Technical Documentation (Turbocharger TCR-16)

PBS Turbo, s. r. o.
Technical Documentation
Turbocharger
Operating Instructions
Turbocharger type ............................. TCR16
Plant No. ........................................... OEM-Version

2014-09-25 - de
Translation of the original instructions

0411-1 C1-01 EN-US 1 (2)
PBS Turbo, s. r. o.
PBS Turbo, s. r. o.
595 01 Velká Bíteš
Czech Republic
Phone +420 566 822 217
2014-09-25 - de
Fax +420 566 531 925

pbst_sales@pbsturbo.eu
www.pbsturbo.cz
Copyright © 2014 PBS Turbo, s. r. o.

All rights reserved, including reprinting, copying (Xerox/microfiche) and translation.
2 (2) 0411-1 C1-01 EN-US

PBS Turbo, s. r. o.
Table of contents
Table of contents
1 Safety
1.0 Organisation and use of the safety instructions
1.1 Responsibility of the user
2 Addresses
2.1 PBS Turbo, s. r. o.
3 Technical data
3.1 Turbocharger
3.1.1 Operating data and alarm points for turbocharger on a gas-pow-
ered engine
3.1.2 Weights, dimensions and connections
3.2 Operating media/ Quality requirements
3.2.1 Fuels for the engine
3.2.2 Lube oil
3.2.3 Intake air
3.2.4 Cleaning agents for compressor and turbine
4 Description
4.1 Turbocharger
4.2 Lube oil system for turbocharger on a gas-powered engine
4.5 Cleaning system – Dry cleaning of the turbine
4.6 Cleaning system – Wet cleaning of the compressor
4.8 Water cooling - bearing casing
5 Operation
5.0 Safety during operation
5.1 Starting operation/Shutting down
5.2 Emergency operation of the engine on failure of a turbocharger
5.3 Malfunctions/faults and their causes
6 Maintenance
6.0 Safety during maintenance/repair
6.1 General remarks
2014-09-25 - de
6.2 Tools
6.3 Maintenance schedule, service life
6.3.1 Maintenance schedule - turbocharger on gas-powered engine
6.4 Remarks on maintenance work
0411-1 C1-01 EN-US 1 (3)

PBS Turbo, s. r. o.
6.5 Inspection of components

Table of contents
6.6 Inspection report

6.7 Service report
6.8 Disposal
7 Work cards
7.1 Preface
7.1.1 Organisation and use of the work cards
7.2 Setting data
7.2.1 Screw connections and tightening torques
7.2.2 Gaps and clearances
7.3 Emergency operation
500.11 Emergency operation with closing device
7.4 Cleaning
500.22 Cleaning the turbine - Dry cleaning
500.23 Cleaning the compressor - Pressure sprayer
500.24 Cleaning the air filter
7.5 Assembly and maintenance
500.31 Complete turbocharger
500.32 Chamber silencer - OPTION
500.33 Air intake casing - OPTION
500.41 Insert, compressor side
500.43 Compressor casing
500.44 Cartridge
500.45 Cartridge components - Major overhaul
500.46 Turbine nozzle ring
500.47 Gas admission casing and turbine-side insert
8 Spare parts catalogue / Tools

8.1 Preface
8.1.1 Organisation and use of the spare parts catalogue
8.1.2 Ordering spare parts
8.2 Overview of subassemblies
500 Overview of subassemblies
2014-09-25 - de
8.3 Spare parts

501.01 Gas admission casing
513.01 Turbine nozzle ring
517.01 Bearing casing
2 (3) 0411-1 C1-01 EN-US

PBS Turbo, s. r. o.
520.01 Rotor assembly, complete
Table of contents
540.01 Insert, compressor side
541.01 Insert, turbine side
541.02 Insert, turbine side with notch
542.01 Diffuser
544.02 Chamber silencer - OPTION
545.01 Air intake casing, 90° - OPTION
545.02 Air intake casing, axial - OPTION
546.01 Compressor casing
562.01 Speed measuring device – OPTION
578.02 Cleaning device for turbine - Dry cleaning
579.02 Cleaning device for compressor - Pressure sprayer
591.01 Covering on gas admission casing
599.01 Cartridge
8.4 Spare parts - sets
595.01 Spare parts for maintenance after 10,000 operating hours
595.02 Spare parts for major overhaul after 20,000 operating hours
8.5 Tools
596.01 Tools – OPTION
9 Index
2014-09-25 - de
0411-1 C1-01 EN-US 3 (3)

PBS Turbo, s. r. o.
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
2014-09-25 - de
Safety
0411-1 1 C1-01 EN-US 1 (1)

PBS Turbo, s. r. o. 1.0
Organisation and use of the safety instructions
Safety
Safety instructions
Safety instructions are always situated before the description of a task. They
are divided into 4 hazard levels. The severity of the hazard for personnel or
equipment is evaluated, as is the probability of the hazard.
Hazard level
The safety instructions for hazard levels 1 – 4 have the following designa-
tions:
▪ Danger,
▪ Warning,
▪ Caution,
▪ Caution (material damage only)
are indicated as follows:
If the corresponding precautionary measures are not taken,

there is a risk of immediate danger.
The direct result of this is:
• Death or severe (irreversible) physical injury.
If the corresponding precautionary measures are not taken,

this will result in a potentially hazardous situation.
The possible result of this is:
• Death or severe (irreversible) physical injury.
A hazardous situation can occur if the corresponding

precautionary measures are not taken.
This can result in:
• Minor (reversible) physical injury.
Material damage to the product can occur if the corresponding

precautionary measures are not taken.
2012-12-12 - de
This can result in:

• Exclusively material damage; no physical injury expected.
General
Safety
Additionally, the element Notice is also used:
C1 6673 1.0-02 EN-US 1 (4)

Identification of special user tips.

Safety
Additional or important notes and information.

No injuries or material damage expected.
A symbol appropriate to the hazard is always depicted in the marginal col-

umn. It either indicates a hazard (hazard symbol) or the corresponding pro-
tective measure (safety symbols):
Safety symbols
Wear Wear Wear Wear Wear

gloves protective gog- hearing protec- hard hat safety boots
gles tion
Wear Read
protective manual
clothing
Danger symbols
Warning of a Danger of slip- Tripping hazard Danger of elec- Corrosive

hazard location ping tric shock materials
Crush hazard Inflammable Hot Danger of sus- Rotating

materials surface pended loads gear hazard
Bans
2012-12-12 - de
Fire, No access for

open flames unauthorized
and smoking persons!
General
Safety
prohibited!
2 (4) C1 6673 1.0-02 EN-US

Safety
Safety instruction sign – engine room
Figure 1: Safety instruction sign - engine room
To point out the most important regulations, bans and hazards during
operation and maintenance, the safety instruction sign enclosed with
each turbocharger must be posted at the entry of the engine room.
2012-12-12 - de
General
Safety
C1 6673 1.0-02 EN-US 3 (4)

Persons, who for operational reasons are to be within the danger area of 2.5
Safety
m around the engine, are to be instructed of the predominant hazards.

Access to the danger area is permitted when the turbocharger is in proper
operating condition and only when wearing suitable protective equipment. It
is prohibited to stay within the danger area without reason.
2012-12-12 - de
General
Safety
4 (4) C1 6673 1.0-02 EN-US

Responsibility of the user
Safety
Personnel requirements
Safe and economical operation of the engine plant including the turbo-
charger requires comprehensive knowledge. Furthermore, it is possible to
maintain or restore the functional capability through maintenance and repair
work only if this is carried out with expertise and skill by trained personnel.
The rules of proper craftsmanship are to be observed; negligence must be
prevented.
Technical documentation
The Technical Documentation supplements this skill with specific information,
draws attention to hazards and points out the safety regulations that have to
be observed. We thus ask you to comply with the following rules:
Risk of accidents resulting from improper use of the

turbocharger!
Improper use of the turbocharger is liable to result in damage to the
turbocharger or individual components. Damaged components
represent a considerable risk of injury to the operating and
maintenance personnel.
• Before starting operation for the first time, read the available Technical
Documentation including the safety regulations contained therein.
• Use the turbocharger only for the purpose intended by the
manufacturer.
• Never remain unnecessarily in the vicinity of the turbocharger. The
presence of personnel in the vicinity of the turbocharger is permitted for
maintenance work that expressly has to be performed during operation!
• Perform the maintenance work on the turbocharger regularly and
correctly within the specified intervals!
• Use only original spare parts from the manufacturer when performing
repair and maintenance work.
The manufacturer disclaims all liability if the above-mentioned safety

regulations are infringed.
2013-02-22 - de
Safety
TCR16
C1 0288 1.1-02 EN-US 1 (3)

Safety
Intended use
The turbocharger is intended for use on diesel-fuel, heavy-fuel and gas
engines. It draws in the fresh air or air/gas mixture required for engine opera-
tion and compresses it. The exhaust gas temperature must not exceed
650°C (720°C only with special materials of turbine stage).
Any application beyond this must be discussed with and approved by the
turbocharger manufacturer. The turbocharger is not designed for operation in
an explosive atmosphere, i.e. the engine room (room with the engine and tur-
bocharger) must be continuously vented.
Each turbocharger is specially adapted to the engine on which it is to be
operated. This means the turbocharger may be operated only on this engine
or one of identical design.
The turbocharger is considered as being implemented in accordance with its
intended use only if the following conditions are additionally fulfilled:
▪ by the engine manufacturer:

The engine manufacturer must ensure that the turbocharger is connected to
a supply of lubricating oil from the engine or plant. Any connection points
located within an explosive atmosphere must be appropriately sealed.
The engine manufacturer must design the engine control system so that the
limit values of the turbocharger (max. admissible rotor speed and exhaust
gas temperature, admissible lube oil temperature and lube oil pressure,
vibrations, use of the specified operating media) are not exceeded in the
anticipated operating conditions.
▪ by the installation contractor / manufacturer of the complete plant:

The installation location must afford sufficient space for maintenance and
installation/removal of the rotor assembly. The use of lifting equipment must
be possible.
Supply, measuring, control and regulating systems must enable troublefree
operation (design in accordance with the turbocharger manufacturer’s rec-
ommendations and state of the art).
It must be possible for operation to be monitored by means of suitable
measures.
▪ by the user:
The operating parameters (max. admissible rotor speed and exhaust gas
temperature, admissible lube oil temperature and lube oil pressure, use of
the specified operating media) must be observed and may not be exceeded
(see type plate, Chapter 3.1.1).
The turbocharger may be operated only when in perfect condition.
2013-02-22 - de
Work on the turbocharger may be carried out only by trained personnel. All
work is subject to compliance with the operating instructions and the statu-
tory occupational health and safety regulations.
Malfunctions that could influence safety must be remedied before starting or
Safety
TCR16
resuming operation.
Service and maintenance work must be performed in accordance with the
maintenance schedule (see Chapter 6.3.1).
2 (3) C1 0288 1.1-02 EN-US

Corrosion must be prevented on components that come into contact with an
Safety
explosive gas mixture.
Only original spare parts and fasteners of the specified quality (bolts, nuts,
washers, seals, etc.) may be used for repairs.
Foreseeable misuse, negligence, improper use

Foreseeable misuse The following operating conditions are considered as misuse:
▪ Operation at operating values resulting in engine shutdown or load
reduction.
▪ Operation without appropriate surveillance/supervision.
▪ Operation without sufficient maintenance.
▪ Operation when supply systems have failed (e.g. lubricating oil system).
▪ Use of other than original spare parts.
▪ Operation and maintenance without the required personal protective
equipment.
▪ Long-term shut-down without taking preservation measures.
▪ Operation and maintenance by unauthorized/unqualified staff.
Gross negligence, improper The following operating conditions are considered as improper use:
use ▪ Operation outside the defined operating parameters.
▪ Operation with unauthorised modifications.
▪ Operation with defective, deactivated or modified safety equipment.
▪ Operation without a suitable fire-extinguishing system.
2013-02-22 - de
Safety
TCR16
C1 0288 1.1-02 EN-US 3 (3)

PBS Turbo, s. r. o.
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
2014-09-25 - de
Addresses
0411-1 2 C1-01 EN-US 1 (1)

PBS Turbo, s. r. o.
Addresses
Address turbocharger manufacturer
Contact persons
Velká Bíteš Plant Telephone/Fax/e-mail/Internet
PBS Turbo, s. r. o. Tel. +420 566 822 284
Vlkovská 279 Fax +420 566 531 925
595 01 Velká Bíteš e-mail pbst_sales@pbsturbo.eu
Czech Republic Internet http://www.pbsturbo.cz
Address service
Contact persons
Velká Bíteš Plant Telephone/Fax/e-mail/Internet
PBS Turbo, s. r. o. Tel. +420 566 822 217
Vlkovská 279 Fax +420 566 531 925
595 01 Velká Bíteš e-mail pbst_sales@pbsturbo.eu
Czech Republic Internet http://www.pbsturbo.cz
You can find a list of authorized service centres worldwide on our website:
http://www.pbsturbo.cz, under “Service Centres” on the “Services” tab.
2013-11-13 - de
Addresses
TCR16
C1 0288 2.1-02 EN-US 1 (1)

PBS Turbo, s. r. o.
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
Technical data
2014-09-25 - de
0411-1 3 C1-01 EN-US 1 (1)

Turbocharger
3.1 Turbocharger
Technical data
2014-09-25 - de
0411-1 3.1-01 EN-US 1 (1)

PBS Turbo, s. r. o. 3.1.1
Operating data and alarm points for turbocharger on a gas-powered engine
Turbocharger
Turbocharger type plate
1 Turbocharger type 8 Max. permissible turbine inlet

temperature, short-term 2)
2 Year of manufacture 9 Exchange interval for plain bear-
ing 3)
3 Works number (serial number) 10 Exchange interval for compres-
sor wheel 3)
4 Part number 11 Exchange interval for shaft with
turbine wheel 3)
5 Max. permissible rotor speed, 12 Exchange interval for gas admis-
long-term sion casing 3)
6 Max. permissible rotor speed, 13 Weight
short-term 1)
7 Max. permissible turbine inlet 14 DATA MATRIX CODE
temperature, long-term
Figure 1: Type plate

1)
Maximum rotor speed that can be reached for a short time only, i.e. a total of several operating hours (approx.
10 operating hours) over the turbocharger service life, in the event of engine overload tests, for safety reasons,
for adjusting the engine control system, etc. The turbocharger speed is affected by the operating conditions
(temperature of the intake air, altitude above sea level, engine load, fouling of turbine nozzle ring and diffuser)
and influences in turn the charge pressure.
2)
Maximum exhaust gas temperature at the turbine inlet at reduced turbocharger load (e.g. in idle mode, before
shut-down of the gas-powered engine, in catalyst regeneration, etc.). The total working time should not
exceed 100 hours in the course of the turbocharger service life.
3)
Time specification in 1000 hours. In the absence of a time specification, 60,000 hours shall apply.
The type plate is attached to the delivery socket of the compressor

casing.
Technical data
2013-11-14 - de
TCR16
C1 0411 3.1.1-01 EN-US 1 (3)

3.1.1 PBS Turbo, s. r. o.
Reference value for pressures in bar

Turbocharger
All pressures specified in bar in this operating manual are relative

pressures.
Conformity with EU directives

Conformity with EU The declaration of conformity with European Directive No. 2006/42/EC for
directives the TCR turbochargers was issued on 30 November 2010.
Operating parameters
Speed Operating limit nmax See
type plate
Speed indicator Indication range 0 to 49,100 rpm
Exhaust gas temperature upstream of Operating limit tmax See
turbine type plate
Lube oil temperature Inlet temperature at full engine load < 100 °C
Lube oil pressure in bearing casing In normal operation and at full engine load 1.9 – 2.3 bar g
(reference height: turbocharger centre-
line)
Lube oil flow rate Info value: 1.7 m3/h
Further specifications See also Lube oil system, chapter[4.2]
Table 1: Operating parameters for TCR16 on a gas-powered engine
Lube oil pressure immediately after start-up

At low lube oil temperature (after start-up), the lube oil pressure may
briefly exceed the defined operating limits. By the time the operating
temperature has been reached, the lube oil pressure must have
dropped to within the defined range.
Alarm points
An alarm must be triggered by the engine control system when the following
operating data are exceeded:
Lube oil pressure Alarm at < 1.6 bar g
(reference height: turbocharger centre-
Technical data
2013-11-14 - de
line) Reduction to engine half load (slow-down) < 1.4 bar g

Engine shut-down < 1.2 bar g
Speed Alarm at 97% nmax
TCR16
Exhaust gas temperature upstream of Alarm at tmax See

turbine [3.1.1]
Table 2: Alarm points
2 (3) C1 0411 3.1.1-01 EN-US

When the limit values are reached, the alarm must be triggered and the
Turbocharger
engine control must react at the same time (without delay) in order to
avoid damage to the turbocharger.
Lube oil requirements

Selection of lube oil SAE class SAE 30 or SAE 40
Lube oil filtration Grade of filtration less than 0.03 mm
Table 3: Lube oil requirements
Technical data
2013-11-14 - de
TCR16
C1 0411 3.1.1-01 EN-US 3 (3)

Weights, dimensions and connections
Turbocharger
Weights
Subassembly Designation Optional Weight
500.000 Turbocharger, complete, with chamber silencer 258.3 kg
500.000 Turbocharger, complete, with air intake casing 90° 227.3 kg
500.000 Turbocharger, complete, with air intake casing axial 216.3 kg
501.000 Gas admission casing 51 kg
513.001 Turbine nozzle ring 3 kg
517.000 Bearing casing 51 kg
520.000 Rotor, complete 14 kg
540.000 Insert, compressor side 12 kg
541.000 Insert, turbine side 12 kg
542.001 Diffuser 3 kg
544.000 Chamber silencer X 51 kg
545.000 Air intake casing 90° X 20 kg
(545.01)
545.000 Air intake casing axial X 9 kg
(545.02)
546.000 Compressor casing 48 kg
562.000 Speed measuring device X 0.3 kg
591.1000 Covering on gas admission casing 13 kg
599.000 Cartridge (517 + 520) 65 kg
Table 1: TCR16 subassemblies and weights (approximate values)
Technical data
2013-11-13 - de
TCR16
C1 0411 3.1.2-01 EN-US 1 (2)

Turbocharger
Dimensions
Figure 1: Main dimensions (in mm)
Connections
Exhaust gas Entry at the gas admission casing (501.01) ∅ 125 mm
Outlet at the gas outlet casing (506.01) ∅ 202 mm

Charge air Entry at the silencer (544.01 optional) ∅ 615 × 242 mm
at the air intake casing (545.01/545.02 optional) ∅ 174 mm
Outlet at the compressor casing (546.01) ∅ 143 mm
Lube oil Inlet at the bearing casing (517.01) ∅ 15 mm
Drain at the bearing casing (517.01) ∅ 37 mm

Table 2: Connections for TCR16 on a gas-powered engine
Technical data
2013-11-13 - de
Different versions of the casing can be installed, depending on the engine

type.
For further details, see drawing: Turbocharger connection dimensions.
TCR16
2 (2) C1 0411 3.1.2-01 EN-US

Operating media/ Quality requirements

3.1 Turbocharger
Technical data
2014-09-25 - de
0411-1 3.2-01 EN-US 1 (1)

Fuels for the engine

Fuel for the gas-powered engine
Quality Requirements on Gas The design of the turbocharger allows operation on gas-powered engines.
Two mixing systems are possible:
▪ in the cylinder or
▪ before the compressor, but only with an aluminium compressor wheel.
Usually, gases with a methane number higher than 70 are used to protect
against misfiring or knocking. If a methane content of less than 92 is used, or
if the gas contains aggressive components, such as S, Cl, F, Ca or Si, use of
the turbocharger must be cleared with the manufacturer of the turbocharger.
In such cases, the maintenance intervals must be modified.
Maintenance intervals
Some components of the gaseous fuel can dramatically reduce the
service life of the turbocharger. Shorter maintenance intervals are
required in such cases.
Applied gas fuel

If the gas fuel is not methane-based, the turbocharger manufacturer
must be informed. The operational reliability of the turbocharger may
be impaired.
Fuels for the engine

Engine fuel influences The quality of the fuel used to operate the engine influences the composition
exhaust gas quality of the exhaust gas flowing through the turbocharger. Contaminants in the
fuel may leave residues in the exhaust gas that could have an abrasive or
corrosive effect on the turbocharger.
Quality requirements on MDO is also referred to as diesel fuel oil, diesel oil, bunker diesel oil or marine
marine diesel oil (MDO) diesel fuel.
MDO is offered as a heavy distillate (ISO-F-DMB) or, exclusively for the ship-
ping industry, as a mixture of distillate and small quantities of residual oil
(ISO-F-DMC). The usual designation for the mixture, which is dark brown to
black in color, is “blended MDO”. MDO is manufactured from crude oil and
must be free from organic acids.
The usability of the fuel depends on the design of the engine and cleaning
Technical data
2012-01-05 - de
device, and on compliance with the characteristic values specified below

which refer to the state at the time of supply.
The definitions of the characteristic values are based on the specifications of
ISO 8217‑1996 and CIMAC‑2003. The characteristic values refer to the
TCR16
specified test methods.
C1 0548 3.2.1-01 EN-US 1 (5)

Characteristics/properties Unit Test method Characteristic value

ISO-F specification DMB DMC

Density at 15 °C kg/m 3
ISO 3675 900 920
Kinematic viscosity at 40 °C mm2/s = cSt ISO 3104 < 11 < 14
Pour point Winter quality °C ISO 3016 <0 <0
Summer quality °C ISO 3016 <6 <6
Flash point Pensky Martens °C ISO 2719 > 60 > 60
Total sediment content Weight by % ISO CD 10307 0.10 0.10
Water content Vol. % ISO 3733 < 0.3 < 0.3
Sulfur content Weight by % ISO 8754 < 2.0 < 2.0
Ash content Weight by % ISO 6245 < 0.01 < 0.03
Carbon residue (MCR) Weight by % ISO CD 10370 > 0.3 < 2.5
Cetane number – ISO 5165 > 35 > 35
Copper strip test – ISO 2160 <1 <1
Vanadium content mg/kg DIN 51790 T2 0 < 100
Aluminum and silicon content mg/kg ISO CD 10478 0 < 25
Visual inspection – * –
Other specifications:
British Standard BS MA 100-1987 Class M2 Class M3
ASTM D 975 2D 4D
ASTM D 396 No. 2 No. 4
* In well-lit conditions at room temperature the fuel should appear clear and transparent.
Table 1: Marine diesel oil (MDO) – characteristic values to be adhered to
Mixing fuels can lead to a reduction of quality. This can result in

combustion with a high degree of residuals, which can cause heavy
contamination of the turbocharger. Extreme contamination can
damage the turbocharger.
Therefore the following points are to be observed:
▪ MDO is handled at transshipment facilities and during transportation as

residual oil. It is thus possible for it to become mixed, for example, with
highly viscous fuel oil or interfuel remaining in the bunker boat, resulting
in serious deterioration of the quality.
▪ Different deliveries (bunkers) of blended MDO (ISO‑F DMC) may be
incompatible and should thus not be mixed. The fuel storage tank in
Technical data
question should therefore be emptied as far as possible before it is refil-

2012-01-05 - de
led with a new delivery.

TCR16
2 (5) C1 0548 3.2.1-01 EN-US

Ocean water in the fuel aides corrosion in the turbocharger and leads

to high-residual combustion. Solid foreign matter increases the
mechanical wear in the nozzle ring and the turbine of the turbocharger.
Therefore the following is to be observed:
▪ If primarily blended MDO (ISO‑F DMC) is used, we recommend using a

centrifugal separator upstream of the fuel filter. This largely eliminates
solid particles (sand, rust, catalyst residues (catalyst fines)) and water,
thus improving the cleaning intervals of the filter inserts.
Operating data:
▪ Separator admission 65% relative to the nominal throughput capacity,
▪ Separating temperature 40 — 50 °C.
Quality requirements on Our turbochargers can be operated with engines that run on a crude oil basis
heavy fuel oil (HFO) if the engines and treatment system are designed accordingly.
The fuels used must correspond to the fuel specifications in the table “Fuel
specifications and corresponding characteristic values”.
The limit values to be complied with are specified in the table “Fuel specifica-
tions and corresponding characteristic values”. The limit values that influence
engine operation must be specified when ordering fuel, e.g. in the bunker or
charter clause.
Adding motor oil (waste oil), mineral-oil-foreign materials (e. g. coal oil)
and remainders from refining or other processes (e. g. solvent) is
prohibited! This ban is specifically to be pointed out in the fuel order,
as it is not yet part of the standard fuel specifications.
Such mixtures result in high-residue combustion and increased wear and

corrosion to turbocharger components. Particularly critical is the addition of
engine oil (used oil), as the lube oil additives have an emulsifying effect and
keep dirt, water and abraded catalyst particles in suspension. This inhibits or
prevents the necessary cleaning of the fuel.
The heavy fuel oils ISO F-RMK 35/45/55, with a maximum density of
1010 kg/m3, can be used only when respectively modern separators
are available.
Technical data
2012-01-05 - de
Fuel specification
TCR16
CIMAC 2003 A10 B/C10 D15 E/F25 G/H35 H45 H55

BS MA-100 M4 M5 M7 8/9 M8/ – M9/ –
C1 0548 3.2.1-01 EN-US 3 (5)

ISO F-RM A10 B/C10 D15 E/F25 G/H35 H45 H55

System-relevant characteristic values

Viscosity (at 50 °C) mm2/s (cSt) max. 40 40 80 180 380 500 700
Viscosity (at 100 ℃) mm2/s (cSt) max. 10 10 15 25 35 45 55
Density (at 15 ℃) g/ml max. 0.975 0.981 0.985 0.991
Flash point °C min. 60
Pour point (summer) °C max. 6 24 30 30
Pour point (winter) °C min. 0 24 30 30
Engine-relevant characteristic values
Carbon residue (Conradson) Weight by % max. 10 10/14 14 15/20 18/22 22 22
Sulfur Weight by % max. 3.5 3.5 4 5 5
Ash Weight by % max. 0.10 0.15 0.20
Vanadium mg/kg max. 150 150/30 350 200/50 300/60 600
0 0 0
Water Vol. % max. 0.5 0.5 0.8 1 1 1 1
Sediment (potential) Weight by % max. 0.1
Additional characteristic values
Aluminum + silicon mg/kg max. 80
Asphalts Weight by % max. 2/3 of the carbon residue (Conradson)
Sodium mg/kg Sodium < 1/3 vanadium, sodium < 100
Cetane number of the low-viscosity component of the mixture: min. 35
Fuel free from non-mineral-oil admixtures, such as coal oil or vegetable oil.
Free from creosote and lube oil (used oil)
Table 2: Fuel specifications and corresponding characteristic values (HFO)
Thorough processing of heavy fuel oil is required for trouble-

free engine operation.
The following points are to be observed for this:
▪ Highly abrasive, inorganic, solid impurities (catalyst fines, rust, sand) must
be eliminated as far as possible.
▪ In the case of an aluminum content >10 mg/kg, abrasive wear to the tur-
bocharger increases greatly.
▪ Only use separators of the new generation that are fully effective over a
wide density range without the need for switching and which eliminate
Technical data
2012-01-05 - de
water up to a heavy fuel oil density of 1.01 g/ml at 15 °C. The cleaning
effect is monitored by the separator itself.
▪ Heavy fuel oil cleaning must be so designed that the characteristic values
specified in the table “Achievable impurity and water content after sepa-
TCR16
ration” are achieved:
4 (5) C1 0548 3.2.1-01 EN-US

Characteristic value Particle size Quantity

Inorganic, solid impurities < 5 µm < 20 mg/kg
(including catalyst fines) (AlSi content < 15 mg/kg)
Water – < 0.2 vol. %
Table 3: Achievable impurity and water content after separation
▪ In the case of an unfavorable vanadium-sodium ratio, the melting point of
the heavy fuel oil ash sinks to the exhaust valve temperature range, caus-
ing hot corrosion. Pre-cleaning of the heavy fuel oil in the settling tank
and in the centrifugal separators can largely eliminate the water and thus
also water-soluble sodium compounds.
In the case of a sodium content greater than 100 mg/kg, increasing salt
deposits in the turbine are to be expected. This jeopardizes turbocharger
operation (e.g. due to turbocharger surging). If PTG is used, the sodium
content must be limited to 50 mg/kg.
Under certain circumstances, hot corrosion can be prevented by means
of a fuel additive that raises the melting point of the heavy fuel oil ash.
▪ Heavy fuel oils with a high ash content in the form of solid impurities,
such as sand, rust and catalyst fines, encourage mechanical wear in the
turbocharger. Heavy fuel oils from catalytic cracking systems may con-
tain catalyst fines. This is generally aluminum silicate that causes high
levels of wear in the turbocharger. The detected aluminum content multi-
plied by 5 — 8 (depending on the composition of the catalyst) gives the
approximate content of the catalyst material in the heavy fuel oil.
Technical data
2012-01-05 - de
TCR16
C1 0548 3.2.1-01 EN-US 5 (5)

Lube oil

Lube oil
Base oil The base oil must comply with the following limit values, especially with
regard to the aging resistance:
Characteristics/properties Unit Test method Characteristic value
Structure – – preferably paraffin-based
Low-temperature behaviour, still fluid °C ASTM D2500 -15
Cleveland flash point °C ASTM D92 >200
Ash content (oxide ash) % by ASTM D482 <0,02
weight
Conradson carbon residue % by ASTM D189 <0,50
weight
Aging tendency after 100 h heating to – Turbocharger manufac- –
135 °C turer’s aging cabinet
n-heptane insolubles % by ASTM D4055 or <0,2
weight DIN 51592
Evaporation loss % by – <2
weight
Drop test (filter paper) – Test by turbocharger There must be no indication that resin-
manufacturer ous or asphaltic aging products are
released.
Table 1: Lube oil – characteristic values to be met
Additives Additives must be dissolved in oil and designed to generate as little ash as
possible on combustion. The ash must exhibit a soft structure. If this require-
ment is not met, increased residues are liable to form in the bearing casing of
the turbocharger. Hard additive ash promotes increased mechanical wear.
Neither when active nor when consumed may additives intensify clogging of
the filter inserts.
Viscosity To ensure proper functioning of the turbocharger, a kinematic oil viscosity of
12 – 150 mm2s-1 must be ensured. The correct oil type must be selected in
accordance with the instructions of the engine manufacturer and, if neces-
sary, the oil manufacturer. The specified requirements are most frequently
met by oils of grade SAE 30 or SAE 40.
Lube oil additives We strongly advise against subsequently admixing additives in the lube oil or
mixing different brands of lube oil, as this is liable to destroy the function of
the active agent package matched to itself and the base oil. It would also
exempt the supplier from his responsibility for the lube oil.
Technical data
2012-09-20 - de
TCR16
C1 0548 3.2.2-01 EN-US 1 (1)

Intake air

Intake air
The quality and condition of the intake air have a decisive influence on the
turbocharger performance. Not only is the atmospheric condition of great
importance but also the solid and gaseous impurities contained in the air.
Mineral dust particles in the intake air have the effect of increasing wear.
Chemical/gaseous constituents on the other hand promote corrosion.
For this reason, effective cleaning of the intake air and regular maintenance/
cleaning of the air filter mat on the silencer are required.
Characteristic values of the The intake air (combustion air) must always be cleaned with a class G3 filter
intake air (in accordance with EN 779), even if there is no silencer installed on the tur-
bocharger.
The following maximum concentrations of particles in the intake air upstream
of the compressor must not be exceeded:
Characteristics/properties Concentration Unit1)
Dust (sand, cement, CaO, Al2O3 etc.) max. 5
Chlorine max. 1.5

mg/m3 (SPC)
Sulphur dioxide (SO2) max. 1.25
Hydrogen sulphide (H2S) max. 15
Salt (NaCl) max. 1

Table 1: Maximum concentration of particles in the intake air
1)
m3 (SPC) = cubic metre at standard temperature and standard pressure
When designing the intake air system, it must be ensured that the total pres-
sure loss (filter, silencer, piping) does not exceed 20 mbar.
Technical data
2012-08-30 - de
General
C1 6673 3.2.3-01 EN-US 1 (1)

Cleaning agents for compressor and turbine

Wet cleaning of the compressor
Use freshwater only.

Salt water causes corrosion on the turbocharger components.
Wet cleaning Only fresh water without chemical additives may be used for wet cleaning of
the compressor during operation.
Dry cleaning of the turbine

Dry cleaning Commercially available granulates that meet the following specifications are
used for dry cleaning of the turbine during operation:
Granulate made of:
▪ Nut shells
▪ Activated charcoal (soft).
Grain size:
▪ 1.0 mm (max. 1.5 mm).
Store and mark granulates in such a manner that they can not be
mistaken for other materials (salt, sand, etc.).
Technical data
2010-11-26 - de
TCR16
C1 0411 3.2.4-01 EN-US 1 (1)

PBS Turbo, s. r. o.
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
2014-09-25 - de
Description
0411-1 4 C1-01 EN-US 1 (1)

Turbocharger
Description
Subassemblies
501.000 Gas admission casing 544.000 Silencer

513.001 Turbine nozzle ring 545.000 Air intake casing
2012-12-14 - de
517.000 Bearing casing 546.000 Compressor casing

520.000 Rotor, complete 562.000 Speed measuring device
Description
540.000 Insert, compressor side 591.1000 Covering

541.000 Insert, turbine side 599.000 Cartridge
542.001 Diffuser
TCR16
Figure 1: TCR16 turbocharger
C1 0411 4.1-01 EN-US 1 (3)

Turbochargers of the TCR series consist mainly of a radial turbine stage and
Description
a radial compressor stage, which are seated on the same turbine shaft. The
exhaust gases of the engine drive the turbine. The compressor draws in fresh
air and compresses it. The compressed fresh air is then forced into the cylin-
ders of the engine.
The turbocharger consists of the following main subassemblies:
▪ Gas admission casing (501.000):
The gas admission casing houses the turbine nozzle ring (513.001) and
the insert (541.000). These components enable optimum adaptation of
the turbocharger to the engine.
▪ Bearing casing (517.000):
The interior bearing of the rotor primarily consists of two bearing bushes
and a thrust bearing, installed in two bearing bodies. The highly stressed
bearing points are lubricated and cooled by means of the turbocharger
lube oil system, which is integrated into the bearing casing. The turbo-
charger lube oil system is supplied with oil from the engine lube oil sys-
tem.
▪ Rotor, complete (520.000):
The turbine wheel and turbine shaft are firmly connected to each other as
the turbine rotor. The compressor wheel is mounted on the turbine rotor
and can be removed.
▪ Silencer (544.000) or air intake casing (545.000):
Choice is optional; generally, silencers are used for marine systems and
air intake casings for stationary systems (power plants).
▪ Compressor casing (546.000):
The compressor casing houses the insert (540.000) and the dif-
fuser (542.001). These components enable optimum adaptation of the
turbocharger to the engine. The insert additionally fulfils a burst protec-
tion function.
The compressor casing is equipped with an outlet socket. A flange for
connecting the optional acceleration system (Jet Assist) is provided on
the side of the compressor casing.
IRC (internal recirculation) is also installed in the admission area of the
compressor casing.
Functional Description
The engine exhaust gases flow through the gas admission casing (501.000)
and the turbine nozzle ring (513.001), and run radially onto the turbine wheel
of the rotor (520.000). The exhaust gases drive the turbine wheel; in this
process, the energy contained in the exhaust gas is transformed into
mechanical rotation energy at the turbine wheel. As the turbine wheel and
the compressor wheel are seated on the same shaft, the compressor wheel
is driven at the same time. The exhaust gas exits the turbocharger through
the integrated gas outlet diffuser and the gas outlet casing (506.000).
The compressor wheel draws in fresh air through the silencer (544.000) or
2012-12-14 - de
the air intake casing (545.000) and the insert (540.000). The fresh air is com-
Description
pressed in the compressor wheel, diffuser (542.001) and compressor cas-

ing (546.000). The compressed fresh air is forced into the cylinders of the
engine via the charge air cooler and charge air pipe.
TCR16
2 (3) C1 0411 4.1-01 EN-US

The rotor (520.000) of the turbocharger is guided in radial direction by two
Description
bearing bushes situated in the bearing casing (517.000) between the turbine
wheel and the compressor wheel. The thrust bearing arranged centrally in
the bearing casing not only performs the function of axial guidance, but also
transfers the thrust in axial direction.
The highly stressed bearing points are lubricated and cooled by means of the
turbocharger lube oil system, which is integrated into the bearing casing. The
turbocharger lube oil system is supplied with oil from the engine lube oil sys-
tem.
2012-12-14 - de
Description
TCR16
C1 0411 4.1-01 EN-US 3 (3)

Lube oil system for turbocharger on a gas-powered engine
Description
Lube oil diagram
1 Lube oil feed with check valve 7 Pressure gauge

2 Orifice* 8 Pressure controller
3 Ring duct * 9 Lube oil drain
4 Bearing casing * 10 Oil spray cooling*
5 Thrust bearing * 11 Bracket (engine)
6 Bearing bushes * * Scope of supply of turbocharger
Figure 1: Lube oil diagram, TCR turbocharger
Functional description
Lube oil circuit The highly stressed bearing points in the turbocharger are lubricated and
cooled by means of a lube oil system integrated into the bearing casing of
the turbocharger.
The lubricating oil is fed from the lube oil system of the engine to the lube oil
system of the turbocharger via the lube oil feed pipe (1).
The lube oil flows to the radial and axial lubrication gaps of the turbocharger
via the ring duct (3) and various bores.
On top of the bearing casing (4) is a connection for a pressure gauge (7)
and/or a pressure controller (8) for checking/monitoring the lube oil pressure.
The lube oil flows back into the lube oil system of the engine via the lube oil
drain (9).
2013-11-13 - de
The pipe for the lube oil outlet must be installed with a sufficient
gradient and diameter to ensure drainage of the lube oil at all times
Description
without any back pressure.

TCR16
C1 0411 4.2-01 EN-US 1 (4)

Danger of fire caused by escaping lube oil!

Description
Back pressure in the lube oil outlet can result in an oil flood in the
turbocharger. In the worst case, the oil can then escape on the turbine
side and cause a fire in the exhaust gas pipe.
The lube oil drain must therefore be installed with an inclination, which is cal-
culated as follows:
Inclination α > max. possible system inclination + 5°.
Venting The oil drain must have a venting facility from a sufficiently large compart-
ment permitting the oil to settle down, e.g. a venting box. The cross section
of the venting pipe should be approximately that of the oil drain pipe.
Priming
Prior to engine start-up, the bearings of the turbocharger must be pre-lubri-
cated. Depending on the engine system, this may take the form of pre-lubri-
cation immediately before start-up, or continuous pre-lubrication. The follow-
ing values are to be observed in this connection:
Pre-lubrication before start-up:
▪ Oil pressure 0.6 – 2.2 bar g, duration 2 - 5 minutes.
Continuous pre-lubrication:
▪ Oil pressure 0.3 – 0.6 bar g
The oil pressure must rise continuously immediately after the engine is
started. If this is not the case, the manufacturer of the turbocharger must be
consulted.
Danger of fire caused by lube oil!

Continuous priming is only possible if there is no chimney draught
effect. A chimney draught can cause lube oil to be drawn into exhaust
gas ducts, leading to coking or fire.
Operational lubrication
2013-11-13 - de
Lube oil quality Commercial engine lubricating oils SAE 30 or SAE 40.
Description
High-alkaline cylinder oils are not suitable. See chapter 3.2.2.

TCR16
Lube oil filtration The turbocharger does not require its own lube oil filter.
2 (4) C1 0411 4.2-01 EN-US

Filtration and conditioning of the lube oil is sufficient when the following val-
Description
ues are observed:
▪ Lube oil filter < 0.030 mm,
▪ Water content < 0.2% by weight,
▪ No solid residues > 0.02 mm.
Lube oil temperature Inlet temperature into the turbocharger: max. 100 °C at full engine load.
In order for the bearings to function reliably, a lube oil inlet viscosity of 12 –
150 mm2.s-1 is required.
Lube oil pressure!

Inadequate lube oil pressure will cause bearing damage.
• The lube oil pressure must be set prior to initial start-up.
• The lube oil pressure must be checked and/or monitored via the
measuring connection (7, 8) at the top of the bearing casing.
Lube oil pressure Lube oil pressure at full engine load and with lube oil at operating tempera-
ture:
Pmin = 1.9 bar g
Pmax = 2.3 bar g
Limit values for monitoring of the lube oil pressure:
▪ < 1.6 bar g - Alarm
▪ < 1.4 bar g - Engine power at half load and
▪ < 1.2 bar g – Engine shut-down
Lube oil pressure immediately after start-up

At low lube oil temperature (after start-up), the lube oil pressure may
briefly exceed the defined operating limits. By the time the operating
temperature has been reached, the lube oil pressure must have
dropped to within the defined range.
When the lower limit values are reached, the alarm must be triggered
and the engine control must react at the same time (without delay) in
order to avoid damage to the turbocharger.
2013-11-13 - de
Lube oil flow rate The lube oil flow rate depends on:
Description
▪ the viscosity (SAE class) and temperature of the lube oil,

▪ the lubrication gaps of the turbocharger.
TCR16
For flow rate values, see Operating parameters, chapter “Operating data and
alarm points”.
C1 0411 4.2-01 EN-US 3 (4)

Description
Post lubrication
After an engine shut-down, the bearing points of the turbocharger must be
post lubricated for 20 – 30 minutes at a lube oil pressure of 0.3 – 0.6 bar (ref-
erence height: turbocharger centreline) for cooling purposes. This is done
either by means of the engine lube oil pumps or using a separate auxiliary
lube oil pump.
If continuous priming is specified for engines (e.g. because of stand-by

starting), post lubrication is not required.
In this case, the continuous priming must be activated as soon as the
engine lube oil pumps are switched off.
Cooling the bearings

In the case of turbochargers with water-cooled bearing casings (on turbine
side), it is possible to leave the water circulation running for an additional 10 –
15 minutes to cool the bearings.
In this case, the water cooling is sufficient for cooling the bearings and post
lubrication can be omitted.
2013-11-13 - de
Description
TCR16
4 (4) C1 0411 4.2-01 EN-US

Cleaning system – Dry cleaning of the turbine
Description
Diagram, dry cleaning of the turbine
1 Tank 8 Turbine wheel

2 Screw plug 9 Compressed air pipe
3 Pipe 10 Sealing air
(extracted downstream of
charge air cooler)
4 Connection point 11 Plate with cleaning instructions
5 Exhaust gas pipe upstream of A Stop cock
turbine
6 Gas admission casing B Three-way cock with
sealing air connection
7 Turbine nozzle ring
Figure 1: Diagram, dry cleaning of the turbine
Operating conditions
Dry cleaning is performed at normal operating load of the engine. The engine
load need not be reduced. Do not perform dry cleaning with the power tur-
bine at a standstill!
Use only commercially available granulates from nut shells or activated char-
coal (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.
At high operating temperatures, water can cause a thermal shock and
possibly destroy turbine components.
2013-02-21 - de
Description
TCR
C1 0288 4.5-02 EN-US 1 (2)

Description
The granulate from the tank (1) is blown in through the connecting pipe (4)
with compressed air. The flow of exhaust gas in the gas admission housing
transports the granulate and distributes it over the turbine nozzle ring and
turbine wheel. Fouling and deposits are removed from the blades of the tur-
bine nozzle ring and turbine wheel by the impact of the granulate particles.
The loosened dirt and the granulate are carried out by the exhaust gas flow
through the gas outlet casing/elbow.
The sealing air (10) prevents clogging of the piping. For this purpose, a small
amount of air is extracted downstream of the charge air cooler and fed con-
tinuously through the corresponding piping system.
Cleaning the turbine with granulates on ship systems can lead to

downfall on deck.
Maintenance interval, see Maintenance Schedule.
2013-02-21 - de
Description
TCR
2 (2) C1 0288 4.5-02 EN-US

Cleaning system – Wet cleaning of the compressor
Description
General
With the small dimensions of the TCR turbochargers, dirt deposits on the
compressor wheel and diffuser blades can lead to a measurable decrease in
efficiency. A wet cleaning facility with pressure sprayer is available for clean-
ing the compressor during operation.
Wet cleaning system for the compressor with pressure sprayer
1 Handle 5 Coupling
2 Pressure sprayer 6 Hand valve
3 Relief valve 7 Turbocharger (compressor)
4 Nipple 8 Plate with cleaning instructions
Figure 1: Diagram, wet cleaning of the compressor with pressure sprayer
Operating conditions
Cleaning of the compressor during operation is required at regular intervals in
accordance with the maintenance schedule.
The cleaning intervals depend on the degree of contamination of the intake
air and range from 100 to 200 operating hours.
For cleaning, use only fresh water without any additives.
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
2010-10-13 - de
to run it for several minutes until dry.

Description
TCR
C1 0288 4.6-02 EN-US 1 (2)

Description
The pressure sprayer (2) is filled with fresh water. Pumping with the han-
dle (1) generates an overpressure in the water tank of the pressure
sprayer (2). By pressing the pushbutton on the hand valve (6), water is
sprayed into the compressor (7) by the pressure sprayer (2). Due to the high
speed of the rotor, the injected water droplets hit the blades of the compres-
sor wheel and the diffuser at high velocity, thus removing the dirt deposits
mechanically.
Maintenance interval, see Maintenance Schedule.
2010-10-13 - de
Description
TCR
2 (2) C1 0288 4.6-02 EN-US

Water cooling - bearing casing
Description
General
1 Bearing casing 3 Cooling water outlet

2 Cooling water inlet 4 Venting
Figure 1: Diagram, water cooling - bearing casing
Operating conditions Water cooling of the bearing casing is recommended in the case of:
▪ an exhaust gas temperature upstream of turbine tT > 600 °C or
▪ a large number of load cycles of the engine
Only fresh water from the cooling system of the engine may be used for cool-
ing.
Operating parameters
Cooling water pressure (inlet) ........................................ max. 6 bar g
Pressure loss (informative) ............................ (pout - pin) = 0,017 bar g
Cooling water inlet temperature ....................... tw,in < ( tw,boiling - 20) °C
Heat increase of cooling water .............................. (tw,out – tw,in) < 8°C
Cooling water flow rate (informative) .................................. 1,3 m3.h-1
2012-12-14 - de
Description
TCR16
C1 0411 4.8-01 EN-US 1 (1)

PBS Turbo, s. r. o.
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
2014-09-25 - de
Operation
0411-1 5 C1-01 EN-US 1 (1)

Safety during operation
Operation
Safety during operation on the gas-powered engine
The turbocharger serves to compress the air and the gas mixture.
The turbocharger must not be used in an explosive environment
(see EN 60079-10-1, EN 1127-1).
The following ground rules must be observed at all times to ensure safe
operation:
▪ Seal all connections using only original seals, original bolts and original
clamping claws.
▪ Electrical conductivity between the turbocharger and the engine must be
ensured.
▪ The connecting elements of the turbocharger casings must correspond
to the specifications of the turbocharger manufacturer.
▪ No corrosion on the compressor casing.
▪ The oil drain pipe must be connected to a tank or the crankcase that is
permanently vented.
▪ Carefully check all gaps after a repair, maintenance or major overhaul.
▪ Compressor casing, bolts and clamping claws must be exchanged if
there has been an explosion in the turbocharging tract.
▪ Exceeding the turbocharger limit values (speed, temperatures, vibrations)
can lead to serious damage.
▪ The use of non-authorised spare parts can cause damage and a danger
to life.
▪ Failure to comply with the maintenance intervals can result in extensive
damage to the turbocharger and in a danger to life.
▪ Even if all protective measures are observed, a slight leakage of air and
gas occurs via the seals (approx. 9 dm3.h-1); adequate ventilation must
therefore be ensured.
Danger of fire caused by electrostatic charging

In the case of turbochargers on gas-powered engines, insulated
mounting can cause electrostatic charging, resulting in ignition of the
air/gas mixture in the air intake.
If the turbocharger is mounted on the engine in such a way that it is
electrically insulated, an earth connection must be installed for the
equipotential bonding between the turbocharger and the engine.
Containment safety
The turbocharger is one of the most highly loaded components on state-of-
2014-09-23 - de
the-art diesel engines. The high rotor speeds of a turbocharger result in high
centrifugal force stresses at the same time as high component temperatures.
If exceptional influences are additionally experienced, it is possible - in very
Operation
rare cases - for component failure to occur.

TCR16
C1 0411 5.0-01 EN-US 1 (5)

Precautions The turbochargers comply with the containment safety requirements accord-
Operation
ing to the rules of the classification societies and Directive 2006/42/EC with
the effect that fragments are prevented from escaping by state-of-the-art
measures.
In extreme cases, however, particularly if the turbocharger has not been suffi-
ciently or properly maintained, there may be a risk of personal injury or mate-
rial damage in the vicinity of the turbocharger.
To eliminate the residual risk to the greatest possible extent, the following
rules must be observed:
Risk of injury!
Under no circumstances are persons permitted to be near the
turbocharger without reason during operation.
▪ The turbine and compressor must be cleaned at regular intervals as

specified in the maintenance schedule.
▪ The maintenance of the turbocharger must only be performed by trained
personnel at the maintenance intervals specified in the operating manual.
▪ Inadmissible operating conditions, such as frequent load shedding, com-
pressor surging and excessive turbocharger speeds, must be avoided.
▪ Corrosive and erosive agents in the intake air must be avoided.
▪ The intake must be clean, without extraneous objects and particles.
The turbochargers were designed in such way, that the fragments will be
caught by the turbocharger casings in the case of the rotor breakdown.
Some of them however can escape through the connections of the com-
pressor and of the turbine, and that´s why it is necessary to run the turbo-
charger with connected pipelines or other equipment (filters, silencer, com-
pensators, etc.), which show out the similar mechanical features and the
stiffness like the casings of the turbocharger itself. Otherwise (e. g. the usage
of the compensator) it is necessary to install another adequate shield in the
compressor suction branch as well as in the turbine outlet.
Technical documentation
The technical documentation of the system, particularly the operating and
maintenance manuals for the engine, turbocharger and the accessories
required for engine operation, must be stored at a location where they are
accessible for the operating and maintenance personnel at all times.
Accident prevention regulations

2014-09-23 - de
When operating the system and for all maintenance and repair work, the rel-
evant Regulations for Prevention of Accidents are to be observed. It is advis-
Operation
able to hang these regulations in the engine room and to repeatedly point out
the dangers of accidents.
TCR16
2 (5) C1 0411 5.0-01 EN-US

Operation
Safety instructions concerning specific hazard sources
Hearing protection
Sound levels exceeding 85 dB(A)!

The danger of hearing impairment is given because sound levels are
permanently above this value in the engine room when the engine is
running.
• Always wear hearing protection in the engine room!
Exhaust gases It is possible that exhaust gases with the harmful components NOx, SO2, CO,
HC and soot will be released in the engine room.
Health risk due to exhaust gases!

The exhaust gases of the engine are harmful to one’s health and
detrimental to the environment when exceeding the limit values.
• Carry out maintenance in accordance with the maintenance schedule!
• Orient the operational management on behalf of the hazards!
• Observe operating results critically!
Fire hazard
Potential danger of fire in the engine room!

Fuel and lube oil are combustible and can easily ignite when
contacting hot components in the engine room.
• Do not conduct fuel and oil pipes alongside hot engine components
(exhaust pipe/turbocharger) that are not insulated!
• After maintenance and repair work on exhaust pipes and turbochargers,
carefully and completely reattach all insulations and coverings!
• Regularly check the tightness of all fuel and oil pipes (maintenance
schedule)!
• Eliminate any leakages immediately!
Extinguishing equipment The engine room must be provided with fire-extinguishing equipment. The
proper functioning of this equipment must be checked regularly.
2014-09-23 - de
Operation
TCR16
C1 0411 5.0-01 EN-US 3 (5)

Danger to life through suffocation!

Operation
When carbon dioxide fire-extinguishing systems are put into operation,

danger of life is given due to suffocation.
• Do not put carbon dioxide fire-extinguishing systems into operation
before it is ensured that no more persons are in the engine room!
Protective covers
Danger of burns and fire hazard from hot system components!

Due to high operating temperatures the system components can
become very hot. Persons can burn themselves on the hot
components and/or inflammable operating fluids can ignite.
• Always have all coverings and insulations mounted to the turbocharger
during operation of the engine!
• Regularly check the tightness of all fuel and oil pipes!
After assembly work, ensure that all coverings and protective covers on mov-
ing components as well as all insulation on hot components are reattached.
Engine operation with coverings removed is permitted only in special cases,
such as for functional tests, and if there is no-one in the vicinity of the turbo-
charger.
Uncontrollable motions
Danger of crushing and shearing due to uncontrolled motions

of the rotor assembly!
If the rotor assembly of the turbocharger is exposed, there is a danger
of uncontrolled and uncontrollable motions of the rotor that could
result in objects becoming jammed and/or cause serious injuries!
• The presence of unauthorized persons in the vicinity of the turbocharger
is prohibited when the rotor assembly is exposed.
Alarm system If important operating values are exceeded, an alarm system will generate
alarm, reduction or stop signals, depending on the danger potential. The
cause of these signals must be thoroughly investigated and the source of the
malfunction must be corrected. The signals must not be ignored or sup-
pressed, except on instructions from the management or in cases of a more
2014-09-23 - de
severe danger.
Operation
TCR16
4 (5) C1 0411 5.0-01 EN-US

Ignoring or suppressing alarms and putting reduction and stop
Operation
signals out of operation can lead to operational malfunctions
which can result in serious personal injury and damage to
property!
Turbocharger and engine are fitted with an alarm system which sounds
an alarm in case of technical problems or malfunctions. Therefore, an
alarm always has a cause which must be rectified!
• Do not ignore or suppress any alarm, reduction or stop signals!
• Investigate the cause of every alarm, reduction or stop signal or report
them!
• As far as possible, provide for swift rectification of the cause of alarms
and signals!
• Ignore or suppress alarms, reduction and stop signals only in cases of
increased danger or when ordered by management!
Personnel/qualifications of The engine and the systems required for its operation may be started, oper-
personnel ated and stopped only by authorised persons. The personnel must be
instructed and trained for this purpose and must be familiar with the system
and the hazards liable to arise.
All persons operating the system or carrying out maintenance or repair work
on the system must have read and understood all accompanying operating
and work instructions.
For marine systems:
Operational management by the chief engineer on board or by an engineer-
ing officer.
Persons supervising operation must be in possession of a certificate of com-
petence (license) conforming to the national regulations and international
conventions (STCW). The number of persons required and their minimum
qualifications are usually stipulated by national regulations or international
conventions (STCW).
For stationary systems (power plants):
The superintendent (engineer) must be available. Supervision/monitoring of
the engine and the associated supply systems by a trained and specially
instructed machine operator or mechanic.
For personnel supervising operation in Germany, proof, among other things,
must be furnished in accordance with the German Energy Industry Law
(EnWG) that management of the technical operation is assured by a sufficient
number of qualified persons. In other countries, comparable laws/directives
must be observed.
2014-09-23 - de
Operation
TCR16
C1 0411 5.0-01 EN-US 5 (5)

Starting operation/Shutting down
Operation
Initial starting of operation
Danger of poisoning from toxic vapours!

The vapour-phase corrosion agent (increased corrosion protection)
with which the openings of the turbocharger are treated sets toxic
vapours free upon heating.
• Thoroughly blow out the turbocharger casing before assembling the
turbocharger!
• Upon initial putting into operation, check if any corrosion protection
agent is on the turbocharger!
1. Unpack the turbocharger.

2. Remove closing covers on gas admission casing, gas outlet casing and
compressor casing.
3. Remove preservation agents from the exhaust gas flanges of the tur-
bine casing as well as from the delivery socket of the compressor cas-
ing with a suitable scraper and cleaning agent.
4. Flush the lube oil system. Plug the oil supply and oil drainage of the tur-
bocharger and join the supply and drain pipes on the engine side, or
use an intake filter with low filter rating (20 µm recommended) in the
lube oil supply. Measurement of the oil pressure after the intake filter.
5. Prior to initial start-up, the lube oil pressure must be set, see “Lube oil
system”, Chapter 4.2.
Before shipment, the oil system of each turbocharger is factory-

checked for cleanliness, and the oil supply and oil drainage are
plugged. Therefore, when flushing the engine oil system, care must be
taken to prevent inadmissible contamination in the oil from entering the
turbocharger.
For additional information on flushing the lube oil system, please refer
to the engine manufacturer’s manual.
For mounting the turbocharger on the engine, see work card Complete
turbocharger.
2014-09-23 - de
Engine control
Operation
TCR16
C1 0411 5.1-01 EN-US 1 (3)

Indication of the pending alarm and the reaction of the engine control
Operation
system must occur at the same time. Therefore, the engine control
system must conform at least to category 3 in compliance with
DIN EN ISO 13849-1.
Work prior to starting the engine

1. Before starting the engine, the bearing points of the turbocharger must
be primed. Depending on the engine system, this is done by
– Priming immediately before starting or
– Continuous priming.
2. Set all shut-off devices of the system pipes of the engine plant to the
operating position.
3. Check the lube oil pressure at the top of the turbocharger, see lube oil
diagram, Chapter [4.2], connection for pressure gauge.
4. Vent water-cooled bearing casing if present.
Starting operation
Turbocharger Start the engine. The engine exhaust gases drive the turbocharger and thus
start it operating. If provided, the “Jet Assist” acceleration system is put into
operation via the control system.
Checks during operation

General Despite automatic control and regulation of the plant, regular checks of the
turbocharger are required so that possible malfunctions can be detected as
early as possible and the causes corrected in time.
The checks listed below are part of the operator's maintenance

obligations. Results, observations and actions in connection with such
monitoring measures are to be recorded in an engine log book.
Reference values are to be defined in order to allow objective
assessment of the results.
Continuous checks on the ▪ Turbocharger speed

turbocharger ▪ Lube oil pressure at top of turbocharger
▪
2014-09-23 - de
Lube oil temperature upstream of turbocharger

▪ Lube oil temperature downstream of turbocharger
Operation
▪ Exhaust gas pressure upstream of turbine

▪ Exhaust gas temperature upstream of turbine
TCR16
▪ Charge air pressure downstream of compressor

▪ Charge air temperature downstream of compressor
2 (3) C1 0411 5.1-01 EN-US

▪ Exhaust gas, charge air and oil pipes for tightness
Operation
▪ Turbocharger for smooth running
▪ Air filter mat on the silencer, if provided, for fouling/saturation
Smooth running An early indication of damage to the rotor and bearings is usually given by
irregular running due to imbalance or contact of rotating parts of the rotor.
Listening to the running noise of the turbocharger often allows unsmooth
operation to be detected at an early stage.
Speed With clean air ducts of the compressor, a certain charge air pressure is
assigned to each speed of the turbocharger. The charge pressure thus gives
an indication of the speed and can be used for approximate speed monitor-
ing.
Shutting down, post lubrication

Shutting down Shutting down the engine also puts the turbocharger out of operation. Due
to the flywheel effect, the rotor of the turbocharger continues to rotate for
approx. 65 – 80 seconds.
The run-down time of the turbocharger gives an indication of its

mechanical condition. Sudden stopping indicates mechanical damage
to the bearing, contact of the compressor or turbine wheel, trapped
foreign objects or heavy fouling.
Post lubrication After an engine shut-down, the bearing points of the turbocharger must be
post lubricated for cooling purposes. This is done either by means of the
engine lube oil pumps or using a separate auxiliary lube oil pump, see “Lube
oil system”, Chapter [4.2].
If continuous priming is specified for engines (e.g. because of stand-by

starting), post lubrication is not required.
In this case, the continuous priming must be activated as soon as the
engine lube oil pumps are switched off.
Danger of fire caused by lube oil!

Continuous priming is only possible if there is no chimney draught
effect. A chimney draught can cause lube oil to be drawn into exhaust
gas ducts, leading to coking or fire.
2014-09-23 - de
Operation
TCR16
C1 0411 5.1-01 EN-US 3 (3)

Emergency operation of the engine on failure of a turbocharger
Operation
Criteria for emergency operation
Turbocharger Damage has occurred to a turbocharger which cannot be corrected immedi-
ately. If required, emergency operation of the engine is still possible under
certain circumstances.
Engine For emergency engine operation, the possibilities, measures and achievable
engine output vary considerably according to:
▪ two-stroke engines or four-stroke engines,
▪ engines with one turbocharger or several turbochargers,
▪ in-line engines or V-type engines,
▪ generator operation or propeller operation.
For relevant instructions, please refer to the operating manual of the engine
concerned.
Options for emergency operation

General emergency The following instruction is obligatory for all options of emergency engine
measures operation in the event of turbocharger failure.
▪ Reduce the engine power in accordance with the engine manufacturer’s
instructions to the degree that
– the maximum permissible exhaust gas temperature downstream of
the cylinders is not exceeded,
– the maximum permissible exhaust gas temperature upstream of the
turbocharger is not exceeded,
– the maximum permissible speed of the turbocharger that is still
operational (on engines with more than one turbocharger) is not
exceeded,
– increased exhaust gas density is minimised.
Emergency measure, option 1

Engine may not be stopped for urgent reasons.
Danger due to further damage of the turbocharger!

Fire or destruction of the turbocharger can occur!
• Do not stay in the area of the turbocharger. Danger to life!
• As a precaution, prepare fire-extinguishing measures!
2011-05-16 - de
Operation
1. Damaged turbocharger remains unchanged.

2. Observe the paragraph “General emergency measures” and the engine
TCR16
manufacturer’s instructions for emergency operation.
C1 0288 5.2-02 EN-US 1 (2)

3. Limit the duration of emergency engine operation to the absolutely nec-

Operation
essary minimum.
Emergency measure, option 2

Emergency operation with closing device
Engine with one turbocharger may be stopped (short-term).
1. Remove the damaged cartridge and carry out measures according to
work card [500.11].
2. Screens (protection grids) have to be mounted on the charge air pipe.
On engines equipped with a charge air bypass, it is also necessary to
mount the blind flange at the connection on the exhaust gas side.
Observe the paragraph “General emergency measures” and the engine man-
ufacturer’s instructions for emergency operation.
Engine with more than one turbocharger may be stopped (short-term).

1. Separate the exhaust gas inlet side of the defective turbocharger from
the gas flow of the second turbocharger by fitting a blind flange.
2. On V-type engines having a common charge air pipe, a blind flange is
to be mounted on the compressor outlet of the defective turbocharger
so as to avoid air losses.
Observe the paragraph “General emergency measures” and the engine man-
ufacturer’s instructions for emergency operation.
2011-05-16 - de
Operation
TCR16
2 (2) C1 0288 5.2-02 EN-US

Malfunctions/faults and their causes
Operation
Operating faults
Indications Operating faults manifest themselves by abnormal readings (e.g. exhaust gas
temperature, charge air pressure, speed), excessive running noise or lube oil
leakage.
Ignoring or suppressing alarms and putting reduction and stop

signals out of operation can lead to operational malfunctions
which can result in serious personal injury and damage to
property!
Turbocharger and engine are fitted with an alarm system which sounds
an alarm in case of technical problems or malfunctions. Therefore, an
alarm always has a cause which must be rectified!
• Do not ignore or suppress any alarm, reduction or stop signals!
• Investigate the cause of every alarm, reduction or stop signal or report
them!
• As far as possible, provide for swift rectification of the cause of alarms
and signals!
• Ignore or suppress alarms, reduction and stop signals only in cases of
increased danger or when ordered by management!
All malfunctions are to be corrected as soon as possible, as minor

malfunctions can also lead to increased subsequent damage of the
turbocharger or engine.
Countermeasures 1. Reduce the engine power or shut down the engine, depending on the
available options.
2. Identify and correct the cause of the malfunction, see Table “Trouble-
shooting”.
3. If the damage cannot be corrected immediately, emergency operation
is possible, see Chapter [5.2].
Troubleshooting
No. Malfunction Possible cause Corrective action Work card
1 Exhaust gas temperature Air filter mat or silencer fouled Clean/replace [500.24]
2010-10-13 - de
upstream of the turbine is [500.32]

too high
Compressor fouled Clean [500.23]
Operation
Turbine wheel heavily fouled Clean

TCR16
[500.22]
C1 0288 5.3-02 EN-US 1 (6)


Operation
Turbine nozzle ring heavily fouled/ Clean/replace

constricted [500.22]
[500.46]
Rotor rubbing Check inserts/rotor/bearing [500.41]
bushes and replace parts if nec- [500.45]
essary, balance check by author- [500.47]
ized service center
Foreign bodies before/in com- Check compressor wheel and/or [500.45]
pressor and/or turbine turbine rotor and replace if neces-
sary
Turbine or compressor wheel Replace compressor wheel [500.45]
damaged and/or turbine rotor
Substantial erosion on turbine Check turbine rotor/turbine nozzle [500.45]
wheel/turbine nozzle ring ring and replace if necessary [500.46]
High air intake temperature Reduce power Engine
Charge air cooler fouled Clean Engine
Charge air pipe leaking Seal charge air pipe, tighten con- Engine/
nections system
Charge air temperature too high Check charge air cooler Engine
Inlet/exhaust valves, valve slots of Clean Engine
engine fouled
Exhaust gas pipe leaking Seal exhaust gas pipe, tighten Engine/
connections system
Exhaust gas back-pressure Clean turbine, check exhaust gas
downstream of turbine too high pipe [500.22]
Engine/
system
Fuel injection on engine faulty Repair fuel injection Engine
Fault on gas mixer Readjust mixture Engine
Change of ignition time of the Readjust ignition Engine
mixture in the cylinder
2 Charge air pressure too low Air filter mat or silencer fouled Clean/replace [500.24]
[500.32]
[500.22]
[500.46]
Defective bearings, imbalance of Check bearing components and [500.45]
the rotor replace parts if necessary, bal-
ance check by authorized service
2010-10-13 - de
center
Operation

TCR16
ized service center
2 (6) C1 0288 5.3-02 EN-US

Operation
sary
nections system
engine fouled
connections system
Engine/
system
Throttle flap not working properly Readjust Engine
3 Charge air pressure too Turbine nozzle ring lightly fouled/ Clean
high constricted [500.22]
Low air intake temperature Reduce power Engine
4 Speed too low Air filter mat or silencer fouled Clean/replace [500.24]
[500.32]
[500.22]
[500.46]
center
ized service center
2010-10-13 - de
sary
Operation

TCR16

C1 0288 5.3-02 EN-US 3 (6)


Operation

nections system
engine fouled
connections system
Engine/
system
5 Speed too high Turbine nozzle ring lightly fouled/ Clean
6 Lube oil pressure too low Lube oil inlet temperature too high Check/adjust lube oil cooling Engine/
system
Lube oil filter fouled Clean/replace lube oil filter Engine/
system
Lube oil pressure gauge defective Replace lube oil pressure gauge Engine/
system
High degree of wear on bearings Replace bearings in turbocharger [500.45]
7 Lube oil loss Piston ring seals defective Replace piston rings [500.45]
Seals damaged, connections Replace seals, check/tighten con- [500.31]
leaking nections Engine
Lube oil pressure too high Reduce oil pressure at operating Engine/
temperature system
Excessive pressure in oil dis- Check/enlarge dimension/inclina- Engine/
charge or in crankcase tion/venting of lube oil discharge system
Increased pressure in crankcase Clean suction pipe and oil separa- Engine/
tor system
8 Hesitant starting, short run- Compressor fouled Clean compressor [500.23]
down time
[500.22]
[500.46]
Retaining ring, thrust ring or coun- Check parts and replace them if [500.45]
ter-thrust ring damaged necessary
2010-10-13 - de

center
Operation

TCR16

ized service center
4 (6) C1 0288 5.3-02 EN-US

Operation
sary
Oil coke downstream of turbine Check/replace piston ring on tur- [500.45]
wheel bine side, observe upper limit of
lube oil pressure during pre-lubri-
cation and operation
9 Abnormally high noise level Retaining ring, thrust ring or coun- Check parts and replace them if [500.45]
center
ized service center
sary
10 Turbocharger vibrates Turbine wheel heavily fouled Clean
[500.22]
Retaining ring, thrust ring or coun- Check parts and replace them if [500.45]
center
ized service center
sary
Anchor bolts inadequately tight- Retighten bolts Engine
ened
Stiff (blocked) compensator Replace compensator Engine
2010-10-13 - de
11 Compressor surges Turbine wheel heavily fouled Clean

[500.22]
Operation

TCR16
[500.46]
C1 0288 5.3-02 EN-US 5 (6)


Operation

sary
Charge air temperature too high Reduce power Engine
engine fouled
Engine/
system
Throttle flap closed Readjust flap Engine
IRC aperture closed Clean [500.43]
Table 1: Troubleshooting
2010-10-13 - de
Operation
TCR16
6 (6) C1 0288 5.3-02 EN-US

PBS Turbo, s. r. o.
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
2014-09-25 - de
Maintenance
0411-1 6 C1-01 EN-US 1 (1)

Safety during maintenance/repair
Maintenance
Qualification of personnel
Performed by machinists or mechanical fitters and their assistants.
Briefing and supervision of difficult work tasks through a technical officer or
the chief engineer.
Shutting down the engine for assembly work
Danger to life from crush injuries or impact!

If the engine starts during the removal of parts of the turbocharger,
there is a risk of coming into contact with rotating components and
being seriously injured.
• Shut down the engine before starting the removal work!
• During the work, lock out the engine to prevent it from starting!
• Set up warning signs!
Only carry out maintenance and repair work after consultation with the
engineering officer or chief engineer and if instructed to do so.
Inform the persons responsible for the operation of the engine and
turbocharger about the commencement and completion of the work.
Opening pipes/pressure tanks
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 escaping lube oil!

The lube oil is under pressure and very hot!
2013-03-01 - de
• Before opening pipes, flanges, screwed connections or fittings, release

Maintenance
the pressure in the system and check that it is depressurised!

• Before opening oil pipes, wait until the lube oil has cooled down
sufficiently!
TCR16
• Wear protective clothing!
C1 0288 6.0-02 EN-US 1 (3)

Maintenance
Removing and refitting pipes

When working on the piping systems, especially for fuel, lube oil and air, par-
ticular cleanliness must be ensured in order to prevent foreign bodies or
impurities from entering the system. When they are removed, all pipes that
are to be refitted must therefore be carefully sealed.
New pipes to be fitted must be checked for cleanliness and flushed if neces-
sary.
Preservation measures must be taken on any components that are to be put
into prolonged storage. Preservation agents appropriate to the storage dura-
tion and storage environment must be used.
Risk of explosion and fire!

Pipes and lines may contain residues of combustible or flammable
liquids and gas-air mixtures.
Components may be treated against corrosion with combustible
substances, e.g. anti-corrosion oil!
• Do not smoke or use naked flames when working on the engine and
turbocharger.
• Remove anti-corrosion agents.
Removal/disassembly of heavy components
Risk of injury due to suspended loads!

Unsuitable or poorly maintained transporting devices as well as
unsuitable storage locations can result in severe personal injury and
severe material damages.
• Use only transporting devices in faultless condition!
• Check if the lifting capacity of the used transporting devices is sufficient.
• Only chose storage locations which have a load carrying capacity
sufficient for the weight of the component (this is not always true for
galeries, landings or grid covers).
Use of cleaning agents

When using cleaning agents, the manufacturer’s notes for usage, possible
dangers and disposal are to be observed.
2013-03-01 - de
Maintenance
TCR16
2 (3) C1 0288 6.0-02 EN-US

Cleaning agents can be caustic!
Maintenance
Cleaning agents on the skin, in the eyes or being inhaled can lead to
serious damage to one’s health or to allergies.
• Always observe the manufacturer’s notes for cleaning agents!
• Wear protective clothing whenever required!
• Wear protective gloves whenever required!
• Wear safety goggles whenever required!
• Wear respiratory protection whenever required!
• Pay attention that other persons also wear the appropriate protective
equipment whenever required or make these persons aware thereof!
Use of high-pressure cleaners

When working with high-pressure cleaners, ensure that they are used cor-
rectly.
Air filters, shaft ends (including those with lip-type sealing rings), governors,
splash-proof monitoring systems, cable sockets as well as sound and heat
insulation under non-watertight coverings must be covered or not subjected
to high-pressure cleaning.
Spare parts
During operation, the components of the turbocharger are subjected to very
high forces. We have therefore developed special materials that can with-
stand these high forces. Only by using original spare parts from the manufac-
turer can you be sure that these high-quality materials have been employed.
Spare parts from other manufacturers may be manufactured

using inferior materials that cannot withstand the loads they
are subjected to during operation of the turbocharger!
This can result in severe damage to the turbocharger, engine room and
engine, and danger to life for the operating personnel.
• Use only original spare parts from the manufacturer!
• Only use spare parts from other manufacturers if they have been
approved by the turbocharger manufacturer!
The manufacturer shall in no way be liable for any personal injury or material
damage caused by use of spare parts from other manufacturers. Further-
more, any and all warranty claims relating to the turbocharger expire when
using non-original spare parts.
2013-03-01 - de
Maintenance
TCR16
C1 0288 6.0-02 EN-US 3 (3)

General remarks
Maintenance
Maintenance work
Maintenance work belongs to the duties of the user, just as regular checks
do. Their purpose is to retain operational readiness and operational safety of
the system. They are to be carried out by competent personnel in accord-
ance with the time schedule for maintenance.
Maintenance work supports the operating personnel in their effort to detect
arising malfunctions/failures in time. They deliver hints towards necessary
maintenance work or repairs to the persons responsible, and influence the
planning of downtimes.
Maintenance and repair work can be carried out properly only when the
required spare parts are available. In addition to these spare parts, it is advis-
able to stock a certain quantity of spares for unexpected outages.
Maintenance schedule
The required tasks are listed in the maintenance schedule, sheet [6.3.1]. The
schedule contains
▪ a brief description of the work,
▪ the repetition intervals,
▪ the personnel and time requirements,
▪ references to the respective work cards.
Work cards
The work cards describe
▪ the aim and object of the work
and contain information about
▪ the required tools/appliances and
▪ detailed descriptions and graphical depictions of the necessary work
sequences and work steps.
See work card [7.1.1]
Spare parts
Order numbers for spare parts can be found
▪ in the spare parts catalogue of the technical documentation and
▪ on the respective work cards of the technical documentation.
Order numbers consist of the three-digit subassembly number and a three-
digit item number, separated by a dot.
Special services/Repair work

2010-10-13 - de
As a turbocharger manufacturer, we offer the following services:

Maintenance
▪ Delivery of spare parts

▪ Consultation and support on questions concerning operation, mainte-
nance and repairs
▪ Practice-oriented training for operating personnel
TCR
▪ Assessment and clarification of damage cases
C1 0288 6.1-01 EN-US 1 (2)

▪ Assignment of fitters and engineers

Maintenance
Addresses and contact persons can be found in Chapter [2.1]
2010-10-13 - de
Maintenance
TCR
2 (2) C1 0288 6.1-01 EN-US

Tools
Maintenance
Optional tools
For maintenance work and emergency operation, special tools are optionally
available for TCR turbochargers.
The optional supply scope of these special tools is listed in the spare parts
catalogue, Chapter “Tools”.
Standard tools
As standard, the special tool “hexagon pin (596.001)” is supplied with each
TCR turbocharger. This hexagon pin is required for removing and refitting the
compressor wheel and is supplied with the tool box (see chapter 596.01
Tools).
Inventory tools
Commercially available tools that are usually included in the inventory of the
engine system.
Inventory tools are not contained in the turbocharger’s scope of supply.
2013-06-28 - de
Maintenance
TCR16
C1 0619 6.2-01 EN-US 1 (1)

Maintenance schedule, service life
Maintenance
Bindingness and adaptability
Validity of the maintenance The maintenance schedule contains a summary of the maintenance and
schedule inspection work, up to major overhaul of the turbocharger.
A major overhaul of the turbocharger must be carried out at the latest after
▪ 12,000 - 20,000 operating hours
.
After each major overhaul, which is best carried out when an engine service
falls due, the maintenance schedule starts from the beginning again.
A major overhaul includes the disassembly of the complete turbocharger for
inspection of the actual condition, thorough cleaning and a check of all parts/
components.
The maintenance must be scheduled well in advance, meaning that, for

example, sailing timetables or power plant inspections must be taken
into account. In order to ensure the operational safety of the
turbocharger and the engine, maintenance work is to be performed as
far as possible on schedule or beforehand.
Adaptation of the The maintenance schedule is based on the following operating conditions
maintenance schedule and an annual operating period of approx. 5000-6000 h:
▪ uniform loading within a range of 60 to 100% of the rated power, approx.
400 starts/year,
▪ compliance with the specified limits for temperatures and pressures of
the operating media,
▪ use of the specified lube oil and fuel qualities,
▪ reliable separation of fuel and lube oil.
The maintenance intervals must be shortened when the following operating
conditions are given:
▪ prolonged operation at peak loads or low loads, long idle periods, sub-
stantial and frequent load changes,
▪ frequent engine starts and repeated warming-up phases without ade-
quate preheating,
▪ high loading of the engine before the specified operating media tempera-
tures are reached,
▪ lube oil, cooling water and charge air temperatures that are too low,
▪ use of inappropriate fuel qualities and insufficient separation,
▪ inadequate filtration of the intake air (particularly with stationary engines),
▪
2014-07-02 - de
more than 1000 m above sea level.

Maintenance
Service life of the The turbocharger is a highly stressed unit and although high-quality materials
turbocharger and sophisticated processes are used in its manufacture, the characteristics
of the individual parts gradually change over time.
TCR16
C1 0434 6.3-01 EN-US 1 (2)

In order to maintain the high level of reliability and safety, the turbocharger is
Maintenance
to be shut down and replaced with a new one after approx. 60,000 hours of
operation (gas-powered engines), or after approx. 60,000 to approx. 90,000
hours of operation (diesel/HFO engines).
2014-07-02 - de
Maintenance
TCR16
2 (2) C1 0434 6.3-01 EN-US

Maintenance schedule - turbocharger on gas-powered engine
Maintenance
Maintenance schedule - turbocharger on gas-powered engine
1, per
2,
3
b)
d)
g)
h)
c)
f)
Inspection (during operation)
901 Check turbocharger for unusual noise and vibrations. A 1 0.1 Turbo X
903 Check turbocharger and system pipes for leaks (charge A 1 0.2 Turbo X
air, exhaust gas, lube oil, cooling water)
905 Check all fixing screws, casing screws and pipe 500.31 1 1 Turbo 2 X
connections for tight fit. 7.2.1
Maintenance (during operation)
911 Clean turbine - dry cleaning (if provided) 500.22 1 0.3 Turbo 1
915 Clean compressor (during operation) 500.23 1 0.3 Turbo 1
Maintenance (engine has been stopped)
917 Clean air filter (if provided) 500.24 1 0.4 Turbo 1
Maintenance (together with engine maintenance)
931 Mechanically clean compressor casing, diffuser, 7.2.1 2 4 Turbo 3
compressor wheel and turbine-side cover. 7.2.2
500.41
500.43
500.45
951 Major overhaul every 12,000 ... 20,000 operating hours: 7.2.1 2 8 Turbo X
Dismantle, clean and check all components of the 7.2.2
turbocharger. Check gaps and clearances on 500.31
reassembly. 500.32
500.33
500.41
500.43
500.44
500.45
500.46
500.47
Legend for maintenance schedule

b) Every 24 operating hours
c) Every 150 operating hours
d) Every 250 operating hours
f) Every 3,000 – 5,000 operating hours, depending on the operating conditions
g) Every 6,000 – 10,000 operating hours, depending on the operating conditions
h) Every 12,000 – 20,000 operating hours, depending on the operating conditions
2014-09-23 - de
X Maintenance work due

Maintenance
1 As required/depending on condition
2 Check new or overhauled parts once after the time specified
TCR16
3 Required in the case of oil mist in the intake air and if no wet cleaning of the compressor (915) is
carried out during operation. This also depends on the engine fuel.
A No work card required/available
C1 0411 6.3.1-01 EN-US 1 (2)

When parts are being checked, the engine must be operated at no

Maintenance
more than 80% of the rated power.

Exchange may only be carried out with the engine shut down.
2014-09-23 - de
Maintenance
TCR16
2 (2) C1 0411 6.3.1-01 EN-US

Remarks on maintenance work
Maintenance
General remarks
Disassembling the The simplest method to use for disassembly is best chosen on the basis of
turbocharger the space available in the engine room. When performing maintenance and
inspection work, it is sufficient in most cases to dismount only subassemblies
of the turbocharger.
Inspection report For a major overhaul of the turbocharger or for repair work concerning major
components, it is recommended to record the condition of individual subas-
semblies and to include this information in the operating log. Inspection
report form, see Chapter [6.6].
In disassembly work, mark the position of the components relative to

each other using a felt-tip marker pen. If required, document the
disassembly/assembly with a camera.
Exchanging components
Components with traces of wear or damage that influence especially the
strength and the balancing precision and thus the smooth running of rotating
parts, must be exchanged with original spare parts or repaired by an author-
ized repair facility or the manufacturer.
For dispatch, components must be packed and protected against corrosion
in such a manner that they are not further damaged during transportation.
Screw connections
Never attempt to loosen seized or tight screw connections with

excessive force.
This can lead to bolts being sheared off or parts being so badly
damaged that they must be replaced. Sheared-off bolts must be drilled
out and the threads retapped.
Loosening seized or tight Apply diesel fuel or special solvent (e.g. Caramba, Omnigliss, WD 40) liberally
screw connections to the screw connections and allow to penetrate for at least ½ hour so that
the solvent can work its way through the thread. Observe the instructions for
use supplied by the solvent manufacturer. Then apply light hammer blows to
2013-02-21 - de
the bolt head until the bolt turns freely in the thread.
Maintenance
Tightening screw All screw connections on the turbocharger must be in satisfactory condition
connections for assembly or be renewed.
TCR
C1 0288 6.4-01 EN-US 1 (2)

Always tighten screws/bolts with the specified tightening

Maintenance
torque!
For reasons of safety, only bolts of the specified quality may be used!
See Technical Documentation, Work Cards.
Figure 1: Lock washer pair

When assembling the lock washer pairs (one pair consisting of 2 identical
washers), make sure that the long wedge surfaces (B) contact each other (on
the inside), otherwise the locking effect will be lost.
Incorrectly tightened and locked bolts and nuts can become loose due to
vibrations and then be driven into the turbocharger by the air or exhaust gas
flow, thereby causing severe damage.
Screw connections on the Due to the high temperatures on the turbine side, bolts, nuts and tab wash-
turbine side ers made of non-scaling materials are used. These are marked on the face
side (SB, SD, SM, VM or 4923, Z1 or 4828) to avoid them from being mis-
taken for regular parts. When disassembling, the fasteners marked in this
manner are to be stored separately until being assembled.
All lock washer pairs on the turbocharger are made of non-scaling material
and are not marked.
In order to avoid the bolts and nuts on the turbine side from fusing together
through overheating, they must be treated with high-temperature lubricant
(e.g. Molykote HSC) prior to each new assembly. Before treating with lubri-
cant, the threads must be cleaned thoroughly.
Screw-in threads of studs are not treated. 2013-02-21 - de
Maintenance
TCR
2 (2) C1 0288 6.4-01 EN-US

Inspection of components
Maintenance
General remarks
The following remarks and questions are intended as a guide, e.g. for
▪ Assessment of the turbocharger condition,
▪ Operating log and inspection report,
▪ Inspection, reusing, repair and replacement of individual components.
Inspection work
Gaps and clearances For permissible limits, see Chapter Gaps and clearances.
Crack detection test Crack detection test on turbine blades (turbine rotor, compressor wheel) by
means of acoustic testing or the fluorescent dye penetration method.
Streaks Streaks all around the circumference of the turbine rotor, compressor wheel
and insert are an indication of wear.
Inspection of gaps and clearances, see Chapter Gaps and clearances
Inspection of bearing parts, see work card Cartridge components
Streaks on parts of the circumference of the turbine rotor, compressor wheel
and insert are an indication of imbalance.
Oil coke downstream of Shaft seal on turbine side damaged or pre-lubrication pressure too high.
turbine wheel
Erosion in HFO operation Where heavy fuel oil is used, the exhaust gas contains small hard particles
(e.g. “cat fines”) which have an erosive effect especially at the outlet of the
turbine nozzle ring, where gas velocities and concentrations of these parti-
cles are high. Here, the flow is also very strongly deflected in circumferential
direction. Moreover, these particles are flung outwards due to the centrifugal
effect.
„Cat Fines“ As a result of the refinery process, “cat fines”, a fine-grained powder of great
hardness (recognizable by the Al and Si content), and other abrasive con-
taminants are contained in the heavy fuel oil, depending on its quality. Their
amount can be reduced by means of amply dimensioned, heated settling
tanks and by adequate separation.
Admixtures Particularly disadvantageous is the admixture of used engine lube oil, charac-
terized by increased concentrations of Ca and Fe. Used engine lube oil con-
tains not only wear residues, but above all “detergent/dispersant additives”,
which bind fine particles and prevent “cat fines” and other impurities from
being extracted through separation. Far more severe erosion damage results
from blending the fuel with “used oil”.
Combustion residue caused by incomplete combustion can also have ero-
sive effects. Clean combustion must therefore be ensured.
Speed measuring device Is the speed transmitter or the speed indicator defective?
Casings Which casings are heavily fouled by soot, oil or oil coke?
Were the casings tight, particularly at the joints and connecting flanges?
2011-09-19 - de
Do the casings show signs of cracks?

Maintenance
Are the threads in order?

Were bolts of the specified material used?
Had bolts broken off?
TCR16
Were all bolts and nuts firmly tightened and locked?

Were oil bores in the bearing casing clogged?
Are the seals in order?
C1 0411 6.5-01 EN-US 1 (2)

Water-cooled bearing casing Are there any leaks?

Maintenance
Are the water channels unblocked and free from deposits?

Compressor wheel Do the turbine blades show signs of cracks or heavy wear? Are any streaks
evident?
Do the leading edges of the turbine blades show impact notches caused by
drawn-in foreign objects?
Are the seat faces bright or are there signs of fretting corrosion?
Turbine rotor Do the turbine blades show signs of cracks, streaks, heavy wear or erosion
at the edges?
Do the leading edges of the turbine blades show impact notches caused by
foreign objects?
Is the shaft running true? What is the condition of the bearings?
Are the seat faces bright or are there signs of fretting corrosion?
Bearing parts of the Are the seat faces bright or are there signs of fretting corrosion?
cartridge Are there any signs of scoring or heavy wear?
Checking for wear, see work card Cartridge components.
Inserts Are any streaks evident?
Are there any signs of corrosion?
Is the IRC aperture unobstructed?
Diffuser Are any blades bent? Are any cracks evident on the blades?
Have foreign objects become jammed in the ducts?
Are there traces indicating the presence of foreign objects?
Are any deposits present?
Turbine nozzle ring Are any blades bent? Are any cracks evident on the blades?
Are the blades heavily worn due to erosion?
Checking for wear, see work card Turbine nozzle ring.
Have foreign objects become jammed in the ducts?
Are there traces indicating the presence of foreign objects?
2011-09-19 - de
Maintenance
TCR16
2 (2) C1 0411 6.5-01 EN-US

Inspection report
Maintenance
Form
2013-11-14 - de
Maintenance
TCR16
C1 0411 6.6-01 EN-US 1 (2)

Maintenance
2013-11-14 - de
Maintenance
TCR16
2 (2) C1 0411 6.6-01 EN-US

Service report
Maintenance
Form
2013-11-12 - de
Maintenance
TCR16
C1 0548 6.7-01 EN-US 1 (1)

Disposal
Maintenance
Disposal of turbochargers
The turbochargers must be disposed of at the end of their service life and in
accordance with the applicable national laws.
In order to achieve the specified service life safely, the intervals for scheduled
maintenance and overhaul of the turbocharger must be adhered to (see Sec-
tions [6.3] and [6.3.1]).
Materials used
Informative overview of the The turbochargers are made of the following materials:
materials used in the basic
Fe alloy 201.6 kg
turbocharger
Ni alloy 8.8 kg
Al alloy 3.9 kg
Cu alloy 1.8 kg
Flat seals, O-rings (all asbestos-free) 0.15 kg
Table 1: Materials used – TCR16 turbochargers
2014-09-25 - de
Maintenance
TCR16
C1 0411 6.8-01 EN-US 1 (1)

PBS Turbo, s. r. o.
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
2014-09-25 - de
Work cards
0411-1 7 C1-01 EN-US 1 (1)

Preface
7.1 Preface
7.2 Setting data
7.4 Cleaning
2014-09-25 - de
Work cards
0411-1 7.1-01 EN-US 1 (1)

Organisation and use of the work cards
Preface
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 num-
ber. The subassembly number 500 represents the collective subassembly
number for turbochargers.
Example - Turbocharger on engine: 500.31
▪ 500 = Subassembly number (500 for turbocharger)
▪ 31 = Counting number (work card No. 31)
Cross-references in work cards are enclosed in square brackets.
Layout of the work cards

Work cards generally contain the following information:
▪ Brief description,
▪ Personnel and time requirements,
▪ Required tools and appliances,
▪ Related work cards, i.e. those work cards containing further necessary or
useful information,
▪ Possibly additional information/technical data and,
▪ The individual work sequences, always beginning with the starting condi-
tion, and followed by the individual work steps.
Parts and tools in the figures and text are each designated with their order
number.
Example - Hexagon bolt in bearing casing: 546.005
▪ 546 = Subassembly number (546 for bearing casing)
▪ 005 = Item number
All subassemblies and subassembly numbers are listed in the spare parts
catalogue.
Order numbers for tools are (generally) identical with the tool number affixed
to the tool.
Personnel and time required

The required time is mentioned in hours, both for the amount and qualifica-
tion of the required personnel. The higher hour rate covers the time require-
ment for the complete scope of the respective work card. Pesonnel with
lower hour rate is required only at times, e.g., for operation of a lifting tackle.
Tools/appliances required
2014-02-10 - de
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.
Work cards
The availability codes in the Status column have the following meaning:
Standard Included in the scope of supply of the turbocharger.
TCR
Optional Tools are supplied by special order.
C2 0288 7.1.1-01 EN-US 1 (2)

Inventory Commercially available tools/appliances

Preface
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 plant.
Special Special tools, e.g. for service centers.
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 tighten-

ing 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!
2014-02-10 - de
Work cards
TCR
2 (2) C2 0288 7.1.1-01 EN-US

Setting data
7.1 Preface
7.2 Setting data
7.4 Cleaning
2014-09-25 - de
Work cards
0411-1 7.2-01 EN-US 1 (1)

Screw connections and tightening torques
Setting data
Brief description
Tightening values for all major screw connections, tightening torques for dif-
ferent friction coefficients µ.
Tightening torques for screw connections

Tightening of screw Whenever possible, screw connections should be tightened with torque
connections by 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 may be noted
from Table 2 “Tightening torques for bolts of 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.
▪ Table 2 “Tightening torques for bolts of strength class 8.8” gives the
tightening torques for the various screw threads depending on their coef-
ficient of friction µ, i.e. depending on the selected lubricant. The tighten-
ing torques apply for bolt materials of strength class 8.8 under utilization
of approx. 70% of their yield strength.
▪ For other strength classes, the conversion factors given in Table 1 are to
be used and multiplied by the tightening torque from Table 2. 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

Thread, nominal size Tightening torque in Nm
2014-09-25 - de
for coefficient of friction µ

Work cards
0.08 0.14
TCR16
M5 4.1 5.8
M6 7 10
C2 0411 7.2.1-01 EN-US 1 (4)

Thread, nominal size Tightening torque in Nm

Setting data
for coefficient of friction µ
0.08 0.14
M8 17 24
M 10 34 49
M 12 59 84
M 14 93 134
M 14×1.5 99 145
M 16 141 205
M 16×1.5 148 220
M 18 196 282
M 18×1.5 213 319
M 18×2 205 300
M 20 275 398
M 20×1.5 295 445
M 20×2 285 422
M 22 368 538
M 22×1.5 393 594
M 22×2 381 566
M 24 473 686
M 24×2 503 753
M 27 694 1017
M 27×2 731 1103
M 30 945 1379
M 30×2 1014 1537
M 33 1271 1870
M 33×2 1353 2061
M 36 1640 2403
M 36×3 1707 2554
M 39 2113 3117
M 39×3 2190 3295
M 42 2623 3856
M 42×3 2757 4166
Table 2: Tightening torques for bolts, strength class 8.8
2014-09-25 - de
Work cards
TCR16
2 (4) C2 0411 7.2.1-01 EN-US

Setting data
Tightening torques for TCR16 turbocharger
501.008 Hexagon nut 541.021 Cylindrical screw

501.044a) Hexagon nut 546.005 Hexagon bolt
517.051 Hexagon bolt 546.009 Hexagon bolt
520.005 Compressor wheel 546.020 Hexagon bolt
Figure 1: Items for special tightening torques on TCR16

a)
not part of standard delivery – must be ordered separately
The special tightening torques given in the table are valid for a friction
coefficient µ=0.08
with lubricants for temperatures
• ≤ 200 °C, e.g. Molykote G-n or Molykote P40
• ≥ 200 °C, e.g. Molykote HSC.
Work Part Designation Nm WAF °C

card order nr.
[500.32] 546.009 Hexagon bolt 83 17 ≤ 200
[500.33] 546.009 Hexagon bolt 83 17 ≤ 200
2014-09-25 - de
[500.41] 546.020 Hexagon bolt 17 10 ≤ 200

Work cards
[500.43] 546.005 Hexagon bolt 100 19 ≤ 200

[500.44] 501.008 Hexagon nut 34 17 ≥ 200
TCR16
[500.45] 517.051 Hexagon bolt 10 10 ≤ 200

[500.45] 520.005 Compressor wheel 120 24 ≤ 200
C2 0411 7.2.1-01 EN-US 3 (4)

Work Part Designation Nm WAF °C

Setting data
card order nr.

[500.47] 541.021 Cylindrical screw 10 5 ≥ 200
[500.47] 501.044 a)
Hexagon nut 34 17 ≥ 200
Table 3: Special tightening torques for TCR16
a)
not part of standard delivery – must be ordered separately
2014-09-25 - de
Work cards
TCR16
4 (4) C2 0411 7.2.1-01 EN-US

Gaps and clearances
Setting data
Values and measurement
Figure 1: Gaps and clearances
Item Designations of parts Order no. When new Replace or

remachine parts
min. in mm max. in mm min. in mm max. in mm
1 a) Compressor wheel (520.005) Axial gap 0.30 0.60 0.30 0.60
b) Insert (540.001)
2 c) Turbine rotor (520.001) Axial gap 0.30 0.60 0.30 0.60
Insert ([541.01]) (541.001)
2 c) Turbine rotor (520.001) Axial gap 0.44 1.11 0.44 1.11
Insert with notch (541.001)
([541.02])
3 d) Thrust bearing (517.002) Axial clear- 0.18 0.22 0.13 *) 0.24
Counter-thrust ring (520.028) ance
5 e) Compressor wheel (520.005) Radial gap B 0.35 0.50 0.35 0.50
Insert (540.001) T 0.40 0.55 0.40 0.55
L/R 0.40 0.50 0.40 0.50
6 e) Turbine rotor (520.001) Radial gap B 0.65 0.80 0.65 0.80
Insert ([541.01]) (541.001) T 0.70 0.85 0.70 0.85
L/R 0.70 0.80 0.70 0.80
2013-11-13 - de
6 e) Turbine rotor (520.001) Radial gap B 0.78 1.21 0.78 1.21

Work cards
Insert with notch (541.001) T 0.83 1.26 0.83 1.26

([541.02])
L/R 0.83 1.21 0.83 1.21
TCR16
4 Compressor wheel (520.005) Permissible axial runout 0.06
C2 0411 7.2.2-01 EN-US 1 (2)

The following instructions must be observed in order to ensure that

Setting data
clearances and gaps are measured correctly.
a) Measure by means of soft metal imprint (lead wire) at 3 points on the circumference and calculate the mean
value. Deduct the measured axial clearance (3) from the calculated mean value with the rotor pushed in direc-
tion (B).
b) Adjustable by means of steel balance ring (540.030), t = 1,25 mm or t = 1,50 mm.
c) Measure by means of soft metal imprint (lead wire) at 3 points on the circumference and calculate the mean
value. Deduct the measured axial clearance (3) from the calculated mean value with the rotor pushed in direc-
tion (A).
d) Measure with a dial gauge while vigorously moving the rotor in directions (A) and (B).
e) Using a feeler gauge, measure at 4 points on the circumference and calculate the mean value.
*) The axial play in installed condition may be the same or no more than 0.05 mm less than the individual compo-
nent measurement.
2013-11-13 - de
Work cards
TCR16
2 (2) C2 0411 7.2.2-01 EN-US

Emergency operation
7.1 Preface
7.2 Setting data
7.4 Cleaning
2014-09-25 - de
Work cards
0411-1 7.3-01 EN-US 1 (1)

Emergency operation with closing device
Emergency operation
Brief description
Emergency operation of the engine by removing the cartridge and closing the
gas admission casing.

Number Qualification Duration in h
1 Technician 1,0
1 Assistant 1,0
Tools/appliances required
Qty Designation Number Status
1 Closing cover 596.006 Option
2 Pipe 596.012 Option
1 Foot 596.028 Option
1 Hexagon nut 596.030 Option
1 Socket wrench (set) - Inventory
- Lifting tackle, ropes, shackles - Inventory
Related work cards

Working Instruction Working Instruction Working Instruction
500.32 500.33 500.41
500.43 500.44 500.46
Requirement
Emergency operation of the engine on failure of a turbocharger must be pos-
sible, see information in the engine operating manual.
With the cartridge removed, the engine exhaust gases are routed through the
gas admission casing, which is sealed off with the closing device.
Danger to life from crush injuries or impact!

If the engine starts during the removal of parts of the turbocharger,
there is a risk of coming into contact with rotating components and
being seriously injured.
2008-12-11 - de
• Shut down the engine before starting the removal work!

Work cards
• During the work, lock out the engine to prevent it from starting!
• Set up warning signs!
TCR
C2 0288 500.11-01 EN-US 1 (2)

Emergency operation
Work sequence - Emergency operation with closing device
501.000 Gas admission casing 596.006 Closing cover

501.007 Lock washer pair 596.012 Pipe
501.008 Hexagon nut 596.028 Foot
506.000 Gas outlet casing 596.030 Hexagon nut
Figure 1: Closing device
Starting condition Coverings are removed to the extent necessary.

Silencer or air intake casing, compressor casing, cartridge and turbine nozzle
ring are removed.
Steps 1. Close the gas admission casing (501.000) with the closing
cover (596.006), lock washer pairs (501.007) and hexagon
nuts (501.008).
2. Fasten the foot (596.028) with hexagon nut (596.030), pipes (596.012)
and engine-side elements.
Make sure that the lube oil feed and lube oil drain are tight.
3. If the engine is operated in naturally aspirated mode, close the air pipe
to the charge air cooler with a protective grid; in other cases, close it
with a cover (observe engine manufacturer’s instructions).
4. For additional measures regarding emergency operation of the engine,
see
2008-12-11 - de
– Chapter [5.2] and

Work cards
– information in the engine operating manual.

TCR
2 (2) C2 0288 500.11-01 EN-US

Cleaning
7.1 Preface
7.2 Setting data
7.4 Cleaning
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Work cards
0411-1 7.4-01 EN-US 1 (1)

Cleaning the turbine - Dry cleaning
Cleaning
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
Preliminary remarks
Cleaning agent Use only commercially available granulates from nut shells or activated char-
coal (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, at normal operating load of the engine.
General The layout of the cleaning device depends on the engine type and can vary
from the illustration.
Assembly instructions ▪ The tank (1) must be installed in a suitable location, not lower than 1.0 m
below the connection point (4).
▪ The pipe (3) may not be longer than 6.0 m and must be supported
against vibrations. An unobstructed flow must be ensured.
▪ The connection point (4) can be provided on the exhaust gas pipe just
before the gas admission casing (5) or on the inlet socket of the gas
admission casing.
▪ Maximum operating temperature of the three-way cock (B): ≤ 150 °C.
2013-06-18 - de
Work cards
TCR
C2 0288 500.22-02 EN-US 1 (2)

Cleaning
1 Tank 8 Turbine wheel

2 Screw plug 9 Compressed air pipe
3 Pipe 10 Sealing air
(extracted downstream of
charge air cooler)
4 Connection point 11 Plate with cleaning instructions
5 Exhaust gas pipe upstream of A Stop cock
turbine
6 Gas admission casing B Three-way cock with sealing air
connection
7 Turbine nozzle ring
Figure 1: Diagram, dry cleaning of the turbine
Work sequence - Dry cleaning of the turbine (during operation)

Steps 1. Stop cock (A) must be closed.
2. Three-way cock (B) must be in position “0”.
3. Unscrew the screw plug (2).
Fill the prescribed quantity of granulate into the tank (1) and close
it with the screw plug (2). See Table “Filling volume”.
4. Open the stop cock (A).
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.
Type Filling volume
2013-06-18 - de
TCR10, TCR12 0.2 litres

Work cards

TCR22 0.5 litres
TCR
Table 1: Filling volume
2 (2) C2 0288 500.22-02 EN-US

Cleaning the compressor - Pressure sprayer
Cleaning
Brief description
Clean the compressor with the engine warmed up and in full load operation.
Carry out the work in time, in accordance with the maintenance schedule.

1 Technician 0,3
Preliminary remarks
Cleaning agent Use exclusively fresh water for cleaning.
Cleaning interval Every 150 operating hours.
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.
General The layout of the cleaning device depends on the engine type and can vary
from the illustration.
2010-10-13 - de
Work cards
TCR
C2 0287 500.23-01 EN-US 1 (2)

Cleaning
1 Handle 5 Coupling
2 Pressure sprayer 6 Hand valve
3 Relief valve 7 Turbocharger (compressor)
4 Nipple 8 Plate with cleaning instructions
Figure 1: Diagram, wet cleaning of the compressor with pressure sprayer
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 fresh water into the tank, filling volume 0.5 litres.
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).
2010-10-13 - de
Work cards
TCR
2 (2) C2 0287 500.23-01 EN-US

Cleaning the air filter
Cleaning
Brief description
Clean the air filter mat regularly in accordance with the maintenance sched-
ule or replace it.

1 Technician 0,4
Tools/Appliances Required
Qty Designation Number Status
– Compressed air – Inventory
– Cleaning agent (non-corrosive) – Inventory
Spare parts
Quantity Designation Number
1 Air filter mat 544.201
2 Clamp 544.202
1 Cover sheet 544.205
Preliminary remarks
Replace the air filter mat only when the engine is at standstill!
The air filter mat may be replaced only when the engine is at standstill.
The entry of dirt and foreign objects must be prevented.
General The dirty air filter mat (544.201) can be cleaned several times or replaced
with a new mat.
Replacement is required if the air filter mat is considerably stretched, tattered
or perforated.
Cleaning agent Warm water to which a non-corrosive cleaning agent has been added
2014-09-23 - de
Cleaning interval Every 250 operating hours.

Work cards

TCR16
Cleaning is necessary when 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.
C2 0288 500.24-02 EN-US 1 (3)

An increase in pressure loss, due to a contaminated air filter mat,

Cleaning
should not be used as a reference for the cleaning interval.
Figure 1: Air filter on the silencer
Work sequence - Removal, cleaning/replacement, refitting

Starting condition Engine has been stopped.
Steps 1. Loosen the clamps (544.202), remove cover sheet (544.205) and air fil-
ter mat (544.201).
2. Clean the air filter mat by flushing with warm water to which a non-cor-
rosive cleaning agent has been added.
Avoid excessive mechanical stress (e.g. wringing, sharp water jet). After
cleaning, blow compressed air through the air filter mat.
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.
2014-09-23 - de
Work cards
3. Place air filter mat (544.201) over the perforated plate of the silencer.
The perforated plate must be completely covered by the air filter mat.
TCR16
4. Place cover sheet (544.205) over the hem of the air filter mat and then
fasten the air filter mat using the clamps (544.202).
2 (3) C2 0288 500.24-02 EN-US

Cleaning
Position of the clamps
Figure 2: Position of the clamps

Correct position of the The clamps must be attached as close as possible to the outer edges of the
clamps silencer in order to prevent dirt and foreign objects from entering the com-
pressor through the silencer.
2014-09-23 - de
Work cards
TCR16
C2 0288 500.24-02 EN-US 3 (3)

Technical Documentation (Turbocharger TCR-16)

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Technical Documentation (Turbocharger TCR-16)

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PBS Turbo, s. r. o.

Turbocharger type ............................. TCR16

Plant No. ........................................... OEM-Version

Translation of the original instructions

Fax +420 566 531 925

Copyright © 2014 PBS Turbo, s. r. o.

2 (2) 0411-1 C1-01 EN-US

0411-1 C1-01 EN-US 1 (3)

6.5 Inspection of components

6.6 Inspection report

8 Spare parts catalogue / Tools

8.3 Spare parts

2 (3) 0411-1 C1-01 EN-US

520.01 Rotor assembly, complete

0411-1 C1-01 EN-US 3 (3)

0411-1 1 C1-01 EN-US 1 (1)

Organisation and use of the safety instructions

If the corresponding precautionary measures are not taken,

If the corresponding precautionary measures are not taken,

A hazardous situation can occur if the corresponding

Material damage to the product can occur if the corresponding

This can result in:

Additionally, the element Notice is also used:

C1 6673 1.0-02 EN-US 1 (4)

Identification of special user tips.

Additional or important notes and information.

A symbol appropriate to the hazard is always depicted in the marginal col-

Wear Wear Wear Wear Wear

Warning of a Danger of slip- Tripping hazard Danger of elec- Corrosive

Crush hazard Inflammable Hot Danger of sus- Rotating

Fire, No access for

2 (4) C1 6673 1.0-02 EN-US

Figure 1: Safety instruction sign - engine room

C1 6673 1.0-02 EN-US 3 (4)

m around the engine, are to be instructed of the predominant hazards.

4 (4) C1 6673 1.0-02 EN-US

Responsibility of the user

Risk of accidents resulting from improper use of the

The manufacturer disclaims all liability if the above-mentioned safety

C1 0288 1.1-02 EN-US 1 (3)

▪ by the engine manufacturer:

▪ by the installation contractor / manufacturer of the complete plant:

2 (3) C1 0288 1.1-02 EN-US

Corrosion must be prevented on components that come into contact with an

Foreseeable misuse, negligence, improper use

C1 0288 1.1-02 EN-US 3 (3)

0411-1 2 C1-01 EN-US 1 (1)

C1 0288 2.1-02 EN-US 1 (1)

0411-1 3 C1-01 EN-US 1 (1)

0411-1 3.1-01 EN-US 1 (1)

Operating data and alarm points for turbocharger on a gas-powered engine

1 Turbocharger type 8 Max. permissible turbine inlet

Figure 1: Type plate

The type plate is attached to the delivery socket of the compressor

C1 0411 3.1.1-01 EN-US 1 (3)

Reference value for pressures in bar

All pressures specified in bar in this operating manual are relative

Conformity with EU directives

Lube oil pressure immediately after start-up

line) Reduction to engine half load (slow-down) < 1.4 bar g

Exhaust gas temperature upstream of Alarm at tmax See

2 (3) C1 0411 3.1.1-01 EN-US

Lube oil requirements