NA29-S Manual

MAN Diesel & Turbo
Technical Documentation
Turbocharger
Operating Instructions
Turbocharger type .............................. NA29/S
Works No. of turbocharger................

2011-01-13 - de
Translation of the original instructions

6663-1 C1-01 EN-US 1 (2)
MAN Diesel & Turbo
MAN Diesel & Turbo SE

86224 Augsburg
Phone +49 (0) 821 322-0
2011-01-13 - de
Fax +49 (0) 821 322-49 4180

primeserv-aug@mandieselturbo.com
www.mandieselturbo.com/primeserv
Copyright © 2011 MAN Diesel & Turbo

All rights reserved, including reprinting, copying (Xerox/microfiche) and translation.
2 (2) 6663-1 C1-01 EN-US

MAN Diesel & Turbo
Table of contents
Table of contents
1 Introduction
1.0 General Safety Instructions
1.1 Preface
1.2 Manufacturer's liability
1.3 Organisation and use of the Operating Manual
1.4 Addresses
2 Technical details
2.1.1 MAN Diesel SE's scope of supply/technical specification
2.2.1 Turbocharger, brief description, function
2.4.1 Lube oil system
2.4.4 Sealing air system (turbocharger on four-stroke engine)
2.4.5 Sealing air system (turbocharger on two-stroke engine)
2.4.7 Acceleration system - Jet Assist
2.5.1 Operating data and alarm points
2.5.3 Weights
2.5.4 Dimensions
2.5.5 Gaps and clearances
3 Operation
3.0 Safety during operation
3.2.2 Intended use/suitability of the turbocharger
3.4.1 Starting operation, shutting down
3.5.1 Monitoring the turbocharger
3.6.1 Malfunctions/faults and their causes (trouble shooting)
3.6.3 Emergency operation in the event of turbocharger failure
3.6.7 Response to out-of-limit conditions and alarms
4 Maintenance/repair
4.0 Safety during maintenance/repair
4.1 General remarks
4.2 Maintenance schedule (explanations)
4.3 Tools/special tools
4.4 Spare parts
4.7 Maintenance schedule (signs/symbols)
4.7.3 Maintenance schedule (turbocharger)
4.8 Remarks on maintenance work
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4.8.1 Cleaning
4.8.5 Checking the individual components
4.8.8 Inspection report
5 Work cards
5.1 Introduction
6663-1 C1-01 EN-US 1 (3)

MAN Diesel & Turbo
5.1.1 Preface
Table of contents
5.1.2 Organisation and use of the work cards

5.2 Work cards
000.31 Screw connections and tightening torques
500.05 Emergency operation with closing device
500.06 Locating bearing and bearing bushes Checking
500.07 Cleaning the turbine - Wet cleaning
500.07 Cleaning the turbine - Dry cleaning
500.08 Cleaning the compressor - with fitted tank
500.08 Cleaning the compressor - pressure sprayer
500.10 Turbocharger or subassemblies Removing and refitting
500.11 Cleaning the air filter
500.12 Silencer
500.13 Air intake casing
500.14 Compressor casing, insert, diffuser, speed transmitter Removing
and refitting
500.16 Cartridge Removing and refitting
500.18 Compressor wheel Removing, refitting, checking
500.19 Sealing cover and labyrinth ring Removing and refitting
500.20 Locating bearing Removing and refitting
500.21 Thrust ring Removing and refitting
500.22 Turbine rotor Removing and refitting
500.23 End cover Removing and refitting
500.24 Bearing bushes Removing, refitting, checking
500.25 Gas admission casing Removing and refitting
500.26 Turbine nozzle ring Removing and refitting
500.27 Shroud ring, diffuser outside wall Removing and refitting
6 Spare parts catalogue

6.1 Introduction
6.1.1 Preface
6.1.2 Spare parts catalogue as a module of the technical documenta-
tion
6.1.3 Organisation and use of the spare parts catalogue
6.1.4 Ordering spare parts
6.2 Spare parts
500 Overview of subassemblies
501.01 Gas admission casing
506.01 Gas outlet casing
509.01 Gas outlet diffuser
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513.01 Turbine nozzle ring

517.01 Bearing casing
518.01 Casing foot
520.01 Rotor, complete
591.01 Covering
542.01 Diffuser
2 (3) 6663-1 C1-01 EN-US

MAN Diesel & Turbo
540.02 Insert, compressor side
Table of contents
544.01 Silencer
545.01 Air intake casing, 90°
545.02 Air intake casing, axial
546.02 Compressor casing
562.01 Speed measuring device
578.01 Cleaning device for turbine/ wet cleaning
578.02 Cleaning device for turbine/ dry cleaning
579.01 Cleaning device for compressor
579.02 Cleaning device for compressor/ pressure sprayer
7 Index
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6663-1 C1-01 EN-US 3 (3)

MAN Diesel & Turbo
1 Introduction
2 Technical details
3 Operation
5 Work cards
7 Index
2011-01-13 - de
Introduction
6663-1 1 C1-01 EN-US 1 (1)

MAN Diesel & Turbo 1.0
General Safety Instructions
Introduction
Safety Instructions
Safety instructions are always noted down prior to the description of any
action. They are categorized in 3 hazard levels and differentiated by the
degree of hazard seriousness for personnel or equipment.
Hazard Levels
The safety instructions for the hazard levels 1 - 3
▪ Danger,
▪ Warning,
▪ Caution
are indicated as follows:
When the respective caution measures are not complied with,

there is imminent danger which will result in:
• Death or serious injury,

• Total damage to property or
• Serious environmental damage.
When the respective caution measures are not complied with, a

potentially hazardous situation will be caused.
This can lead to:
• Death or serious injury,
• Serious damage to property or
• Serious environmental damage.
When the respective caution measures are not complied with, a

hazardous situation can be caused.
This can lead to:
• Personal injury,
• Possible damage to property.
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For notes concerning fault sources/handling errors; material damage

Introduction
can occur.
Additional notes, information and tips.
General
C1 6673 1.0-02 EN-US 1 (3)

1.0 MAN Diesel & Turbo
A symbol appropriate to the hazard is always depicted in the marginal col-

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

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

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

materials surface pended loads gear hazard
Bans
Fire, No access for

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

Introduction
Safety Instruction Sign - Engine Room
Figure 1: Safety Instruction Sign - Engine Room
To point out the most important regulations, bans and hazards during
operation and maintenance, the safety instruction sign enclosed with
each turbocharger must be posted at the entry of the engine room.
2007-11-15 - de
Introduction
Persons, who for operational reasons are to be within the danger area of 2.5
m around the engine, are to be instructed of the predominant hazards.
General
Access to the danger area is permitted when the turbocharger is in proper

operating condition and only when wearing suitable protective equipment. It
is prohibited to stay within the danger area without reason.
C1 6673 1.0-02 EN-US 3 (3)

Preface
Introduction
General remarks
MAN Diesel & Turbo Turbochargers produced by MAN Diesel & Turbo have evolved from decades
turbochargers of continuous, successful research and development work. They satisfy high
standards of performance and have ample reserves for withstanding adverse
or detrimental influences. However, to meet all the requirements of practical
service, they have to be used as intended and maintained properly. Only if
these prerequisites are satisfied can unrestricted efficiency and long useful
life be expected.
Purpose of the operating The operating manual as well as the work cards are designed to assist you in
manual and work cards becoming familiar with the turbocharger and the equipment. They are also
intended to provide answers to questions that may turn up later on, and to
serve as a guideline in your activities of engine operation, inspection and
servicing. Furthermore, we attach importance to familiarising you with func-
tions, interrelations, causes and consequences, and to conveying the empiri-
cal knowledge we have. Not least, in providing the technical documentation
including the operating manual and work cards, we comply with our legal
duty of warning the user of the hazards which can be caused by the turbo-
charger or its components - in spite of a high level of development and the
greatest design efforts - or which an inappropriate or unintended use of our
products involves.
The operating manual is continually updated, and matched to the design of
the turbocharger as ordered. There may nevertheless be deviations between
pages with primarily descriptive/illustrative content and the actual design.
Numbering The numbering of the chapters follows an internally defined document struc-
ture. Due to this structure gaps in the numbering can occur. This is intended
and is not an indication of missing sections in the document. The table of
contents always lists the full scope of the documentation.
Personnel The operating manual must be accessible to personnel for the purpose of
operation, monitoring/inspection and maintenance/repair of the turbo-
charger. The personnel entrusted with these tasks are responsible for famili-
arising themselves with the composition of the operating manual so that they
are able to find the necessary information without lengthy searching.
2007-11-05 - de
Introduction
NR, NA
C1 6685 1.1-02 EN-US 1 (1)

Manufacturer's liability
Introduction
Personnel Requirements
Safe and economic operation of the engine system including the turbo-
charger requires extensive knowledge. Also, the operatability can be main-
tained or regained only through maintenance and repair work when these are
carried out with expertise and skill by trained personnel. The rules of proper
craftsmanship are to be observed. Negligence is to be prevented.
The technical documentation supplements this ability through specialized
information, draws attention to dangers and points out the safety regulations
to be observed. The MAN Diesel & Turbo SE asks you to observe the follow-
ing guidelines:
For improper usage of the turbocharger, the danger of

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

safety regulations are infringed.
2007-03-21 - de
Introduction
NR, NA
C1 6685 1.2-02 EN-US 1 (1)

Organisation and use of the Operating Manual
Introduction
Instructions for use
The numbering of the chapters follows an internally defined document struc-
ture. Due to this structure gaps in the numbering can occur. This is intended
and is not an indication of missing sections in the document. The table of
contents always lists the full scope of the documentation.
The operating manual contains written and illustrated information that is both
generally useful and specially significant. This information is intended to sup-
plement the knowledge and skills of the personnel entrusted with
▪ operation,
▪ monitoring and inspection,
▪ maintenance and repair
of the turbocharger. Conventional knowledge and practical experience alone
will not be adequate.
The operating manual must be made available to these persons. The person-
nel entrusted with these tasks are responsible for familiarising themselves
with the composition of the operating manual so that they are able to find the
necessary information without lengthy searching.
We assist them in doing so by providing a clearly organised structure and
writing readily understandable texts.
Structure and special features

The operating manual consists of the main sections
1. Introduction,
2. Technical details,
3. Operation/Operating media,
4. Maintenance/Repair.
The operating manual deals only with the most important subjects. It mainly
focuses on:
▪ understanding the functions and interrelations,
▪ operation in routine and emergency modes,
▪ ensuring operational prerequisites on the turbocharger and the peripheral
systems, and
▪ maintaining the operability of the turbocharger/engine, carrying out pre-
ventive or scheduled maintenance work, performing simple repair work,
and commissioning and supervising more difficult work.
The manual does not deal with:
▪ transportation and installation of the turbocharger,
▪ procedures and checks when putting the engine into operation for the
first time,
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▪ difficult repair work requiring special tools, equipment and experience,

Introduction
▪ behaviour in the event of fire, water penetration, severe damage and

average.
NR, NA
C1 6685 1.3-02 EN-US 1 (2)

Introduction
What is also of importance

Turbocharger design The operating manual is continually updated, and matched to the design of
the turbocharger as ordered. There may nevertheless be deviations between
pages with primarily descriptive/illustrative content and the actual design.
The operating manual covers the standard applications. It covers turbo-
chargers for ships' main and auxiliary engines and turbochargers in station-
ary plants. Special features of these applications are indicated in the text.
Such sections are to be read selectively.
Technical details Technical details of your turbocharger are included in
▪ Chapter 2 “Technical details”,
▪ in the work cards in Part “C2”.
Maintenance schedule / The maintenance schedule (turbocharger) is closely related to the work cards
work cards of Part C2. The work cards describe how a job is to be performed, and
which tools and facilities are required. The maintenance schedule, on the
other hand, specifies the periodic intervals and the average requirements in
terms of personnel and time.
2007-03-27 - de
Introduction
NR, NA
2 (2) C1 6685 1.3-02 EN-US

Addresses
Introduction
Headquarters
Contact persons The following table contains addresses for MAN Diesel & Turbo in Germany,
together with telephone and fax numbers for the departments responsible
and ready to provide advice and support on request.
Augsburg plant Telephone/Fax/e-mail/Internet
Headquarters
MAN Diesel & Turbo SE Tel. +49 821 322 0

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

Spare parts Fax +49 821 322 3998
e-mail PrimeServ-TC-Commercial@mandieselturbo.com
PrimeServ Academy Tel. +49 821 322 1397

Training courses for turbochargers Fax +49 821 322 1170
and engines
e-mail PrimeServ.Academy-info@mandieselturbo.com
Internet www.mandieselturbo.com/primeserv-academies
Worldwide Service Addresses

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Introduction
Internet MAN Diesel & Turbo service addresses and authorized service partners
(ASP) can be found on the Internet under MAN | PrimeServ Worldwide Net-
work:
General
www.mandieselturbo.com/primeserv
C1 6685 1.4-03 EN-US 1 (1)

MAN Diesel & Turbo
1 Introduction
2 Technical details
3 Operation
5 Work cards
7 Index
Technical details
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6663-1 2 C1-01 EN-US 1 (1)

MAN Diesel & Turbo 2.1.1
MAN Diesel SE's scope of supply/technical specification
Technical details
General remarks
For all items supplied by For all questions you have on items supplied by us, please contact
us ... ▪ MAN Diesel & Turbo SE in Augsburg
and for typical service questions,
▪ MAN Diesel & Turbo service centres,
▪ agencies and
▪ authorised repair workshops all over the world.
For all items not supplied by For all items not supplied by us, please directly contact the subsuppliers,
us ... unless the components/systems supplied by MAN Diesel & Turbo SE are
involved to a significant extent or other obvious reasons apply.
Technical specification The order confirmation, the technical specification related to the order confir-
mation and the technical specification of the turbocharger contain supple-
mentary information.
Technical details
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General
C1 6685 2.1.1-02 EN-US 1 (1)

Turbocharger, brief description, function
Technical details
Longitudinal section
1 Gas admission casing 6.2 Silencer

2 Turbine nozzle ring 7 Insert
3 Turbine wheel 8 Compressor wheel
4 Gas outlet diffuser 9 Diffuser
5 Gas outlet casing 10 Compressor casing
6.1 Air intake casing 11 Bearing casing
Figure 1: Turbocharger NA29/S
Brief description
Turbocharger with one axial turbine stage and one radial-flow compressor
stage. Rotor supported in two floating bearing bushes and a 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. Air intake casing
(6.1) or silencer (6.2). Bearing lubrication integrated in engine lube oil circuit.
No water cooling. Casings on turbine side with heat insulation.
Function
Simultaneously, fresh air is drawn in via the air intake casing (6.1) or silencer
(6.2) and insert (7) and compressed via the compressor wheel (8), diffuser (9)
and compressor casing (10).
Technical details
The compressed fresh air is forced into the cylinders of the engine via the
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charge air cooler and charge air pipe.

Overall, this process achieves a tremendous increase in the performance of
the engine. Cross sections and directions of flow are adapted to the individ-
NA29/S
ual application.
C1 6663 2.2.1-01 EN-US 1 (2)

2.2.1 MAN Diesel & Turbo
The turbocharger rotor is guided in radial direction through 2 floating bearing

bushes arranged between turbine wheel (3) and compressor wheel (8) in the
Technical details
bearing casing (11). The locating bearing on the compressor side serves for
axial positioning and for taking the axial thrust.
The turbocharger bearings are supplied with oil from the engine lube oil cir-
cuit through a common feed pipe. The lube oil also serves the purpose of
cooling the bearings.
Technical details
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NA29/S
2 (2) C1 6663 2.2.1-01 EN-US

Lube oil system
Technical details
Lube oil diagram
1 Feed pipe (engine) 9 Pressure gauge

2 Feed pipe (turbocharger) 10 Pressure controller
3 Throttle device (orifice / pressure reducing 11 Sealing air *
valve)
4 Bearing bush * 12 Feed pipe (interval priming)
5 Locating bearing * 13 Non-return valve
6 Drain pipe 13 Non-return valve
7 Sight glass or venting box 15 Hydropneumatic accumulator *
8 Venting pipe * Scope of supply of turbocharger
Figure 1: Lube oil diagram, NA29/S turbocharger
Versions Various lube oil supply options are illustrated in the diagram. The required
scope of installation for the specific engine system can be selected in
accordance with the following criteria:
▪ Engines with priming immediately before start-up (standard version).
Feed pipe (2), throttle device (3), drain pipe (6), sight glass/venting box
(7), venting pipe (8), connection for pressure monitoring (9, 10).
▪ Engines with interval priming or continuous priming (e.g. engines with
stand-by starting).
Technical details
Feed pipe (2) with non-return valve (14), throttle device (3), additional
feed pipe (12) with non-return valve (13), drain pipe (6), sight glass/vent-
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ing box (7), venting pipe (8), connection for pressure monitoring (9, 10).
The non-return valve (14) must be installed as close as possible to the
feed pipe (1) and designed in such a way that it is closed during priming
and after the lube oil pumps are switched off. This prevents flooding of
NA29/S
the turbocharger during priming and also prevents the feed pipe (2) from
running dry and collecting air.
C1 6663 2.4.1-02 EN-US 1 (4)

▪ Engines with delayed engine shut-down in the case of falling lube oil
pressure (special version)
Technical details
In addition to the scope of the two options described above, a connec-

tion for the hydropneumatic accumulator (15) is required. Furthermore, in
the case of engines with priming immediately before start-up, a non-
return valve (14) must be installed; this valve must open at the slightest
priming pressure.
Turbine rotor bearings

General The turbocharger rotor is guided in radial direction through 2 floating bearing
bushes (4) arranged between turbine wheel and compressor wheel in the
bearing casing. The locating bearing on the compressor side (5) serves for
axial positioning and for taking the axial thrust.
The turbocharger bearings are supplied with oil from the engine lube oil cir-
cuit through a common feed pipe (2). The lube oil also serves the purpose of
cooling the bearings.
Shaft sealing The oil space is sealed on the turbine and compressor sides by labyrinths fit-
ted on the rotor shaft. The radial labyrinth clearance is dimensioned so that,
during the initial operating phase, the rotating labyrinth tips dig lightly into the
softer layer of the sealing covers. At higher speeds, the rotor is slightly ele-
vated corresponding to the thickness of the lubricating film. The labyrinth tips
then run freely. The rotor is lowered again when the turbocharger stops. The
labyrinth tips are then inserted into the grooves of the sealing covers, as a
result of which a better sealing effect is achieved during priming and post
lubrication. Local running-in grooves in the bore of the sealing covers are
therefore desirable and not a reason for parts to be replaced.
Sealing air system For sealing the shaft on the turbine side, sealing air (compressed air) is addi-
tionally required.
See [2.4.4] “Sealing air system (turbocharger on four-stroke engine).”
See [2.4.5] “Sealing air system (turbocharger on two-stroke engine)”.
Lube oil supply, setting the lube oil pressure

Lube oil pressure The required lube oil pressure is set by means of a throttle device (3), e.g.
orifice or pressure reducing valve, in the feed pipe (2).
For engine lube oil pressures ≥ 2.5 bar, MAN Diesel recommends installation
of a pressure reducing valve with outlet control.
The measuring connections (9 and 10) on top of the bearing casing are to be
used for checking and monitoring the lube oil pressure.
The lube oil pressure is set correctly when the specified lube oil pressure is
indicated at the measuring points during engine operation with the lube oil at
operating temperature.
Permissible lube oil pressures during operation of the turbocharger:
See chapter [2.5.1] “Operating data and alarm points”.
Technical details
On start-up and during heating up of the engine, when the lube oil tempera-
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ture is relatively low: up to 4.0 bar for a short period of time.

Lube oil temperature Permissible inlet temperature into the turbocharger:
Lube oil flow rate The required lube oil flow rate depends on the viscosity of the lube oil and
NA29/S
may vary in accordance with the temperature.

2 (4) C1 6663 2.4.1-02 EN-US

Alarm points/engine shut- See chapter [2.5.1] “Operating data and alarm points”.
Technical details
down
Differences in height
Differences in height between the indicating instrument and the

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

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

The gradient of the pipe must be at least 5° greater than the maximum
possible system inclination.
Venting The oil drain pipe must have a venting facility from a sufficiently large com-
partment permitting the oil to settle down, e.g. a sight glass or venting box
(7).
The cross section of the venting pipe (8) should be approximately that of the
oil drain pipe (6).
Priming and post lubrication of the bearing points

Priming Prior to engine start-up, the bearings of the turbocharger must be primed,
which, depending on the lube oil system of the engine plant, may take the
form of priming immediately before start-up, interval priming or continuous
priming.
Priming immediately before start-up:
10 – 30 minutes with a lube oil pressure of 0.6 – 2.2 bar.
Danger of fire caused by escaping lube oil!

Continuous priming of the turbocharger bearings is only permissible in
conjunction with an external sealing air supply (sealing the lube oil
Technical details
space from the exhaust pipe)!

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NA29/S
C1 6663 2.4.1-02 EN-US 3 (4)

Post lubrication For cooling the plain bearings, the turbocharger has to be lubricated with a
lube oil pressure of at least 0.3 bar after engine shut-down. The engine lube
Technical details
oil pumps or the auxiliary pumps must therefore continue running for
10 — 30 minutes.
Lube oil requirements

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

Delayed engine shut-down In plants with lube oil pressure monitoring (alarm and/or engine shut-down if
the pressure falls below specified limits), the delayed engine shut-down
allows a certain amount of time in which a decision can be made as to
whether the engine should be shut down in order to avoid damage to the
turbocharger and engine or whether a necessary manoeuvre should be exe-
cuted in order to prevent greater damage. The prerequisite for this is an oil
pressure accumulator that briefly takes over lubrication of the turbocharger.
Oil pressure accumulator Installation of a hydropneumatic accumulator (15) with a nominal capacity of
10 litres allows the decision to shut down the engine to be delayed by a
maximum of 10 seconds. A longer delay could jeopardize operational safety
and result in damage to the turbocharger. The hydropneumatic accumulator
(15) is installed in a suitable position no more than 2.0 metres below the
highest point on the feed pipe (2) and connected between the throttle device
(3) and the non-return valve (14). Maximum operating temperature 80 °C.
Technical details
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NA29/S
4 (4) C1 6663 2.4.1-02 EN-US

Sealing air system (turbocharger on four-stroke engine)
Technical details
General
1 Turbocharger * 6 Sealing air valve *

2 Charge air cooler C Compressor *
3 Charge air pipe T Turbine *
4 Sealing air pipe
5 Orifice* * Scope of supply of turbocharger
Figure 1: Sealing air diagram for turbochargers on four-stroke engines
Sealing air In addition to the labyrinth seals of the turbocharger, sealing air is required as
a medium:
▪ to prevent lube oil from seeping into the compressor,
▪ to prevent exhaust gas from entering the oil space,
▪ to prevent lube oil from seeping into the turbine (oil coke),
▪ to reduce axial thrust on the locating bearing.
Sealing air diagram The sealing air is led via the sealing air pipe (4) and sealing air bores in the
bearing casing to the labyrinth seal on the turbine side and compressor side
of the turbine rotor.
The sealing air is to be extracted downstream of the charge air cooler (2).
The extraction point must be protected against penetration of condensation
and dirt. It must therefore be located in the upper area of the charge air pipe
(3). For this reason, the pipe should protrude approx. 100 mm into the
charge air pipe in order to keep out dirt and water blown along the wall.
The sealing air is led to the turbocharger via the sealing air pipe (4) and,
Technical details
depending on the size of the turbocharger, reduced to the required value by

means of a supplied orifice (5) shortly before entering the bearing casing. In
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the case of operation of the turbocharger on the four-stroke engine, this ori-
fice is integrated into a sealing air valve (6) that is designed in such a way that
a vacuum in the charge air pipe closes the sealing air pipe, thereby prevent-
NA29/S
ing a connection between the oil space and the atmosphere. This prevents
lube oil from being sucked out via the labyrinth seal.
C1 6663 2.4.4-01 EN-US 1 (2)

Venting on the compressor The pressurised space behind the compressor wheel is vented via a bore in
the bearing casing to the gas outlet casing, thereby reducing the axial force
Technical details
side
acting on the rear of the compressor wheel.
Technical details
2011-01-13 - de
NA29/S
2 (2) C1 6663 2.4.4-01 EN-US

Sealing air system (turbocharger on two-stroke engine)
Technical details
General
1 Turbocharger * C Compressor *
2 Charge air cooler T Turbine *
3 Charge air pipe
4 Sealing air pipe * Scope of supply of turbocharger
5 Orifice*
Figure 1: Sealing air diagram for turbochargers on two-stroke engines
Sealing air In addition to the labyrinth seals of the turbocharger, sealing air is required as
a medium:
▪ to prevent lube oil from seeping into the compressor,
▪ to prevent exhaust gas from entering the oil space,
▪ to prevent lube oil from seeping into the turbine (oil coke),
▪ to reduce axial thrust on the locating bearing.
Sealing air diagram The sealing air is led via the sealing air pipe (4) and sealing air bores in the
bearing casing to the labyrinth seal on the turbine side and compressor side
of the turbine rotor. The sealing air is to be extracted downstream of the
charge air cooler (2) and, if applicable, downstream of an auxiliary fan. The
extraction point must be protected against penetration of condensation and
dirt. It must therefore be located in the upper area of the charge air pipe (3).
For this reason, the pipe should protrude approx. 100 mm into the charge air
pipe in order to keep out dirt and water blown along the wall. The sealing air
is led to the turbocharger via the sealing air pipe (4) and, depending on the
size of the turbocharger, reduced to the required value by means of a sup-
Technical details
plied orifice (5) shortly before entering the bearing casing.

2011-01-13 - de
Venting on the compressor The pressurised space behind the compressor wheel is vented via a bore in
side the bearing casing to the gas outlet casing, thereby reducing the axial force
acting on the rear of the compressor wheel.
NA29/S
C1 6663 2.4.5-01 EN-US 1 (1)

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

B 2/2 way solenoid valve E Compressor wheel
C Orifice F Turbocharger
Figure 1: Jet Assist diagram
Functional description The Jet Assist acceleration system is used to meet special requirements with
regard to fast and soot-minimised acceleration, and/or the dynamic load
response of the engine.
The engine control actuates the 2/2 way solenoid valve (B).
Compressed air at 30 bar now flows from the starting air cylinder (A) through
the orifice (C), where it is reduced to a maximum of 4 bar. The compressed
air is now blown at max. 4 bar onto the blades of the compressor wheel (E)
via a ring duct and the inclined bores in the insert (D). On the one hand, this
provides additional air to the compressor while on the other hand, the com-
pressor wheel is accelerated, thus increasing the charge air pressure for the
engine.
Technical details
2007-11-05 - de
NR, NA
C1 6685 2.4.7-01 EN-US 1 (1)

Operating data and alarm points
Technical details
Turbocharger Type Plate
1 Turbocharger type 5 Unit of temperature

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

casing or to the air intake casing (if provided).
Operating data
Speed Operating limit nmax see type plate
Speed Indication range of the speed indicator 0 to 40,000 rpm
Exhaust gas temperature upstream of Operating limit tmax see type plate
turbine
Lube oil temperature Inlet temperature 40 - 70 °C
Lube oil temperature Max. outlet temperature See engine
commissioning
report IBN1)
Lube oil temperature Δ inlet temperature/outlet temperature ≤ 40 °C2)
Lube oil pressure3) Normal operation and full engine load 1.3 - 2.2 bar
Lube oil flow rate with SAE 30 at 60 ℃ or SAE 40 at 65 ℃ and 1.5 2.5 - 3.0 m3/h
bar operating pressure
Quantity of heat Quantity of heat dissipated in oil 42 kW
Jet Assist (optional) Pressure in starting air cylinder 30 bar
Max. permissible inlet pressure in turbocharger 4 bar
Technical details
2010-03-19 - de
1) IBN = German abbreviation for commissioning

2) Only in the case of turbocharger retrofits
3) Reference measuring height: turbocharger centreline
NA29/S
Table 1: Operating parameters NA29/S

For further details, see also [2.4.1] “Lube oil system”.
C1 6663 2.5.1-02 EN-US 1 (2)

Technical details
Alarm points/engine shut-down
When the limit values are reached, the alarm must be triggered and the
engine control must react at the same time (without delay) in order to
avoid damage to the turbocharger.
An alarm must be triggered by the engine control system when the following
operating data are exceeded:
Speed Alarm at 97% of nmax nmax see
type plate
Exhaust gas temperature upstream of Alarm at tmax tmax see
turbine type plate
Lube oil temperature Alarm at max. outlet temperature See engine
commissioning
report IBN1)
Lube oil temperature Alarm at Δ inlet temperature/outlet temperature ≥ 40 °C2)
Lube oil pressure3) Alarm at < 1.3 bar
Lube oil pressure3) Reduction to engine half load (slow-down) < 1.0 bar
Lube oil pressure3) Engine shut-down < 0.8 bar
1) IBN = German abbreviation for commissioning
2) Only in the case of turbocharger retrofits
3) Reference measuring height: turbocharger centreline
Table 2: Alarm points
Lube oil requirements

Selection of lube oil SAE class SAE 30 or SAE 40
Lube oil filtration Grade of filtration less than 0.05 mm
Table 3: Lube oil requirements
See also [2.4.1] “Lube oil system”

Technical details
2010-03-19 - de
NA29/S
2 (2) C1 6663 2.5.1-02 EN-US

Weights
Technical details
Weights assigned to subassemblies (approximate values)
500 Turbocharger, complete with silencer max. 925 kg
501 Gas admission casing, complete, axial 60 kg
506 Gas outlet casing, complete 200 kg
509 Gas outlet diffuser, complete 30 kg
513 Turbine nozzle ring 10 kg
517 Bearing casing, complete 305 kg
518 Casing feet, complete 30 kg
520 Rotor, complete (turbine rotor 25 kg, compressor wheel 12 kg) 40 kg
540 Insert, complete 40 kg
542 Diffuser 10 kg
544 Silencer, complete (if provided) 85 kg
545 Intake casing, complete (if provided), axial 10 kg
Intake casing, complete (if provided), 90 ° 85 kg
546 Compressor casing, complete 105 kg
591 Covering, complete 10 kg
Table 1: Weights by subassemblies
Technical details
2007-11-15 - de
NA29/S
C1 6663 2.5.3-01 EN-US 1 (1)

Dimensions
Technical details
Pipe connections
Medium Casing/subassembly Dimensions in mm
Exhaust gas Entry at the gas admission casing (501) ∅ 300
Outlet at the gas outlet casing (506) 250 × 600
Charge air Entry at the air intake casing (545), axial ∅ 450
Entry at the air intake casing (545), radial 225 × 650
Outlet at the compressor casing (546) ∅ 190
Lube oil Inlet at top of bearing casing (517), flange connection for pipe 26.9 × 3.2
Drain at bottom of bearing casing (517), flange connection for pipe 60.3 × 3.6
Venting pipe on oil drain for pipe 60.3 × 3.6
Sealing air Connection at side of bearing casing (517) for pipe 25.0 × 2.0
Jet Assist Connection at side of compressor casing (546), flange connection for 38.0 × 2.5
(if provided) pipe
Table 1: Pipe connection dimensions
Technical details
2007-11-15 - de
NA29/S
C1 6663 2.5.4-01 EN-US 1 (1)

Gaps and clearances
Technical details
Values
Figure 1: Gaps and clearances, measuring points
Item Designations of parts Order No. When new Replace or remachine parts
min. mm max. mm min. mm max. mm
3 Bearing bush (517.161) Radial clearance See Part C2, work card 500.06
Turbine rotor (520.001)
6 a) Turbine rotor (520.001) Radial gap at
Shroud ring (509.008) h = 54 mm 0.65 0.85 (0.55) * 1.15
h = 48 mm 0.60 0.80 (0.50) * 1.10
8 d) Locating bearing (517.075) Axial clearance 0.29 0.32 See work card 500.06
Labyrinth ring (520.035)
10 b) Compressor (520.044) Axial gap 0.35 0.75 0.30 0.85
c) wheel (540.001)
Insert
11 a) Compressor (520.044) Radial gap 0.70 0.80 (0.60) * 1.00
wheel (540.001)
Insert
16 Compressor (520.044) Permissible axial runout 0.06 mm
wheel
Table 1: Gaps and clearances, measuring points
Technical details
a) Using a feeler gauge, measure at 8 points on the circumference and calculate the mean value.
2011-01-13 - de
( ......... ) * = At no point on the circumference may the value fall below the minimum 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 (8) from the calculated mean value with the rotor
pushed in direction (B).
NA29/S
C1 6663 2.5.5-01 EN-US 1 (2)

c) Adjustable by remachining or by shim at balance ring (S).

Technical details
d) Measure with a dial gauge while vigorously moving the rotor in directions (A) and (B). In case of labyrinth
seals already run in, the measured value might be smaller.
Exact measurement of the axial clearance (8)
Figure 2: Exact measurement of the axial clearance (8)

1. Measure and note the distance (K5).
2. Measure and note the width (B) of the locating bearing (517.075).
3. Axial clearance (8): actual value = (K5) - (B). Permissible value, see
Item (8) in table.
Technical details
2011-01-13 - de
NA29/S
2 (2) C1 6663 2.5.5-01 EN-US

MAN Diesel & Turbo
1 Introduction
2 Technical details
3 Operation
5 Work cards
7 Index
2011-01-13 - de
Operation
6663-1 3 C1-01 EN-US 1 (1)

Safety during operation
Operation
Containment Safety
The turbocharger is one of the highest loaded components in modern diesel
engines. The high rotor speeds of a turbocharger result in high centrifugal
force stresses at simultaneous high component temperatures. A conse-
quence of additional extraordinary influences might be - in extremely rare
cases - a failure of the components.
Precautions MAN Diesel & Turbo turbochargers correspond to the required containment
safety according to the rules stipulated by the classification societies so that
the state of the art prevents fragments from escaping.
In extreme cases, particularly if the turbocharger has not been sufficiently or
properly maintained, there may be the risk of damages to persons or prop-
erty in vicinity of the turbocharger.
To eliminate residual risks we kindly ask you to observe following rules:
Risk of injury!
Under no circumstances are persons permitted to be near the
turbocharger without reason during operation.
▪ Turbine and compressor are to be cleaned at regular intervals as speci-

fied in the maintenance schedule.
▪ The maintenance of the turbocharger may only be carried out by trained
personnel as well as in the maintenance intervals as stipulated in the
operating manual.
▪ Inadmissible operating conditions, such as frequent load releases, com-
pressor surging, excessive turbocharger speeds, must be avoided.
▪ Corrosive and erosive media in the intake air are to be avoided.
The technical documentation of the system, particularly the operating and
maintenance manuals for the engine, turbocharger and the accessories
required for engine operation, must be stored at a location where they are
accessible for the operating and maintenance personnel at all times.
Regulations for Prevention of Accidents

When operating the system and for all maintenance and repair work, the rel-
evant Regulations for Prevention of Accidents are to be observed. It is advis-
able to hang these regulations in the engine room and to repeatedly point out
2008-11-14 - de
the dangers of accidents.

Operation
Safety Instructions Concerning Specific Danger Sources

NR, NA
Hearing Protection
C1 6685 3.0-01 EN-US 1 (4)

Sound levels exceeding 85 dB(A)!

Operation
The danger of hearing impairment is given because sound levels are

permanently above this value in the engine room when the engine is
running.
• Always wear hearing protection in the engine room!
Exhaust Gases In the engine room, exhaust gases with the harmful components NOx, SO2,
CO, HC and soot can be set free.
Health risk due to exhaust gases!

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

Fuel and lube oil are combustible and can easily ignite when
contacting hot components in the engine room.
• Do not conduct fuel and oil pipes alongside hot engine components
(exhaust pipe/turbocharger) that are not insulated!
• After maintenance and repair work on exhaust pipes and turbochargers,
carefully and completely reattach all insulations and coverings!
• Regularly check the tightness of all fuel and oil pipes (maintenance
schedule)!
• Eliminate any leakages immediately!
Fire-extinguishing The engine room must be equipped with fire-extinguishing equipment. The
Equipment proper function of this equipment is to be checked regularly.
Danger to life through suffocation!

When carbon dioxide fire-extinguishing systems are put into operation,
danger of life is given due to suffocation.
• Do not put carbon dioxide fire-extinguishing systems into operation
2008-11-14 - de
before it is ensured that no more persons are in the engine room!

Operation
NR, NA
Protective Covers
2 (4) C1 6685 3.0-01 EN-US

Danger of burns and fire hazard from hot system components!
Operation
Due to high operating temperatures the system components can
become very hot. Persons can burn themselves on the hot
components and/or inflammable operating fluids can ignite.
• Always have all coverings and insulations mounted to the turbocharger
during operation of the engine!
• Regularly check the tightness of all fuel and oil pipes!
After assembly work, ensure that all coverings and protective covers from
moving components as well as all insulations from hot components are reat-
tached again. Engine operation with coverings removed is permitted only in
special cases, such as for functional tests.
Alarm System If important operating data are exceeded, an alarm system will set off alarm,
reduction or stop signals, depending on the danger potential. The cause of
the signals is to be thoroughly investigated and the source of the malfunction
to be corrected. The signals may not be ignored or suppressed, except
when ordered by management or in cases of increased danger.
Ignoring or suppressing alarms and putting reduction and stop

signals out of operation can lead to operational malfunctions
which can result in serious personal injury and damage to
property!
Turbocharger and engine are fitted with an alarm system which sounds
an alarm in case of technical problems or malfunctions. Therefore, an
alarm always has a cause which must be rectified!
• Do not ignore or suppress any alarm, reduction or stop signals!
• Investigate the cause of every alarm, reduction or stop signal or report
them!
• As far as possible, provide for swift rectification of the cause of alarms
and signals!
• Ignore or suppress alarms, reduction and stop signals only in cases of
increased danger or when ordered by management!
Personnel/ Qualification of The engine and the systems required for its operation may be started, oper-
Personnel ated and stopped only by authorized persons. The personnel must be edu-
cated, trained and familiar with the system and the occurring dangers.
All persons operating the system or carrying out maintenance or repair work
on the system must have read and understood all accompanying operating
and maintenance instructions.
For ship systems:
2008-11-14 - de
Operational management through the chief engineer on board or through a

technical officer.
Operation
Persons managing the operation must be in possession of a competence

certificate that corresponds with the national regulations and international
NR, NA
agreement (STCW). The number of required persons and their minimum

qualification are usually stipulated through the national regulations or the
international agreement (STCW).
C1 6685 3.0-01 EN-US 3 (4)

For stationary systems (power plants):

Operation
The superintendent (engineer) must be available. Supervision/controlling of

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

In the case of turbochargers on gas-powered engines, insulated
mounting can cause electrostatic charging, resulting in ignition of the
air/gas mixture in the air intake.
• If the turbocharger is mounted on the engine in such a way that it is
electrically insulated, an earth connection must be installed for the
equipotential bonding between the turbocharger and the engine.
2008-11-14 - de
Operation
NR, NA
4 (4) C1 6685 3.0-01 EN-US

Intended use/suitability of the turbocharger
Operation
Intended use
Intended use
The turbocharger delivered is intended (firstly) for operation within the con-
straints stipulated:
▪ Operating data and alarm points [2.5.1]
▪ Scope of supply/technical specification
▪ Order confirmation.
It is additionally (secondly) intended for
▪ operation using the specified operating media,
▪ taking into consideration the design/layout of the supply, measuring,
control and regulating systems as well as specification of the constraints
(e.g. removal space/crane capacities) in accordance with the recommen-
dations of MAN Diesel & Turbo or according to the state of the art.
It is additionally (thirdly) intended for
▪ start, operation and stopping of the engine in accordance with the usual
organisational rules, exclusively by authorised, qualified, trained persons
who are familiar with the plant.
Conditionally intended/suitable for
Conditionally intended/suitable for

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

The turbocharger is not intended/suitable for
▪ operation at operating values resulting in engine shut-down or load
reduction,
▪ operation in case of failure of supply equipment,
▪ operation within barred speed ranges,
▪ operation without appropriate surveillance/supervision,
▪ operation without maintenance or with considerably reduced mainte-
nance,
2007-11-05 - de
▪ unauthorised modifications,
Operation
▪ use of other than original spare parts,

▪ long-term shut-down without taking preservation measures.
NR, NA
C1 6685 3.2.2-02 EN-US 1 (1)

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

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

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

checked for cleanliness, and the oil supply and oil drainage are
plugged. Therefore, when flushing the engine oil system, care must be
taken to prevent inadmissible contamination in the oil from entering the
turbocharger.
For additional information on flushing the lube oil system, please refer
to the engine manufacturer’s manual.
For mounting the turbocharger on the engine, see work card [500.10]
Engine control
Indication of the pending alarm and the reaction of the engine control
2007-11-05 - de
system must occur at the same time. Therefore, the engine control
system must conform at least to category 3 in compliance with
Operation
DIN EN 954-1.
NR, NA
C1 6685 3.4.1-02 EN-US 1 (2)

Operation
Preparations for start

Turbocharger Prior to engine start-up, the bearings of the turbocharger must be primed,
which, depending on the lube oil system of the engine plant, may take the
form of priming immediately before start-up, or interval priming.
See [2.4.1] “Lube oil system”.
Engine/Turbocharger 1. Ensure that the shut-off elements of the systems have been set to the
in-service position.
2. Check the lube oil pressure upstream of the turbocharger.
Starting Operation
Turbocharger Start the engine. The engine exhaust gases drive the turbocharger and thus
start it operating. If provided, the “Jet Assist” acceleration system is put into
operation via the control system.
Shutting down
1. Shut down the engine. The turbocharger gradually comes to a stop.
The run-down time of the turbocharger gives an indication of its

mechanical condition. Sudden stopping indicates mechanical damage
to the bearing, contact of the compressor or turbine wheel, trapped
foreign objects or heavy fouling.
Post lubrication See [2.4.1] “Lube oil system”.

Shutting down/preserving The instructions given for the Diesel engine are also valid for the preservation
the turbocharger and prolonged storage of the turbocharger
(refer to the Diesel engine operating manual).
2007-11-05 - de
Operation
NR, NA
2 (2) C1 6685 3.4.1-02 EN-US

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

obligations. Results, observations and actions in connection with such
monitoring measures are to be recorded in an engine log book.
Reference values are to be defined in order to allow objective
assessment of the results.
Regular checks on the The regular checks should include the following measures:
turbocharger ▪ Turbine speed
▪ Lube oil pressure upstream of turbocharger
▪ Lube oil temperature upstream of turbocharger
▪ Lube oil temperature downstream of turbocharger
▪ Exhaust gas pressure upstream of turbine
▪ Exhaust gas temperature upstream of turbine
▪ Charge air pressure downstream of compressor
▪ Charge air temperature downstream of compressor
▪ Exhaust gas, charge air and oil pipes for tightness
▪ Air filter mat on the silencer for fouling/saturation
▪ Turbocharger for smooth running
Smooth running An early indication of damage to the rotor and bearings is usually given by
irregular running due to imbalance or contact of rotating parts. Listening to
the running noise of the turbocharger often allows unsmooth operation to be
detected at an early stage.
Speed With clean air ducts of the compressor, a certain charge air pressure is
assigned to each speed of the turbocharger. The charge pressure thus gives
an indication of the rotor speed and can be used for approximate speed
monitoring.
2007-11-05 - de
Operation
NR, NA
C1 6685 3.5.1-01 EN-US 1 (1)

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

success.
Fault-finding chart
The following fault-finding chart is intended to assist in reliably identifying
trouble, isolating its cause and taking prompt remedial action.
FAULTS OCCURRING
┌ Exhaust gas temperature upstream of turbine too high
┌ Charge air pressure too low
┌ Charge air pressure too high
┌ Speed too low
┌ Speed too high
┌ Lube oil pressure too low
┌ Lube oil loss
┌ Hesitant starting, short run-down time
┌ Abnormally high noise level
┌ Turbocharger vibrating
┌ Compressor surging
POSSIBLE CAUSES
● ● ● Silencer or air filter fouled
● ● ● ● Compressor fouled
2007-11-05 - de
● ● ● ● ● ● Turbine wheel heavily fouled

● ● Nozzle ring lightly fouled/constricted
Operation
● ● ● ● ● Turbine nozzle ring heavily fouled/constricted

NR, NA
● ● ● ● Thrust ring, labyrinth ring or locating ring damaged

● Labyrinth seals defective
C1 6685 3.6.1-02 EN-US 1 (2)

FAULTS OCCURRING
Operation
┌ Exhaust gas temperature upstream of turbine too high

┌ Charge air pressure too low
┌ Charge air pressure too high
┌ Speed too low
┌ Speed too high
┌ Lube oil pressure too low
┌ Lube oil loss
┌ Hesitant starting, short run-down time
┌ Abnormally high noise level
┌ Turbocharger vibrating
┌ Compressor surging
POSSIBLE CAUSES
● Seals damaged, connections leaking
● ● ● ● ● Defective bearings, imbalance of the rotor
● ● ● ● ● ● Rotor rubbing
● ● ● ● ● ● ● Foreign bodies before or in turbine
● ● ● ● ● ● ● Foreign bodies before or in compressor
● ● ● ● ● ● Turbine or compressor wheel damaged
● ● Sealing air ineffective, oil coke downstream of turbine wheel
● ● ● Substantial erosion on turbine wheel/shroud ring, nozzle ring
● ● ● High air intake temperature
● ● ● Low air intake temperature
● ● ● ● Charge air cooler fouled
● ● ● Charge air pipe leaking
● ● Charge air temperature too high
● Lube oil inlet temperature too high
● Lube oil pressure too high
● Lube oil filter fouled
● Lube oil pressure gauge defective
● Excessive pressure in oil discharge or crankcase
● ● ● ● Inlet, exhaust valves/slots of engine fouled
● ● ● Exhaust gas pipe leaking
● ● ● ● Exhaust gas back-pressure downstream of turbine too high
● ● ● ● Fuel injection on engine faulty
2007-11-05 - de
Table 1: Fault-finding chart

Operation
NR, NA
2 (2) C1 6685 3.6.1-02 EN-US

Emergency operation in the event of turbocharger failure
Operation
Preliminary remarks
Turbochargers are highly stressed turbo-machines which must reliably
ensure the complete gas renewal of an engine at very high speeds and rela-
tively high temperatures and pressures. Like the engine, the turbocharger
can also suffer disturbances, despite careful system operation, and in most
cases emergency operation is also possible if the damage cannot be
repaired immediately.
Available devices The following devices are availabe for emergency operation of the engine
while the turbochargers are defective:
NR turbochargers: refer to work card 500.05 in Part C2
▪ Closing cover to close the turbine rear side with the rotor and bearing
casing removed (cartridge).
NA turbochargers: refer to work card 500.05 in Part C2
▪ Arresting key to block the rotor from the compressor side (intake cross
section remains open)
key also available for NR 34/S.
▪ End cover to close the compressor and turbine rear side with the rotor
removed.
All these devices are designed in such a manner that continuous flow
through the air and exhaust gas sides of the turbocharger is possible.
Devices for use on the engine:
▪ Screen (protection grid) for the end of the charge air pipe facing away
from the turbocharger (remove the charge air bypass pipe beforehand if
necessary). This screen is designed to facilitate natural aspiration of the
engine.
▪ Blind flange for the exhaust gas pipe at the end facing away from the tur-
bocharger (if there is a charge air bypass pipe). The blind flange serves to
close the exhaust gas pipe during natural aspiration with the bypass pipe
removed.
▪ In the case of V-type engines, depending on the layout of the charge air
and exhaust gas pipes on the engine, blind flanges for the charge air
socket and exhaust gas socket (charge air side: downstream of the com-
pressor, exhaust gas side: upstream of the turbine). These blind flanges
serve to prevent wrong switching/backflow/leakage in emergency opera-
tion.
2009-11-11 - de
Operation
NR, NA
C1 6685 3.6.3-02 EN-US 1 (3)

Operation
Emergency operation on failure of a turbocharger
Despite compliance of the following measures, the danger of

turbocharger destruction is still given!
For this case, there is imminent danger of personal injury or damage to
property!
• Limit the duration of emergency operation to the absolute necessary
minimum!
• Use the securing fixture (measure A) for emergency operation only when
removal of the rotating element is not possible!
• Do not unnecessarily stay in the vicinity of the turbocharger during
emergency operation!
Emergency operation after The following possibilities exist if the rotor of the turbocharger can no longer
failure of one or both rotate freely, or must be prevented from rotating. Please refer to Table 1.
turbochargers
Emergency measures Code number
Engine may not be stopped for urgent reasons
Turbocharger remains unchanged 0—3
Engine may be stopped (short-term)
NR turbocharger
▪ Dismantle the rotor and bearing casing (cartridge), mount the closing 0—7
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 gas side.
These measures are possible in the event of failure of
1 turbocharger: in-line engine, V-type engine
2 turbochargers: V-type engine
NA turbocharger
▪ Measure A 0 — 4, 7
Block the rotor from the compressor side using the arresting key (intake (5 — 7 according to the sit-
cross section remains open). Afterwards, mount the silencer or air intake uation, as required)
casing again.
➤ work card 500.05.
Carry out measure A only if measure B cannot be performed for reasons
of time. Consequential damage possible.
▪ Measure B
Dismantle the rotor with bearings, close the bearing casing by mounting
end covers on the compressor and turbine sides. Remount the silencer/
intake casing and, if applicable, the gas admission casing. 0—7
2009-11-11 - de
These measures are possible in the event of failure of

1 turbocharger: in-line engine, V-type engine
Operation
2 turbochargers: V-type engine

Table 1: Emergency operation after failure of a turbocharger
NR, NA
2 (3) C1 6685 3.6.3-02 EN-US

Carry out measure A (see Table “Emergency operation in the event of
Operation
turbocharger failure”) only when measure B cannot be performed for
reasons of time. Consequential damage possible.
Explanations
Code number Supplementary measures/precautions
0 Observe engine manufacturer’s instructions!
1 Reduce engine power. The maximum exhaust gas temperatures downstream of the cylinders and
upstream of the turbocharger and (on engines equipped with 2 turbochargers) the maximum permis-
sible turbocharger speed must not be exceeded. Pay attention to density of exhaust gas.
2 Take all action that appears appropriate to reduce consequential damage.
3 With the rotor arrested or dismantled, cut off the lube oil supply to avoid fouling and fire hazards.
4 The engine has to be operated in the naturally aspirated mode, or (if equipped with 2 turbochargers)
with reduced turbocharging.
5 In-line engines:
Screens (protection grids) have to be mounted on the charge air pipe. On engines equipped with a
charge air bypass, it is also necessary to mount the blind flange at the connection on the exhaust
gas side.
6 V-type engines:
On V-type engines having a common charge air pipe, a blind flange is to be mounted on the com-
pressor outlet of the defective turbocharger so as to avoid air losses.
7 V-type engines:
Separate the exhaust gas inlet side of the defective turbocharger from the gas flow of the second
turbocharger by fitting a blind flange.
Attainable output/speed
The following rating data apply only as reference values:
Failure of 1 turbocharger In-line engine V-type engine
Fixed-pitch propeller 15% up to 50%
of the rated output at the of the rated output at the
corresponding speed corresponding speed
Controllable-pitch pro- 20% up to 50%
peller/ of the rated output at the of the rated output at the
generator service rated speed rated speed
Table 2: Attainable output/speed
2009-11-11 - de
Operation
NR, NA
C1 6685 3.6.3-02 EN-US 3 (3)

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

signals out of operation can lead to operational malfunctions
which can result in serious personal injury and damage to
property!
Turbocharger and engine are fitted with an alarm system which sounds
an alarm in case of technical problems or malfunctions. Therefore, an
alarm always has a cause which must be rectified!
• Do not ignore or suppress any alarm, reduction or stop signals!
• Investigate the cause of every alarm, reduction or stop signal or report
them!
• As far as possible, provide for swift rectification of the cause of alarms
and signals!
• Ignore or suppress alarms, reduction and stop signals only in cases of
increased danger or when ordered by management!
2007-11-05 - de
Liability claims for damages due to nominal values being exceeded or alarm
Operation
and safety signals being suppressed or ignored will on no account be

NR, NA
accepted.
C1 6685 3.6.7-02 EN-US 1 (1)

MAN Diesel & Turbo
1 Introduction
2 Technical details
3 Operation
5 Work cards
7 Index
Maintenance/repair
2011-01-13 - de
6663-1 4 C1-01 EN-US 1 (1)

Safety during maintenance/repair
Maintenance/repair
Qualification of Personnel
Performed by machinists or mechanical fitters and their assistants.
Briefing and supervision of difficult work tasks through a technical officer or
the chief engineer.
Opening pipes/pressure tanks
Danger of burns from hot components!

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

The lube oil is under pressure and very hot!
• Before opening pipes, flanges, screwed connections or gauges, free the
system of pressure and check that it is pressure-free!
• Before opening oil pipes, wait until the lube oil has cooled down
sufficiently (1-2 h)!
• Drain the system and check that the lube oil has been drained
completely!
Disassembly and Assembly of Pipes

During any work on the pipe systems, especially for fuel, lubrication oil and
air, ensure utmost cleanness in order to avoid foreign objects or debris from
entering the system. Therefore, all pipes subject to reassembly should be
blocked with care upon disassembly.
New pipes being installed should be checked for cleanness and flushed, if
required.
For extended storage, all individual parts are to be preserved.
Maintenance/repair
2008-09-01 - de
General
C1 6685 4.0-01 EN-US 1 (3)

Maintenance/repair
Removal/Disassembly of Heavy Components
Danger of injury from suspended loads!

Unsuitable or poorly maintained transport equipment as well as
unsuitable set-down locations can lead to serious injury of people and
to major damage.
• Use only transport equipment which is in perfect condition!
• Check if the transport equipment being used has the required carrying
capacity!
• Choose only set-down locations that have sufficient loading capacity for
the heavy component (this is not always the case for galleries, half-
landings or grid-iron coverings)!
Danger of Crush Injuries from Rotating Components
Danger of crush injuries or from blows!

When the engine is running during disassembly or assembly work,
there is danger of becoming entangled in or coming against rotating
components.
• Carry out all disassembly or assembly work while the turbocharger is
shut down!
• During the work, secure the engine against starting!
• Set up danger signs!
Use of Cleaning Agents

When using cleaning agents, the manufacturer’s notes for usage, possible
dangers and disposal are to be observed.
Cleaning agents can be caustic!

Cleaning agents on the skin, in the eyes or being inhaled can lead to
serious damage to one’s health or to allergies.
• Always observe the manufacturer’s notes for cleaning agents!
• Wear protective clothing whenever required!
Maintenance/repair
• Wear protective gloves whenever required!

• Wear safety goggles whenever required!
2008-09-01 - de
• Wear respiratory protection whenever required!

• Pay attention that other persons also wear the appropriate protective
equipment whenever required or make these persons aware thereof!
General
2 (3) C1 6685 4.0-01 EN-US

Maintenance/repair
Use of High-pressure Cleaners
When working with high-pressure cleaners ensure proper usage.
Air filters, shaft ends (also including such with lipped sealing rings), gover-
nors, splash-proof monitoring systems, cable sockets as well as sound and
heat insulations under non-watertight coverings, must be covered or exempt
from the high-pressure cleaning.
Spare Parts
During operation, the components of the turbocharger are subjected to very
high forces. MAN Diesel has therefore developed special materials that can
withstand these high forces. Only by using MAN Diesel original spare parts
can you be sure that these high-quality materials have been employed.
Spare parts from other manufacturers may be manufactured

using inferior materials that cannot withstand the loads they
are subjected to during operation of the turbocharger!
This can result in severe damage to the turbocharger, engine room and
engine, and danger to life for the operating personnel.
• Use only original spare parts from MAN Diesel & Turbo!
• Only use spare parts from other manufacturers if they have been
approved by MAN Diesel!
MAN Diesel shall in no way be liable for any personal injury or material dam-
age caused by use of spare parts from other manufacturers. Furthermore,
any and all warranty claims relating to the turbocharger expire when using
non-original spare parts.
Maintenance/repair
2008-09-01 - de
General
C1 6685 4.0-01 EN-US 3 (3)

General remarks
Maintenance/repair
Maintenance Work
Maintenance work belongs to the duties of the user, just as regular checks
do. Their purpose is to retain operational readiness and operational safety of
the system. They are to be carried out by competent personnel in accord-
ance with the time schedule for maintenance.
Maintenance work supports the operating personnel in their effort to detect
arising malfunctions/failures in time. They deliver hints towards necessary
maintenance work or repairs to the persons responsible, and influence the
planning of downtimes.
Maintenance and repair work can be carried out properly only when the
required spare parts are available. In addition to these spare parts, it is advis-
able to stock a certain quantity of spares for unexpected outages.
Maintenance Schedule
The jobs to be done are shown in:
➤ 4.7.3 “Maintenance schedule (turbocharger on four-stroke engine)”
➤ 4.7.3 “Maintenance schedule (turbocharger on two-stroke engine)”
The schedule contains
▪ a brief description of the work,
▪ the repetition intervals,
▪ the personnel and time requirements,
▪ references to the respective work cards/working instructions.
Work cards
The work cards describe
▪ the aim and object of the work
and contain information about
▪ the required tools/appliances and
▪ detailed descriptions and graphical depictions of the necessary work
sequences and work steps.
Spare Parts
Order numbers for spare parts can be found
▪ Turbocharger: in the spare parts catalogue of the technical documenta-
tion
▪ Tools: list of contents for tools
▪ On the respective work cards of the technical documentation.
Maintenance/repair
Order numbers consist of the three-digit subassembly number and a three-

digit item number, separated by a dot.
2010-10-04 - de
Special Services/Repair Work

As a turbocharger manufacturer, we offer the following services:
NR, NA
▪ Delivery of spare parts
C1 6685 4.1-03 EN-US 1 (2)

▪ Consultation and support on questions concerning operation, mainte-

nance and repairs
Maintenance/repair
▪ Practice-oriented training for operating personnel

▪ Assessment and clarification of damage cases
▪ Assignment of fitters and engineers
Addresses and contact persons can be found in Chapter [1.4]

Maintenance/repair
2010-10-04 - de
NR, NA
2 (2) C1 6685 4.1-03 EN-US

Maintenance schedule (explanations)
Maintenance/repair
Reliability and adaptability
Validity of the maintenance The maintenance schedule contains a summary of the maintenance and
schedule inspection work, up to major overhaul of the turbocharger.
A major overhaul of the turbocharger must be carried out at the latest after
▪ 12,000 — 18,000 operating hours for NR turbochargers,
▪ 12,000 — 18,000 operating hours for NA turbochargers (four-stroke
engine),
▪ 24,000 — 30,000 operating hours for NA turbochargers (two-stroke
engine).
After each major overhaul, which is best carried out when an engine service
falls due, the maintenance schedule starts from the beginning again.
A major overhaul includes the disassembly of the complete turbocharger for
inspection of the actual condition, thorough cleaning and a check of all parts/
components.
The maintenance must be scheduled well in advance, meaning that, for

example, sailing timetables or power plant inspections must be taken
into account. In order to ensure the operational safety of the
turbocharger and the engine, maintenance work is to be performed as
far as possible on schedule or beforehand.
Adaptation of the The maintenance schedule is based on the following operating conditions
maintenance schedule and an annual operating period of approx. 6000 h:
▪ uniform loading within a range of 60 to 90% of the rated power,
▪ compliance with the specified limits for temperatures and pressures of
the operating media,
▪ use of the specified lube oil and fuel qualities,
▪ reliable separation of fuel and lube oil.
The maintenance intervals must be shortened when the following operating
conditions are given:
▪ prolonged operation at peak loads or low loads, long idle periods, sub-
stantial and frequent load changes,
▪ frequent engine starts and repeated warming-up phases without ade-
quate preheating,
▪ high loading of the engine before the specified operating media tempera-
tures are reached,
Maintenance/repair
▪ lube oil, cooling water and charge air temperatures that are too low,
▪ use of inappropriate fuel qualities and insufficient separation,
2007-11-05 - de
▪ inadequate filtration of the intake air (particularly with stationary engines).

NR, NA
C1 6685 4.2-02 EN-US 1 (1)

Tools/special tools
Maintenance/repair
Inventory Tools
Commercially available tools that are usually included in the inventory of the
engine system.
Inventory tools are not contained in the turbocharger’s scope of supply.
Standard Tools
Included as standard in the turbocharger’s scope of supply.
Normally, one set of standard tools is sufficient for a system with several tur-
bochargers. The usual maintenance work can be carried out with these
standard tools and the inventory tools.
The standard tool kit for the turbocharger(s) is combined in one or more
boxes and supplied with a table of contents. The order numbers of the indi-
vidual tools can also be taken from the table of contents.
Tools Requested by the Customer

Additional tools and appliances can be ordered at the MAN Diesel & Turbo
SE, as required.
Special Tools
Available only at the Service Centers; these tools are not required by the user
of the turbocharger.
Some jobs, -more repair work than maintenance-, require special knowl-
edge, experience and auxiliary equipment/appliances. For jobs like this, addi-
tional specialty tools are available to our Service Centers and possibly to
some authorized repair shops. Therefore, we recommend that you always
consult these Partners or commission work to them when your own time
schedule, or the professional or personnel capacities are not sufficient.
Maintenance/repair
2007-11-05 - de
NR, NA
C1 6685 4.3-02 EN-US 1 (1)

Spare parts
Maintenance/repair
General remark
Maintenance and repair work can be carried out properly only if the
required spare parts are available.
The information given below is intended to assist you in quickly and reliably
finding the correct information source for identifying and ordering spare parts
as required.
Spare parts for turbocharger

Spare parts for the turbocharger can be identified by means of the spare
parts catalogue contained in Part 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, 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 Part 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, separated by a dot.
The order numbers, however, can also be looked up in the respective work
cards contained in Part C2.
Maintenance/repair
2007-11-05 - de
NR, NA
C1 6685 4.4-02 EN-US 1 (1)

Maintenance schedule (signs/symbols)
Maintenance/repair
Explanation of signs and symbols
The header of the maintenance schedule contains signs and symbols. They
have the following meaning:
Serial number of the maintenance work. The series of numbers contains gaps for changes/
1, 2, 3 updates which might become necessary.
Brief description of the maintenance job
Relevant work cards.

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

Signs used in the columns of intervals.
Their meaning is repeated on each sheet.
X, 1, 2 We assume, on the other hand, that the signs and symbols used in the header are suffi-
ciently pictorial and that it is not necessary to repeat them constantly.
Table 1: Explanation of signs and symbols of the maintenance schedule
Maintenance/repair
2007-11-05 - de
NR, NA
C1 6685 4.7-02 EN-US 1 (1)

Maintenance schedule (turbocharger)
Maintenance/repair
Maintenance schedule (turbocharger)
1, per
2,
12000
3000
6000
3
150
250
24
Inspection (during operation)
901 Check turbocharger for unusual noise and vibrations. A 1 0.10 Turbo X
903 Check turbocharger and system pipes for leaks (sealing A 1 0.20 Turbo X
air, charge air, exhaust gas, lube oil)
905 Check all the fixing screws, casing screws and pipe 500.10 1 1 Turbo 2 X
connections for tight fit
Maintenance (during operation)
911 Clean turbine - Dry cleaning, if provided 500.07 1 0.30 Turbo 1
913 Clean turbine - Wet cleaning, if provided 500.07 1 0.60 Turbo 1
915 Clean compressor (during operation) 500.08 1 0.30 Turbo 1
917 Clean air filter (if provided) 500.11 1 0.40 Turbo 1
Maintenance (together with engine maintenance)
921 Clean sealing air pipe (sealing air pipe upstream of A 1 1 Turbo X
bearing casing)
931 Clean and check compressor casing, insert, diffuser 500.10 2 4 Turbo X
and compressor wheel (visual inspection). Establish 500.14
operational readiness of the turbocharger again.
951 Major overhaul 12,000 ... 18,000 operating hours: 000.31 2 20 Turbo X
Dismantle, clean and check all components of the 500.06
turbocharger. Check gaps and clearances on 500.10
reassembly. 500.16
500.24
500.27
Legend for maintenance schedule

24 ... 12000 Repetition intervals in operating hours
X Maintenance work due
1 As required/depending on condition
2 Check new or overhauled parts once after the time specified
Maintenance/repair
2010-05-07 - de
NA29/S
C1 6663 4.7.3-01 EN-US 1 (1)

Remarks on maintenance work
Maintenance/repair
General remark
Disassembling the The simplest method to use for disassembly is best chosen on the basis of
turbocharger the space available in the engine room. When carrying out maintenance and
inspection work, in most cases it is sufficient to dismount only subassemblies
of the turbocharger.
Inspection report For a major overhaul of the turbocharger or for repair work concerning major
components, it is recommended to record the condition of individual subas-
semblies and to include this information in the operating log.
A form for the inspection report is included in this documentation as a sam-
ple:
➤ 4.8.7 for NR turbochargers
➤ 4.8.8 for NA turbochargers
In disassembly work, mark the position of the components relative to

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

excessive force.
This can lead to screws being sheared off or parts being so badly
damaged that they must be replaced. Sheared-off screws must be
drilled out and the threads retapped.
Loosening seized or tight Apply Diesel fuel or special solvent (e.g. Caramba, Omnigliss, WD 40) liberally
screw connections to the screw connections and allow to penetrate for at least ½ hour so that
Maintenance/repair
the solvent can work its way through the thread. Observe the instructions for
use supplied by the solvent manufacturer. Then apply light hammer blows to
the screw head until the screw turns freely in the thread.
2010-10-04 - de
Tightening screw All screw connections on the turbocharger must be in satisfactory condition
connections for assembly or be renewed.
NR, NA
C1 6685 4.8-02 EN-US 1 (2)

Always tighten screws/bolts with the specified tightening

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

When assembling the lock washer pairs (one pair consisting of 2 identical
washers), make sure that the long wedge surfaces (B) contact each other (on
the inside), otherwise the locking effect will be lost.
Incorrectly tightened and locked screws/bolts and nuts can become loose
due to vibrations and then be driven into the turbocharger by the air or
exhaust gas flow, thereby causing severe damage.
Screw connections on the Due to the high temperatures on the turbine side, screws/bolts, nuts and tab
turbine side washers made of non-scaling materials are used. These are marked on the
face side (SB, SD, SM, VM or 4923, Z1 or 4828) to avoid them from being
mistaken for regular parts. When disassembling, the fasteners marked in this
manner are to be stored separately until being assembled.
All lock washer pairs on the turbocharger are made of non-scaling material
and are not marked.
In order to avoid the screws/bolts and nuts on the turbine side from fusing
together through overheating, they must be treated with high-temperature
lubricant (e.g. Molykote HSC) prior to each new assembly. Before treating
with lubricant, the threads must be cleaned thoroughly.
Screw-in threads of studs are not treated.
Maintenance/repair
2010-10-04 - de
NR, NA
2 (2) C1 6685 4.8-02 EN-US

Cleaning
Maintenance/repair
Air filter
Air filter mat The air intake opening of the silencer is covered by an 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 clean-
ing or replacement of the air filter mats 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 has been exhausted and dirt is begin-
ning to emerge from the filter. Taking the pressure differential as an indicator
is not reliable because it depends on the rate of air flow prevailing and thus
on the service point and the position in the operating map.
Cleaning intervals For recommended cleaning intervals, please refer to the maintenance sched-
ule [4.7.3] “Turbocharger” and work card 500.11 “Cleaning air filter”.
Compressor
Cleaning by injecting water Due to the reduced dimensions in the case of turbocharger sizes smaller
during operation than NA48, dirt deposits on the compressor wheel and diffuser blades can
lead to a measurable decrease in efficiency.
We therefore recommend a compressor washing device, especially in cases
of heavily fouled intake air. Fresh water 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 at operating temperature and
under full load.
Cleaning intervals For recommended cleaning intervals, please refer to the maintenance sched-
ule [4.7.3] “Turbocharger” and work card 500.08 “Cleaning the compressor”.
Versions available A portable water container with accumulator which is to be connected to the
cleaning opening on the compressor casing, silencer or air intake casing.
Alternatively, a water tank can be permanently installed at an easily accessi-
ble point. The tank is to be located not less than 600 mm lower than the
point of injection to avoid the water being 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, air diffuser and compres-
sor volute can be removed by means of a steam jet during maintenance
work. A further possibility is to soak the dirt deposits in Diesel fuel or other
liquid cleansers and then to brush them off.
Cleaning agents containing chlorine are liable to attack the aluminium alloy
(of the compressor wheel) and must therefore not be used.
Maintenance/repair
Under no circumstances may cleaning agent or loosened dirt

enter the lube oil system.
2007-11-15 - de
The use of high-pressure cleaners is not permitted.

NA29/S
C1 6663 4.8.1-01 EN-US 1 (2)

Maintenance/repair
Turbine
Cleaning during operation Depending on the fuel oil grade and the engine operating mode, residues
from combustion may accumulate on the vanes/blades of the nozzle ring and
turbine. The progressive build-up of dirt deposits and the resultant consider-
able deterioration of operating performance may lead to compressor surging
or to excessive and 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.
Charge air pressure drops as fouling increases. This causes the exhaust gas
temperature to rise.
For recommended cleaning intervals, please refer to the maintenance sched-
ule [4.7.3] and work card 500.07 “Cleaning the turbine”. 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. 0 — 15% output for this pur-
pose to avoid overloading of the turbine blades (thermal shock). The medium
used for cleaning is fresh water introduced without any chemical additives
upstream of the turbine.
Dry cleaning Granulates of nut shells or activated charcoal (soft) with a grain size of
1 to 1.5 mm are introduced upstream of the turbine, under normal engine
service load and using compressed air from the on-board system. The
engine loading need not be reduced for this purpose.
The cleaning device is designed to introduce the necessary amount of granu-
late over a period of 20 to 30 seconds rather than all at once. This will pre-
vent a sudden speed drop and surging of the compressor, especially where
several turbochargers are operated in parallel.
The required granulate can be ordered from:
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 must be repeated several times. Soaking can
be done in an appropriate vessel over several hours.
It must under all circumstances be ensured that water and

loosened dirt do not enter the lube oil system.
Maintenance/repair
2007-11-15 - de
NA29/S
2 (2) C1 6663 4.8.1-01 EN-US

Checking the individual components
Maintenance/repair
General Remarks
The following remarks and questions are intended as a guide, e. g. for
▪ Assessment of the turbocharger condition,
▪ Operating log and inspection report,
▪ Inspection, reusing, repair and replacement of individual components.
Inspection work
Gaps and clearances Permissible values ➤ 2.5.5 “Gaps and clearances”.
Crack detection test Crack detection test on the turbine blades of the turbine rotor and compres-
sor wheel by means of acoustic testing or the fluorescent dye penetration
method.
Streaks over the entire Turbine rotor, compressor wheel or inserts:
circumference ▪ Check the bearings
➤ work card 500.06
▪ Check gaps and clearances
➤ [2.5.5] “Gaps and clearances”
Streaks on parts of Turbine rotor, compressor wheel or inserts:
circumference ▪ Sign of imbalance
Oil coke downstream of ▪ Sealing air bore in the bearing casing clogged
turbine wheel ▪ Shaft seal on turbine side damaged
▪ Priming pressure too high
Erosion in HFO operation Where heavy fuel oil is used, the exhaust gas contains small hard particles
(e.g. “cat fines”) which have an erosive effect especially at the outlet of the
turbine nozzle ring, where gas velocities and concentrations of these parti-
cles are high. Here, the flow is also very strongly deflected in circumferential
direction. Moreover, these particles are flung outwards due to the centrifugal
effect. The flow is also very strongly deflected in circumferential direction.
Moreover, the particles in the exhaust gas are flung outwards due to the cen-
trifugal effect. Erosion can thus be observed at the outlet of the nozzle ring,
on the inner diameter of the shroud ring and on the outer area of the turbine
blades.
“Cat fines” Where do these erosive solid particles come from?
As a result of the refinery process, “cat fines”, a fine-grained powder of great
hardness (recognizable by the Al and Si content) as well as other abrasive
contaminants are contained in the heavy fuel oil, depending on its quality.
Their amount can be reduced by means of amply dimensioned, heated set-
tling tanks and by adequate separation.
Maintenance/repair
Admixtures Particularly disadvantageous is the admixture of used engine lube oil, charac-
terized by increased concentrations of Ca and Fe. Used engine lube oil con-
2007-11-05 - de
tains not only wear residues, but above all “detergent/dispersant additives”,
which bind fine particles and prevent “cat fines” and other impurities from
being extracted through separation. Far more severe erosion damage results
from blending the fuel with “used oil”.
Combustion residue caused by incomplete combustion can also have ero-
NA
sive effects. Clean combustion must therefore be ensured.
C1 6685 4.8.5-01 EN-US 1 (3)

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

Maintenance/repair
▪ What is the condition of the felt linings?

▪ Are there cracks on any of the components?
Inserts ▪ Are any streaks evident?
Electronic speed measuring Was the speed transmitter or the speed indicator defective?
device
Casings ▪ Which casings are heavily fouled by soot, oil or oil coke?
▪ Were the casings tight, particularly at the joints and connecting flanges?
▪ Do the casings show signs of cracks?
▪ Had bolts broken off?
▪ Were all bolts and nuts firmly tightened and locked?
▪ Were the sealing air or oil bores in the bearing casing clogged?
▪ Are the seals in order?
Compressor wheel ▪ Do the turbine blades show signs of cracks or heavy wear?
▪ Do the leading edges of the turbine blades show impact notches caused
by drawn-in foreign objects?
▪ Are any streaks evident?
▪ What is the condition of the seat of the compressor wheel?
▪ Is the seating surface bright, or does it show fretting corrosion?
Turbine rotor ▪ Is the damping wire (if present) in good condition?
▪ Is the shaft running true?
▪ What is the condition of the bearings?
▪ Are the labyrinth tips severely worn?
▪ Are the seat faces bright or are there signs of fretting corrosion?
▪ Are blades damaged or is heavy wear or erosion evident at the edges?
Do the blades show signs of cracks?
▪ Are there any streaks to be found on the blades, wheel or shaft?
▪ Are the locating elements at the base of the blades used in order?
In new condition, the blades are not fastened but inserted into the disc
with clearance. At the blade end, they can be moved several millimeters
both in axial and in radial direction. Due to deposits, this movability is
limited after extended periods of operation.
Shroud ring ▪ Are there streaks from the turbine blades?

The radial gap between the shroud ring and the turbine blade must not fall
below the minimum value at any point; this is to prevent contact during oper-
ation. Erosion can cause the gap to become larger. This has a considerable
Maintenance/repair
effect on efficiency. For this reason, during checking, the gap is measured at
8 points around the circumference (every 45°) and the mean value is calcu-
2007-11-05 - de
lated.
Permissible values ➤ [2.5.5] “Gaps and clearances”
Turbine nozzle ring ▪ Are any blades bent?
▪ Are the blades heavily worn due to erosion?
▪ Have foreign objects become jammed in the ducts?
NA
▪ Are there traces indicating the presence of foreign objects?
2 (3) C1 6685 4.8.5-01 EN-US

▪ Are any cracks evident on the blades?
Maintenance/repair
Thrust ring, locating ring ▪ Are the seat faces bright or are there signs of fretting corrosion?
▪ Are there any signs of scoring or heavy wear?
Bearings ▪ Check the locating bearing and the plain bearing
▪ Diagonal wear on both bearings suggests rotor imbalance.
▪ What is the condition of the seat of the bearing in the casing bore?
▪ Are the axial clearance of the rotor and the bearing clearance within the
permissible range?
When the axial bearing clearance is determined by axial displacement

of the rotating element, then the rotating element is to be lifted lightly
so that the labyrinth tips come free, out of the grooves in the cover
seal.
Labyrinth disk, end cover Is the run-in pattern of the labyrinth tips normal?
Maintenance/repair
2007-11-05 - de
NA
C1 6685 4.8.5-01 EN-US 3 (3)

Inspection report
Maintenance/repair
Inspection report form
Maintenance/repair
2007-11-05 - de
C1 6685 4.8.8-01 EN-US 1 (2)

Maintenance/repair Maintenance/repair
2 (2)
4.8.8
C1 6685 4.8.8-01 EN-US

MAN Diesel & Turbo
2007-11-05 - de
MAN Diesel & Turbo
1 Introduction
2 Technical details
3 Operation
5 Work cards
7 Index
2011-01-13 - de
Work cards
6663-1 5 C1-01 EN-US 1 (1)

Introduction
5.1 Introduction
5.2 Work cards
2011-01-13 - de
Work cards
6663-1 5.1-01 EN-US 1 (1)

Preface
Introduction
General remarks
Work cards and maintenance The work cards are closely related to the maintenance schedule of the turbo-
schedule charger.
While the maintenance schedule only briefly specifies the maintenance work
to be done, the work cards give a step-by-step description, with illustrations,
of the procedures required to maintain the operational reliability and effi-
ciency of the turbocharger. The work cards include, among other things,
information about the required tools and appliances. For most of the jobs,
further associated work cards have to be consulted.
Work cards serve the particular purpose of providing essential information in
concise form.
See chapter [4.7.3] – Maintenance schedule
Chapter 5.2 – Work cards
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Work cards
NR, NA
C2 6686 5.1.1-01 EN-US 1 (1)

Organisation and use of the work cards
Introduction
Numbering
The ordinal number of the work cards is located at the top right of the title. It
consists of a three-digit subassembly number and a two-digit counting num-
ber. The subassembly number 500 represents the collective subassembly
number for turbochargers.
Example - Turbocharger on engine: 500.10
▪ 500 = Subassembly number (500 for turbocharger)
▪ 10 = Counting number (work card No. 10)
Cross-references in work cards to related work cards are enclosed in square
brackets.
Example - Cross-reference in work card 500.10: [500.12]
In work card 500.10 (Removing and refitting turbocharger or subassemblies),
there is a reference to work card 500.12 (Removing and refitting silencer).
Layout of the Work Cards

Work cards generally contain the following information:
▪ Required personnel and time,
▪ Affiliated work cards, meaning work cards that contain additional neces-
sary or other useful information,
▪ The required tools and appliances,
▪ Possibly additional information/technical data and,
▪ The individual work sequences, always beginning with the starting condi-
tion, and followed by the individual work steps.
Parts and tools in the figures and text are each designated with their order
number.
Example for the turbine rotor: 520.001
▪ 520 = Subassembly group number (520 für „Rotor, complete“)
▪ 001 = Position number
All assemblies and subassembly group numbers are listed in the spare parts
catalog.
Order numbers for tools are (generally) identical with the tool number affixed
on the tool.
Required Personnel and Time

The required time is mentioned in hours, both for the amount and qualifica-
tion of the required personnel. The higher hour rate covers the time require-
ment for the complete scope of the respective work card. Personnel with
lower hour rate is required only at times, e. g., for operation of a lifting tackle.
2010-04-15 - de
Tools / Appliances
Work cards
The numbers in the Designation column refer to width across flats, given in
mm, e.g. socket wrench 10 = socket wrench width across flats 10 mm.
NR, NA
Availability codes in the Status column have the following meaning:
C2 6686 5.1.2-01 EN-US 1 (2)

Standard Included in the scope of supply of the turbocharger.

Introduction
Optional Tools are supplied by special order.

Inventory Commercially available tools/appliances
These are not included in the scope of supply of the turbo-
charger. It is assumed that these tools/appliances are included
in the inventory of the engine system.
Special Special tools, e.g. for service centres.
Tips and Pictographs
For notes concerning fault sources/handling errors; material damage

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

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

lock washers tightening torques!
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Work cards
NR, NA
2 (2) C2 6686 5.1.2-01 EN-US

Work cards
5.1 Introduction
5.2 Work cards
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Work cards
6663-1 5.2-01 EN-US 1 (1)

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

Tightening of screw Whenever possible, screw connections should be tightened with torque
connections acc. to the wrenches.
torque For particularly important screw connections on the turbocharger, the tight-
ening torques are prescribed in the relevant work cards.
For all other screw connections that are to be tightened with torque
wrenches, the approximate values for the tightening torques are specified in
the Table “Tightening torques for bolts, strength class 8.8”.
When tightening screw connections the following must be observed:
▪ Apart from the applied tightening torque, the clamping force of a screw
connection depends on the lubricant being used, the condition of the
contact surface and thread, as well as on the material combination. It is
therefore very important that all these conditions are satisfied.
▪ The Table “Tightening torques for bolts, strength class 8.8” gives the
tightening torques for the various screw threads depending on their coef-
ficient of friction µ, i.e. depending on the selected lubricant. The tighten-
ing torques apply for bolt materials in strength class 8.8 under utilization
of approx. 70% of their yield strength. For other stength classes, conver-
sion factors are to be used and multiplied by the tightening torques from
the Table “Tightening torques for bolts, strength class 8.8”. The strength
class is stamped on the bolt head.
Strength class 5.6 6,8 8.8 10.9 12.9
Conversion factor x 0.47 0.75 1.0 1.40 1.70
Table 1: Conversion factors for tightening torques depending on the strength class of
the bolts
Friction coefficient µ For the friction coefficient µ use approximately:
µ = 0.08 with lubricants for temperatures
≤ 200 °C, e.g. Molykote G-n or Molykote P40
≥ 200 °C, e.g. Molykote HSC
µ = 0.14 for lightly oiled surfaces without refinishing
Tightening torques in general

Thread, nominal size Tightening torque in Nm
for coefficient of friction µ
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Work cards
0.08 0.14
M5 4.1 5.8
NR, NA
M6 7 10
M8 17 24
C2 6686 000.31-01 EN-US 1 (2)

Thread, nominal size Tightening torque in Nm

Work cards
for coefficient of friction µ
0.08 0.14
M 10 34 49
M 12 59 84
M 14 93 134
M 14×1,5 99 145
M 16 141 205
M 16×1,5 148 220
M 18 196 282
M 18×1,5 213 319
M 18×2 205 300
M 20 275 398
M 20×1,5 295 445
M 20×2 285 422
M 22 368 538
M 22×1,5 393 594
M 22×2 381 566
M 24 473 686
M 24×2 503 753
M 27 694 1017
M 27×2 731 1103
M 30 945 1379
M 30×2 1014 1537
M 33 1271 1870
M 33×2 1353 2061
M 36 1640 2403
M 36×3 1707 2554
M 39 2113 3117
M 39×3 2190 3295
M 42 2623 3856
M 42×3 2757 4166
M 45 3262 4821
M 45×3 3414 5178
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M 48 3952 5823
Work cards
M 48×3 4184 6367

Table 2: Tightening torques for bolts, strength class 8.8
NR, NA
2 (2) C2 6686 000.31-01 EN-US

Emergency operation with closing device
Work cards
Brief description
Emergency operation by removing the cartridge.
Personnel and time required

Number Qualification Duration in h
1 Technician 1,0
1 Assistant 1,0
Tools/appliances required
Quan- Designation Number Status
tity
1 Closing cover (with support) 596.027 Option
1 Open-jaw wrench 19 - Inventory
- Lifting tackle, ropes, shackles - Inventory
Related work cards

Work card Work card Work card
500.10 500.12 500.13
500.14 500.16
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Work cards
NA29/S
C2 6663 500.05-01 EN-US 1 (3)

Work cards
Preliminary remarks
Figure 1: Closing device
Work sequence - Emergency operation with closing device

During emergency operation of the engine, the exhaust gas must continue
passing through the damaged turbocharger.
Danger to life from crush injuries or impact!

If the engine starts during the removal of parts of the turbocharger,
there is a risk of coming into contact with rotating components and
being seriously injured.
• Shut down the engine before starting the removal work!
• During the work, lock out the engine to prevent it from starting!
• Set up warning signs!
Danger of fire caused by lube oil!

2011-01-13 - de
During emergency operation without rotating element, the danger of

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

In emergency operation, always shut the oil supply pipe to the
turbocharger!
NA29/S
2 (3) C2 6663 500.05-01 EN-US

Steps 1. Undo all the connections to prepare the cartridge for removal (refer to
work card [500.10] “Removing and refitting the turbocharger or subas-
Work cards
semblies”).
2. Remove the silencer or air intake casing, compressor casing and car-
tridge, either individually or together (see work cards [500.12] “Remov-
ing and refitting the silencer” up to [500.16] “Removing and refitting the
cartridge”).
3. Close the lube oil pipes.
4. Attach the closing cover (596.027) with sleeves (517.101) and hexagon
nuts (517.102) to the gas outlet casing (506.001).
Screw the support for the closing cover (596.027) onto the bracket.
5. Further information about emergency operation:
➤ Turbocharger operating instructions
➤ Engine operating instructions
2011-01-13 - de
Work cards
NA29/S
C2 6663 500.05-01 EN-US 3 (3)

Locating bearing and bearing bushes
Work cards
Checking
Brief description
Check the bearings, replace if necessary

1 Technician 0,3
tity
1 Sliding caliper - Inventory
Related work cards

500.20 500.24
Preliminary remarks with regard to checking the locating bearing (517.075) and bearing
bushes (517.161)
Signs of wear!
If fretting marks, uneven or rapid wear are found, the causes such as
imbalance, irregularities on the sealing air and lube oil systems (dirt,
pressure, flow rate, temperature, priming and post lubrication) must be
remedied prior to installing new bearings.
2011-01-13 - de
Work cards
NA29/S
C2 6663 500.06-01 EN-US 1 (2)

Work cards
Work sequence 1 - Checking the locating bearing (517.075)
Figure 1: Checking the locating bearing

Steps
1. Measure the length ( l ) of the wedge surfaces (a) on the turbine side
and compressor side.
Length ( l ) extends up to the edge (v) on the bearing contact face (b).
Depending on the angle of light incidence, a dark band may appear in
front of the edge (v) on the wedge surface (a). This band is to be
included in the measurement of length ( l ).
2. Replace the locating bearing (517.075) if one of the lengths ( l ) is ≤ 4.0
mm.
Work sequence 2 - Checking the bearing bushes (517.161)
2011-01-13 - de
Figure 2: Checking the bearing bushes

Work cards
Steps 1. Measure the diameters D4 and D5.

2. Replace the bearing bush (517.161) if D4 ≤ Ø 64.71 mm,
NA29/S
D5 ≥ Ø 45.04 mm.
2 (2) C2 6663 500.06-01 EN-US

Cleaning the turbine - Wet cleaning
Work cards
Brief description
If provided: Wet cleaning of the turbine during operation in the case of signifi-
cantly reduced engine performance. Carry out the cleaning in time, in
accordance with the maintenance schedule.

1 Technician 0,6
Preliminary remarks
Cleaning agent Use exclusively fresh water for cleaning.
Cleaning interval Every 150 operating hours, with reduced engine load.
In order to save time, carry out the cleaning shortly after engine start-
up, provided the components to be cleaned are not yet too hot.
This allows step 2 of the work sequence to be omitted.
Brief information See also cleaning instructions given on plate (attached to the engine).
2007-11-15 - de
Work cards
NA29/S
C2 6663 500.07-01 EN-US 1 (3)

Work cards
1 Turbocharger A Stop cock

2 Exhaust gas pipe upstream of B Pressure reducing valve with
turbine pressure gauge
3 Water admission (fresh water) C Three-way cock:
ZERO POSITION
BLOW-OUT
WASHING
4 Dirt water discharge downstream D Three-way cock:
of turbine, if provided ● (= zero position)
●● (= check position)
●●● (= washing position)
E Drain cock, if provided
Figure 1: Diagram: Wet cleaning of the turbine
The number and arrangement of exhaust gas pipes depends on the engine
type and may vary from the above diagram. Every individual exhaust gas
pipe has its own three-way cock (D) for turbine cleaning.
Work sequence - Wet cleaning of the turbine (during operation)

Steps 1. Reduce engine load to 0 — 15%, making sure that the maximum per-
missible exhaust gas temperature is not exceeded.
2. Following reduction of the engine load from a higher load range, wait
approx. 10 minutes (for the temperature to reach a stable condition).
3. First check all the three-way cocks (D) one after the other in the check
position ●● (if no exhaust gas is blown out, the passage to the exhaust
gas pipe is clogged and must be cleared using a 2.5-mm dia. piece of
wire); then switch over to washing position ●●●.
4. Open the drain cock (E) if fitted, check that exhaust gas is blown out; if
necessary, clear the passage.
2007-11-15 - de
5. Switch the three-way cock (C) to BLOW-OUT.

Work cards
6. Open the stop cock (A) on the water admission (3); set the water pres-
sure to 2 bar on the pressure reducing valve (B), and check on the
NA29/S
pressure gauge.
7. Switch the three-way cock (C) to WASHING.
2 (3) C2 6663 500.07-01 EN-US

8. Wash for 10 minutes at 2 bar water pressure (check on the pressure

gauge).
Work cards
9. Close the stop cock (A) on the water admission (3).
10. Temporarily switch the three-way cock (C) to BLOW-OUT, then to
ZERO POSITION.
11. Switch all the three-way cocks (D) to zero position ● .
12. Close the drain cock (E), if fitted.
13. Run the turbocharger dry for 10 minutes at reduced engine power, then
slowly increase the load.
Vibrations caused by dirt accumulations

Should vibrations occur on the turbocharger that were not evident
before, repeat the washing procedure.
If these vibrations, caused by irregular dirt accumulations, cannot be
eliminated by washing, the turbocharger must be dismantled and the
parts involved must be subjected to mechanical cleaning.
2007-11-15 - de
Work cards
NA29/S
C2 6663 500.07-01 EN-US 3 (3)

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

1 Technician 0,3
tity
- Granulates (grain size 1.0 — 1.5 mm) - nut shells/ - Inventory
activated charcoal - soft
Introductory Remarks
Cleaning agent Appropriate cleaning materials are granulates from nut shells or activated
charcoal (soft) with a grain size of 1.0 mm (max. 1.5 mm).
Do not use water for cleaning the turbine by this method, as in this case
the cleaning is carried out at normal operating load of the engine.
Cleaning interval Every 24 operating hours, at normal service load of the engine.
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Work cards
NA29/S
C2 6663 500.07-02 EN-US 1 (3)

Work cards
1 Tank 6 Exhaust gas pipe

2 Screw plug 7 Compressed air pipe
3 Pipe
4 Connection point A Stop cock (compressed air)
5 Plate B Stop cock (exhaust gas)
Figure 1: Diagram: Dry cleaning of the turbine
Depending on the type of engine and turbocharger, the arrangement of the

individual parts might not correspond exactly to the drawing “Diagram: Dry
cleaning of the turbine”.
The tank (1) must be installed in a suitable location, not lower than 1.0 m
below the connection point (4). The pipe (3) must be no longer than 6.0 m,
be properly supported to prevent it from vibrating and allow unimpeded flow.
Maximum operating temperature of the stop cock (B): ≤ 300 °C.
Connection point (4) is provided on the exhaust gas pipe, immediately
upstream of the turbine.
Work Sequence – Dry Cleaning of 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 (1) and close it with the screw plug (2). For the quantities
required, refer to Table 1.
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).
Filling volume
NA29 0.5 litres
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NA34 0.5 litres

Work cards
NA40 1.0 litres

NA48 1.5 litres
NA29/S
NA57 2.0 litres
2 (3) C2 6663 500.07-02 EN-US

Filling volume
Work cards
NA70 2.5 litres
NA83 3.0 litres
Table 1: Granulate filling volume
2010-04-15 - de
Work cards
NA29/S
C2 6663 500.07-02 EN-US 3 (3)

Cleaning the compressor - with fitted tank
Work cards
Brief description
Clean the compressor with the engine warmed up and in full load operation.
Carry out the cleaning in time, in accordance with the maintenance schedule.

1 Technician 0,3
Due to the high speed of the rotor, the injected water droplets hit the blades
of the compressor wheel and the diffuser at high velocity, thus removing the
dirt deposits mechanically.
Cleaning interval We recommend the following cleaning intervals:
▪ NR turbochargers: every 150 operating hours,
▪ NA turbochargers: every 150 operating hours.
The cleaning intervals depend on the degree of contamination of the intake
air and range from 100 to 200 operating hours.
In the smaller turbocharger sizes (NR, NA34, NA40), dirt deposits on the
compressor wheel and diffuser blades may lead to a considerable drop in
efficiency.
From turbocharger size NA48 upwards, compressor cleaning is not neces-
sary if the air filter mat is serviced as specified.
Carry out the cleaning only with the engine warmed up and in
full load operation.
Do not shut down the engine immediately after cleaning, but continue
to run it for several minutes until dry.
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Work cards
NR, NA
C2 5649 500.08-02 EN-US 1 (2)

Work cards
1 Screw-type cap 5 Charge air cooler

2 Tank 7 Turbocharger (compressor)
3 Hydrometer cock 10 Plate (cleaning instructions)
4 Charge air line
Figure 1: Diagram: Cleaning of the compressor (with fitted tank)
individual parts might not correspond exactly to the diagram.
Work Sequence – Compressor Cleaning (during Operation)

Steps 1. Operate engine at full load.
2. Open screw-type cap (1) and fill tank (2) with clean, fresh water.
3. Close full tank with screw-type cap (1).
4. Depress pushbutton of hydrometer cock (3) for about 20 seconds.
2007-11-05 - de
Work cards
NR, NA
2 (2) C2 5649 500.08-02 EN-US

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

1 Technician 0,3
Due to the high speed of the rotor, the injected water droplets hit the blades
of the compressor wheel and the diffuser at high velocity, thus removing the
dirt deposits mechanically.
Cleaning interval We recommend the following cleaning intervals:
▪ NR turbochargers: every 150 operating hours,
▪ NA turbochargers: every 150 operating hours.
In the smaller turbocharger sizes (NR, NA34, NA40), dirt deposits on the
compressor wheel and diffuser blades may lead to a considerable drop in
efficiency.
From turbocharger size NA48 upwards, compressor cleaning is not neces-
sary if the air filter mat is serviced as specified.
Carry out the cleaning only with the engine warmed up and in
full load operation.
Do not shut down the engine immediately after cleaning, but continue
to run it for several minutes until dry.
Brief information See also cleaning instructions given on plate (10), attached to the pressure
sprayer (2).
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Work cards
NR, NA
C2 5649 500.08-03 EN-US 1 (2)

Work cards
1 Handle 5 Coupling
2 Pressure sprayer 6 Hand valve
3 Relief valve 7 Turbocharger (compressor)
4 Nipple 10 Plate (cleaning instructions)
Figure 1: Diagram: Cleaning of the compressor (with pressure sprayer)
individual parts might not correspond exactly to the diagram.
Work Sequence – Compressor Cleaning (during Operation)

Steps 1. Operate engine at full load.
2. Turn handle (1) on pressure sprayer tank (2) in counter-clockwise direc-
tion and take out the pump.
3. Fill a maximum of 2.0 litres of fresh water into the tank (up to the mark 2
L on the tank).
4. Screw in the pump and operate it until the relief valve (3) blows off.
5. Connect hose with nipple (4) to the coupling (5).
6. Depress pushbutton (see large arrow in figure) on the hand valve (6)
until the water is completely injected into the compressor (7) (for
approx. 30 seconds).
7. Release plug-in connection and vent the tank. For venting, pull spindle
on the relief valve (3) outwards (see small arrow in figure).
2007-11-05 - de
Work cards
NR, NA
2 (2) C2 5649 500.08-03 EN-US

Turbocharger or subassemblies
Work cards
Removing and refitting
Brief description
Remove the turbocharger in subassemblies or as a complete unit.

1 Technician 4,5
1 Assistant 1,0
tity
1 Open-jaw and ring wrenches (set) - Inventory
1 Socket wrench (set) - Inventory
1 Screwdriver - Inventory
- Wood (as a support) - Inventory
- High-temperature lubricant (e.g. Molykote HSC) - Inventory
Technical data
Designation Information
Turbocharger 925 kg
Preliminary remarks
For maintenance work on the turbocharger, individual subassemblies and
parts are normally removed in succession.
See work cards [500.12] “Removing and refitting silencer” to [500.27]
“Removing and refitting shroud ring, diffuser outside wall”.
2011-01-13 - de
Work cards
NA29/S
C2 6663 500.10-01 EN-US 1 (4)

Work cards
Figure 1: Connections on the turbocharger
Work sequence 1 - Separating or removing the connections
Danger of burns from hot components!

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

The lube oil is under pressure and very hot!
• Before opening pipes, flanges, screwed connections or gauges, free the
system of pressure and check that it is pressure-free!
• Before opening oil pipes, wait until the lube oil has cooled down
sufficiently (1-2 h)!
• Drain the system and check that the lube oil has been drained
completely!
Steps 1. Air intake (1) on air intake casing (if provided), compressor cleaning (2, if
provided).
Removal of silencer (544, if provided) or air intake casing (545, if pro-
2011-01-13 - de
vided) is possible.
➤ Work card [500.12] “Removing and refitting silencer” or
Work cards
➤ Work card [500.13] “Removing and refitting air intake casing”.

2. Cable to speed indicator in terminal box (3, if provided), Jet Assist (4, if
NA29/S
provided), air outlet (5).

Removal of speed transmitter, insert, compressor casing and diffuser is
2 (4) C2 6663 500.10-01 EN-US

possible.
➤ Work card [500.14] “Removing and refitting compressor casing,
Work cards
insert, diffuser, speed transmitter”.
3. Lube oil feed (6), lube oil drain (7), connecting points (8) for lube oil
pressure and interval priming or continuous priming (if provided), sealing
air pipe (9)
Removal of cartridge is possible.
➤ Work card [500.16] “Removing and refitting the cartridge”.
4. Turbine cleaning (10, if provided), exhaust gas admission (11)
Removal of gas admission casing, turbine nozzle ring and shroud ring is
possible.
➤ Work card [500.25] “Removing and refitting gas admission casing”,
➤ Work card [500.26] “Removing and refitting turbine nozzle ring”,
➤ Work card [500.27] “Removing and refitting shroud ring, diffuser out-
side wall”.
5. Exhaust gas outlet (12), dirty water or condensed water discharge (13,
if provided)
Removal of complete turbocharger is possible.
➤ Work card 500.10 (work sequence 2)
Work sequence 2 - Removing the complete turbocharger
Figure 2: Removing and refitting the complete turbocharger

Steps
1. For separating or removing the connections, refer to work sequence 1.
Also separate or detach other special connections (such as for pressure
2011-01-13 - de
and temperature measuring, etc.).

Work cards
2. Attach suspension device (506.170) and lifting tackle to the turbo-

charger using 2 shackles and a rope of adequate strength, and carefully
NA29/S
tension the rope. Attach secondary ropes at appropriate points to assist

in balancing.
C2 6663 500.10-01 EN-US 3 (4)

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

Work cards
No persons may be present in the area of danger around and

underneath a suspended load.
• Lifting tackle, ropes and attachment points must be able to take the
load safely and be in perfect condition.
• Use the eye bolts on the subassemblies only for lifting individual
(detached) subassemblies and not for lifting the turbocharger.
• All lifting, moving and setting down of the load must be carried out
slowly.
3. Undo the screw connections (14 and 15) between the casing feet and
the bracket.
4. Carefully lift off the turbocharger and set it down on a wooden support.
Risk of fouling!
During storage and assembly, the openings for air, exhaust gas and
lube oil must be appropriately sealed to prevent foreign objects or
water from entering.
Work sequence 3 - Refitting
Procedures to be observed when mounting the turbocharger onto the

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

connections, is carried out by reversing the removal procedure.
Tighten the screw connections (14 and 15) between the casing feet and the
bracket lightly at first, and then torque them finally after connection of the
casing pipes.
Observe tightening torques during assembly!

Screw connection of the casing feet to the engine bracket: see engine
manual.
2011-01-13 - de
Work cards
NA29/S
4 (4) C2 6663 500.10-01 EN-US

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

1 Technician 0,4
Preliminary remarks
General The dirty air filter mat (544.201) can be cleaned several times or replaced
with a new mat.
Replacement is required if the air filter mat is considerably stretched, tattered
or perforated.
An increase in pressure loss, due to a contaminated air filter mat,

should not be used as a reference for the cleaning interval.
Cleaning interval Every 250 operating hours.

Cleaning is necessary when the inside of the air filter mat starts to
discolour, turning grey.
The air filter is then saturated and the contamination starts to advance
towards the compressor and the charge air cooler. The inside of the air
filter mat may be inspected by loosening one of the clamps (544.202).
In case of heavy contamination, it may be necessary to immerse the air
filter mat into a cleaning agent for several hours. Therefore it is
recommended to have a second air filter mat in stock at all times.
2007-11-15 - de
Work cards
NR
C2 6660 500.11-01 EN-US 1 (2)

Work cards
Figure 1: Air filter, mounted on the silencer
Work sequence - Removal, cleaning/replacement, refitting
Avoid excessive mechanical stress (e.g. wringing, sharp water jet). After
cleaning, blow compressed air through the air filter mat.
Steps 1. Loosen the clamps (544.202), remove cover sheet (544.205) and air fil-
ter mat (544.201).
2. Clean the air filter mat by flushing with warm water to which a mild
detergent has been added.
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 them using the
clamps (544.202).
2007-11-15 - de
Work cards
NR
2 (2) C2 6660 500.11-01 EN-US

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

1 Technician 0,2
1 Assistant 0,2
Required Tools/Appliances
tity
1 Hexagon screw driver 8 - Inventory
1 Torque wrench - Inventory
Related work cards

500.10 500.11
Technical Data
Silencer 85 kg
2010-03-10 - de
NA29/S;NR29/S
Work cards
C2 6660 500.12-02 EN-US 1 (3)

Work cards
Figure 1: Silencer, mounted on the compressor casing

General For air filter cleaning, please refer to work card [500.11] “Cleaning the air fil-
ter”.
For disassembling, cleaning and reassembling the silencer, refer to work
sequence 3.
Disassembling of the silencer (e.g. for cleaning) only if necessary.
Work sequence 1 - Removing the complete silencer

Starting condition Connection for compressor cleaning is released (if provided).
Steps
1. Attach lifting tackle to the silencer using rope and shackles.
2. Loosen the V-profile clamp (546.004) on both sides of the circumfer-
ence.
3. Remove the silencer in axial direction and place it on a wooden support
with the flange face down.
Work sequence 2 - Refitting the complete silencer

Steps For refitting, proceed in the reverse order of removal.
2010-03-10 - de
NA29/S;NR29/S
Work cards
2 (3) C2 6660 500.12-02 EN-US

Observe tightening torques during refitting!
Work cards
• Apply oil to the threads and contact surfaces.
• Tightening torque for the V-profile clamp (546.004) on both sides of the
circumference: 30 Nm
Work sequence 3 - Disassembling, cleaning and reassembling the silencer
Bonded joints
On no account may trichlorethylene (or substitutes) or any other
solvents containing acetone be used for removing greasy dirt.
Use of such products will dissolve the bonded joints.
Steps 1. Remove the air filter mat (544.201) and clean it, see work card
[500.11] “Cleaning the air filter”.
2. Unscrew the hexagon nuts (544.074) and take off the washers
(544.075).
3. Take off the front wall (544.041), perforated plate (544.034), damping
plates (544.021) and spacer pipes (544.032) individually. The rear wall
(544.001) remains in place, with the studs (544.069) screwed in.
4. If the fouling matter is dry, the felt linings are best cleaned with com-
pressed air or a brush which is not too hard.
5. For reassembly, proceed in the reverse order of disassembly.
Observe tightening torques during installation!

• Apply Molykote P40 lubricant to the threads and contact surfaces.
• Tightening torque for hexagon nuts (544.074): 40 Nm
2010-03-10 - de
NA29/S;NR29/S
Work cards
C2 6660 500.12-02 EN-US 3 (3)

Air intake casing
Work cards
Short Version
The air intake casing has to be removed for all work that is to be performed
from the compressor side.

1 Technician 0,2
1 Assistant 0,2
Required Tools/Appliances
tity
Related work cards

500.10
2010-03-10 - de
Work cards
NR29/S
C2 6660 500.13-03 EN-US 1 (3)

Work cards
Figure 1: Air intake casing, mounted on the compressor casing
Work sequence 1 - Removing

Starting condition Pipe at the air intake is released or removed.
Connection for compressor cleaning is released (if provided).
Steps 1. Attach lifting tackle to the air intake casing (545.001) using a rope.
Carefully tension the rope.
ence.
3. Remove the air intake casing (545.001) in axial direction and place it on
a wooden support.

2010-03-10 - de
Work cards
NR29/S
2 (3) C2 6660 500.13-03 EN-US

Work cards
• Apply oil to the threads and contact surfaces.
• Tightening torque for the V-profile clamp (546.004) on both sides of the
circumference: 30 Nm
2010-03-10 - de
Work cards
NR29/S
C2 6660 500.13-03 EN-US 3 (3)

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

1 Technician 1,6
1 Assistant 0,4
tity
1 Socket wrench 10 - Inventory
Spare parts required

Quantity Designation Number
1 O-ring seal 517.063
1 Sealing ring 546.051
Related work cards

500.10 500.12 500.13
2011-01-13 - de
Work cards
NA29/S
C2 6663 500.14-02 EN-US 1 (5)

Work cards
Technical data
Insert 40 kg
Diffuser 10 kg
Compressor casing 105 kg
Preliminary remarks
Figure 1: Removing and refitting the speed transmitter, insert, compressor casing, diffuser
General Removing the insert (540.001) without removing the compressor casing
allows the compressor wheel to be dismounted up to removal of the locating
bearing.
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Before the insert or the compressor casing is removed, the speed

transmitter (562.040) must be removed in order to avoid damage to the
Work cards
two pole shoes at the end of the speed transmitter.

NA29/S
Starting condition Connecting pipes, silencer or air intake casing are removed.
2 (5) C2 6663 500.14-02 EN-US

Work cards
Work sequence 1 - Removing the speed transmitter
Steps
1. Disconnect the cable end of the speed transmitter (562.040) in the ter-
minal box (562.083, if provided) and pull it carefully through the opened
cable socket (see Figure 1, detail X) and the opened gland (546.060).
2. Unscrew the hexagon nuts (540.021), take off the tab washers
(540.022) and the closing cap (540.010).
3. Unscrew the hexagon nut (562.005), remove the holding disk (562.004)
and carefully pull out the speed transmitter (562.040).
Do not bend the pole shoes of the speed transmitter.
Work sequence 2 - Removing the insert

Steps 1. Unscrew the hexagon bolts (546.020) and take off the lock washer
pairs (546.023).
2. Carefully remove the insert (540.001) in axial direction, paying attention
to the O-ring seals (540.015 and 540.016).
Work sequence 3 - Removing the compressor casing
The insert must be disassembled before removal of the compressor

casing!
Take care not to damage blades of the compressor wheel during

removal.
Steps
1. Attach lifting tackle to the compressor casing (546.001) using a rope,
and carefully tension the rope.
ence, remove the compressor casing carefully in axial direction and
place it on a wooden support.
2011-01-13 - de
Work cards
Work sequence 4 - Removing the diffuser

Steps
NA29/S
1. Unscrew the hexagon bolt (546.008).

2. Take off the diffuser (542.001) in axial direction.
C2 6663 500.14-02 EN-US 3 (5)

Work cards

General For refitting, proceed in the reverse order of removal.
Seals Make sure that the O-ring seals (517.018, 540.015, 540.016) and the sealing
ring (546.051) are in flawless condition.
Screw connections All screw connections must be properly locked.
Observe the correct use of lock washer pairs!
Long wedge surfaces to contact each other (on the inside), otherwise there will be no
locking effect.
Figure 2: V-profile clamp for connecting the bearing casing and the compressor casing
V-profile clamp Fit the two halves of the V-profile clamp (546.005) over the flange connection
(bearing casing / compressor casing) so that the tapped holes are aligned
with the holes of the holding sheets (546.114).
It is imperative to observe the sequence of tightening torques

during refitting without using any lubricants.
Fasten the V-profile clamp (546.005, Figure 2) with resilient sleeves
(546.112), undercut bolts (546.111) and hexagon nuts (546.113)
uniformly and alternately round the circumference in the following 4
stages:
1st stage: 30 Nm
2nd stage: 80 Nm
3rd stage: 125 Nm
4th stage: 150 Nm
2011-01-13 - de
Secure the clamp halves on both sides with holding sheets (546.114), lock
Work cards
washer pairs (546.116) and hexagon bolts (546.115).

Speed transmitter, speed The speed transmitter (562.040) and speed indicator (562.100) may be con-
NA29/S
indicator nected either way round in the terminal box (562.083) (alternating voltage).
Strain relief and grounding by clamping the shielding braid between conical
rings, sealing by means of sealant (e.g. Adaptol), see Figure 1, detail X.
4 (5) C2 6663 500.14-02 EN-US

Checking Check the gaps (items 10 and 11), refer to Operating Instructions, Technical
data, Gaps and clearances, sheet 2.5.5.
Work cards
2011-01-13 - de
Work cards
NA29/S
C2 6663 500.14-02 EN-US 5 (5)

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

1 Technician 0,6
1 Assistant 0,6
tity
1 Suspension device 596.130 Standard
Spare Parts
1 Seal 517.109
Related work cards

500.10 500.12 500.13
500.14
Technical data
2011-01-13 - de
Work cards
Cartridge (517 + 520) 345 kg

NA29/S
C2 6663 500.16-01 EN-US 1 (3)

Work cards
Preliminary remarks
Figure 1: Cartridge, removed from the gas outlet casing

General The cartridge is the complete bearing casing (517.000) with an installed rotor
(520.000).
Removing the cartridge makes the turbine nozzle ring and turbine rotor
accessible without the need to remove the gas admission casing. Turbine
nozzle ring for inspection, turbine rotor for removal.

Starting condition Connecting pipes, silencer or air intake casing and compressor casing are
removed.
Steps 1. Screw the suspension device (596.130) onto the bearing casing
(517.000) with hexagon bolts (517.111).
2. Attach lifting tackle to the cartridge (517.000 + 520.000) using shackles
and a rope, and carefully tension the rope.
3. Unscrew the hexagon nuts (517.102) and take off the sleeves
(517.101).
2011-01-13 - de
4. Carefully extract the cartridge in axial direction and set it down on a

Work cards
wooden support.
NA29/S
2 (3) C2 6663 500.16-01 EN-US

Take care not to damage blades of the turbine rotor and compressor
Work cards
wheel during removal.

Apply high-temperature lubricant (e.g. Molykote HSC) to the thread of bolts
and nuts but not to screw-in threads when replacing studs (517.100).
• Apply high-temperature lubricant (e.g. Molykote HSC) to the threads and

contact surfaces.
• Tightening torque for hexagon nuts (517.102): 65 Nm
Checking For checking the gaps, refer to Operating Manual, Technical details, Gaps
and clearances, sheet 2.5.5.
2011-01-13 - de
Work cards
NA29/S
C2 6663 500.16-01 EN-US 3 (3)

Compressor wheel
Work cards
Removing, refitting, checking
Brief description
Remove the compressor wheel for inspection.

1 Technician 0,6
tity
1 Dial gauge with retainer - Inventory
- Special preservative (Molykote P40) - Inventory
Related work cards

500.10 500.12 500.13
500.14 500.16
Technical data
Compressor wheel 12 kg
2011-01-13 - de
Work cards
NA29/S
C2 6663 500.18-01 EN-US 1 (3)

Work cards
Preliminary remarks
Figure 1: Removing and refitting the compressor wheel

Starting condition Connecting pipes, silencer or air intake casing and compressor casing are
removed. Cartridge is removed if turbine rotor is also to be dismounted. The
magnetic shaft (520.126) has to be unscrewed only if it is to be replaced.
Steps 1. Unscrew the undercut bolt (520.067) (right-hand thread) while holding
the turbine rotor.
2. Pull off the carrier (520.061).
3. The feather keys (520.056) are not normally removed, but must not be
lost.
4. Pull off the compressor wheel (520.044) by hand in axial direction.
Heat treatment in the event of a seized compressor wheel!

Overheating of the compressor wheel causes a structural
transformation of the aluminium alloy and thus renders the
compressor wheel unusable!
• Wear protective clothing.
• Heat only the hub of the compressor wheel and on no account the
2011-01-13 - de
blades.
Work cards
• Heat the hub uniformly round the entire circumference (not locally),
quickly and gently using a soft flame at no more than 80 °C.
NA29/S
2 (3) C2 6663 500.18-01 EN-US

Work cards
Steps 1. Apply a thin protective film of Molykote P40 to the fitting surfaces of the
turbine shaft (for compressor wheel and carrier).
2. Insert the feather keys (520.056) into the turbine shaft. Push the com-
pressor wheel (520.044) and carrier (520.061) onto the turbine shaft
until there is firm contact with the labyrinth ring (520.035).
The balancing marks (W) of the turbine rotor (520.001), compressor

wheel (520.044) and carrier (520.061) must be aligned radially.
If heat treatment is required, observe the following:

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

Screw in the undercut bolt (520.067) in accordance with the following
combined tightening procedure.
Observe tightening torques and sequence!

Apply Molykote P40 lubricant to the threads and contact surfaces of
the undercut bolt.
For an aluminium compressor wheel:
• Tighten with a torque of 180 Nm, then release the initial load
• Tighten with a torque of 60 Nm
• Tighten by an additional angle of + 60°
4. Check the axial clearance (item 8) of the complete rotor and the axial
runout (item 16) of the compressor wheel using a dial gauge.
For items and admissible values, refer to Operating Instructions, Technical
data, Gaps and clearances (Part C1, sheet 2.5.5).
2011-01-13 - de
Work cards
NA29/S
C2 6663 500.18-01 EN-US 3 (3)

Sealing cover and labyrinth ring
Work cards
Brief description
Remove and refit the sealing cover and labyrinth ring for inspection. Check
the state and wear condition.

1 Technician 0,6
tity

1 Seal 517.085
Related work cards

500.10 500.12 500.13
500.14 500.16 500.18
2011-01-13 - de
Work cards
NA29/S
C2 6663 500.19-01 EN-US 1 (3)

Work cards
Preliminary remarks
Figure 1: Removing and refitting the sealing cover and labyrinth ring

Starting condition Connecting pipes, silencer or air intake casing, compressor casing and com-
pressor wheel are removed.
Cartridge is removed if turbine rotor is also to be dismounted.
Steps
1. Unscrew the hexagon bolts (517.093) and take off the lock washer
pairs (517.095).
2. Evenly force off the sealing cover (517.089) with 3 hexagon bolts (M10,
thread length ≥ 40 mm) and take off the seal (517.085).
Slight grooves in the bore of the sealing cover produced by the

labyrinth tips of the labyrinth ring improve the sealing effect and are no
reason for replacing this part.
3. Withdraw the labyrinth ring (520.035) in axial direction.

Replace the labyrinth ring if labyrinth tips are damaged or worn:
D ≤ Ø 87.8 mm or fretting marks evident on the axial running surface.
2011-01-13 - de

Work cards
For refitting, proceed in the reverse order of removal.

NA29/S
Apply a thin protective film of Molykote P40 to the fitting surface of the tur-
bine shaft for the labyrinth ring.
2 (3) C2 6663 500.19-01 EN-US

Apply Molykote P40 lubricant to the threads and contact surfaces of the hex-
agon bolts (517.093).
Work cards
The balancing marks (W) of the turbine rotor (520.001) and labyrinth ring
(520.035) must be aligned radially.
When fitting the seal (517.085), pay attention to the flawless condition
and position of the holes.

locking effect.
2011-01-13 - de
Work cards
NA29/S
C2 6663 500.19-01 EN-US 3 (3)

Locating bearing
Work cards
Brief description
Remove locating bearing for inspection.

1 Technician 0,6
tity
Related work cards

500.06 500.10 500.12
500.13 500.14 500.16
500.18 500.19
Preliminary remarks
2011-01-13 - de
Work cards
NA29/S
Figure 1: Removing and refitting the locating bearing
C2 6663 500.20-01 EN-US 1 (2)

Work cards

Starting condition Connecting pipes, silencer or air intake casing, compressor casing, com-
pressor wheel, sealing cover and labyrinth ring are removed.
Steps 1. Unscrew the hexagon nuts (517.134) and take off the lock washer pairs
(517.133).
2. Evenly force off the locating bearing (517.075) with 3 hexagon bolts
(M10, thread length ≥ 40 mm).
3. Check the locating bearing. See work card [500.06] “Checking the
locating bearing and bearing bushes”.

locking effect.
2011-01-13 - de
Work cards
NA29/S
2 (2) C2 6663 500.20-01 EN-US

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

1 Technician 0,3
tity
Related work cards

500.10 500.12 500.13
500.14 500.16 500.18
500.19 500.20
Preliminary remarks
2011-01-13 - de
Work cards
NA29/S
Figure 1: Removing and refitting the thrust ring
C2 6663 500.21-01 EN-US 1 (2)

Work cards

Starting condition Connecting pipes, silencer or air intake casing, compressor casing, com-
pressor wheel, sealing cover, labyrinth ring and locating bearing are
removed.
Steps 1. Pull off the distance sleeve (520.031) in axial direction.
2. Pull off the thrust ring (520.028) in axial direction.
If the distance sleeve and/or thrust ring have seized, remove these
parts together with the turbine rotor (see work card 500.22). The thrust
ring and distance sleeve are stripped off by knocking the plain bearing
(517.055).

Steps 1. Apply a thin protective film of Molykote P40 to the fitting surfaces of the
turbine shaft (for thrust ring and distance sleeve).
2. Push the thrust ring (520.028) and distance sleeve (520.031) onto the
turbine shaft.
The balancing marks (W) of the turbine shaft, thrust ring (520.028) and
distance sleeve (520.031) must be aligned radially.
2011-01-13 - de
Work cards
NA29/S
2 (2) C2 6663 500.21-01 EN-US

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

1 Technician 0,4
tity
Related work cards

500.10 500.12 500.13
500.14 500.16 500.18
500.19 500.20 500.21
Technical data
Turbine rotor 25 kg
2011-01-13 - de
Work cards
NA29/S
C2 6663 500.22-01 EN-US 1 (2)

Work cards
Preliminary remarks
Figure 1: Removing and refitting the turbine rotor

Starting condition Cartridge is removed. Compressor wheel, sealing cover, labyrinth ring, locat-
ing bearing and thrust ring are removed.
Steps 1. Lift the turbine rotor (520.001) slightly and pull it out as concentrically as
possible.
2. Check the turbine nozzle ring.
Replace the turbine rotor if:
D1 ≤ Ø 44.92 mm,
D2 ≤ Ø 44.92 mm and/or
D3 ≤ Ø 73.70 mm.

2011-01-13 - de
Work cards
NA29/S
2 (2) C2 6663 500.22-01 EN-US

End cover
Work cards
Brief description
Remove the end cover for inspection.

1 Technician 0,4
tity

1 Seal 517.070
Related work cards

500.10 500.12 500.13
500.14 500.16 500.18
500.19 500.20 500.21
500.22
2011-01-13 - de
Work cards
NA29/S
C2 6663 500.23-01 EN-US 1 (2)

Work cards
Preliminary remarks
Figure 1: Removing and refitting the end cover

Starting condition Cartridge is removed. Compressor wheel, sealing cover, locating bearing,
thrust ring and turbine rotor are removed.
Steps 1. Unscrew the hexagon nuts (517.094) and take off the lock washer pairs
(517.103).
2. Remove the end cover (517.072) in axial direction with labyrinth disk
(517.064) bolted on and studs (517.068) screwed in.
3. Remove the seal (517.070).
4. Unscrew the hexagon bolts (517.081) and take off lock washer pairs
(517.082) if the labyrinth disk (517.064) has to be removed.
Slight grooves in the bore of the end cover (517.072) produced by the
labyrinth tips of the turbine rotor improve the sealing effect and are no
reason for replacing this part.

2011-01-13 - de

Work cards
Use only flawless seals.

When fitting the seal (517.070), pay attention to the position of the holes.
NA29/S
Bore for sealing air must be clean and unobstructed.
2 (2) C2 6663 500.23-01 EN-US

Bearing bushes
Work cards
Removing, refitting, checking
Brief description
Remove and refit the bearing bushes for inspection. Check the state and
wear condition of the components.

1 Technician 0,6
tity
Related work cards

500.06 500.10 500.12
500.13 500.14 500.16
500.18 500.19 500.20
500.21 500.22 500.23
2011-01-13 - de
Work cards
NA29/S
C2 6663 500.24-01 EN-US 1 (2)

Work cards
Preliminary remarks
Figure 1: Removing and refitting the bearing bushes

Starting condition Cartridge is removed. Compressor wheel, sealing cover, locating bearing,
thrust ring, turbine rotor and end cover are removed.
Steps 1. Unscrew the cylindrical screws (517.157) and take off the lock washer
pairs (517.156).
2. Take off both covers (517.159).
3. Take off the bearing bushes (517.161).
Check the bearing bushes (517.161), refer to work card [500.06]
“Checking the locating bearing and bearing bushes”.
4. Check the bearing body (517.162).
Replace bearing body if: D1 ≥ Ø 65.03 mm, D2 ≥ Ø 65.03 mm.
Loosen and push out the bearing body (517.162) and/or distance sleeve
(517.164) by means of light hammer blows with a copper pin only if they
are to be replaced. The distance sleeve can be removed only after the
grooved pin (517.163) has been withdrawn.
2011-01-13 - de

Work cards

The bearing bushes (517.161) are symmetrical and may therefore be fitted in
NA29/S
any position.
2 (2) C2 6663 500.24-01 EN-US

Gas admission casing
Work cards
Brief description
Remove the gas admission casing for inspection.

1 Technician 1,0
1 Assistant 1,0
tity
Related work cards

500.10
Technical data
Gas admission casing 60 kg
Turbine nozzle ring 10 kg
2011-01-13 - de
Work cards
NA29/S
C2 6663 500.25-01 EN-US 1 (2)

Work cards
Preliminary remarks
Figure 1: Removing and refitting the gas admission casing

Starting condition Connecting pipes and exhaust gas pipe are disconnected, or complete tur-
bocharger is removed from engine.
Steps 1. Unscrew the hexagon bolts (591.035) and take off the two-part annular
lagging (591.001).
2. Attach lifting tackle to the gas admission casing (501.001) using a rope
and shackles, and carefully tension the rope.
pairs (506.107).
4. Screw 3 hexagon bolts (506.106) into the forcing-off threads of the fas-
tening flange. Evenly force off the complete gas admission casing, care-
fully extract it in axial direction and set it down on a wooden support,
making sure that it is properly balanced.

Steps Apply high-temperature lubricant (e.g. Molykote HSC) to the threads of the
bolts.
2011-01-13 - de

Work cards
locking effect.
NA29/S
2 (2) C2 6663 500.25-01 EN-US

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

1 Technician 0,6
tity
Related work cards

500.10 500.25
2011-01-13 - de
Work cards
NA29/S
C2 6663 500.26-01 EN-US 1 (2)

Work cards
Preliminary remarks
Figure 1: Removing and refitting the turbine nozzle ring

Starting condition Gas admission casing is removed.
Steps 1. Unscrew the hexagon bolts (513.022), take off the lock washer
pairs (513.014) and the clamping ring (513.010).
2. Unscrew the hexagon bolts (513.025), take off the lock washer
pairs (513.024) and the nozzle ring (513.001).

Apply high-temperature lubricant (e.g. Molykote HSC) to the threads of the
bolts.
locking effect.
2011-01-13 - de
Work cards
NA29/S
2 (2) C2 6663 500.26-01 EN-US

Shroud ring, diffuser outside wall
Work cards
Brief description
Check shroud ring, replace if necessary. Check the state and wear condition
of the components.

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

500.10 500.16 500.25
Technical data
Diffuser outside wall 20 kg
2011-01-13 - de
Work cards
NA29/S
C2 6663 500.27-01 EN-US 1 (3)

Work cards
Preliminary remarks
Figure 1: Removing and refitting the shroud ring, removing and refitting the diffuser outside wall (only if necessary)
General For normal maintenance work, removal of the diffuser outside wall (509.001)
is not necessary.
Work sequence 1 – Removing the shroud ring

Starting condition Gas admission casing is removed.
Steps 1. Unscrew the hexagon bolts (509.012) and take off the lock washer
pairs (509.014). Evenly force off the clamping ring (509.010) with 3 hex-
agon bolts (M10, thread length ≥ 30 mm).
2. Remove the shroud ring (513.008).
Work sequence 2 – Removing the diffuser outside wall (only if necessary)

Starting condition Connecting pipes, cartridge, gas admission casing and shroud ring are
removed.
Steps 1. Attach lifting tackle to the diffuser outside wall (509.001) using a rope
through the outlet opening of the gas outlet casing (506.001).
pairs (509.015).
3. Loosen the diffuser outside wall in axial direction and lift off through the
outlet opening of the gas outlet casing.
2011-01-13 - de

Work cards

NA29/S
Steps For checking the gap between the shroud ring and the turbine rotor, refer to
Operating Instructions, Technical data, Gaps and clearances.
2 (3) C2 6663 500.27-01 EN-US

If the gap is less than the minimum value at any point on the circumference,
centre the clamping ring (509.010) together with the shroud ring (513.008)
Work cards
relative to the turbine rotor. If the available radial clearance is not sufficient for
this, the outside diameter of the clamping ring (509.010) can be reworked
locally.
Apply high-temperature lubricant (e.g. Molykote HSC) to the threads of the
bolts.
Pay attention to the position of the screw-on thread. 3× 120° division for fas-
tening the diffuser outside wall.
locking effect.
2011-01-13 - de
Work cards
NA29/S
C2 6663 500.27-01 EN-US 3 (3)

MAN Diesel & Turbo
1 Introduction
2 Technical details
3 Operation
5 Work cards
7 Index
Spare parts catalogue
2011-01-13 - de
6663-1 6 C1-01 EN-US 1 (1)

Introduction
6.1 Introduction
6.2 Spare parts

2011-01-13 - de
6663-1 6.1-01 EN-US 1 (1)

Preface
Introduction
General remarks
Spare parts/spare parts Maintenance and repair work can be carried out properly only if the required
catalogue spare parts are available. They are to be kept on stock or ordered in time.
The order numbers required for ordering spare parts can be looked up in the
spare parts catalogues.
Yours sincerely,

2010-04-15 - de
NR, NA
C3 6687 6.1.1-01 EN-US 1 (1)

Spare parts catalogue as a module of the technical documentation
Introduction
Spare parts for turbocharger
Spare parts for the turbocharger can be identified by means of the spare
parts catalogue.
Illustration and text sheets with order numbers are available in the spare
parts catalogue. An order number consists of a three-digit subassembly
number and a three-digit item number, separated by a dot. The spare parts
catalogue is arranged in the order of the subassemblies.
See chapter [500] – Overview of subassemblies
The order numbers can also be looked up in the respective work cards.
Chapter 5.2 – Work cards
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, separated by a dot.
The order numbers can also be looked up in the respective work cards.
Chapter 5.2 – Work cards, tables “Tools/appliances required”.
Spare parts for measuring, control and regulating systems

Information on spare parts for measuring, control and regulating instruments,
e.g. temperature sensors, relays, measuring transducers, pneumatic and
hydraulic valves, can be gathered from the documents contained in the tech-
nical 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 manufac-
turer.
2010-04-15 - de
NR, NA
C3 6687 6.1.2-01 EN-US 1 (1)

Organisation and use of the spare parts catalogue
Introduction
Instructions for use
The spare parts catalogue covers
▪ all essential components of the turbocharger.
The spare parts catalogue does not contain
▪ subordinate or plant-specific insulations/coverings.
▪ subordinate cabling, or cabling leading away from the turbocharger/
cabling and pipes installed out by other manufacturers.
What to do if spare parts are If parts have to be ordered which the spare parts catalogue does not contain
not found? or that are not found, the component and the installation location should be
described as precisely as possible, with a photo possibly attached. Where
parts from subsuppliers are concerned, which cannot be found in their docu-
mentation, the information given on the technical data plate should be
stated.
Validity
Scope of supply The spare parts catalogue is valid for the specified turbocharger type. To
identify parts, the individual pages of the spare parts catalogue must be
selected in accordance with the object concerned and/or the scope of sup-
ply of the turbocharger works number.
Modified components Since our turbochargers undergo upgrading development, it may happen
that when spare parts are ordered later on the parts supplied differ from the
ones supplied originally, which, however, serve the same purpose as the lat-
ter. In such cases, the identity card of the part supplied will contain a corre-
sponding reference.
Organisation of the spare parts catalogue

Overview of subassemblies The overview of the subassemblies consists of an illustration and a table. The
table is arranged in ascending order of the turbocharger subassemblies.
See “Overview of subassemblies” [500]
Subassembly Designation
517 Bearing casing
(578) Cleaning device for turbine
Subassemblies whose numbers are shown in parentheses are not installed on all
turbochargers (optional design).
Table 1: Examples of subassembly designations
Spare parts sheets The sheets in the spare parts catalogue are ordered in accordance with the
subassemblies system of the turbocharger. They consist of one or more illus-
trations each with an associated parts list.

2010-04-15 - de
NR, NA
C3 6687 6.1.3-01 EN-US 1 (2)

Ordinal number The ordinal number at the upper right of the spare parts
Introduction
e.g. 517.01 sheets consists of the three-digit subassembly number

and a variant number corresponding to the design variant.
517 (subassembly number)
01 (variant number)
Order No. The order number consists of a three-digit subassembly
e.g. 517.024 number and a three-digit item number. The subassembly
number and the item number are separated by a dot.
517 (subassembly number)
024 (item number)
Table 2: Spare parts catalogue sheet, organisational principle
2010-04-15 - de
NR, NA
2 (2) C3 6687 6.1.3-01 EN-US

Ordering spare parts
Introduction
Information required
To avoid queries, the following information should be provided when ordering
spare parts:
Turbocharger type xxxxxxxxx
Works number of turbocharger x xxx xxx
Order number xxx.xxx
IMO number (for flow-guiding parts) xxxxxx
Designation of part xxxxxxxxx
Quantity xx
Shipping address xxxxxxxxx
Mode of shipment xxxxxxxxx
Table 1: Information required in the order
Addresses
Headquarters
MAN Diesel & Turbo SE Tel. +49 821 322 0

PrimeServ Augsburg Fax +49 821 322 49 4180
86224 Augsburg
Germany
e-mail PrimeServ-Aug@mandieselturbo.com
PrimeServ Turbocharger Tel. +49 821 322 4010 Axial turbochargers (24 hours)
Technical service Tel. +49 821 322 4020 Radial turbochargers (24 hours)
Fax +49 821 322 3998
e-mail PrimeServ-TC-Technical@mandieselturbo.com
PrimeServ Turbocharger Tel. +49 821 322 4030 (24 hours)

Spare parts
2010-10-04 - de
Fax +49 821 322 3998
e-mail PrimeServ-TC-Commercial@mandieselturbo.com
NR, NA
C3 6687 6.1.4-01 EN-US 1 (2)


Introduction
Headquarters
PrimeServ Academy Tel. +49 821 322 1397
Training courses for turbochargers Fax +49 821 322 1170
and engines
e-mail PrimeServ.Academy-info@mandieselturbo.com
Internet www.mandieselturbo.com/primeserv-academies
If parts have to be ordered which the spare parts catalogue does not
contain or that are not found, the component and the installation
location should be described as precisely as possible, with a photo
possibly attached.
2010-10-04 - de
NR, NA
2 (2) C3 6687 6.1.4-01 EN-US

Spare parts
6.1 Introduction
6.2 Spare parts

2011-01-13 - de
6663-1 6.2-01 EN-US 1 (1)

MAN Diesel & Turbo 500
Overview of subassemblies
Spare parts
Subassemblies
Subassembly Designation
500 Exhaust gas turbocharger
501 Gas admission casing
506 Gas outlet casing
509 Outlet diffuser
513 Turbine nozzle ring
517 Bearing casing
518 Casing foot
520 Rotor, complete
540 Insert
542 Diffuser
(544) Silencer
(545) Air intake casing
546 Compressor casing

562 Speed measuring device
2010-04-15 - de
(578) Cleaning device for turbine

(579) Cleaning device for compressor
591 Covering
NA29/S
(...) if provided
C3 6663 500-01 EN-US 1 (1)

Gas admission casing
Spare parts
Spare parts 501.01
Order No. Designation

501.000 Gas admission casing, complete
501.001 Gas admission casing
501.023 Screw plug
501.024 Sealing ring

2010-04-15 - de
NA29/S
C3 6663 501.01-01 EN-US 1 (1)

Gas outlet casing
Spare parts
Spare parts 506.01

506.000 Gas outlet casing, complete
506.001 Gas outlet casing
506.102 Hexagon bolt
506.105 Hexagon nut
506.107 Lock washer pair
506.170 Suspension device Spare parts catalogue
2010-04-15 - de
NA29/S
C3 6663 506.01-01 EN-US 1 (1)

Gas outlet diffuser
Spare parts
Spare parts 509.01

509.000 Gas outlet diffuser, complete
509.001 Diffuser outside wall
509.008 Shroud ring
509.0010 Clamping ring
2010-04-15 - de
NA29/S
C3 6663 509.01-01 EN-US 1 (1)

Turbine nozzle ring
Spare parts
Spare parts 513.01

513.000 Turbine nozzle ring, complete
513.001 Nozzle ring
513.010 Clamping ring
513.025 Hexagon bolt Spare parts catalogue
2010-04-15 - de
NA29/S
C3 6663 513.01-01 EN-US 1 (1)

Bearing casing
Spare parts
Spare parts 517.01
Figure 1: Bearing casing
Order No. Designation / spare parts for Figure 1

517.000 Bearing casing, complete
517.055 Plain bearing, complete (517.156 – 517.164)
517.063 O-ring seal
517.064 Labyrinth disk
517.068 Stud
517.069 Stud
517.070 Seal
517.072 End cover
517.075 Locating bearing

517.085 Seal
517.089 Sealing cover
2010-04-15 - de

517.094 Hexagon nut
NA29/S

517.100 Undercut bolt
C3 6663 517.01-01 EN-US 1 (3)


Spare parts
517.101 Sleeve
517.102 Hexagon nut
517.134 Hexagon nut
517.157 Cylindrical screw
517.159 Cover
517.161 Bearing bush
517.162 Bearing body
517.163 Grooved pin
517.164 Distance sleeve
517.174 Diffuser inside wall
Figure 2: Bearing casing – lube oil supply and drain pipes, sealing air

2010-04-15 - de

517.013* Seal
517.022 Flange
NA29/S
517.023* Stud
517.025 Flange
2 (3) C3 6663 517.01-01 EN-US

Spare parts
517.026 O-ring seal
517.036 Sealing air pipe
517.040* Hexagon nut
517.044* Valve casing
517.047* Screw plug
517.048* Valve plate
517.049* Valve protection
517.050* Hose clamp
517.051* Screw connection
517.052* Sealing ring
517.054* Orifice
517.104** Hexagon bolt
517.105** Hexagon nut
517.106** Flange
517.107** Seal
517.108** Orifice
517.109 Seal
517.115 Flange
517.118 Seal
517.215 Flange
* only for four-stroke engine
** only for two-stroke engine Spare parts catalogue
2010-04-15 - de
NA29/S
C3 6663 517.01-01 EN-US 3 (3)

Casing foot
Spare parts
Spare parts 518.01

518.000 Casing foot, complete
518.001 Casing foot
518.025 Sleeve

2010-04-15 - de
NA29/S
C3 6663 518.01-01 EN-US 1 (1)

Rotor, complete
Spare parts
Spare parts 520.01

520.000 Rotor, complete
520.001 Turbine rotor
520.028 Thrust ring
520.031 Distance sleeve
520.035 Labyrinth ring
520.044 Compressor wheel
520.056 Feather key
520.061 Carrier
520.126 Magnetic shaft
2010-04-15 - de
NA29/S
C3 6663 520.01-01 EN-US 1 (1)

Covering
Spare parts
Spare parts 591.01

591.000 Covering, complete
591.001 Annular lagging

2010-04-15 - de
NA29/S
C3 6663 591.01-01 EN-US 1 (1)

Diffuser
Spare parts
Spare parts 542.01

542.001 Diffuser

2010-04-15 - de
NA29/S
C3 6663 542.01-01 EN-US 1 (1)

Insert, compressor side
Spare parts
Spare parts 540.02

540.000 Insert, compressor side, complete
540.001 Insert
540.010 Closing cap
540.015 O-ring seal
540.016* O-ring seal
540.020 Stud
540.021 Hexagon nut
540.022 Tab washer
540.030 Balance ring
* only for Jet Assist
2008-02-20 - de
C3 6660 540.02-01 EN-US 1 (1)

Silencer
Spare parts
Spare parts 544.01

544.000 Silencer, complete
544.001 Rear wall
544.021 Damping plate
544.032 Spacer pipe
544.034 Perforated plate
544.041 Front wall
544.069 Stud
544.074 Hexagon nut
544.075 Washer
544.077* Hexagon bolt
544.078* Lock washer pair
544.201 Air filter mat
544.202 V-profile clamp

544.205 Cover sheet
2007-12-21 - de
* if provided
C3 6660 544.01-01 EN-US 1 (1)

Air intake casing, 90°
Spare parts
Spare parts 545.01

545.000 Air intake casing, 90°, complete
545.001 Air intake casing
545.090 Injection pipe
545.093 Seal
2008-02-20 - de
NA29/S
C3 6660 545.01-01 EN-US 1 (1)

Air intake casing, axial
Spare parts
Spare parts 545.02

545.000 Air intake casing, axial, complete
545.001 Air intake pipe
545.020 Screw connection
545.021 Pipe
545.022 Screw plug
545.023 Sealing ring Spare parts catalogue
2008-02-20 - de
NA29/S
C3 6660 545.02-01 EN-US 1 (1)

Compressor casing
Spare parts
Spare parts 546.02

546.000 Compressor casing, complete
546.001 Compressor casing
546.008 Countersunk bolt
546.025 Type plate
546.026 Notched nail
546.033 Screw plug
546.035 Screw plug

546.050 Flange
2007-12-21 - de

546.061 Seal disk
C3 6660 546.02-01 EN-US 1 (1)

Speed measuring device
Spare parts
Spare parts 562.01

562.000 Speed measuring device, complete
562.004 Holding disk
562.005 Hexagon nut
562.040 Speed transmitter
562.061 Stud
562.077 Sealing agent (e.g. Adaptol)
562.083 Terminal box
562.086 Cable socket
562.100* Speed indicator
562.135* Teflon-armoured cable
* if provided
2007-12-21 - de
C3 6660 562.01-01 EN-US 1 (1)

Cleaning device for turbine/ wet cleaning
Spare parts
Spare parts 578.01

578.01.000 Cleaning device for turbine, complete (wet cleaning)
578.01.002 Screw connection
578.01.003 Sealing ring
578.01.005 Sealing ring
578.01.006 Pressure reducing station
578.01.010 Plate (with cleaning instructions)
578.01.020 Three-way cock Spare parts catalogue
2007-12-19 - de
NR
C3 6661 578.01-01 EN-US 1 (1)

Cleaning device for turbine/ dry cleaning
Spare parts
Spare parts 578.02

578.02.000 Cleaning device for turbine, complete (dry cleaning)
578.02.001 Tank
578.02.020 Screw plug
578.02.029 U-bolt
578.02.030 Ball cock
578.02.031 Stop cock
578.02.035 Plate (with cleaning instructions)
2007-12-19 - de
NR
C3 6661 578.02-01 EN-US 1 (1)

Cleaning device for compressor
Spare parts
Spare parts 579.01

579.000 Cleaning device for compressor, complete (separate tank)
579.029 Tank
579.030 Screw-type cap
579.080 Suction pipe
579.090 Hose
579.091 Hose clamp
579.120 Connecting piece
579.122 Hydrometer cock
579.126 Pipe
579.127 Hose
579.128 Hose clamp
2008-02-20 - de
579.130 Support
579.178 Plate (with cleaning instructions)
C3 6659 579.01-01 EN-US 1 (1)

Cleaning device for compressor/ pressure sprayer
Spare parts
Spare parts 579.02

579.000 Cleaning device for compressor, complete (pressure sprayer)
579.029 Pressure sprayer
579.090 Hose
579.091 Hose clamp
579.095 Coupling
579.096 Nipple
579.100 Screwed socket
579.102 Angular screw connection
579.130 Retainer
579.179 Plate
2007-12-19 - de
NR, NA
C3 6661 579.02-01 EN-US 1 (1)

MAN Diesel & Turbo
1 Introduction
2 Technical details
3 Operation
5 Work cards
7 Index
2011-01-13 - de
Index
6663-1 7 C1-01 EN-US 1 (1)

MAN Diesel & Turbo
Index
A D
Addresses and contact persons 1.4 (1) Danger of Fire/Fire-extinguishing 3.0 (2)
Admission casing 501.01 (1) Systems
Air filter mat 4.8.1 (1) Danger Symbols 1.0 (2)
Air intake casing 500.13 (2) Difference in height 2.4.1 (3)
Air intake casing, 90° 545.01 (1) Differences in height 2.4.1 (3)
Air intake casing, axial 545.02 (1) Diffuser 542.01 (1)
Alarm points 2.5.1 (2) Diffuser 500.14 (2)
Alarm System 3.0 (3) Diffuser outside wall 500.27 (2)
Availability code 5.1.2 (1) Dimensions 2.5.4 (1)
Dry cleaning 4.8.1 (2)
B
E
Bans (symbols) 1.0 (2)
Bearing bushes 500.06 (2) Emergency measures (in the event 3.6.3 (2)
Bearing bushes 500.24 (2) of turbocharger failure)
Bearing casing 517.01 (1) Emergency operation 3.6.3 (2)
Emergency operation
C Closing device 500.05 (2)
End cover 500.23 (2)
Cartridge 500.16 (2) Exhaust Gases 3.0 (2)
Casing foot 518.01 (1)
Cat fines 4.8.5 (1)
F
Checking
Bearing bushes 500.06 (2) Fire-extinguishing Equipment 3.0 (2)
Locating bearing 500.06 (2) Friction coefficient µ 000.31 (1)
Checks 3.5.1 (1)
3.5.1 (1) G
Clamp 500.14 (4) Gaps and clearances 2.5.5 (1)
Cleaning 4.8.1 (1) Gas admission casing 500.25 (2)
Cleaning 4.8.1 (2)
Cleaning the air filter 500.11 (1) 501.01 (1)
Cleaning the compressor Gas outlet casing 506.01 (1)
Tank 500.08 (2)
Cleaning the compressor H
Pressure sprayer 500.08 (2) Hazard levels
Cleaning the turbine Level 1 - 3 1.0 (1)
Dry cleaning 500.07 (2) Hearing Protection 3.0 (1)
Wet cleaning 500.07 (2)
Closing cover for emergency oper- 3.6.3 (1)
I
ation
Closing device 500.05 (2) Insert
Compressor casing 546.02 (1) Compressor side 540.02 (1)
546.02 (1) Insert 500.14 (2)
Compressor casing 500.14 (2) Inspection of Individual Compo- 4.8.5 (1)
Compressor cleaning nents (General)
Pressure sprayer 579.02 (1) Inspection report 4.8 (1)
2011-01-13 - de
Separate tank 579.01 (1) Intake air 4.8.1 (1)

Compressor wheel 500.18 (2) Intended use 3.2.2 (1)
Containment Safety 3.0 (1)
J
Jet Assist 2.4.7 (1)
6663-1 C1-01 EN-US 1 (3)

MAN Diesel & Turbo
L S
Labyrinth ring 500.19 (2) Safety
Locating bearing 500.06 (2) during Maintenance/Repair 4.0 (1)
Locating bearing 500.20 (1) during operation 3.0 (1)
Lube oil diagram 2.4.1 (1) General Safety Instructions 1.0 (1)
Lube oil drainage 2.4.1 (3) Safety instruction
2.4.1 (3) Caution 1.0 (1)
Lube oil filtration 2.4.1 (4) Danger 1.0 (1)
Lube oil quality 2.4.1 (4) Warning 1.0 (1)
Safety Symbols 1.0 (2)
M Scope of supply 2.1.1 (1)
Screen 3.6.3 (1)
Maintenance schedule 4.7.3 (1) Screw connections 4.8 (1)
5.1.1 (1) Sealing air diagram
Maintenance schedule 4.7 (1) Four-stroke engine 2.4.4 (1)
Maintenance work Two-stroke engine 2.4.5 (1)
Remarks 4.8 (1) Sealing cover 500.19 (2)
Maintenance Work Shaft sealing 2.4.1 (2)
General Remarks 4.1 (1) Shroud ring 500.27 (2)
Mechanical cleaning 4.8.1 (1) Shutting down 3.4.1 (2)
4.8.1 (2) Silencer 544.01 (1)
Silencer 500.12 (2)
Spare parts
N
General 4.0 (3)
Numbering Order numbers 4.1 (1)
Work cards 5.1.2 (1) Special services/Repair work 4.1 (1)
Special Tools 4.3 (1)
O Speed transmitter 500.14 (2)
Starting operation 3.4.1 (2)
Order number 6.1.3 (2) Starting operation (first time) 3.4.1 (1)
Order Numbers 5.1.2 (1) Status
Ordering spare parts 6.1.4 (1) Inventory 5.1.2 (2)
Outlet casing 506.01 (1) Optional 5.1.2 (2)
Overview of subassemblies 500 (1) Special 5.1.2 (2)
Standard 5.1.2 (2)
P System accessories 6.1.2 (1)
Product Liability 1.2 (1)
Protective Covers 3.0 (2) T
Thrust ring 500.21 (1)
Q Tightening of screw connections
Qualification of Personnel General 000.31 (1)
Maintenance/Repair 4.0 (1) Tool Number 5.1.2 (1)
Ship systems 3.0 (3) Tools 4.3 (1)
Stationary systems 3.0 (4) Trouble shooting 3.6.1 (1)
Turbine cleaning
Dry cleaning 578.02 (1)
R
Wet cleaning 578.01 (1)
Regulations for Prevention of Acci- 3.0 (1) Turbine nozzle ring 500.26 (2)
2011-01-13 - de
dents Turbine rotor 500.22 (2)

Required Personnel and Time Turbocharger
general 5.1.2 (1) Checks 3.5.1 (1)
Rotor 520.01 (1) Type plate 2.5.1 (1)
2 (3) 6663-1 C1-01 EN-US

MAN Diesel & Turbo
V Work cards
General remarks 4.1 (1)
Venting 2.4.1 (3)
V-profile clamp 500.14 (4)
W
Weights 2.5.3 (1)
Wet cleaning 4.8.1 (2)
2011-01-13 - de
6663-1 C1-01 EN-US 3 (3)

NA29-S Manual

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MAN Diesel & Turbo

Turbocharger type .............................. NA29/S

Works No. of turbocharger................

Translation of the original instructions

MAN Diesel & Turbo SE

Fax +49 (0) 821 322-49 4180

Copyright © 2011 MAN Diesel & Turbo

2 (2) 6663-1 C1-01 EN-US

6663-1 C1-01 EN-US 1 (3)

5.1.2 Organisation and use of the work cards

6 Spare parts catalogue

513.01 Turbine nozzle ring

2 (3) 6663-1 C1-01 EN-US

540.02 Insert, compressor side

6663-1 C1-01 EN-US 3 (3)

6663-1 1 C1-01 EN-US 1 (1)

General Safety Instructions

When the respective caution measures are not complied with,

• Death or serious injury,

When the respective caution measures are not complied with, a

When the respective caution measures are not complied with, a

For notes concerning fault sources/handling errors; material damage

C1 6673 1.0-02 EN-US 1 (3)

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

tective measure (safety symbols):

Wear Wear Wear Wear Wear

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

Crush hazard Inflammable Hot Danger of sus- Rotating

Fire, No access for

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

Figure 1: Safety Instruction Sign - Engine Room

Access to the danger area is permitted when the turbocharger is in proper

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

C1 6685 1.1-02 EN-US 1 (1)

For improper usage of the turbocharger, the danger of

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

C1 6685 1.2-02 EN-US 1 (1)

Organisation and use of the Operating Manual

Structure and special features

▪ difficult repair work requiring special tools, equipment and experience,

▪ behaviour in the event of fire, water penetration, severe damage and

C1 6685 1.3-02 EN-US 1 (2)

What is also of importance

2 (2) C1 6685 1.3-02 EN-US

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

Fax +49 821 322 3998

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

PrimeServ Academy Tel. +49 821 322 1397

Worldwide Service Addresses

C1 6685 1.4-03 EN-US 1 (1)

6663-1 2 C1-01 EN-US 1 (1)

MAN Diesel SE's scope of supply/technical specification

C1 6685 2.1.1-02 EN-US 1 (1)

Turbocharger, brief description, function

1 Gas admission casing 6.2 Silencer

charge air cooler and charge air pipe.

C1 6663 2.2.1-01 EN-US 1 (2)

The turbocharger rotor is guided in radial direction through 2 floating bearing

2 (2) C1 6663 2.2.1-01 EN-US