O 2000 MAN B&W Diesel AG

All rights reserved, including the reproduction in any form or by photomechanical means (photocopy/microcopy),
in whole or in part, and the translation. -
 Warranty Policy
for Turbocharger and Spare Parts
manufactured by MAN B&W Diesel AG
We grant as standard for all Turbochargem a one (1) year Warranty, beginning wCth the day of the first
operation, ending hovrever m every case at latest two (2) years after delivery from our facbories.
For Spare Parts we grant a six (6) month Warranty period beginning with the day of del'iery.

This Warranty is Hmited to material manufactured by us. It does not apply to material delivered by our
authorized Repair Shops, Licensees or any other third party except we can be dearly determined as the
manufacturer.

The Warranty covers the repiacement of failed parts, and parts of ow Turbochatgets damaged by the failed
parts, as well as the installation of such parts by our technicians or by w r designated workshops.

The Warranty for replacement parts shall expire in every case with the end of the above mentioned
Warranty Period for the Turbocharger.

Warranty claims shall only be accepted for Turbochargers, which have been registered in our TurboGharger
Service Division. For registration the properly completed ENTRY-INTOSERVICE-FORM has to be returned
to:

MAN W Diesel AG
Turbod.larger Service TSW
86224 Augsburg
-any
Any daims shall be M e d to the above address by completing the Warranty Claim Farm,which is
contained in the Operating Manual.

Warranty is excluded in any of the following ms-:

1. If the defect is not described in a properly and timely manner (not later than 4 weeks after the
occurrence)and the other data required for review of the warranty claim are not transmitted within
this time period.
2. If an obvious defect has not been reported h writing wiihin 4 weeks han he beginning of the
Warranty Period. (The duties to examine the goods and report any defects pwsuant to the legal
relationship among general merchants shall not be affected hereby).
3. If we request the retwn of a defective part and such defective part is not returned to us not later than
6 weeks after the date of the request.
4. If the defect is due to normal wear and tear, Force Majeure, improper or negligent handling,
excessive stress, non-obsenrance of legal requhemmts, tedmbl or operating instntctions
5. For defective parts, which after takeover have been modified, ovemauled or repaired, by the
Customer or third parties u n h s proof is furnished that we caused the defect.
6. For the delivery of used parts unless certain characteristics of the parts have been wananted.
7. If no ENTRY-INTO-SERVICE-FORM has been completed and returned to our Turbocharger
Service, attention Warranty Department -TSW -.

Material orders within the Warranty Period shall always be made wi# a 'No-Cost Purchase-Order"( W O ) .
On the basis of this NC-PO, we sham be authorized to issue an mvoicet for the respective pat In cam a
warranty claim has to be denied.
 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 t o the engine

TYPE:

Work No.:

has begun its operation on Date:

The engine will be operated

as a Power Station Country: ...............................................................................................................

i n 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, mail or fax to:

MAN B&W Diesel AG Fa: +49-821-322-3998

Turbocharger Service Mail: service-auasbura@manbw.de
86224 Augsburg
Germany
Operator:

LocationlRegistered in:

Turbocharger type: Work No.: ...................................................................

Fitted to engine type: Work No.: ...................................................................
Actual operating hours:

Contractual begin of warranty:

Contractual end of warranty:

Rectification:

....................................................................................... ..................................................................................................................................
Name, Title Signature Date

MAN B&W Diesel AG

Turbocharger Service Fa: +49-821-322-3998
86224 Augsburg Mail: service-auasburq@manbw.de
Germany
Operator:
LocationIRegistered in:
Turbocharger type:
Fitted to engine type:
Actual operating hours:
Contractual begin of warranty:
Contractual end of warranty:
Name, Title
MAN B&W Diesel AG
Turbocharger Service
86224 Augsburg
Germany
...............................................
...............................................
............................................... Work No.: ...................................................................
............................................... Work No.: ...................................................................
...............................................
...............................................
...............................................
..................................................................................................................................
Signature Date
Fax: +49-82l-322-3998
Mail: service-aucasburs@manbw.de
Operator:

LocationlRegistered in:

Turbocharger type: Work No.: ...................................................................

Fitted to engine type: Work No.: ...................................................................
Actual operating hours:

Contractual begin of warranty:

Contractual end of warranty:

....................................................................................... ......................................................................... .........................................................

Name, Title Signature Date

MAN B&W Diesel AG

Turbocharger Service
86224 Augsburg Mail: service-auqsburs~manbw.de
Germany
Technical Documentation
Exhaust Gas Turbocharger
Operating Manual

Exhaust gas turbocharger . . . . . . . . . . NR17IS

MAN B&W Diesel Aktiengesellschaft 86224 Augsburg, Germany Phone +49 821 322 0 Fax +49 821 322 3382

6657 C1-01 E 02.02 2%

L..
......3. a o eg
O 2001 MAN B&W Diesel AG
-
All rights reserved, including the reproduction in any form or by photomechanical means (photocopy/microcopy),in
whole or in part, and the translation.
Table of contents

Introduction

Preface
Product Liability
How the Operating Instruction Manual is organized, and how to use it
AddressesRelephone numbers

Technical details

MAN B&W Diesel AG's Scope of SupplyRechnical Specification

Exhaust gas turbocharger Brief description, function
Lube oil system
Acceleration system "Jet Assist"
Rating data
Operating data, temperatures, pressures
Weights
Dimensions
Gaps and clearances

OperationIOperating media

Prerequisites
Safety regulations
Destinationlsuitability of the turbocharger
Risksldangers
Safety instructions
Preparations for start, Starting, Stopping
Control the turbocharger
Faults/Deficiencies and their causes (Trouble Shooting)
Emergency operation on failure of one turbocharger
Behaviour in case operating values are exceeded1 alarms are released
3.7.1 Shut downlpreserve the turbocharger

MaintenanceiRepair

General remarks
Maintenance schedule (explanations)

Maintenance schedule (signs/syrnbols)

4.7.3 Maintenance Schedule (Turbocharger)

4.8.7 Check list

4.8.9 Service Report

-
Introduction

0 Introduction
Introduction

Technical details

Operation1
Operating media

MaintenancehZepair

Annex
Table of contents
Preface

Characteristics of turbochargers,
justified expectations,
prerequisites
Turbochargers produced by MAN B&W Diesel AG have evolved from
periods of continuous, successful research and development work. They
satisfy high standards or performance and have ample redundancy of
withstanding adverse or detrimental influences. However, to meet all the
requirements of practical service, they have to be used to purpose and
serviced properly. Only with these prerequisites can unrestricted efficiency
and long useful life be expected.

Purpose of the The operating manual as well as the work cards are thought to assist you
operating manual in becoming familiar with the turbocharger and the equipment. They are
and also thought to provide answers to questions that may turn up later on,
work cards and to serve as a guidance in your activities of engine operation, checking
and servicing. Furthermore, we attach importance to familiarising you with
the functions, relations, causes and consequences, and to conveying the
empirical knowledge we have. Not the 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 turbocharger or its components - in spite of a high level of
development and much constructive efforts - or which an inappropriate or
wrong use of our products involve.

Condition 1 The technical management and also the persons in charge of servicing
works (possibly on order) have to be familiar with the operating manual
and work cards. These should all times be available.

AA Caution! Missing information and disregard for information

can cause injury to persons, damage to property and the
environment.
Please read the operating manual and work cards.

Condition 2 The servicing and overhaul of turbochargers will in each case require
previous training of the personnel in charge. The level of knowledge that is
acquired during such training is a prerequisite to using the operating
manual and work cards. No warranty claims can be derived from the fact

'A' that a corresponding note is missing in these.

A A Caution! Untrained persons can cause injury to persons,

damage to property and the environment.
Never give orders which may exceed the level of knowledge and
experience. Access must be denied to unauthorised personnel.

Condition 3 The technical documentation is valid for one certain order only. There can
be considerable differences to other plants. Informations valid in one case
can lead to problems in others.

'A' A Attention! Technical documents are valid for one certain order
only. Using information of another order or from foreign sources can
lead to disturbanceddamages.
Only use the correct information, never use information from foreign
sources.
To be observed as well ... Please observe also the notes on product liability given in the following
section and the introductional passages and safety regulations in
Section 3.
Product Liability

The reliable and economically efficient operation of a propulsion system

(inclusive turbocharger) requires that the operator has a comprehensive
knowledge. Similarly, proper performance can only then be restored by
maintenance or repair work if such work is done by qualified specialists
with the adequate expertise and skill. Rules of good workmanship have to
be observed, negligence is to be avoided.

This Technical Documentation complements these faculties by specific

information, and draws the attention to existing dangers and to the safety
regulations in force. MAN B&W Diesel AG asks you to observe the
following:

A A Caution! Neglection of the Technical Documentation, and

'A' especially of the Operating Instructions, Work Cards and Safety

Regulations, the use of the system for a purpose other than intended
by the supplier, or any other misuse or negligent application may
involve considerable damage to property, pecuniary damage and/or
personal injury, for which the supplier rejects any liability
whatsoever.
How the Operating Instruction Manual
is organized, and how to use it

Instructions for use

The operating manual contains written and illustrated information that is

both generally useful and specially significant. This information is thought
to supplement the knowledge and faculties which the persons have who
are entrusted with
0 the operation,
0 the control and supervision,
0 the maintenance and repair
of the engine. The conventional knowledge and practical experience alone
will not be adequate.

The operating instructions should be made available to these persons. The

people in charge have the task to familiarise themselves with the
composition of the operating manual so that they are able to find the
necessary information without lengthy searching.

We attempt to render assistance by a clearly organised composition and

by a clear diction of the texts.

Structure and special features

The operating instruction manual mainly consists of the sections

1 Introduction
2 Technical details
3 Operationloperating media,
4 MaintenancelRepair

The operating manual is limited to the vital subjects. It mainly focuses on:
Understanding the functions/coherences;
0 operating it in routine and emergency modes;
0 ensuring operational prerequisites on the turbocharger and the
peripheral systems, and
0 Maintaining the operability of the turbochargertengine,
carrying out preventive or scheduled maintenance work,
doing unsophisticated repair work, and contracting and supervising
more difficult work.

What is also of importance
The sheet "Scope of supply"
Turbocharger design
Technical details
Maintenance schedule/
work cards
The manual does not deal with:
The moving and erection of the turbocharger, -
Steps and checks when putting the engine into operation for the first
time,
Difficult repair work requiring special tools, facilities and experience and
the
Behaviour after fire, inrush of water, severe damage and average.
The content of the operating manual and structural details of it can be
seen at a glance from the table of contents. We would like to draw your
particular attention to the sheet "Scope of supply" in Section 2. The sheet
named "Scope of supply" lists and briefly describes all the items that were
supplied by MAN B&W Diesel AG. This sheet shows for which
components you may expect to receive assistance and spare parts, -
supplies from us. This is the scope to which our information, our
maintenance schedules and specifications refer to. Where problems are
encountered with systems for which we have supplied but a few items, it
will possibly be more helpful to consult the system supplier directly, unless
MAN B&W's scope of supply is mainly concerned, or similar, obvious
reasons apply.
The operating manual will be continually updated, and matched to the
design of the engine as ordered. There may nevertheless be deviations
between the sheets of a primiarily describing/illustrating content and the
definite design.
Technical details of your engine are included in
the "Technical Data" in Section 2,
in the work cards in Volume C2, and
the test run or commissioning certificate included in Volume C5.
-
The maintenance schedule (turbocharger) is closely related to the work
cards of Volume C2. The work cards describe how a job is to be done, and
which tools and facilities are required for doing it. The maintenance
schedule, on the other hand, gives the periodical intervals and the average
requirements in personnel and time.
AddressesFrelephone numbers

Addresses Table 1 contains the addresses of Works of the

MAN B&W Diesel Aktiengesellschaft.

The addresses of MAN B&W service centers, agencies and authorised

repair workshops can be looked up in the brochure
"Diesel and Turbocharger Service Worldwide"
from the MAN B&W Diesel Aktiengesellschaft.

MAN B&W Diesel AG Zompany Address

Nork Augsburg MAN B&W Diesel Aktiengesellschaft
86224 Augsburg
Germany
Phone +49 821 322 0
Fax +49 821 322 3382
MAN B&W Diesel Aktiengesellschaft
86224 Augsburg
- Engine Service Germany
Phone +49 821 322 3930
Fax +49 821 322 3838
MAN B&W Diesel Aktiengesellschaft
86224 Augsburg
- Turbocharger Service Germany
Phone +49 821 322 3994
Fax +49821 3223998
Nork Hamburg MAN B&W Diesel Aktiengesellschaft
Service Center Werk Hamburg
Rossweg 6
20457 Hamburg
Germany
Phone +49 40 7409 0
Fax +49 40 7409 lo4
rechnical Branch Off ice Hamburg MAN B&W Diesel Aktiengesellschaft
Vertriebsburo Hamburg
AdmiralitatstraOe
20459 Hamburg
Germany
Phone +49403785150
Fax +49 40 37851 5 1 0
Table I. Companies and addresses of the MAN B&W Diesel Aktiengesellschaft
Technical details

1 Introduction

2 Technical details

3 Operation1
Operating media

4 MaintenanceIRepair

5 Annex
Table of contents

Technical details

2.1.1 MAN B&W Diesel AG's Scope of Supplyrrechnical Specification

2.2.1 Exhaust gas turbocharger Brief description, function
2.4.1 Lube oil system
2.4.7 Acceleration system "Jet Assist"
2.5.1 Rating data
2.5.2 Operating data, temperatures, pressures
2.5.3 Weights
2.5.4 Dimensions
2.5.5 Gaps and clearances

Intended for ...

MAN B&W Diesel AG's
Scope of SupplyITechnical Specification
For all items supplied by us ...
For all items not supplied by us ...
Technical Specification
2.1 .I
For all questions you have on items supplied by us, please contact
MAN B&W Diesel AG in Augsburg,
and for typical service questions,
MAN B&W service centers,
agencies and
authorised repair workshops all over the world.
For all items not supplied by us, please directly contact the subsuppliers,
except the components/systems supplied by MAN B&W Diesel AG are
concerned to a major extent or similar, obvious reasons apply.
The order confirmation, technical specification related to order
confirmation and technical specification of the turbocharger contain
supplementary information.
Exhaust gas turbocharger
Brief description, function

Figure 1. Exhaust gas turbocharger NR/S

Brief description Turbocharger with one radial-flow turbine stage and one radial-flow compressor stage.
Rotor supported on 2 floating bearing bushes and one locating bearing 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 lubrication integrated in engine lube oil circuit.
No water cooling. Casings on turbine side with heat insulation.

Function In operation the engine exhaust gases drive the turbocharger rotor by converting the
exhaust gases into energy. The exhaust gases flow from the engine exhaust pipe
through the turbocharger via the gas-admission casing (I), turbine 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 silencer (6a) or air intake casing (6b) and
insert (7) and compressed via compressor wheel (8), diffuser (9) and compressor
casing (10). Via charge air cooler and charging air pipe the compressed air is pressed
into the engine cylinders.
Generally this process achieves a tremendous increase in the performance of the
engine. Flow areas and directions of flow are adjusted to the individual application.
The turbocharger Rotor is guided in radial direction through 2 floating bearing bushes
arranged between turbine wheel (3) and compressor wheel (8) in the bearing
casing (11). The locating bearing on the compressor side serves both for axial
positioning and for taking the axial thrust.
The turbocharger bearings are lubricated by the lube oil circuit of the engine via a
common feed pipe. The lube oil serves as well for the cooling of the bearings.
Lube oil system

Lube oil system The turbocharger rotor is guided in radial direction through 2 floating bearing
(see figure 1) bushes (4) arranged between turbine wheel and compressor wheel in the bearing
casing. The locating bearing (5) on the compressor side serves both for axial
positioning and for taking the axial thrust.
, The turbocharger bearings are lubricated by the lube oil circuit of the engine via a
common feed pipe (2). The lube oil serves as well for the cooling of the bearings.

Designslpossibilities The figure @ shows several possibilities of lube oil supply. The scope required
for the installation of the respective engine system can be selected by the
following criteria:
For engines ... that are mimed immediatelv ~ r i oto
r start-UD (standard design)
Feed pipe (2), throttle point (3), discharge pipe (6), sight glasslventing box (7),
venting pipe (a), connection for pressure monitoring (9, 10).
For engines ... beina Drimed at intervals or continuouslv (e.g. stand-by engines)
Feed pipe (2) with non-return valve (14)' throttle point (3), additional feed
pipe (12) with non-return valve (13), discharge pipe (6), sight glasslventing
box (7), venting pipe (a), connection for pressure monitoring (9, 10).
The non-return valve (14) is to be fitted as closely to the feed pipe (1) as
possible, and it should be in closed position during priming and after the lube oil
pumps have been switched off. Tis prevents overlubrication of the turbocharger
on priming on the one hand, and a draining of the feed pipe (2) causing air to
enter, on the other.
For engines ... with retarded enaine shut-down in case of dromina lube oil Dressure (special
design)
Further to the two possibilities mentioned above, a connection of the
hydro-pneumatic accumulator (15) is necessary. Moreover, engines being primed
immediately prior to start-up a non-return valve (14) which, however, is to open
at minimal priming pressure already.

Lube oil pressure The measuring connection at the top of the bearing casing is to be used for
controlling and monitoring the lube oil pressure.
The lube oil pressure is to be so adjusted that a pressure of 1.5 * 0.2 bar prevails at
this point at full engine load and with the lube oil at service temperature (inlet
temperature max. 75 "C).
On start-up and during heating up of the engine, when the lube oil temperature is
relatively low, a lube oil pressure of up to 2.0 bar is admissible for a short period of
time.
The necessary lube oil pressure is set by means of a throttle point (3, e.g. an orifice
or pressure reducing valve) in the feed pipe (2).
In case of engine lube oil pressures r 2.5 bar, we recommend the installation of a
pressure reducing valve with outlet control.

Differences in hight Differences in height between the indicating instrument and turbocharger
centreline must be made allowance for with * 0.1 bar per 1.0 metres difference.
Example: If the pressure gauge (9) and/or the pressure controller (10) is located
3.0 metres lower, the pressure gauge must indicate a by 0.3 bar higher pressure
and/or the setting of the pressure controller must by 0.3 bar be higher than the
operating pressure specified above.
Alarmlengine shut-down The alarm point is to be adjusted to a value of 1.O. When an alarm is triggered,
the engine performance has to be reduced simultaneously (without delay) to half
load (engine slow-down). -

If the oil pressure continues to drop, the engine is to be stopped 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 allowed to stop the engine for an important reason, damages of the
turbocharger are to be expected.

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 (see sheet 2.5.2).

Lube oil quality The plain bearings are rated for use of standard engine lube oils SAE3O or
SAE40 and can therefore be directly connected to the lube oil system of the
engine.

Lube oil filtration The turbocharger does not require its own lube oil filter. The filtration which
nowadays is the standard for engines is adequate, provided that the fineness is
smaller thanlequal to 0.05 mm. A precondition is that the engine lube oil is
permanently treated by separation and excessive concentrations of water of more -
than 0.2 % portion by weight and solid residues larger than 0.02 mm are avoided.
Prior to initial operation of the engine or after major servicing work, the pipes
between the filter and turbocharger are to be cleaned, pickled and flushed
carefully.

Priming Prior to engine start-up, the bearings of the turbocharger must be primed, which,
depending on the lube oil system of the engine system, is done by priming
immediately prior to start-up, or by interval or continuous priming.

Post lubrication For cooling the plain bearings, the turbocharger has to be lubricated after engine
stop with a lube oil pressure of min. 0.3 bar. The engine lube oil pumps or the
auxiliary pumps must therefore continue running for 10 ... 30 minutes.

Lube oil drain The discharge pipe (6) should have a gradient as steep as possible, and it should
be amply dimensioned and free of resistances and back pressures. On ships, the
inclination of the line should be not less than 5" more than the maximum possible
inclination of the vessel.
The oil discharge pipe must have a venting facility from a sufficiently large
compartment permitting the oil to settle down, e.g. a sight glasslventing box (7).
The cross section of the venting pipe (8) should be approximately that of the oil -
discharge pipe (6).

Shaft sealing The oil space is sealed on the turbine and compressor sides by labyrinths fitted
on the rotor shaft. The radial labyrinth clearance should be such that the rotating
labyrinth tips slightly dig into the softer sealing cover layer. At higher speeds, the
rotor is slightly lifted corresponding to the lubricating film, so that the labyrinth tips
come clear. The rotor will be lowered when the turbocharger stops. The labyrinth
tips will then come down into the grooves in the sealing covers, providing better
sealing during priming. Local running-in grooves in the bore of the sealing covers
are therefore desirable and no reason for replacement of parts.

Sealing air For the shaft sealing on turbine side, sealing air (compressed air) is additionally
required:
against entry of exhaust gas into the oil space,
against trickle of lube oil into the turbine (oil coke)
During operation, the sealing air (11) is withdrawn downstream of the compressor
wheel and led to the labyrinth seal on the turbine side via ducts drilled into the
bearing casing. -
 1 Feed pipe (engine) 6 Discharge pipe 12 Feed pipe
2 Feed pipe (turbocharger) 7 Sight glass or (interval priming)
3 Throttle point (orifice or venting box 13 Non-return valve
pressure reducing valve) 8 Venting pipe 14 Non-return valve
4* Bearing bush 9 Pressure gauge 15 * Hydro-pneumatic
5* Locating bearing 10 Pressure controller accumulator
11 * Sealing air
* Scope of supply of turbocharger
Flgure 1. Lube oil system, Turbochargers NWS

Retarded engine shut-down (special design)

Retarded engine shut-down
In engine systems with lube oil pressure monitoring (alarm and/or engine stop
when the set points are fallen below), a retarded engine shut-down leaves a
moment to decide whether the engine should be stopped to avoid damage to the
engine and turbocharger, or whether a necessary manoeuvre should be continued
to avert major damage. An oil pressure accumulator providing for temporary
lubrication of the turbocharger is required for this purpose.

Pressure accumulator
A hydro-pneumatic accumulator (15) with a nominal capacity of 10 litres permits
the decision of engine shut-down to be retarded by a maximum of 10 seconds. If
retarded longer, operational safety will be jeopardised, and the turbocharger must
be expected to suffer damage.The hydro-pneumatic accumulator (15) is to be
appropriately positioned max. 2.0 metres below the highest point of feed pipe (2),
between the throttle point (3) and the non-return valve (14).
The service temperature is max. +80°C.
Acceleration system
"Jet Assistw

1 Pressure reducing valve 5 Turbocharger

2 3/2- way solenoid valve
3 Control valve A Starting air bottle (30 bar)
4 Non-return valve C Compressor wheel

F~gure 1. System 'Yet Assist"

Accelerator The accelerator "Jet Assist" is used where special demands exist
"Jet Assist" regarding fast and virtually soot-free acceleration and/or load application.

System description In such cases, compressed air is drawn from the starting air bottles (A)
and reduced from 30 bar to a maximum pressure (gauge) of 4 bar,' and
then passed into the compressor casing of the turbocharger (5) to be
admitted to the compressor wheel (C) via inclined bored passages of the
insert. In that way, additional air is supplied to the compressor which in
turn is accelerated, thereby increasing the charge air pressure.

Control Operation of the accelerator "Jet Assist" is initiated by a control, and

limited to a fixed load range.

System "Jet Assist" System "Jet Assist", please refer to the figure 1.
Rating data

Relation of the Turbochargerlengine

Turbocharger Engine
Type Type Rating [kW] Speed [rpm]
NR17lS ...

Type plate of the turbocharger

NR17lS ... .......... refer to the type plate

(mounted at the pressure socket
of the compressor)

Works- No. ....................... refer to the type plate

(mounted at the pressure socket
of the compressor)

Maximum admissible speed n ,

, .......... 52,600 [rpm]
(operating limit)

Maximum admissible exhaust ,,t ............. 650 [ "C ]

gas temperature before turbine
(operating limit)

Further data

Display range of the 0 ... 60,000 [rpm]

speed transmitter

Operating speed of the refer to the Acceptance Records of the turbocharger

turbocharger

Further operating data refer to the Acceptance Records and Operating Manual of the engine
Operating data,
temperatures, pressures

Lube oil

Selection of lube oil SAE-class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 30 or SAE 40

Filtration of lube oil grade of filtration smaller than . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm

Operating temperature maximum permissible oil admission temperature

at full engine load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 " C

Operating pressure using SAE 30 at 60" C or SAE 40 at 65" C

(reference measuring height on turbocharger centreline)

normal operation and full engine load ............... 1.5 + 0,2 bar

alarm and reduction to engine half load (slow-down) . . . . . I1.0 bar

engine stop (shut-down) ............................. r 0.8 bar

Flow rate of lube oil usingSAE30at60°CorSAE40at650C ................. 1,200 I/h

Further remarks refer also to the "Lube oil system", sheet 2.4.1
Weights

Weiahts assianed to assemblies/components (approximate values)

500 Exhaust gas turbocharger, complete with silencer (544), without intermediate flange (593) . . . . 310 kg

Gas-admission casing, complete (with covering) .........................................70 kg

Gas outlet casing, complete (with covering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

. kg

Turbinenozzle ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. . kg

Bearing casing, complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

.. kg

Rotor complete (turbine rotor .... 7 kg, compressor wheel ... 3 kg) ........................10 kg

Insert,compressorside ...............................................................15 kg

Insert,turbineside ....................................................................8 kg

Diffuser ..............................................................................
5 kg

Silencer,complete ...................................................................
40 kg

Air intake casing, complete ............................................................ 10 kg

Compressor casing, complete ......................................................... 35 kg

593 Intermediate flange, complete (if provided) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

. kg

599 Cartridge, complete (517 + 520) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60. kg

'f?
7
9
(U
X X

C
([I
C
-
a,
-
C

W
7
0
d:'f?
(U
Gaps and clearances 2.5.5

Figure 1. Gaps and clearances

Item Designations Order No. When new Replace or

No. of parts remachine parts
min [mm] max [mm] min [mm] max [mm]
1 a) Compressor wheel (520.005) Radial gap
0.40 0.50 0.30 0.70
Insert (540.001)
2 b) Compressor wheel (520.005) Axials gap
0.20 0.50 0.15 0.60
c) Insert (540.001)
3 a) Turbine rotor (520'001) Radial gap 0.50 0.60 0.40 0.80
lnsert (541.001)
4 d) Turbine rotor
Insert
(520.001)
(541.001)
Axials gap
0.20 0.70 --- 0.80

5 e) Locating bearing
Labyrinth ring
(517.002) Axial clearance
0.19 0.21 --- 0.29
(520.006)

1 1 Compressor wheel (520.005) admissible aberration from the plane of rotation

(face runout) ................... 0.06 mm
a) Using feeler gauge, measure at 4 points on the circumference and calculate 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 calculated mean value with the rotor pushed up
in direction (B).
c) Adjustable by remachining or by shim at balance ring (S).
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 calculated mean value with the rotor pushed up
in direction (B).
e) Using the dial gauge, measure while vigorously moving the rotor in the directions (A) and (B). In case of
labyrinth seals already run in it might be possible that the measured value is smaller.
 F~gure 2. Exact measurement of the axial clearance (5)

Exact mesurement of the axial clearance (5)

1. Measure the distance (K5) and note down.

2. Measure the width (B) of the locating bearing (517.002) and note
down.
3. Axial clearance (5): actual value = (K5) - (B).
OperationIOperating media

1 Introduction

2 Technical details

3 Operation/
O~erationl
Operating media
4 Maintenance/Repair

5 Annex
Table of contents

Operationloperating media

Prerequisites
Safety regulations
Destinationlsuitability of the turbocharger
Risksldangers
Safety instructions
Preparations for start, Starting, Stopping
Control the turbocharger
FaultsIDeficiencies and their causes (Trouble Shooting)
Emergency operation on failure of one turbocharger
Behaviour in case operating values are exceeded/ alarms are released
Shut downlpreserve the turbocharger

Categories of information

Intended for ...

Prerequisites

Prerequisites dating back into the past

Some of the prerequisites for successful operation of the enginelengine

plant are already dating back into the past when the phase of day-to-day
operation commences. Other prerequisites can, or have to be directly
influenced.

The factors that are no longer accessible to direct influence, are

0 the source of the engine,
0 qualified manufacture including careful controlling under the eyes of
control boards/classification societies,
0 reliable assembly of the engine and its exact tuning during the trials.
The factors dating back into the past and having effects on future
performance also include
the care invested in the planning, layout and construction of the
system,
the level of cooperation of the buyer with the projecting firm and the
supplier, and
the consistent, purpose activities during the commissioning, testing and
breaking-in phases.

Day-to-day prerequisites

The prerequisites directly required for day-to-day operation and to be

provided for again and again are, for example
the selection of appropriate personnel and its instruction and training,
the availability of technical documentation for the system, and of
operating instructions and safety regulation in particular,
ensuring operational availability and reliability, in due consideration of
operational purposes and results,
the organisation of controlling, servicing and repair work,
the putting into operation of systems, ancillaries and engines in
accordance with a chronologically organised checklist, and
definition of the operating purposes, compromising between expense
and benefit.
Detailed information on the above items is given in the following.
Safety regulations
Preliminary remarks
Personell
Technical documentation
Service log book
Accident prevention regulations
Warranty claims
Precautions
Opening of pipestpressure
vessels
Disassemblinglassembling
pipelines
Removingtrefitting of heavy
engine components
The engine and the systems required for its operation may only be started,
operated and stopped by authorised personell. The personell has to be
trained for this purpose, possess complete understanding of the plant and
should be aware of the existing potential risks.
The personnel must be familiar with the technical documentation of the
plant, in particular the operating manual of the engine, the turbocharger
and the accessories requiered for engine operation, particularly the safety
regulations contained therein.
It is advisable to keep a service log book into which all the essential jobs
and deadlines for their performance, the operating results and special
events can be entered. The purpose of this log book is that in the event of
a change in personnel the successors are in a position to duly continue
operation using this data log. Moreover, the log book permits to derive a
certain trend analysis and to trace back faults in operation.
The accident prevention regulations applicable for the plant should be
observed during engine operation as well as during maintenance
operations and overhauls. It is advisable to post those regulations
conspicously in the engine room and to stress the danger of accidents
over and over again.
The given advices does not claim to be complete. Safety requirements
mentioned in other passages of the technical documentation are
supplementarily valid and are to be observed in the same way.
Please also note that incorrect behaviour might result in the loss of
warranty claims.
Before opening pipes, flanges, screwed connections or fittings, check if
the system is depressurised respectively emptied.
A Attention! Disregarding this means: risk of burns when hot
fluids are involved, fire hazard in case of fuel, injuries caused by
flungout screw plugs or similar objects when loosening same under
pressure.
In case of disassembly, all pipes to be reinstalled, especially those for fuel
oil, lube oil and air, should be carefully locked. New pipes to be fitted
should be checked whether clean, and flushed if necessary. It should in
each case be avoided that any foreign matter gets into the system. All
parts involved have to be subjected to preservation treatment for
prolonged storage.
When removing or detaching heavy engine components it is imperative to
ensure that the transportation equipment is in perfect condition and has
the adequate capacity of carrying the load. The place selected for
 depositing must also have the appropriate carrying capacity. This is not
always the case with platforms, staircase landings or gratings.

Coverings Following assembly work, check whether all the coverings over moving
parts and laggings over hot parts have been mounted in place again.
Engine operation with coverings removed is only permissible in special
cases, e.g. if the valve rotator is to be checked for proper performance.

A Attention! Loose clothing and long hair might get entangled.

Spontaneous supporting against moving parts when loosing ones
balance may result in serious injury. In addition, there is the risk of
burning anuor fire.

Use of cleaning agents When using cleaning agents, observe the suppliers instructions with
respect to use, potential risks and disposal.

A Attention! Disreagarding this means: danger of caustic skin and

eye injury, and also of the respiratory tract if vapours are produced.

A Attention! Using Diesel fuel for cleaning purposes involves the

risk of fire or even explosion. Otto fuel (petrol) or chlorinated
hydrocarbons must not be used for cleaning purposes.

Use of high-pressure cleaning
equipment
When using high-pressure cleaning equipment, be careful to apply this
properly. Air filters, shaft ends including ones with lip seal rings,
controllers, splash water protected monitoring equipment, cable entries
and soundlheat insulating parts covered by water-permeable materials
have to be appropriately coverd or excluded from high-pressure cleaning.

Fire hazard The use of fuel and lube oils involves an inherent fire hazard in the engine
room. Fuel and lube oil pipes must not be installed in the vicinity of
unlagged, hot engine components (exhaust pipe, turbocharger). After
carrying out overhaul work on exhaust gas pipes and turbochargers, all
insulations and coverings must be carefully refitted completely. The
tightness of all fuel oil and oil pipes should be checked regularly. Leaks are
to be repaired immediately.

Fire extinguishing equipment must be available and is to be inspected

periodically.

In case of fire, the supply of fuel and lube oil must be stopped immediately
(stop the engine, stop the supply pumps, shut the valves), and the fire
must be attempted to be extinguished using the portable fire-fighting
equipment. Should these attempts be without success, or if the engine
room is no longer accessible, all openings are to be locked, thus cutting off
the admission of air to quench the fire. It is a prerequisite for success that
all openings are efficiently sealed (doors, skylights, ventilators, chimney as
far as possible). Fuel oil rquires much oxygen for combustion, and the
isolation from air is one of the most effective measures of fighting the fire.

A Danger! Carbon dioxide fire extinguishing equipment must

not be used until it has been definitely ensured that no one is in the
engine room. Ignoring this means danger of life!
of the turbocharger

Use in accordance with the destination

The delivered turbocharger is destined for (firstly) operation under the

marginal conditions stipulated
under Technical Data, Section 2.5,
in the scope of supplyltechnical specification and
in the order confirmation.
Furthermore destined for (secondly)
operation using the specified operating media,
taking into consideration the designllayout of the supply, measuring,
control and regulating systems as well as laying down of the marginal
conditions (e.g. removal spacelcrane capacities) in accordance with the
recommendations of MAN B &W Diesel AG or according to the state of
the art.
Furthermore destined for (thirdly)
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.

With restrictions destinedlsuitablefor

The turbocharger is with restrictions destinedlsuitable for:

0 operation at operating values resulting in an alarm situation,
operation in case of failure of supply equipments,
operation at reduced maintenance expenditures,
speeded-up accelerationlabrupt loadinglunloading to a moderate
extent,

Not destinedlsuitablefor

The Turbocharger is not destinedlsuitable for:

operation at operating values due to which engine stop or load
reduction was effected,
operation in case of failure of supply equipments,
operation within barred speed ranges,
operation without appropriate surveillancelsupervision,
operation without maintenance expenditures or if they have been
reduced to a great extent,
unauthorised modifications,
use of other than original spare parts,
long-term shut-down without taking preservation measures.
Dangers due to deficiencies concerning personnel/level of training
Expectations in case of vessel
plants
Supplementary, the following
applies
Expectations in case of
stationary plants (power plants)
Supplementary, the following
applies
Dangers due to components/systems
Propeller operatiodgenerator operation (normal operatiodoperation in
road stead):
Chief engineer on board. Operational control by technical officer.
Maintenance workhepair work in the port:
To be carried out by engine operator, technical assistants or technicians
and helpers. For instructions and in difficult cases: technical officer or chief
engineer.
Generator operation (in port):
Operational control by technical officer.
Maintenance workhepair work in port:
As mentioned above.
Persons responsible for the operational control must be in possession of a
qualification certificatetpatent which is in accordance with the national
requirements and international agreements (STCW). The number of
required persons and their minimum qualification are, as a rule, specified
by national requirements, otherwise by international agreements (STCW).
During operation:
Plant manager (engineer) available. Operational control/supervision of the
engine and the belonging supply systems by trained and specially
instructed engine operator or technical assistant.
Maintenance worwrepair work:
Execution by engine operator, technical assistants or technicians and
helpers. For instructions and in difficult cases: engineer or chief engineer.
For persons responsible for the operational control and for persons
carrying out/supervising maintenance and repair work, proof must be
furnished in Germany in accordance with the power economy law
(Energiewirtschaftsgesetz = EnWG) that, among other things, the
technical operation is ensured by a sufficient number of qualified
personnel. In other countries, comparable laws/guidelines are to be
observed. Deficiencies regarding personneltlevel of training cannot be
compensated by other efforts.
Certain dangers do of course originate from technical products and from
certain operating conditions or actions taken. This also applies to engines
and turbochargers in spite of all efforts in development, design and
manufacturing. They can be safely operated in normal operation and also
under some unfavourable conditions. Nevertheless, some dangers
remain, which cannot be avoided completely. Some of them are only
potential risks and some do only occur under certain conditions or in case
of unforeseen actions. Others do absolutely exist.
Dangers due to emissions

Emission Danger Preventivdprotective measure

Treated cooling water, lube oil, Harmful to skin and noxious,
hydraulic oil, fuel polluts water
Cleaning agents and aids According to the manufacturers'
specification
Exhaust gas with the dangerous Noxious, has a negative effect on
constituents NO, SO2, CO, HC, soot the the environment in case the
limit values are exceeded
Sound Noxious, has a negative effect on
the environment in case the limit
values are exceeded
Useldispose in accordance with the
instructions of the
manufacturers/suppliers
Useldispose in accordance with the
instructions of the
manufacturerslsuppliers
Carry out maintenance work
according to the maintenance
schedule, maintain danger-oriented
operational control, critically
observe operating results
Wear ear protection, restrict
exposure to the necessary
minimum

Planned working places

Engines are usually operated under remote control. Regular rounds

according to the rules of "observation-free operation" are required. In this
connection, measurement, control and regulating devices as well as other
areas of the plant, which require special attention, are preferably checked.
A continuous stay in the immediate vicinity of the running engine1
turbocharger is not planned.

Personal protective measures

The regulations for prevention of accidents (Unfallverhiitungsvorschriften =

UVV) and other regulations of the proper trade association or other
comparable institutions are to be observed without restriction.
-
This includes wearing of protective working clothing and safety shoes, the
use of a safety helmet, safety goggles, ear protection and gloves.

The relevant sections of the technical documentation must be read and

comprehended.
Safety instructions

Characterisationldanger scale

Characterisation According to the relevant laws, guidelines and standards, attention must
be drawn to dangers by means of safety instructions. This applies to the
marking used on the product and in the technical documentation. In this
connection, the following information is to be provided:

0 type and source of danger,

0 imminencelextent of danger,
0 possible consequences,
0 preventive measures.

The statements in Section 3.2.3follow this regulation, just as the other

safety instructions in the technical documentation do.
Danger scale The imminencelextent of danger is characterised by a five-step scale as
follows:

A A A Danger! Imminent danger

Possible consequences:
Death or most severe injuries,
total damage to property

A A Caution! Potentially dangerous situation

Possible consequences: Severe injuries

A Attention! Possibly dangerous situation

Possible consequences: Slight injuries,
possible damage to property

AA Important! For calling attention to error sources/handling errors

A Tip! For tips regarding use and supplementary information

Preparations for start,
Starting, Stopping

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 system, is done by
priming immediately prior to start-up, or by interval or continuous priming.

Enginerrurbocharger Ensure that the shut-off elements of the systems have been set to
in-sevice position.
Check the lube oil pressure upstream of the turbocharger.

Starting

Turbocharger The turbocharger is driven by the exhaust gases and starts automatically
on engine start.

Stopping

Turbocharger The rotor of the turbocharger continues rotating for some more time on
engine shut-down, due to the flywheel effect. The run-down time of the
rotor is indicative of the mechanical condition of the turbocharger.
An early stop suggests mechanical damage to the bearings, a touching of
the compressor or turbine wheel, a solid object that has got caught
somewhere or the like.

Post lubrication Refer to the lube oil system 2.4.1 of the turbocharger.
Control the turbocharger

Monitorina the turbocharaerlroutine checks

General State-of-the-art engine systems are operated automatically as a rule,

using intelligent control and regulation systems. Dangers and damage are
precluded to a large extent by internal testing routines and monitoring
equipment. 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 should be
done as and when required.

It is the operator's duty to carry out the checks listed below, at least during
the warranty period. However, they should be continued on expiry of the
warranty term. The expense in time and costs is low as compared to that
for remedying faults or damage not recognised in time. Results, observa-
tions and actions taken in connection with such checks should be entered
in an engine log book. Reference values should be defined so as to make
an objective assessment of findings possible.

Regular checks The regular checks should include the following measures:
on the 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-carrying pipes and conduits for tightness
Air filter mat on the silencer for dirt accumulation I saturation
Turbocharger for quiet running
Rotor for unimpeded running
Quiet running Damage to the rotor and bearings is in most cases announced by irregular
running due to imbalance or contact of rotating parts. Listening to the run-
ning noise of the turbocharger in many cases permits to recognise irregu-
lar running at an early time.

Speed Provided the air ducts of the compressor are properly clean, a specific
charge-air pressure is related to every turbine rotor speed. Therefore it is
possible to conclude the rotor speed from the charge-air pressure as a
rough method of speed control.
FaultslDeficiencies
and their causes (Trouble Shooting)

Preliminary conditions

Operating faults Operating faults normally manifests itself by abnormal readings (exhaust
gas temperature, charge-air pressure and speed), by distinct running
noice or by leaks in the oil pipes.

Possible consequential Should anomalies turn up on the turbocharger on starting or during engine
damage operation, the cause is to be traced immediately, if possible, and the fault
is to be eliminated. Otherwise, there will be risk of minor initial faults
causing consequential damage to the turbocharger, and also to the
engine.

First preparations In case of faults, the engine load should be reduced, if possible, or the
engine shoukl be shut down completely and not be restarted before the
cause of faults has been eliminated.

AA Important! Unsystematic trying out should be avoided because it

will lead to success in rare cases only.

Fault-finding chart The fault-finding chart (refer to page 2) is thought to contribute to reliably
recognising trouble that turns up and finding the cause it is due to, and to
taking prompt remedial action.
Exhaust gas temperature before turbine too high
Charge air pressure too low TROUBLES
Charge air pressure too high EXPERIENCED
I
Speed too low
Speed too high
I

Lubricating oil pressure too low

Lubricating oil losses
Sluggish starting or short run-down time
Abnormally high noise level
Turbocharger developing vibrations
Compressor surging -
POSSIBLE CAUSES
Silencer or air filter fouled
Compressor fouled
Turbine wheel heavily fouled
Turbine nozzle ring slightly fouled / narrowed
Turbine nozzle ring heavily fouled / narrowed
Trust ring, labyrinth ring or locating ring damaged
Labyrinth seals defective
Seals damaged, leaking connections
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 behind turbine wheel
Large erosion on turbine wheel/shroud ring, nozzle ring

------- High air inlet temperature

Low air inlet temperature
Intercooler fouled
Leaking charge air pipe
ICharge air temperature too high
----- Lubricating oil inlet temperature too high
Lubricating oil pressure too high
Dirty lubricating oil filter

----Lubricating oil pressure gauge disturbed

Excessive pressure in oil discharge or crankcase
IDeposits on inlet or exhaust valves / slots of engine
Leaking exhaust gas pipe
Exhaust gas backpressure after turbine too high
Fuel injection system on engine disturbed
Emergency operation on failure
of one turbocharger
Preliminary remarks
Means available
Emergency operation with one
or both turbochargers failing
Turbochargers are turbo machines subjected to high stresses which must
reliably ensure the entire gas renewal performance of the engine at very
high speeds and relatively high temperatures and pressures. Like the
engine, the turbocharger can also suffer disturbances, despite careful
system operation, and emergency operation is also possible in most cases
unless the damage can be repaired immediately.
The following means are availabe for emergency operation of the engine
with the turbochargers defective:
NR turbocharaers: refer to work card 500.05 in Volume C2
End cover to close the turbine rear side with the rotor and bearing
housing removed (cartidge)
NA turbocharaers: refer to work cards 500.05 in Volume C2
Arresting key to block the rotor from the compressor side (the suction
-
cross-sectionalopening remains unclosed) such a key is also
available for NR 34/S,
end cover to close the compressor and turbine rear side with the rotor
dismantled.
All of these elements are so designed that the flow is not obstructed on the
air side and exhaust side of the turbocharger.
Means for use on the enaine:
Cover piece (protection grid) for the far end of the turbocharger
charge-air pipe (remove the charge-air bypass pipe before if required).
This cover piece serves to facilitate suction.
Blind flange for the exhaust gas pipe at the end opposite the
turbocharger (if there is a charge-air bypass). The blind flange serves
to lock the exhaust pipe during suction, with the bypass removed.
In the case of V-type engines, depending on the layout of charge-air
and exhaust pipes on the engine, blind flanges for the charge-air pipe
socket and exhaust pipe socket (charge air side: downstream of the
compressor, exhaust gas side: upstream of the turbine). These blind
flanges serve to prevent wrong switching/bacMlow/leakage in
emergency operation.
The following possibilities exist if the rotor of the turbocharger can no
longer rotate freely, or must be prevented from rotating. Please refer to
Table 1.
 Emergency measures Supplementary measured
pro visiones

I 1 Code number
I
Engine stop not permitted for compulsory reasons
/ Nothing is changed on the turbocharger I
I
1-3
Engine may be stopped (temporarily)
NR turbocharaer
~ i s m a n t kthe rotor and bearing housing (cartridge), mount the end cover on
the rear of the turbine (see turbocharger operating manual and relevant work
cards). Gas renewal of the engine is through the partly stripped turbocharger
on the air side and exhaust side.

This possibility exists in case of failure of

1 turbocharger In-line engine
V-type engine
2 turbochargers V-type engine
NA turbocharger
Measure A
Block the rotor from the compressor side using the arresting key (suction 1-4, 7
opening remains open). Subsequently re-assemble intake air silencer or intake (5-7 depending on
casing. Please refer to turbocharger operating manual and work card 500.05. situation and required)
Take measure A only if measure B cannot be taken for reasons of time.
Consequential damage possible.
Measure B
Dismantle the rotor with bearings, block the bearing casing by mounting end
covers on the compressor and turbine sides. Reassemble the silencerlintake
casing and the turbine inlet casing, if applicable. Please refer to the
turbocharger operating manual and work card 500.05.

Possibilities in case of failure of

1 turbocharger In-line engine
V-type engine
2 turbochargers V-type engine L
Table I . Emergency operation with one or both turbochargers failing (continued from precedin!

Explanations

Code number Supplementary measuredprovisions

1 Reduce the engine output. The maximum exhaust gas temperatures

downstream of the cylinders and upstream of the turbocharger and (on
engines equipped with two turbochargers) the maximum admissible
turbocharger speed must not be exceeded. Observe the exhaust gas for
discolouration.

2 Use all the endeavours that appear 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, (if

equipped with two turbochargers) with reduced super-charging.
Code number Supplementary measuredprovisions

5 In-line engines:

Cover pieces (protection girds) 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 exhaust gas side connection.

6 V-type engines

On V-type engines having a common charge-air pipe, a blind flange is to

be mounted on the compressor outlet of the defective turbocharger so as
to avoid air losses.

7 V-type engines

Separate the exhaust gas inlet side of the defective turbocharger from the
gas flow of the second turbocharger by fitting a blind flange.

1 turbocharger failing In-line engine V-type engine

Fixed-pitch propeller 15% up to 50%
of the rated output at the
corresponding speed
Controllable-pitch 20% up to 50%
propellerlgenerator o f the rated outout at tt!e rated soeed
Table 2. Output/speed that can be reached
Behaviour in case
operating values are exceeded1
alarms are released
General remarks
Operating values/limit values
Alarms, reduction and stop
signals
Beha.viour in emergency cases
technical possibilities
Fixing alarm and limit values
Legal situation
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.
Depending on the extent to which values are exceeded and on the
potential risks, alarms, reduction or stop signals are released for the more
important operating values. This is effected by means of the alarm system
and the safety controls. Reduction signals cause a reduction of the engine
output on vessel plants. This is effected by reducing the pitch of
controllable-pitch propeller plants. Stop signals cause an engine stop.
- Acoustic or visual warnings can be acknowledged. The displays remain
active until the malfunction is eliminated. Reduction or stop signals can in
the case of vessel plants be suppressed by means of the override function
of the valuation "ship takes precedence over engine". For stationary
plants, this possibility is not provided. For these, there is also no reducing
function.
For fixing the alarm and the safety-relevant limit values, the requirements
of the classification societies and the own assessment are decisive.
Alarm, reduction and safety signals serve the purpose of warning against
dangers or of avoiding them. Their causes are to be traced with the
necessary care. The sources of malfunctions are to be eliminated
consistently. They must not be ignored or suppressed, except on
instructions from the management or in cases of a more severe danger.
A Caution! Ignoring or suppressing of alarms, the cancellation of
reduction and stop signals is highly dangerous, both for persons
and for the technical equipment.
Liability claims for damages due to exceeded nominal values and
supressed or ignored alarm and safety signals respectively, can in no case
be accepted.
Shut down/preserve the turbocharger 3,7,1

The instructions given for the Diesel engine (refer to the Diesel engine op-
erating manual) also apply correspondingly to a preservation and pro-
longed storage of the turbocharger.
MaintenancelRepair

1 Introduction

2 Technical details

3 Operation1
Operating media

44 Maintenance/Repair
MaintenancelRepair

5 Annex
Table of contents

MaintenanceIRepair

General remarks
Maintenance schedule (explanations)
ToolsISpecial tools

Maintenance schedule (signslsymbols)

4.7.3 Maintenance Schedule (Turbocharger)
Maintenance work
4.8.1 Cleaning
4.8.4 Checking the individual Components
4.8.7 Check list
4.8.9 Service Report
General remarks
Purpose of maintenance work/
prerequisites
Maintenance schedule1
maintenance intervals1
personnel and time required
Work cards in Volume C2
respectively
Similarly to regular checks, maintenance work belongs to the user's
duties. Both serve the purpose of maintaining the reliable and safe
serviceability of the system. Maintenance work should be done by qualified
personnel and at the times defined by the maintenance schedule.
Maintenance work is of support to the engine operators in their
endeavours to recognise future failures at an early stage. It provides
useful notes on overhaul or repair becoming due, and is of influence on
the planning of downtimes.
Maintenance and repair work can only be carried out properly if the
necessary spare parts are available. It is advisable besides these spare
parts to keep an inventory of parts in reserve for unforeseen failures.
Please request MAN B&W Diesel AG to submit a quotation whenever
required.
The jobs to be done are shown in the maintenance schedule
(Turbocharger) 4.7.3,
which contains
a brief description of the job,
the intervals of repetition,
the personnel and time required, and it makes reference to
the corresponding work cards1instructions.
The work cards, comprised in Part C2 of the technical documentation,
contain brief descriptions of
the purpose of jobs to be done.
They contain
information on the toolslappliances required, and
detailed descriptions and drawings.of the operating sequences and
steps required.
Maintenance schedule (explanations)

Preliminary remarks

General The maintenance schedule of the turbocharger comprises works to be

done on components/subassemblies of the turbocharger (see 4.7 and
4.7.3).

Binding character and adaptabilities

Validity of the maintenance The maintenance schedule (turbocharger) 4.7.3 is a summary of all the
schedule maintenance and inspektion works up to a major overhaul of the
turbocharger after an operating period of

12,000 -1 8,000 hours for NR-turbochargers,

12,000 -1 8,000 hours for NA-turbochargers

at four-stroke engines,
0 24,000 - 30,000 hours for NA-turbochargers
at two-stroke engines.

Whenever major overhaul of the turbocharger has been carried out, for
practical considerations in common with an engine maintenance being
doe, the maintenance schedule is to be started anew.

A major overhaul comprises the disassembly of the complete turbocharger

for the inspection of the actual condition, careful cleaning and checking of
all parts.

A Attention! In consideration of the operational safety of the

turbocharger and engine, the maintenance works should be carried
out as timely as possible and not later than scheduled.
Adaption of the maintenance
schedule
The maintenance schedule has been drawn up for standard operating
conditions and an operation of 6,000 hours per year. After a critical
evaluation of the operating values and conditions shorter intervals may
become necessary provided external operating conditions as timetable1
timetable of shipslinspection time for plants allow it.
Favourable operating conditions are:
constant load within the range of 60% to 90% nominal load,
observing the specified temperature and pressure of the operating
media,
using the specified lube oil and fuel quality,
as well as a proper separation of the fuel and lube oil.
Adverse operating conditions are:
long-term operation at maximum or minimum load; prolonged idling
times; frequent, drastic load changes,
frequent engine starting and repeated warming-up phases without
adequate preheating,
higher loading of the engine before the specified cooling water and lube
oil temperatures are reached,
lube oil, cooling water and charge air temperatures that are too low,
using inappropriate fuel qualities and insufficient separation,
inadequate combustion air filtering (e.g. on stationary engines).
ToolslSpecial tools

Tools for turbochargers

Commercial tools are not included in the delivery scope of the

Inventory tools
turbocharger. It is expected that these tools are contained in the inventory
of the plant.

Standard tools If included in the delivery scope, the turbochargers are equipped with a set
of standard tools. For a plant with several turbochargers, 1 set of
standard tools is generally sufficient. These standard tools and the
inventory tools permit the usual maintenance work to be carried out.

The tools set intended for the turbocharger(s) is contained in one box (or
in several boxes), and a table of contents is also included.
A list specifying the extent and designations of these tools is also
contained in Volume C6 of the Technical Documentation.

Tools on customer's request In particular case, such tools/devices are supplied on request.
MAN B&W Diesel AG will gladly submit an offer, if desired.

Special tools Certain jobs, which are rather repair jobs than maintenance jobs, require
special expert knowledge, experience and supplementary
equipment/auxiliary means. Further special tools are made available to our
service bases, and possibly also our authorised workshops, for such
purposes. We therefore recommend that you consult these partners, or
entrust them to do jobs for you whenever the own capacities in terms of
time, qualification or personnel are inadequate.
Spare Parts

Since it is so important, we are repeating below a sentence which we have

used already:

A Tip Maintenance and repair work can only be carried out properly if
the necessary spare parts are available.

The information given below is thought to assist you in quickly and reliably
finding the correct information source in case of need.

Spare parts for turbocharger

Spare parts for the turbocharger can be identified by means of the spare
parts catalogue contained in Volume C3 of the technical documentation.
For this purpose, illustration and text sheets with order numbers are
available. An order number consists of a three-digit subassembly number
and a three-digit item number, which are 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 contained in Volume C2.

Spare parts for tools/ordering of tools (turbocharger)

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, which are separated
by a dot.
The order numbers, however, can also be looked up in the respective work
cards contained in Volume C2.
Special serviceslRepair work

No matter whether routine cases or really intricate problems are

concerned,
MAN B&W Diesel AG, Augsburg works,
MAN B&W Diesel AG, Service Center Hamburg,
MAN B&W Diesel Pte. Ltd., Service Center Singapore,
service bases and authorised repair workshops
are readily available to offer you a wide spectrum of services and expert
advice, ranging from spare parts supplies, consultation and assistance in
operating, maintenance and repair questions, ascertaining and settling
cases of damage through to the assignment of fitters and engineers all
over the world. Some of these services are doubtless the standard offered
by suppliers, shipyards, repair workshops or specialist firms. Some of this
whole range of services, however, can only be rendered by someone who
can rely on decades of experience in Diesel engine systems. The latter are
considered as a part of the expert commitment towards the users of our
engines and for our products.

Please note the supplementary information contained in the printed

publications of Volume A1 of the Technical Documentation. In these, you
will also find the addresses and telephone numbers of the nearest service
bases which you can approach whenever required.

Information on turbochargers, see also Volume C1 of the Technical

Documentation, Page 1.4.
Maintenance schedule (signslsymbols)

Explanation of signs and symbols

The heading of the maintenance schedule shows symbols instead of

entries in two languages. They have the following meaning:

Serial number of the maintenance work.

The series shows gaps for changeslup-dates which could become
necessary.

Brief description of the job

Related work cards.

The work cards listed contain detailed information on the work steps
required.
A No Work card required/available

Relation between working cards.

These notes are of particular significance within the maintenance
system CoCoS. They give you information on the jobs with a temporal
connection to the work in question.

Required personnel

Time required in hours per person

Relational term to indicate the time required

Repetition intervals given in operating hours

24 ... 18,000 (NR)
24 ... 18,000 (NA, at the four-stroke engine)
24 ... 30,000 (NA, at the two-stroke engine)

Signs used in the columns of intervals.

Their meaning is repeated in each sheet.
We assume that the signs and symbols used in the head are sufficiently
pictorial and that it is not necessary to repeat them constantly.
Table 1. Explanation of signs and symbols of the maintenance schedule
Wartungsplan (Turbolader)
Maintenance Schedule (Turbocharger)

lnspektion (wahrend des Betriebes) Inspection (during operation)

901 1 Turbolader auf abnormale Gerausche
und Vibrationen kontrollieren
- for unusual noise I
I Check turbocharaer
and vibrations

303 Turbolader und Systemleitungen auf Check turbocharger and system pipes
Leckagen kontrollieren (Sperrluft, for leakages (sealing air, charge air,
Ladeluft, Abgas, Schmierol) exhaust gas, lube oil)

305 Alle Befestigungsschrauben, Check all the f i n g screws, casing

Gehauseschrauben und screws and pipe connections for tight fit
Rohrleitungsanschlusseauf festen Sitz
prufen

Wartung (wahrend des Betriebes) Maintenance (during operation)

311 1 Turbine reininen (im Schwerolbetrieb) Turbo- I1

t
- Trockenreiiigurig, falls vorhanden ' - Dry cleaning, if irovided ' lader
Turbo-
charger
Clean the turbine (in HFO operation) Turbo-
- Wet cleaning, if provided lader
Turbo-
charger I I I I I I I I I

X Wartungsarbeitfallig X Maintenance work is necessary

1 Nach Bedarfnustand 1 As required/depending on condition
2 Kontrolle neuer oder uberholter Teile erforderlich (einmal nach der angegebenen Zeit) 2 Check new or overhauled parts once after the time given in the column
Wartungsplan (Turbolader)
Maintenance Schedule (Turbocharger)

Verdichter reinigen
(im Betrieb)

917 Luftfilter reinigen

(falls vorhanden)

War vng (gemeinsam mit einer Motomartr ig)

- - --

Verdichtergehause, Einsatzstuck,
Nachleitapparat und Verdichterrad
reinigen und kontrollieren
(Sichtkontrolle).
Cleaning the compressor
(in operation)

Clean the air filter

(if provided)
500.08

500.11

Maintenance (in common with an engine maintenance)

Clean and check (visually check) the
compressor casing, insei-t, diffuser and
commessor wheel.
~ e s i o r ethe turbocharger for operation
I
t
0.3

0.4
Turbo-
lader
Turbo-
charger
Turbo-
lader
Turbo-
charger

Betriebsbereitschaft des Turboladers

wieder herstellen
Grunduberholung
12 000 ...18 000 Betriebsstunden:
Alle Komponenten des Turboladers
abbauen, reinigen und kontrollieren.
Spalte und Spiele beim Zusammenbau
kontrollieren
Major overhaul
12,000 ... 18,000 operating hours:
Remove, clean and check all
components of the turbocharger. Check
gaps and clearances on reassembly

Wartungsarbeitfallig X Maintenance work is necessary

1 Nach Bedarfnustand 1 As required/depending on condition
2 Kontrolle neuer oder uberholter Teile erforderlich (einmal nach der angegebenen Zeit) 2 Check new or overhauled parts once after the time given in the column
Maintenance work

General To keep the exhaust gas turbocharger in a good, reliable condition, it is to

be subjected to inspection and checking at various points and at specific
intervals as specified in the maintenance schedule.

Depending on the special conditions in the engine room, the best way of
disassembly has to be chosen. To perform maintenance and control jobs,
it will in most cases be sufficient to strip subassemblies of the
turbocharger. Dismounting the complete turbocharger from the engine
normally will only be required for basic overhaul.

For basic overhaul of the turbocharger, or for repair work involving

essential components, it is recommended to note down the condition of
the individual subassemblies and to include this information in the engine
operating records. A form sheet "Check list" (4.8.7 for NR-Turbochargers
or 4.8.8 for NA-Turbochargers) has been enclosed herein as a sample.

Spare parts Wear and damage suffered, specifically if affecting the strength or balance
precision and hence the running smoothness of rotating parts, require
replacement by original spare parts or repair in an authorised repair shop
or at the works. Rotor components sent out for repair have to be
appropriately packed and protected against corrosion to prevent further
damage in transit.

For ordering original spare parts, please refer Volume C3 (Technical

-
Documentation - Exhaust Gas Turbocharger Spare Parts Catalogue).

Screwed connections Where screws and nuts cannot be loosened straight away because they
have seized, avoid applying excessive force because the components
might be destroyed in this way and would have to be replaced. It may also
become necessary to bore broken bolts out of casings and to retap the
bored-out threads. Seizures can in most cases be slackened by
lubricating the threads with Diesel fuel oil or low-viscosity special lubricants
(such as Caramba or Omnigliss) and by slightly tapping the bolt head with
a hammer. Such solvents should be applied liberally and allowed to act
upon the bolted or screwed joint for some time (112 hour or longer) so that
they will be able to penetrate right down into the threads. The
recommendations issued by the suppliers of such solvents should be
observed.

Screws, nuts and lockwashers used in joints on the turbine side and
exposed to elevated temperatures are made of non-scaling materials. In
order to prevent such non-scaling screws and nuts from being mixed up
with normal ones, they are identified by markings on their face (SM, VM or
4923, 2'1 or 4828). During disassembly, such elements should therefore
be put down somewhere separately until being reassembled.
All the lockwasher pairs used on the turbocharger are of non-scaling
material but not marked.

To prevent screws and nuts from sticking, thereby facilitating later

disassembly, screwed connections and seats should be made sure to be
treated with a high-temperature lubricant (such as Molykote HSC) prior to
every reassembly. Before applying this lubricant, clean the threads
carefully. Threads of stud screws remain untreated.
All the bolted and screwed connections of the turbocharger must be in an
unobjectionable condition on assembly, or replacement is necessary.
Inappropriately tightened and secured screws and nuts may come loose -
by vibratory effects and be drawn into the turbocharger by the air or gas
flow, causing severe damage.

When assembling the lockwasher pairs (one pair consisting of 2 identical

washers), make sure that the long wedged surfaces (B) contact each other
(on the inside), otherwise the securing effect will be lost.
Cleaning

Air filter

Air filter mat The air intake opening of the silencer is covered by a air filter mat of high
filtering effect. The silencer, compressor and charge-air cooler are therefore
effectively protected against fouling. To maintain this efficiency, timely
cleaning or replacement of the air filter mat is necessary and is definitely
due when the inside of the air filter mat starts getting dark, a reliable sign
that the absorbing capacity of the air filter mat is exhausted and dirt begins
to appear at the filter. Taking the pressure differential as an indicator is not
reliable because it depends on the rate of air flow as prevailing, which is to
say on the service point and the position in the map.

Cleaning intervals For recommended cleaning intervals, please refer to the maintenance
schedule (4.7.3) and work card (500.11).

Compressor

Cleaning during operation In the case of NR turbochargers, dirt depositing on the blades of the
by injecting water compressor wheel and on the nozzle ring vanes may cause a measurable
loss in efficiency, because of the relatively small dimensions.
We therefore recommend a compressor washing device, especially in cases
of extremely dirt-laden intake air. Freshwater is to be used exclusively. Sea
water and chemical additives and cleansers are not permitted. Cleaning
agents for the charge-air cooler have to be introduced downstream of the
compressor.
Cleaning should be carried out with the engine being at operating
temperature and under full load.

Cleaning intervals For recommended cleaning intervals, please refer to the maintenance
schedule (4.7.3) and work cards (500.08).

Versions available A portable water container with accumulator to be connected to the

cleaning opening on the compressor casing, silencer or air intake casing.

A syringe is provided for small frame sizes such as NR12.

As an alternative, a water tank can be installed at a fixed, easily

accessible point. The tank is to be located not less than 600 mm lower
than the point of injection to avoid that the water is prematurely extracted
by a vacuum in the compressor as the tank is topped up with water. The
air required to draw the water out of the tank should be withdrawn
downstream of the charge-air cooler.

Mechanical cleaning Dirt that has deposited on the compressor wheel, the air diffuser and
compressor volute can be removed during maintenance periods by means
of the steam jet. A further possibility is the soaking in Diesel fuel or other
liquid cleansers and the subsequent brushing off of the dirt deposits.
Chlorous cleaning agents may attack the aluminium alloy (of the
compressor wheel) and must therefore not be used.
 It should in each case be avoided that some of the cleaning agent or
dissolved dirt gets into the lube oil system. It is not allowed to use
high-pressure cleaners.

Turbine

Cleaning during operation Depending on the fuel oil grade and the engine operating mode, residues
from combustion may accumulate on the vanes 1 blades of the nozzle ring
and turbine. The progressing build-up of dirt deposits and the considerable
deterioration of operating performance involved may lead to compressor
surging or to the excitation of dangerous vibrations of the turbine wheel
blades due to uneven fouling of the nozzle ring. Incipient fouling is indicated
by a rising charge-air pressure as a result of the narrower nozzle ring cross
section. The charge-air pressure will drop as fouling proceeds, and the
exhaust gas temperature will rise as a result.
Contrary to the HFO-operated engines, gas engines or engines using gas oil
do not need a cleaning device.

IA' Turbochargers of HFO-operated engines require cleaning at regular intervals

from initial operation onwards.

Cleaning intervals For recommended intervals of cleaning, please refer to the maintenance
schedule (4.7.3) and work card (500.07). Depending on the fuel oil grade
and engine operating mode, other intervals may be appropriate.

Two methods are available for cleaning the turbine during operation:

Wet cleaning The engine has to be brought down to approx. 10 ... 15% output for this
purpose so as to avoid an overloading of the turbine blades (thermo shock).
The medium used for cleaning is freshwater introduced without any
chemical additives upstream of the turbine.

Dry cleaning Granulates of nut shells or activated charcoal (soft) of a grain size of
1 ... 1.5 mm are introduced upstream of the turbine, under normal engine
service load and using compressed air from the board mains.
The engine loading need not be reduced for this purpose.
The cleaning device is designed to introduce the necessary amount of
granulate over a period of 20 to 30 seconds rather than at a time. This will
prevent a sudden speed drop and surging of the compressor, especially
where several turbochargers are operated in parallel.

The required granulate can be ordered by:

MAN B&W Diesel Aktiengesellschaft
Turbocharger Service Dept.
86224 Augsburg, Germany

Mechanical cleaning During maintenance work, severe fouling (such as heavy fuel oil deposits or
oil coke) accumulated on the nozzle ring and turbine wheel can be soaked in
water treated with standard domestic detergents and subsequently brushed
off. If necessary, the process has to be repeated several times. Soaking can
be done in an appropriate vessel over several hours.

It must be made absolutely sure that the water and dissolved dirt cannot
get into the lube oil system.
Checking the individual Components

The following notes and questions are intended for guidance, e.g. for

judging the condition of the turbocharger

recording engine operating data and preparing checklists
checking, reusing, repairing and replacing components

Oil coke downstream of the Sealing air bore in the bearing casing clogged
turbine wheel Shaft seal on turbine side damaged
Priming pressure too high

Touching marks over the entire Check of the bearings (refer to work card 500.06)
circumference (turbine rotor, Check of gaps and clearances (refer to sheet 2.5.5)
compressor wheel, inserts)

Touching marks in sections of Signs of imbalance

circumference (turbine rotor,
compressor wheel, inserts)

Crack detection tests on the By acoustic testing or fluorescent dye penetration method
blades (turbine rotor,
compressor wheel)

Gaps and clearances For admissible limits, refer to sheet 2.5.5

Erosion in HFO operation
Where heavy fuel oil is used, the exhaust gas contains solids of small size
(e.g. "Cat fines") which have an erosive effect especially at the outlet of
the turbine nozzle ring, where gas velocities and concentrations of these
particles are high. Moreover, there is a very pronounced deflection of the
flow in circumferential direction, and the particles are furthermore subject
to the centrifugal effect.

"Cat Fines'' Where do these erosive solid particles come from?

As a result of the refining process, and depending on the quality, heavy
fuel oil contains "Cat fines", fine-grained and very hard powdered solids
(indicators are the Al and Si concentrations), and other impurities of
abrasive effect. Amply dimensioned, heated settling tanks and adequate
separation are means to reduce their concentration.

Admixtures Of a particularly negative effect is the admixing of used engine lube oil,
characterised by more-than-normalCa and Fe concentrations. Used
engine lube oil not only contains wear residues but specifically "detergent
dispersant additives". Fine-grained solids are bound by these additives so
that "Cat fines" and other impurities cannot be extracted by separating.
Much more severe erosion damage is the result of blending the fuel with
"Waste oil".
Residues from incomplete combustion may also have an erosive effect.
Clean combustion should therefore be ensured.
Casings Which casings are heavily fouled by soot, oil or oil coke?
Were the casings tight, especially at the joints and connecting flanges?
-
Did the casings have cracks?
Had bolts broken off?
Had all the bolts and nuts been firmly tightened and secured?
Were any sealing air or oil ducts in the bearing casing clogged?
Are the seals in order?

Silencer, if provided What is the condition of the air filter mat?

What is the condition of the felt linings?
Have cracks formed on components?

Electronic speed measuring Was the speed transmitter or the speed indicator defective?
device Were the two pole plates on the speed transmitter deformed?

Compressor wheel Are blades affected by cracks or pronounced wear?

Do the blades show impact marks at the leading edge, caused by solid
objects drawn in?
Are traces of touching found?
What is the seat of the compressor wheel?
Is the seating surface bright, or does it show fretting corrosion?

Turbine rotor Have blades been damaged or are blades affected by pronounced wear or
erosion on the edges?
Are blades affected by cracks?
Are any traces of touching found on blades, on the wheel or shaft?
Concentricity of the shaft?
Condition of the bearing points?
Have the labyrinth tips of the locating ring been severly worn?
Are the seating faces bright or do they show fretting corrosion?

Inserts Are there any signs of touching?

Thrust ring, labyrinth ring Are there traces of fretting or pronounced wear?
Are the seating faces bright or do they show fretting corrosion?

Bearings Check the bearings (refer to work card 500.06)

Wear diagonally across on both bearings suggests rotor imbalance.

Sealing cover Does the pattern of labyrinth tip running-in appear normal?

Turbine nozzle ring
Are there vanes that have been bent?
Have vanes suffered serious erosive wear?
Have foreign objects got jammed in the ducts?
Are there traces that are indicative of foreign objects?
Are cracks found on the vanes?
Check list
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. .

Air intake casinq, if provided Comeressor casing Turbine rotor

fouled fouled fouled
by ..................... by ......................
Silencer, if provided 0 cracks signs of touching
damage by foreign object radial
air filter mat
replaced Diffuser over the entire circumference
in sections of circumference
reason: ............... 13 used 13 replaced
0 fouled blades
felt linings
by . . . . . . . . . . . . . . . . . . . . . . 0 bent
0 fouled
wavy vanes bent
0 with cracks
erosion
separated 13 vanes with incipient cracks 13 damage by foreign objects
damage by foreign object
bearing points
Seeed transmitter, if provided
0 defective Com~ressorwheel 13 fretting marks
wear
0 pole plates deformed 13 fouled
seating faces
by .....................
Seeed indicator, if provided fretting corrosion
signs of touching
13 defective 13 axial labyrinth tips
radial 13 oil coke
Insert on comeressor side 13 over the entire circumference wear
13 used replaced in sections of circumference
13 fouled blades
Labvrinth rinq
by . . . . . . . . . . . . . . . . . . . . . bent
signs of touching 13 with cracks 13 used 13 replaced
damage by foreign object 0 fretting marks
radial
over the entire circumference bore wear
in sections of the circumference fretting corrosion 13 fretting corrosion
 Thrust rinq Bearina bush turbine side Insert turbine side
13 used 13 replaced 0 used 13 replaced 13 used 17 replaced
fretting marks fretting marks 13 fouled
13 wear 13 wear 13 erosion
13 fretting corrosion outside diameter
signs of touching
Bearina casinq 13 inside diameter 17 over the entire circumference
0 fouled 13 in section of the circumference
Sealina cover compressor side
by .....................
13 used 13 replaced Gas-admission casinq
13 cracks
abnormal running-in pattern 13 fouled
sealing air bores 13 wear
0 clogged 13 cleaned signs of touching by . . . . . . . . . . . . . . . . . . . . . .
oil bore Sealina cover turbine side
13 cracks
13 clogged 13 cleaned erosion
13 used 13 replaced 13 damage by foreign object
seals
replaced 0 abnormal running-in pattern screwed connections
13 wear 0 slack
Locatina bearinq oil coke 13 cleaned 13 torn off
used 13 replaced Cover disc 17 replaced
17 fretting marks used 13 replaced
17 wear Gas outlet casinq
13 axial face, compressor side 13 wear
axial face, turbine side 17 oil coke cleaned 13 fouled
13 inside diameter
Bearina bush compressor side Turbine nozzle rinq 13 cracks
used replaced 0 used 13 replaced 13 damage by foreign object
fretting marks vanes bent screwed connections
wear vanes with incipient cracks 13 slack
outside diameter 13 damage by foreign object torn off
13 inside diameter erosion 13 replaced

[rtl please tick the appropriate box

s clearances, (for admissible values refer to sheet 2.5.5)

G a ~ and
Item 1 Compressor wheel / insert (radial gap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Item 2 Compressor wheel / insert (axialgap) ........................................ mm
Item 3 Turbine rotor / insert (radial gap) ........................................ mm
Item 4 Turbine rotor / insert (axialgap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Item 5 Locating bearing / labyrinth ring (axial clearance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm
Item 6 Face runout, compressor wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm

Remarks: ......................................................................................
Technical Documentation
Exhaust Gas Turbocharger
Work Cards

Exhaust gas turbocharger . . . . . . . . . . NR171S

MAN B&W Diesel Aktiengesellschaft 86224 Augsburg, Germany Phone +49 821 322 0 Fax +49 821 322 3382
0 2001 MAN B&W Diesel AG -
All rights reserved, including the reproduction in any form or by photomechanical means (photocopy/microcopy), in
whole or in part, and the translation.
Table of contents

Introduction

How the work cards are organised, and how to use them

Work cards

Intended for ...

Introduction

1I Introduction

2 Work cards
Table of contents
Preface 1.I

Work cards and maintenace The work cards are closely related to the maintenance schedule of the
schedule turbocharger contained in Volume C1 (Operating Manual) of the technical
documentation . The latter briefly specifies the maintenance work to be
done, whereas this volume gives a step-by-step description, with
illustrations, of the operating sequences required to maintain the
operational reliability and efficiency of the turbocharger. The work cards
have an introductory part describing the purpose of the work, and contain
information also stating which tools and appliances are required. For most
of the jobs, several work cards have to be consulted.

Work cards serve the particular purpose of providing essential information

in concise form.
How the work cards are organised,
and how to use them 1.2
Numbering - -
The ordinal number of the work cards on top at the right is composed of
the three-digit subassembly group number 500 (basic subassembly
number for turbochargers) and a two-digit counting number, or of a neutral
numerical combination (e.g. 000, for universally valid instructions) and a
two-digit counting number.

-
Example:
Turbocharger or subassemblies
Removing and refitting ............................. 500.10
-r T
Subassembly group number (500 for turbocharger) 1
Counting number (work card number 10)

How to find the work cards The work cards are contained in the list (Table of contents) of Section 2.
required
Structure Work cards contain the following information as a rule:
Notes on the purpose of the jobs to be done,
Personnel and time required
on the relevant work cards, i.e. those work cards containing further
essential or useful information,
on the necessary tools and appliances,
any supplementary detailsltechnical data and
the individual operating sequences, starting in each case with the
original condition and followed by the individual working steps.
Parts and tools are marked with the order number in illustrations and texts.
Order numbers for tools are identical with the tool number punched into
the tool (as a rule).

Personnel and time required
The time required is given in hours, indicating the number and qualification
of the required personnel for a single job. The higher amount covers the
time for the entire extent of the particular work card. Personnel with a
smaller number of hours is required only temporarily, eg. for operating the
lifting tackle.

Toolslappliances Remarks:
The number in the column Denomination are width across flats given in
mm, e.g. socket wrench 22 = socket wrench width across flats 22 mm.
The availability keys in the column Availability have following meaning:
Standard Standard tools (with tool numbers)
If included in the delivery scope, the turbochargers are equipped with a set
of standard tools.
Optional Tools on customer's request (with tool numbers)
Inventory Commercial toolslappliances
These are not included in the delivery scope. It is expected that these
toolslappliances are contained in the inventory of the plant.
Extra Extra tools, e.g. for service bases
Safety notes Text passages in italic type draw the attention to dangers sources of
failure, technical necessities, supplementary information. The following are
used:

A A A Danger! Imminent danger.

Possible consequences: Death or most severe injuries, total damage
to property.

A A Caution! Potentially dangerous situation.

Possible consequences: Severe injuries.

A Attention! Possibly dangerous situation.

Possible consequences: Slight injuries, possible damage to
property

AA Important! For calling attention to error sources/handling errors.

A Tip! For tips regarding use and supplementary information.

Remarks next to this sign are of special importance on the basis of service
experiences.
However, only the signs of the safety instructions indicate the importance.

Technical data Technical data (Ratings data, Operating data, Weights, Dimensions, Gaps
and clearances) are contained in Section 2.5, Volume C1 (Technical
Documentation - Exhaust Gas Turbocharger - Operating Manual).

Ordering tools Information concerning the ordering of tools or parts of these are
contained in the sheet 4.3 of Volume C1 (Technical Documentation -
-
Exhaust Gas Turbocharger Operating Manual), and/or in the sheet 1.2 of
Volume C3 (Technical Documentation - Exhaust Gas Turbocharger -
Spare Parts Catalogue).
Work cards

1 Introduction

22 Work
Workcards
cards
Table of contents

Tightening of screw connections

General tightening torques
Turbine nozzle ring
Checking
Emergency operation
with closing device
Locating bearing and bearing bushes
Checking
Cleaning the turbine (in HFO operation)
Wet cleaning
Cleaning the turbine (in HFO operation)
Dry cleaning
Clean the compressor (in operation)
with fitted tank
Cleaning the compressor (in operation)
with pressure sprayer
Turbocharger or subassemblies
Removing and refitting
Air filter
Cleaning
Silencer
Removing and refitting
Air intake casing
Removing and refitting
Insert, compressor casing, diffuser
Removing and refitting
Cartridge
Removing and refitting
Compressor wheel
Removing, refitting, checking
Sealing cover and labyrinth ring
Removing and refitting
Locating bearing
Removing and refitting
Thrust ring
Removing and refitting
Turbine rotor
Removing and refitting

Categories of information
 Covering disk and sealing cover
Removing and refitting
Bearing bushes
Removing, refitting, checking
Turbine nozzle ring
Removing and refitting
Gas outlet casing
Removing and refitting
Insert, turbine side
Removing and refitting

Categories of information

Intended for ...

Tightening of screw connections
Generally tightening torques
Pur~ose
of iobs to be done
Brief descri~tion
Generallv tiahtenina toraues for screw connections
Tightening of screw
connections acc. to the torque
Indicating tightening torques for essential bolted connections.
Guaranteeing operating safety.
Screw connections should be tightened by means of torque wrenches as
far as possible.
The work includes:
Refitting of components.
Screw connections should be tightened by means of torque wrenches as
far as possible.
For importent screw connections on the turbocharger, the tightening
torques are prescribed in the relevant work cards.
For all the other screw connections, which are tightened using a torque
wrench, guide values for the tightening torques are stated in table 2.
The following should be observed:
The load acting on a screw connection depends on the tightening
torque applied, on the lubricant used, the finished condition of the
surfaces and threads, and on the materials paired. It is, therefore, of
great importance that all these conditions are met.
Table 2 lists the tightening torques for various threads as a function of
the coefficient of friction, i.e. of the lubricant used. The torques are
based on bolt material of the strength class 8.8with the bolts stressed
up to approximately 70 % of the elastic limit. For other strength
classes, the tightening torques listed in the table have to be multiplied
by the corresponding conversion factors. The strength class is stamped
on the bolt head.
Strength class 5.6 6.8 10.9 12.9
Conversion factor x 0.47 0.75 1.40
-
1.70
-
Table 1. Conversion factors for tightening torques as a function of the bolt strength
class
Approximate coefficient of friction p :
p = 0.08 with lubricants, for temperatures
5 200°C, e.g. Molykote G-n or Molykote P40
r 200°C, e.g. Molykote HSC
p = 0.14 for surfaces that are not finish-treated, with a thin film of oil
E
Tightening torque
Thread - in ~m Thread -
Nominal Coefficient of Nominal Coefficient of
size friction p size friction p
0.08 0.14 0.08 0.14
M5 4 6 475 690
M6 7 10 500 750
700 1020
730 1100
950 1380
1015 1540
Turbine nozzle ring
Checking

Puraose of iobs to be done

Check statelwear condition of components,

ensurelrestore operational reliability.

Brief descri~tion

Checking the turbine nozzle ring,

replace if necessary.
The work includes:
checking components.

guide vane
trailing edge
(original)
contour of the reduction
mean reduction
(area F P 2 areas E)
negative areas
(on the left of D)
positive area
(on the right of D)
root of the guide vane

F~gure 1. Erosion of the turbine nozzle ring

General The erosive wear of the guide vanes (A) is caused by the outlet flow mainly
in the area of the trailling edges (B). The original position of the trailling
edges (B) can be recognised at the roots (G) of the guide vanes (A).
Since the guide vanes do not wear evenly, the mean value of the reduction
from the guide vanes (Lm) is calculated as follows:

Lm =
+ +
(L1 L2 L3 ... Ln)+ +
n
n = number of the guide vanes (A)
Replacement Replace the turbine nozzle ring, if Lm 2 as the indicated value of the
table:
--

Turbocharger Lm r [mm] Turbocharger Lm r [mm]

NR12lRS 6 NR24lS 12
NRl4lS 7 NR29lS 14
NR17lS 9 NR34lS 17
NR20lS 10
Emergency operation
with closing device

Purpose of jobs to be done

Enabling emergency operation.

Brief descri~tion

Emergency operation by removing the cartridge.

The worwsteps include:
behaviour in case of problems,
removing components,
installing components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 1
I I I Assistant I I I
Tools/appliances required

Qty Designation No. A vailability

1 Closing cover 596.027 Standard
1 Open-jaw wrench 17 - Inventory
- Lifting tackle, ropes, shackles - Inventory

Related work cards

I Work card I Work card I Work card

Preliminary conditions

During emergency operation of the engine, the exhaust gas must continue
passing through the damaged turbocharger.
Figure 1. Closing device

Operating sequence 1 - Emergency operation with closing device

-
Steps Undo all the connections to clear the cartridge for removal
(refer to work card 500.10).
Remove the silencer or air intake casing, compressor casing and
cartridge
(refer to work cards 500.12 up to 500.16).
The turbine nozzle ring (513.001) to remain in place.
Close the lube oil pipes.
Attach the closing cover (596.027) with clamping claws (501.005),
lock washer pairs (501.007) and hexagon nuts (501.008) to the
gas-admission casing (501.001).
For further notes on emergency operation, refer to the Operating
Manual for Turbocharger and to the Operating Manual for Engine,
Section Operating Faults.
Locating bearing and bearing bushes
Checking

Puroose of iobs to be done

Check statelwear condition of components,

ensurelrestore operational reliability.

Brief description

Checking the bearings, replace if necessary

The worklsteps include:
removal of components,
checking of components,
installation of components.

Personnel and time required

I Numb 1 Qualification Time [h] ]

I 1 I Qualified mechanic I 0.3 1

Tools/appliances required

Qty ( Designation I No. Availability I

1 -
I I I

1 Sliding caliper Inventory

Related work cards

Work card Work card Work card

500.20 500.24

Preliminary conditions for checking the locating bearina (517.0021and the bearina bushes f517.003)

A A Important! If fretting marks, uneven or rapid wear is found, the

causes such as, e.g. imbalance, irregularities on the sealing air and lube
oil system (dirt, pressure, rates, temperatures, priming and post
lubrication) should be remedied prior to installing new bearings.
 Operating sequence 1.1 - Checking the locating bearing (517.002)

F~gure 1. Checking the locating bearing (517.002)

Steps 1. Measure the length ( I ) of the wedge surfaces (a) on the compressor
and turbine sides.
Length ( I ) extends up to the edge (v) on the bearing face (b).
~ependingon the angle of light incidence, a dark b&d may appear in
front of the edge (v) on the wedge surface (a). This band is to be
included in measuring the length ( I ).

2. Replace the locating bearing (517.002)

if one of the length ( l ) I2.2 mm.

Operating sequence 1.2 - Checking the bearing bushes (517.003)

Figure 2. Checking the bearing bush (517.003)

Steps 1. Measure the diameters D4 and D5.

2. Replace the bearing bush (517.003)

if D4 I 38.81 mm dia.,
D5 r 27.04 mm dia.
Cleaning the turbine
(in HFO operation)
Wet cleaning

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

free components from contaminations/residues,
ensurelrestore operational reliability.

Brief description

Clean the turbine (in HFO operation)

-Wet cleaning, if provided
Maintenance (during operation)

Personnel and time rewired

Numb Qualification Time requ

1 Technical assistant 0.6

Preliminary conditions

General The number and location of exhaust gas pipes depends on the engine
type and may vary from the above schematic. Every individual exhaust
gas pipe has its own three-way cock (D) for turbine cleaning.

Cleaning agent Use freshwater for cleaning exclusively.

Cleaning interval Every 150 operating hours, with reduced engine load.

A Tip! To save time, we recommend washing shortly after engine

start-up, when the parts to be washed are not very hot yet. In that way,
the step 2. of the operating sequence 1 can be omitted.

Brief information See also cleaning instructions given in plate (mounted to the engine).
Cleaning the turbine
(in HFO operation)
Dry cleaning

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

free components from contaminations/residues,
ensurelrestore operational reliability.

Brief description

Clean the turbine (in HFO operation)

- Dry cleaning, if provided
Maintenance (during operation)

Personnel and time reauired

I I
Numb Qualification I Timerequ 1
I
1 Technical assistant 0.3

Tools/a~~liances
reauired

I
Qty Denomination I No. Availability I
- Granulates (grain size 1.0 ... 1.5 mm) - Inventory
nut shellslactivated soft-charcoal

Preliminary conditions

General Depending on the type of engine and turbocharger, the arrangement of

items may also differ somewhat from that shown in the schematic.
The tank (1) should be installed at an approximate place, not lower than
1.0 m below the connection point (4). The pipe (3) should not be longer
than 6.0 m and properly supported to preclude that it oscillates, permitting
free flow.
The maximum service temperature of the stop cock (6): I300 "C.
Connection point (4) is provided on the exhaust gas pipe, immediately
upstream of the turbine.
Cleaning agent Appropriate cleaning materials are granulates from nut shells or activated
charcoal (soft) of a grain size of 1.0 mm (max. 1.5 mm).
A AHenUon! Do not use water for cleaning with this facility, because
herewith the cleaning to be carried out with the engine operated at
normal service load.

Cleaning interval Every 24 operating hours, at normal service load of the engine.
Brief information See also cleaning instructions given in plate (mounted to the engine).
 1 Tank
2 Screw plug
3 Pipe
4 Connection point
5 Data plate
6 Exhaust gas pipe
7 Compressed air pipe

A Stop cock
(compressed air)

B Stop cock
(exhaust gas)

Flgure 1. Arrangement: Dry cleaning of the turbine

Operating sequence 1 - Dry cleaning of the turbine (during operation)

Steps 1. Stop cocks (A and B) must be closed.

2. Unscrew the screw plug (2). Fill the prescribed quantity of granulate into
the tank ( I ) and close it with the screw plug (2).

Quantities required: NR12, NR14, NR15, NR17, NR20 . . 0.3 litres

NR24, NR26 .................... 0.4 litres
NR29, NR34 .................... 0.5 litres

3. Open the stop cock (A). Slowly open the stop cock (B) until a
whistling sound is heard indicating the introduction of the granulate.
Granulate injection time approx. 30 seconds.

4. Close the stop cocks (A and B).

Clean the compressor
(in operation)
with fitted tank
Pumose of iobs to be done
Brief descriation
Personnel and time required
Preliminarv conditions
General
Cleaning agent
Cleaning interval
Brief information
Carry out the work in time according to the maintenance schedule,
free components from contaminations/residues,
ensuretrestore operational reliability.
Clean the compressor
(in operation)
Maintenance (during operation)
'g3P
$$,
Numb Qualification Time requ
1 Technical assistant 0.3
Depending on type of engine and turbocharger, the arrangement of the
individual parts may not coincide completely with the ones shown in the
drawing.
Use freshwater for cleaning exclusively.
When injecting, the water droplets, due to the high speed of the rotor, are
hitting the blades of the compressor wheel and the final diffuser at high
velocity, thus removing the dirt deposits mechanically.
We recommend the following cleaning intervals:
NR-Turbocharger: every 150 operating hours,
NA-Turbocharger: every 150 operating hours.
The cleaning intervals depend on the degree of contamination of the air
taken in and are between 100 and 200 operating hours. In the smaller
turbocharger sizes (NR, NA34, NA40), the dirt deposits on blades of
compressor wheel and final diffuser may lead to a considerable drop of
efficiency.
From turbocharger size NA48 onwards, compressor cleaning is not
necessary if the air filter mat is serviced as per instruction.
A A Important! Cleaning must only be made with the engine warm and
running at full load. Engine must not be shut down immediately after
completion of the cleaning process.
See also cleaning instructions given in plate (1O), mounted to the engine.
 1 Screw-type cap
2 Tank
3 Hydrometer cock
4 Charge air line
5 Intercooler
7 Turbocharger (compressor)
10 Plate (cleaning instructions)

F~gure 1. System: Cleaning of the compressor (with fitted tank)

-
Operating sequence 1 Cleaning of the compressor (during operation)

Steps 1. Operating engine at full load.

2. Open screw-type cap (1) and fill tank (2) with clean, fresh water.
3. Close tank by means of screw-type cap (1).
4. Depress pushbutton of hydrometer cock (3) for about 20 seconds.
A A Important! Cleaning must only be made with the engine warm and
running at full load. Engine must not be shut down immediately after
completion of the cleaning process.

c:,
:.....: ,f (+ & o : g
Cleaning the compressor
(in operation)
with pressure sprayer
Purbose of iobs to be done
Brief description
Personnel and time required
Preliminary conditions
General
Cleaning agent
Cleaning interval
Brief information
Carry out the work in time according to the maintenance schedule,
free components from contaminationslresidues,
ensurelrestore operational reliability.
Cleaning the compressor
(in operation)
Maintenance (during operation)
I I
Numb Qualification I Time requ 1
I 1 I Technical assistant I 0.3 1
Depending on type of engine and turbocharger, the arrangement of the
individual parts may not coincide completely with the ones shown in the
drawing.
Use freshwater for cleaning exclusively.
When injecting, the water droplets, due to the high speed of the rotor, are
hitting the blades of the compressor wheel and the final diffuser at high
velocity, thus removing the dirt deposits mechanically.
We recommend the following cleaning intervals:
NR-Turbocharger: every 150 operating hours,
NA-Turbocharger: every 150 operating hours.
The cleaning intervals depend on the degree of contamination of the air
taken in and are between 100 and 200 operating hours. In the smaller
turbocharger sizes (NR, NA34, NA40), the dirt deposits on blades of
compressor wheel and final diffuser may lead to a considerable drop of
efficiency.
From turbocharger size NA48 onwards, compressor cleaning is not
necessary if the air filter mat is serviced as per instruction.
A A Important! Cleaning must only be made with the engine warm and
running at full load. Engine must not be shut down immediately after
completion of the cleaning process.
See also cleaning instructions given in plate (1O), mounted to the pressure
sprayer (2).
 Handle
Pressure sprayer
Relief valve
Nipple
Coupling
Hand valve
Turbocharger (compressor)
Plate (cleaning instructions)

F~gure 1. System: Cleaning of the compressor (with pressure sprayer)

Operating sequence 1 - Cleaning of the compressor (during operation)

Steps Operating the engine at full load.

Turn handle (1) on pressure sprayer tank (2) in counter-clockwise
direction and take out the pump.
Fill maximal 2.0 litres of fresh water into the tank
-
(up to the mark 2 L- on the tank).
Screw in the pump and operate until the pressure relief valve (3)
blows off.
Connect hose with nipple (4) to the coupling (5).
Depress pushbutton (see big arrow in figure) on the hand valve (6)
until the water is completely injected into the compressor
(for approx. 30 seconds).
Release plug-in connection and vent the tank. For venting, pull -
spindle on the relief valve (3) outwards (see small arrow in figure).
A A Important! Cleaning must only be made with the engine warm and
running at full load. Engine must not be shut down immediately after
completion of the cleaning process.
Turbocharger or subassemblies
Removing and refitting

Pur~oseof iobs to be done

Check statelwear condition of components.

Brief descri~tion

Remove the turbocharger complete or in subassemblies.

The worklsteps include:
dismounting components,
mounting components.

Personnel and time reauired

Numb Qualification Time [h]

1 Qualified mechanic 4.5
I 1 I Assistant I 1 I
Tools/a~~liances
reauired

Qty Designation No. Availability

1 Open-jaw and ring wrenches (set) - Inventory
1 Socket wrench (set) - Inventory
1 I Torque wrench I
- Inventory
I
1 Screw driver
I I
- I

I
Inventory
- I Lifting- tackle, ropes, shackles - Inventory
I I I

- I Wood (for placing underneath) _. Inventory

- I High-temperature lubricant
(e.g. Molykote HSC)

Technical details

1 Term Information ]
Turbocharger 310 kg

Preliminary conditions

In general for maintenance work at the turbocharger individual subassemblies

are successively to be removed (see work cards 500.12 to 500.27).
Figure I . Connections at the turbocharger

Operating sequence 1 - Separating or removing the connections

Steps 1. Cable to the speed indicator in the terminal box (3, if provided)
Removing of speed transmitter (if provided) is possible
*Work card 500.12 or 500.13
2. Air entry (1) on the air intake casing (if provided),
ompressor cleaning (2, if provided),
Removing of silencer (if provided) or air intake casing (if provided) is
possible
* Work card 500.12 or 500.13
3. Jet assist (4, if provided), air outlet (5)
Removing of insert, compressor casing and diffuser is possible
* Work card 500.14
4. Lube oil feed (6), lube oil drain (7), connecting points (8) for lube oil
pressure and interval or continuous priming (if provided), two-part
plate (9)
Removing of cartridge, turbine nozzle ring, insert at turbine side is
possible
* Work cards 500.16, 500.25 and 500.27
5. Exhaust gas outlet (lo), dirty water or condensed water discharge
(11, if provided), exhaust gas blow-off pipe (12, if provided)
Removing of gas outlet casing is possible
* Work card 500.26
6. Exhaust gas admission (13)
Removing of the complete turbocharger is possible
*Work card 500.10 (Operating sequence 2)
F~gure2. Removing and refitting the complete turbocharger

Operating sequence 2 - Removing the complete turbocharger

Steps 1. For separating or removing the connections, refer to operating

sequence 1. Also separate or take off other special connections
(such as for pressure and temperature measuring, etc.).
2. Suspend the turbocharger from the lifting tackle with a rope of
appropriate strength slung around the bearing casing, and carefully
stretch the rope. Attach secondary ropes to appropriate points to
assist in balancing.
A A A Danger! Eye bolts serve the purpose of lifting off individual
subassemblies. They must not be used for suspending the main
load of the complete turbocharger. Make sure to observe safety
regulations for the lifting of loads.
3. Undo the screw connection on the casing foot (14, if provided).
4. Carefully lift off the turbocharger and put it down onto a wooden
support.
A A Important! For the time of storage and during assembly, openings
for air, exhaust gas and lube oil are to be appropriately sealed to prevent
that foreign objects or water can enter.
Operating sequence 3 - Refitting
Refitting the complete turbocharger or its subassemblies, and restoring of
the connections is carried out in the reverse order of removing.

A A Important! Prior to reassembly, make sure to take off protective

caps from pipes.
Make sure to use unobjectionable gasketstseals and screw securing
elements only. Apply high-temperature lubricant (such as Molykote HSC)
to the threads of heat-resistant screws and nuts on the turbine side.
Slightly tighten the screw connection on the casing foot (14, if provided)
initially, and finally tighten it on connection of the casing pipestconduits.
For tightening torgue, see working instructionstworkcards of engine.
Air filter
Cleaning

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

free components from contaminationslresidues,
ensurelrestore operational reliability.

Brief description

Clean or replace the air filter mat.

Maintenance (during operation)

Personnel and time reauired

Numb Qualification Time regu

1 Technical assistant 0.4

Preliminary conditions

General The dirty air filter mat (544.201) can be cleaned several times or replaced
by a new one.
Replacement is required if the air filter mat is considerably dilated, plucked
or perforated.

A A Important! The increase of pressure loss by contamination of the air

filter mat is insignificant and does not serve as an indication of the time
cleaning is required

Cleaning intervals Every 250 operating hours.

The cleaning intervals depend on the degree of contamination of the air
taken in, and are located between 250 and 500 operating hours.

A Tip! Cleaning is necessary when the inside of the air filter mat starts to
discolour grey. Then the air filter is saturated and the contamination starts
to advance towards the compressor and the intercooler. The inside of the
air filter mat may be inspected by loosening of one of the clamps (544.202).

A Tip! In case of intense contamination, it may be necessary to immerse

the air filter mat in the cleanser and soak it for several hours. It is,
therefore, advisable to keep a second air filter mat available for exchange.
Flgure 1. Air filter mat, mounted on the silencer

Operating sequence 1 - Removing, cleaningfreplacement, refitting

Steps 1. Loosen the clamps (544.202), remove cover sheet (544.205) and air
filter mat (544.201).
2. Air filter mat to be cleaned by flushing with warm water to which fine
cleanser has been added. Avoid intense mechanical stress
(e.g. wringing , sharp water jet). Subsequently, blow air filter mat
through with compressed air.
A Tip! In case of intense contamination, it may be necessary to immerse
the air filter mat in the cleanser and soak it for several hours. It is,
therefore, advisable to keep a second air filter mat available for exchange.
3. Place air filter mat (544.201) over perforated plate of silencer and
cover sheet (544.205) over joint of air filter mat and fasten it by using
the clamps (544.202).
Silencer
Removing and refitting

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

check statelwear condition of the components.

Brief description

Remove and refit the silencer in complete condition.

Disassembling (e.g. for cleaning) only if necessary.
The work/steps include:
dismounting components,
mounting components.

Personnel and time reauired

Numb Qualification Time [h]

1 Qualified mechanic 0.4

Tools/appliances required

1 Qty I Designation I No. A vailabilitv I

1 Open-jaw wrench 19 - Inventory
1 Open-jaw wrench 22 - lnventorv
1 Hexagon screw driver 6 - Inventory
1 Screw driver - Inventory
1 Torque wrench - Inventory
- Lifting tackle, ropes, shackles - Inventory
- Wood (for placing underneath) - lnventorv

Related work cards

I Work card I Work card I Work card I

I I I I

Technical details

Term Information
Silencer 40 kg
Figure 1. Silencer,mounted on the compressor casing

Preliminarv conditions

General For air filter cleaning, please refer to work card 500.11.
For disassembling, cleaning and reassembling the silencer, refer to
operating sequence 3.
A A Important! Disassembling of the silencer (e.g. for cleaning) only if
necessary.

Operating sequence 1 - Removing of the complete silencer

Steps Screw off the bolts (544.053) and take off the cover (544.050).
Screw off the hexagon nuts (544.067), take off the holding
disk (562.004) and speed transmitter (562.040).
Suspend the silencer from the lifting tackle, using the rope.
4. Loosen the V-profile clamp (546.005) on both sides of the
circumference.
5. Remove the silencer in axial direction and place it on wooden pad
with the flange surface down.

Operating sequence 2 - Refitting of the complete silencer

For refitting, proceed in the reverse order of removing.

A Aiieniion! During refitting, the following tightening torques are to

be observerd. Apply oil to the threads and contact surfaces.
Tightening torque for V-profile clamp (546.005)
on both sides of the circumference: . . . . . . . . . . . 12 [Nm] -
Operating sequence 3 - Disassembling, cleaning and reassembling the silencer

Steps 1. Remove the air filter mat (544.201) and clean it,
refer to work card 500.11.
2. Loosen the hexagon nuts (544.074) and take off the
washers (544.075).
3. Take off the front wall (544.041), spacer pipes (544.032), damping
plates (544.021) and casing (544.001) individually. This leaves the
flange (544.1 0) with the studs (544.069) screwed in.
4. Cleaning of the felt linings if the fouling matter is dry is best done with
compressed air or a brush which is not too hard.

A Ailenlion! Diesel fuel can be used for removing smeary dirt. Sol-
vents containing acetone are not to be used; in particular, use no
trichlorethylene(or substitutes of it), because this will dissolve the
bonding.

5. For reassembly, proceed in the reverse order of disassembly.

A Allenlion! During refitting, the following tightening torques are to

be observerd. Apply lubricant Molykote P40 to the threads and contact
surfaces.
Tightening torque for hexagon nuts (544.074) . . . . . . . . . 69 [Nm]
Air intake casing
Removing and refitting

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

check statelwear condition of the components.

Brief description

Remove air intake casing for inspection.

The worwsteps include:
dismounting components,
mounting components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.4

ToolsJappliances required

Qty I Designation I No. A vailabilitv I

1 Socket wrench 10 - lnventoy
1 Hexagon screw driver 6 - lnventorv
1 Torque wrench - Inventory
1 Screw driver - Inventory
- Lifting tackle, ropes, shackles - lnventory
- Wood (for placing underneath) - Inventory

Related work cards

Work card Work card Work card

500.10

Technical details

Term Information
Air intake casing 10 kg
 - --

F~gure I. Air intake casing, mounted on the compressor casing

Operating sequence 1 - Removing

Starting condition Pipe at the air intake released or removed.
Connection for compressor cleaning released (if provided).

Steps 1. Screw off the hexagon nuts (545.069), take off the holding
disk (562.004) and speed transmitter (562.004).
2. Suspend the air intake casing (545.001) from the lifting tackle, using -
the rope. Carefully stretch the rope.
3. Loosen the V-profile clamp (546.005) on both sides of the
circumference.
4. Remove the air intake casing (545.001) in axial direction and place it
on wooden pad.

Operating sequence 2 - Refitting

For refitting, proceed in the reverse order of removing.

A A ttentionl During refitting, the following tightening torques are to

be observed. Apply oil to the threads and contact surfaces.
Tightening torque for V-profile clamp (546.005)
on both sides of the circumference: . . . . . . . . . . . . 12 [Nm]
Insert, compressor casing,
diffuser
Removing and refitting

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

check state/wear condition of the components.

Brief description

Remove insert, compressor casing, diffuser for inspection, matching or

change.
The worklsteps include:
removal of components,
checking of components,
installation of components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.8
1 Assistant 0.2

Tools/appliances required

Qty Designation No. A wailability

1 Open-jaw wrench 17 - Inventory
1 Socket wrench 13 - lnventorv
1 Hexagon screw driver 6 - Inventory
1 Torque wrench - Inventory
- Lifting tackle, ropes, shackles - Inventory
- Wood (for placing underneath) - Inventory

Spare parts reauired

Qty I Designation No. 1

1 O-ring seal 517.018
1 O-ring seal 540.015
1 O-ring seal 540.016
Related work cards

( Work card I Work card I Work card

I I I I

Technical details

Term Information
Compressor casing 35 kg
Insert 15 kg

546.023
546.020

540.001
540.015

Y O . 030

Flgure 1. Insert, compressor casing, diffuser

Operating sequence 1 - Removing

Starting condition Connecting pipes, air intake casing or silencer removed.

Steps 1. If insert (540.001) is to be removed:

Screw off the hexagon bolts (546.020) and take off the lock washer
pairs (546.023).
2. Take off the insert (540.001) in axial direction.
 3. Attach the compressor casing (546.001) to rope and suspend from
lifting tackle, carefully tension the rope.
4. Loosen the v-profile-clamp (546.005) on both sides of the
circumference, carefully detach the compressor casing in axial
direction and put it down on wooden pad.
A Allention! Take care not to damage blades of the compressor wheel.
5. If diffuser (542.001) is to be removed:
Loosen countersunk bolt (546.008) and take off diffuser in axial
direction.

Operating sequence 2 - Refitting

For refitting, proceed in the reverse order of removing.
Make sure that the O-ring seals (517-018, 540.01 5, 540.016) are in proper
condition.

A A Important! Lock washer pairs (546.023): Long wedged surfaces to

contact each other (on inside), otherwise there will be no securing effect.

A Ailenlion! During refitting, the following tightening torques are to

be observed. Apply oil to the threads and contact surfaces.
Tightening torque for v-profile-clamp (546.005):
on both sides of the circumference ....... 12 [Nm].
For checking the gaps (positions 1 and 2), refer to Operating Manual,
Technical Data, Gaps and Clearances.
Cartridge
Removing and refitting

Pur~oseof iobs to be done

Carry out the work in time according to the maintenance schedule,

check statelwear condition of the components.

Brief description

Remove the cartridge for inspection or emergency operation.

The worwsteps include:
dismounting components,
mounting components.

Personnel and time reauired

Numb Qualification Time [h]

1 Qualified mechanic 0.6
I 1 I Assistant I 0.6 1

Qty Designation No. Availability

1 Open-jaw wrench 17 - Inventory
I 2 1 Open-jaw wrench 24
I
1-
I
I
I
Inventory I
1 I Torque wrench - Inventory
I I I

I
4 pipe 1 596.008 Standard
I
I

I
I I

4 1I Hexagon
- bolt 1 596.009
I I
Standard
1
4 Hexagon nut ( 596.010 Standard
- Lifting tackle, ropes, shackles - Inventory
- Wood (for placing underneath) - Inventory

I -I High-temperature lubricant
(e.g. Molykote HSC)

Spare parts required

Qty ( Designation No. ( '

I 1 I Seal 1 517.0681
Related work cards

Work card Work card Work card

500.10 500.12 500.13

Technical details

Term Information
Cartridge 60 kg

F~gure 1. Cartridge, removed from the gas-admission casing

Operating sequence 1 - Removing

Starting condition Connecting pipes, silencer or air intake casing and compressor casing
removed.

Steps 1. Take off the two-part plate (591.060), if provided.

2. Detach or remove the casing foot (if provided), depending on
attachment.
 3. Attach the cartridge (599.000) to rope and suspend from lifting tackle,
carefully tension the rope.
4. Unscrew the hexagon nuts (501.008), take off the lock washer
pairs (501.007) and the clamping claws (501.005).
5. Evenly jack off the cartridge (599.000) at 4 points of the circumference,
using tools (596.008, 596.009, 596.01O), see figure @, carefully move
it out in axial direction, and cautiously put it down on wooden pad.
A Attention! Take care not to damage blades of the turbine rotor.

F~gure2. Jack off the cartridge

Operating sequence 2 - Refitting

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

Screwed connections Apply high-temperature lubricant (such as Molykote HSC) to screws and
nuts but not to the screw thread when replacing studs.
A A Important! Lock washer pairs: Long wedged surfaces to contact
each other (on the inside), otherwise there will be no securing effect.

A Attention! During refitting, the following tightening torques are to

be observed. Apply high-temperature lubricant (such as Molykote HSC) to
the threads and contact surfaces.
Tightening torque for hexagon nuts (501.008) . . . . . . . . . 34 [Nm]

Checking For checking the gaps, refer to Operating Manual, Technical Data, Gaps
and Clearances, sheet 2.5.5.
Compressor wheel
Removing, refitting, checking

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

check statelwear condition of the components.

Brief description

Remove compressor wheel for inspection.

The worklsteps include:
removal of components,
checking of components,
installation of components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.6

Tools/appliances required

Qty I Designation I No. Availability

I I I
I
1 Open-jaw wrench 19 - Inventory
1 Torque wrench - Inventory
1 Dial gauge with retainer - Inventory
- Special protective agent - Inventory
(Molykote P40)

Related work cards

I Work card I Work card I Work card I

Technical details

1 Term Information I
I Compressor wheel 3 kg I
Figure 1. Removing and refitting the compressor wheel

Operating sequence 1 - Removina

Starting condition Connecting pipes, Silencer or air intake casing and compressor casing
removed. Cartridge removed if turbine rotor is also to be dismantled.
The magnetic shaft (520.124) has only to be removed in case of
replacement.

Steps 1. Unscrew the undercut bolt (520.068) which has a right-hand thread,
while holding the turbine rotor fast.
-
2. Pull off the carrier (520.009).
3. Feather keys (520.018) are not stripped normally, they must not get
lost, however.
4. Pull off the compressor wheel (520.005) by hand in axial direction.
A Tip! If the compressor wheel seizes (e.g. due to fretting corrosion),
apply a low-viscosity special agent (such as Caramba) to the joint of the
shaft seat and wait for a while to take effect. Then pull the compressor
wheel off by moving it to and fro.
Operating sequence 2 - Refitting
Steps 1. Apply a thin protective film of Molykote P40 to the fitting surfaces of
the turbine shaft (for the compressor wheel and carrier).
2. Insert the feather keys (520.01 8) in the turbine shaft. Push the
compressor wheel (520.005) and carrier (520.009) onto the turbine
shaft until there is firm contact with the labyrinth ring (520.006).
A A Important! The balancing marks (W) of the turbine rotor (520.001),
compressor wheel (520.005) and carrier (520.009) must coincide radially.
3. Screw in the undercut bolt (520.068) according to the following
combined tightening procedure.
A Allention! there by^ the following tightening torques are to be
observed.
Apply lubricant Molykote P40 to the threads and contact surfaces of
the undercut bolt.
With Aluminium comDressor wheel:
3.1 Tighten with tightening torque . . . . . . . . . . . . . 40 [Nm],
afterwards loosen the pretightening.
3.2 Tighten with tightening torque . . . . . . . . . . . . . 10 [Nm].
3.3 Additional tighten with twisting angle . . . . . . + 60".

With Titanium comDressor wheel:

(marked with ''Tin at position X, please refer to figure 1)
3.1 Tighten with tightening torque . . . . . . . . . . . . . 40 [Nm],
afterwards loosen the pretightening.
3.2 Tighten with tightening torque ............. 10 [Nm].
3.3 Additional tighten with twisting angle ...... + 90".

4. Check the axial clearance (position 5) of the complete rotor and the
face runout (position 6) of the compressor wheel using the dial
gauge.
For positions and admissible values, refer to Operating Manual,
Technical Data, Gaps and Clearances (Volume C1, sheet 2.5.5).
Sealing cover and labyrinth ring
Removing and refitting

Puroose of iobs to be done

Carry out the work in time according to the maintenance schedule,

check statelwear condition of the components.

Brief descri~tion

Remove sealing cover and labyrinth ring for inspection.

The work/steps include:
removal of components,
checking of components,
installation of components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.6

Tools/a~~liances
reauired

I
Qty Designation I No. A vailability 1
1 Socket wrench 13 - Inventory
1 Socket wrench 17 - Inventory
1 Torque wrench - Inventory
- Special protective agent - Inventory
(Molykote P40)

S~are
Darts reauired

I Qty I Designation I No. I

Related work cards

Work card Work card Work card

500.1 0 500.12 500.13
I

F~gure I . Removing and refitting of the sealing cover and the labyrinth ring

Operating sequence 1 - Removing

Starting condition Connecting pipes, silencer or air intake casing, compressor casing and
compressor wheel removed.
Cartridge removed if turbine rotor is also to be dismantled.

Steps 1. Loosen the hexagon nuts (517.032) and take off the lock washer
pairs (517.033).
2. Evenly jack off the sealing cover (517.087) using 2 hexagon bolts
(M10, thread length r 40 mm) and take off the seal (517.031).
A A Important! Slight grooves in the bore of the sealing cover produced -
by the tips of the labyrinth ring improve the sealing effect and are no
reason to replace this part.
3. Pull off the labyrinth ring (520.006) in axial direction.

Replace the labyrinth ring if labyrinth tips have been damaged or worn:
D I55.8 rnm dia., or if fretting marks are on the axial surface.
Operating sequence 2 - Refitting
For refitting, proceed in the reverse order of removing.
Apply a thin protective film of Molykote P40 to the fitting surfaces of the
turbine shaft for the labyrinth ring

A A Important! The balancing marks (W) of the turbine rotor (520.001)

and labyrinth ring (520.006) must coincide radially.
When fitting the seal (517.031) take care of unobjectionable condition and
position of the holes.

A A Important! Lock washer pairs: Long wedged surfaces to contact

each other (on the inside), otherwise there will be no securing effect.

A Affeniion! During assembling, the following tightening torques

are to be observed. Apply lubricant Molykote P40 to the threads and
contact surfaces.
Tightening torque for hexagon nuts (517.032) . . . . . . . . . 17 [Nm]
Locating bearing
Removing and refitting

Purpose of iobs to be done

Carry out the work in time according to the maintenance schedule,

check statelwear condition of the components.

Brief description

Remove locating bearing for inspection.

The worklsteps include:
removal of components,
checking of components,
installation of components.

Personnel and time required

Numb Qualification Time [h]

1 Qualified mechanic 0.6

Tooldappliances required

I
Qty Designation I No. A vailabilitv I
1 Socket wrench 13 - lnventorf
1 Hexagon screw driver 6 - Inventory

Related work cards

Work card I Work card I Work card

F~gure 1. Removing and refitting of the locating bearing

Operating sequence 1 - Removing

Starting condition Connecting pipes, silencer or air intake casing, compressor casing,
compressor wheel, sealing cover and labyrinth ring removed.
Cartridge removed if turbine rotor is also to be dismantled.

Steps 1. Unscrew the cylindrical screws (517.006) and take off the lock
washer pairs (517.044).
2. Evenly jack off the locating bearing (517.002) using 3 hexagon bolts
(M8, thread length r 40 mm).
3. For checking the locating bearing, refer to work card 500.06.

Operating sequence 2 - Refitting

For refitting, proceed in the reverse order of removing.

A A Important! Lock washer pairs: Long wedged surfaces to contact

each other (on the inside), otherwise there will be no securing effect.
Thrust ring
Removing and refitting

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

check statelwear condition of the components.

Brief descri~tion

Remove thrust ring for inspection.

The work/steps include:
removal of components,
checking of components,
installation of components.

Personnel and time required

I I
Numb Qualification Time [h] I
I 1 I Qualified mechanic I 0.3 1
Tools/appliances required

Qty Designation No. Availability

- Special protective agent - Inventory
(Molykote P40)
--

Related work cards

I Work card I Work card I Work card I

F~gure 1. Removing and refitting the thrust ring

O~eratinaseauence 1 - Removina

Starting condition Connecting pipes, silencer or air intake casing, compressor casing,
compressor wheel, sealing cover, labyrinth ring and locating bearing
removed.
Cartridge removed if turbine rotor is also to be dismantled.

Steps 1. Pull off the distance sleeve (520.031) in axial direction.

2. Pull off the thrust ring (520.028) in axial direction.
A Tip! If the distance sleeve andor thrust ring seizes, dismantle this parts -
together with the turbine rotor (refer to work card 500.22). The thrust ring and
distance sleeve will in this way be pressed against the intermediate
disk (5 17.038) and come off.

O~eratinaseauence 2 - Refitting

Steps 1. Apply a thin protective film of Molykote P40 to the fitting surfaces of
the turbine shaft (for the thrust ring and distance sleeve).
2. Push the thrust ring (520.028) and distance sleeve (520.031) onto the
turbine shaft.
A A Important! The balancing marks (W) of the turbine rotor (520.001),
thrust ring (520.028) and distance sleeve (520.031) must coincide radially.
Turbine rotor
Removing and refitting

Pur~oseof iobs to be done

Carry out the work in time according to the maintenance schedule,

check statelwear condition of the components.

Brief description

Remove turbine rotor for inspection.

The work/steps include:
removal of components,
checking of components,
installation of components.

Personnel and time reauired

Numb Qualification Time [h]

1 Qualified mechanic 0.4

Tools/appliances required

Qty I Designation I No. Availability I

I 1 I Sliding caliper I- I Inventory I

Related work cards

I Work card I Work card I Work card

Technical details

Term Information
Turbine rotor 7 kg
Figure 1. Removing and refitting the turbine rotor

Operating sequence 1 - Removing

Starting condition Cartridge removed. Compressor wheel, sealing cover, labyrinth ring,
locating bearing and thrust ring removed.

Steps 1. Slightly lift the turbine rotor (520.001) and pull it out as concentrically
as possible.
2. Check the turbine rotor.

Replace the turbine rotor if

Dl I 26.94 mm dia.,
D2 5 26.94 mm dia. and/or
D3 5 49.80 mm dia.

Operating sequence 2 - Refitting

For refitting, proceed in the reverse order of removing.
Covering disk and sealing cover
Removing and refitting

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

check statelwear condition of the components.

Brief descri~tion

Remove covering disk and sealing cover for inspection.

The workhteps include:
removal of components,
checking of components,
installation of components.

Personnel and time required

I I
Numb Qualification Time [h] I
I
1 Qualified mechanic
- -

0.4

Qty Designation No. Availability

1 Open-jaw wrench 17 - lnventorv

Spare parts required

Qty Designation No.

1 Seal 517.031

Related work cards

Work card Work card Work card

500.10 500.12 500.13
F~gure 1. Removing and refitting the covering disk and the sealing cover

Operating sequence 1 - Removing

Starting condition Cartridge removed. Compressor wheel, sealing cover, labyrinth ring,
locating bearing, thrust ring and turbine rotor removed.

Steps 1. With the studs (517.029) screwed in, pull the covering disk (517.009)
out of the bearing casing (517.001) in axial direction.
2. Evenly jack off the sealing cover (517.017) using 2 hexagon
bolts (M10, thread length r 20 mm).
3. Take off the seal (517.031).
-
A A Important! Slight grooves in the bore of the sealing cover produced
by the labyrinth tips of the turbine rotor improve the sealing effect and are
no reason to replace this part.

Operating sequence 2 - Refitting

For refitting, proceed in the reverse order of removing.
Make sure to use unobjectionable seal.
When refitting the seal (517.031) take care of position of the holes.
The bores for sealing air and lube oil must be clean, with unobstructed
passage.
Bearing bushes
~emoving,refitting, checking

Pur~ose
of iobs to be done

Carry out the work in time according to the maintenance schedule,

check statelwear condition of the components.

Brief description

Remove bearing bushes for inspection.

The work/steps include:
removal of components,
checking of components,
installation of components.

Personnel and time required

Numb 1 Qualification Time [hl I

I 1 ( Qualified mechanic I 0.6 1

Tools/appliances required

Qty Designation No. Availability

1 Hexagon screw driver 5 - Inventory
1 Sliding caliper - lnventorv

Related work cards

I Work card I Work card I Work card

F~gure 1. Removing and refitting the bearing bushes

Operating seauence 1 - Removina

Starting condition Cartridge removed. Compressor,wheel, sealing cover, labyrinth ring,

locating bearing, thrust ring, turbine rotor, covering disk and sealing cover
removed.

Steps 1. Unscrew the cylindrical screws (517.051) and take off the lock washer
pairs (517.052).
2. Take off the covers (517.037 and 517.038).
3. Take off the bearing bushes (517.003).
For checking the bearing bushes (517.003), refer to work card 500.06. -
4. Checking the bearing sleeve (517.005).
Replace the bearing sleeve if
D l 2 39.03 mm dia.,
D2 r 39.03 mm dia.
A A Important! Only in case of replacement, loosen and force out the
bearing sleeve (5 17.005) andlor the distance sleeve (5 17.027) by slight
hammer blows, using a copper bolt. Removal of the distance sleeve only
possible after having removed the grooved pin (517.085).

Operating seauence 2 - Refittinn

For refitting, proceed in the reverse order of removing.
The bearing bushes (517.003) are symmetric, mounting position at
discretion.
Turbine nozzle ring
Removing and refitting

Purpose of jobs to be done

Carry out the work in time according to the maintenance schedule,

check statelwear condition of the components.

Brief descri~tion

Remove turbine nozzle ring for inspection.

The worklsteps include:
removal of components,
checking of components,
installation of components.

Personnel and time required

I Numb 1 Qualification Time [h] I

I 1 I Qualified mechanic I 0.2 1
Related work cards

I Work card I Work card I Work card

F~gure 1. Removing and refitting the turbine nozzle ring

Operating sequence 1 - Removing

Starting condition Cartridge removed.

Steps 1. Pull the turbine nozzle ring (513.001) axially out of the gas-admission
casing (501.001).
2. For checking the turbine nozzle ring (513.001), please refer to work
card 500.04.

Operating sequence 2 - Refitting

For refitting, proceed in the reverse order of removing.
Insert, turbine side
Removing and refitting

Puraose of iobs to be done

Check statelwear condition of components.

Brief descri~tion

Remove insert, if necessary.

The worklsteps include:
dismounting components,
mounting components.

Personnel and time required

I 1
Numb Qualification Time [h] I
I 1 I Qualified mechanic I 0.4 1
Tools/a~~liances
reauired

I
Qty Designation I No. A wailability I
1 Hammer - Inventory
1 Punch - Inventory

Related work cards

I Work card I Work card I Work card I

Technical details

1 Term Information I
I Insert, turbine side I 8 kg I
I

F~gure 1. Removing and refitting the insert

Preliminary remarks

General Removing of the insert is only necessary in case of replacement.

Starting condition Connecting pipes, cartridge, turbine nozzle ring and gas-admission casing
removed.

Operating sequence 1 - Removing

Steps 1. Pull the insert (541.001) axially out of the gas-admission
casing (501.001).
A Tip! If the insert seizes, force it out by slight hammer blows, using a
punch.

Operatinn sequence 2 - Refitting

Steps 1. Install the insert (541.001) until there is firm contact with the
gas-admission casing (501.001).
A A Important! Take care that the position on the circumference of the
hole (in the insert) and of the collar pin (501.009) concide.

Checking During assembly of the turbocharger (refitting the cartridge):

For checking the gaps (positions 3 and 4) refer to Operating Manual,
Technical Data, Gaps and Clearances, sheet 2.5.5.
Technical Documentation
Exhaust Gas Turbocharger
Spare Parts Catalogue

Exhaust gas turbocharger . . . . . . . . . . NR17IS

MAN B&W Diesel Aktiengesellschaft 86224 Augsburg, Germany Phone +49 821 322 0 Fax +49 821 322 3382

a 6657 C3-01 E 02.02

.......
O 2001 MAN B&W Diesel AG
-
All rights reserved, including the reproduction in any form or by photomechanical means (photocopy/microcopy), in
whole or in part, and the translation.
Table of contents
Introduction

11 Introduction
Introduction

2 List of Assemblies

3 Spare parts
Spare parts/ Maintenance and repair work can only be carried out properly if the
spare parts catalogues necessary spare parts are available. They are to be kept on stock or
ordered in time. The order numbers required for the ordering of spare
parts can be looked up in the spare parts catalogues. This is the spare
parts catalogue for the turbocharger.
The organisational pattern of this spare parts catalogue is explained in
Section 1.3. Order numbers for components of the engine, for measuring,
control and regulating equipment and for the engine and systems
accessories are given in other modules of the technical documentaton.
References to this are given in Section 1.2.

Yours sincerely,

MAN B&W Diesel AG

Spare Parts Catalogues as Modules
of the Technical Documentation

Survev

Spare parts catalogues serve for ordering spare parts and/or to identify
components from MAN B&W Diesel AG's scope of supply. The required
information is partly to be taken from other means of information. For the
turbocharger, the following modules are available within the technical
documentation system:

Volume of the
Components/subassemblies Means of information
technical information
Turbocharger Spare parts catalogue turbocharger C3
List in the turbocharger tool box I
Tools (turbocharger)
Information contained in the work cards C2

1 Engine I Spare parts catalogue engine

I See I
technical
Measuring, control and regulating List of measuring and regulating instruments documentation
instruments engine and plant

1 Engine and system

Spare parts cataloguelspare parts sheet
depending on manufacturer and product
Table I. Spare parts catalogues and comparable means of information

Spare parts for turbocharger

Spare parts for the turbocharger can be identified by means of the spare
parts catalogue contained in Volume C3 of the technical documentation.
For this purpose, illustration and text sheets with order numbers are
available. An order number consists of a three-digit subassembly number
and a three-digit item number, which are 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 contained in Volume C2.

Spare parts for tools/ordering of tools (turbocharger)

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, which are separated
by a dot.
The order numbers, however, can also be looked up in the respective work
cards contained in Volume C2.
Spare parts for measuring, control and regulating systems

Information on spare parts for measuring, control and regulating

instruments, e.g. temperature sensors, relays, measurement converters,
pneumatic and hydraulic valves, can be gathered from the documents
contained in the technical documentation of the respective engine or plant
manufacturer.

Spare parts for engine and system accessories

For information concerning spare parts for the engine accessories, e.g. the
oil mist detector, and for the system accessories, e.g. filters, separators,
water softening plants and the like, please refer to the documents
contained in the technical documentation of the respective engine or plant
manufacturer.
Organisation and Use
of the Spare Parts Catalogue
Instructions for use
What does the spare parts
catalogue containlwhat not?
What can be done if parts are
not found?
Validitylsources of fault
Exchange sheets
1.3
The spare parts catalogue covers
all essential components of the turbocharger.
The spare parts catalogue does not contain
subordinate or plant-specific insulationslcoverings and
subordinate cabling, or cabling leading away from the
turbochargerlcabling and pipes carried out by other parties.
If parts have to be ordered which the spare parts catalogue does not
contain or that are not found, the component and the place where it is
installed should be described as precisely as possible with instant photos
possibly attached. Where parts from subsuppliers are concerned, that
cannot be found in their documentation, the information given on the
technical data plate should be stated.
Spare parts catalogues are specifically compiled for the turbocharger type
concerned. The present spare parts catalogue is therefore only applicable
for the turbocharger or the turbocharger group of the works number or
group of works numbers given on the cover sheet.
AA Important! Spare parts catalogues cannot be transferred from one
turbocharger to another.
An exception are catalogues called "Office editions", in which all the
available sheets of variants of all subassembly groups are contained.
Because of the numerous possibilities of faulty use, spare parts
catalogues of this type are restricted to internal use.
Spare parts catalogues, which are handed over in advance for information,
are marked as "lnformation editionnby means of a red reference sheet.
AA Important! lnformation editions are
Not suitable for ordering spare parts!
Not suitable for stock planning!
Not suitable for taking over into EDP systems!
Due to the order-specific revision of the spare parts catalogue, a later
exchange service is not necessary as a rule.
In case supplementary sheets or exchange sheets are sent to you in spite
of that, they are of particular significance.
Please make sure that such supplementary sheets or exchange sheets
are integrated in all the spare parts catalogues concerned, which were
allocated to you.
Further sources of fault
Supply of modified components
Organisation and characteristic features
Organisational pattern
Subassembly groups
Ordinal number
Sheet number
ltem number
Order number
Spare parts designation
If a turbocharger undergoes modifications in the course of operating time
and MAN B&W Diesel AG does not execute new drawings reflecting such
modifications and if therefore a new spare parts sheet is not drawn up
either, the engine operator himself should enter a warning in his spare
parts catalogue to avoid that wrong equipment is ordered.
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 latter. In such cases, the identity card of the part supplied will contain
a corresponding reference.
The order of the sheets in the spare parts catalogue follows the
subassembly group system of the turbocharger.
The subassembly group list is part of the following section.
It consists of an illustration sheets and a table. The table is arranged in
the order of the subassembly group numbers.
-
The subassembly group column is characterised by the symbol shown at
the left. Subassembly groups of which the numbers are put in
parentheses, are not available on all turbochargers. Subassembly groups
of which the numbers are marked with *, are not shown in the
subassembly group list.
The ordinal number at the right-hand top of the spare parts sheets
consists of the three-digit subassembly group number and a variant
number corresponding to the constructional variant.
The sheet number consists of the four-digit print number (e.g. 6661) at the
bottom left, and the ordinal number (e.g. 520.01 D) right of it.
The item numbers can be found in the text sheet underneath the symbol
shown at the left. They are mentioned here for the turbocharger for
technical reasons only.
The order numbers in the second column of the text sheet - underneath
-
the symbol of a writing hand shown at the left consist of a three-digit
subassembly group number and a three-digit item number. Subassembly
group number and item number are structured by a dot.
520 . 001 Order number (e.g. turbine rotor)
ltem number
Subassembly group number
The spare parts designation can be found under the respective language
symbol in the columns 3 to 6.
Replacement of Components
by the New-for-old Principle

Components of high value that are defective or worn and whose

reconditioning or repair requires special know-how or equipment, can be
replaced by the "Overhauled for o l d principle. This is the case with
completely assembled rotors of exhaust gas turbochargers (cartridges).
These parts are available from stock as a rule. If not, they will be
reconditionedhepaired and returned to you. If such a requirement arises,
please ask MAN B&W Diesel AG or the nearest Service Center to send
you an offer that is specifically matched to your demand.
Ordering Spare Parts

Information required To avoid queries, the following information should be provided when
ordering spare parts:

Type of the turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . xxxxxxxxx

Works number of the turbocharger .................. x xxx xxx

(Typeoftheengine) ............................... xxxxxxxxx

(Works number of the engine) ...................... x xxx xxx

Designation of part ................................ xxxxxxxxx

Order number .................................... xxx . xxx
Quantity ......................................... xx

Shipping address ................................. xxxxxxxxx

Mode of shipment ................................. xxxxxxxxx

Address Please address your order to:

MAN B&W Diesel Aktiengesellschaft

86224 Augsburg
Germany

Phone +49 821 322 3994

Fax +49 821 322 3998
List of Assemblies

1 Introduction

2 List of Assemblies

3 Spare Parts
Baugruppenubersicht
List of Assemblies
A p e r ~ udes sous-ensembles
Lista de todos 10s grupos
Baugruppenubersicht
List of Assemblies
Apercy des sous-ensembles
Lista de todos loo grupos

500 Abgasturbolader Exhaust gas turbocharger Turbocompresseur a gaz Turbosobrealimentador de gas de

d' echappement escape
501 Turbinen-Zustromgehause Gas-admission casing Corps d'admission de turbine Carcasa de afluencia de la turbina
506 Turbinen-Abstromgehause Gas outlet casing Corps d'echappement de turbine Carcasa de evacuacion de la turbina
513 Turbinenleitapparat Turbine nozzle ring Distributeur de turbine Distribuidor de gases de la turbina

540 Einsatzstuck lnsert lnsert Pieza de insertion

541 Einsatzstuck lnsert lnsert Pieza de insercion
542 Nachleitapparat Diffuser Diff useur Difusor

546 Verdichtergehause Compressor casing Corps de compresseur Caja del compresor

(562) DrehzahlmeOeinrichtung Speed measuring device Dispositif de mesure de regime Instalaci6n para la medicion del
numero de revoluciones
(578) Reinigungseinrichtungfur Turbine Cleaning device for turbine Dispositif de nettoyage pour Dispositivo de lavado para turbina
turbine
(579) Reinigungseinrichtungfiir Cleaning device for compressor Dispositif de nettoyage pour Dispositivo de lavado para compresor

~ntermediateflange Bride intermediaire Brida intermedia

Baugruppenilbersicht
List of Assemblies
A p e r ~ udes sous-ensembles
Lista de todos 10s grupos

599 Rurnpfgruppe (517 + 520) Cartridge (517 + 520) Groupe base (517 + 520) Grupo base (517 + 520)
* Diese Baugruppen sind in den Bildern nicht sichtbar
These assemblies are not shown in the figures
Ces sous-groupes ne sont pas illustrds sur les figures
Estos grupos constructivos no estan visibles en las figuras
(. ..) falls vorhanden
if provided
s'il existe
si existe
Spare Parts

1 Introduction

2 List of Assemblies

3 Spare Parts
Parts
--
Turbinen- Zustromgehause
Gas- admission casing
Corps d'admission de turbine
Carcasa de afluencia de la turbina
Turbinen- Zustromgehause
Gas- admission casing
Corps d'admission de turbine
Carcasa de afluencia de la turbina

000 501.OOO Turbinen-Zustromgehause, Gas-admission casing, Corps d'admission de turbine, Carcasa de afluencia de la
komplett compl. compl. turbina,
compl.
001 501.001 Turbinen-Zustromgehause Gas-admission casing Corps d'admission de turbine Carcasa de afluencia de la
turbina
005 501.005 Spannpratze Clamping claw Patte de serrage Garra tensora
006 501.006 Stiftschraube Stud Goujon Esphrrago

501.009 Bundbolzen collar pin Boulon a coilet Perno con collar

501.040 V-Profil-Spannschelle V-profile clamp Agrafe de serrage profile en V Abrazadera de sujeci6n perfil
en V
Turbinen=Abstr6mgehause
Gas outlet casing
Corps d'echappement de turbine
Carcasa de evacuacitin de la turbina
Turbinen-Abstromgehause
Gas outlet casing
Corps d18chappementde turbine
Carcasa de evacuacidn de la turbina

506.000 Turbinen- Abstromgehiiuse, Gas outlet casing, complete Corps d'echappement de Carcasa de evacuacion de la
komplett turbine, compl. turbina, compl.
506.001 Turbinen-Abstromgehause Gas outlet casing Corps d'echappement de turbine Carcasa de evacuacion de la
turbina
506.074 VerschluOschraube Screw plug Bouchon filete Tap6n roscado
506.075 Dichtring Sealing ring Anneau-joint Anillo-junta
Turbinenleitapparat
Turbine nozzle ring
Distributeur de turbine
Distribuidor de gases de la turbina
Turbinenleitapparat
Turbine nozzle ring
Distributeur de turbine
Distribuidor de gases de la turbina

001 513.001 Turbinenleitapparat Turbine nozzle ring Distributeur de turbine Distribuidor de gases de la
turbina
Lagergehause
Bearing casing
Bolte de paliers
Carcasa de cojinetes
Lagergehause
Bearing casing
Bolte de paliers
Carcasa de cojinetes

000 517.000 Lagergehause, komplett Bearing casing, compl. Boite de paliers, compl. Carcasa de cojinetes, compl.
001 517.001 Lagergehause Bearing casing Boite de paliers Carcasa de cojinetes
002 517.002 Fiihrungslager Locating bearing Palier de guidage Cojinete-guia
003 517.003 Lagerbuchse Bearing bush Coussinet de palier Casquillo de cojinete

009 517.009 Abdeckscheibe Covering disk Disque de recouvrement Disco de cubierta

017 517.017 Dichtdeckel Sealing cover Couvercle dS6tanch6it6 Tapa de estanqueidad
018 517.018 Runddichtring O-ring seal Joint torique d16tanch6ite Junta torica
024 517.024 Verschlut3schraube Screw plug Bouchon filete Tapon roscado

027 517.027 Abstandshiilse ~istancesleeve Douille d'kartement ~ a n ~ ~distanciador

i t o
029 517.029 Stiftschraube Stud Goujon Espiirrago
031 517.031 Dichtung Seal Joint Junta
032 517.032 Sechskantmutter Hexagon nut Ecrou hexaaonal Tuerca hexaaonal

037 517.037 Deckel Cover Couvercle Tapa

038 517.038 Deckel Cover Couvercle Tapa
044 517.044 Sicherungsscheibenpaar Lock washer pair Paire de rondelles d'arret Par de arandelas de seguridad
051 517.051 Zylinderschraube Cvlindrical screw Vis a tQtecvlindriaue Tornillo de cabeza cilindrica

.
067 517.067 Flansch Flange Bride Brida
068" 517.068 Dichtung Seal Joint Junta
078 517.078 Sicherungsscheibenpaar Lock washer pair Paire de rondelles d'arret Par de arandelas de seguridad
082 517.082 Sechskantschraube Hexagon bolt Boulon A tete hexagonale Tornillo de cabeza hexaaonal
Lagergehause
Bearing casing
Bo'ite de paliers
Carcasa de cojinetes

087 517.087 Dichtdeckel Sealing cover Couvercle d'etancheite Tapa de estanqueidad

* falls vorhanden
if provided
si present
si existe
Laufer komplett
Rotor complete
Rotor complet
Rotor completo
Laufer komplett
Rotor complete
Rotor complet
Rotor cornpleto

000 520.000 Laufer kornplett Rotor complete Rotor cornplet Rotor cornpleto
001 520.001 Turbinenlaufer Turbine rotor Rotor de turbine Rotor de la turbina
005 520.005 Verdichterrad Compressor wheel Roue de cornpresseur Rodete cornpresor
006 520.006 Labyrinthring Labyrinth ring Bague A labyrinthe Anillo de laberinto
009 520.009 Mitnehrner Carrier ~ntraineur Arrastrador

018 520.018 PaOfeder Feather key Clavette Chaveta de aiuste

028 520.028 Laufring Thrust ring Bague A billes Anillo de rodadura
031 520.031 Abstandshijlse Distance sleeve Douille d'bcarternent Manguito distanciador
068 520.068 Dehnschraube Undercut bolt Vis de dilatation Tornillo extensible
124 520.124 Magnetwelle Magnetic shaft Arbre rnagnetique Eje del irnan
Einsatzstuck
Insert
Insert
Pieza de insercidn
Einsatzstuck
lnsert
lnsert
Pieza de insercidn

540.000 Einsatzstuck, kornplett Insert, complete Insert, cornplet Pieza de insercidn, cornpleta
540.001 Einsatzstuck Insert Insert Pieza de insercidn
540.015 Runddichtring O-ring seal Joint torique d18tanch6ite Junta tdrica
540.016 Runddichtring O-ring seal Joint torique d'etancheite Junta tdrica
540.030 Ausgleichsring Balance ring Bague de compensation Anillo de cornpensacidn
EinsatzstUck
Insert
Insert
Pieza de insercidn
Einsatzstuck
lnsert
lnsert
Pieza de insercidn

001 541.001 Einsatzstuck lnsett Insert Pieza de insercion

Nachleitapparat
Diffuser
Diffuseur
Difusor
Nachleitapparat
Diffuser
Diffuseur
Difusor

1 Nachleitapparat Diffuser Diffuseur Difusor

Schalldampfer
Silencer
Silencieux
Silenciador
Schalldiimpfer
Silencer
Silencieux
Silenciador

000 544.000 Schalldampfer, komplett Silencer, complete Silencieux, complet Silenciador, completo
001 544.001 Gehause Casing Boitier Carcasa
010 544.010 Flansch Flange Bride Brida
021 544.021 Dampfungsplatte Damping plate Plaque d' amortissement Placa de amortiguacion
032 544.032 Distanzrohr S ~ a c e~
r i ~ e Tuvau d'ecartement Tubo distanciador

046 * 544.046 VerschluOschraube Screw plug Bouchon filete Tapdn roscado

050 544.050 Deckel Cover Couvercle Tapa
053 544.053 Blechschraube Tapping screw Vis a t81e Tornillo autorroscante
066 544.066 Stiftschraube

067 544.067 Sicherungsmutter

069 544.069 Gewindestange Threaded rod Tige filetee Varilla roscada
074 544.074 Sechskantmutter Hexagon nut Ecrou hexagonal Tuerca hexagonal
075 544.075 Scheibe Washer Rondelle Arandela

201 544.201 Luftfiltermatte Air filter mat Natte de filtre a air Estera de filtro de aire
202 544.202 Spannschelle Clamp Agrafe de serrage Abrazadera de sujecion
205 544.205 Abdeckblech Cover sheet T81e de recouvrement Chapa de revestimiento
* falls vorhanden
if provided
si present
si existe
Ansauggehause
Air intake casing
Corps d'aspiration
Caja de aspiracidn
Ansauggehause
Air intake casing
Corps d'aspiration
Caja de aspiracidn

000 545.000 Ansauggehause, komplett Air intake casing, complete Corps d'aspiration, complet Caja de aspiration, completa
001 545.001 Ansauggehause Air intake casing Corps d'aspiration Caja de aspiracion
014 545.014 Sechskantschraube Hexagon bolt Boulon A tQtehexagonale Tornillo de cabeza hexagonal
018 545.018 VerschluOschraube Screw plug Bouchon filete Tapon roscado
019 545.019 Dichtring Sealing ring Anneau-joint Anillo-junta

069 545.069 Sechskantmutter Hexagon nut ~ c r o uhexagonal ~ u e r c ahexagonal

Verdichtergehause
Compressor casing
Corps de compresseur
Caja del compresor
Verdichtergehause
Compressor casing
Corps de compresseur
Caja del compresor

000 546.000 Verdichtergehause, komplett Compressor casing, compl. Corps de compresseur, compl. Caja del compresor, compl.
001 546.001 Verdichtergehause Compressor casing Corps de compresseur Caja del compresor
005 546.005 V-Profil-Spannschelle V-profile clamp Agrafe de serrage profile en V Abrazadera de sujecion perfil
en V
008 546.008 Senkschraube Countersunk bolt Vis t6te fraiske Tornillo de cabeza avellanada
020 546.020 Sechskantschraube Hexagon bolt Boulon a t6te hexagonale Tornillo de cabeza hexagonal

023 546.023 Sicherungsscheibenpaar Lock washer pair Paire de rondelles d'arret Par de arandelas de seguridad
-
025 546.025 enschi child Type plate Plaque de type Placa de tip0
026 546.026 Kerbnagel Notched nail Clou a rainures Clavo entallado
050 546.050 Flansch Flange Bride Brida
051 546.051 Dichtring Sealing ring Anneau-joint Anillo-junta
DrehzahlmeBeinrichtung
Speed measuring device
Dispositif de mesure de regime
lnstalacidn para la medicidn del numero de revoluciones
DrehzahlmeBeinrichtung
Speed measuring device
Dispositif de mesure de regime
lnstalacidn para la medicidn del numero de revoluciones

000 562.000 DrehzahlmeOeinrichtung, Speed measuring device, Dispositif de mesure de r6gime, Instalaci6n para la medici6n del
komplett compl. compl. numero de revoluciones, compl.
004 562.004 Haltescheibe Holding disk Disque de support Disco de soporte
040 562.040 Drehzahlgeber Speed transmitter Transmetteur de vitesse Transmisor de velocidad
083 * 562.083 Klemmenkasten Terminal box Boite ZI bornes Caja de bornes
100" 562.100 Drehzahlanzeiaer Speed indicator lndicateur de vitesse lndicador de revoluciones

* falls vorhanden
if provided
si present
si existe
Reinigungseinrichtung fur Turbine
Cleaning device for turbine
Dispositif de nettoyage pour turbine
Dispositivo de lavado para turbina
Reinigungseinrichtung fur Turbine
Cleaning device for turbine
Dispositif de nettoyage pour turbine
Dispositivo de lavado para turbina

000 578.01.000 Reinigungseinrichtung Cleaning device Dispositif de nettoyage Dispositivo de lavado

fiir Turbine, komplett for turbine, complete pour turbine, complet para turbina, completo
(NaOreinigung) (wet cleaning) (nettoyage par voie humide) (limpieza por via hlimeda)
002 578.01.002 Verschraubung Screwed connection Raccord Racor
003 578.01.003 Dichtring Sealing ring Anneau-joint Anillo-junta
005 578.01.005 Dichtring Sealing ring Anneau-joint Anillo-junta
006 578.01.006 Druckminderstation Pressure reducinn station Station de reduction de pression Equipo de reduccion de presi6n

(mit Reinigungsvorschrift) (with cleaning instructions) (avec cahier de nettoyage) (con instrucciones de limpieza)
020 578.01.020 Dreiwegehahn Three-way cock Robinet A trois voies Grifo de tres pasos
Reinigungseinrichtung fur Turbine
Cleaning device for turbine
Dispositif de nettoyage pour turbine
Dispositivo de lavado para turbina
Reinigungseinrichtung fur Turbine
Cleaning device for turbine
Dispositif de nettoyage pour turbine
Dispositivo de lavado para turbina

000 578.02.000 Reinigungseinrichtung Cleaning device Dispositif de nettoyage Dispositivo de lavado

fur Turbine, komplett for turbine, complete pour turbine, complet para turbina, completo
(Trockenreinigung) (dry cleaning) (nettoyage A sec) (limpieza en seco)
001 578.02.001 Behalter Tank Reservoir Recipiente
020 578.02.020 VerschluOschraube Screw plug Bouchon filete Tap6n roscado
025 578.02.025 Verschraubung Screwed connection Raccord Racor
026 578.02.026 Verschraubuna Screwed connection Raccord Racor

028 578.02.028 Verschraubung Screwed connection Raccord Racor

029 578.02.029 Bugelschraube U-bolt Etrier filete Horquilla roscada
030 578.02.030 Kugelhahn Ball cock Robinet spherique Grifo esferico
031 578.02.031 Abs~errhahn S t o cock
~ Robinet a boisseau Llave de cierre

(mit Reinigungsvorschrift) (with cleaning instructions) (avec cahier de nettoyage) (con instrucciones de limpieza)
Reinigungseinrichtung fur Verdichter
Cleaning device for compressor
Dispositif de nettoyage pour compresseur
Dispositivo de lavado para compresor

6661 579.01 E 09.99 NR, NA

...........:-
:
1
.
Reinigungseinrichtung fiir Verdichter
Cleaning device for compressor
Dispositif de nettoyage pour compresseur
Dispositivo de lavado para compresor

000 579.000 Reinigungseinrichtung Cleaning device Dispositif de nettoyage Dispositivo de lavado

fur Verdichter, komplett for compressor, complete pour compresseur, compl. para compresor, compl.
(abgesetzter Behalter) (separate tank) (reservoir s6par6) (recipiente separado)
029 579.029 Behalter Tank Reservoir Recipiente
030 579.030 SchraubverschluO Screw plug Vis de fermeture Tap6n roscado
042 579.042 Sechskantschraube Hexagon bolt Boulon tQte hexagonale Tornillo de cabeza hexagon;
080 579.080 Saugrohr Suction pipe Tuvau d'as~iration Tuberia de as~iraci6n

090 579.090 Schlauch Hose Tuvau flexible Tubo flexible

091 579.091 Schlauchschelle Hose clamp ~g-rafeflexible Abrazadera de manguera
103 579.103 Verschraubung Screwed connection Raccord Racor
104 579.104 Reduzierverschraubung Reducing connection Raccord vis pour reduction Racor de reducci6n
120 579.120 AnschluOstuck Connectina piece Piece de raccordement Pieza de racor

122 579.122 Hydrometerhahn Hydrometer cock Robinet hydrometre Llave del hidr6metro
123 579.123 Dichtring Sealing ring Anneau-joint Anillo-junta
124 579.124 Verschraubung Screwed connection Raccord Racor
127 579.127 Schlauch Hose Tuyau flexible Tubo flexible
128 579.128 Schlauchschelle Hose clamp ~g-rafeflexible Abrazadera de manguera

178 579.178 Schild Plate Plaque Placa

(mit Reinigungsvorschrift) (with cleaning instructions) (avec cahier de nettoyage) (con instrucciones de limpieza)

6661 579.01 E 09.99 NR, NA ...........:-

:
1
.
Reinigungseinrichtung fur Verdichter
Cleaning device for compressor
Dispositif de nettoyage pour compresseur
Dispositivo de lavado para compresor

6661 579.02 E 09.99 NR, NA

...........:-
:
1 .
Reinigungseinrichtung fur Verdichter
Cleaning device for compressor
Dispositif de nettoyage pour compresseur
Dispositivo de lavado para compresor

000 579.000 Reinigungseinrichtung Cleaning device Dispositif de nettoyage Dispositivo de lavado

fijr Verdichter, komplett for compressor, complete pour compresseur, compl. para compresor, compl.
(Druckspritze) (pressure sprayer) (dispositif d'aspersion a (dispositivo de chorrear a
pression) presibn)
029 579.029 Druckspritze Pressure sprayer Dispositif d'aspersion a pression Dispositivo de chorrear a presion
090 579.090 Schlauch Hose Tuyau flexible Tubo flexible
091 579.091 Schlauchschelle Hose clamp Agrafe flexible Abrazadera de manguera
095 579.095 Kupplung Coupling ~ccou~lement Acoplamiento

096 579.096 Nippel Nipple Raccord Boquilla

100 579.100 ~inschraubstutzen screwed socket Tubulure filetee Union roscada
101 579.101 Dichtring Sealing ring Anneau-joint Anillo-junta
102 579.102 Winkelverschraubung Angular screw connection Raccord a vis coude Racor angular
103 579.103 Verschraubung Screwed connection Raccord Racor

130 579.130 Halter Retainer Support Soporte

179 579.179 Schild Plate Placa

6661 579.02 E 09.99 NR, NA

...........:-
:
1 .
Verschalungen
Coverings
Revetements
Revestimientos
Verschalungen
Coverings
Revetements
Revestimientos

001 591.001 Verschalung mit lsolierung Covering with insulation RevQtement avec calorifugeage Revestimiento con aislamiento
am Turbinen-Zustromgehause on gas-admission casing sur corps d'admission de turbine en la caja de afluencia de la
turbina
060 591.060 Schild zweiteilig Two-part plate Plaque en deux pieces Placa de dos piezas
101 591.101 Verschalung mit lsolierung Covering with insulation RevQtementavec calorifugeage Revestimiento con aislamiento
am Turbinen-Abstromgehause on gas outlet casing sur corps d'echappement de en la caja de evacuacion de la
turbine turbina
160 591.160 Ringverschalung Annular lagging RevQtementannulaire Revestimiento anular
Zwischenflansch
Intermediate flange
Bride intermediaire
Brida intermedia
Zwischenflansch
lntermediate flange
Bride intermediaire
Brida intermedia

000 593.000 Zwischenflansch, komplett Intermediate flange, complete Bride intermediaire, complet Brida intermedia, completa
001 593.001 Zwischenflansch Intermediate flange Bride intermediaire Brida intermedia
002 593.002 Dichtung Seal Joint Junta
004 593.004 Stiftschraube Stud Goujon Esphrrago
005 593.005 Sechskantmutter Hexagon nut Ecrou hexagonal Tuerca hexagonal

021 593.021 Dichtung Joint Junta

022 593.022 Sechskantschraube Hexagon bolt Boulon a tQte hexagonale Tornillo de cabeza hexagonal
023 593.023 Sechskantmutter Hexagon nut Ecrou hexagonal Tuerca hexagonal
Rumpfgruppe
Cartridge
Groupe base
Grupo base
Rumpfgruppe
Cartridge
Groupe base
Grupo base

-- -- -

000 599.000 Rumpfgruppe Cartridge Groupe base Grupo base

* 599.000 = (517.000) und (520.000) zusammengebaut
599.000 = (517.000) and (520.000) assembled
599.000 = (517.000) et (520.000) assembles
599.000 = (517.000) y (520.000) ensamblados