C2-Working Instructions

MAN Diesel
Technical Documentation
Turbocharger
Working Instructions
Turbocharger type........... NR34/S

2008-06-23
C2
C2 6661-5 C2-5 EN 1 (2)

MAN Diesel
MAN Diesel SE
86224 Augsburg
Phone +49 (0) 821 322-0
2008-06-23
Fax +49 (0) 821 322-3382

service-augsburg@de.manbw.com
www.manbw.com
Copyright © MAN Diesel

All rights reserved, including reprinting, copying (Xerox/microfiche) and translation.
2 (2) C2 6661-5 C2-5 EN

MAN Diesel
Table of contents
Table of contents
1 Introduction
1.1 Preface
1.2 Organisation and use of the work cards
2 Work cards
000.31 Screw connections and tightening torques
500.04 Checking the turbine nozzle ring
500.05 Emergency operation with blocking device
500.05 Emergency operation with closing device
500.06 Checking the bearings
500.07 Cleaning the turbine - wet cleaning
500.07 Cleaning the turbine - dry cleaning
500.08 Cleaning the compressor - pressure sprayer
500.10 Turbocharger or subassemblies
500.11 Cleaning the air filter
500.12 Silencer
500.13 Air intake casing
500.14 Compressor casing, insert, diffuser, speed transmitter
500.16 Cartridge
500.18 Compressor wheel
500.19 Labyrinth disk
500.20 Locating ring
500.21 Locating bearing
500.22 Thrust ring
500.23 Turbine rotor
500.24 End cover, covering disk
500.25 Plain bearing
500.26 Turbine nozzle ring
500.27 Gas outlet casing
3 Index
2008-06-23
C2 6661-5 C2-5 EN 1 (1)

MAN Diesel
Introduction
1 Introduction
2 Work cards
3 Index
2008-06-23
C2 6661-5 1-5 EN 1 (1)

MAN Diesel 1.1
Preface
Introduction
General remarks
Work cards and maintenance The work cards are closely related to the maintenance schedule of the tur-
schedule bocharger contained in Part C1 (Operating Manual) of the technical docu-
mentation. The latter briefly specifies the maintenance work to be done,
whereas this volume gives a step-by-step description, with illustrations, of
the procedures required to maintain the operational reliability and efficiency
of the turbocharger. The work cards include, among other things, informa-
tion about the required tools and appliances. For most of the jobs, further
associated work cards have to be consulted.
Work cards serve the particular purpose of providing essential information
in concise form.
2007-11-05
Introduction
NR, NA
C2 6686 1.1-02 EN 1 (1)

MAN Diesel 1.2
Organisation and use of the work cards
Introduction
Numbering
The ordinal number of the work cards is located at the top right of the title.
It consists of a three-digit subassembly number and a two-digit counting
number. The subassembly number 500 represents the collective subas-
sembly number for turbochargers.
Example - Turbocharger on engine: 500.10
▪ 500 = Subassembly number (500 for turbocharger)
▪ 10 = Counting number (work card No. 10)
Cross-references in work cards to related work cards are enclosed in square
brackets.
Example - Cross-reference in work card 500.10: [500.12]
In work card 500.10 (Removing and refitting turbocharger or subassem-
blies), there is a reference to work card 500.12 (Removing and refitting
silencer).
Layout of the Work Cards
Work cards generally contain the following information:
▪ Required personnel and time,
▪ Affiliated work cards, meaning work cards that contain additional nec-
essary or other useful information,
▪ The required tools and appliances,
▪ Possibly additional information/technical data and,
▪ The individual work sequences, always beginning with the starting con-
dition, and followed by the individual work steps.
Parts and tools in the figures and text are each designated with their order
number.
Example for the turbine rotor: 520.001
▪ 520 = Subassembly group number (520 für „Rotor, complete“)
▪ 001 = Position number
All assemblies and subassembly group numbers are listed in the spare parts
catalog.
Order numbers for tools are (generally) identical with the tool number affixed
on the tool.
Required Personnel and Time
The required time is mentioned in hours, both for the amount and qualifi-
2008-07-25
cation of the required personnel. The higher hour rate covers the time
Introduction
requirement for the complete scope of the respective work card. Personnel
with lower hour rate is required only at times, e. g., for operation of a lifting
NR, NA
tackle.
C2 6686 1.2-01 EN 1 (2)

1.2 MAN Diesel
Tools / Appliances
Introduction
The numbers in the Designation column refer to width across flats, given in
mm, e.g. socket wrench 10 = socket wrench width across flats 10 mm.
Availability codes in the Status column have the following meaning:
Standard Included in the scope of supply of the turbocharger.
Optional Tools are supplied by special order.
Inventory Commercially available tools/appliances
These are not included in the scope of supply of the turbo-
charger. It is assumed that these tools/appliances are included
in the inventory of the engine system.
Special Special tools, e.g. for service centres.
Tips and Pictographs
For notes concerning fault sources/handling errors; material damage can

occur.
Additional notes, information and tips.
The instructions “Lubricate contact surfaces and threads”, “Observe tight-

ening torques” and “Use lock washer pairs” are additionally indicated by
means of symbols in the marginal column:
Grease, lubricate and oil Use Observe

lock washers tightening torques!
2008-07-25
Introduction
NR, NA
2 (2) C2 6686 1.2-01 EN

MAN Diesel
Work cards
1 Introduction
2 Work cards
3 Index
2008-06-23
C2 6661-5 2-5 EN 1 (1)

MAN Diesel 000.31
Screw connections and tightening torques
Work cards
Short Version
Tightening values for all important bolted connections/tightening torques
for various friction coefficients μ.
Tightening Torques for Bolted Connections

Tightening of screw connec- Whenever possible, screw connections should be tightened with torque
tions acc. to the torque wrenches.
For particularly important screw connections on the turbocharger, the tight-

ening torques are prescribed in the relevant work cards.
For all other screw connections that are to be tightened with torque
wrenches, the approximate values for the tightening torques are specified
in the Table “Tightening torques for bolts, strength class 8.8”.
When tightening screw connections the following must be observed:
▪ Apart from the applied tightening torque, the clamping force of a screw
connection depends on the lubricant being used, the condition of the
contact surface and thread, as well as on the material combination. It is
therefore very important that all these conditions are satisfied.
▪ The Table “Tightening torques for bolts, strength class 8.8” gives the
tightening torques for the various screw threads depending on their
coefficient of friction µ, i.e. depending on the selected lubricant. The
tightening torques apply for bolt materials in strength class 8.8 under
utilization of approx. 70% of their yield strength. For other stength
classes, conversion factors are to be used and multiplied by the tight-
ening torques from the Table “Tightening torques for bolts, strength
class 8.8”. The strength class is stamped on the bolt head.
Strength class 5.6 6,8 8.8 10.9 12.9
Conversion factor x 0.47 0.75 1.0 1.40 1.70
Table 1: Conversion factors for tightening torques depending on the strength
class of the bolts
Friction coefficient µ For the friction coefficient µ use approximately:
µ = 0.08 with lubricants for temperatures

≤ 200 °C, e.g. Molykote G-n or Molykote P40
≥ 200 °C, e.g. Molykote HSC
µ = 0.14 for lightly oiled surfaces without refinishing
Tightening torques in general
2007-11-05
Tightening torque in Nm
for coefficient of friction µ
Work cards
Thread, nominal size

0.08 0.14
NR, NA
M5 4 6
M6 7 10
C2 6686 000.31-01 EN 1 (2)

000.31 MAN Diesel
Tightening torque in Nm
Work cards
Thread, nominal size for coefficient of friction µ

0.08 0.14
M8 17 25
M 10 34 50
M 12 60 85
M 14 95 135
M 14×1.5 100 145
M 16 140 205
M 16×1.5 150 220
M 18 200 280
M 18×1.5 215 320
M 18×2 205 300
M 20 275 400
M 20×1.5 295 450
M 20×2 285 425
M 22 370 540
M 22×1.5 385 595
M 22×2 380 565
M 24 475 690
M 24×2 500 750
M 27 700 1020
M 27×2 730 1100
M 30 950 1380
M 30×2 1015 1540
M 33 1270 1870
M 33×2 1350 2060
M 36 1640 2400
M 36×3 1710 2550
M 39 2115 3120
M 39×3 2190 3300
M 42 2630 3860
M 42×3 2760 4170
M 45 3260 4820
M 45×3 3415 5180
M 48 3950 5820
M 48×3 4185 6370
2007-11-05
Table 2: Tightening torques for bolts, strength class 8.8

Work cards
NR, NA
2 (2) C2 6686 000.31-01 EN

MAN Diesel 500.04
Checking the turbine nozzle ring
Work cards
Brief description
Check the turbine nozzle ring and replace it if necessary.
A Guide vane E Negative areas (on the left of D)

B Trailing edge (original) F Positive area (on the right of D)
C Contour of the reduction G Root of the guide vane
D Mean reduction
(area F = ∑ areas E)
Figure 1: Erosion of the turbine nozzle ring
General The erosive wear of the guide vanes (A) is caused by the outlet flow mainly
in the area of the trailing edges (B). The original position of the trailing edges
(B) can be recognised at the roots (G) of the guide vanes (A).
Since the guide vanes do not wear evenly, the mean value of the guide vane
reduction (Lm) is calculated as follows:
(L1 + L2 + L3 + … + Ln)
Lm = ____________________ n = number of guide vanes (A)
n
Replacement Replace the turbine nozzle ring if Lm ≥ the value specified in the table:
Turbocharger Lm ≥ mm Turbocharger Lm ≥ mm
NR12/RS 8 NR20/S 12
NR12/S 8 NR24/S 14
NR14/S 9 NR29/S 16
NR17/S 11 NR34/S 19
2007-11-19
Work cards
NR/S
C2 6660 500.04-03 EN 1 (1)

MAN Diesel 500.05
Emergency operation with blocking device
Work cards
Brief description
Emergency operation by blocking the turbine rotor.
Personnel and time required

Number Qualification Duration in h
1 Technician 1,5
1 Assistant 1,5
Tools/appliances required
Quantity Designation Number Status
1 Arresting wrench 596.018 Standard
1 Hexagon bolt 596.021 Standard
1 Washer 596.022 Standard
1 Socket wrench 19 - Inventory
- Lifting tackle, ropes, shackles - Inventory
Related work cards

Work card Work card Work card
500.10 500.12 500.13
500.14
Preliminary remarks
During emergency operation of the engine, the exhaust gas must continue
passing through the damaged turbocharger.
2007-11-20
Work cards
NR34/S
C2 6661 500.05-01 EN 1 (3)

500.05 MAN Diesel
Work cards
Figure 1: Blocking device

The damaged turbocharger can be shut down using either the blocking
device (refer to work card [500.05] “Emergency operation with blocking
device”) or the closing device (refer to work card [500.05] “Emergency oper-
ation with closing device”).
The blocking device should only be used if it is not possible (e.g. for lack of
time) to remove the rotor.
Further damage to the rotor can be avoided by using the closing device.
Work sequence - Emergency operation with blocking device
Danger to life from crush injuries or blows!

When the engine starts during assembly of the holding device, there is
danger of becoming entangled in or coming against rotating components
and being seriously injured.
▪ Shut down the engine before installing the holding device in the
turbocharger!
▪ During the work, secure the engine against starting!
▪ Set up danger signs!
Danger of fire caused by lube oil!

2007-11-20
During emergency operation with the holding device, the danger of fire
Work cards
is given when lube oil gets into the turbocharger.

In emergency operation, always shut the oil supply pipe to the
NR34/S
turbocharger!
2 (3) C2 6661 500.05-01 EN

MAN Diesel 500.05
1. Detach the silencer or air intake casing, refer to work card [500.12] or
Work cards
[500.13].
2. Dismantle the insert (540.001) and spacer ring (540.030), refer to work
card [500.14].
3. Place the arresting wrench (596.018) onto the nut (520.067) and attach
nut to compressor casing (546.001) together by means of washer
(596.022) and hexagon bolt (596.021).
4. Mount the silencer or air intake casing.
5. For further information about emergency operation, refer to the Oper-
ating Manual for the turbocharger and the Operating Manual for the
engine, Section “Operating Faults”.
2007-11-20
Work cards
NR34/S
C2 6661 500.05-01 EN 3 (3)

MAN Diesel 500.05
Emergency operation with closing device
Work cards
Brief description
Emergency operation by removing the cartridge

1 Technician 2,0
1 Assistant 2,0
1 Closing cover (with support) 596.027 Standard
1 Open-jaw wrench 30 - Inventory
Related work cards

500.10 500.12 500.13
500.14 500.16
Technical details
Designation Information
Closing cover (with support) 52 kg
Cartridge 245 kg
Preliminary remarks
During emergency operation of the engine, the exhaust gas must continue
passing through the damaged turbocharger.
2007-11-20
Work cards
NR34/S
C2 6661 500.05-02 EN 1 (3)

500.05 MAN Diesel
Work cards
Figure 1: Closing device

The damaged turbocharger can be shut down using either the blocking
device (refer to work card [500.05] “Emergency operation with blocking
device”) or the closing device (refer to work card [500.05] “Emergency oper-
ation with closing device”).
The blocking device should only be used if it is not possible (e.g. for lack of
time) to remove the rotor.
Further damage to the rotor can be avoided by using the closing device.
Work sequence - Emergency operation with closing device
Danger to life from crush injuries or blows!

When the engine starts during removal of the rotating element or during
assembly of the closing mechanism, there is danger of becoming
entangled in or coming against rotating components.
▪ Shut down the engine before removal of the running gear as well as
before installing the closing mechanism in the turbocharger!
▪ During the work, secure the engine against starting!
▪ Set up danger signs!
Danger of fire caused by lube oil!

2007-11-20
During emergency operation without rotating element, the danger of fire

Work cards
is given when lube oil gets into the turbocharger.

In emergency operation, always shut the oil supply pipe to the
NR34/S
turbocharger!
2 (3) C2 6661 500.05-02 EN

MAN Diesel 500.05
Steps 1. Undo all the connections to prepare the cartridge for removal (refer to
Work cards
work card [500.10] “Turbocharger or subassemblies”).
2. Remove the silencer or air intake casing, post lubrication tank, com-
pressor casing and cartridge (refer to work cards [500.12] “Silencer” up
to [500.16] “Cartridge”).
The turbine nozzle ring (513.001) remains in place.
3. Close the lube oil pipes.
4. Attach the closing cover (596.027) with clamping claws (501.005), lock
washer pairs (501.007) and hexagon nuts (501.008) to the gas admission
casing (501.001).
Screw the support for the closing cover onto the bracket.
5. For further information about emergency operation, refer to the Oper-
ating Manual for the turbocharger and the Operating Manual for the
engine, Section “Operating Faults”.
2007-11-20
Work cards
NR34/S
C2 6661 500.05-02 EN 3 (3)

MAN Diesel 500.06
Checking the bearings
Work cards
Brief description
Check the bearings, replace if necessary
1 Sliding caliper - Inventory
Related work cards

500.21 500.25
Preliminary remarks with regard to checking the locating bearing (517.002) and the plain
bearing (517.003)
Signs of wear!
If fretting marks, uneven or rapid wear are found, the causes such as
imbalance, irregularities on the sealing air and lube oil systems (dirt,
pressure, flow rate, temperature, priming and post lubrication) must be
remedied prior to installing new bearings.
Checking the locating bearing (517.002)

2008-02-20
Work cards
Figure 1: Checking the locating bearing (517.002)

NR34/S
Carefully clean and check the locating bearing (517.002). The bearing bore
is not circular.
C2 6661 500.06-01 EN 1 (2)

500.06 MAN Diesel
Replace the locating bearing (517.002) if the reflecting band

Work cards
width (B) ≥ 25 mm.

1. Measure the length ( l ) of the wedge surfaces (a) on the turbine side and
compressor side.
Length ( l ) extends up to the edge (v) on the bearing contact face (b).
Depending on the angle of light incidence, a dark band may appear in
front of the edge (v) on the wedge surface (a). This band is to be included
in the measurement of length ( l ).
Replace the locating bearing (517.002) if one of the lengths ( l ) ≤ 3.30 mm.
Checking the plain bearing with floating bearing bush (517.003)
Figure 2: Checking the plain bearing (517.003)

Disassemble the plain bearing (517.003). Carefully clean and measure the
component parts.
Replace the plain bearing (517.003) if D1 ≥ ∅ 70.00 mm, D2 ≤ ∅ 89.73 mm
or D3 ≥ ∅ 90.03 mm.
If the component parts are in order, assemble the plain bearing.
Observe the correct use of lock washer pairs!
Long wedge surfaces to contact each other (on the inside), otherwise there will be
no locking effect.
2008-02-20
Work cards
NR34/S
2 (2) C2 6661 500.06-01 EN

MAN Diesel 500.07
Cleaning the turbine - wet cleaning
Work cards
Brief description
Wet cleaning of the turbine during operation in the case of significantly
reduced engine performance. Carry out the cleaning in time, in accordance
with the maintenance schedule.

1 Technician 0,6
Preliminary remarks
Cleaning agent Use exclusively fresh water for cleaning.
Cleaning interval Every 150 operating hours (or less, depending on the operating conditions),
at reduced engine load.
Maximum exhaust gas temperature upstream of turbine: 320 °C
The exhaust gas temperature of 320 °C must not be exceeded under any
circumstances, otherwise the turbine is liable to make contact during
washing.
In order to save time, carry out the cleaning shortly after engine start-up,
provided the components to be cleaned are not yet too hot.
This allows step 2 of the work sequence to be omitted.
Brief information See also cleaning instructions given on plate (attached to the engine).
2008-07-25
Work cards
NR
C2 6660 500.07-03 EN 1 (3)

500.07 MAN Diesel
Work cards
1 Water admission (fresh water) 6 Sealing air (extracted down-

stream of charge air cooler)
2 Exhaust gas pipe upstream of 7 Plate with cleaning instructions
turbine
3 Gas admission casing A Three-way cock with sealing air
connection
4 Turbine nozzle ring B Pressure gauge *
5 Turbine wheel * Scope of supply of engine
Figure 1: Diagram: Wet cleaning of the turbine
General The layout of the cleaning device depends on the engine type and can vary
from the illustration.
Work sequence - Wet cleaning of the turbine (during operation)
Steps 1. Reduce engine load to a maximum exhaust gas temperature upstream
of turbine ≤ 320 °C, observe turbocharger speed.
2. Following reduction of the engine load from a higher load range, wait
approx. 10 minutes (for the temperature to reach a stable condition).
3. Switch the three-way cock (A) to position “I” (washing),
water pressure approx. 2 — 3 bar.
4. Washing duration approx. 30 seconds, then repeat the washing proce-
dure 10 times with an interval of 1 minute after each procedure.
5. Switch the three-way cock (A) to position “0” (sealing air).
The sealing air prevents clogging and corrosion of the piping.
6. Continue to run the engine at reduced engine load for 10 minutes (until
the washing water has dried), then slowly increase the engine load.
2008-07-25
Work cards
NR
2 (3) C2 6660 500.07-03 EN

MAN Diesel 500.07
Work cards
Vibrations caused by dirt accumulations
Should vibrations occur on the turbocharger that were not evident
before, repeat the washing procedure.
If these vibrations, caused by irregular dirt accumulations, cannot be
eliminated by washing, the turbocharger must be dismantled and the
parts involved must be subjected to mechanical cleaning.
2008-07-25
Work cards
NR
C2 6660 500.07-03 EN 3 (3)

MAN Diesel 500.07
Cleaning the turbine - dry cleaning
Work cards
Brief description
Dry cleaning of the turbine during operation in the case of normal engine
operating load. The engine load need not be reduced. Carry out the cleaning
in time, in accordance with the maintenance schedule.

1 Technician 0,3
- Granulates (grain size 1.0 — 1.5 mm) - nut shells/acti- - Inventory
vated charcoal - soft
Preliminary remarks
Cleaning agent Use only commercially available granulates from nut shells or activated
charcoal (soft) with a grain size of 1.0 mm (max. 1.5 mm).
Do not use water for cleaning the turbine by this method, as in this case
the cleaning is carried out at normal operating load of the engine.
Cleaning interval Every 24 operating hours (or less, depending on the operating conditions),
at normal operating load of the engine.
Brief information See also cleaning instructions given on plate (attached to the engine).
2007-11-20
Work cards
NR
C2 6660 500.07-04 EN 1 (3)

500.07 MAN Diesel
Work cards
1 Tank 8 Turbine wheel

2 Screw plug 9 Compressed air pipe
3 Pipe 10 Sealing air (extracted down-
stream of charge air cooler)
4 Connection point 11 Plate with cleaning instructions
5 Exhaust gas pipe upstream of tur-
bine
6 Gas admission casing A Stop cock
7 Turbine nozzle ring B Three-way cock with sealing air
connection
Figure 1: Diagram: Dry cleaning of the turbine
The layout of the cleaning device depends on the engine type and can vary
from the illustration.
The tank (1) must be installed in a suitable location, not lower than 1.0 m
below the connection point (4). The pipe (3) must be no longer than 6.0 m,
be properly supported to prevent it from vibrating and allow unimpeded
flow.
Connection point (4) on the exhaust gas pipe just before the gas admission
casing (5) or on the admission socket of the gas admission casing.
Maximum operating temperature of the three-way cock (B): ≤ 150 °C.
Work sequence - Dry cleaning of the turbine (during operation)
Steps 1. Stop cock (A) must be closed.
2007-11-20
2. Three-way cock (B) must be in position “0”.

Work cards
3. Unscrew the screw plug (2). Fill the prescribed quantity of granulate into
the tank (1) and close it with the screw plug (2). For the quantities
required, refer to Table 1.
NR
2 (3) C2 6660 500.07-04 EN

MAN Diesel 500.07
4. Open the stop cock (A).
Work cards
Slowly turn the stop cock (B) to position “I” until a whistling sound is
heard indicating introduction of the granulate.
Granulate injection time approx. 30 seconds.
5. Close the stop cock (A).
6. Switch the three-way cock (B) to position “0” (sealing air).
The sealing air prevents clogging of the piping.
Filling volume
NR12, NR14, NR15, NR17, NR20 0.3 litres
NR24, NR26 0.4 litres
NR29, NR34 0.5 litres
Table 1: Filling volume
Vibrations caused by dirt accumulations

Should vibrations occur on the turbocharger that were not evident
before, repeat the washing procedure.
If these vibrations, caused by irregular dirt accumulations, cannot be
eliminated by washing, the turbocharger must be dismantled and the
parts involved must be subjected to mechanical cleaning.
2007-11-20
Work cards
NR
C2 6660 500.07-04 EN 3 (3)

MAN Diesel 500.08
Cleaning the compressor - pressure sprayer
Work cards
Brief description
Clean the compressor with the engine warmed up and in full load operation.
Carry out the cleaning in time, in accordance with the maintenance sched-
ule.

1 Technician 0,3
Introductory Remarks
Cleaning agent Use exclusively fresh water for cleaning.
Due to the high speed of the rotor, the injected water droplets hit the blades
of the compressor wheel and the diffuser at high velocity, thus removing the
dirt deposits mechanically.
Cleaning interval We recommend the following cleaning intervals:
▪ NR turbochargers: every 150 operating hours,

▪ NA turbochargers: every 150 operating hours.
The cleaning intervals depend on the degree of contamination of the intake
air and range from 100 to 200 operating hours.
In the smaller turbocharger sizes (NR, NA34, NA40), dirt deposits on the
compressor wheel and diffuser blades may lead to a considerable drop in
efficiency.
From turbocharger size NA48 upwards, compressor cleaning is not neces-
sary if the air filter mat is serviced as specified.
Carry out the cleaning only with the engine warmed up and in full
load operation.
Do not shut down the engine immediately after cleaning, but continue to
run it for several minutes until dry.
Brief information See also cleaning instructions given on plate (10), attached to the pressure
sprayer (2).
2007-11-05
Work cards
NR, NA
C2 5649 500.08-03 EN 1 (2)

500.08 MAN Diesel
Work cards
1 Handle 5 Coupling
2 Pressure sprayer 6 Hand valve
3 Relief valve 7 Turbocharger (compressor)
4 Nipple 10 Plate (cleaning instructions)
Figure 1: Diagram: Cleaning of the compressor (with pressure sprayer)
Depending on the type of engine and turbocharger, the arrangement of the
individual parts might not correspond exactly to the diagram.
Work Sequence – Compressor Cleaning (during Operation)
Steps 1. Operate engine at full load.
2. Turn handle (1) on pressure sprayer tank (2) in counter-clockwise direc-

tion and take out the pump.
3. Fill a maximum of 2.0 litres of fresh water into the tank (up to the mark
2 L on the tank).
4. Screw in the pump and operate it until the relief valve (3) blows off.
5. Connect hose with nipple (4) to the coupling (5).
6. Depress pushbutton (see large arrow in figure) on the hand valve (6) until
the water is completely injected into the compressor (7) (for approx. 30
seconds).
7. Release plug-in connection and vent the tank. For venting, pull spindle
on the relief valve (3) outwards (see small arrow in figure).
2007-11-05
Work cards
NR, NA
2 (2) C2 5649 500.08-03 EN

MAN Diesel 500.10
Turbocharger or subassemblies
Work cards
Removing and refitting
Short Version
Remove and refit the turbocharger from and to the engine, in subassemblies
or in complete condition.

1 Technician 4,5
1 Assistant 1,0
1 Torque wrench - Inventory
1 Open-jaw and ring wrenches (set) - Inventory
1 Socket wrench (set) - Inventory
1 Screwdriver - Inventory
- Wood (as a support) - Inventory
- High-temperature lubricant (e.g. Molykote HSC) - Inventory
Technical details
Turbocharger 1 840 kg
Preliminary remarks
For maintenance work on the turbocharger individual subassemblies and
components are normally removed in succession (see work cards 500.12 ...
500.27).
2008-02-25
Work cards
NR34/S
C2 6661 500.10-05 EN 1 (5)

500.10 MAN Diesel
Work cards
Figure 1: Connections on the turbocharger

Work sequence 1 - Separating or removing the connections
Danger of burns from hot components!

Many engine and turbocharger components become very hot during
operation and require ample time for cooling down afterwards.
▪ Prior to taking any action, allow the engine and turbocharger to cool
down sufficiently (1-2 h)!
▪ Wear protective clothing!
Danger of burning/scalding from running-out lube oil!

The lube oil is under pressure and very hot!
▪ Before opening pipes, flanges, screwed connections or gauges, free
the system of pressure and check that it is pressure-free!
▪ Before opening oil pipes, wait until the lube oil has cooled down
sufficiently (1-2 h)!
▪ Drain the system and check that the lube oil has been drained
completely!
▪ Wear protective clothing!
2008-02-25
Work cards
Steps 1. Air intake (1) on air intake casing (if provided), compressor cleaning (2)
Removal of silencer or air intake casing is possible.
NR34/S
➤ Work card [500.12] “Removing and refitting silencer” or

➤ Work card [500.13] “Removing and refitting air intake casing”.
2 (5) C2 6661 500.10-05 EN

MAN Diesel 500.10
2. Cable to speed transmitter in the terminal box (3)
Work cards
Removal of insert on compressor side, speed transmitter, compressor
wheel, locating bearing is possible.
➤ Work cards [500.14], “Removing and refitting compressor casing,
insert, diffuser, speed transmitter”, [500.18] “Removing, refitting and
checking compressor wheel” to [500.21] “Removing and refitting locat-
ing bearing”.
3. Cable to speed indicator in the terminal box (3), jet assist (4, if provided),
air outlet (5)
Removal of compressor casing, diffuser is possible.
➤ Work card [500.14] “Removing and refitting compressor casing,
insert, diffuser, speed transmitter”.
4. Connecting point (8) for pressure indicator and/or pressure controller,
lube oil feed (9), lube oil drain (10), two-part plate (11)
Removal of cartridge, turbine nozzle ring, insert on turbine side is pos-
sible.
➤ Work card [500.16] “Removing and refitting cartridge”,
➤ Work card [500.26] “Removing and refitting turbine nozzle ring”.
5. Exhaust gas outlet (12), dirty water or condensed water discharge (13,
if provided)
Removal of gas outlet casing is possible.
➤ Work card [500.27] “Removing and refitting gas outlet casing”.
6. Exhaust gas admission (14)
Removal of complete turbocharger is possible.
➤ Work card 500.10 (work sequence 2)
Work sequence 2 - Removing the complete turbocharger

2008-02-25
Work cards
NR34/S
Figure 2: Removing and refitting the turbocharger
C2 6661 500.10-05 EN 3 (5)

500.10 MAN Diesel
Work cards
Risk of serious or fatal injury when lifting and moving loads!

No persons may be present in the area of danger around and underneath a suspended
load.
▪ Lifting tackle, ropes and attachment points must be able to take the
load safely and be in perfect condition.
▪ Use the eye bolts on the subassemblies only for lifting individual
(detached) subassemblies and not for lifting the turbocharger.
▪ All lifting, moving and setting down of the load must be carried out
slowly.
Risk of fouling!
During storage and assembly, the openings for air, exhaust gas and lube
oil must be appropriately sealed to prevent foreign objects or water from
entering.
Steps 1. For separating or removing the connections, refer to work sequence 1.

Also separate or detach other special connections (such as for pressure
and temperature measuring, etc.).
2. Undo the screw connections (15) between the attaching parts (503) and
the bracket, please refer to work card 500.12 “Removing and refitting
silencer” or 500.13 “Removing and refitting air intake casing”.
3. Carefully lift off the silencer (544, if provided) or the air intake casing
(545, if provided) together with attaching parts (503) and set it down on
a wooden support.
4. Attach lifting tackle to the remaining turbocharger using a rope of ade-
quate strength slung around the bearing casing, and carefully tension
the rope. Attach secondary ropes to appropriate points to assist in bal-
ancing.
5. Undo the screw connections (16) between the casing feet and the
bracket.
6. Carefully lift off the turbocharger and set it down on a wooden support.
Work sequence 3 - Refitting
Procedures to be observed when mounting the turbocharger onto the

engine:
▪ Remove protective caps from pipe connections/pipes.
▪ Use only flawless seals and screw locking elements.
▪ Apply high-temperature lubricant (e.g. Molykote HSC) to the threads of
heat-resistant screws and nuts on the turbine side.
Refitting the complete turbocharger or its subassemblies, and restoring the

2008-02-25
connections, is carried out by reversing the removal procedure.

Work cards
Tighten the screw connections (16) between the casing feet and the bracket
NR34/S
lightly at first, and then torque them finally after connection of the casing
pipes.
4 (5) C2 6661 500.10-05 EN

MAN Diesel 500.10
Work cards
Observe tightening torques during assembly!
Screw connection of the casing feet to the engine bracket: see engine
manual.
2008-02-25
Work cards
NR34/S
C2 6661 500.10-05 EN 5 (5)

MAN Diesel 500.11
Cleaning the air filter
Work cards
Brief description
Clean the air filter mat regularly in accordance with the maintenance sched-
ule or replace it. The work can be carried out during operation.

1 Technician 0,4
Preliminary remarks
General The dirty air filter mat (544.150) can be cleaned several times or replaced
with a new one.
Replacement is required if the air filter mat is considerably stretched, tat-
tered or perforated.
An increase in pressure loss, due to a contaminated air filter mat, should

not be used as a reference for the cleaning interval.
Cleaning interval Every 250 operating hours.
The cleaning intervals depend on the degree of contamination of the intake

air and range from 250 to 500 operating hours.
Cleaning is necessary when the inside of the air filter mat starts to
discolour, turning grey. The air filter is then saturated and the
contamination starts to advance towards the compressor and the charge
air cooler. The inside of the air filter mat may be inspected by loosening
the outer lashing strap (544.160).
In case of heavy contamination, it may be necessary to immerse the air
filter mat into a cleaning agent for several hours. Therefore it is
recommended to have a second air filter mat in stock at all times.
2008-02-20
Work cards
NR34/S
C2 6661 500.11-01 EN 1 (2)

500.11 MAN Diesel
Work cards
Figure 1: Air filter, mounted on the silencer

Work sequence - Removal, cleaning/replacement, refitting
1. Loosen lashing straps (544.160), remove cover sheet (544.170) and air
filter mat (544.150). Depending on the version, 2 or 3 lashing straps are
fitted.
2. Clean the air filter mat by flushing with warm water to which a mild
detergent has been added.
Avoid excessive mechanical stress (e.g. wringing, sharp water jet). After
cleaning, blow compressed air through the air filter mat.
3. Place air filter mat (544.150) over perforated plate of silencer, and cover
sheet (544.170) over joint of air filter mat and fasten them using the
lashing straps (544.160).
2008-02-20
Work cards
NR34/S
2 (2) C2 6661 500.11-01 EN

MAN Diesel 500.12
Silencer
Work cards
Brief description
Remove and refit the silencer in complete condition. Disassembling (e.g. for
cleaning) only if necessary.
Required Personnel and Time

1 Technician 0,8
1 Assistant 0,8
1 Open-jaw wrenches (set) - Inventory
Related work cards

500.10 500.11
Technical details
Silencer 300 kg
Attaching parts for silencer 200 kg
2007-11-20
Work cards
NR34/S
C2 6661 500.12-03 EN 1 (3)

500.12 MAN Diesel
Preliminary remarks
Work cards
Figure 1: Silencer with attaching parts

General For air filter cleaning, please refer to work card [500.11] “Cleaning air filter”.
For disassembling, cleaning and reassembling the silencer, refer to work

sequence 3.
Disassembling of the silencer (e.g. for cleaning) only if necessary.
Starting condition Connection for compressor cleaning is released (if provided).
Work sequence 1 - Removing the complete silencer (with attaching parts 503.000)
Steps 1. Attach lifting tackle to the silencer and attaching parts using ropes.
2. Unscrew the hexagon bolts (503.065, 503.075). Take off the lock washer
2007-11-20
pairs (503.066).
Work cards
3. Unscrew the hexagon bolts (503.050). Take off the lock washer
pairs(503.051).
NR34/S
4. Remove the silencer with attaching parts in axial direction and place it
on a wooden support, making sure that it is properly balanced.
2 (3) C2 6661 500.12-03 EN

MAN Diesel 500.12
Work sequence 2 - Removing the complete silencer (without attaching parts 503.000)
Work cards
Steps 1. Suspend the silencer from lifting tackle using rope and shackles
attached to the lug and eye bolt (544.250).
2. Unscrew the hexagon bolts (503.065) on the foot (503.042). Take off the
lock washer pairs (503.066).
3. Unscrew the hexagon nuts (503.052) and take off the hexagon bolts
(503.060, 503.061) and lock washer pairs (503.051).
4. Remove the silencer in axial direction and place it on a wooden support
with the flange face down.
Work sequence 3 - Refitting the complete silencer

General For refitting, proceed in the reverse order of removal.

no locking effect.
Work sequence 4 - Disassembling, cleaning and reassembling the silencer
Bonded joints
On no account may trichlorethylene (or substitutes) or any other solvents
containing acetone be used for removing greasy dirt.
Use of such products will dissolve the bonded joints.

Apply Molykote P40 lubricant to the threads and contact surfaces.
Tightening torque for hexagon nuts (544.064): 40 Nm
Tightening torque for hexagon nuts (544.071): 725 Nm
Steps 1. Remove the air filter mat (544.150) and clean it, see work card
[500.11] “Cleaning air filter”.
2. Loosen the hexagon nuts (544.064 and 544.071) and take off the wash-
ers (544.065) and foot (503.042).
3. Take off the front wall (544.050), spacer pipes (544.080), intermediate
disks (544.030) and casing (544.020) individually. The flange (544.010)
remains in place, held by the threaded rods (544.070).
2007-11-20
Work cards
4. If the fouling matter is dry, the felt linings are best cleaned with com-
pressed air or a brush which is not too hard.
NR34/S
5. For reassembly, proceed in the reverse order of disassembly.
C2 6661 500.12-03 EN 3 (3)

MAN Diesel 500.13
Air intake casing
Work cards
Brief description
Remove the air intake casing for inspection.

1 Technician 0,8
1 Assistant 0,8
1 Open-jaw and ring wrenches (set) - Inventory
Related work cards

500.10
Technical details
Attaching parts for air intake casing 200 kg
Air intake casing 90 kg
2007-11-20
Work cards
NR34/S
C2 6661 500.13-03 EN 1 (3)

500.13 MAN Diesel
Preliminary remarks
Work cards
Figure 1: Air intake casing with attaching parts

Work sequence 1 - Removing the air intake casing (with attaching parts 503.000)
Starting condition Pipe at the air intake is released or removed.
Connection for compressor cleaning is released (if provided).

Steps 1. Attach lifting tackle to the air intake casing and attaching parts using a
rope. Carefully tension the rope.
2. Unscrew the hexagon bolts (503.065, 503.075). Take off the lock washer
pairs (503.066).
3. Unscrew the hexagon bolts (503.050). Take off the lock washer
pairs(503.051).
4. Remove the air intake casing with attaching parts in axial direction and
place it on a wooden support, making sure that it is properly balanced.
Work sequence 2 - Removing the air intake casing (without attaching parts 503.000)
2007-11-20
Steps
Work cards
1. Attach lifting tackle to the air intake casing (545.001) using a rope. Care-
fully tension the rope.
NR34/S
2. Unscrew the hexagon bolts (503.065) on the foot (503.042). Take off the
lock washer pairs (503.066).
2 (3) C2 6661 500.13-03 EN

MAN Diesel 500.13
3. Unscrew the hexagon nuts (545.427) and take off the hexagon bolts
Work cards
(545.425) and lock washer pairs (545.428).
4. Remove the air intake casing in axial direction and place it on a wooden
support.
Work sequence 3 - Refitting the air intake casing

For refitting, proceed in the reverse order of removal.
no locking effect.
2007-11-20
Work cards
NR34/S
C2 6661 500.13-03 EN 3 (3)

MAN Diesel 500.14
Compressor casing, insert, diffuser, speed transmitter
Work cards
Brief description
Remove the compressor casing, insert, diffuser, speed transmitter for
inspection, adaptation or exchange.

1 Technician 1,8
1 Assistant 0,6
2 Shackle A2.0 596.134 Standard
1 Suspension plate 596.201 Standard
- Lifting tackle with rope - Inventory
Spare Parts
Quantity Designation Number
1 O-ring seal 517.018
Related work cards

2007-11-20
500.10 500.12 500.13

Work cards
Technical details
NR34/S
Compressor casing 300 kg
C2 6661 500.14-03 EN 1 (6)

500.14 MAN Diesel
Work cards
Diffuser 20 kg
Insert 55 kg
Preliminary remarks
General The compressor casing should only be removed for cleaning purposes, or
if it is intended to dismantle the diffuser (542.001) or the cartridge (517.000
+ 520.000).
Removal of insert (540.001) without removal of compressor casing permits
removal of speed transmitter (562.040) or removal of compressor wheel up
to removal of locating bearing.
Starting condition Connecting pipes, air intake casing or silencer are removed.
Work sequence 1 - Removing the insert
Figure 1: Removing and refitting the insert, speed transmitter

Steps 1. Disconnect the cable end of the speed transmitter (562.040) in the ter-
minal box (562.083) and pull it through the opened cable socket
(546.049).
See Figure “Removing and refitting the insert, speed transmitter”.
2. Unscrew the undercut bolts (546.055) and take off the distance sleeves
(546.056).
3. Evenly force off the insert (540.001) using 3 hexagon bolts (M12), care-
2007-11-20
fully dismount it in axial direction together with the spacer ring (540.030),
Work cards
set it down on a wooden support.

NR34/S
2 (6) C2 6661 500.14-03 EN

MAN Diesel 500.14
Work cards
Take care not to damage blades of the compressor wheel during
removal.
Work sequence 2 - Removing the speed transmitter

Steps 1. Pull the cable end of the speed transmitter (562.040) through the opened
cable socket (540.025).
See Figure “Removing and refitting the insert, speed transmitter” and
Figure “Speed measuring device”.
2. Unscrew the lock nut on the speed transmitter and screw the speed
transmitter out.
Work sequence 3 - Removing the compressor casing
Figure 2: Removing and refitting the compressor casing, diffuser
Steps 1. Fix suspension plates (596.201 and 596.202) with hexagon bolts
2007-11-20
(596.203) and washers (596.108) at the top of the compressor casing.

Work cards
Attach lifting tackle to the compressor casing (546.001) using a rope and
shackles (596.134). Carefully tension the rope.
NR34/S
See Figure “Removing and refitting the compressor casing, diffuser.”
C2 6661 500.14-03 EN 3 (6)

500.14 MAN Diesel
2. Unscrew the hexagon nuts (546.033), unscrew the hexagon bolts

Work cards
(546.096) and take off the lock washer pairs (546.074).

3. Screw 3 hexagon bolts (596.096) into the forcing-off threads of the
bearing casing flange. Evenly force off the compressor casing, carefully
extract it in axial direction and set it down on a wooden support.
Work sequence 4 - Removing the diffuser

Steps 1. Unscrew the hexagon nuts (546.047) and countersunk bolts (546.045).
See Figure “Removing and refitting the compressor casing, diffuser”.
2. Take off the diffuser (542.001).

Make sure that the O-ring seals (517.018, 540.015, 540.016) are in flawless
condition. O-ring seal (540.015) is only provided in the case of jet assist.
no locking effect.
Tightening torques

Apply Molykote P40 lubricant to the threads and contact surfaces.
Tightening torque for undercut bolts (546.055, Figure 1): 47 Nm
Tightening torque for hexagon nuts (546.033, Figure 2): 63 Nm
Tightening torque for hexagon bolts (546.096): 84 Nm
Speed transmitter Screw the speed transmitter (562.040) into place, applying a permanent seal
(562.003, e.g. Hylomar M), and secure it with one lock nut only.
For cable connection, refer to Figure “Speed measuring device” and Fig-
ure “Cable connection of the speed measuring device”.
Checking For checking the gaps, refer to Operating Manual, Technical details, Gaps
and clearances, sheet 2.5.5.
2007-11-20
Work cards
NR34/S
4 (6) C2 6661 500.14-03 EN

MAN Diesel 500.14
Work cards
Figure 3: Speed measuring device
2007-11-20
Work cards
NR34/S
C2 6661 500.14-03 EN 5 (6)

500.14 MAN Diesel
Cable connection of the speed measuring device

Work cards
Figure 4: Cable connection of the speed measuring device

B Connection for frequency converter (562.200) and
analog speed indicator (562.100) and/or measured data transmission.
D Connection for digital speed indicator (562.310) ....“Hornel”.
Optional: Additionally analog speed indicator (562.100) and/or measured data transmission.
2007-11-20
Work cards
NR34/S
6 (6) C2 6661 500.14-03 EN

MAN Diesel 500.16
Cartridge
Work cards
Brief description
Remove the cartridge for inspection or emergency operation.

1 Technician 0,6
1 Assistant 0,6
4 Pipe 596.008 Standard
4 Hexagon nut 596.010 Standard
1 Suspension device 596.130 Standard
1 Lifting eye bolt 596.134 Standard
Related work cards

500.10 500.12 500.13
500.14
Technical details
2007-11-20
Work cards
Cartridge 245 kg
NR34/S
C2 6661 500.16-01 EN 1 (3)

500.16 MAN Diesel
Preliminary remarks
Work cards
Figure 1: Cartridge, removed from the gas admission casing

Work sequence 1 - Removing
Starting condition Connecting pipes, silencer or air intake casing and compressor casing with
post lubrication tank are removed.
Take care not to damage blades of the turbine rotor during removal.
2007-11-20
Steps
Work cards
1. Take off the two-part plate (591.060), if provided.

NR34/S
2. Detach or remove the casing foot (518.001), depending on form of

attachment.
2 (3) C2 6661 500.16-01 EN

MAN Diesel 500.16
3. Screw the suspension device (596.130) onto the cartridge (599.000)
Work cards
using hexagon bolts (596.106), washers (596.108) and hexagon nuts
(596.107).
4. Attach lifting tackle to the cartridge using rope and shackles. Carefully
tension the rope.
5. Unscrew the hexagon nuts (501.008), take off the lock washer pairs
(501.007) and the clamping claws (501.005).
6. Evenly force off the cartridge (599.000) at 4 points on the circumference,
using tools (596.008, 596.009, 596.010) (see Figure “Forcing off the car-
tridge”). Carefully extract the cartridge in axial direction and set it down
on a wooden support.
Figure 2: Forcing off the cartridge

Screw connections Apply high-temperature lubricant (e.g. Molykote HSC) to the thread of screw
connections but not to screw-in threads when replacing studs.
no locking effect.
Observe tightening torques during installation!

▪ Apply high-temperature lubricant (e.g. Molykote HSC) to the threads
and contact surfaces.
▪ Tightening torque for hexagon nuts (501.008): 42 Nm
2007-11-20
Work cards
NR34/S
C2 6661 500.16-01 EN 3 (3)

MAN Diesel 500.18
Compressor wheel
Work cards
Removing, refitting, checking
Brief description
Remove and refit the compressor wheel for inspection.

1 Technician 1,0
1 Oil pump 596.053 Standard
1 Retainer 596.054 Standard
1 High-pressure pipe 596.057 Standard
1 Press-on device 596.501 Standard
1 Press-off device 596.502 Standard
1 Fixing ring with thrust ring 596.503 Standard
1 Impact wrench 55 - Inventory
1 Hammer - Inventory
1 Dial gauge with retainer - Inventory
- Special lubricant (Molykote G Rapid, Molykote G-n) - Inventory
- Lubricating oil (SAE 30 - SAE 40) - Inventory
2007-11-20
Related work cards

Work cards
NR34/S

500.10 500.12 500.13
500.14 500.16
C2 6661 500.18-02 EN 1 (5)

500.18 MAN Diesel
Technical details
Work cards
Compressor wheel 20 kg
Preliminary remarks
Oil pressure Oil pressure for removal: 2,400 — 3,000 bar
Oil pressure for installation: 1,000 — 1,300 bar
Risk of injury due to high pressure

▪ Always check high-pressure pipe (596.057) for possible defects (ball
stuck, pipe deformed) before using it.
▪ Never use a high-pressure pipe if it shows even the slightest traces of
damage.
▪ The high-pressure pipe must be bent in the desired direction before the
connecting nipple is tightened because otherwise the balls might
become loose.
▪ Check that the O-ring seals (596.048, 596.049, 596.061) are in flawless
condition.
▪ Keep at a safe distance during the forcing-off operation, keep hands
away from the gap (b) - Risk of injury!
2007-11-20
Work cards
NR34/S
Figure 1: Removing the compressor wheel
2 (5) C2 6661 500.18-02 EN

MAN Diesel 500.18
Starting condition Connecting pipes, silencer or air intake casing, insert or compressor casing
Work cards
with post lubrication tank are removed.
Steps 1. Unscrew the screw plug (520.090).
2. Loosen the nut (520.067) with the impact wrench and unscrew until gap
(b) = 7.00 mm.
3. Screw the press-off device (596.502) into the turbine shaft (520.001).
4. Attach the suspension plate (596.202) with hexagon bolts (596.203) and
washers (596.108) to the compressor casing (546.001) or with hexagon
bolts (596.106), washers (596.108) and hexagon nuts (596.107) to the
bearing casing.
5. Attach the retainer (596.054) to the suspension plate (596.202) by means
of hexagon bolts (596.056) and hexagon nuts (596.068).
Connect the oil pump (596.053) and the high-pressure pipe (596.057).
6. Unscrew the feeder of the oil pump (596.053), dip the mouth piece in
clean lube oil (SAE 30 - SAE 40) and pull the piston outwards by means
of the lug. For venting, hold the mouth piece upwards and press the ball
inwards. Then screw the oil feeder onto the pump again.
7. With T-screw (K) opened, pump until bubble-free oil is discharged.
Close the T-screw (K) and continue pumping until it becomes appreci-
ably more difficult. If the compressor wheel does not come off immedi-
ately, wait for a few minutes to allow the oil to distribute in the gap
between the turbine shaft and the conical sleeve. Then continue pump-
ing until the compressor wheel comes loose.
8. Unscrew the nut (520.067). Take off the claw sleeve (520.061), the
feather keys (520.056) and the compressor wheel.
2007-11-20
Work cards
NR34/S
C2 6661 500.18-02 EN 3 (5)

500.18 MAN Diesel

Work cards
Figure 2: Refitting the compressor wheel

Steps 1. Carefully remove any traces of lubricants from the cone of the turbine
shaft, the conical sleeve and the bore of the compressor wheel. Apply
a thin film of special lubricant (Molykote G Rapid or Molykote G-n) to
the bore of the compressor wheel and the outside diameter of the con-
ical sleeve.
Make sure that both the cone of the turbine shaft and the bore of the
conical sleeve are free of lubricants (grease, oil or Molykote).
2. Push the conical sleeve onto the turbine shaft and the compressor wheel
until there is firm contact with the locating ring.
The balancing marks of the turbine shaft, the compressor wheel and the
conical sleeve must coincide radially.
2007-11-20
Work cards
3. Insert 2 feather keys (520.056) into the turbine shaft (520.001) and mount
NR34/S
the fixing ring (596.045) with the pressed-in thrust ring (596.046).
4 (5) C2 6661 500.18-02 EN

MAN Diesel 500.18
4. Screw the press-on device (596.501) up to the point where the thrust
Work cards
ring (596.046) firmly contacts the conical sleeve and the plunger
(596.050) is fully pressed in.
5. Attach the retainer (596.054) to the suspension plate (596.202) on the
compressor casing (546.001) or bearing casing (517.001) by means of
hexagon bolts (596.056) and hexagon nuts (596.068).
Connect the oil pump (596.053) and high-pressure pipe (596.057), mak-
ing sure that the venting screw (596.052) is on top.
6. Unscrew the feeder of the oil pump (596.053), dip the mouth piece in
clean lube oil (SAE 30 - SAE 40) and pull the piston outwards by means
of the lug. For venting, hold the mouth piece upwards and press the ball
inwards. Then screw the oil feeder onto the pump again.
7. Open the venting screw (596.052) and T-screw (K) and continue pump-
ing until bubble-free oil is discharged. Then close the screws again.
8. Continue operating the oil pump until the compressor wheel is just held
in place.
This position (preloading distance S1) can be recognised by the fact that
the compressor wheel can no longer be rotated freely within the claw
clearance relative to the turbine shaft in circumferential direction.
The press-on distance S must remain within the upper and lower limits.
9. Measure and note down preloading distance S1.

Press-on distance S = 3.7 — 3.9 mm.
Calculate total distance S2: S2 = S1 + S
10. Operate the oil pump (596.053) again until the calculated total distance
S2 is reached.
11. Depressurise the press-on tool by opening the T-screw (K) and detach
the complete tool.
12. Push the claw sleeve (520.061) into place. Pay attention to feather keys
(520.056).
The balancing marks of the claw sleeve and compressor wheel must
coincide radially.
13. Lightly oil the thread on the turbine rotor and contact surface of the nut
(520.067). Tighten the nut (520.067) using the impact wrench. Tightening
torque approx. 650 Nm.
14. Screw in the screw plug (520.090).
15. Check the axial runout of the compressor wheel (520.044) at the largest
radial distance. For admissible values, refer to Operating Manual, Tech-
nical details, Gaps and clearances, sheet 2.5.5.
2007-11-20
Work cards
NR34/S
C2 6661 500.18-02 EN 5 (5)

MAN Diesel 500.19
Labyrinth disk
Work cards
Brief description
Remove labyrinth disk for inspection.

1 Technician 0,4
Spare Parts
1 Seal 517.031
Related work cards

500.10 500.12 500.13
500.14 500.16 500.18
Technical details
Labyrinth disk 11 kg
2007-11-20
Work cards
NR34/S
C2 6661 500.19-01 EN 1 (3)

500.19 MAN Diesel
Preliminary remarks
Work cards
Figure 1: Labyrinth disk mounted on the bearing casing

with post lubrication tank and compressor wheel are removed.
Cartridge is removed if turbine rotor is also to be dismounted.
Steps 1. Unscrew the hexagon bolts (517.035), take off the lock washer pairs
(517.036).
2. Screw 2 hexagon bolts (M10, thread length ≥ 40 mm) into the forcing-
off threads and uniformly force off the labyrinth disk (517.087).
Should labyrinth tips of the locating ring (520.035) have worn in and
obstruct removal, either slightly lift the shaft end of the turbine rotor
(520.001) or unscrew the ring nut (520.038) - refer to work card 500.20 -
and force off the labyrinth disk (517.087) together with the locating ring
(520.035).
Slight grooves in the bore of the labyrinth disk produced by the labyrinth
tips of the locating ring improve the sealing effect and are no reason for
replacing the part.
2007-11-20

Work cards
NR34/S
2 (3) C2 6661 500.19-01 EN

MAN Diesel 500.19
Work cards
When fitting the seal (517.031), pay attention to the flawless condition
and position of the holes.

no locking effect.
2007-11-20
Work cards
NR34/S
C2 6661 500.19-01 EN 3 (3)

MAN Diesel 500.20
Locating ring
Work cards
Brief description
Remove the locating ring for inspection.

1 Technician 0,4
1 Spanner 596.065 Standard
1 Hammer - Inventory
Spare parts required

1 Intermediate ring 520.039
Related work cards

500.10 500.12 500.13
500.14 500.16 500.18
500.19
2007-11-20
Work cards
NR34/S
C2 6661 500.20-01 EN 1 (3)

500.20 MAN Diesel
Preliminary remarks
Work cards
Figure 1: Removing, checking and refitting the locating ring

with post lubrication tank, compressor wheel and labyrinth disk are
removed.
Steps 1. Remove the intermediate ring (520.039).
2. Unscrew the ring nut (520.038) with the claw side of the spanner
(596.065) by slightly hammering on one jaw of the spanner. Make sure
that the claws are in exact contact.
3. Withdraw the locating ring (520.035) in axial direction by using the
threaded side of the spanner (596.065).
Replace the locating ring if labyrinth tips have been damaged or worn:
D ≤ Ø 99.75 mm or if fretting marks are evident on the axial running
surface.

Steps 1. Push the locating ring (520.035) into place.
The balancing marks of the locating ring and turbine rotor (520.001) must
2007-11-20
coincide radially.
Work cards
NR34/S
2. Tighten the ring nut (520.038) gently (no hammering) by using the claw
side of the spanner (596.065).
2 (3) C2 6661 500.20-01 EN

MAN Diesel 500.20
3. Insert the intermediate ring (520.039).
Work cards
2007-11-20
Work cards
NR34/S
C2 6661 500.20-01 EN 3 (3)

MAN Diesel 500.21
Locating bearing
Work cards
Brief description
Remove locating bearing for inspection.

1 Technician 0,6
1 Protecting sleeve 596.075 Standard
1 Bridge 596.076 Standard
2 Wing screw 596.080 Standard
Related work cards

500.06 500.10 500.12
500.13 500.14 500.16
500.18 500.19 500.20
2007-11-20
Work cards
NR34/S
C2 6661 500.21-01 EN 1 (3)

500.21 MAN Diesel
Preliminary remarks
Work cards
Figure 1: Removing and refitting the locating bearing

with post lubrication tank, compressor wheel, labyrinth disk and locating
ring are removed.
Steps 1. For protection of the conical shaft section, screw the protecting sleeve
(596.075) onto the turbine rotor (520.001).
2. Unscrew the hexagon nuts (517.032), washers (517.033), hexagon bolts
(517.055), take off the lock washer pairs (517.056) and clamping disk
(517.092).
3. Attach the bridge (596.076) to the bearing casing (517.001) by means of
wing screws (596.080). Screw the hexagon bolts (596.081) into the forc-
ing-off threads of the locating bearing (517.002).
4. Pull the locating bearing off by uniformly turning the hexagon nuts
(596.084). Detach the bridge (596.076).
5. Check the locating bearing (517.002), refer to work card
[500.06] “Checking bearing”.

2007-11-20
Steps 1. Carefully insert the locating bearing (517.002) into the bearing casing
Work cards
and mount the clamping disk (517.092), paying attention to the position
relative to the cylindrical screw (517.015).
NR34/S
2. Unscrew the protecting sleeve (596.075).
2 (3) C2 6661 500.21-01 EN

MAN Diesel 500.21

Work cards
no locking effect.
2007-11-20
Work cards
NR34/S
C2 6661 500.21-01 EN 3 (3)

MAN Diesel 500.22
Thrust ring
Work cards
Brief description
Remove the thrust ring for inspection.

1 Technician 0,6
1 Assembly ring 596.086 Standard
Related work cards

500.10 500.12 500.13
500.14 500.16 500.18
500.19 500.20 500.21
2007-11-20
Work cards
NR34/S
C2 6661 500.22-01 EN 1 (3)

500.22 MAN Diesel
Preliminary remarks
Work cards
Figure 1: Removing and refitting the thrust ring

with post lubrication tank, compressor wheel, labyrinth disk, locating ring
and locating bearing are removed.
Steps 1. For protection of the conical shaft section, screw the protecting sleeve
(596.075) onto the turbine rotor (520.001).
2. Screw the assembly ring (596.086) onto the thrust ring (520.028).
3. Attach the bridge (596.076) to the bearing casing (517.001) by means of
wing screws (596.080). Screw the hexagon bolts (596.081) into the forc-
ing-off threads of the assembly ring (596.086).
4. Pull the thrust ring (520.028) off by uniformly turning the hexagon nuts
(596.084). Detach the bridge (596.076) and the assembly ring (596.086).
If the thrust ring has seized and cannot be pulled off, dismantle the thrust
ring together with the turbine rotor, plain bearing and end cover (refer to
work cards 500.23 and 500.24).
Then detach the thrust ring by careful heating.
2007-11-20

Work cards
Steps 1. Push the thrust ring (520.028) onto the turbine rotor (520.001) up to the
NR34/S
stop. The bridge (596.076) can be used for centring the turbine rotor.
2 (3) C2 6661 500.22-01 EN

MAN Diesel 500.22
Work cards
The balancing marks of the turbine rotor and thrust ring must coincide
radially and the claws must engage properly.
2. Unscrew the protecting sleeve (596.075).

2007-11-20
Work cards
NR34/S
C2 6661 500.22-01 EN 3 (3)

MAN Diesel 500.23
Turbine rotor
Work cards
Brief description
Remove the turbine rotor for inspection.

1 Technician 0,6
- Lifting tackle with rope - Inventory
Related work cards

500.10 500.12 500.13
500.14 500.16 500.18
500.19 500.20 500.21
500.22
Technical details
Turbine rotor 35 kg
2007-11-20
Work cards
NR34/S
C2 6661 500.23-01 EN 1 (3)

500.23 MAN Diesel
Preliminary remarks
Work cards
Figure 1: Removing, checking and refitting the turbine rotor

Starting condition Connecting pipes, silencer or air intake casing, post lubrication tank, com-
pressor casing, cartridge or gas admission casing are removed. Compres-
sor wheel, labyrinth disk, locating ring, locating bearing and thrust ring are
removed.
Steps 1. Attach the protecting sleeves (596.075 and 596.095) to the turbine rotor
(520.001). Fasten the bridge (596.076) to the bearing casing (517.001)
with wing screws (596.080).
2. Push out the turbine rotor far enough to allow ropes to be attached.
3. Withdraw the turbine rotor as concentrically as possible to avoid dam-
age to the plain bearing.
4. Place the turbine rotor on a wooden support.
The turbine blades must not be damaged.
5. Check the turbine rotor.

Replace the turbine rotor if
2007-11-20
D1 ≤ ∅ 63.85 mm
Work cards
D2 ≤ ∅ 69.84 mm
D3 ≤ ∅ 99.65 mm.
NR34/S
2 (3) C2 6661 500.23-01 EN

MAN Diesel 500.23
Work cards
2007-11-20
Work cards
NR34/S
C2 6661 500.23-01 EN 3 (3)

MAN Diesel 500.24
End cover, covering disk
Work cards
Brief description
Remove the end cover for inspection.

1 Technician 0,4
Spare parts required

1 Seal 517.030
Related work cards

500.10 500.12 500.13
500.14 500.16 500.18
500.19 500.20 500.21
500.22 500.23
2007-11-20
Work cards
NR34/S
C2 6661 500.24-02 EN 1 (2)

500.24 MAN Diesel
Preliminary remarks
Work cards
Figure 1: Removing and refitting the end cover and the covering disk
sor wheel, labyrinth disk, locating ring, locating bearing, thrust ring and tur-
bine rotor are removed.
Steps 1. Unscrew the hexagon nuts (517.032) and take off the washers (517.033).
2. Remove the turbine-side end cover (517.017) in axial direction with cov-
ering disk (517.009) bolted on and studs (517.028 and 517.029) screwed
in.
3. Unscrew the hexagon bolts (517.053) and take off lock washer pairs
(517.054) if the covering disk (517.009) has to be removed.
Slight grooves in the bore of the sealing cover, which have developed
through the tips of the labyrinth ring, increase the sealing effect and are
no reason for replacing the part.

When fitting the seal (517.030), pay attention to the flawless condition and
position of the holes.
Apply high-temperature lubricant (e.g. Molykote HSC) to the threads and
2007-11-20
screws.
Work cards

NR34/S
no locking effect.
2 (2) C2 6661 500.24-02 EN

MAN Diesel 500.25
Plain bearing
Work cards
Brief description
Remove plain bearing for inspection.

1 Technician 0,4
Related work cards

500.06 500.10 500.12
500.13 500.14 500.16
500.18 500.19 500.20
500.21 500.22 500.23
500.24
2007-11-20
Work cards
NR34/S
C2 6661 500.25-01 EN 1 (2)

500.25 MAN Diesel
Preliminary remarks
Work cards
Figure 1: Removing and refitting the plain bearing

sor wheel, labyrinth disk, locating ring, locating bearing, thrust ring, turbine
rotor and end cover are removed.
Steps 1. Place the bridge (596.076) onto the bearing casing (517.001) and screw
the hexagon bolts (596.081) into the forcing-off threads of the plain
bearing (517.003).
2. Pull off the plain bearing by uniformly turning the hexagon nuts
(596.084). Remove the bridge.
3. Check the plain bearing (517.003), refer to work card [500.06] “Checking
bearing”.

Steps Carefully insert the plain bearing (517.003) into the bearing casing, paying
attention to the position relative to the spring pin (517.014).
When replacing the plain bearing, the turbine-side end cover (517.017)
must also be exchanged if the labyrinth tips of the turbine shaft have
2007-11-20
worn in excessively, refer to work card 500.24.

Work cards
NR34/S
2 (2) C2 6661 500.25-01 EN

MAN Diesel 500.26
Turbine nozzle ring
Work cards
Brief description
Remove and refit the turbine nozzle ring for inspection.

1 Technician 0,4
Related work cards

500.10 500.12 500.13
500.14 500.16
Preliminary remarks
General The insert has to be removed only if it is to be replaced.
Starting condition Cartridge is removed.
Figure 1: Turbine nozzle ring and insert, mounted on the gas admission casing
Work sequence 1 - Removing the turbine nozzle ring
2007-11-20
Steps 1. Pull the turbine nozzle ring (513.001) axially out of the gas admission
Work cards
casing (501.001).
NR34/S
2. Check the turbine nozzle ring (513.001), refer to work card [500.04].
C2 6661 500.26-02 EN 1 (2)

500.26 MAN Diesel
Work sequence 2 - Removing the insert

Work cards
Steps 1. Pull the insert (541.001) axially out of the gas admission casing
(501.001).

For refitting, proceed in the reverse order of removal.
For checking the gaps between the insert and the turbine rotor, refer to
Operating Manual (C1), Technical details, Gaps and clearances, sheet 2.5.5.
2007-11-20
Work cards
NR34/S
2 (2) C2 6661 500.26-02 EN

MAN Diesel 500.27
Gas outlet casing
Work cards
Brief description
Replace the gas outlet casing, if necessary.

1 Technician 0,3
1 Assistant 0,3
1 Socket ring wrench 19 - Inventory
Related work cards

500.10
Technical details
Gas outlet casing 200 kg
2007-11-20
Work cards
NR34/S
C2 6661 500.27-02 EN 1 (3)

500.27 MAN Diesel
Preliminary remarks
Work cards
Figure 1: Removing and refitting the gas outlet casing

Starting condition Connecting pipes and exhaust gas pipe are disconnected, or complete tur-
bocharger is removed from engine.
Steps 1. Attach lifting tackle to the gas outlet casing (506.001) using a rope.
2. Take off the annular lagging (591.160), loosen the hexagon nuts
(506.103) and take off the lock washer pairs (506.107).
3. Pull the gas outlet casing out in axial direction, paying attention to the
casing foot (518.002).
4. Set down the gas outlet casing on a wooden support, paying attention
to the lagging.

2007-11-20
Work cards

NR34/S
Screw connections Apply high-temperature lubricant (e.g. Molykote HSC) to the thread of screw
connections but not to screw-in threads when replacing studs.
2 (3) C2 6661 500.27-02 EN

MAN Diesel 500.27
Work cards
Observe tightening torques!
▪ Apply high-temperature lubricant (e.g. Molykote HSC) to the threads
and contact surfaces.
▪ Tightening torque for hexagon nuts (506.103): 50 Nm

no locking effect.
2007-11-20
Work cards
NR34/S
C2 6661 500.27-02 EN 3 (3)

MAN Diesel
Index
1 Introduction
2 Work cards
3 Index
2008-06-23
C2 6661-5 3-5 EN 1 (1)

MAN Diesel
Index O
Index
Order Numbers 1.2 (1)
A
Air filter 500.11 (2) P
Air intake casing 500.13 (2) Plain bearing 500.06 (2)
Availability code 1.2 (2) 500.25 (2)
Bearing bush 500.06 (2)
B
Blocking device 500.05 (2) R
Required Personnel and Time 1.2 (1)
C general 1.2 (1)
Cartridge 500.16 (2)
Cleaning the compressor 500.08 (2) S
Pressure sprayer 500.08 (2) Silencer 500.12 (2)
Closing cover 500.05 (3) Speed measuring device 500.14 (5, 6)
Closing device 500.05 (2) Cable connection 500.14 (6)
Compressor casing 500.14 (3) Speed transmitter 500.14 (2)
Compressor wheel 500.18 (2, 4) Status 1.2 (2)
Covering disk 500.24 (2) Inventory 1.2 (2)
Optional 1.2 (2)
D Special 1.2 (2)
Diffuser 500.14 (3) Standard 1.2 (2)
E T
Emergency operation 500.05 (1, 2) Thrust ring 500.22 (2)
500.05 (1, 2) Tightening of screw connections 000.31 (1)
Blocking device 500.05 (2) General 000.31 (1)
Closing device 500.05 (2) Tool Number 1.2 (1)
End cover 500.24 (2) Turbine nozzle ring 500.04 (1)
500.26 (1)
F Turbine rotor 500.23 (2)
Friction coefficient µ 000.31 (1) Turbocharger 500.10 (1)
Removing and refitting 500.10 (1)
G
Gas outlet casing 500.27 (2)
I
Insert 500.14 (2)
500.26 (1)
L
Labyrinth disk 500.19 (2)
Locating bearing 500.06 (1)
500.21 (2)
Locating ring 500.20 (2)
Inspection 500.20 (2)
M
2008-06-23
Maintenance schedule 1.1 (1)
N
Numbering 1.2 (1)
Work cards 1.2 (1)
C2 6661-5 C2-5 EN 1 (1)

C2-Working Instructions

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

C2-Working Instructions

Uploaded by

Copyright:

Available Formats

MAN Diesel

Turbocharger type........... NR34/S

C2 6661-5 C2-5 EN 1 (2)

Fax +49 (0) 821 322-3382

Copyright © MAN Diesel

2 (2) C2 6661-5 C2-5 EN

C2 6661-5 C2-5 EN 1 (1)

C2 6661-5 1-5 EN 1 (1)

C2 6686 1.1-02 EN 1 (1)

Organisation and use of the work cards

C2 6686 1.2-01 EN 1 (2)

Tips and Pictographs

For notes concerning fault sources/handling errors; material damage can

The instructions “Lubricate contact surfaces and threads”, “Observe tight-

Grease, lubricate and oil Use Observe

2 (2) C2 6686 1.2-01 EN

C2 6661-5 2-5 EN 1 (1)

Screw connections and tightening torques

Tightening Torques for Bolted Connections

For particularly important screw connections on the turbocharger, the tight-

µ = 0.08 with lubricants for temperatures

Thread, nominal size

C2 6686 000.31-01 EN 1 (2)

Thread, nominal size for coefficient of friction µ

Table 2: Tightening torques for bolts, strength class 8.8

2 (2) C2 6686 000.31-01 EN

Checking the turbine nozzle ring

A Guide vane E Negative areas (on the left of D)

C2 6660 500.04-03 EN 1 (1)

Emergency operation with blocking device

Personnel and time required

Related work cards

C2 6661 500.05-01 EN 1 (3)

Figure 1: Blocking device

Danger to life from crush injuries or blows!

Danger of fire caused by lube oil!

is given when lube oil gets into the turbocharger.

2 (3) C2 6661 500.05-01 EN

C2 6661 500.05-01 EN 3 (3)

Emergency operation with closing device

Personnel and time required

Related work cards

C2 6661 500.05-02 EN 1 (3)

Figure 1: Closing device

Danger to life from crush injuries or blows!

Danger of fire caused by lube oil!

During emergency operation without rotating element, the danger of fire

is given when lube oil gets into the turbocharger.

2 (3) C2 6661 500.05-02 EN

C2 6661 500.05-02 EN 3 (3)

Checking the bearings

Related work cards

Checking the locating bearing (517.002)

Figure 1: Checking the locating bearing (517.002)

C2 6661 500.06-01 EN 1 (2)

Replace the locating bearing (517.002) if the reflecting band

width (B) ≥ 25 mm.

Figure 2: Checking the plain bearing (517.003)

2 (2) C2 6661 500.06-01 EN

Cleaning the turbine - wet cleaning

Personnel and time required

C2 6660 500.07-03 EN 1 (3)

1 Water admission (fresh water) 6 Sealing air (extracted down-

2 (3) C2 6660 500.07-03 EN