: 1
Spare parts required: (9950)
Weight of exhaust-gas elbow (9100): 25 kg
Removing the exhaust-gas elbow
• 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.
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Mounting the exhaust-gas elbow
Apply ceramic paste to the threads during each assembly.
Clean the contact surfaces between the two casings!
1. Carefully mount the exhaust-gas elbow and support in the axial direction.
2. Fit the locking washers and tighten the nuts (MA = 40 Nm).
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4.4.8 Removing and installing the cartridge
ST4
Persons required: 2
Time required: 1h
Weight of cartridge (1200): 57 kg
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!
Removing the cartridge
• The connection to the speed sensor has been disconnected.

• The air intake bend / silencer / air intake flange and the compressor casing have been
removed.
• The turbine casing has been supported.
1. Loosen the connecting elements between the cartridge and engine bracket.
2. Loosen the nuts and remove the locking washers.
* depending on the exhaust-gas turbocharger specification
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3. Attach the cartridge to suitable lifting gear according to the lifting instructions and force it off.
The turbine casing can be forced off with the forcing device (9726).
Use diesel fuel or penetrating oil to separate seized joints!
4. Carefully pull the cartridge out of the turbine casing in the axial direction.
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Installing the cartridge
1. Insert the O-rings for the oil inlet (B) and oil outlet (C) into the engine bracket.
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).
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3. Attach the cartridge to suitable lifting gear according to the lifting instructions and carefully
slide it into the turbine casing and onto the engine bracket in the axial direction.
* depending on the exhaust-gas turbocharger specification
4. Pull out the assembly protecting sheet (9712).

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4.4.9 Removing and mounting the turbine casing
ST4
Persons required: 1
Weight of turbine casing (5010): 43 kg

Weight of turbine casing insert (5020): 9 kg
Weight of containment ring (5220) 3 kg
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!
Removing the turbine casing

• All connection piping has been disconnected from the turbine casing.
• The insulation and exhaust-gas elbow have been removed.
• The radial clearance (S12) between the turbine wheel and turbine casing insert has been
measured and recorded in the service report (see Annex) before the turbine casing is
removed.
1. Mark the position of the turbine casing on the bearing casing!

2. Attach the turbine casing to suitable lifting gear according to the lifting instructions.
3. Loosen the nuts and remove the locking washers.
4. Carefully dismantle the turbine casing from the exhaust-gas turbocharger in the axial direction.
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The turbine casing can be forced off with the forcing device (9726).
Mounting the turbine casing

• The turbine nozzle ring has been inserted correctly in the turbine casing.
1. Carefully mount the turbine casing in the axial direction and align to the mark.
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4.4.10 Removing and installing the turbine nozzle ring
ST4
Persons required: 1
Weight of turbine nozzle ring (7010): 4 kg
Removing the turbine nozzle ring
• Either the cartridge has been removed or

• the turbine casing has been removed.
1. Remove the turbine nozzle ring from the turbine casing.
2. Remove the metal seal from the turbine casing.

3. Check the turbine nozzle ring according to chapter “Maintenance of the turbine nozzle ring”.
Installing the turbine nozzle ring

1. Insert the metal seal into the turbine casing.
2. Insert the turbine nozzle ring into the turbine casing.
Only one position allows a positive fit of the turbine nozzle ring.
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4.4.11 Removing and installing the turbine casing insert
ST4
Persons required: 1
Weight of turbine casing insert (5020): 9 kg

Weight of containment ring (5220) 3 kg
Make sure that the turbine wheel is not damaged when removing and installing the
turbine casing insert!
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Removing the turbine casing insert (the turbine casing is mounted on the TC)
• The exhaust-gas elbow has been removed.
1. Remove the locking washers (5072) with a screw driver.
2. Force off the turbine casing insert with the forcing screws (9707) (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!
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Installing the turbine casing insert
Install in the reverse order.
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).
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4.4.12 Removing the rotor
ST4
Persons required: 1
Time required: 1h

Weight of shaft (2010): 8.6 kg
Weight of compressor wheel (2040): 2.5 kg
Weight of bearing guide sleeve (3020): 3.8 kg
Weight of heat shield (3030): 3.3 kg
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.
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Removing the rotor
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.
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2. Loosen the compressor wheel with the torque spanner.
3. Remove the compressor wheel carefully by turning.
Use the protective cap (9856) as shown in the figure when setting the compressor
wheel down.
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4. Important: Loosen the locking device before carrying out the following operations.
5. Remove the compressor bearing cover (3042) as shown in the figure.
Pay attention to the gaskets under the compressor bearing cover!
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6. Carefully pull the spacer (2030) off the shaft using the two-arm extractor.
Use the magnetic centre protector (9723) to protect the shaft centring device.
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7. Force off the compressor bearing (4020) and carefully pull off from the shaft by turning.
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.
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8. Slide the extractor (9703) over the shaft (2010), screw to the thrust ring (2020) and carefully
pull it off the shaft. If the thrust ring jams, use the centre protector for shafts (9723) and
hexagon head screw (9730) as shown in figure to loosen the thrust ring (2020).
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.
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10. Pull out the shaft as described below.
The guide sleeve (9705) has to be fitted to the shaft as protection.
Push the shaft towards the turbine up and attach to suitable lifting gear as shown in the figures
for case A or B.
The heat shield may fall off!
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11. Remove the bearing guide sleeve as described below.
Unscrew the hexagon socket screws (3021) and pull out the bearing guide sleeve (3020)
carefully. If the bearing guide sleeve jams, use the threaded bores (C) to force it off
12. Remove the turbine bearing (4010) as shown in the figure.
The rotor is removed. Dismantling of the cartridge is now complete. All parts can be checked and
cleaned.
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4.4.13 Installing the rotor
ST4
Persons required: 1
Time required: 1h

Weight of shaft (2010): 8.6 kg
Weight of compressor wheel (2040): 2.5 kg
Weight of bearing guide sleeve (3020): 3.8 kg
Weight of heat shield (3030): 3.3 kg
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.
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Installing the rotor
1. Moisten the turbine bearing (4010) with lubricating oil and fit it in the bearing guide sleeve
(3020) as shown in the figure.
2. Install the bearing guide sleeve as described below.

Moisten the bearing guide sleeve's centring with oil and carefully slide into the bearing casing
in the axial direction. Fasten the bearing guide sleeve with the hexagon socket screws (3021)
(MA = 16 Nm).
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3. Prepare the shaft for installation as shown in the figure.
The shaft, guide sleeve and turbine bearing must be clean!

Moisten the shaft, guide sleeve and turbine bearing with lubricating oil.
Replace the piston rings during each assembly.
4. Attach the shaft to suitable lifting gear and carefully insert it into the bearing casing.
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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.
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6. Remove the guide sleeve (9705).
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.
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8. Clean the bearing disk (4030), moisten with lubricating oil and slide onto the shaft. Fit shims
(3071, 3072) with the corresponding thickness.
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). Screw in place with the hexagon socket bolts (MA = 16 Nm).
Edition 10 01/2019 Page 92 of 108

ST4
Place the dial gauge on the shaft end of the compressor side in the axial direction. Pull the shaft
towards the compressor side and set the dial gauge to "0". Loosen the two hexagon socket
screws on the compressor bearing. Slowly continue pulling the shaft towards the compressor
side and read clearance S18 on the dial gauge.
Admissible clearance S18 = 0.2 (+0.1)
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 = 16 Nm)!
10. The following operations require that the shaft has been fixed with the corresponding locking
device and is thus pushed towards the compressor.
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ST4
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.
12. Remove the compressor bearing cover.
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ST4
13. Moisten the spacer and bearing surface of the compressor bearing with lubricating oil and
carefully slide onto the shaft.
The assembly mark on the spacer and the assembly mark on the shaft (2010) must
be in alignment!
Y Contact surface with WGF130 grease

Z Contact surface free from oil and grease!
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 is calculated as shown below: S19 = L1 – L2

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.
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ST4
14. The compressor bearing cover can now be fastened with all hexagon socket screws (MA = 16
Nm). Use the gaskets as determined during the measurement of clearance S19. The piston
ring can be inserted into the compressor bearing cover.
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ST4
15. Lubricate the compressor wheel with grease as shown in the figure and carefully fit to the
shaft by turning.
Y Contact surface with WGF130 grease

Z Contact surface free from oil and grease!
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ST4
16. Tighten the compressor wheel with the torque spanner.
Required torque at the compressor wheel: 155 (+10) Nm
17. Remove all devices and measure clearance S15.
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.
Axial bearing clearance S15 cannot be adjusted.

The assembly is incorrect or one of the parts is defective if the clearance is too small.
Check the respective lengths of the thrust ring, compressor bearing and shaft after
dismantling!
The axial bearing clearance S15 may be measured slightly smaller due to a thin oil
film as a consequence of the assembly.
Switch the lubrication pump off when taking control measurements otherwise the
measuring results may be inaccurate!
The rotor is installed. The cartridge assembly is now complete.
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ST4
4.5 Adjusting and checking the clearances
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
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ST4
4.5.2 Admissible clearances
Limit
Clearance New
clearance
S1 (compressor-side radial clearance) 0.5 (±0.05) 0.8
S2 (compressor-side axial clearance) 0.7 (+0.1) 0.9
0.6 (±0.05) *) 0.9 *)
S12 (turbine-side radial clearance)
0.8 (±0.05) **) 1.1 **)
0.5 (+0.3) *) 1.0 *)
S14 (turbine-side axial clearance) optional
0.7 (+0.3) **) 1.2 **)
S15 (axial bearing clearance) 0.21 (+0.14) -
S18 (turbine-side piston ring clearance) 0.2 (+0.1) -
S19 (compressor-side piston ring clearance) 0.3 (+0.05) -
*) Valid for turbine casing insert 7421122 / 7421123

**) Valid for turbine casing insert 7421132 / 7421133
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ST4
4.5.3 Adjusting the clearance S2
Clearance S2 has to be checked and readjusted as required if the cartridge, compressor casing insert,
compressor casing or compressor diffuser has been replaced.
Initial situation:
• The compressor casing and compressor diffuser have been removed.
• The compressor casing insert has been removed from the compressor casing.
• The locking device has been fitted and fastened tight. It pushes the shaft towards the
compressor.
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ST4
Work sequence:
1. Carefully place the compressor casing insert against the compressor wheel as shown in the
figure and fix with the corresponding pliers (9713) on the bearing casing.
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.
3. Remove the compressor casing insert and pliers.
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ST4
4. Mount the compressor diffuser and corresponding shims (8011, 8013) on the cartridge with
the hexagon socket screws.
5. Place the compressor casing insert against the compressor wheel again and fix on the bearing
casing with the pliers.
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.
7. Clearance S2 is calculated as shown below:

S2 = L2 – L1
Clearance S2 can only be adjusted by changing the shim (8011, 8013).

Increase the shim thickness to increase clearance S2.
Reduce the shim thickness to reduce clearance S2.
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ST4
4.5.4 Checking the clearances S1 and S12
Initial situation:
• Access to the compressor wheel and turbine wheel has been provided.
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).
The clearances S1 and S12 cannot be adjusted!
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ST4
4.5.5 Checking the clearance S14
Initial situation:
• The compressor wheel has been removed.
• The compressor bearing has been firmly installed.
• The turbine casing has been mounted.
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.
Clearance S14 cannot be adjusted!
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ST4
4.5.6 Checking the clearance S15
Initial situation:
• Access to the compressor wheel has been provided.
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.
The axial bearing clearance S15 cannot be adjusted!

The assembly is incorrect or one of the parts is defective if the clearance is too small.
Check the respective lengths of the thrust ring, compressor bearing and shaft after
dismantling!
The axial bearing clearance S15 may be measured slightly smaller due to a thin oil
film as a consequence of the assembly.
Switch the lubrication pump off when taking control measurements otherwise the
measuring results may be inaccurate!
Edition 10 01/2019 Page 106 of 108

Operating instructions Appendix
ST4
Appendix
Parts catalogue
Attachment of the declaration of incorporation
Service report
Edition 10 01/2019 Page 107 of 108

Operating instructions Appendix
ST4
Edition 10 01/2019 Page 108 of 108

Teilekatalog ST4
Parts catalogue ST4 ST4_D_01
Teilekatalog
Parts catalogue
ST4
Kompressorenbau Bannewitz GmbH

Windbergstraße 45
01728 Bannewitz
Deutschland
Tel.: +49 351 40 85 603 (Verkauf / sales)
+49 351 40 85 669 (Service / service)
+49 172 35 16 045 (24-Stunden-Service / 24-hour service)
Telefax: +49 351 40 85 648 (Service / service)
E-Mail: service-24/7@kbb-turbo.com
Website: www.kbb-turbo.com
Seite 1 von 26
Prepared: J. Scholze Page 1 of 26 Released: K. Buchmann
Teilekatalog ST4
Seite 2 von 26
Page 2 of 26
Teilekatalog ST4
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.
Benötigte Ersatzteile und Werkzeuge für Durchsichten
Durchsichten Bauteile Ersatzteile Werkzeuge

0* (max. aller 6000 h) (9980) (9700)
I (max. aller 12.500 h) (7010)* (9981) (9700), (9720)
II (max. aller 25.000 h) (7010)* (9971) (9700), (9720)
III (max. aller 50.000 h) (7010)*, (2000) (9971) (9700), (9720)
* Bei HFO-Betrieb (Heavy Fuel Oil)
Seite 3 von 26
Page 3 of 26
Teilekatalog ST4
Durchsicht 0 (max. aller 6000 Stunden)

Die Durchsicht 0 soll abhängig von der Schwerölqualität, den Betriebsregimen und
der Turbinenwaschung bei Bedarf oder einem Leistungsabfall vor Erreichen der
Intervallzeiten durchgeführt werden.
• Demontage des Abgasturboladers mit

o Abbau des Schalldämpfers
o Abbau des Verdichtergehäuses
o Ausbau der Rumpfgruppe
• Schalldämpferreinigung und Austausch der Filtermatten
• Reinigen der Turbinenseite
• Montage des Abgasturboladers
Durchsicht I (max. aller 12.500 Stunden)
Abhängig vom Ort der Inspektion (vor Ort oder in Servicewerkstatt), sowie der
verfügbaren Stillstandszeiten, ist der Umfang der Durchsicht entsprechend
zwischen Option "a" und "b" zu reduzieren oder zu erweitern.
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
b) Vollständige Durchsicht (wie bei "a" und zusätzlich folgende Arbeiten)

• Demontage des Rotors
• Prüfen von betriebswichtigen Abmessungen, (Durchmesser der Wellensitze,
Verdichterraddurchmesser), Oberflächengüte und Rundlauf
• Prüfen der Turbinen- und Verdichterschaufeln auf Risse
• Prüfen der Lager und Lagerspiele
• Prüfen des Wuchtzustandes
• Montage mit neuen Dichtungen, O-Ringen und Sicherungselementen
• Kontrolle von Spielen
Durchsicht II (max. aller 25.000 Stunden)
• wie bei Durchsicht I (Umfang wie bei b)

• Lagerwechsel
Durchsicht III (max. aller 50.000 Stunden)
• wie bei Durchsicht II
• Rotorwechsel
Seite 4 von 26
Page 4 of 26
Teilekatalog ST4
Instructions
Warranty claims are excluded if the rotor is dismantled and assembled by

unauthorised staff!
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!
Sets of spare parts are offered for the inspections 0 - III.
Inspection Components Spare parts Tools

0* (every 6000 h max.) (9980) (9700)
I (every 12,500 h max.) (7010)* (9981) (9700), (9720)
II (every 25,000 h max.) (7010)* (9971) (9700), (9720)
III (every 50,000 h max.) (7010)*, (2000) (9971) (9700), (9720)
Seite 5 von 26
Page 5 of 26
Teilekatalog ST4
Inspection 0 (every 6000 hours max.)

Inspection 0 should be carried out before the interval time is reached, either as
required or after a performance loss, depending on the quality of the heavy fuel oil,
operating regimes and turbine washing.

• Cleaning the turbine side
• Assembly of the exhaust-gas turbocharger
Inspection I (every 12,500 hours max.)
The scope of the inspection should be extended or reduced between options "a" and
"b" depending on the place of inspection (on site or in the service workshop) and on
the available standstill times.
a) Minimum scope
• 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
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
• 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 ST4
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
Ersatzteile für Durchsicht 0 (9980)

Spare parts for inspection 0
für Durchsicht I (9981)
for inspection I
für Durchsicht II und III (9971)
for inspection II and III
Dichtungen (9911)
Bearings
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
Lagerung (4000)
Bearings
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 ST4
Abgasturbolader komplett (1000)

Exhaust-gas turbocharger complete (1000)
Teil-Nr. Ersatzteil Enthalten in

Part-no. Spare part Included in
Basisturbolader
1100
Exhaust-gas turbocharger, basic unit
Mutter
5090 9950
Nut
Sicherungsscheibe
5101 9950
Locking washer
V-Band
6020
V-band
Zylinderschraube
6190 9922
Hexagon socket screw
Schalldämpfer
9010
Silencer
Ansauggehäuse
9020
Air intake bend
Luftanschlussflansch
9025
Air intake flange
Abgaskrümmer
9100
Exhaust elbow
Seite 8 von 26
Page 8 of 26
Teilekatalog ST4
Basisturbolader (1100)
Exhaust-gas turbocharger, basic unit (1100)

Rumpfgruppe
1200
Cartridge
Turbinengehäuse
5010
Turbine casing
Mutter
5080 9931
Nut
Sicherungsscheibe
5100 9931
Locking washer
Klemmstück
5150
Clamping flange
Verdichtergehäuse
6010
Compressor casing
O-Ring
6030 9911
O-ring
Klemmstück
6140
Clamping flange
Mutter
6160 9922
Nut
Sicherungsscheibe
6170 9922
Locking washer
Verdichterleitgitter
8010
Compressor diffuser
8011
Beilage
8012 9915
Shim
8013
8014 Beilage
8015 Shim
Zylinderschraube
8040 9922
Seite 9 von 26
Page 9 of 26
Teilekatalog ST4
Rumpfgruppe (1200)
Cartridge (1200)

Welle
2010
Shaft
Druckring
2020
Thrust ring
Distanzscheibe
2030
Spacer
Verdichterrad
2040
Compressor wheel
Rechteckring
2070 9911
Piston ring
Passfeder
2080 9922
Feather key
Rechteckring
2090 9911
Piston ring
Lagergehäuse
3010
Bearing casing
Lagerführungsbuchse
3020
Bearing guide sleeve
Zylinderschraube
3021 9922
Hitzeschild
3030
heat shield
Lagerdeckel Verdichter
3044
Bearing cover compressor
Zylinderschraube
3052 9922
Sicherungsscheibe
3055 9922
Locking washer
Seite 10 von 26
Page 10 of 26
Teilekatalog ST4

Trennblech
3060
Separator plate
Sechskantschraube
3063 9922, 3044
Hexagon head screw
Sicherungsscheibe
3064 9922, 3044
Locking washer
3065
Dichtung
3066 9915
Gasket
3067
Dichtung
3068
Gasket
3071 Beilage
9915
3072 Shim
Zylinderschraube
3100 9922
Gewindestift
3110
Thread plug
Verschlussschraube
3120 9922
Screw plug
Verschlussschraube
3200 9922
Screw plug
Federscheibe
3210 9922
Spring washer
Turbinenlager
4010 4000
Turbine bearing
Verdichterlager
4020 4000
Compressor bearing
Lagerscheibe
4030 4000
Bearing disc
Seite 11 von 26
Page 11 of 26
Teilekatalog ST4
Rumpfgruppe, wassergekühlt (1200)

Cartridge, water cooled (1200)

Welle
2010
Shaft
Druckring
2020
Thrust ring
Distanzscheibe
2030
Spacer
Verdichterrad
2040
Compressor wheel
Rechteckring
2070 9911
Piston ring
Passfeder
2080 9922
Feather key
Rechteckring
2090 9911
Piston ring
Lagergehäuse
3010
Bearing casing
Zylinderschraube
3011
Sicherungsscheibe
3013
Locking washer
Hitzeschild
3030
heat shield
Lagerdeckel Verdichter
3044
Bearing cover compressor
Seite 12 von 26
Page 12 of 26
Teilekatalog ST4

Zylinderschraube
3052 9922
Sicherungsscheibe
3055 9922
Locking washer
Trennblech
3060
Separator plate
Sechskantschraube
3063 9922, 3044
Hexagon head screw
Sicherungsscheibe
3064 9922, 3044
Locking washer
3065
Dichtung
3066 9915
Gasket
3067
Dichtung
3068
Gasket
Lagerdeckel Turbine
3070
Bearing cover turbine
3071 Beilage
9915
3072 Shim
3075 Dichtung
3076 Gasket
Zylinderschraube
3100 9922
Verschlussschraube
3120 9922
Screw plug
Verschlussschraube
3200 9922
Screw plug
Federscheibe
3210 9922
Spring washer
Turbinenlager
4010 4000
Turbine bearing
Verdichterlager
4020 4000
Compressor bearing
Lagerscheibe
4030 4000
Bearing disc
Seite 13 von 26
Page 13 of 26
Teilekatalog ST4
Rotor (2000)
Rotor (2000)

Welle
2010
Shaft
Druckring
2020
Thrust ring
Distanzscheibe
2030
Spacer
Verdichterrad
2040
Compressor wheel
Rechteckring
2070 9911
Piston ring
Passfeder
2080 9922
Feather key
Rechteckring
2090 9911
Piston ring
Seite 14 von 26
Page 14 of 26
Teilekatalog ST4
Schalldämpfer (9010)
Silencer (9010)

Schalldämpfer
9010
Silencer
Filtermatte
9012
Filter mat
Spannband
9014
Tension tape
Ansauggehäuse (9020)
Air intake bend (9020)

Ansauggehäuse
9020
Air intake bend
Verschlussschraube
9030 9922
Screw plug
Dichtring
9040 9922
Sealing ring
Verschlussschraube
9070
Screw plug
Dichtring
9080 9922
Sealing ring
Seite 15 von 26
Page 15 of 26
Teilekatalog ST4
Luftanschlussflansch (9025)
Air inlet flange (9025)

Luftanschlussflansch
9025
Air inlet flange
Verschlussschraube
9030 9922
Screw plug
Dichtring
9040 9922
Sealing ring
Verschlussschraube
9070
Screw plug
Dichtring
9080 9922
Sealing ring
Seite 16 von 26
Page 16 of 26
Teilekatalog ST4
Verdichtergehäuse (6010)
Compressor casing (6010)

Verdichtergehäuse
6010
Compressor casing
Verdichtergehäuseeinsatz
6040
Compressor casing insert
O-Ring
6041 9911
O-ring
Verschlussschraube
6050 9922
Screw plug
Dichtring
6060 9922
Sealing ring
O-Ring
6090 9911
O-ring
Verschlussschraube
6110
Screw plug
Dichtring
6120 9922
Sealing ring
Blech
6130
Plate
Zylinderschraube
6131 9922
Sicherungsscheibe
6132 9922
Locking washer
Stiftschraube
6150 9922
Stud bolt
Mutter
6160 9922
Nut
Sicherungsscheibe
6170 9922
Locking washer
Seite 17 von 26
Page 17 of 26
Teilekatalog ST4
Lagergehäuse (3010)
Bearing casing (3010)

Lagergehäuse
3010
Bearing casing
Verschlussschraube
3012 9922
Screw plug
Dichtring
3014 9922
Sealing ring
Ringschraube
3015
Lifting eye bolt
Verschlussschraube
3140 9922
Screw plug
Dichtring
3150 9922
Sealing ring
Gewindestift
3220
Thread plug
Seite 18 von 26
Page 18 of 26
Teilekatalog ST4
Lagergehäuse, wassergekühlt (3010)

Bearing casing, water cooled (3010)

Lagergehäuse
3010
Bearing casing
Verschlussschraube
3012 9922
Screw plug
Dichtring
3014 9922
Sealing ring
Ringschraube
3015
Lifting eye bolt
Verschlussschraube
3016
Screw plug
Dichtring
3017
Sealing ring
Verschlussschraube
3140 9922
Screw plug
Dichtring
3150 9922
Sealing ring
Gewindestift
3220
Thread plug
Seite 19 von 26
Page 19 of 26
Teilekatalog ST4
Turbinengehäuse (5010)
Turbine casing (5010)

Turbinengehäuse
5010
Turbine casing
Turbinengehäuseeinsatz
5020
Turbine casing insert
Verschlussschraube
5050
Screw plug
Dichtring
5060 9950
Sealing ring
Gewindestift
5071
Thread plug
Achsenklemmring
5072
Quick Fastening element
Mutter
5080 9931
Nut
Mutter
5090 9950
Nut
Sicherungsscheibe
5100 9931
Locking washer
Sicherungsscheibe
5101 9950
Locking washer
Dehnhülse (optional)
5105
Expansion sleeve (optional)
5110 Stiftschraube
9950
5120 Stud bolt
Stiftschraube
5130 9931
Stud bolt
Berstschutz
5210
Containment shield
Berstring
5220
Containment ring
Sechskantschraube
5230 9950
Hexagon head screw
Sicherungsscheibe
5250 9950
Locking washer
Seite 20 von 26
Page 20 of 26
Teilekatalog ST4

Turbinenleitgitter
7010
Turbine nozzle ring
Arretierbolzen
7020 9931
Locating bolt
Metalldichtung
7040
Metal seal
Seite 21 von 26
Page 21 of 26
Teilekatalog ST4
Abgaskrümmer (9100)
Exhaust elbow (9100)

Verschlussschraube
9050
Screw plug
Verschlussschraube
9055
Screw plug
Dichtring
9060 9950
Sealing ring
Dichtring
9065 9950
Sealing ring
Abgaskrümmer
9100
Exhaust elbow
Flansch
9101
Flange
Sechskantschraube
9102 9950
Hexagon head screw
Sicherungsscheibe
9103 9950
Locking washer
Dichtung
9104 9911
Gasket
Seite 22 von 26
Page 22 of 26
Teilekatalog ST4
Weiteres Zubehör
Further accessories
Teil-Nr. Zubehör Bemerkung

Part-no. Accessoir Comment
Drehzahlsensor
9110
Speed sensor
Verlängerungskabel
9113 3m
Extension cable
Verlängerungskabel
9113 8m
Extension cable
Verlängerungskabel
9113 14 m
Extension cable
Drehzahlanzeiger
9117
Speed indicator
Turbinenwaschdüse
9134
Turbine spray nozzle
Verdichterwaschanlage
9250
Compressor wash system
Abdichtvorrichtung
9704
Sealing device
Abstellvorrichtung
9722
Rack
Seite 23 von 26
Page 23 of 26
Teilekatalog ST4

Spare parts for inspection 0
für Durchsicht I (9981)
for inspection I
für Durchsicht II und III (9971)
for inspection II and III
Dichtungen (9911)
Bearings
Beilagen (9915)
Shims
Verbindungselemente Verdichterseite inklusive Rumpfgruppe (9922)
Verbindungselemente Turbinengehäuse - Lagergehäuse (9931)
Verbindungselemente Turbinengehäuse - Abgaskrümmer (9950)
Connection elements turbine casing - exhaust elbow
Lagerung (4000)
Bearings
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 ST4

Spare parts for inspection 0 (9980)
Teil-Nr. Ersatzteil
Part-no. Spare part
Dichtungen
9911
Gaskets
Verbindungselemente Verdichterseite inklusive Rumpfgruppe
9922
Verbindungselemente Turbinengehäuse - Lagergehäuse
9931
Verbindungselemente Turbinengehäuse - Abgaskrümmer
9950
Connection elements turbine casing – exhaust elbow
Ersatzteile für Durchsicht I (9981)

Spare parts for inspection I (9981)
Teil-Nr. Ersatzteil
Part-no. Spare part
Dichtungen
9911
Gaskets
Beilagen
9915
Shims
9922
9931
9950
Ersatzteile für Durchsicht II und III (9971)

Spare parts for inspection II and III (9971)
Teil-Nr. Ersatzteil
Part-no. Spare part
Lagerung
4000
Bearings
Dichtungen
9911
Gaskets
Beilagen
9915
Shims
9922
9931
9950
Seite 25 von 26
Page 25 of 26
Teilekatalog ST4
Seite 26 von 26
Page 26 of 26
Ersatzteile ST4 (9911) 7492002
Spare parts ST4 (9911) 07-17-120
Teil-Nr. Stück Dichtungen Bemerkung

Part-no. Quantity Gaskets Comment
Rechteckring
2070 1 48x2,5 mm
Piston ring
Rechteckring
2090 1 54x2,5 mm
Piston ring
O-Ring
30511) 1 155x5
O-ring
O-Ring
6030 1 330x5
O-ring
O-Ring
6041 2 205x5
O-ring
O-Ring
6090 1 240x5
O-ring
Dichtschnur
70301) 1 0,68 m
Sealing cord
Dichtung
9104 3 t = 2 mm
Gasket
1) Für älteren Konstruktionsstand

For older design version
Seite 1 von 2
Page 1 of 2
Spare parts ST4 (9911) 07-17-120
Dichtungen
Gaskets
Seite 2 von 2
Page 2 of 2
Spare parts ST4 (9915) 02-18-224
Ab 11/2018: (9915) ersetzt (9912)

From 11/2018: (9915) replaces (9912)
Teil-Nr. Stück Beilagen Bemerkung

Part-no. Quantity Shims Comment
Dichtung
3065 1 t = 0,1 mm
Gasket
Dichtung
3066 1 t = 0,15 mm
Gasket
Dichtung
3067 2 t = 0,2 mm
Gasket
Beilage
3071 1 t = 0,1 mm
Shim
Beilage
3072 1 t = 0,15 mm
Shim
Dichtung
30811) 1 t = 0,1 mm
Gasket
Dichtung
30821) 1 t = 0,15 mm
Gasket
Dichtung
30831) 1 t = 0,2 mm
Gasket
Beilage
8011 1 t = 0,1 mm
Shim
Beilage
8012 1 t = 0,15 mm
Shim
Beilage
8013 1 t = 0,2 mm
Shim

Seite 1 von 2
Page 1 of 2
Spare parts ST4 (9915) 02-18-224
Beilagen
Shims
Seite 2 von 2
Page 2 of 2
Spare parts ST4 (9922) 01-18-196
Ab 11/2018: (9922) ersetzt (9920)

From 11/2018: (9922) replaces (9920)
Teil-Nr. Stück Verbindungselemente Bemerkung

Part-no. Quantity Connection elements Comment
Passfeder
2080 2 4x4x10
Feather key
3012
3140 Verschlussschraube
1 M18x1,5
6050 Screw plug
9030
3014
3150 Dichtring
1 18
6060 Sealing ring
9040
3021
Zylinderschraube M6x30
3052 4
Hexagon socket screw MA = 16 Nm
3100
3055
Sicherungsscheibe
31301) 20 6
Locking washer
6132
Sechskantschraube
3063 2 M4x10
Hexagon head screw
Sicherungsscheibe
3064 7 4
Locking washer
30901)
6131 4
8040
3120 Verschlussschraube M10x1
4
3200 Screw plug MA = 18 Nm
Federscheibe
3210 1 10
Spring washer
Dichtring
6120 1 26
Sealing ring
Stiftschraube
6150 4 M8x18
Stud bolt
Mutter
6160 4 M8
Nut
Sicherungsscheibe
6170 24 8
Locking washer
6190 1
Dichtring
9080 1 16
Sealing ring

Seite 1 von 2
Page 1 of 2
Spare parts ST4 (9922) 01-18-196
Verbindungselemente
Connection elements
Seite 2 von 2
Page 2 of 2
Spare parts ST4 (9931) 00-17-120

Mutter M10
5080 16
Nut MA = 40 Nm
Sicherungsscheibe
5100 16 10
Locking washer
Stiftschraube
5130 16 M10x25
Stud bolt
Arretierbolzen Altes Design
7020 3
Locating bolt Old design
Arretierbolzen Neues Design
7020* 3
Locating bolt New design
Seite 1 von 2
Page 1 of 2
Spare parts ST4 (9931) 00-17-120
Verbindungselemente
Connection elements
Seite 2 von 2
Page 2 of 2
Spare parts ST4 (9950) 01-18-196
Ab 11/2018: (9950) ersetzt (9930)

From 11/2018: (9950) replaces (9930)

5060
Dichtring
9060 4 18
Sealing ring
9065
Mutter M10
5090 12
Nut MA = 40 Nm
5101 Sicherungsscheibe
16 10
9103 Locking washer
Stiftschraube
5110 4 M10x35
Stud bolt
Stiftschraube
5120 2 M10x45
Stud bolt
Sechskantschraube
5230 2 M10x22
Hexagon head screw
Scheibe
5250 6 10,5
Washer
Dichtring 27
9065 1
Sealing ring optional
Sechskantschraube M10x25
9102 4
Hexagon head screw MA = 40 Nm
Seite 1 von 2
Page 1 of 2
Spare parts ST4 (9950) 01-18-196
Verbindungselemente
Connection elements
Seite 2 von 2
Page 2 of 2
Ersatzteile ST4/ST4-EP/HSR4 (4000) 7430983
Spare parts ST4/ST4-EP/HSR4 (4000) 01-17-205
Lagerung
Bearings
Teil-Nr. Stück Teil Bemerkung

Part-no. Quantity Part Comment
Turbinenlager
4010 1
Turbine bearing
Verdichterlager
4020 1
Compressor bearing
Lagerscheibe
4030 1
Bearing disc
Seite 1 von 1
Page 1 of 1
Werkzeuge ST4 (9700) 7497001
Tools ST4 (9700) 07-19-016
Teil-Nr. Stück Werkzeuge Bemerkung

Part-no. Quantity Tools Comment
Abdrückschraube
9707 4 M10 x 35
Forcing screw
Einschlagdorn
9711 1
Mandrel
Abziehblech
9712 1
Assembly protecting sheet
Hahnenfuß-Schlüssel
9714 1 SW24
Crowfoot wrench
Verlängerung
9716 1
Extension
Abdrückvorrichtung
9726 3
Forcing device
Sechskantschraube
9765 2 M10 x 20
Hexagon head screw
Ringschraube
9782 2 M10
Lifting eye bolt
Ringschraube
9783 1 M12
Lifting eye bolt
Ringmutter
9792 2 M10
Lifting eye nut
Montagehülse
9855 1
Mounting sleeve
Seite 1 von 2
Page 1 of 2
Werkzeuge ST4 (9700) 7497001
Tools ST4 (9700) 07-19-016
Werkzeuge
Tools
Seite 2 von 2
Page 2 of 2
Werkzeuge ST4 (9720) 7497020
Tools ST4 (9720) 08-17-030
Teil-Nr. Stück Werkzeuge Bemerkung

Part-no. Quantity Tools Comment
Halteblech
9702 1
Locking plate
Abziehhülse
9703 1
Extractor
Führungshülse
9705 1
Guide sleeve
Schweißer Gripzange
9713 2
Welding grip pliers
Zweiarmiger Abzieher
9721 1
Two-arm puller
Magnetischer Zentrumsschoner
9723 1
magnetic centre protector
Sechskantschraube
9730 1 M12 x 80
Hexagon head screw
Verbindungswinkel
9733 1
Connecting angle
Gabel
9734 2
Fork
Halteblech
9735 1
Locking plate
Steckschlüsseleinsatz
9748 1 SW24
Socket wrench
Sechskantschraube
9758 1 M12 x 20
Hexagon head screw
Schutzkappe
9856 1
Protection cap
Sechskantschraube
52086 2 M8 x 20
Hexagon head screw
Teil-Nr. Vorrichtungen Seite

Part-no. Devices Page
Feststellvorrichtung (ohne Turbinengehäuse)
9701 3
Locking device (without turbine casing)
Feststellvorrichtung für Lagergehäuse mit Wasserkühlung
(ohne Turbinengehäuse)
9869 3
Locking device for bearing casing with water cooling
(without turbine casing)
Seite 1 von 3
Page 1 of 3
Werkzeuge ST4 (9720) 7497020
Tools ST4 (9720) 08-17-030
Werkzeuge
Tools
Seite 2 von 3
Page 2 of 3
Werkzeuge ST4 (9720) 7497020
Tools ST4 (9720) 08-17-030
Vorrichtungen
Devices
Seite 3 von 3
Page 3 of 3
Service Stations

Please visit kbb-turbo.com for updates.
Argentina Hungary Norway

Australia Iceland Pakistan
Bangladesh India Philippines
Brazil Indonesia Poland
Canada Iran Russia
Chile Italy Singapore
China Japan South Africa
Denmark Korea Spain
Ecuador Mexico Turkey
Germany Namibia UAE
Greece Netherlands UK
Guatemala New Zealand USA
KBB_ServiceStations_May 2019 page 1 of 6 9th edition (03/2019)

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

Service Stations
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

Service Stations
Italy New Zealand

La Meccanica Turbo Diesel srl NZ Marine Turbochargers Ltd.
Calata Gadda 136 Vanguard Street
Ship repair area Nelson
16128 Genova Porto Phone: +64 3 546 6188
Phone: +39 010 246 7499 Fax: +64 3 548 0974
Fax: +39 010 246 1144 E-mail: service@turbocharger.co.nz
E-mail: mtd@mtd.it Web: www.turbocharger.co.nz
Web: www.mtd.it
NZ Marine Turbochargers Ltd.
Japan 4a Grayson Avenue
Papatoetoe
Kobayashi Industries, Ltd. Auckland
1025-176, Hamano-Cho, Chuo-Ku, Phone: +64 9 250 4288
Chiba 260 0824
Phone: +81 43 208 0511 Norway
Fax: +81 43 208 1511
Frydenbo Industri AS
E-mail: kobayashi-ind@kbysh-ind.co.jp
Lurudveien 5
Kobe Marine Engineering Co., Ltd. 2020 Skedsmokorset
1-3-21 Kajiya-cho Phone: +47 6387 1700
Hyogo-ku, Kobe 652-0832 Fax: +47 6387 1667
Phone: +81-78-681-7421 Mobile: +47 9590 3557
Fax: +81-78-681-7424 E-mail: jge@frydenbo.no
E-mail: ship@kobe-marine.co.jp Web: www.frydenbo.no
Web: www.kobe-marine.co.jp
Turbo Power Norway
Korea Egnervegen 275
N-2040 Kløfta
Jonghap Maritime Inc. Phone: +27 95 90 35 57
27, Haeyang-ro 23 beon-gil, E-Mail: jge@tpnorway.no
Yeongdo-gu, Busan (postal code: 49000)
Phone: +82 51 413 4277 (24hrs on duty) Pakistan
Fax: +82 51 413 7442
Orient Energy Systems (Private) Ltd.
E-mail: infoturbo@jonghap.co.kr
Web: www.jonghap.co.kr Plot No 9
Sector 24
Korangi Industrial Area
Mexico Karachi
DP Marine Service SA de CV Phone: +92 21 111507 507
Calle 47. Int. 5B Fax: +92 21 3507 2095
Col. Pallas E-mail: noman.majeed@orient-power.com
Cd. Del. Carmen, Campeche Web: www.orient-power.com
24140 Mexico
Phone: +52 (938) 384 11 82 Turbo Internacional Services Ltd
E-mail: service@dpmarineservice.com Kot Bagh Ali, Plot Bhata Pind.
Web: www.dpmarineservice.com 10-KM-Raiwind Road.
54000 Lahore
Namibia Phone: +92 42 3545 9401
Cell: +92 303 7288804
Namib Diesel CC
E-Mail: info@turbointernacional.pk
28, 2nd Street East
P.O. Box 2449 Turbo Internacional Services Ltd
Walvis Bay Plot No. 11/1 Sector No.17
Phone: +264 64 203971 Korangi Industrial Area
Fax: +264 64 203255 74900 Karachi
Mobile: +264 81 1283987 Phone: +92 21 3521 4517
E-mail: info@namibdiesel.com.na Cell: +92 301 8668145
Web: www.namibdiesel.com.na Web: www.turbointernacional.pk
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

Service Stations
Philippines South Africa

Rurex Fabrication and Trading Co., Inc. Majestic Engineering cc t/a Turbocharger Services
238 M. Santos St. Santolan 48 Karim Lane, Rossburgh
Malabon City, Manila 4094 Durban
Phone: +63 2 294 6887/89 Phone: +27 31 459 0749
Fax: +63 2 292 9453 Fax: +27 31 459 0748
E-mail: lyndon@rurexturbo.com E-Mail: turbocharger@telkomsa.net
Rurex Fabrication and Trading Co., Inc. Sturrock Grindrod Marine Tech
P.C. Sulco St., Tabok, Unit 8 Ludel Park, Koeberg Rd,
Mandaue City, Cebu Montague Gardens,
Phone: +63 32 343 9861 Cape Town, 7441
Fax: +63 32 343 7165
PO Box 349, Paarden Eiland, Cape Town,
E-mail: lyndon@rurexturbo.com
7420, South Africa
Poland Phone: +27 21 831 7600
Fax: +27 21 511 1770
Cassiopeia Ltd. E-Mail: info@sturrockgrindrod.com
5A, Uczniowska Str. Web: www.sturrockgrindrod.com
70-893 Szczecin
Nouum (Pty) Ltd
Phone: +48 91 350 7351
Fax: +48 91 469 3064 51 Auckland Street, Paarden Eiland
7405, Cape Town, Western Cape
E-mail: info@cassiopeia-service.com
Web: www.cassiopeia-service.com Phone: +27 21 201 1468
Fax: +27 86 427 9069
Russia E-Mail: tom.martin@nouum.com
Web: www.nouum.com
Baltic Turbo Ltd.
Verbnaya str. 27, office 725 Spain
197375, St. Petersburg
Turbo 10, S.L.
Phone: +7-812-4488 334
Muelle de Reparaciones de Bouzas, s/n
E-mail: info@balticturbo.ru 36208 Vigo - Pontevedra
Web: www.balticturbo.ru
Phone: +34 986 213669
Fax: +34 986 214077
Singapore
E-mail: info@turvo10.com
Tru-Marine Pte Ltd. Web: www.turvo10.es
35 Tuas Basin Link
Turbo Cadiz S.L.
Singapore 638769
Calle del Progreso, 17A-20A
Phone: +65 6861 8398
11130 Chiclana de la Frontera, Cádiz
Fax: +65 6861 8396
Phone: +34 956 407 949 / 950
E-mail: turbo@trumarine.com
Fax: +34 956 407 951
E-mail: tc@turbocadiz.com
Web: www.turbocadiz.com
Turbo Cadiz S.L. Canarias
Puerto de Las Palmas
Av Pantalan de Cory - Esq. Compañia Navegacion Paquet
35008 – Las Palmas de Gran Canaria
E-mail: tc@turbocadiz.com
Web: www.turbocadiz.com
Turbo Internacional, S.L.
Uranio 33
28500 Arganda del Rey
Madrid
Phone: +34 91 872 01 81
Fax: +34 91 87067 28
E-Mail: info@turbointernacional.com

Service Stations
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
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

Declaration of incoporation
Attachment to Declaration of incorporation

According to 2006/42/EG, Annex II, Nr. 1B
Description of the essential health and safety requirements pursuant to 2006/42/EG, Annex I, that are
applicable and that have been fulfilles with:
No. Essential requirements applicable fulfilled

1.1.1. Definition of terms
1.1.2. Principles of safely Integration
1.1.3. Materials and products
1.1.4. Lighting
1.1.6. Design of machinery to facilitate its handling
1.1.6. Ergonomics
1.1.7. Operating positions
1.1.8. Seating
1.2. Control systems
1.2.1. Safety and reliability of control systems
1.2.2. Control devices
1.2.3. Starting
1.2.4. Stopping
1.2.4.1. Normal stop
1.2.4.2. Operational stop
1.2.4.3. Emergency slop
1.2.4.4. Assembly of machinery
1.2.5. Selection of control or operating modes
1.2.6. Failure of power supply
1.3. Protection against mechanical hazards
1.3.1. Risk of loss of stability
1.3.2. Risk of break-up during operation
1.3.3. Risks due to falling or ejected objects
1.3.4. Risks due to surfaces, edges or angles
1.3.5. Risks related to combined machinery
1.3.6. Risks related to variations In operating conditions
1.3.7. Risks related to moving parts
1.3.8. Choice of protection against risk arising from moving parts
1.3.8.1. Moving transmission parts
1.3.8.2. Moving parts Involved in the process
1.3.9. Risks of uncontrolled movements
1.4. Required characteristics of guards and protective devices
1.4.1. General requirements
1.4.2. Special requirements for guards
1.4.2.1. Fixed guards
1.4.2.2. Interlocking movable guards
1.4.2.3. Adjustable guards restricting access
1.4.3. Special requirements for protective devices
1.5. Risks due to other hazardsdevices
st
Attachment_Declaration_20140112 Page 1 of 2 1 Edition (11/2013)
Declaration of incoporation
No. Essential requirements applicable fulfilled

1.5.1. Electricity supply
1.5.2. Static electricity
1.5.3. Energy supply older than electricity
1.5.4. Errors of filling
1.5.5, Extreme temperatures
1.5.6. Fire
1.5.7. Explosion
1.5.8. Noise
1.5.9. Vibration
1.5.10. Radiation
1.5.11. External radiation
1.5.12. Laser radiation
1.5.13. Emissions of hazardous materials and substances
1.5.14. Risk of being trapped In a machine
1.5.15. Risk of slipping, tripping or falling
1.5.16. Lightning
1.6. Maintenance
1.6.1. Machinery maintenance
1.6.2. Access to operating positions and servicing points
1.6.3. Isolation of energy sources
1.6.4. Operator intervention
1.6.5. Cleaning of Internal parts
1.7. Information
1.7.1. Information and warnings on the machinery
1.7.1.1. Information and Information devices
1.7.1.2. Warning devices
1.7.2. Warning of residual risks
1.7.3. Marking of machinery
1.7.4. Instructions
1.7.4.1. General principles fort he drafting of Instructions
1.7.4.2. Contents of the Instructions
1.7.4.3. Sales literature
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)
Kompressorenbau Bannewitz GmbH Telephone:

Windbergstraße 45 +49 351 40 85 603 (sales)
01728 Bannewitz +49 351 40 85 669 (service)
Germany +49 172 35 16 045 (24-hour-service)
The condition of the turbocharger components should be documented with photos if possible!
Service specifications
Inspection / Repair on: by:
Reason of Inspection:
Turbocharger specifications:
Turbocharger type (e.g. ST5):
Spezification No.: Serial No.:
Commissioning TC on: Letzte Durchsicht am:
Operating hours total: since last inspection:
Engine specifications:
Engine type: Engine No.:
Fule: ☐ HFO ☐ MDO ☐ Gas ☐ other:
Application:
Name of customer:
Address of customer:
Installation location, name of vessel:
S-radial-EN-01_20171114 Page 1 of 4 Edition 1

Prepared: J. Scholze Approved: S. Käseberg Released: K. Buchmann
Service report
for radiale exhaust gas turbocharger
Shaft
Serial No. (old): (new): IMO-No.:
Turbine blades: ☐ well ☐ cracked ☐ blade parts missing
☐ traces of foreign matter ☐ scratch marks
Contamination / deposit: ☐ no ☐ slight ☐ heavy
Bearing seats: ☐ good ☐ marks ☐ bearing material applied
Scratch marks on the shaft: ☐ no ☐ yes
Compression rings run in: ☐ no ☐ yes
Rotor rebalanced: ☐ no ☐ yes

Notes:
Compressor impeller
IMO-No.: Serial No. (old): (new):
Compressor blades: ☐ well ☐ cracked ☐ blade parts missing
☐ traces of foreign matter ☐ scratch marks
Condition of centre: ☐ good ☐ marks ☐ fretting corrosion

Notes:
Thrust ring
will be: ☐ used ☐ replaced → Cause:
Bearing surface: ☐ good ☐ marks ☐ bearing material applied
Spacer
Bearing surface: ☐ good ☐ marks ☐ bearing material applied
Turbine nozzle ring

IMO-No.: T
Cross section:
Condition, guide vanes: ☐ good ☐ twisted ☐ part torn out
☐ scaled ☐ worn ☐ traces of foreign matter

Notes:

Service report
Compressor diffusor
IMO-Nr.: C
Damages: ☐ no ☐ yes
Notes:
Turbine casing
Incipient cracks: ☐ no ☐ yes
Scratch marks on insert: ☐ no ☐ yes

Notes:
Compressor casing
Incipient cracks: ☐ no ☐ yes
Scratch marks on insert: ☐ no ☐ yes

Notes:
Bearing casing
Sealing air bore: ☐ clean ☐ narrowed ☐ blocked ☐ screwed

The contact surfaces of the piston rings in covers on the bearing casing must also be inspected!
Contact surfaces for compressor-side piston ring: ☐ well ☐ damaged
Contact surfaces for turbine-side piston ring: ☐ well ☐ damaged

Notes:
Compressor bearing
Diameter: D C: mm marks: ☐ no ☐ yes
Wedge height: tC: mm marks: ☐ no ☐ yes

Notes:

Service report
Turbine side thrust bearing disk

Wedge height: tT: mm marks: ☐ no ☐ yes

Notes:
Turbine bearing
Diameter: D C: mm marks: ☐ no ☐ yes

Notes:
Other defects:
Engine test run: ☐ yes ☐ no

Notes:
Documentation of the clearances

Measure, adjust and document the clearances according to the respective documentation.
Clearance Reference value after documentation measured during
in mm dismantling assembly
S1
S2
S5
S12
S14
S15
S18
S19
S1: Compressor-side radial clearance (Verdichterrad – Verdichtergehäuseeinsatz)

S2: Compressor-side axial clearance (Verdichterrad – Verdichtergehäuseeinsatz)
S5: Radial deflection (tilt clearance of the rotor, not required for all TC)
S12: Turbine-side radial clearance (Turbinenrad – Turbinengehäuseeinsatz)
S14: Turbine-side axial clearance (Turbinenrad – Turbinengehäuseeinsatz)
S15: Axial bearing clearance
S18: Turbine-side piston ring clearance
S19: Compressor-side piston ring clearance

Operating Instructions For Exhaust-Gas Turbocharger

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Operating Instructions For Exhaust-Gas Turbocharger

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Operating instructions

Kompressorenbau Bannewitz GmbH

Edition 10 01/2019 Page 1 of 108

Edition 10 01/2019 Page 2 of 108

2 Technical data ........................................................................................ 19

Edition 10 01/2019 Page 3 of 108

Appendix ........................................................................................................................ 107

Edition 10 01/2019 Page 4 of 108

Tighten with the indicated torque.

Tighten hand-tight without tools.

Apply high-temperature grease / ceramic paste.

Free from grease, free from oil, dry.

Measure the value.

Record the value.

Carry out a visual inspection.

Observe the information in the documentation.

Dispose of all waste in a correct and environmentally responsible manner and in

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Edition 10 01/2019 Page 6 of 108

1.2 Product description

1.2.1 Brief description

1.2.4 Intended use

Edition 10 01/2019 Page 7 of 108

1.3 Product identification

1.3.1 Marking of the exhaust-gas turbocharger

Edition 10 01/2019 Page 8 of 108

1.3.2.3 Identification of components

Edition 10 01/2019 Page 9 of 108

1.4.2 Definition of safety instructions and mandatory signs

 Warnings and orders must be followed.

Edition 10 01/2019 Page 10 of 108

Use protective equipment as required!

Use protective equipment as required!

Wear head protection!

Use protective equipment as required!

Wear breathing protection!

Use protective equipment as required!

Use skin protection!

Use protective equipment as required!

Wash your hands!

Use protective equipment as required!

Wear protective clothing!

Protective equipment that must be worn when working on the exhaust-gas

Wear foot protection!

Protective equipment that must be worn when working on the exhaust-gas

Edition 10 01/2019 Page 11 of 108

Wear heat-resistant gloves!

Danger due to rotating parts

Wear protective gloves!

Danger due to noise

Wear ear protectors!

Danger due to tipping over

Edition 10 01/2019 Page 12 of 108

Danger due to operating and auxiliary materials

Wear protective gloves!

Wear protective clothing!

Wear breathing protection!

Use skin protection!

Wash your hands at the end of work!

Danger to the environment

Edition 10 01/2019 Page 13 of 108

Warnings on the V-band (2 piece, every 180°)

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