2 (b2 4) Turbocharger

MAKER'S FINAL DRAWING
No. gi'^t-
QtheF
Important Note:
No Warranty Claim will be
processed without completed
ENTRY-INTO-SERVICE-FORM
ENTRY - INTO - SERVICE - FORM
We herewith confirm that the following Turbocharger
TYPE:
Work No.:
fitted to the engine
TYPE:
Work No.:
has begun its operation on^ Date:
The engine will be operated
as a Power Station Q Country:
in a Vessel \__\ Name:
Address of Operator and if required Country of Registration if not identical with address:
Address of Owner:
Name, Title Signature Date
Please post, e-mail or fax to:
MAN Diesel & Turbo S E

PrimeServ T u r b o c h a r g e r
86224 Augsburg Fax: +49 821 322-3998
Germ£iny E-Mail: primeserv-tc-warranty@mandieselturbo.com
MAN Diesel & Turbo
Technical Documentation
Turbocharger
Operating Instructions
Turbocharger type NR20/R
Translation of the original instructions

5649-3 C1-03 EN-US 1 (2)
MAN Diesel & Turbo
MAN Diesel & Turbo SE

86224 Augsburg
Phone +49 (0) 821 322-0
Fax +49 (0) 821 322-49 4180
pr1meserv-aug@mandieselturbo.com
www.mandieselturbo.com/prlmeserv
Copyright © 2013 MAN Diesel & Turbo

All rights reserved, including reprinting, copying (Xerox/microfiche) and translation.
2(2) 5649-3 C I - 0 3 EN-US

MAN Diesel & Turbo
Table of contents
1 introduction / Technical data

1.0 Organisation and use of the safety instructions
1.1 Preface
1.2 Manufacturer's liability
1.4 Addresses
1.51.1 Turbocharger - Brief description, function
1.51.2 Operating data and alarm points
1.51.4 Weights
1.51.5 Dimensions
1.52 Gaps and clearances
2 Systems
2.51 Lube oil system
2.54 Acceleration system - Jet Assist
3 Operation
3.0 Safety during operation
3.2.2 Intended use/suitability of the turbocharger
3.51 starting operation, operation, shutting down
3.52 Operating faults, troubleshooting (fault-finding chart)
3.53 Emergency operation in the event of turbocharger failure
3.6.7 Response to out-of-limit conditions and alarms
4 Maintenance
4.0 Safety during maintenance/repair
4.51 Remarks on maintenance work
4.52 Cleaning
4.53 Checking the individual components
4.54 Maintenance schedule (explanations)
4.55 Maintenance schedule (signs/symbols)
4.56 Maintenance schedule (turbocharger)
4.57 Inspection report
4.58 Service report
5 Work cards
5.1 Organisation and use of the work cards
000.31 Screw connections and tightening torques
5649-3 C1-03 EN-US 1 (3)

MAN Diesel & Turbo
500.04 Checking the turbine nozzle ring

500.05 Emergency operation with closing device
500.06 Lateral play of the rotor Checking

500.07 Cleaning the turbine - wet cleaning
500.07 Cleaning the turbine - dry cleaning

500.08 Cleaning the compressor - with fitted tank
500.08 Cleaning the compressor - Pressure sprayer
500.10 Turbocharger or subassemblies

500.11 Cleaning the air filter
500.12 Silencer
500.13 Air intake casing
500.14 Compressor Casing, Insert, Diffuser, Speed Transmitter
500.16 Removing and refitting the cartridge
500.17 Checking and cleaning the cartridge
500.18 Cartridge - checking the individual components
500.19 Gas outlet casing, gas outlet diffuser
500.20 Turbine nozzle ring, insert
6 Spare parts catalogue

6.1 Organisation and use of the spare parts catalogue
6.2 Ordering spare parts
500.01 Oven/iew of subassemblies
501.01 Gas admission casing
506.01 Gas outlet casing
509.01 Gas outlet diffuser
513.01 Turbine nozzle ring

517.01 Bearing casing
520.01 Rotor, complete
540.01 Insert, compressor side
541.01 Insert, turbine side
542.01 Diffuser . -
544.01 Silencer
546.02 Compressor Casing
562.01 Speed measuring device
578.01 Cleaning device for turbine/ wet cleaning
578.02 Cleaning device for turbine/ dry cleaning
579.01 Cleaning device for compressor / tank fitted
2(3) 5649-3 C1-03 EN-US

MAN Diesel & Turbo
579.02 Cleaning device for compressor/ pressure sprayer
591.01 Coverings
599.01 Cartridge
7 Spare parts / Tools

594.01 List of spare parts
596.01 List of tools
8 Index
5649-3 01-03 EN-US 3(3}

MAN Diesei & Turbo
1 Introduction / Technical data

2 Systems
3 Operation
4 Maintenance
5 Work cards
8 Index
5649-3 1 C I - 0 3 EN-US 1 (1)

MAN Diesel & Turbo 1.0
Organisation and use of the safety instructions
Safety instructions
Safety instructions are alv^âys 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 follov/ing designa-
tions;
Danger,
Warning,
• Caution,
• Caution (material damage only)
are indicated as follows:
If the corresponding precautionary measures are not taken,

A DANGER, 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,

A
A vWARNING 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

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

CAUTION precautionary measures are not taken.
This can result in:
• Exclusively material damage; no physical injury expected.
Additionally, the element Notice is also used:
C 03
C I 6673 1,0-02 EN-US 1 (3)

1.0 MAN Diesel & Turbo
Identification of special user tips.

Additional or important notes and information.
NOTICE 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 1 tion
Wear Read
protective manual
clothing
Danger symbols
r
A A A A
Warning of a Danger of slip- Tripping hazard Danger of elec- Corrosive
hazard location ping trie shock materials.
5CS A A A Danger of sus-

A
Rotating
Crush hazard Inflammable Hot
matâls surface pended loads, gear hazard
Bans
Fire, No access for

open flames unauthorized
and smoking persons!
prohibited!
2(3) C I 6673 1.0-02 EN-US

Safety instruction sign - engine room
Figure 1: Safety Instruction Sign - Engine Room
To point out ttie most important regulations, bans and hazards during
operation and maintenance, the safety instruction sign enclosed with
NOTICE each turbocharger must be posted at the entry of the engine room.
Persons, who for operational reasons are to be within the danger area of 2.5
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.
1 s
C I 6673 1.0-02 EN-US 3(3)

Preface
General remarks
MAN Diesel & Turbo Turbochargers produced by MAN Diesel & Turbo have evolved from decades
turbochargers of continuous, successful research and development work. They satisfy high
standards of performance and have ample reserves for withstanding adverse
or detrimental influences. However, to meet all the requirements of practical
service, they have to be used as intended and maintained properly. Only if
these prerequisites are satisfied can unrestricted efficiency and long useful
life be expected.
Purpose of the operating The operating manual as well as the work cards are designed to assist you in
manual and work cards becoming familiar with the turbocharger and the equipment, They are also
intended to provide answers to questions that may turn up later on, and to
serve as a guideline in your activities of engine operation, inspection and
servicing. Furthermore, we attach importance to familiarising you with func-
tions, interrelations, causes and consequences, and to conveying the empiri-
cal knowledge we have. Not least, in providing the technical documentation
including the operating manual and work cards, we comply with our legal
duty of warning the user of the hazards which can be caused by the turbo-
charger or its components - in spite of a high level of development and the
greatest design efforts - or which an inappropriate or unintended use of our
products involves.
The operating manual is continually updated, and matched to the design of

the turbocharger as ordered. There may nevertheless be deviations between
pages with primarily descriptive/illustrative content and the actual design.
Numbering The numbering of the chapters follows an internally defined document struc-
ture. Due to this structure gaps in the numbering can occur. This is intended
and is not an indication of missing sections in the document. The table of
contents always lists the full scope of the documentation.
Personnel The operating manual must be accessible to personnel for the purpose of
operation, monitoring/inspection and maintenance/repair of the turbo-
charger. The personnel entrusted with these tasks are responsible for famili-
arising themselves with the composition of the operating manual so that they
are able to find the necessary information without lengthy searching.
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C I 6685 1.1-02 EN-US 1 (1)

Manufacturer's liability
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.
Teclinical Documentation
The technical documentation supplements this ability through specialized
information, draws attention to dangers and points out the safety regulations
to be observed. The MAN Diesel & Turbo SE asks you to observe the follow-
ing guidelines:
For improper usage of the turbocharger, the danger of

A WARNING accidents is given!
Improper usage of the turbocharger can lead to damage of the
turbocharger or its individual components. Damaged components
pose a potential risk of injury for the operating and maintenance
personnel.
• Before putting into operation for the first time, carefully read the
technical documentation at hand with the therein included safety
instructions!
• Use the turbocharger only for the purpose intended for by the
manufacturer!
• Do not unnecessarily stay in the vicinity of the turbocharger. Staying
within the vicinity of the turbocharger is permitted for maintenance which
is expressly to be carried out during operation!
• Carry out maintenance on the turbocharger regularly and properly within
the specified intervals!
• Carry out any and all repair work exclusively with original MAN Diesel &
Turbo spare parts!
MAN Diesel & Turbo S E disclaims all liability if the above-mentioned

safety regulations are infringed.
NOTICE
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0 1 6685 1.2-02 EN-US 1 (1)

Addresses
Headquarters
Contact persons The following table contains addresses for MAN Diesel & Turbo in Germany,
together with telephone and fax numbers for the departments responsible
and ready to provide advice and support on request.
jAugsburg plant Te)e[^)one/Fax/e-mail/lntemet

1 Headquarters
MAN Diesel & Turbo SE Tel. +49 821 322 0

PrimeServ Augsburg Fax +49 821 322 49 4180
86224 Augsburg
Germany
e-mai I PnmeServ-Aug@mandieselturbo.com
Internet www.mandieselturbo.com/primeserv
PrimeSen/ Turbocharger Tel. +49 821 322 4010 Axial turbochargers (24 hours)
Technical service Tel. +49 821 322 4020 Radial turtochargers (24 hours)
Fax +49 821 322 3998
e-mail PrimeServ-TC-Technical@mandieselturbo.com
Internet, wvw.mandieselturbo.com/primeserv
PrimeServ Turbocharger Tel. +49 821 322 4030 (24 hours)

Spare parts -1-49 821 322 3998 ^ ^ ^ ^
^Hr e-mail PrimeServ-TO-Commercial@mandiesetturtio.com

Internet www.mandieseiturbo.com/primesen/
PrimeServ Academy Tel. +49 821 322 1397

Training courses for turiDochargers Fax -t-49 821 3221170
and engines
^^^^S e-mail Prime^rv.Acaderny-info@mandieseftuftx5.6OTri"'

Internet ww/w.mandieselturbo.com/pnmesen/-academies
Worldwide Service Addresses

Internet MAN Diesel & Turbo service addresses and authorized service partners
(ASP) can be found on the Internet under MAN | PrimeServ Worldwide Net-
work:
vww.mandieselturbo.com/primeserv
C I 6685 1.4-03 EN-US 1 (1)

MAN Diesel & Turbo 1.51.1
Turbocharger - Brief description, function
Longitudinal section
1 Gas admission casing 6b Air intake casing

2 Turbine nozzle ring 7 Insert
3 Turbine wheel 8 Compressor wheel
4 Insert 9 Diffuser
5 Gas outlet casing W Compressor casing
6a Silencer 11 Bearing casing
Figure 1: Turbocharger NR20/R
Brief description
Turbocharger with one radial-flow/ turbine stage and one radial-flow com-
pressor stage. Rotor supported on two floating bearing bushes arranged
inboard.
Turbine wheel (3) with shaft in one integral piece, compressor wheel (8)
mounted on shaft.
Compressor (10) with one outlet socket.
Silencer (6a) or air intake casing (6b), if provided.
Bearing lubhcation integrated in engine lube oil circuit.
No water cooling. Casings on turbine side with heat insulation.
Function
In operation the energy contained in the engine exhaust gases is converted
to drive the turbocharger rotor. The exhaust gases flow from the engine
exhaust pipe through the turbocharger via the gas admission casing (1), tur-
bine nozzle ring (2), turbine wheel (3), insert (4) and gas outlet casing (5) with
integrated gas outlet diffuser. Simultaneously, fresh air is drawn in via the •S SE
silencer (6a) or air intake casing (6b) and insert (7) and compressed via com- o o
pressor wheel (8), diffuser (9) and compressor casing (10).
C I 5649 1.51.1-01 EN-US 1 (2)

1.51.1 MAN Diesel & Turbo
The compressed fresh air is forced into the cylinders of the engine via the
charge air cooler and charge air pipe. Overall, this process achieves a tre-
mendous increase in the p>erformance of the engine. Cross sections and
directions of f\ow are adapted to the individual application.
The turbocharger rotor is guided through 2 floating bearing bushes arranged
between turbine wheel (3) and compressor wheel (8) in the bearing casing
(11). The turbocharger bearings are supplied with oil from the engine lube oil
circuit through a common feed pipe.
The lube oil also serves the purpose of cooling the bearings.
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^ cc
2(2) C I 5649 1.51.1-01 EN-USi

Operating data and alarm points
Turbochargertype plate
O O
exhaust gas turbocharger

type [ T W/No.
"maxf RPM max.temp I 4
O type-tested | 6 j year O
7 Turbocharger type 5 Unit of temperature

2 Works number (serial number) 6 Type approval
3 Max. permissible rotor speed 7 Year of ex-works delivery
4 Max. permissible turbine inlet
temperature
Figure 1: Type plate
The type plate is attached to the delivery socket of the compressor

casing or to the air intake casing (if provided).
NOTICE
Operating parameters
Speed Operating limit r w g^^^^^g Hm see type plate
Exhaust gas temperature upstream of Operating limit tâ^ see type plate
turbine
Lube oil temperature at full engine load Maximum permissible inlet temperature 75 "C
105 X
Maximum permissible outlet temperature
Lube oil pressure' Full engine load and lube oil at operating tempera- 1.3-1.7 bar
ture
r~ •— "^VRKHBr" ——- with SAE 30 at 60 *'C or SAE 40 at 65 "C 1.0001^
T-ube oil flow rate
Jet Assist (optional) Pressure in starting air cylinder 30 bar
Max. permissible inlet pressure in turbocharger 4 bar
iFurther specifications see also Lube oil system, sheet [2.511

' Reference measuring height; turbocharger centreline
. . , — ~ • — J
Table 1: Operating parameters NR20/R
Alarm points/engine shut-down

An alarm must be triggered by the engine control system when the follow/ing
operating data are exceeded:
•S SE
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1 CM
C I 5649 1.51.2-01 EN-US 1 (2)

1.51.2 MAN Diesel & Turbo
Alarm at 97% of n , ^ n^see

type plate
Exhaust gas temperature upstream of Alarm at t^^ ^max see

turbine type plate
Lube oil pressure' Marmat s 1.2 bar

Reduction to engine half load (slow-down) £ 1.0 bar
Engine shut-down £ 0.8 bar
• Reference measuring height: turbocharger centreline

Table 2: Alarm points
Lube oil requirements

Selection of tube oil SAE class SAE 30 or SAE 40
Lube oil filtration Grade of filtration less than 0.05 mm

1
Table 3: Lube oil requirements
See also [2.51] "Lube oil system"
Furtiier data
Indication range of the speed indi- 0... 50,000 rpm
cator
Operating speed of the turbo- refer to the Acceptance Records of the turbocharger
charger
Furtha-operating data refer to the Acceptîce Records and Operating Manual of the engine f
-a SE
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1 CM
2(2) C I 5649 1.51.2-01 EN-US

MAN Diesel & Turbo 1.51.4:
Weights j
Weights assigned to subassemblies (approximate values);

500 Exhaust gas tur1x)charger, complete Oncluding 506 and 544) 375 kg
501 Gas admission casing, complete (with covering) 100 kg
B 506 Gas outlet casing, conplete (with covering) 75 kg
509 Gas outiet diffuser. complete 26 kg
TLffblne nozzle ring 3 kg
517 Bearing casing, compiete 42 kg
Rotw, complete (turbine rotor 8 kg, corTp-essa- wheel 3 kg) ^ j ^ ^l ^ ^ ^ ^ ^ 1 2 k g

540 Insert, compressor side 20 kg
541 Insert, turbine side ...M HHP 8 kg

542 Diffuser 5 kg
544 Silencer, complete Of provided) j

545 Air intake casing, complete (if provided) 15 kg
52 kg
ft ^ Compressor casing, complete I^^^H^^HHHE.. ""'T
599 Cartridge, complete (517 + 520) 55 kg
bN^rview of subassemblies (500 — 599} see spare parts catalogue I^^^^^^^^^^^B
p o
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0 1 5649 1.51.4-01 EN-US 1 (1)

Dimensions
Pipe connections
Connection Dimensions in mm '
Exhaust gas afthe gas admission casing (501) 1 X 0 205

or 2 x 0 120
Exhaust gas Outlet at the gas outlet casing (506) 150 X 560
Charge air Outlet at ttie ccHTipressor casing (546) 0 138

Lube oil Inlet at top of bearing casing (517) 15,0x1,5
flange connection for pipe
Lube oil Drain at bottom of bearing casing (517) 30.0 X 2.0

flange connection for pipe i
Additional lubrication Inlet at side of bearing casing (517) for pipe 8.0 X 1.5
(if provided)
Jet Assist Connection at side of compressor casing (546) 25.0 X 2.0 j
flange connection for pipe
fif prowded)
O O
»- CM
C I 5649 1.51.5-01 EN-US 1 (1)

Gaps and clearances
Values
501.001
541.001
540.001
520.005 ^ 520.006 517.002 520.001
Figure 1: Gaps and clearances
ItBin Designations of parts Order No. When new R ^ c e or remachlne

min. in mm max. in mm min. in mm max. in mm
^ j Compressor wheel (520.005) Radial gap" 'r 050 0.60 0.40 0.70
t^ytnsert (540.001)
2 b) Compressor wheel (520.005) Axial gap 0.30 0.80 0.25 0.90
Insert (540001)
3 a) Turbine rotor (520.001) Radial gap 0.50 0.57 0.40 0.70
Insert (541.001)
1
4 d) Turtiine rotor (520001) Axial gap 0.65 1.15 0.55 1.25

Insert (541.001)
e) Bearing bush (517.002) Axial clear- 022 0.30 —

(520.006) ance
Labyrinth ring
6 Compressor wheel (520.005) Permissibie axiai mnout 0,06
Lateral play of the rotor in the beaings see work card [500.061
r
a) Using a feeler gauge, measure at 4 points on the circumference and calculate the mean value.
b) Measure by means of soft metal imprint (lead wire) at 3 points on the circumference and calculate the
mean value. Deduct the measured axial clearance (5) from the calculated mean value with the rotor
pushed in direction (B).
d) Measure by means of soft metal imprint (lead wire) at 3 points on the circumference and calculate the
mean value. Deduct the measured axial clearance (5) from the calculated mean value with the rotor
pushed in direction (A).
e) Measure with a dial gauge while vigorously moving the rotor in directions (A) and (B). In case of lE^yrinth
seals already run in, the measured value might be smaller.
0 1 5649 1.52-03 EN-US 1 (1)

MAN Diesel & Turbo
2 Systems
3 Operation
4 Maintenance
5 Work cards
8 Index
5649-3 2 C I -03 EN-US 1 (1)

Lube oil system
Lube oil diagram
mm
o
o
15 o
CN
• X OUJ
••
14
Feed pipe (engine) 9 Pressure gauge

Feed pipe (turbocharger) 10 Pressure controller
Throttle device 11 Sealing air *
(orifice or pressure reducing valve)
Bearing bush * 12 Feedpipe
(interval priming)
6 Drainpipe 14 Non-return valve
7 Sight glass or venting box 15 Hydropneumatic accumulator *
8 Venting pipe * Scope of supply of turbocharger
Figure 1: Lube oil diagram, NR turbocharger

Versions Various lube oil supply options are illustrated in the diagram. The required
scope of installation for the specific engine system can be selected in
accordance with the following criteria:
Engines with priming immediately before start-up (standard version).
Feed pipe (2), throttle device (3), drain pipe (6), sight glass/venting box
(7), venting pipe (8), connection for pressure monitoring (9, 10).
Engines with interval priming (e.g. engines with stand-by starting)
Feed pipe (2) with non-return valve (14), throttle device (3), additional
feed pipe (12), drain pipe (6), sight glass/venting box (7), venting pipe (8),
connection for pressure monitoring (9, 10).
The non-return valve (14) must be installed as close as possible to the
feed pipe (1) and designed in such a way that it is closed during priming
and after the lube oil pumps are switched off. This prevents flooding of
the turbocharger during priming and also prevents the feed pipe (2) from C/3
running dry and collecting air.
C I 5649 2.51-03 EN-US 1 (4)

Engines w/ith delayed engine shut-down in the case of falling lube oil
pressure (special version)
In addition to the scope of the two options described above, a connec-
tion for the hydropneumatic accumulator (15) is required. Furthermore, in
the case of engines with priming immediately before start-up, a non-
return valve (14) must be installed; this valve must open at the slightest
priming pressure.
Turbine rotor bearings

General The turbocharger rotor is guided In radial direction through 2 floating bearing
bushes (4) arranged between turbine wheel and compressor wheel in the
bearing casing.
The turbocharger bearings are supplied with oil from the engine lube oil cir-
cuit through a common feed pipe (2). The lube oil also serves the purpose of
cooling the bearings.
Shaft sealing The oil space is sealed on the turbine and compressor sides by labyrinths fit-
ted on the rotor shaft. The radial labyrinth clearance is dimensioned so that,
during the initial operating phase, the rotating labyrinth tips dig lightly into the
softer layer of the sealing covers. At higher speeds, the rotor is slightly ele-
vated corresponding to the thickness of the lubricating film. The labyrinth tips
then run freely. The rotor is lowered again when the turbocharger stops. The
labyrinth tips are then inserted into the grooves of the sealing covers, as a
result of which a better sealing effect is achieved during priming and post
lubrication. Local running-in grooves in the bore of the sealing covers are
therefore desirable and not a reason for parts to be replaced.
Sealing air For sealing the shaft on the turbine side, sealing air (compressed air) is addi-
tionally required:
To prevent exhaust gas from entering the oil space,
to prevent lube oil from seeping into the turbine (coking).
During operation, the sealing air (11) is withdrawn downstream of the com-
pressor wheel and led to the labyrinth seal on the turbine side via ducts dril-
led into the bearing casing.
Priming and post lubrication of the bearing points

Priming Prior to engine start-up, the bearings of the turbocharger must be primed,
which, depending on the lube oil system of the engine plant, may take the
form of priming immediately before start-up, or interval priming. Lube oil
pressure 0.3 — 0.6 bar for a duration of 5 — 10 minutes.
Post lubrication For cooling the plain bearings, the turbocharger has to be lubricated with a
lube oil pressure of 0.3 — 0.6 bar after engine shut-down. The engine lube
oil pumps or the auxiliary pumps must therefore continue running for
15 — 30 minutes.
Lube oil supply, setting the lube oil pressure

Lube oil pressure The measuring connection on the bearing casing is to be used for checking
and monitoring the lube oil pressure.
E The lube oil pressure must be set so that a pressure of 1.3 — 1.7 bar is
a present at these points at full engine load and with the lube oil at sen/ice
s QC temperature (inlet temperature max. 75 °C).
>
(A Z
2(4) C I 5649 2.51-03 EN-US

On start-up and during heating up of the engine, when the lube oil tempera-
ture is relatively low, a lube oil pressure of up to 2.0 bar is admissible for a
short period of time.
The required lube oil pressure is set by means of a throttle device (3), e.g.
orifice or pressure reducing valve, in the feed pipe (2). For engine lube oil
pressures > 2.5 bar, we recommend installation of a pressure reducing valve
with outlet control.
Lube oil flow rate
The required lube oil flow rate depends on the viscosity of the lube oil and
may differ from that stated in the operating data in accordance with the tem-
perature (see sheet 1.51.2 "Operating data and alarm points").
Alarm points, engine shut- The alarm point for lube oil pressure is to be set to a value of 1.2 bar.
down At a lube oil pressure < 1.0 bar the engine performance has to be reduced to
half load (engine slow-down).
If the oil pressure continues to drop, the engine is to be shut down and the
causes are to be remedied. The limit value for engine shut-down is at 0.8 bar
lube oil pressure.
If it is not permitted to shut down the engine for an important reason, the tur-
bocharger is liable to be damaged.
When the limit values are reached, the alarm must be triggered and the
engine control must react at the same time (without delay) in order to
NOTICE avoid damage to the turbocharger.
Differences in height
Differences in height between the Indicating instrument and the

turbocharger centreline are to be taken into account with ± 0.1 bar per
NOTICE 1 m height difference (Indicator installed higher - lower pressure;
Indicator installed lower - higher pressure).
Example: difference in height If the pressure gauge (9) and/or the pressure controller (10) are located 3.0 m
lower, the pressure gauge must indicate a pressure 0.3 bar higher and/or the
setting of the pressure controller must be 0.3 bar higher than the operating
pressure specified above.
Lube oil drainage and venting

Lube oil drainage The drain pipe (6) should have as steep a gradient as possible, and it should
be amply dimensioned and free of resistances and back pressures.
The lube oil drain pipe must be installed with a gradient:

The gradient of the pipe must be at least 5° greater than the maximum
NOTICE possible system inclination.
(A
cc
CO z
C I 5649 2,51-03 EN-US 3(4)

Venting The oil drain pipe must have a venting facility from a sufficiently large com-
partment permitting the oil to settle down, e.g. a sight glass or venting box
(7). The cross section of the venting pipe (8) should be approximately that of
the oil drain pipe (6).
Lube oil requirements

Lube oil quality The plain bearings are rated for use of standard SAE 30 or SAE 40 engine
lube oils and can therefore be directly connected to the lube oil system of the
engine.
High-alkaline cylinder oils are not suitable.
Lube oil filtration The turbocharger does not require its own lube oil filter. The filtration which is
currently standard for engines is adequate, provided the fineness is less than
or equal to 0.050 mm. A precondition is that the engine lube oil is constantly
treated by means of separation and that a water content in excess of 0.2%
by weight and solid residues larger than 0.020 mm are avoided. Prior to initial
operation of the engine or after major sen/icing work, the pipes between the
filter and the turbocharger are to be cleaned, pickled and flushed carefully.
Delayed engine shut-down (special version)

Delayed engine shut-down in plants with lube oil pressure monitoring (alarm and/or engine shut-down if
the pressure falls below specified limits), the delayed engine shut-down
allows a certain amount of time in which a decision can be made as to
whether the engine should be shut down in order to avoid damage to the
turbocharger and engine or whether a necessary manoeuvre should be exe-
cuted in order to prevent greater damage. The prerequisite for this is an oil
pressure accumulator that briefly takes over lubrication of the turbocharger.
Oil pressure accumulator Installation of a hydropneumatic accumulator (15) with a nominal capacity of
10 litres allows the decision to shut down the engine to be delayed by a
maximum of 10 seconds. A longer delay could jeopardize operational safety
and result in damage to the turtjocharger. The hydropneumatic accumulator
(15) is installed in a suitable position no more than 2.0 metres below the
highest point on the feed pipe (2) and connected between the throttle device
(3) and the non-return valve (14). Maximum operating temperature 80 °C.
4(4) C I 5649 2.51-03 EN-US

Acceleration system - Jet Assist
Diagram and function
30 bor
30 bor
A Starting air cylinder (30 bar) D Insert

B 2/2 way solenoid valve E Compressor wheel
C Orifice F Turbocharger
Figure 1: Jet Assist diagram

Functional description The Jet Assist acceleration system is used to meet special requirements with
regard to fast and soot-minimised acceleration, and/or the dynamic load
response of the engine.
The engine control actuates the 2/2 way solenoid valve (B).
Compressed air at 30 bar now flows from the starting air cylinder (A) through
the orifice (C), where it is reduced to a maximum of 4 bar. The compressed
air is now blown at max. 4 bar onto the blades of the compressor wheel (E)
via a ring duct and the inclined bores in the insert (D). On the one hand, this
provides additional air to the compressor while on the other hand, the c o m -
pressor wheel is accelerated, thus increasing the charge air pressure for the
engine.
v>
i <
C I 5649 2.54-01 EN-US 1 (1)

3
MAN Diesel & Turbo
2 Systems
3 Operation
4 Maintenance
5 Work cards
8 Index
5649-3 3 C I - 0 3 EN-US 1 (1)

Safety during operation
Containment Safety
The turbocharger is one of the most highly loaded components on state-of-
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
rare cases - for component failure to occur.
Precautions MAN Diesel & Turbo turbochargers comply with the containment safety
requirements according to the rules of the classification societies, with the
effect that fragments are prevented from escaping by state-of-the-art meas-
ures.
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
A CAUTION
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, c o m -
pressor surging and excessive turbocharger speeds, must be avoided.
Corrosive and erosive agents in the intake air must be avoided.
Technical documentation
The technical documentation of the system, particularly the operating a n d ;
maintenance manuals for the engine, turbocharger and the accessories •
required for engine operation, must be stored at a location where they arei
accessible for the operating and maintenance personnel at all times. i
Accident prevention regulations

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-
able to hang these regulations in the engine room and to repeatedly point out
the dangers of accidents.
CD <
Safety Instructions Concerning Specific Danger Sources o. ec

O z
Hearing Protection
C I 6685 3.0-01 EN-US 1 (4)

Sound levels exceeding 85 dB(A)l

The danger of hearing impainment is given because sound levels are
A WARNING
permanently above this value in the engine room when the engine is
running.
• Always wear hearing protection in the engine room!
Exhaust Gases In the engine room, exhaust gases with the harmful components NO^, SO2,
CO, HC and soot can be set free.
Health risk due to exhaust gases!

The exhaust gases of the engine are harmful to one's health and
A WARNING
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!
Danger of fire
Potential danger of fire in the engine room!

Fuel and lube oil are combustible and can easily ignite when
NING 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!
Fire-extinguishing The engine room must be equipped with fire-extinguishing equipment, The
Equipment proper function of this equipment is to be checked regularly.
Danger to life through suffocation!

When carbon dioxide fire-extinguishing systems are put into operation,
A DANGER.
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!
re 4
a. cc Protective Covers
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2(4) C1 6685 3.0-01 EN-US

Danger of burns and fire hazard from hot system components!

A WARNING Due to high operating temperatures the system components can
become very hot. Persons can bum 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 from
moving components as well as all insulations from hot components are reat-
tached again. Engine operation with coverings removed Is permitted only in
special cases, such as for functional tests.
Alarm System If Important operating data are exceeded, an alarm system will set off alarm,
reduction or stop signals, depending on the danger potential. The cause of
the signals is to be thoroughly Investigated and the source of the malfunction
to t>e corrected. The signals may not be ignored or suppressed, except
when ordered by management or in cases of increased danger.
Ignoring or suppressing alarms and putting reduction and stop

WARNING 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
alami 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/ Qualification of The engine and the systems required for its operation may be started, oper-
Personnel ated and stopped only by authorized persons. The personnel must be edu-
cated, trained and familiar with the system and the occurring dangers.
All persons operating the system or carrying out maintenance or repair work
on the system must have read and understood all accompanying operating
and maintenance instructions.
For ship systems:
Operational management through the chief engineer on board or through a
technical officer.
Persons managing the operation must be in possession of a competence
certificate that corresponds with the national regulations and International CO <
agreement (STCW). The number of required persons and their minimum 53 =.
qualification are usually stipulated through the national regulations or the
international agreement (STCW).
& i
C1 6685 3.0-01 EN-US 3(4)

For stationary systems (power plants):

The superintendent (engineer) must be available. Supervision/controlling of
the engine and the accompanying supply system through a trained and spe-
cially briefed machinist or mechanic.
For managing persons in Germany, proof, among other things, must be fur-
nished in accordance with the energy economy law (EnWG) that the techni-
cal operation management is guaranteed by qualified and sufficiently num-
bered personnel. In other countries, comparable laws/ guidelines are to be
observed.
Safety during operation on the gas-powered engine
Danger of fire caused by electrostatic charging

In the case of turbochargers on gas-powered engines, insulated
A DANGER,
mounting can c a u s e 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
©quipotential bonding between the turbocharger and the engine.
CO <
o. cc
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4(4) C1 6685 3.0-01 EN-US

Intended use/suitability of the turbocharger
Intended use
Intended use
The turbocharger delivered is intended (firstly) for operation within the con-
straints stipulated:
Operating data and alarm points
• Scope of supply/technical specification
Order confirmation.
It Is additionally (secondly) intended for
operation using the specified operating media,
taking into consideration the design/layout of the supply, measuring,
control and regulating systems as well as specification of the constraints
(e.g. removal space/crane capacities) in accordance with the recommen-
dations of MAN Diesel & Turbo or according to the state of the art.
It is additionally (thirdly) intended for
start, operation and stopping of the engine in accordance with the usual
organisational rules, exclusively by authorised, qualified, trained persons
who are familiar with the plant.
Conditionally intended/suitable for
Conditionally intended/suitable for

Tlie turbocharger is conditionally intended/suitable for
operation at operating values resulting in an alarm situation,
operation in case of failure of supply equipment,
operation with reduced maintenance,
• faster acceleration/abrupt loading and unloading to a moderate extent
Not intended/suitable for
Not intended/suitable for

The turbocharger is not intended/suitable for
operation at operating values resulting in engine shut-down or load
reduction,
operation in case of failure of supply equipment,
operation within barred speed ranges,
operation without appropriate surveillance/supervision,
operation without maintenance or with considerably reduced mainte-
nance,
unauthorised modifications,
use of other than original spare parts,
long-term shut-down without taking preservation measures.
§ i
C1 6685 3.2.2-02 EN-US 1 (1)

Starting operation, operation, shutting down
Initial starting of operation
' Danger of poisoning from toxic vapours!

The vapour-phase corrosion agent (increased corrosion protection)
A WARNING
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 |jm recommended) in the
lube oil supply. Measurement of the oil pressure after the intake filter.
Before shipment, the oil system of each turbocharger is factory-

checked for cleanliness, and the oil supply and oil drainage are
NOTICE
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 [500.10]
NOTICE
Engine Control
Indication of the pending alarm and the reaction of the engine control
system must occur at the same time. Therefore, the engine control
NOTICE
system must conform at least to category 3 In compliance with
DIN EN ISO 13849-1.
C I 5649 3.51-02 EN-US 1 (3)

Preparations for start

Turbocharger Prior to engine start-up, the bearings of the turbocharger must be primed,
which, depending on the lube oil system of the engine plant, may take the
form of priming immediately before start-up, or interval priming.
See [2.51] "Lube oil system".
Engine/Turbocharger 1. Ensure that the shut-off elements of the systems have been set to the
in-service position.
2. Check the lube oil pressure upstream of the turbocharger.
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.
Monitoring the turbocharger

General State-of-the-art engine systems are operated automatically as a rule, using
intelligent control and regulation systems. Dangers and damage are pre-
cluded to a large extent by internal testing routines and monitoring equip-
ment. Regular checks are necessary nevertheless so as to recognise the
cause of potential problems as early as possible, and to take remedial action
in due time. Moreover, the necessary maintenance work must be performed
as and when required.
The checks listed below are part of the operator's maintenance

obligations. Results, observations and actions in connection with such
NOTICE 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.
Regular checks on the The regular checks should include the following measures:
turbocharger • Turbine speed
Lube oil pressure upstream of turbocharger
Lube oil temperature upstream of turbocharger
Lube oil temperature downstream of turbocharger
Exhaust gas pressure upstream of turbine
Exhaust gas temperature upstream of turbine
Charge air pressure downstream of compressor
Charge air temperature downstream of compressor
Exhaust gas, charge air and oil pipes for tightness
Air filter mat on the silencer for fouling/saturation
Turbocharger for smooth running
CO 4 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. Listening to
O z the njnning noise of the turbocharger often allows unsmooth operation to be
detected at an early stage.
2(3) 0 1 5649 3.51-02 EN-US

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 rotor speed and can be used for approximate speed
monitoring.
Shutting down
1. Shut down the engine. The turbocharger gradually comes to a stop.
The run-down time of the turbocharger gives an indication of its

mechanical condition. Sudden stopping indicates mechanical damage
NOTICE
to the bearing, contact of the compressor or turbine wheel, trapped
foreign objects or heavy fouling.
Post lubrication See [2.511 "Lube oil system".

Shutting down/preserving The instructions given for the Diesel engine are also valid for the preservation
the turbocharger and prolonged storage of the turbocharger
(refer to the Diesel engine operating manual).
re <x
a. cr
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C I 5649 3.51-02 EN-US 3(3)

Operating faults, troubleshooting (fault-finding chart)
Trouble shooting - description

Operating faults Operating faults normally manifest themselves by abnormal readings
(exhaust gas temperature, charge air pressure and speed), by excessive run-
ning noise or by leaks In the oil pipes.
Possible consequential Should anomalies become evident on the turbocharger on starting or during
damage engine operation, the cause must be traced Immediately. If possible, and the
fault eliminated. Otherwise, there will be a risk of initially minor faults causing
consequential damage to the turbocharger, and also to the engine.
Initial measures In case of faults, the engine load should be reduced, if possible, or the
engine shut down completely and not restarted before the cause of the fault
has been eliminated. .
Unsystematic trials should be avoided because they only rarely lead to

success.
NOTICE
Fault-finding chart
The following fault-finding chart is intended to assist in reliably identifying
trouble, Isolating Its cause and taking prompt remedial action.
FAULTS OCCURRING
i- Extiaust gas temperature upstream of turt)ine too hl^
J- Charge air pressure too low
i- Charge air pressure too high
[-Speed too low
i-Speed too high
i-Lube oil pressure too low
i-Lube oil loss
f Hesitant starting, short run-down time
i- Abnormally high noise level
i- TurtxKharger vibrating
p Compressor surging
POSSIBLE CAUSES
•• • Silencer or air filter fouled

•• • • .
Compressor fouled
•• • • •• Turbine wheel heavily fouled

• • Nozzle ring lightly fouled/constncted
• • 'TT-- 1 • • Turt)ine nozzleringheavily fouled/constricted ^

•• • Thrust ring, labyrinth nng or locating ring damaged
"1 • Labyrinth seats defective ^^t^P
0 1 5649 3.52-02 EN-US 1 (2)

FAULTS OCCURRING
r Exhaust gas temperature upstream of turt)ine too high
Charge air pressure too low
Charge air pressure too high
(-Speed too low
[- Speed too high
Lube oil pressure too low
Lube 01 OSS
r Hesitant starting, short njn-down time
r Abrwrmally high noise level
Turbocharger vibrating
Compressor surging
POSSIBLE CAUSES
Seals damaged, connections leaking

Defective bearings, imbalance of the rotor
Rotor rubbing
Foreign bodies before or in turbine
Foreign bodies before or in compressor
Turbine or compressor wheel damaged
Sealing air ineffective, oil coke downstream of turbine wheel
Substantial erosion on turbine vwheel/shroud ring, nozzle ring
High air intake temperaturh'

Low air intake temperature
Charge air cooler fouled
Charge air pipe leaking
Charge air temperature too high
Lube oil inlet temperature too high
LLII e oil pressure too high
Lube oil filter fouled
Lube oil pressure gauge defective
Excessive pressure in oil discharge or crankcase
Inlet, exhaust valves/slots of engine fouled
Exhaust gas pipe leaking
Exhaust gas back-pressure downstream of turbine too high
Fuel injection on engine faulty
Table 1: Fauft-finding chart
2(2) C I 5649 3.52-02 EN-US

Emergency operation in the event of turbocharger failure
Preliminary remarks
Turbochargers are highly stressed turbo-machines which must reliably
ensure the complete gas renewal of an engine at very high speeds and rela-
tively high temperatures and pressures. Like the engine, the turbocharger
can also suffer disturbances, despite careful system operation, and in most
cases emergency operation is also possible if the damage cannot be
repaired immediately.
Available devices The following devices are available for emergency operation of the engine
while the turbochargers are defective:
NR turtK)chargers:
Closing device to close the turbine rear side with the rotor and bearing
casing removed (cartridge).
See work cards [500.051
Devices for use on the engine:
Screen (protection grid) for the end of the charge air pipe facing away
from the turbocharger (remove the charge air bypass pipe beforehand if
necessary). This screen is designed to facilitate natural aspiration of the
engine.
Blind flange for the exhaust gas pipe at the end facing away from the tur-
bocharger (if there is a charge air bypass pipe). The blind flange serves to
close the exhaust gas pipe during natural aspiration with the bypass pipe
removed.
In the case of V-type engines, depending on the layout of the charge air
and exhaust gas pipes on the engine, blind flanges for the charge air
socket and exhaust gas socket (charge air side: downstream of the com-
pressor, exhaust gas side: upstream of the turbine). These blind flanges
serve to prevent wrong switching/backflow/leakage in emergency opera-
tion.
Emergency operation on failure of a turbocharger
Even if the following measures are observed, there is still a risk

iA WARNING of destruction of the turbocharger!
In this case, there is an acute risk of personal injury and material
damage!
• Limit the duration of emergency operation to an absolute minimum!
• Under no circumstances should you be near the turbocharger without
reason during emergency operation.
Emergency operation after failure of one or both turbochargers

The following possibilities exist if the rotor of the turbocharger can no longer
rotate freely, or must be prevented from rotating.
O z
C I 5649 3.53-03 EN-US 1 (2)

3.53 MAN Diesel 8, Turbo
Emergency measures Code number
Engine may not be stopped for urgent reasons

• Turbocharger remains unchanged ^jmm
Engine may be stopped (short-temi)
NR turbocharger
Dismantle the rotor and bearing casing (cartridge), mount the closing 0-7
device on the rear of the turbine.
Work card [500.05] - Emerqencv operation with closing device
These measures are possible in the event of failure of

1 turbocharger: in-line engine, V-type engine
2 turbochargers: V-type engine
Table 1: Emergency operation after failure of a turbocharger
Explanations
Code number Supplementary measures/precautions
0 Obsen/e engine manufacturer's instructions!
1 Reduce engine power. The maximum exhaust gas temperatures downstream of the cylinders and
upstream of the turbocharger and (on engines equipped with 2 turbochargers) the maximum permis-
sible turtxx;harger speed must not be exceeded. Pay attention to density of exhaust gas.
2 Take all action that appears appropriate to reduce consequential damage.
3 With the rotor arrested or dismantled, cut off the lube oil supply to avoid fouling and fire hazards.
4 The engine has to be operated in the naturally aspirated mode, or (if equipped with 2 turbochargers)
with reduced turbocharging.
5 In-line engines:
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.
6 V-type engines:
On V-type engines having a common charge air pipe, a blind flange is to be mounted on the com-
pressor outlet of the defective turbocharger so as to avoid air losses.
7 V-type engines:
Separate the exhaust gas inlet side of the defective turbocharger from the gas flow of the second
turtx)ctiarger by fitting a blind flange.
Attainable output/speed
The following rating data apply only as reference values:
Falure of 1 birtwcharger In-line engine V-type engine
Pixediaitch propeller 15% up to 50%

of the rated output at the of the rated ouût at the
corresponding speed corresponding speed D
•o
O)
Controllable-pitch pro- 20% up to 50% 6
peller/ of the rated output at the of the rated output at the 6
generator service rated speed rated speed 5
CM
Table 2: Attainable output/speed

0)
Q. CC
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2(2) C I 5649 3.53-03 EN-US

Response to out-oMimit conditions and alarms
General remarks
Operating values/limit values operating values, e.g. temperatures, pressures, flow resistances and all
other safety-relevant values/characteristics, must be kept within the range of
nominal values. Limit values must not be exceeded.
Alarms, reduction and stop Depending on the extent to which values are exceeded and on the potential
signals risks, alarms, reduction or stop signals are triggered for the more Important
operating values. This is done by means of the alarm system and the safety
controller. Reduction signals cause the engine output to be reduced on
marine propulsion systems. This is achieved by reducing the pitch of control-
lable-pitch propeller systems. Stop signals cause the engine to shut down.
Response in emergencies Acoustic or visual warnings can be acknowledged. The displays remain
technical options active until the malfunction is eliminated. In the case of marine propulsion
systems, it is possible to override reduction or stop signals (with the excep-
tion of the "Overspeed" signal) in accordance with the principle "ship takes
precedence over engine". For stationary plants, this option is not possible.
Nor is there a reduction function.
Defining alarm and limit Definition of the alarm and safety-relevant limit values depends on the
values requirements of the classification societies and the user's own assessment.
Legal situation
Alarm, reduction and safety signals serve the purpose of warning against
dangers or of avoiding them. Their causes are to be traced with the neces-
sary care. The sources of malfunctions are to be eliminated in all cases. They
must not be ignored or suppressed, except on instructions from the man-
agement or in cases of a more severe danger.
Ignoring or suppressing alarms and putting reduction and stop

A WARNING 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
A 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 alanns, reduction and stop signals only in cases of
increased danger or when ordered by management!
Liability claims for damages due to nominal values being exceeded or alarm
and safety signals being suppressed or ignored will on no account be
accepted. ca <
a. Qc
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C I 6685 3.6.7-02 EN-US 1 (1)

MAN Diesel & Turbo
2 Systems
3 Operation
4 Maintenance
5 Work cards
8 Index
5649-3 4 C I - 0 3 EN-US 1 (1)

Safety during maintenance/repair
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.
A •
•
•
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.
NOTICE 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
A CAUTION 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)l
• Wear protective clothing!
Danger of burning/scalding from running-out lube oil!

The lube oil is under pressure and very hot!
A CAUTION
• Before opening pipes, flanges, screwed connections or gauges, free the
system of pressure and check that it is pressure-free!
• Before opening oil pipes, wait until the lube oil has cooled down
sufficiently (1 -2 h)!
• Drain the system and check that the lube oil has been drained
completely!
S 15
.E ^
• Wear protective clothing! TO 5=
C I 6685 4.0-01 EN-US 1 (3)

4.0 MAN Diese! & Turbo
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
A DANGEa 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 w/hen 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 welt a s
A WARNING unsuitable storage locations can result In severe personal injury and
severe material damages.
A •
•
•
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.
CD
cu F.
2(3) C I 6685 4.0-01 EN-US

Cleaning agents can be caustic!

C l e a n i n g a g e n t s on the s k i n , in the e y e s or b e i n g i n h a l e d c a n l e a d to
A WARNING
s e r i o u s d a m a g e to o n e ' s health or to allergies.
A l w a y s observe the m a n u f a c t u r e r ' s notes for cleaning a g e n t s i
W e a r protective clothing w h e n e v e r required!
Wear protective gloves w h e n e v e r required!
Wear safety g o g g l e s w h e n e v e r required!

Wear respiratory p r o t e c t i o n w h e n e v e r required!
Pay attention that other p e r s o n s also w e a r t h e a p p r o p r i a t e protective
e q u i p m e n t w h e n e v e r required or m a k e t h e s e p e r s o n s a w a r e thereof!
Use of higti-pressure cleaners

W h e n w o r k i n g with high-pressure cleaners, ensure that t h e y are u s e d cor-
rectly.
Air filters, shaft e n d s (including t h o s e with lip-type sealing rings), g o v e m o r s ,
s p l a s h - p r o o f monitoring s y s t e m s , cable s o c k e t s as well as s o u n d a n d heat
insulation under n o n - w a t e r t i g h t coverings m u s t b e c o v e r e d or not s u b j e c t e d
t o high-pressure cleaning.
Spare Parts
During operation, t h e c o m p o n e n t s of t h e turiôcharger are s u b j e c t e d t o very
high forces. M A N Diesel & T u r b o has therefore d e v e l o p e d special materials
that can w i t h s t a n d these high f o r c e s . Only by using M A N Diesel & T u r b o
original spare parts c a n y o u b e sure that t h e s e high-quality materials have
been employed.
Spare parts from other manufacturers may be manufactured

A DANGER. using inferior materials that cannot withstand the loads they
are subjected to during operation of the turbocharger!
T h i s c a n result in s e v e r e d a m a g e to the t u r b o c h a r g e r , e n g i n e r o o m a n d
e n g i n e , a n d d a n g e r to life for the operating p e r s o n n e l .
• Use only original s p a r e parts f r o m M A N Diesel & T u r b o !
• Only use spare parts from other manufacturers if they have b e e n

a p p r o v e d by M A N Diesel & T u r b o !
M A N Diesel & T u r b o shall in no w a y be liable for any personal injury or m a t e -

rial d a m a g e c a u s e d b y use of spare parts f r o m other manufacturers. Further-
m o r e , any a n d all w a r r a n t y claims relating t o the t u r b o c h a r g e r expire w h e n
using non-original s p a r e parts.
re
CO F.
0 1 6685 4.0-01 EN-US 3(3)

Remarks on maintenance work
General remarks
Disassembling the T h e simplest m e t h o d to use for d i s a s s e m b l y is best c h o s e n o n the basis of
turbocharger t h e s p a c e available in the engine r o o m . W h e n carrying out m a i n t e n a n c e a n d
inspection w o r k , in m o s t c a s e s it is sufficient to d i s m o u n t only s u b a s s e m b l i e s
of t h e turbocharger.
Inspection report For a major overhaul of t h e t u r b o c h a r g e r or for repair work c o n c e r n i n g m a j o r

c o m p o n e n t s , it is r e c o m m e n d e d to r e c o r d t h e c o n d i t i o n of individual s u b a s -
s e m b l i e s a n d to include this information in the operating l o g .
S e e [4.57] "Inspection report".
In d i s a s s e m b l y work, m a r k the position of the c o m p o n e n t s relative to

e a c h other u s i n g a felt-tip m a r k e r p e n . If r e q u i r e d , d o c u m e n t the
NOTICE d i s a s s e m b l y / a s s e m b l y with a c a m e r a .
Exchanging components
C o m p o n e n t s with traces of w e a r or d a m a g e that influence especially t h e
s t r e n g t h a n d t h e balancing precision a n d thus t h e s m o o t h running of rotating
p a r t s , m u s t b e e x c h a n g e d with original s p a r e parts or repaired b y a n a u t h o r -
ized repair facility or t h e manufacturer.
For d i s p a t c h , c o m p o n e n t s m u s t b e p a c k e d a n d p r o t e c t e d against c o r r o s i o n
In s u c h a m a n n e r that they are not further d a m a g e d during t r a n s p o r t a t i o n .
Screw connections
Never attempt to loosen seized or tight screw connections with

NOTICE excessive force.
T h i s c a n l e a d to bolts b e i n g s h e a r e d off or p a r t s being s o badly
d a m a g e d that they m u s t b e r e p l a c e d . S h e a r e d - o f f bolts m u s t b e drilled
out a n d the t h r e a d s r e t a p p e d .
Loosening Seized or Tight A p p l y diesel fuel or special solvent (e.g. C a r a m b a , Omnigliss, W D 40) liberally
Screw Connections t o t h e s c r e w c o n n e c t i o n s a n d allow t o penetrate for at least V? hour s o that
t h e solvent can w o r k its w a y t h r o u g h the t h r e a d . O b s e r v e t h e instructions f o r
u s e s u p p l i e d b y t h e solvent manufacturer. T h e n a p p l y light h a m m e r b l o w s t o
t h e bolt h e a d until t h e bolt turns freely in the t h r e a d .
Tightening Screw All s c r e w c o n n e c t i o n s o n t h e t u r b o c h a r g e r m u s t b e in satisfactory c o n d i t i o n

Connections f o r a s s e m b l y or b e r e n e w e d .
Always tighten screws/bolts with the specified tightening

NOTICE torque!
F o r r e a s o n s of s a f e t y , only bolts of the s p e c i f i e d quality m a y be u s e d !
S e e T e c h n i c a l D o c u m e n t a t i o n , VVprk C a r d s .
C I 5 6 4 9 4.51-03 EN-US 1 (2)

Figure 1: Lock washer pair

W h e n a s s e m b l i n g t h e lock w a s h e r pairs {one pair consisting of 2 identical
w a s h e r s ) , m a k e sure t h a t t h e l o n g w e d g e surfaces (B) c o n t a c t e a c h o t h e r (on
t h e inside), othenwise t h e locking effect will b e lost.
Incorrectly tightened a n d l o c k e d bolts a n d nuts c a n b e c o m e loose d u e t o

vibrations a n d t h e n be driven into t h e t u r b o c h a r g e r by t h e air or exhaust g a s
flow, thereby c a u s i n g severe d a m a g e .
Screw Connections on the D u e t o t h e high t e m p e r a t u r e s o n t h e t u r b i n e side, bolts, nuts a n d t a b w a s h -

Turbine Side ers m a d e of non-scaling materials are u s e d . T h e s e are m a r k e d o n t h e f a c e
s i d e ( S B , S D , S M , V M o r 4 9 2 3 , Z 1 or 4 8 2 8 ) t o a v o i d t h e m f r o m b e i n g m i s -
t a k e n for regular parts. W h e n d i s a s s e m b l i n g , the fasteners m a r k e d in this
m a n n e r are t o b e s t o r e d separately until being a s s e m b l e d .
All lock w a s h e r pairs o n t h e t u r b o c h a r g e r are m a d e of n o n - s c a l i n g material

a n d are not m a r k e d ,
In order t o avoid t h e bolts a n d nuts o n t h e turbine side f r o m fusing t o g e t h e r
t h r o u g h overheating, they m u s t be t r e a t e d with h i g h - t e m p e r a t u r e lubricant
(e.g. M o l y k o t e H S C ) prior t o e a c h n e w assembly. Before treating w i t h lubri-
cant, t h e t h r e a d s m u s t b e cleaned thoroughly.
S c r e w - I n t h r e a d s of s t u d s are not t r e a t e d .
2(2) C I 5649 4.51-03 EN-US

Cleaning
Air filter
Air filter mat T h e air intake o p e n i n g of t h e silencer is c o v e r e d b y an air filter m a t of h i g h
filtering effect. T h e silencer, c o m p r e s s o r a n d c h a r g e air cooler are therefore
effectively p r o t e c t e d against fouling. T o maintain this efficiency, timely c l e a n -
i n g o r r e p l a c e m e n t of t h e air filter m a t s is necessary a n d is definitely d u e
w h e n t h e inside of t h e air filter m a t starts getting dark, a reliable sign that t h e
a b s o r b i n g capacity of t h e air filter m a t has b e e n e x h a u s t e d a n d dirt is b e g i n -
ning t o e m e r g e f r o m t h e filter. T a k i n g t h e pressure differential a s an indicator
is not reliable b e c a u s e it d e p e n d s o n t h e rate of air flow prevailing a n d t h u s
o n t h e service point a n d t h e position in t h e operating m a p .
Cleaning intervals For r e c o m m e n d e d cleaning intervals, please refer t o

>- Sheet [4.56] " M a i n t e n a n c e s c h e d u l e "
* - W o r k c a r d f500.ni "Cleaning t h e air filter".
Compressor
Cleaning by injecting water In t h e c a s e of N R t u r b o c h a r g e r s , dirt d e p o s i t e d o n t h e blades of t h e c o m -
during operation pressor w h e e l a n d o n t h e diffuser m a y c a u s e a measurable loss in efficiency,
b e c a u s e of t h e relatively small d i m e n s i o n s .
W e therefore r e c o m m e n d a c o m p r e s s o r w a s h i n g device, especially in c a s e s
of heavily fouled intake air. Fresh w a t e r is t o b e u s e d exclusively. Sea w a t e r
a n d c h e m i c a l additives a n d cleansers are not p e r m i t t e d . Cleaning a g e n t s for
t h e c h a r g e air cooler have t o b e i n t r o d u c e d d o w n s t r e a m of t h e c o m p r e s s o r .
Cleaning s h o u l d b e carried o u t w i t h t h e engine at operating t e m p e r a t u r e a n d

under full load.
Cleaning intervals R e c o m m e n d e d cleaning intervals:

*- Sheet [4.56] " M a i n t e n a n c e s c h e d u l e "
W o r k c a r d [500.081 "Cleaning t h e c o m p r e s s o r "
Versions available A portable w a t e r container w i t h a c c u m u l a t o r w h i c h Is t o b e c o n n e c t e d t o t h e

cleaning o p e n i n g o n t h e c o m p r e s s o r casing, silencer o r air intake c a s i n g . A
h a n d - o p e r a t e d syringe is p r o v i d e d for small frame sizes s u c h a s N R 1 2 . Alter-
natively, a w a t e r t a n k c a n b e permanently installed at a n easily accessible
point. T h e t a n k is t o b e l o c a t e d n o t less t h a n 6 0 0 m m lower t h a n t h e p o i n t of
injection t o avoid t h e w a t e r being prematurely extracted b y a v a c u u m in t h e
c o m p r e s s o r as t h e t a n k is t o p p e d u p with water. T h e air required t o d r a w t h e
w a t e r o u t of t h e t a n k s h o u l d b e w i t h d r a w n d o w n s t r e a m of t h e c h a r g e air
cooler.
Mectianical cleaning Dirt that h a s d e p o s i t e d o n t h e c o m p r e s s o r w h e e l , air diffuser a n d c o m p r e s -

sor volute c a n b e r e m o v e d b y m e a n s of a s t e a m jet during m a i n t e n a n c e
w o r k . A further possibility is t o s o a k t h e dirt d e p o s i t s in Diesel fuel o r o t h e r
liquid cleansers a n d t h e n t o b r u s h t h e m off.
Cleaning a g e n t s containing chlorine are liable t o a t t a c k t h e aluminium alloy

(of t h e c o m p r e s s o r wheel) a n d m u s t therefore not b e u s e d .
Under no circumstances may cleaning agent or loosened dirt

NOTICE enter the lube oil system.
T h e u s e of h i g h - p r e s s u r e c l e a n e r s Is not permitted.
C I 5649 4.52-03 EN-US 1 (2)

Turbine
Cleaning during operation D e p e n d i n g o n t h e fuel oil g r a d e a n d the engine operating m o d e , residues
from c o m b u s t i o n m a y a c c u m u l a t e o n t h e vanes/blades of t h e nozzle ring a n d
turbine. T h e progressive build-up of dirt d e p o s i t s a n d t h e resultant consider-
able deterioration of o p e r a t i n g p e r f o r m a n c e m a y lead t o c o m p r e s s o r surging
or t o excessive a n d d a n g e r o u s vibrations of t h e turbine w h e e l b l a d e s d u e t o
uneven fouling of the nozzle ring. Incipient fouling is indicated by a rising
c h a r g e air pressure as a result of t h e narrower nozzle ring c r o s s section.
C h a r g e air pressure d r o p s as fouling increases. This c a u s e s t h e exhaust g a s
t e m p e r a t u r e t o rise.
Cleaning intervals R e c o m m e n d e d cleaning inten/als:

Sheet r4.561 " M a i n t e n a n c e s c h e d u l e "
» W o r k c a r d f500.071 "Cleaning t h e turbine"
D e p e n d i n g o n t h e fuel oil g r a d e a n d engine operating m o d e , other inten/als
may be appropriate.
T w o m e t h o d s are available for cleaning t h e turbine d u r i n g o p e r a t i o n :
Wet cleaning T h e engine h a s t o b e b r o u g h t d o w n t o a p p r o x . 0 — 1 5 % o u t p u t for this p u r -

p o s e ( m a x i m u m exhaust g a s t e m p e r a t u r e u p s t r e a m of turtjine 3 2 0 "C) t o
avoid thermal s h o c k of t h e turbine blades. The m e d i u m u s e d for cleaning is
fresh w a t e r i n t r o d u c e d w i t h o u t any chemical additives u p s t r e a m of the tur-
bine.
Dry cleaning Granulates of nut shells or activated charcoal (soft) with a grain size of
1 — 1.5 m m a r e i n t r o d u c e d u p s t r e a m of t h e turbine, u n d e r n o r m a l e n g i n e
service load a n d using c o m p r e s s e d air f r o m the o n - b o a r d s y s t e m . The
engine loading n e e d not b e r e d u c e d for this p u r p o s e . T h e cleaning d e v i c e is
d e s i g n e d t o i n t r o d u c e t h e necessary a m o u n t of granulate over a period of 2 0
t o 3 0 s e c o n d s rather t h a n all at o n c e . This will prevent a s u d d e n s p e e d d r o p
a n d surging of t h e c o m p r e s s o r , especially v^fhere several t u r b o c h a r g e r s are
o p e r a t e d in parallel.
The required granulate c a n b e o r d e r e d f r o m :
M A N Diesel & T u r b o S E
PrimeServ T u r b o c h a r g e r
86224 Augsburg, Germany
Mechanical cleaning During m a i n t e n a n c e w o r k , severe fouling (such as heavy fuel oil d e p o s i t s o r

oil coke) a c c u m u l a t e d o n t h e nozzle ring a n d turbine w h e e l c a n b e s o a k e d in
water treated w i t h s t a n d a r d d o m e s t i c d e t e r g e n t s a n d s u b s e q u e n t l y b r u s h e d
off. If necessary, t h e p r o c e s s m u s t b e r e p e a t e d several t i m e s . S o a k i n g c a n
b e d o n e in a n a p p r o p r i a t e vessel over several h o u r s .
It must under all circumstances be ensured that water and

NOTICE loosened dirt do not enter the lube oil system.
2(2) C1 5649 4.52-03 EN-US

Checking the individual components
General remarks
T h e following remarks a n d questions are intended as a g u i d e , e . g . for
• A s s e s s m e n t of t h e turiDOCharger c o n d i t i o n ,
Operating log a n d inspection report,
Inspection, reusing, repair a n d replacement of individual c o m p o n e n t s .
Inspection work
Oil coke downstream of Sealing air b o r e in t h e bearing casing c l o g g e d .
turbine wheel Shaft seal o n turbine side d a m a g e d .
Priming pressure t o o high.
Streaks over the entire Turbine rotor, c o m p r e s s o r w h e e l , inserts:

circumference C h e c k t h e bearing b u s h e s >~ W o r k c a r d [500.181
C h e c k g a p s a n d clearances >• Sheet [1.52]
Streaks on parts of Turbine rotor, c o m p r e s s o r w h e e l , inserts:

circumference Signs of imbalance.
Crack test on the turt)ine Turbine rotor, c o m p r e s s o r w h e e l :

blades By acoustic testing or fluorescent d y e penetration m e t h o d
Gaps and clearances Permissible values ^ Sheet [1.52] " G a p s a n d clearances".
Erosion in HFC operation W h e r e heavy fuel oil is u s e d , t h e exhaust g a s c o n t a i n s small h a r d particles

(e.g. "cat fines") w h i c h have an erosive effect especially at t h e outlet of t h e
turbine nozzle ring, w h e r e g a s velocities a n d c o n c e n t r a t i o n s of these parti-
cles are high. Moreover, there is a very p r o n o u n c e d deflection of the flow in
circumferential direction, a n d t h e particles are also s u b j e c t e d t o t h e centrifu-
gal effect.
"Cat fines" W h e r e d o t h e s e erosive solid particles c o m e from?

A s a result of t h e refinery p r o c e s s , " c a t fines", a fine-grained p o w d e r of great
hardness (recognizable by t h e Al a n d Si content) as well as other abrasive
c o n t a m i n a n t s are c o n t a i n e d in t h e heavy fuel oil, d e p e n d i n g o n its quality.
Their a m o u n t c a n b e r e d u c e d b y m e a n s of a m p l y d i m e n s i o n e d , h e a t e d set-
tling t a n k s a n d by a d e q u a t e separation.
Admixtures Particularly d i s a d v a n t a g e o u s is the a d m i x t u r e of u s e d engine lube oil, c h a r a c -

terized by increased c o n c e n t r a t i o n s of C a a n d Fe. U s e d engine lube oil c o n -
tains not only w e a r residues, but a b o v e all "detergent/dispersant additives",
w h i c h bind fine particles a n d prevent "cat fines" a n d other impurities f r o m
being extracted t h r o u g h separation. Far m o r e severe erosion d a m a g e results
f r o m blending the fijel with " u s e d oil".
C o m b u s t i o n residue c a u s e d by i n c o m p l e t e c o m b u s t i o n c a n also have e r o -

sive effects. Clean c o m b u s t i o n m u s t therefore b e e n s u r e d .
Casings W h i c h casings are heavily fouled by soot, oil or oil c o k e ?

W e r e the casings tight, particularly at the joints a n d c o n n e c t i n g fianges?
Do t h e casings s h o w signs of c r a c k s ?
H a d bolts b r o k e n off?
W e r e all s c r e w s / b o l t s a n d nuts firmly tightened a n d l o c k e d ?
W e r e the sealing air or oil b o r e s in t h e bearing casing c l o g g e d ?
A r e the seals in o r d e r ?
C I 5649 4.53-03 EN-US 1 (2)

Silencer, if proviijed W h a t is t h e c o n d i t i o n of t h e air filter m a t ?

W h a t is t h e c o n d i t i o n of t h e felt linings?
Are there c r a c k s o n any of t h e c o m p o n e n t s ?
Electronic speed measuring W a s t h e s p e e d t r a n s m i t t e r or t h e s p e e d indicator defective?

device W e r e t h e two pole plates o n the s p e e d transmitter d e f o r m e d ?
Compressor wheel Do t h e turbine blades s h o w signs of c r a c k s or heavy w e a r ?

Do t h e leading e d g e s of t h e turbine blades s h o w i m p a c t n o t c h e s c a u s e d b y
d r a w n - i n foreign o b j e c t s ?
A r e any streaks evident?
W h a t is t h e c o n d i t i o n of t h e seat of the c o m p r e s s o r w h e e l ?
Is t h e seating surface bright, or d o e s it s h o w fretting c o r r o s i o n ?
Turbine rotor Are t h e turbine blades d a m a g e d or is heavy wear or erosion evident at t h e

edges?
D o t h e t u r b i n e blades s h o w signs of c r a c k s ?
Are there any streaks t o b e f o u n d o n t h e blades, w h e e l or shaft?
Is the shaft running true?
W h a t is t h e c o n d i t i o n of t h e bearings?
Have t h e labyrinth tips of t h e locating ring b e e n severely w o r n ?
A r e t h e seat f a c e s bright o r are there signs o f fretting c o r r o s i o n ?
Inserts Are any streaks evident?
Distance sleeve, labyrintti Are t h e seat f a c e s bright or are there signs of fretting c o r r o s i o n ?
ring A r e there any signs of s c o r i n g or heavy w e a r ?
Bearing bushes C h e c k t h e b e a r i n g b u s h e s >- W o r k c a r d [ 5 0 0 . 1 8 ] "Cartridge - c h e c k i n g t h e

individual c o m p o n e n t s " .
Diagonal w e a r o n b o t h bearings s u g g e s t s rotor i m b a l a n c e .
Sealing cover Is t h e run-in pattern of t h e labyrinth tips nomnal?
Turbine nozzle ring A r e t h e blades b e n t ?

A r e t h e blades heavily w o r n d u e t o erosion?
Have foreign o b j e c t s b e c o m e j a m m e d in t h e d u c t s ?
Are there traces indicating the p r e s e n c e of foreign o b j e c t s ?
Are any c r a c k s evident o n t h e blades?
2(2) C I 5649 4.53-03 EN-US

Maintenance schedule (explanations)
Reliability and adaptability

Validity of the maintenance T h e maintenance s c h e d u l e c o n t a i n s a s u m m a r y of t h e m a i n t e n a n c e a n d
schedule inspection w o r k , u p t o major overhaul of the t u r b o c h a r g e r .
A major overhaul of t h e t u r b o c h a r g e r m u s t b e carried out at t h e latest after
1 2 , 0 0 0 — 1 8 , 0 0 0 operating hours for NR t u r b o c h a r g e r s ,
1 2 , 0 0 0 — 1 8 , 0 0 0 operating h o u r s for NA t u r b o c h a r g e r s (four-stroke
engine),
• 24,000 - 3 0 , 0 0 0 operating h o u r s for NA t u r b o c h a r g e r s ( t w o - s t r o k e
engine).
After e a c h major overhaul, w h i c h is best carried out w h e n a n engine service

falls due, t h e maintenance s c h e d u l e starts f r o m the beginning again.
A major overhaul includes the d i s a s s e m b l y of t h e c o m p l e t e t u r b o c h a r g e r for
inspection of the actual c o n d i t i o n , t h o r o u g h cleaning a n d a c h e c k of all p a r t s /
components.
T h e m a i n t e n a n c e m u s t b e s c h e d u l e d well in a d v a n c e , m e a n i n g that, for

e x a m p l e , sailing t i m e t a b l e s or p o w e r plant i n s p e c t i o n s m u s t b e t a k e n
NOTICE into a c c o u n t . In order to e n s u r e the operational safety of the
t u r b o c h a r g e r a n d the e n g i n e , m a i n t e n a n c e w o r k is to b e p e r f o r m e d a s
far a s p o s s i b l e on s c h e d u l e or b e f o r e h a n d .
Adaptation of the T h e maintenance schedule is b a s e d o n t h e following o p e r a t i n g c o n d i t i o n s

maintenance schedule a n d a n annual operating p e r i o d of a p p r o x . 6 0 0 0 h;
uniform loading within a range of 6 0 t o 9 0 % of t h e rated p o w e r ,
• c o m p l i a n c e w i t h t h e specified limits for t e m p e r a t u r e s a n d p r e s s u r e s of
t h e operating media,
use of t h e specified lube oil a n d fuel qualities,
reliable separation of fuel a n d lube oil.
The maintenance intervals m u s t be s h o r t e n e d w h e n t h e following operating
c o n d i t i o n s are given:
p r o l o n g e d operation at peak loads or low loads, long idle p e r i o d s , s u b -
stantial a n d frequent load c h a n g e s ,
• frequent engine starts a n d repeated w a r m i n g - u p p h a s e s w i t h o u t a d e -
q u a t e preheating,
high loading of t h e engine before t h e specified o p e r a t i n g m e d i a t e m p e r a -
tures are r e a c h e d ,
lube oil, cooling w a t e r a n d c h a r g e air t e m p e r a t u r e s that are t o o low,
use of inappropriate fuel qualities a n d insufficient s e p a r a t i o n ,
inadequate filtration of t h e intake air (particularly w i t h stationary engines).
Tools for turbocharger

Inventory tools Commercially available tools that are generally present in t h e inventory of t h e
engine s y s t e m .
C I 5649 4.54-03 EN-US 1 (2)

Inventory tools are not included in t h e s c o p e of supply of t h e t u r b o c h a r g e r .
standard tools I n c l u d e d a s s t a n d a r d in t h e s c o p e o f s u p p l y of t h e t u r b o c h a r g e r .
1 set of s t a n d a r d tools is normally sufficient for a s y s t e m w i t h several t u r b o -
c h a r g e r s . These s t a n d a r d tools a n d t h e inventory tools c a n be u s e d to per-
f o r m routine m a i n t e n a n c e w o r k ,
T h e set of s t a n d a r d tools for the turbocharger(s) is k e p t in o n e or m o r e c a s e s

w i t h a list of c o n t e n t s . This list of c o n t e n t s m a y also b e referred t o for t h e
o r d e r n u m b e r s of the individual tools.
Tools for customer Additional tools a n d fixtures c a n be o r d e r e d f r o m M A N Diesel S E if r e q u i r e d .

requirements
Special tools T h e s e are only available at t h e service centres a n d are not required by the
o p e r a t o r of t h e turtôcharger.
S o m e t a s k s , particulariy repair t a s k s rather t h a n m a i n t e n a n c e t a s k s , require
special technical k n o w l e d g e , experience a n d additional e q u i p m e n t / a p p l i a n -
c e s . Our service c e n t r e s a n d , in certain c a s e s , authorized w o r k s h o p s have
additional special tools at their disposal for s u c h tasks. W e thus r e c o m m e n d
that y o u consult t h e s e partners or entrust t h e w o r k t o t h e m in s u c h c a s e s
w h e r e y o u d o not have sufficient t i m e , technical resources or personnel.
2(2) C1 5649 4.54-03 EN-US

Maintenance schedule (signs/symbols)
Explanation of signs and symbols

T h e header of t h e m a i n t e n a n c e schedule contains signs a n d s y m b o l s . They
have t h e following m e a n i n g :
Serial number of the maintenance work. The series of numbers contains gaps for changes/
1,2,3 updates which might become necessary.
Brief description of the maintenance job
^ ^
Relevant work cards.

The work cards listed contain detailed information on the work steps required.
— A = No work card required/available
Personnel required
i Time required in hours per person
per Relational term to indicate the time required
Signs used in the columns of intervals.

Their meaning is repeated on each sheet.
X, 1,2 We assume, on the other hand, that the signs and symbols used in the header are suffi-
ciently pictorial and that it is not necessary to repeat them constantly.
Table 1: Explanation of signs and symbols of the maintenance sctiedule;
C I 5649 4.55-03 EN-US 1 (1)

Maintenance schedule (turbocharger)
Maintenance schedule (turbocharger)

1, per
2,
3000
250"
1200
150
3 — "
•
Inspection (during o p e r a f i b ^ ^ J ^
901 Check turbocharger for unusual noise and vibrations. 0.10 I Turbo X
903 Check turbocharger and system pipes for leaks (sealing • 0.20 ' Turbo X
air, charge air, exhaust gas, lube oil)
905 Check all the fixing screws, casing screws and pipe 500.10 1 Turbo
connections for fight fif
intenance (during op&ation)
'911 Clean turbine - Dry cleaning, if provided 500.07 1 0.30 TurtX) 1
913 Clean turbine - Wet cleaning, if provided 500.07 1 0.60 Turbo 1
915 Clean compressor (during operation) 500.08 1 0.30 Turbo 1
M^ntenance (engine has been stopped)

917 Clean air filter {if provided) 500.11 1
Maintenance (together wHt) engine mainterjance)

931 Clean and check compressor casing, insert, diffuser 500.10 '2 Turbo X
! and compressor wheel (visual inspection). Establish 500.14
operational readiness of the turbocharger again.
Major overhaul 12,000 ... 18,000 operating hours: "ooisT 15 ; Turbo
Dismantle, clean and check all components of the 500.04
turbocharger. Check gaps and clearances upon 500.06
assembly 500.10
500.16
500.17
500.18
500.19
500.20
Legend for maintenance schedule

24 ... 12000 Repetition intervals in operating hours
X Maintenance work due
1 As required/depending on condition
2 Check new or overhauled parts once after the time specified
1 £
0 1 5649 4.56-03 EN-US 1 (1)

Inspection report
Inspection report form

Relating to service report of Date
Name of customer Turbocharger
Address Works No. . .
Site Engine type .
Ship's name Works No.. .
Turbocharger inspected / overhauled on by

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

if provided
• fouled • fouled
air filter mat by by
• replaced signs of touching
• cracks
reason: • damage by foreign object D radial
felt linings • over the entire circumference
• fouled • in section of the circumference
• wavy DillUSSr (542.001)
blades
• separated • used • replaced • bent
• with cracks
Air intake casing (545.001), • fouled
• erosion
if provided by
• damage by foreign object
• fouled n vanes bent
bearing points
by • vanes with incipient cracks
• fretting marks
s p e e d transmitter (562.040), • wear
if provided seating faces
• defective Compressor wheel (520.005) • fretting corrosion
• pole plates deformed • fouled labyrinth tips
by • oil coke
Speed indicator (562.100), • wear
if provided signs of touching
• axiai
n defective • radiaJ Labyrinth ring (520.006)
Insert (540.001) • over the entire circumference u used • replaced
n in section of the circumference • fretting marks
• used • replaced
blades • wear
n fouled
• bent • fretting corrosion
by
• with cracks
signs of touching • damage by foreign object Distance sleeve (517.003)
• radial
• over the entire circumference bore • used 'O replaced
• in section of the circumference) • fretting corrosion ^ • fretting marks
C I 5649 4.57-03 EN-US 1 (2)

Bearing c a s i n g (517.001) Sealing c o v e r (517.087), G a s - a d m i s s i o n casing

if provided (501.001)
• fouled
by • used • replaced • fouled
• cracks • abnormal running-in pattern by
sealing air lx>res • wear • cracks
• clogged _] cleaned • signs of touching • erosion
oil bores
S e a l i n g c o v e r (517.017) screwed connections
• clogged • cleaned
if provided • slack
seals • torn off
• replaced
• abnormal running-in pattern • replaced
B e a r i n g b u s h compressor side
• wear
(517.002) G a s outlet c a s i n g
• oil coke cleaned (506,001)
• fretting marks • fouled
• wear Turbine nozzle ring (513.001)
by
• outside diameter • used • replaced
• inside diameter • cracks
• vanes bent • damage by foreign object
B e a r i n g b u s h turbine side • vanes witti incipient cracks
(517.002) screwed connections
O slack
• used n replaced • erosion
• torn off
• fretting marks • replaced
• wear I n s e r t (541.001)
• outside diameter • used L replaced
G a s outlet diffuser
n inside diameter • fouled (509.001)
C o v e r t n g d i s k (517.009) by
• fouled
Intermediate r i n g (517.009) n erosion
by
• used _ replaced signs of toucfiing
• wear • over the entire circumference • cracks
• oil coke • cleaned • in section of the circumference • damage by foreign object
IE please tick the appropriate box
G a p s and clearances, (for admissible values, please refer to sheet 1.52)
Item 1 Compressor wheel / insert (radial gap) mm

Item 2 Compressor wheel / insert (axial gap) nim
Item 3 Turbine rotor / insert (radial gap) mm
Item 4 Turbine rotor / insert (axial gap) mm
Item 5 Bearing bush / labyrinth ring (axial clearance) mm
Item 6 Face runout, compressor wheel mm
Remarks:
2(2) C I 5649 4.57-03 EN-US

Service report
Form
Service Report
Turbocharger NR/R
Author:
Customer:
Plant/vessel:
Turbocharger type: Engine type:
Turbocharger work No. Engine work No.
Compressor wheel, gap (1) Turbine rotor, gap (3)
before maintenance before maintenance
after maintenance after maintenance
maintenance 2 5 Turbine rotor Compressor wheel

COC-No. COC-No.
before —
after
Remarks:
Date Chief Inspectw Service Engineer
C I 5649 4.58-01 EN-US 1 (1)

MAN Diesel & Turbo

2 Systems
3 Operation
4 Maintenance
5 Work cards^
8 Index
5649-3 5 C I - 0 3 EN-US 1 (1)

Organisation and use of the work cards
Numbering
T h e ordinal n u m b e r of the w o r k c a r d s is located at the t o p right of t h e title. It
c o n s i s t s of a three-digit s u b a s s e m b l y n u m b e r a n d a t w o - d i g i t c o u n t i n g n u m -
ber. The s u b a s s e m b l y n u m b e r 5 0 0 represents the collective s u b a s s e m b l y
n u m b e r for t u r b o c h a r g e r s .
Example - T u r b o c h a r g e r o n engine: 5 0 0 . 1 0
• 5 0 0 = S u b a s s e m b l y n u m b e r (500 for turbocharger)
10 = C o u n t i n g n u m b e r (work c a r d N o . 10)
C r o s s - r e f e r e n c e s in w o r k c a r d s t o related w o r k c a r d s are e n c l o s e d in s q u a r e
brackets.
E x a m p l e - C r o s s - r e f e r e n c e in w o r k c a r d 5 0 0 . 1 0 : [500.12]
In w o r k c a r d 5 0 0 . 1 0 (Removing a n d refitting t u r b o c h a r g e r or subassemblies),
there is a reference t o w o r k c a r d 5 0 0 . 1 2 (Removing a n d refitting silencer).
Layout of the work cards

W o r k c a r d s generally c o n t a i n t h e following information:
Brief d e s c r i p t i o n ,
Personnel a n d time r e q u i r e m e n t s ,
Required tools a n d appliances.
Related w o r k c a r d s , i.e. t h o s e w o r k c a r d s containing further necessary or
useful information.
Possibly additional information/technical d a t a a n d .
T h e individual w o r k s e q u e n c e s , always beginning with t h e starting c o n d i -
tion, a n d f o l l o w e d by t h e individual w o r k s t e p s .
Parts a n d tools in t h e figures a n d text are e a c h d e s i g n a t e d w i t h their o r d e r
number.
E x a m p l e - H e x a g o n bolt in bearing c a s i n g : 5 4 6 . 0 0 5
5 4 6 - S u b a s s e m b l y n u m b e r (546 for bearing casing)
0 0 5 ^ Item n u m b e r
All s u b a s s e m b l i e s a n d s u b a s s e m b l y n u m b e r s are listed in t h e spare p a r t s
catalogue.
O r d e r n u m b e r s for tools are (generally) identical w i t h t h e tool n u m b e r affixed
to the tool.
Personnel and time required

The required time is m e n t i o n e d in hours, b o t h for t h e a m o u n t a n d qualifica-
tion of t h e required personnel, The higher hour rate covers t h e time require-
m e n t for t h e c o m p l e t e s c o p e of t h e respective w o r k c a r d . Pesonnel w i t h
l o w e r h o u r rate is required only at t i m e s , e.g., for o p e r a t i o n o f a lifting t a c k l e .
Tools/appliances required
T h e n u m b e r s in t h e Designation c o l u m n refer to w i d t h a c r o s s flats, given in
m m , e.g. s o c k e t w r e n c h 10 = s o c k e t w r e n c h w i d t h a c r o s s flats 10 m m .
C 2 5 6 4 9 5.1-01 E N - U S 1 (2)
T h e availability c o d e s in t h e S t a t u s c o l u m n have the following m e a n i n g :
Standard Included in the scope of supply of the turbocharger.
Optional Tools are supplied by special order.
Inventory Commercially available toois/apptiances

These are not included in the scope of supply of the turbo-
charger. It is assumed that these tools/appliances are included
in the inventory of the engine system.
Special Special tools, e.g. for service centers.
Tips and pictographs
F o r n o t e s c o n c e r n i n g fault s o u r c e s / h a n d l i n g errors; material d a m a g e

can occur.
NOTICE Additional n o t e s , information a n d t i p s .
T h e instructions "Lubricate c o n t a c t surfaces a n d threads", " O b s e r v e t i g h t e n -

ing t o r q u e s " a n d "Use lock w a s h e r pairs" are additionally indicated b y m e a n s
of s y m b o l s in the marginal c o l u m n :
Grease, lubricate and oil Use Observe

lock washers tightening torques!
2(2) C 2 5 6 4 9 5.1-01 E N - U S
Screw connections and tightening torques
Short Version
Tightening values for all important b o l t e d c o n n e c t i o n s / t i g h t e n i n g t o r q u e s for
various friction coefficients M-
Tightening Torques for Bolted Connections

Tightening of screw W h e n e v e r possible, screw/ c o n n e c t i o n s s h o u l d b e t i g h t e n e d w i t h t o r q u e
connections acc. to the wrenches.
torque For particularly i m p o r t a n t s c r e w c o n n e c t i o n s o n t h e turbocharger, t h e t i g h t -
ening t o r q u e s are p r e s c r i b e d in the relevant w o r k c a r d s .
For all other s c r e w c o n n e c t i o n s that are t o be t i g h t e n e d w i t h t o r q u e

w r e n c h e s , the a p p r o x i m a t e values for t h e tightening t o r q u e s a r e specified in
t h e Table "Tightening t o r q u e s for bolts, strength class 8 . 8 " .
W h e n tightening s c r e w c o n n e c t i o n s t h e following m u s t be o b s e r v e d :
Apart f r o m t h e applied tightening t o r q u e , the c l a m p i n g f o r c e of a s c r e w
c o n n e c t i o n d e p e n d s o n the lubricant being u s e d , the condition of t h e
c o n t a c t s u r f a c e a n d t h r e a d , a s well a s o n t h e material c o m b i n a t i o n . It is
therefore very important that all these c o n d i t i o n s are satisfied.
T h e Table "Tightening t o r q u e s for bolts, s t r e n g t h class 8 . 8 " gives t h e
tightening t o r q u e s for t h e various s c r e w t h r e a d s d e p e n d i n g o n their c o e f -
ficient of friction p, i.e. d e p e n d i n g o n t h e selected lubricant. The t i g h t e n -
ing t o r q u e s apply for bolt materials in strength class 8 . 8 under utilization
of a p p r o x . 7 0 % of their yield s t r e n g t h . For other s t e n g t h classes, c o n v e r -
sion f a c t o r s a r e t o b e u s e d a n d multiplied b y t h e tightening t o r q u e s f r o m
t h e Table "Tightening t o r q u e s for bolts, s t r e n g t h class 8 . 8 " . T h e s t r e n g t h
class is s t a m p e d o n t h e bolt h e a d .
Strengtii class 5.6 6.8 8.8 10.9 12.9
Conversion factor x 0.47 0.75 1.0 1.40 1.70
the bolts
Friction coefficient \i For t h e friction coefficient M use approximately:
M = 0 . 0 8 w i t h lubricants for t e m p e r a t u r e s
< 2 0 0 ° C , e.g. Molykote G - n or Molykote P 4 0
> 2 0 0 °C, e.g. M o l y k o t e H S C

M = 0 . 1 4 for lightly oiled surfaces w i t h o u t refinishing
Tightening torques in general

Thread, nominal size Tlîtening torque in Nm
for coefffcient of friction \i
0.08 0.14
•^^û 4.1 5.8
M6 10 ^"^^H
U8 ^ 24 1
C2 6 6 8 6 000.31-01 EN-US 1 (2)

Thread, nominal size Tightening torque in Nm

for coefficient of friction \i
0,08 i 0.14^
M 10 34 49
12 59 84
M 14 93 134 i
M 14x1.5 99 145 ""J

M 16 141 205
M 16x1.5
18x1.5
M 18x2
M 20x1.5
22x1.5
M 22x2
M 24x2
M 27x2
M30x2
M33x2
M 36x3
M39x3
M 42x3
Table 2: Tightening torques for bolts, strength class 8.8
2(2) C2 6686 000.31-01 EN-US

Checking the turbine nozzle ring
Brief description
C h e c k t h e turbine nozzle ring a n d replace it if necessary.
A Guide vane E Negative areas (to tiie left of D)

B Trailing edge (original) F Positive area (to ttie right ofD)
C Contour of the reduction G Root of the guide vane
D Mean reduction
(area F ^1 areas E)
Figure 1: Erosion of the turbine nozzle ring
General T h e erosive wear of t h e g u i d e vanes (A) is c a u s e d by t h e outlet flow mainly in

t h e area of t h e trailing e d g e s (B). T h e original position of t h e trailing e d g e s (B)
c a n b e r e c o g n i s e d at t h e roots (G) of t h e g u i d e vanes (A).
Since t h e guide vanes d o n o t w e a r evenly, t h e m e a n value of t h e g u i d e v a n e

reduction (Lm) is calculated as follows:
(LI + L2 + L 3 + ... + Ln)
Un = n = number of guide vanes (/^
Replacement Replace t h e turbine nozzle ring if L m > t h e value specified in t h e table:
TurtxKharger Lm £ mm TurtXKharger Lm ^ mm 1
NR15/R 10 PTG 18 8 •'^'1^

NR20/R PTG23
14
1
NR24/R ^ P T G 26
NR26/R 16 PTG 30
u i
C2 5649 500.04-02 EN-US 1 (1)

Emergency operation with closing device
Brief description
E m e r g e n c y operation by r e m o v i n g tine cartridge

Number Qualification Duration in fi '
Tesfinician 1,0
- • • --•- - - J - •
1 Assistant 1.0 1
r Oty Designation iNumber Status
L 1 Closing covw (with support} 596.027 Standard
1 Open-jaw wrench 17 - inventory
- Lifting tackle, rcpes, shackles - lnventc»y
Related work cards

Work Card Work Card WorkCam j
• —-
500.10 ' • "' 500.12 500.13
500.14 500.16
Preliminary remarks
During e m e r g e n c y operation of t h e engine, t h e exhaust g a s m u s t c o n t i n u e
passing t h r o u g h t h e d a m a g e d t u r b o c h a r g e r .
Danger to life from crush injuries or impact!

If the e n g i n e starts during the r e m o v a l of p a r t s of the t u r b o c h a r g e r ,
A DANGER.
there is a risk of c o m i n g into c o n t a c t with rotating c o m p o n e n t s a n d
being s e r i o u s l y injured.
A •
•
•
Shut d o w n t h e engine before starting t h e removal w o r k !
During t h e w o r k , lock o u t t h e engine to prevent It f r o m starting!
Set u p w a r n i n g signs!
Danger of fire caused by lube oil!

A l w a y s s h u t off the oil s u p p l y pipe to the t u r b o c h a r g e r in e m e r g e n c y
A WARNING
operation!
if o
5 S
C2 5 6 4 9 500.05-03 EN-US 1 (2)

501.001
501.005
506.001
501,008
501.007
596.027
509.001
513.001
501.072
Figure 1: Closing device • , . - - M . . - . - „ ..
Work sequence - Emergency operation with closing device

steps 1. U n d o all the c o n n e c t i o n s t o p r e p a r e t h e cartridge for removal.
W o r k c a r d [500.10] " R e m o v i n g a n d refitting t u r b o c h a r g e r o r s u b a s -
semblies"
2. R e m o v e the silencer or air intake c a s i n g , c o m p r e s s o r casing a n d car-
tridge.
>- W o r k c a r d s [500.12] " R e m o v i n g a n d refitting t h e silencer"
u p t o [500.16] " R e m o v i n g a n d refitting the cartridge".
The turbine nozzle ring (513.001) a n d covering ring (501.072) r e m a i n i n '
place.
3. Close t h e lube oil pipes.
4. A t t a c h t h e closing cover (596.027) with c l a m p i n g c l a w s (501.005), lock
w a s h e r pairs (501.007) a n d h e x a g o n nuts (501.008) to t h e g a s a d m i s -
sion casing (501.001).
5. For additional m e a s u r e s regarding e m e r g e n c y o p e r a t i o n of t h e engine,
see
- Chapter 3.53 and
- information in t h e engine operating m a n u a l .
CM
2(2) C2 5649 500.05-03 EN-US

Lateral play of the rotor

Checking
Brief description
C h e c k lateral play of t h e rotor. C h e c k t h e state a n d w e a r c o n d i t i o n of t h e
components.

Number Qualification Duration in h
[ Technician 0,3
Qty Designation Number Status
Dial gauge with retainer ^^^^^^^^^H Inventory
Related work cards

1 Work Card Work Canl Work Card
^ B ^ ' 500.10 ' ' "^ 500.12 ^
1 500.14
Preliminary remarks
General A s s e s s m e n t of t h e c o n d i t i o n of t h e bearings by m e a s u r i n g t h e lateral piay is
only possible if t h e labyrinth seal is already run in (after a p p r o x . 2 5 0 o p e r a t i n g
hours).
Starting condition Silencer or air intake casing a n d c o m p r e s s o r casing or cartridge are

removed.
520.005 517.002
520.001
520.124
Figure 1: Checking the lateral play
n CM
0 2 5649 500.06-03 EN-US 1 (2)

Work sequence - Checking the lateral play

steps 1 . A t t a c h dial g a u g e w i t h retainer in s u c h a w a y that t h e p r o b e of t h e dial
g a u g e Is radially in c o n t a c t w i t h t h e m a g n e t i c nut (520.124).
2 . P u s h t h e shaft of t h e t u r b i n e rotor (520.001) vigorously in d i r e c t i o n s A

a n d B by h a n d (perpendicular t o t h e axis of t h e turbine rotor).
Read a n d note t h e overall deflection of t h e dial g a u g e .
3 . R e c o m m e n d e d m e a s u r e s , particularly w h e n a p p r o a c h i n g t h e u p p e r
limit value: see table.
Measurementrangein mm Comments
S1.00
Permissible range for lateral play 'vHHP'
( c c H T e ^ n d s to tolerance range for radl£d b e a r i n g o K m ^ ) . ^ ^ ^ ^
1.00 - 1.25 At the next opportunity, inspection of the individual components of the cartndge by trained
service personnel.
Check; lube oil quality and lube oil pressure.
'operational safety jeopardized.

Have affected parts exchanged by trained service personnel or exchange the cartridge.
Check: lube oil quality and lube oil pressure.
Table 1: fêasurement ranges for lateral play
2(2) 0 2 5649 500.06-03 EN-US

Cleaning the turbine - wet cleaning
Brief description
W e t cleaning of t h e turbine during operation in t h e case of significantly
r e d u c e d engine p e r f o r m a n c e . Carry o u t the cleaning in time, in a c c o r d a n c e
w i t h t h e m a i n t e n a n c e schedule.

' Number Qualification ' Duration In h
^ 1 Technician 0,6 ~^BIBB
Preliminary remarks
Cleaning agent U s e exclusively fresh w a t e r for cleaning.
Cleaning Interval Every 1 5 0 operating hours, with r e d u c e d engine l o a d .

M a x i m u m exhaust g a s t e m p e r a t u r e u p s t r e a m of turbine: 3 2 0 ° C .
T h e e x h a u s t g a s t e m p e r a t u r e of 3 2 0 ° C m u s t not b e e x c e e d e d u n d e r ]
a n y c i r c u m s t a n c e s , o t h e r w i s e the turbine is liable to m a k e c o n t a c t |
NOTICE during w a s h i n g .
In order to s a v e time, c a r r y out the c l e a n i n g shortly after e n g i n e start-

u p , p r o v i d e d the c o m p o n e n t s to b e c l e a n e d a r e not yet too hot.
NOTICE T h i s a l l o w s s t e p 2 of the w o r k s e q u e n c e to b e omitted. f
Brief information See also cleaning instructions given o n plate {attached t o t h e engine).;
C2 6660 500.07-01 EN-US 1 (3)

1 Turbocharger A Stopcock
2 Exhaust gas pipe upstream of B Pressure reducing valve with
turbine pressure gauge
3 Water admission (fresh water) C Three-way cock:
ZERO POSITION
BLOW-OUT
WASHING
4 Dirt water discharge down- D Three-way cock:
stream of turbine, if provided • (= zero position)
• • (= check position)
• • • (= washing position)
E Drain cock, if provided
Figure 1: Diagram: Wet cleaning of the turbine
The n u m b e r a n d a r r a n g e m e n t of exhaust g a s pipes d e p e n d s o n the engine

type a n d m a y vary f r o m the a b o v e d i a g r a m . Every individual exhaust g a s
pipe h a s its o w n t h r e e - w a y c o c k (D) for turbine cleaning.
Work sequence - Wet cleaning of the turbine (during operation)

steps 1 R e d u c e engine load to 0 — 1 5 % , m a k i n g sure that t h e m a x i m u m per-
missible exhaust g a s t e m p e r a t u r e is not e x c e e d e d .
Following r e d u c t i o n of t h e engine l o a d f r o m a higher l o a d r a n g e , wait
a p p r o x . 10 minutes (for t h e t e m p e r a t u r e t o r e a c h a stable condition).
First c h e c k all t h e t h r e e - w a y c o c k s (D) o n e after t h e other in t h e c h e c k

position • • (if no exhaust g a s is b l o w n o u t , t h e p a s s a g e t o t h e exhaust
g a s pipe is c l o g g e d a n d m u s t b e cleared using a 2 . 5 - m m dia. piece of
wire); t h e n s w i t c h over t o w a s h i n g position
o p e n t h e drain c o c k (E) if fitted, c h e c k that exhaust g a s is b l o w n out; ff

necessary, clear t h e p a s s a g e .
S w i t c h t h e t h r e e - w a y c o c k (0) t o B L O W - O U T .
O p e n t h e s t o p c o c k (A) o n t h e w a t e r a d m i s s i o n (3); set t h e w a t e r p r e s -
s u r e t o 2 bar o n t h e p r e s s u r e r e d u c i n g valve (B), a n d c h e c k o n t h e
pressure gauge.
S w i t c h t h e t h r e e - w a y c o c k (C) to W A S H I N G .
2 (3) C2 6660 500.07-01 EN-US

MAN Diese! & Turbo 500.07
8. W a s h for 10 minutes at 2 bar w a t e r pressure (check o n t h e pressure

gauge).
9. Close t h e s t o p c o c k (A) o n the w a t e r a d m i s s i o n (3).
10. Temporarily s w i t c h t h e t h r e e - w a y c o c k (C) to B L O W - O U T , t h e n to

Z E R O POSITION.
1 1 . S w i t c h ail t h e t h r e e - w a y c o c k s (D) to zero position • .
12. Close t h e drain c o c k (E), if fitted.

13. Run the t u r b o c h a r g e r dry for 10 minutes at r e d u c e d engine p o w e r , t h e n
slowly increase the load.
Vibrations caused by dirt accumulations

NOTICE S h o u l d vibrations o c c u r on the t u r b o c h a r g e r that w e r e not evident
before, repeat the w a s h i n g p r o c e d u r e .
If t h e s e vibrations, c a u s e d by irregular dirt a c c u m u l a t i o n s , c a n n o t b e
eliminated by w a s h i n g , t h e t u r b o c h a r g e r m u s t b e d i s m a n t l e d a n d the
p a r t s involved m u s t b e s u b j e c t e d to m e c h a n i c a l c l e a n i n g .
02 6 6 6 0 5 0 0 . 0 7 - 0 1 E N - U S 3(3)
Cleaning the turbine - dry cleaning
Brief description
Dry cleaning of t h e turbine d u r i n g o p e r a t i o n in t h e c a s e of n o r m a l engine
o p e r a t i n g load. The engine load n e e d not b e r e d u c e d . Carry out the cleaning
in time, in a c c o r d a n c e with t h e m a i n t e n a n c e schedule.

Number Ouallficatfon ' Duration In h
^ 1 Technician
Qty DesignatkHi Number Status
r • Inventory
Granulates (grain size 1.0 — 1.5 mm) - nut -
shells/activated charcoal - soft
Introductory Remarks
Cleaning agent A p p r o p r i a t e cleaning materials are granulates f r o m nut shells or activated
charcoal (soft) w i t h a grain size of 1.0 m m (max. 1.5 m m ) .
D o not u s e w a t e r for c l e a n i n g the turbine by this m e t h o d , a s In this

c a s e the c l e a n i n g Is c a r r i e d out at normal operating load of the e n g i n e .
NOTICE
Cleaning inten/al Every 2 4 operating hours, at norma! service load of t h e engine.
Brief information See also cleaning instructions given o n plate (attached to t h e engine).
C2 6660 500.07-02 EN-US 1 (2)

A
io.}
5-8 bor
Tank 6 Exhaust gas pipe

Screw plug 7 Compressed air pipe
Pipe
4 Connection point A Stop cock (compressed air)
5 Plate . __ B Stop cock (exhaust gas)
Figure 1: Diagram: Dry cleaning of the turbine
D e p e n d i n g o n t h e t y p e of engine a n d t u r b o c h a r g e r , t h e a r r a n g e m e n t of t h e
individual parts might not c o r r e s p o n d exactly t o t h e d r a w i n g " D i a g r a m : Dry
cleaning of t h e turbine".
T h e t a n k (1) m u s t b e installed in a suitable location, not lower t h a n 1.0 m
lêlow t h e c o n n e c t i o n point (4). T h e pipe (3) m u s t b e no longer t h a n 6.0 m,
b e properly s u p p o r t e d to prevent it f r o m vibrating a n d allow u n i m p e d e d f l o w .
M a x i m u m operating t e m p e r a t u r e of t h e s t o p c o c k (B): < 300 ° C .

C o n n e c t i o n point (4) is p r o v i d e d o n t h e exhaust g a s pipe, immediately
u p s t r e a m of t h e t u r b i n e .
Work Sequence - Dry Cleaning of Turbine (during Operation)

steps 1. S t o p c o c k s (A a n d B) m u s t b e c l o s e d .
2 . U n s c r e w t h e s c r e w p l u g (2). Fill t h e p r e s c r i b e d quantity o f granulate Into
t h e tank (1) a n d close it w i t h t h e s c r e w plug (2). For the quantities
required, refer to Table 1.
3. O p e n t h e s t o p c o c k (A). Slowly o p e n t h e s t o p c o c k (B) until a whistling
s o u n d is h e a r d indicating t h e introduction of t h e granulate. Granulate
injection t i m e a p p r o x . 30 s e c o n d s .
4 . C l o s e t h e s t o p c o c k s (A a n d B).
Filling volume
NR12, NR14, NR15, NR17, NR20 0.3 litres
NR24, NR26 0.4 litres
NR29, NR34 0.5 litres

Table 1: Filling volume
2(2) C2 6660 500.07-02 EN-US

Cleaning the compressor - with fitted tank
Brief description
Glean the c o m p r e s s o r with the engine w a r m e d u p a n d in full load o p e r a t i o n .
Carry out t h e cleaning in t i m e , in a c c o r d a n c e with t h e m a i n t e n a n c e s c h e d u l e .

1 Technician 0,3
Cleaning agent Use exclusively fresh w a t e r for cleaning.
D u e to the high s p e e d of t h e rotor, t h e injected w a t e r droplets hit t h e blades
of t h e c o m p r e s s o r wheel a n d t h e diffuser at high velocity, thus removing t h e
dirt deposits mechanically,
Cleaning inten/al W e r e c o m m e n d t h e following cleaning intervals:

• NR t u r b o c h a r g e r s : every 1 5 0 operating hours,
NA t u r b o c h a r g e r s : every 1 5 0 operating hours.
The cleaning intervals d e p e n d o n the d e g r e e of c o n t a m i n a t i o n of t h e intake
air a n d range f r o m 1 0 0 to 2 0 0 operating hours.
In t h e smaller t u r b o c h a r g e r sizes (NR, N A 3 4 , NA40), dirt d e p o s i t s o n t h e
c o m p r e s s o r wheel a n d diffuser blades m a y lead t o a considerable d r o p in
efficiency.
F r o m t u r b o c h a r g e r size N A 4 8 u p w a r d s , c o m p r e s s o r cleaning is not n e c e s -
sary if the air filter m a t is sen/iced as specified.
Carry out the cleaning only with the engine warmed up and in
NOTICE full load operation.
D o not s h u t d o w n the e n g i n e immediately after c l e a n i n g , but c o n t i n u e
to run it for s e v e r a l m i n u t e s until dry.
C2 5649 500.08-02 EN-US 1 (2)

OH i 10
1 Screw-type cap 5 Charge air cooler

2 Tanl< 7 Turbocharger (compressor)
3 l-lydrometer cock, 10 Plate (cleaning instructions)
4 Charge air line
Figure 1: Diagram: Cleaning of the compressor (with fitted tank)

D e p e n d i n g o n t h e type of engine a n d t u r b o c h a r g e r , the a r r a n g e m e n t of t h e
individual parts might not c o r r e s p o n d exactly to t h e d i a g r a m .
Brief information S e e a l s o cleaning i n s t n j c t i o n s given o n plate (attached t o t h e engine).
Work Sequence - Compressor Cleaning (during Operation)

steps 1 . o p e r a t e engine at full load.
2. O p e n s c r e w - t y p e c a p (1) a n d fill t a n k (2) w i t h c l e a n , fresh w a t e r .
* 3. C l o s e full t a n k with s c r e w - t y p e c a p (1).
4 . D e p r e s s p u s h b u t t o n of h y d r o m e t e r c o c k (3) for a b o u t 2 0 s e c o n d s .
2(2) C2 5649 500.08-02 EN-US

Cleaning the compressor - Pressure sprayer
Brief description
Clean the c o m p r e s s o r with t h e engine w a r m e d u p a n d in full load o p e r a t i o n .
Carry out t h e cleaning in t i m e , in a c c o r d a n c e w i t h t h e m a i n t e n a n c e s c h e d u l e .

Number Oualificatlon Duration in h
1 Technician 0,3
Cleaning agent U s e exclusively fresh w a t e r f o r cleaning.
D u e t o t h e high s p e e d of t h e rotor, t h e injected w a t e r droplets hit t h e blades
of t h e c o m p r e s s o r w h e e l a n d t h e diffuser at high velocity, t h u s r e m o v i n g t h e
dirt d e p o s i t s mechanically.
Cleaning interval Every 1 5 0 operating h o u r s

The cleaning intervals d e p e n d o n t h e d e g r e e of c o n t a m i n a t i o n of t h e intake
air a n d range f r o m 1 0 0 t o 2 0 0 operating hours.
Carry out the cleaning only with the engine warmed up and in
NOTICE full load operation.
D o not s h u t d o w n t h e e n g i n e immediately after c l e a n i n g , but c o n t i n u e
to run it for s e v e r a l m i n u t e s until dry.
Brief information See also cleaning instructions given o n plate (10), a t t a c h e d to t h e pressure
sprayer (2).
C2 5649 500.08-04 EN-US 1 (2)

7 Handle 5 Coupling
2 Pressure sprayer 6 Hand valve
3 Relief valve 7 Turbocharger (compressor)
4 Nipple 10 Plate (cleaning instructions)
Figure 1: Diagram: Cleaning of the compressor (with pressure sprayer)

D e p e n d i n g o n t h e t y p e of engine a n d turboclnarger, tine a r r a n g e m e n t of t h e
individual parts might not c o r r e s p o n d exactly t o t h e d i a g r a m .
Work sequence - Compressor cleaning (during operation)

steps 1 • O p e r a t e engine at full load.
2 . T u r n handle (1) o n pressure sprayer t a n k (2) in c o u n t e r - c l o c k w i s e direc-
tion a n d take out t h e p u m p .
3. Fill fresh w a t e r into t h e tank, filling v o l u m e 0.5 litres.
4 . S c r e w in the p u m p a n d operate it until the relief valve (3) b l o w s off.
5. C o n n e c t h o s e w i t h nipple (4) t o the c o u p l i n g (5).

6 . D e p r e s s p u s h b u t t o n {see large a r r o w in figure) o n the h a n d valve (6)
until t h e w a t e r Is completely injected into t h e c o m p r e s s o r (7) (for
approx. 3 0 seconds).
7. Release plug-in c o n n e c t i o n a n d vent t h e t a n k . For venting, pull spindle
o n the relief valve (3) o u t w a r d s (see small a r r o w In figure).
2(2) 0 2 5649 500.08-04 EN-US

Turbocharger or subassemblies
Short Version
R e m o v e a n d refit t h e t u r b o c h a r g e r f r o m a n d t o t h e engine, in s u b a s s e m b l i e s
or in c o m p l e t e c o n d i t i o n .

Number Oualincatlon Duration in h |
'4.5 -'""^
[ V
Assistant ,, 1 . 0 ~ ~
1 1
Tools/appiiances required
Qty Designation Number status
[ Open-jaw and ring wrenches (set)
Socket wrench [set)

- Invaitory
Inventory
1 1
Torque wrench Invwitory
Screwdriver - Inventory
Lifting tacWe, ropes, shackles Inventory
Wood (as a support) - Inventory
High-temperature lubricant (e.g. Molykote . - Inventory

HSC)
Technical data!
Designation Information 1
|Turl30Charger ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ B 375 kg " " ^ ^ B
Preliminary remarks
General For m a i n t e n a n c e w o r k o n t h e t u r b o c h a r g e r , individual subassemblies a n d
c o m p o n e n t s are normally r e m o v e d in s u c c e s s i o n .
>- W o r k c a r d s [500.12] " R e m o v i n g a n d refitting t h e silencer" t o [500.20]
" R e m o v i n g , refitting a n d c h e c k i n g t h e turbine nozzle ring a n d insert"
5 s
C2 5649 500.10-03 EN-US 1 (5)

•W 10
Figure 1: Connections on the turtiocharger
Work sequence 1 - Separating or removing the connections
Danger of burns from hot components!

M a n y e n g i n e a n d t u r b o c h a r g e r c o m p o n e n t s b e c o m e v e r y hot during
A CAUTION
o p e r a t i o n a n d require a m p l e time for c o o l i n g d o w n a f t e r w a r d s .
• Prior to taking any a c t i o n , allow t h e engine a n d t u r b o c h a r g e r to c o o l
d o w n sufficiently (1 -2 h)!
• W e a r protective clothing!
Danger of buming/scalding from escaping lube oil!

T h e l u b e oil is u n d e r p r e s s u r e a n d very hot!
A CAUTION
• Before o p e n i n g pipes, flanges, s c r e w e d c o n n e c t i o n s or fittings, release
t h e pressure in t h e s y s t e m a n d c h e c k that it is d e p r e s s u r i s e d !
• Before o p e n i n g oil pipes, wait until t h e lube oil has c o o l e d d o w n

sufficiently!
• W e a r protective clothing!
Steps 1 . Air intake {1) o n air intake casing (if provided).

R e m o v a l of silencer {if provided) or air intake casing (if provided) is p o s -
sible.
>• W o r k c a r d [500.121
" cc *- W o r k c a r d 5 0 0 . 1 3
if o
CM
2(5) C2 5 6 4 9 500.10-03 EN-US

C o m p r e s s o r cleaning (2), c a b l e to s p e e d indicator in terminal b o x (3, if

provided}, Jet Assist (4, if provided), air outlet (5).
Removal of s p e e d transmitter, insert, c o m p r e s s o r casing a n d diffuser is
possible.
>- W o r k c a r d [500.141
Tvô-part plate (6), lube oil f e e d (7), lube oil drain (8), c o n n e c t i n g p o i n t s
for lube oil pressure a n d interval pre-lubrication (if provided), c a s i n g f o o t
{9, if provided).
Removal of cartridge is possible.
W o r k c a r d [500.161
Exhaust g a s outlet (10, if provided), dirty vâter or c o n d e n s e d w a t e r d i s -
c h a r g e ( 1 1 , if provided).
Removal of gas outlet casing is possible.
W o r k c a r d [500.191
Exhaust g a s a d m i s s i o n (12).
R e m o v a l of c o m p l e t e t u r b o c h a r g e r is possible.
>- W o r k c a r d 5 0 0 . 1 0 , w o r k s e q u e n c e 2
Work sequence 2 - Removing the complete turbocharger
Figure 2: Removing and refitting the complete tuitocfiarger
CM
C2 5649 500.10-03 EN-US 3(5)

Risk of serious or fatal injury when lifting and moving loads!

No p e r s o n s m a y b e p r e s e n t in t h e a r e a of d a n g e r a r o u n d a n d
A DANGER,
underneath a s u s p e n d e d load.
• Lifting tackle, r o p e s a n d a t t a c h m e n t points m u s t b e able t o t a k e t h e
l o a d safely a n d b e In perfect c o n d i t i o n .
• Use t h e eye bolts o n t h e s u b a s s e m b l i e s only for lifting individual

(detached) s u b a s s e m b l i e s a n d not for lifting t h e t u r b o c h a r g e r .
• All lifting, m o v i n g a n d setting d o w n of the load m u s t be carried out
slowly.
Risk of fouling!
NOTICE During s t o r a g e a n d a s s e m b l y , t h e o p e n i n g s for air, e x h a u s t g a s a n d
lube oil m u s t b e appropriately s e a l e d to prevent foreign o b j e c t s or
w a t e r from entering.
Steps
1. For separating or r e m o v i n g t h e c o n n e c t i o n s , refer t o w o r k s e q u e n c e 1 .
A l s o separate or d e t a c h other special c o n n e c t i o n s (such as for pressure
a n d t e m p e r a t u r e m e a s u r i n g , etc.).
2 . A t t a c h lifting tackle t o t h e t u r b o c h a r g e r using a r o p e of a d e q u a t e
s t r e n g t h slung a r o u n d t h e bearing casing a n d carefully t e n s i o n e d .
A t t a c h s e c o n d a r y r o p e s at a p p r o p r i a t e points to assist in b a l a n c i n g .
3. U n d o the s c r e w c o n n e c t i o n o n t h e casing f o o t (9, If provided).
4. Carefully lift off t h e t u r b o c h a r g e r a n d set it d o w n o n a w o o d e n s u p p o r t .
Work sequence 3 - Refitting
P r o c e d u r e s to b e o b s e r v e d w h e n mounting the t u r b o c h a r g e r onto the

engine:
NOTICE
• R e m o v e protective c a p s f r o m pipe c o n n e c t i o n s / p i p e s .
• Use only flawless seals a n d s c r e w locking elements.
• A p p l y h i g h - t e m p e r a t u r e lubricant (e.g. f\*1olykote HSC) t o t h e t h r e a d s of
heat-resistant s c r e w s a n d nuts o n t h e turbine side.
\
Refitting t h e c o m p l e t e t u r b o c h a r g e r or its s u b a s s e m b l i e s , a n d restoring t h e

c o n n e c t i o n s , is carried out by reversing t h e removal p r o c e d u r e .
Tighten the s c r e w c o n n e c t i o n o n t h e casing foot (9, if provided) lightly at first,
a n d t h e n t o r q u e it finally after c o n n e c t i o n of t h e c a s i n g pipes.
•5£ o
« CM
4(5) C2 5649 500.10-03 EN-US

Observe tightening torques during assembly!

NOTICE S c r e w c o n n e c t i o n of the c a s i n g feet to the e n g i n e b r a c k e t : s e e e n g i n e
manual.
Nm
Refitting the turbocharger on a gas-powered engine
Danger of fire caused by electrostatic charging

In the c a s e of t u r b o c h a r g e r s o n g a s - p o w e r e d e n g i n e s , insulated
A DANGER mounting c a n c a u s e e l e c t r o s t a t i c c h a r g i n g , resulting in ignition of t h e
a i r / g a s mixture in the air intake.
• If t h e t u r b o c h a r g e r is m o u n t e d o n t h e engine in s u c h a w a y that it is
electrically insulated, a n earth c o n n e c t i o n m u s t be installed for t h e
equipotential b o n d i n g b e t w e e n t h e t u r b o c h a r g e r a n d t h e engine.
5 S
C2 5649 500.10-03 EN-US 5(5)

Cleaning the air filter
Brief description
Clean t h e air filter mat regularly in a c c o r d a n c e w i t h t h e m a i n t e n a n c e s c h e d -
ule o r replace it.

1 Number Qualificatjon Duration in h
Technician ^^^^^1^^^^V '0.4
Tools/Appliances Required
1 Qty Designation Number Status
Compressed air l ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ l t- Inventory
Cleaning agent (non-corrosive) Inventory

r -
Spare Parts
Quantity Designation Number
Air fitter 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!
NOTICE T h e air filter m a t m a y b e r e p l a c e d only w h e n the e n g i n e is a t standstill.
T h e entry of dirt a n d foreign o b j e c t s m u s t b e p r e v e n t e d .
General The dirty air filter mat (544.201) c a n b e cleaned several times o r replaced
with a n e w mat.
R e p l a c e m e n t is required if t h e air filter m a t is considerably s t r e t c h e d , t a t t e r e d
or perforated.
Cleaning agent W a r m w a t e r t o w h i c h a n o n - c o r r o s i v e cleaning a g e n t has b e e n a d d e d
Cleaning interval Every 2 5 0 operating hours.

T h e cleaning intervals d e p e n d o n t h e d e g r e e o f c o n t a m i n a t i o n of t h e i n t a k e
air a n d range f r o m 2 5 0 t o 5 0 0 operating hours.
Cleaning is necessary w h e n t h e air filter mat starts to discolour, turning grey.
T h e air filter is t h e n saturated a n d t h e c o n t a m i n a t i o n starts t o a d v a n c e
t o w a r d s t h e c o m p r e s s o r a n d the c h a r g e air cooler. ^ cc
0 2 6660 500.11-02 EN-US 1 (3)

A n i n c r e a s e in p r e s s u r e l o s s , d u e to a c o n t a m i n a t e d air filter mat,

s h o u l d not b e u s e d a s a r e f e r e n c e for the c l e a n i n g Interval.
NOTICE
544.201
544.205
544.202
544.202
Figure 1: Air filter or) the s/Zencer
Work sequence - Removal, cleaning/replacement, refitting

starting condition Engine h a s b e e n s t o p p e d .
Steps 1 . L o o s e n t h e c l a m p s (544.202), r e m o v e c o v e r sheet (544.205) a n d air fil-
ter m a t (544.201).
2. C l e a n t h e air filter m a t by flushing w i t h w a r m w a t e r t o w h i c h a n o n - c o r -
rosive cleaning agent has b e e n a d d e d .
A v o i d excessive mechanical stress {e.g. w r i n g i n g , s h a r p w a t e r jet). After
cleaning, b l o w c o m p r e s s e d air t h r o u g h t h e air filter m a t .
In c a s e of h e a v y c o n t a m i n a t i o n , it m a y b e n e c e s s a r y to i m m e r s e the air
filter mat into a c l e a n i n g a g e n t for s e v e r a l h o u r s . T h e r e f o r e it i s
NOTICE r e c o m m e n d e d to h a v e a s e c o n d air filter mat in s t o c k at all t i m e s .
3. Place air filter m a t (544.201) over t h e perforated plate of t h e silencer.

T h e perforated plate m u s t b e c o m p l e t e l y c o v e r e d by t h e air filter mat.
4. Place c o v e r sheet (544.205) over t h e h e m of the air filter m a t a n d t h e n
fasten t h e air filter mat using t h e c l a m p s (544.202).
2(3) C2 6 6 6 0 500.11-02 EN-US

Position of the clamps
Figure 2: Position of the clamps
Correct position of ttie The c l a m p s m u s t be a t t a c h e d as close as possible to t h e outer e d g e s o f t h e

clamps silencer in order to prevent dirt a n d foreign o b j e c t s f r o m entering the c o m -
pressor t h r o u g h t h e silencer.
5 S
C2 6660 500.1 V 0 2 EN-US 3(3)

Silencer
Brief description
R e m o v e a n d refit t h e silencer in c o m p l e t e c o n d i t i o n . Disassembling (e.g. for
cleaning) only if necessary.

[ _ l Technician ^^"^H^^^Ê^
1 Assistant 0,2 1
Oty Designation ! Number Status
1 Open-jaw 19 -^^^^^^^H Irwentory r;i
1 Hexagon screw driver 6 - Inventory
^H^1 Torque w r m c h Inv^tory^
- Lifting tackle, ropes, shackles Inventory
mm - Wood (as a support) Inventory
Related work cards

Work Card Work Card Work Card
500.10 500.11
Technical data
Designation Information 1
|Sil©icer 31 kg
S CNJ
C2 5649 500.12-04 EN-US 1 (3)

Preliminary remarks
544.034
544.202
544.201
546.005
544.069
544.074 546.001
544.075 544.010
544.033 544.032
544.021 544.001 544.201
544.0'il 544.205
544.202
544.034
Figure 1: Silencer, mounted on the compressor casing

General For air filter cleaning >- VJork c a r d [5(X).11] "Cleaning air filter"
For d i s a s s e m b l i n g , cleaning a n d reassembling t h e silencer, refer t o w o r k
s e q u e n c e 3.
Disassembling of the silencer (e.g. for cleaning) only if necessary.
Starting condition C o n n e c t i n g p i p e for c o m p r e s s o r cleaning Is released, If p r o v i d e d .
Work sequence 1 - Removing the complete silencer

Steps 1 . A t t a c h lifting tackle t o t h e silencer using r o p e a n d shackles.
2 . L o o s e n t h e V-proflle c l a m p (546.005) o n b o t h sides of t h e circumfer-
ence.
3. R e m o v e t h e silencer in axial direction a n d p l a c e it o n a w o o d e n s u p p o r t
with t h e flange face d o w n .
Work sequence 2 - Refitting the complete silencer

steps For refltting, p r o c e e d in t h e reverse order of removal.
Observe tightening torques during refitting!

NOTICE
• A p p l y oil t o t h e t h r e a d s a n d c o n t a c t surfaces.
• Tightening t o r q u e for t h e V-proflle c l a m p (546.005) o n b o t h sides of t h e
c i r c u m f e r e n c e : 12 N m
•5£ S
« CM
2(3) C2 5649 500.12-04 EN-US

Work sequence 3 - Disassembling, cleaning and reassembling the silencer
Bonded joints
O n no a c c o u n t m a y trichlorethylene (or s u b s t i t u t e s ) or a n y other
A CAUTION
s o l v e n t s containing a c e t o n e b e u s e d for r e m o v i n g g r e a s y dirt.
U s e of s u c h p r o d u c t s will d i s s o l v e the b o n d e d joints.
Steps R e m o v e the air filter mat (544,201} a n d clean it.

>- W o r k c a r d fSOO.III "Cleaning t h e air filter"
U n s c r e w t h e h e x a g o n nuts (544.074) a n d take off t h e w a s h e r s
(544.075).
T a k e off t h e front wall (544.041), perforated plate (544.034). s p a c e r
pipes ( 5 4 4 . 0 3 3 a n d 5 4 4 . 0 3 2 ) , d a m p i n g plates (544.021) a n d rear wall
(544.001) individually. The flange (544.010) remains in place, held b y
t h e s c r e w e d - i n s t u d s (544.069).
If t h e fouling m a t t e r is dry, t h e felt linings are best cleaned w i t h c o m -
p r e s s e d air or a b r u s h w h i c h is not t o o h a r d .
For reassembly, p r o c e e d in t h e reverse o r d e r of disassembly.
T h e outer 6 s p a c e r pipes (544.033) are slightly longer t h a n the s p a c e r
pipes (544.032).

NOTICE A p p l y Molykote P 4 0 lubricant to the t h r e a d s a n d c o n t a c t s u r f a c e s .
Tightening torque for h e x a g o n n u t s (544.074): 6 9 N m
" cc
5 S
C2 5649 500.12-04 EN-US 3(3)

Air intake casing
Short Version
The air intake casing has to b e r e m o v e d for all w o r k t h a t is t o be p e r f o r m e d
f r o m t h e c o m p r e s s o r side.

[ . J _ Technician ^"^""^SHI^^ÎjiK^ 0.2 -^m^

1 !
Assistant
,0.2 1
Oty De^gnation • Number status
^ 1 Hexagon screw driver 6 Inventory
1 Torque wrench 1- Inventory
^ - Lifting tadde, ropes, shackles ^ ^ ^ ^ Inventory
1 -1 Wood (as a support) r 1 Inventory ^
Related work cards

' Work Card J Work Card Work Cam
^ 500.10 J
Technical data
Designation Information
|Air intake casing _ , j

i^M^.„- - - „
C2 5649 500.13-04 EN-US 1 (3)

Preliminary remarks
546.005
546.001
545.001
Figure 1: Air intake casing, mounted on the compressor casing
Work sequence 1 - Removing

starting condition Pipe at ttie air intake is released or r e m o v e d .
Steps 1 . A t t a c h lifting tackle t o t h e air intake c a s i n g (545.001) using a r o p e .

Carefully tension t h e r o p e .
2. L o o s e n t h e V-profile clannp (546.005) o n b o t h s i d e s of t h e circumfer-
ence.
3. R e m o v e t h e air intake casing (545.001) in axial direction a n d place it o n
a v\/ooden s u p p o r t .

steps For refitting, p r o c e e d in t h e reverse order of removal.
2(3) C2 5649 500,13-04 EN-US


NOTICE
• A p p l y oil to t h e t h r e a d s a n d c o n t a c t surfaces.
• Tightening t o r q u e for the V-profile c l a m p (546.005) o n b o t h sides of t h e

c i r c u m f e r e n c e : 12 N m
•5£ S
CM
C2 5649 500.13-04 EN-US 3(3)

Compressor Casing, Insert, Diffuser, Speed Transmitter
Brief description
Remove the compressor casing, insert, diffuser, speed transmitter for
inspection, adaptation or exchange.

Technician
Assistant
Tools/Appliances Required
Qty Designation Status
||||||^cl<et wrench 1^ Inventory
1 Socket wrench 13 Inventory
1 j Socket wrench 1 T * * * ^ Inv^tory
1 Socket wrench 19 Inventory
1 ^ Hexagon screw driver^ Inventory
1 Screv/cirver Inventory
1 , Gripping pliers Inventory
- Wood (as a support) Inventory
Spare Parts
L...1 O-rinaseal ... , .„ . , , 517.018
1 0-ring seal 540.015
O-ringseal ^^^^^^^^^^^1[ 540.016
1 Seal 546.043
Sealing ring 546.051
Related work cards

Work Card Work Card Work Card
500.10 500.12^ 500.13 i
CM
C2 5649 500.14-05 EN-US 1 (6)

Technical data
Designation Information
2
' 0 kg ^'^HB
Diffuser 5 kg
R>3mpresscH'casing ^ ^ ' ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ H fekg
Preliminary remarks
546.044
546.043 517.018
546.040
X 546.001 517.000
540.016
540.001
520.000
540.020 540.015
540.022
562.100
540.010
562.004
562.005
562.040
546.020
546.023 542.001
546.008
562.083 546.060
546.005
546.06)
546.051
Figure 1: Removing and refitting tlie speed transmitter, insert, compressor casing, diffuser
Starting condition Connecting pipes, silencer or air intake casing are removed.
Before the insert or the compressor casing is removed, the speed

transmitter (562.040) must be removed in order to avoid damage to the
NOTICE two pole shoes at the end of the speed transmitter.
" cc
« CM
2(6) C2 5649 500.14-05 EN-US

Risk of injury due to suspended ioads!

Unsuitable or poorly maintained transport equipment and unsuitable
A WARNING set-down locations can result in severe injuries and major damage.
Swinging components are difficult to maneuver and are thus liable to
A A injure people seriously and damage material.

•
•
Only use transport equipment that is in flawless condition!
Check whether the transport equipment used has the required load-
bearing capacity!
• Move suspended components slowly!
• Only select flat set-down locations that do not frequently have people
moving through them!
Work sequence 1 - Removing tlie speed transmitter <

steps 1
1. Disconnect the cable end of the speed transmitter (562.040) in the ter- :
minal box (562.083, if provided) and pull it carefully through the opened.
cable socket (see Figure 1, detail X) and the opened gland (546.060). 1
2. Unscrew the cylindrical screws (540.020), take off the lock washers i
(540.022) and the closing cap (540.010). |
3. Unscrew the hexagon nut (562.005), remove the holding disk (562.004)i
and carefully pull out the speed transmitter (562.040).
Do not bend the pole shoes of the speed transmitter.

NOTICE
Work sequence 2 - Removing the insert

Steps 1. Unscrew the hexagon bolts (546.044) and take off the injection pipe
(546.040) and seal (546.043).
2. Unscrew the hexagon bolts (546.020) and take off the lock washer
pairs (546.023).
3. Carefully remove the insert (540.001) in axial direction, paying attention
to the 0-ring seals (540.015 and 540.016).
0-ring seal (546.015) is only provided in the case of Jet Assist.
Work sequence 3 - Removing the compressor casing
The insert must be disassembled before removal of the compressor

casing!
NOTICE
Steps
C2 5649 500.14-05 EN-US 3(6)

1. Attach lifting tackle to the compressor casing (546.001) using a rope,

and carefully tension the rope.
2. Mark the installation position of the V-profile clamp.
3. To remove the V-profile clamp, first unscrew and take off the undercut
bolts (546.111), resilient sleeves (546.112) and hexagon nuts (546.113)
on both sides of the circumference.
4. Unscrew the hexagon bolts (546.115), take off the lock washer
pairs (546.116), holding sheets (546.114) and clamp halves (546.005).
5. Remove the compressor casing carefully in axial direction, place it on a
wooden support and take measures to prevent it from rolling off.
Note! Take care not to damage blades of the compressor wfieel during
removal.
Work sequence 4 - Removing the diffuser

steps
1. Unscrew the hexagon bolt (546.008).
2. Take off the diffuser (542.001) in axial direction.
Work Sequence 5 - Refitting

Seals Make sure that the 0-ring seals (517.018, 540.015, 540.016) and the sealing
rings (546.043, 546,051) are in flawless condition.
Note! Only install O-ring seal (540.015) in the case of Jet Assist!
Steps 1. Insert the diffuser (542.001) into the compressor casing (546.001) in
axial direction and fasten it with countersunk bolt (546.008). Lock the
screw connection with medium-strength screw locking agent and
tighten with the standard tightening torque.
2. Check the O-ring seal (517.018) and, if necessary, insert a new O-ring
seal into the groove of the bearing casing (517.000).
O-ring seals must be tensed all around the circumference and may not
be twisted upon mounting.
NOTICE
3. Attach lifting tackle to the compressor casing (546.001) using a rope,

and carefully tension the rope.
4. Position the compressor casing carefully against the flange of the bear-
ing casing (517.000) in axial direction,
4(6) 0 2 5649 500.14-05 EN-US

546.001
546.111
546.112
546.114
546.116
546.005
546.115
546.005
546.112
546.113
Figure 2: V-profile clamp with expansion elements

5. Fit the two halves of the V-profile clamp {546.005) over the flange con-
nection (bearing casing / compressor casing) so that the tapped holes
are aligned with the holes of the holding sheets (546.114). When doing
so, the undercut bolts {546.111) should be as vertical as possible, see
Figure. Observe the initial installation position, as marked.
6. Fasten the V-profile clamp {546.005) with resilient sleeves {546.112).
undercut bolts {546. I l l ) and hexagon nuts (546.113).
Risk of material damage and personal injury due to Incorrectly

CAUTION^ tightened screw connection!
In the very rare c a s e of rotor failure, the V-proflfe clamp {546.005} plays
a significant part in assuring safety of the turbocharger. However, this
presupposes that the clamp is correctly fitted. It is therefore imperative
for the clamp to be fitted in compliance with these instructions.
• Assemble the undercut bolt {546.111) - hexagon nut (546.113) screw
connection without using any lubricants!
• Observe the correct use of the lock washer pairs! Long wedge surfaces
to contact each other {on the inside), othen/vise there will be no locking
effect.
• Tighten undercut bolts (546,111) uniformly and altemately with the
specified tightening torque in the following 4 stages:
•=? 1st stage: 12 Nm
2nd stage: 33 Nm
3rd stage: 52 Nm
4th stage: 63 Nm
7. Secure the clamp halves on both sides with holding sheets (546.114),
lock washer pairs (546.116) and hexagon bolts (546.115).
8. Check 0-ring seals (540.015) if provided and, if necessary, insert new
O-ring seals into the grooves of the insert (540.001).
C 2 5649 500.14-05 EN-US 5(6)

O-ring seals must be tensed all around the circumference and may not
be twisted upon mounting.
NOTICE
9. Carefully insert the insert into the compressor casing and fasten with
hexagon bolts (546,020) and lock washer pairs (546.023).
Caution! Do not damage the compressor wheel v^nth the insert!
10. Insert the injection pipe (546.040) and seal (546.043) and fasten with
hexagon bolts (546.044).
11. Carefully insert the speed transmitter (562.040) and fasten with holding
disk (562.004) and hexagon nut (542.005).
12. Fit the closing cap (540.010) and fasten with cylindrical screws
(540.022) and lock washers (540.022).
13. Feed the cable end of the speed transmitter (562.040) through the
opened cable socket (see Figure 1, detail X) and the opened gland
(546.060), fit the cable socket and gland, and connect the cable end in
the terminal box (562.083, if provided).
Notel "me speed transmitter (562.040) and speed indicator (562.100)
may be connected either way round in the tenninal box (562.083) (alter-
nating voltage).
14. Establish strain relief and grounding by clamping the shielding braid
between conical rings, and seal by means of sealant (e.g. Adaptol); see
Figure 1, detail X.
Gaps and Clearances Check the gaps (items 1 and 2), see sheet 1.52 "Gaps and Clearances".
•2£ 3
7^ 04
6(6) C2 5649 500.14-05 EN-US

Removingand refitting the cartridge
Brief description
Remove and refit the cartridge for inspection or emergency operation.

1 Number Qualification Duration In h
mm Technician
Assistant
0,6
0,6
Qty Designation
Numbor
1 Opwi-jaw wrench 17 Inventory
L_ . . . 1
1 Torque wrench Inventory

596,008 Standard
3 Spindle 596.009 Standard
596.010 Standard
1 « Hexagon nut ^^^^^^^^B^
Lifting tackle, ropes, shackles - Inventory
Inventory
[ - Wood (as a support)
High-temperature lubricant {e.g. Molykote - Inventory
HSC)
Spare parts required

1 Sealing ring 517.064

1 Seal 517.068
Related work cards

1 Work Card Work Card Work Card
500.10 500.12 ^1 500.13 '
1 500.14 1 1
Technical datai
Designatkm Information
Cartridge 55 kg
C2 5649 500.16-04 EN-US 1 (3)

Preliminary remarks
591.060
501.008
517.06^
501.007
501.005
599.000
3_
517.068
501.001
Figure 1: Cartridge, removed from the gas admission cas/ngr

starting condition Connecting pipes, silencer or air intake casing and compressor casing are
removed.
Take care not to damage blades of the turbine rotor during removal.
NOTICE
steps
1. Take off the two-part plate (591.060), if provided.
2. Detach or remove the casing foot (if provided), depending on form of
attachment.
3. Attach lifting tackle to the cartridge (599.000) using a rope, and carefully
tension the rope.
" cc 4. Unscrew the hexagon nuts (501.008), take off the lock washer pairs
7^ c\J (501.007) and the clamping claws (501.005).
2(3) 0 2 5649 500.16-04 EN-US

5. Evenly force off the cartridge (599.000) at 3 points on the circumfer-

ence, using tools (596.008, 596.009, 596.010), see Figure.
Remove cartridge carefully in axial direction and place it on a wooden
support,
596.009
596.010 596.008
596.008
501.001
599.000
Figure 2: Forcing off the cartridge

General For refitting, proceed in the reverse order of removal.
Screw connections Apply high-temperature lubricant (e.g. Molykote HSC) to the thread of screw
connections but not to screw-in threads when replacing studs.
Observe the correct use of lock washer pairs!

Long wedge surfaces to contact each other (on the inside), otherwise there will be no
locking effect.

NOTICE • Apply high-temperature lubricant (e.g. Molykote HSC) to the contact
surfaces and threads.
• Hexagon nuts (501.008): 34 Nm
Checking Check the gaps, see sheet [1.52] "Gaps and clearances".
C2 5649 500.16-04 EN-US 3(3)

Checking and cleanina the cartridge
Brief description
Check and clean the cartridge. Check the state and wear condition of the
components.
Preliminary remarks
General Checking and cleaning the cartridge is limited to the cartridge in its assem-
bled state.
Disassembly and assembly of the cartridge for the purpose of cleaning

or exchanging individual components may only be carried out by
NOTICE trained service personnel.
If a cartridge is to be sent in for overhaul, it must be packaged in such

a way a s to avoid additional damage during transportation.
A CAUTION
Checking the cartridge

starting condition Cartridge Is removed.
Checklist The following checklist contains details of assessment and any measures
that may be required for repairing the cartridge (see Table 1).
Options If multiple options are available (a, b or c), the most favourable in the specific
case is to be selected (see Table 1).
Assessment features Options

Lateral play of the rotor
• See work card 500.06:
Measurement permissible
Measurement exceeded
Streaks
Turbine rotor blade contour and/or compressor wheel:
On one side over the entire circumference: sign of imbalance
Uniformly over the entire circumference: check gaps and clearances (sheet
1.52)
Fouling
" At the axial gap between turbine rotor (wheel) and bearing casing:
Narrow trace of oil: no cause for concern; may come from post lubrication
Heavy oil residue
Heavy oil coke: sign of major oil leaks; generally causes sluggishness of the
rotor
C2 5649 500.17-03 EN-US 1 (3)

^^^^
Assessinent features Options
Fouling
• At the turbine rotor (visible part of the turbine blade wheel):
Heavy oil residue or other dirt deposits a
Fouling
• At the compressor wheel (visible part of the turbine blade wheel):
Dusty or oily deposit a
^^^^^
Damage
Turbine rotor, compressor wheel, bearing casing:
Charging severely impaired, major oil leak, risk of weakening b c
Sluggishness of the rotor

Rotor very sluggish or t i g h t : '
Oil coke deposits behind turbine w h e ^ or labyrinth seal, bearing damage b
* The run-in labyrinths in a new or used turbocharger can cause a certain degree of sluggishness.
This is not a problem, as the rotor rises up during operation and then runs freely,
Check: lift rotor concentrically and turn it.
Table 1: Assessment features and options
Options:
a Cartridge can still be used, clean it.
b Replace cartridge, or
c Disassemble cartndge, check individual components, replace if necessary
(trained service personnel only).
Cleaning the cartridge

Burnt-on deposits Soak burnt-on dirt deposits, particulaHy on the turbine side (e.g. heavy fuel oil
deposits, oil coke), with P3 solution and brush off. If necessary, repeat this
procedure several times. Then neutralize with soda water.
Oily deposits Remove oily deposits with fuel or some other liquid cleanser.
The cleaning fluid and the dissolved dirt must not be allowed to
penetrate into the interior of the cartridge and from there into the
A CAUTION bearing or lube oil circuit. The gaps behind the turbine rotor wheel and
compressor wheel must therefore be suitably covered.
Soaking To soak dirt deposits on the turbine wheel, the cartridge can be placed verti-
cally, turbine side down, in a container with suitable support surtaces. Fill
with cleaning fluid, but only so far that it cannot enter the interior of the car-
tridge (see diagram).
2(3) C2 5649 500.17-03 EN-US

Figure 1: Cleaning the cartridge

Dimensions Type Din mm H In mm
NR15/R 250
NR20/R 310 130
NR24/R 365 J 145

NR26/R 425 180
02 5649 500,17-03 EN-US 3(3)

Cartridge - checking tlie individual components
Brief description
Check individual components. Check the state and wear condition of the
components.

Number Qualffication Duration in h 1
r ^ Technician
1 Assistant
1 ^
Qty Designation Number Status
[ ^ Open-jaw wnîcês (sel)

1 Dial gauge with retainer
C
^^Hl Inventory
Inventory
Special preservative (Molykote P40) ^^^^^B Inventory

[ -
Related work cards

Woiic Card Work Card Work Card
500.10 500.12 500.13 1
500,14 500.16 500.17
Preliminary remarks
starting condition Cartridge is removed.
The cartridge must be disassembled.
>- Work card [500.17] "Checking and cleaning the cartridge"
Disassembly and assembly of the cartridge for the purpose of cieaning

or exchanging individual components may only be carried out by
NOTICE trained service personnel.
« CM
C2 5649 500.18-02 EN-US 1 (6)

Work sequence 1 - Disassembling the cartridge
517.033
517.004
517.001
520.006
520.005
520.009
520.124
Figure 1: Disassembling the cartridge

Steps
1. Unscrew the magnetic nut (520.124) (right-hand thread) while holding
the turbine rotor.
2. Pull off the carrier (520.009).
3. Pull off the compressor wheel (520.005) by hand in axial direction.
Heat treatment in the event of a seized compressor wheel!

A CAUTION Overheating of the compressor wheel causes a structural
transformation of the aluminium alloy and thus renders the
compressor wheel unusable!
A •
•
Wear protective clothing.
Heat only the hub of the compressor wheel and on no account the
blades.
• Heat the hub uniformly round the entire circumference (not locally),
quickly and gently using a soft flame at no more than 80 °C.
4. Lift the turbine rotor (520.001) slightly and pull it out as concentrically as
o Si possible.
2(6) C2 5649 500.18-02 EN-US

Run-in labyrinths or coke deposits can impede removal; knock with a

wooden block if necessary. The labyrinth ring (520.006) is stripped off
NOTICE when the turbine rotor is removed. The feather keys (520.018) are not
normally removed, but must not be lost.
5. Remove labyrinth ring (520.006) and both bearing bushes (517.002)

from the bearing casing (517.001).
If the labyrinth ring is firmly held in place in the bearing casing, it can be
pushed out together with the distance sleeve (517.003} and bearing
bush on the compressor side after the bearing bush on the turbine side
has been removed.
6. Unscrew the holding screw (517.004) (right-hand thread),
7. Push out the distance sleeve (517.003) towards the compressor side.
Removing a seized distance sleeve:
Loosen and push out the distance sleeve by means of light hammer
blows or using a press with a wooden or copper pin.
8. Unscrew the hexagon nuts (517.032), take off the lock washer
pairs (517.033) and the intermediate ring (517.009).
Cleaning and checking the individual components:
>• Work sequence 3
Work sequence 2 - Reassembling the cartridge
517.003
517.033
517.004
517.032
517.001
517.009
520.005 520.001
520.124
520.018 520.009 520.005 517.002
Figure 2: Reassembling the cartridge

General it is particulariy important to ensure that the individual components are clean
when reassembling the cartridge. Ughtly coat the sliding surfaces of the
bearing points with clean lube oil.
Steps 1. Fasten the intermediate ring (517.009) to the bearing casing (517.001) CM
with lock washer pairs (517.033) and hexagon nuts (517.032).
C2 5649 500.18-02 EN-US 3(6)

Insert the distance sleeve (517.003) into the bearing casing, obsen/ing
the correct installation position. The axial distance of the bore for the
holding screw (517.004) is smaller on the compressor side.
Screw in holding screw (517.004) all the way to the stop, tightening only
slightly.
Insert bearing bushes (517.002) into bearing casing on turbine and
compressor side. The bearing bushes are symmetrical and may there-
fore be fitted in any position.
Apply a thin protective film of Molykote P40 to the fitting surfaces of the
turbine shaft (for labyrinth ring, compressor wheel and carrier). Carefully
insert turbine rotor in axial direction.
Push on the labyrinth ring (520.006) and insert feather keys (520.018).
Push the compressor wheel (520.005) and carrier (520.009) onto the
turbine shaft as far as the stop.
The balancing marks (W) of the turbine rotor (520.001), labyrinth ring
(520.006), compressor wheel (520.005) and carrier (520.009) must be
NOTICE aligned radially.
If heat treatment is required, observe the following:

A CAUTION Overheating of the compressor wheel causes a structural
transformation of the aluminium alloy and thus renders the
compressor wheel unusable!
• Wear protective clothing.
• If necessary, heat compressor wheel to max. 80 °C using suitable
means (e.g. in a water bath or on a burner).

NOTICE • Apply Molykote P40 to the threads and contact surfaces of the
magnetic nut.
Tightening torque for magnetic nut (520.124):
• 120 Nm for magnetic nut made of steel (27 mm)
• 58 Nm for magnetic nut made of aluminium (30 mm)
• Once the compressor wheel has cooled, loosen the magnetic nut
(520.124) and retighten it with the specified tightening torque.
7. Measure axial clearance of the rotor and axial runout of the compressor
wheel with a dial gauge. Permissible values:
>• Sheet n.521 "Gaps and clearances", items (5) and (6).

Long wedge surfaces to contact each other (on the inside), othenwise there will be no
locking effect.
CM
4(6) C2 5649 500.18-02 EN-US

Work sequence 3 - Cleaning and checking the individual components

Cleaning • Burnt-on dirt deposits
Particularly on the turbine side (e.g. heavy oil residues, oil coke), soak
with P3 solution and brush off. If necessary, repeat this procedure sev-
eral times. Then neutralize with soda water.
Oily dirt deposits
Remove with fuel or some other liquid cleanser.
Sealing air and oil bores
Flush with fuel and then blow clean with compressed air.
Checking The following checklist contains details of assessment and measures
required for repairing the cartridge.
Designation . _ 1 Options
Order No.
Beating casing Damage or cracks if risk of weakening or oil leak a
517.001 Signs of scoring or wear in the bearing bore: a
d > 0 52.03 mm
Run-in pattern of the labyrinth tips abnormal a
The labyrinth clearance is less than the bearing clearance. The labyrinth tips thus
wear into the bore of the bearing casing. The grooves are wom slightly to one
side of the circumference; this corresponds to the position of the bearing.
—
Bearing bush • Signs of scoring In the contact pattern of the axial surfaces a
517.002 Wear: a
(identical on tur- D < 0 51.82 mm, d > 0 31.04 mm, b < 30.95 mm
bine and com-
pressor sides) Uniform glazing is not a problem; outside and inside diameter cannot be
assessed by means of a visual inspection.
Distance sleeve Signs of scoring on the axial surfaces a
517.003
IntOTTiediate ring Damage If risk of malfunction or weakening a
1 517.009
Turbine rotor Damage to the blades, e.g. caused by foreign bodies a
520.001 • Cracks a
(testing; e.g. acoustic testing, fluorescent dye penetration method)
Streaks on the blade contour, on one side over the entire circumfer- a b
ence:
Sign of imbalance
- '
• Streaks on the blade contour over the entire circunnference: a

If permissible gap exceeded,
see sheet [1.521 "Gaps and clearances", items (3) and (4).
^ ——• . -^^••Vl
Labyrinth tips damaged or worn: a b

D < 0 64.85 mm
Bearing points damaged or w o m : '^^^^^^^^^^^f-

D^0 30.94 mm ^Pj^^^^^^^K
C2 5649 500.18-02 EN-US 5(6)

Designation Options
Order No.
• True running check: Clean centring elements, hold between tips, a b
measure true running at both bearing points and compressor wheel
seat (3 points), if radial runout greater than 0.01 mm
If eccentiicity at these 3 points is in the same circumferential position and is lin-
ear, then the centring elements are damaged and the actual radial runout is
smaller (max. permissible 0.01 mm)
^"SSpressor • Damage to the blades, e.g. caused by foreign bodies a
wheel Cracks a
520.005 (testing: e.g. acoustic testing, fluorescent dye penetration method)
• Streaks on the blade contour, on one side over the entire circumfer- a b
ence:
Sign of imbalance
Streaks on the blade contour over the entire circumference: a
If permissible gap exceeded,
see sheet f1.52] "Gaps and clearances", items (1) and (2)
Labyrinth ring Labyrinth tips damaged or worn: a

520.006 D < 0 64.85 mm
Exchange dimensions: D ^ outside diameter, d - inside diameter, b = width

Table 1: individual components and options
Options If multiple options are available {a or b), the more favourable in the specific
case is to be selected:
a = exchange individual component.
b = send individual component in for repair.
CM
6(6) C2 5649 500.18-02 EN-US

Gas outlet casing, gas outlet diffuser
Brief description
Remove the gas outlet casing and gas outlet diffuser for inspection. Check
the state and wear condition of the components.

r 1 Technician ^^^JHH||^^^^^^ 1,0 ' '"^J
1 Assistant 1,0 1
Qty Designation Numt)er Status
Open-jaw wrench 19 - Inv^tory
Screwdriver - Inventory
High-temperature lubricant {e.g. M o l y l ^ ^ ^ ^ ^^^^^^^^^^^^ Inventory
HSC)
Wood (as a support] Inventory
Related work cards

WorkCanI Work Card Work Card
i— . ,
500.10
Teciinical data!
designation information
Gas outlet casing ^75kg
Gas outlet diffuser 26 kg
5 s
C2 5649 500.19-02 EN-US 1 (3)

Preliminary remarks
501.001 591.160 506.001
609.105
509.107
509.001
Figure 1: Removing and refitting the gas outlet casing and gas outlet diffuser

starting condition Connecting pipes and exhaust gas pipe are disconnected, or complete tur-
bocharger is removed from engine.
Steps
1. Take off the annular lagging (591.160).
2. Attach lifting tacl<le to the gas outlet casing (506.001) using a rope, and
carefully tension the rope.
3. Unscrew the hexagon nuts (509.105) and take off the lock washer pairs
(509.107), Carefully remove the gas outlet casing in axial direction and
set it down on a wooden support, paying attention to coverings and
removed gas outlet diffuser (509.001).
4. Take off the gas outlet diffuser (509.001) in axial direction.


locking effect.
2(3) C2 5649 500.19-02 EN-US


NOTICE
• Apply high-temperature lubricant (e.g. Molykote HSC) to the threads and
contact surfaces.
• Tjahtening torque for hexagon nuts (509.105); 59 Nm ^ ^ ^
5 S
C2 5649 500.19-02 EN-US 3(3)

MAN Diesei & Turbo 500.20
Turbine nozzle ring, insert
Brief description
Remove and refit the turbine nozzle ring for inspection. Check the state and
wear condition.
Personnei and time required

Number Qualification
Numt Duration in ii I
1 Technician 0.6
Tools/appiiances required
Oty Numt}er Status
Designation
Socket w r e n d T l S j j ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ l Inventory
Punch - Inventory
Hammer Inventory
High-temperature lubricant [e.g. Motykote - Inventory
HSC)
Related woric cards

Work Card Work Card Work Canl 1
. . , . 500.04 500.16 500.19 ^
Preiiminary remarics
General The turbine nozzle ring and/or insert has to be removed only if it is to be
replaced.
Starting condition Gas outlet casing, gas outlet diffuser and cartridge are removed.
0 2 5649 500.20-01 EN-US 1 (3)

501.001
SI S1-S1
501.072 ~ ^ 501.009
501.017
501.025
513,001 541.001
501.024
Figure 7; Removing and refitting the turbine nozzle ring and/or insert

steps 1. Remove covering ring (501.072).
2. Check the turbine nozzle ring (513.001), refer to wori< card r500.04]
"Checking the turbine nozzle ring".
3. Remove turbine nozzle ring (513.001) by uniformly hitting in direction
"A" with a hammer and punching the 4 collar pins (501.009).
4. If the insert (541.001) has to be removed;
Unscrew the hexagon nuts (501.025) and take off lock washer pairs
(501.017).
5. Remove insert (541.001) in axial direction.
Worl( sequence 2 - Refitting


locking effect.
Turbine nozzle ring

1. Press longer, chamfered section of 4 collar pins (501.009) into the gas
admission casing (501.001) as far as the stop.
2. Place the turbine nozzle ring (513.001) on the collar pins in such a way
that the angled guide vanes are in line with the separating webs of the
•2£ o gas admission casing (points "Z", see diagram).
CM 3. Push in the turbine nozzle ring uniformly; do not tilt it and do not push
on ttie guide vanes.
2(3) C2 5649 500.20-01 EN-US

The number of separating w e b s depends on the design of the gas

admission casing.
NOTICE
C2 5649 500.20-01 EN-US 3(3)

MAN Diesel & Turbo

2 Systems
3 Operation
4 Maintenance
5 Work cards
8 Index
5649-3 6 C1-03 EN-US 1 (1)

Organisation and use of tlie spare parts catalogue
Spare parts for turbocharger

Spare parts/spare parts Maintenance and repair work can be carried out properiy only if the required
catalogue spare parts are available. They are to be kept on stock or ordered in time.
The order numbers required for ordering spare parts can be looked up in the
spare parts catalogues.
Spare parts Spare parts for the turbocharger can be identified by means of the spare
parts catalogue. For this purpose, illustration and text sheets with order num-
bers are available. An order number consists of a three-digit subassembly
number and a three-digit item number, separated by a dot. The spare parts
catalogue is arranged in the order of the subassemblies.
The order numbers, however, can also be looked up in the respective work
cards.
Spare parts for maintenance A basic set of spare parts is supplied by special order; these parts are listed
work in the "List of spare parts". The numbers in the list are the order numbers
and match the numbers o n the parts themselves.
All parts that are not packed in plastic bags must be stored well coated in
grease. Parts that have rusted must be cleaned and greased.
It is advisable to re-order Immediate replacements for spare parts that have
been used, as transportation (and customs clearance procedures) can signif-
icantly delay the delivery of the parts. In the case of repair work, however, it
is essential to have the required parts to hand as quickly as possible.
Tools Complete or individual tools for turbochargers can be ordered with the aid of
the list of contents for tools, stating the respective order numbers, This list of
contents is included in the tool box for the turbocharger. An order number is
composed of a three-digit subassembly number 596 (= subassembly for
tools) and a three-digit item number, separated by a dot.
The order numbers, however, can also be looked up in the respective work
cards.
Instructions for use

The spare parts catalogue covers
all essential components of the turbocharger.
The spare parts catalogue does not contain
subordinate or plant-specific insulations/coverings.
subordinate cabling, or cabling leading away from the turbocharger/
cabling and pipes installed out by other manufacturers.
What to do if spare parts are If parts have to be ordered which the spare parts catalogue does not contain
not found? or that are not found, the component and the installation location should be
described as precisely as possible, with a photo possibly attached. Where
parts from subsuppliers are concerned, which cannot be found in their docu-
mentation, the information given on the technical data plate should be
stated.
« DC
c5 ?=
Q. <
C3 5654 6.1-01 EN-US 1 (2)

6.ii MAN Diesel & Turbo
Vaiidity
Scope of supply The spare parts catalogue is valid for the specified turbocharger type. To
Identify parts, the individual pages of the spare parts catalogue must be
selected in accordance with the object concerned and/or the scope of sup-
ply of the turbocharger works number.
Modified components Since our turbochargers undergo upgrading development, it may happen
that when spare parts are ordered later on the parts supplied differ from the
ones supplied originally, which, however, serve the same purpose as the lat-
ter. In such cases, the identity card of the part supplied will contain a corre-
sponding reference.
Organisation of the spare parts catalogue

Oven/iew of subassemblies The overview of the subassemblies consists of an illustration and a table. The
table is arranged in ascending order of the turbocharger subassemblies.
See [500.011 "Overview of subassemblies".
Subassemt)ly Designation
Bearing casing ^^^^^^1

857^ Cleaning device fCH* turbine
Subassemblies whose numbers are shown in parentheses are not installed on all
turbochargers (optional design).
Table 1: Examples of subassembly designations
Spare parts sheets The sheets in the spare parts catalogue are ordered in accordance with the
subassemblies system of the turbocharger. They consist of one or more Illus-
trations each with an associated parts list.
Odinal numb&r The ordinal numtjer at the upper right of tfie ^Dare parts
e.g. 517.01 sheets consists of the three-digit subassembly number
and a variant number corresponding to the design variant.
517 (subassembly number)
01 (variant number) ^
i _.— i The order number consists of a three-digit subassembly
Order No. number and a three-digit item numt)er. The subassembly
e.g. 517.024 number and the item number are separated by a dot.
517 (subassembly number)
024 (item number)
Tatite 2: Spare parts catalogue sheet, organisational principle
==
a. <
cn z
2(2) C3 5654 6.1-01 EN-US

Ordering spare parts
Information required
To avoid queries, the following information should be provided when ordering
spare parts:
Turbochargertype XXXXXXXXX
Works number of turbocharger X XXX XXX
Ordernumber ^ XXX.XXX
IMO number (for fiow-guiding parts) XXXXXX
Designation of part XXXXXXXXX
Quantity XX
Shipping address l^^^^m XXXXXXXXX
Mode of shipment XXXXXXXXX
Table 1: Infonnation required in the order
Addresses
Augsburg plant Telephone/Fax/e-mail/Internet
Headquarters
MAN Diesel & Turbo SE Tel, +49 821 322 0

PrimeServ Augsburg ^ ^ ^ ^ ^ Fax +49 821 322 49 4180 """^
86224 Augsburg
1
Germany ^^^PP^ e^nail PrimeServ-Aug@mandtese1turbo.com
Internet wvwi/.mandieselturbo.com/primesery-
PrimeServ Turbocharger Tel. +49 821 322 4010 Axial turbochargers (24 hours)
Technical service 449 821 322 4020 Radial turbochargers (24 hours) M
Fax +49 821 322 3998
e-mail PnmeServ-TC-Technlcal@mandieseHurtx).com
Internet www.mandieselturbo.com/primeservl
03
3
o>
_o
PrimeServ Turbocharger Tei. +49 821 322 4030 (24 hours) re
CO
Spare parts +49821322 3998 u
CO
e-mail PnmeServ-TC-Commercial@mandieselturbo.corr* re
Q.
03
Internet www.mandieselturbo.com/primeserv
re z
a.
CO
C3 5654 6.2-01 EN-US 1 (2)

Augsburg plant Telephone/Fax/e-mail/!ntemet

Headquarters
PrimeServ Academy Tel. +49 821 322 1397
Training courses for turbochargers .... Fax +49 821 322 1170 _
and engines
PrimeSen/.Academy-info@mandieselturbo.com
Internet www.mandieselturbo.com/primesery-academies
(5 ==
a. <
CO z
2(2) C3 5654 6.2-01 EN-US

Overview of subassemblies
Subassemblies
^ tH m tjj M
Subassembly Designation
500^ Exhaust gas turbocharger

Gas admission casing
506 Gas outlet casing
509 Gas outlet diffuser
51^ Turbine nozzle ring
517; Bearing casing
520i Rotor, complete
540 Insert, compressor side
541 Insert, turbine side
542 Diffuser
(544) Silencer
(545) Air intake casing
546 Compressor casing
(562) Speed measuring device
(578) Cleaning device for turbine
(579) Cleaning device for compressor
(591) Coverings
599 Cartridge (517-1-520) CO CM
a. cc
(...) If provided C/3 Z
C3 5649 500.01-01 EN-US 1 (1)

Gas admission casing
Spare parts 501.01
501.000 (506.001)
501.00
(513.001)
501.034
501.017
599.000)
501.072
501.025
501.005
501,009
501.OOB
501.007
531.001
501.006
Order No. Designation

501.000 Gas admission caang, complete
501.001 Gas admission casing
501.005 claw ^^^^^^^^^^^^^^^B -^^^^^^^B
501.006 Stud
^^501.007 Lxx^ wash^ pair ^j^^^l^^P" ^^^^^^^^Îf
501.008 Hexagon nut |
^ 501.009 Collar pffi "^^^^HH— —
\ 501.017 Lock washer pair
^ 501.024 Stud
501.025 Hexagon nut
501.072 Covering ring
C3 5649 501.01-01 EN-US 1 (1)

Gas outlet casing
Spare parts 506.01
506.000
(501.001)
506,001
[509,001
(591.1011
1509.105)
506.001
1591,001) 506.075
El
506.07^
1 JXU-i
506.000 Gas outlet casing, complete
506.001 Gas outlet casing
506.074
Screw plug ^^^Ûll^^ll ^^^^K ^HHHII^
506.075 Sealing ring
03 St
CO z
C3 5649 506.01-01 EN-US 1 (1)

Gas outlet diffuser
Spare parts 509.01
509.107 509.000
I5C1.001) 509.-OS
509,10^
509.001
r
(599.000)
1506.001
509.001 Gas outlet diffuser
509.001 Outlet diffuser '
509.104 Stud i^^^V

509.105 Hexagon nut
1 509.107 Lock washer pair'
a. az
CO z
C3 5649 509.01-01 EN-US 1 (1)

(L) L s n - N 3 L0-i-0'eLS6t'9g e o
30 -a
o —^
^ CD
6uu 91ZZ0U e u t q j n i LOO'S 1-9
-
uofteuBjssa •0NJ9PJ0
(lOO'lK)
(600'loi;)
(100-109
lOO-fIS
|.0'£l-9 sped ajeds
BUN aizzou aujqjni
o q j n i ^ |8S8!a NVIAI
Bearing casing j
i
Spare parts 517.011
517.018 517.000
517.029
517.033
517.033
517.009
517,004
517.M)? 517.002
517.068
517.003
517.067
517.078
517,083
Order No. Designabor)
517.000 Bearing casing, complete
517,001 Bearing casing
517.002 Bearing busii
517.003 •.stance sleeve
517.004 Holding screw
517.009 Intermediate ring
517.018 O-ring seal
517.029
517.032 Hexagon nut
517.033 Lock washer pair
517.063
517.065 Hexagon bolt
517.067 Flange
517.068
517.082 Hexagon bolt Q . GC

C/3 Z
517.121 Screw plug
C3 5649 517.01-01 EN-US 1 (2)

Order No. Desfîation
517.122 Injection pipe
Sealing ring " " ' B
2(2) C3 5649 517.01-01 EN-US

Rotor, complete
Spare parts 520.01
520.000
520.001
52C.O09
520.005
520.1?'*
520.006
520-018

^ '—T-^ —--•—i\i:-.î:,!i< . ' ~ ~ ______
520.000
Rotor, complete
520.001 Turbine rotor
^ 520.005 Compressor wheel ^ ^ ^ ^ ^ ^ ^ K i ^ ^ ^ ^ B

520.006 Labyrinth ring
P 520.009 Carrier — ^ ^ ^ ^
520.018 Feather key
520.124 Magr>etlc rnjt
C3 5649 520.01-01 EN-US 1 (1)

Insert, compressor side
Spare parts 540.01
0.000 (545,020)
5^0.001
540.010
540.022
(562,040)
540.015
540.016
(546.CW0)
(546.001
540.000 Insert, compressor side, complete
540.001 Insert
540.010 Closing cap ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ B .
540.015 O-nng seal
^"'"540.016 0-ring seal
540.020 Cylindrical screw i
^ 540.022 Lod< w a ^ e r
C3 5649 540.01-01 EN-US 1 (1)

MAN Diesel & Turbo 5 4 1 .OT
Insert, turbine side
Spare parts 541.01
541.001
501.025)
511,001
(599,000)
Order No Designation
1.001 Insert
as i t
CM
C/3 Z
C3 5649 541.01-01 EN-US 1 (1)

Diffuser
Spare parts 542.01
542.001
(5^6.0011
542,001
(5«.008)
542.001 Diffuser .^^^^^^^^^1
0) H:
CO CM
O . EC
C/3 Z
C 3 5 6 4 9 542.01-01 E N - U S 1 (1)
Silencer
Spare parts 544.01
5<4,03^ 544.000
5^4,202
5^4.20'
1546.005)
544.069
544,074 546,001)
54*.075 5*1,010
544,033 511.032
SI
514,001 544,201
5*4.021
544,205
5^4.041
544,202
5 4 4 , 0 J*
Order No. Designabon
544.000 Silencer, complete
544.001 Rear \va
544.010
544.021 Damping plate
544.032 Spacer pipe
544,033 Spacer pipe
544.034 Perforated plate
544,041 Front wall
544.069
544.074 Hexagon nut
544.075 Washer
544.2C1 A t f'ter mat
544.202
544.205 Cover sheet
is o
CO CM
Q. CC
C/3 Z
C3 5649 544.01-01 EN-US 1 (1)

Air intake casing
Spare parts 545.01
1546.0051
545.000
(546.001)
545.001
545.014
5^000 Air intat^ casing, complet&^^^^|^^
545.014 Hfficagon bott '^^^^^ ^^^1
CD CM
O. CC
CO z
C3 5649 545.01-01 EN-US 1 (1)

Compressor Casing
Spare Parts 546.02
546,040 —
546,0*3 ^Js^^
545 005
546,004
I I
546 001
5*6 C
546-052
546,020
546.008
546 023 -
546 065
546 05 1
546 050
546.000 Compressor casing, complete
546.001 Compressor casing
546.003 Spring pin
546.004 V-profile clamp
546.005 V-profile clamp, consisting of:
(546.110) Clamp half
(546.111) Undercut bolt
(546.112) Resilient sleeve
(546.113) Hexagon nut
(546.114) Holding sheet
(546.115) Hexagon bolt
(546.116) Lock washer pair
546.008 Countersunk bolt
546.020 Hexagon bolt
546.025 Type plate
C3 5649 546.02-01 EN-US 1 (2)

546.026 Notched nail
546.040 Injection pipe
546.043
546,044 Hexagon bolt
546.050 Flange
546,051 Sealing ring
546.052 Hexagon boft
546.060 Gland
546.065 Screw locking agent, medium-strength
2(2) C3 5649 546.02-01 EN-US

Speed measuring device
Spare parts 562.01
562.040
562,000
562.004
15*0.0101
562.051
562.005
562.100
(510.001
5 6 2 . \ 35
562.083 (515.001
562.000 Speed measuring device, complete
562.004 Holding disk
562.005 Hexagon nut
562.040 Speed transmitter
562.061
562.083 Terminal box
562.100 - Speed indicator
562.135' Tel on-armored cable
if provided
CD CNJ
CO z
0 3 5649 562.01-01 EN-US 1 (1)

Cleaning device for turbine/ wet cleaning
Spare parts 578.01
578.01,000
578,01,030
578,01,010
578-01,006
578.01,003
578.01.002
0 n rrni
578.01.000 Cieaning device for turbine, compiete (wet cleaning)

-, ..V .,J
578.01.002 Screw connection
578.01.003
578.01.005 Sealing ring
P^578.01.006 Pressure reducirig station ^^^^^^^1

578,01.010 Plate {with cleaning instructions)
ft 578.01.020 Three-way cocl<
CO
O . GC
CO Z
C3 6661 578.01-01 EN-US 1 (1)

Cleaning device for turbine/ dry cleaning
Spare parts 578.02
578-02.000
578,02,020
578.02.QJ5
578,02,001
578,02.031
578.02.027 578,02.026
mo.,300-C
578,02,025
578.02.C2e 578,02,029
578,02,050
578.02.000 Cleaning device for turbine, complete (dry cleaning)
578.02.001
578.02.020 Screw plug
578.02.029 Ll-bolt
578.02.030 Ball cock
578.02.031 Stop cock I
578.02.035 Plate (with cleaning instructions)
CO
Q. DC
C/3 Z
C3 6661 578.02-01 EN-US 1 (1)

Cleaning device for compressor / tanic fitted
Spare parts 579.01
579.000 (544.000)
(545.0001
. 0 16 rrm
579.124
579.123 G 1/2
u 579,091
579.089
o
o
579.090
L
579.090
579.124 579.120
579.090
579.091
- r - 579 126
579.122 579.127
579.128
4^
579.029
579.178
579-130
579.044
579.042
579.000 Cleaning device for compressor, complete
579.029
579,042 Hexagon bolt
579.089 Hose piece
579,090 Hose
579.091 Hose otamp
579.103' Screw connection
579.104' Reducing connection
579.120 Connecting piece
579.122 Hydrometer cock
579.124 Screw connection
579.127 Hose
579.123 Hose clamp
579.130 Support
0}
579.178 Plate (with cleaning instnjctions) Js <=>
CO CM
if provided o. cc
CO z
C3 6661 579.01-02 EN-US 1 (1)

Cleaning device for compressor/ pressure sprayer
Spare parts 579.02
0 1 0 mm 579.OCO
579.103
579.liO
579.102
579.100
579.101
579.095
tatQ
579.D96
579.091 579.029
579.090
579 09
579.179
579.000 Cleaning device fcx* compressor, complete O^ressure s p r a ^ 1^^^^^ ^

579.029 Pressure sprayer
579.090
579.091 Hose clamp
579.095
579.096 Nipple
1 579.100 Screwed socket '^^f^^^^^^^^^^^^^^^^K'

579.102 A n g u l ^ screw connection ^^^^^^^^^^^^^^^B ^^^1

579.103 Screw connection
579.130 Retains '^''^^^^^^^l ^

579.179 Plate
C3 6661 579.02-01 EN-US 1 (1)

^^^^
Coverings
Spare parts 591.01
591.000 (506.001)
591.001
591.060
b91.160 591.101
[599.000)
[501.001]
591.001 Covering with insulation on admission casing
591.060 Two-part plate
591.101 Covering with insulation on gas outlet casing ^^^^^^mil^^^^^^^^^l

591.160 Annular lagging
CU CM
C/3 Z
C 3 5649 591.01-01 EN-US 1 (1)

Cartridge
Spare parts 599.01
599.000
^Bsgg.ooo* Cartridge
* 599.000 = (517.000) and (520.000) assembled
C3 5649 599.01-01 EN-US 1 (1)

MAN Diesel & Turbo

2 Systems
3 Operation
4 Maintenance
5 Work cards

8 Index
5649-3 7 C I - 0 3 EN-US 1 (1)

List of spare parts
811.59400-0075, X11.59400-0076 (X11.59500-0115)

Order No. , Designation Sketch mm Quantity
501.006 Stud D = 10.0 6

L = 49.0 (24)'
501.007 Lock washer pair D = 16.6 24

S= 2.2 (24)*
501.008 Hexagon nut W = 17.0 6

VW B = 8.0 (24)*
L
517.002 Bearing bush D = 52.0 2

•4 u ^ 8 = 31.0 (2)*
1
/ t m
1 r
1 f
517.018 0-ring seal D= 421,0 1

S= 4.0 (ir
C3 5649 594.01-01 EN-US 1 (3)

Order No. Designation Sketch mm Quantity
517.029 Stud' D= 6.0 2

L = 27.0 (4r
517.032 Hexagon nut W=10.0 2

VM B= 5.0 (4)'

8= 2.2 (4)'
517.064 Sealing ring D = 38.0 1
D S S= 1.5 (ir

S= 2.2 (2)"
— H * ^
1-
517.068 Seal L = 96.0 1

S= 2.0 (2r
1 rv
2(3) C3 5649 594.01-01 EN-US

Order Ho. Designation Sketdi mm QuanUty
517.078 Locl< washier pair D = 19.5 2
D S S= 2.2 (4)'
W T
* Quantity installed in turt)Ocharger
C3 5 6 4 9 594.01-01 EN-US 3(3)

List of tools
El 1.59600-0124, X11.59600-0126 (X11.59700-0118)

Order No. Designation Sketch mm Quantity
596.008' , Segment L = 85
B = 50
(0.530 kg)
596.009 * Spindle D = 12
L = 95
(0.069 kg)
596.010* Hexagon nut W = 19

B = 10
(0.017 kg)
* For removal of cartridge (see work card [500.16] "Removing and refitting the cartridge")
C3 5649 596.01-01 EN-US 1 (1)

MAN Diesel & Turbo

2 Systems
3 Operation
4 Maintenance
5 Work cards
8 Ifiêx
5649-3 8 C I - 0 3 EN-US 1 (1)

MAN Diesel & Turbo
Index
Addresses and contact persons 1.4 (1) E m e r g e n c y measures (in t h e event 3 . 5 3 (2)
Air filter m a t 4 . 5 2 (1) of t u r b o c h a r g e r failure)
Air intake casing 500.13(2) E m e r g e n c y operation 3.53 (1)
5 4 5 . 0 1 (1) E m e r g e n c y operation 500.05 (1)
500.13(2) Engine s h u t - d o w n 2.51 (3)
Air intake casing
1.51.2 (2) Exhaust G a s e s 3.0 (2)
A l a r m points
A l a r m points 2.51 (3)
Alarm System 3.0 (3)
Fire-extinguishing E q u i p m e n t 3.0 (2)

B Friction coefficient p 0 0 0 . 3 1 (1)
B a n s (symbols) 1.0(2)
C G a p s a n d clearances 1.52 (1)

500.16(3) G a s outlet c a s i n g 500.19(2)
Cartridge
G a s outlet diffuser 500.19(2)
500.18(2)
Cartridge 500.16(2)
H
C a t fines 4 . 5 3 (1)
Checks 3.51 (2) H a z a r d levels
3 . 5 1 (2) Stufe 1 - 4 1-0 (1)
Cleaning Hearing Protection 3.0 (1)
High-pressure 4 . 0 (3) High-pressure cleaner 4 . 0 (3)
Cleaning 4 . 5 2 (1)
4 . 5 2 (2)
Cleaning t h e air filter 5 0 0 . 1 1 (1) Inbetriebnahme (erste) 3.51 (1)
Cleaning t h e c o m p r e s s o r Insert 500.14(2)
Tank 5 0 0 . 0 8 (2)
5 0 0 . 2 0 (2)
Cleaning t h e c o m p r e s s o r
Pressure sprayer 5 0 0 . 0 8 (2) 5 4 0 . 0 1 (1)
Cleaning t h e turbine 5 4 1 . 0 1 (1)
Dry cleaning 500.07 (2) Inspection 4.56 ( 0 )
W e t cleaning 500.07 (2) Inspection of individual c o m p o - 4 . 5 3 (1)
Closing device 500.05 (2) nents (general)
Closing device for e m e r g e n c y 3.53 (1) Inspection report 4 . 5 1 (1)
operation Intake air 4 . 5 2 (1)
C o m p r e s s o r casing 500.14(2) Intended use 3.2.2 (1)
C o m p r e s s o r cleaning
Pressure sprayer 579.02 (1) J
Tank mounted 579.01 (1)
Jet Assist 2 . 5 4 (1)
C o m p r e s s o r , cleaning 4.52 (1)
C o n t a i n m e n t safety 3.0 (1)
L
D Lateral play 5 0 0 . 0 6 (1)
D a n g e r of Rre/Fire-extinguishlng 3.0 (2) L o c k w a s h e r pairs

A s s e m b l y , general 4 . 5 1 (2)
Systems
L u b e oil drainage 2.51 (3)
Danger symbols 1.0 (2)
Difference in height 2.51 (3) 2.51 (3)
Differences in height 2.51 (3) L u b e oil filtration 2.51 (4)
Diffuser 500.14(2) L u b e oil pressure
Dimensions 1.51.5 (1) Limit values 2.51 (3)
Dry cleaning 4 . 5 2 (2) L u b e oil quality 2.51 (4)
5649-3 C I - 0 3 EN-US 1 (2)

MAN Diesel & Turbo
M Danger 1.0 (1)

Warning 1.0(1)
Maintenance schedule 4 . 5 6 (1)
Safety s y m b o l s 1.0 (2)
Maintenance schedule 4 . 5 5 (1)
Screen 3 . 5 3 (1)
Maintenance work
Screw connections
Renriar1<s 4.51 (1)
Loosening 4 . 5 1 (1)
M e c h a n i c a l cleaning 4 . 5 2 (1)
Lubricant 4.51 (2)
4 . 5 2 (2) Special materials 4 . 5 1 (2)
Shaft sealing 2.51 (2)
N Shutting d o w n 3.51 (3)
Silencer 5 4 4 . 0 1 (1)
Numbering
Silencer 500.12(2)
Work cards 5.1 (1)
Spare parts
General 4 . 0 (3)
0
S p e e d measuring d e v i c e
Order n u m b e r 6.1 (1) Cable socket 5 4 0 . 0 1 (1)
S p e e d transmitter 500.14(2)
6.1 (2)
5.1 (1) Starling operation 3 . 5 1 (2)
Order n u m b e r s
O r d e r i n g s p a r e parts 6.2(1)
Tightening of s c r e w c o n n e c t i o n s
General 0 0 0 . 3 1 (1)
Personnel
Tool n u m b e r 5.1 (1)
Qualification 1.2(1)
Personnel a n d t i m e required Tools
Availability 5.1 (2)
General 5.1 (1)
3.0 (2) Inventory 5.1 (2)
Protective C o v e r s
Optional 5.1 (2)
Special 5.1 (2)
Q
Standard 5.1 (2)
Qualification Trouble s h o o t i n g 3.52 (1)
Personnel 1.2(1) Turbine cleaning
Qualification of Personnel Dry cleaning -1 578.02(1)
Maintenance/Repair 4 . 0 (1) W e t cleaning 5 7 8 . 0 1 (1)
Ship s y s t e m s 3.0 (3) Turbine nozzle ring 5 0 0 , 0 4 (1)
Stationary s y s t e m s 3.0(4) Turbine nozzle ring 500.04(1)
5 0 0 . 2 0 (2)
R Turbocharger
Checks 3.51 (2)
Regulations for Prevention of A c c i - 3.0 (1)
T y p e plate 1.51.2 (1)
dents
Venting 2.51 (4)

Safety
during Maintenance/Repair 4.0(1)
during O p e r a t i o n 3.0(1) W
General safety instructions 1.0(1) Weights 1.51.4 (1)
Safety Instruction W e t cleaning 4 . 5 2 (2)
Caution 1.0 (1)
C a u t i o n (material d a m a g e only) 1.0 (1)
2(2) 5649-3 C I - 0 3 EN-US

2 (b2 4) Turbocharger

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MAKER'S FINAL DRAWING

ENTRY - INTO - SERVICE - FORM

We herewith confirm that the following Turbocharger

fitted to the engine

has begun its operation on^ Date:

The engine will be operated

as a Power Station Q Country:

in a Vessel \__\ Name:

Name, Title Signature Date

Please post, e-mail or fax to:

MAN Diesel & Turbo S E

Turbocharger type NR20/R

Translation of the original instructions

MAN Diesel & Turbo SE

Copyright © 2013 MAN Diesel & Turbo

2(2) 5649-3 C I - 0 3 EN-US

1 introduction / Technical data

2.54 Acceleration system - Jet Assist

5649-3 C1-03 EN-US 1 (3)

500.04 Checking the turbine nozzle ring

500.06 Lateral play of the rotor Checking

500.07 Cleaning the turbine - dry cleaning

500.10 Turbocharger or subassemblies

6 Spare parts catalogue

513.01 Turbine nozzle ring

2(3) 5649-3 C1-03 EN-US

579.02 Cleaning device for compressor/ pressure sprayer

7 Spare parts / Tools

5649-3 01-03 EN-US 3(3}

1 Introduction / Technical data

5649-3 1 C I - 0 3 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

Additionally, the element Notice is also used:

C I 6673 1,0-02 EN-US 1 (3)

Identification of special user tips.

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

Wear Wear Wear Wear Wear

5CS A A A Danger of sus-

Fire, No access for

2(3) C I 6673 1.0-02 EN-US

Safety instruction sign - engine room

Figure 1: Safety Instruction Sign - Engine Room

C I 6673 1.0-02 EN-US 3(3)

The operating manual is continually updated, and matched to the design of

C I 6685 1.1-02 EN-US 1 (1)

For improper usage of the turbocharger, the danger of

MAN Diesel & Turbo S E disclaims all liability if the above-mentioned

0 1 6685 1.2-02 EN-US 1 (1)

jAugsburg plant Te)e[^)one/Fax/e-mail/lntemet

MAN Diesel & Turbo SE Tel. +49 821 322 0

Fax +49 821 322 3998

PrimeServ Turbocharger Tel. +49 821 322 4030 (24 hours)

^Hr e-mail PrimeServ-TO-Commercial@mandiesetturtio.com

PrimeServ Academy Tel. +49 821 322 1397

^^^^S e-mail Prime^rv.Acaderny-info@mandieseftuftx5.6OTri"'

Worldwide Service Addresses

C I 6685 1.4-03 EN-US 1 (1)

Turbocharger - Brief description, function

1 Gas admission casing 6b Air intake casing