MAN Diesel & Turbo

MAN | PrimeServ Hamburg

Page 1 of 4

Cartridge Exchange Guide NR, NR/R & NR/S

Before commencement of the works fully familiarize yourself with the Operating Manual and the
relevant Work Cards as to the disassembly and assembly incorporating the procedures below
learnt from past service experiences.

Record the stamped markings/IMO numbers from the turbine rotor/compressor wheel, if the nozzle
ring is exchanged also record the stamped markings/IMO number and square area

Work Card 500.14

Disassemble the fixation bolts to the compressor casing /cooler flange connection. Separate the
flanges as this is usually seized together by silicone/sealing compound
Release the V Clamp-bolts to the compressor casing and remove the V Clamp. If the compressor
casing is seized in position a suitable slot screwdriver knocked between the bearing/compressor
casing connection will free the compressor casing, then disassemble the compressor casing.
Beware of contact of the compressor casing with the compressor wheel

Work Card 500.16

If an orifice is installed in the lube oil inlet pipework set aside for re-use. Protect the open bores of
the lube oil inlet/outlet pipe work
Remove the nuts, lock washer and clamping claws fixating the cartridge within the gas inlet casing
(to assist with release use releasing agent ie – WD 40)
Remove the bolts which fixate the cartridge to the foot

Clean the gas admission casing and turbine side insert piece ensuring that all carbon residues are
removed.
A needle gun is the best tool to achieve the above, then use a suitable abrasive paper to polish the
surfaces, ensure when needle gunning by the nozzle ring collar pin that it is not damaged is not
damaged. After descaling is completed remove debris from the inner scroll of the gas inlet casing

MAN Diesel &Turbo SE PrimeServ Hamburg , Postadresse:Postfach 11 09 09, 20409 Hamburg, Germany, Hausadresse:Rossweg 6, 20457 Hamburg, Germany
Telefon: +49 40-7409-0, Telefax: +49 40-74 09-104
http://www.mandieselturbo.com, E-Mail: PrimeServ-ham@mandiesel.com
MAN Diesel & Turbo

MAN | PrimeServ Hamburg

Page 2 of 4

Nozzle ring cleaning if time allows immerse in water or transfer to a local workshop for – do not
needle gun this component

Clean all connection flanges to the turbocharger casings, engine & exhaust pipe, with suitable
abrasive

Polish the V clamps within the V and connection surfaces to the respective casings with a suitable
abrasive

To the gas inlet casing apply a thin layer of high temperature molykote to the area were the nozzle
ring and cartridge are mounted plus the studs

Install cleaned/new turbine nozzle ring, ensure the locating bore is positioned on the collar pin

Prepare cartridge for axial gap (turbine rotor/insert) position lead wire to at least 3 of the turbine
rotor vanes at an axial position

MAN Diesel &Turbo SE PrimeServ Hamburg , Postadresse:Postfach 11 09 09, 20409 Hamburg, Germany, Hausadresse:Rossweg 6, 20457 Hamburg, Germany
Telefon: +49 40-7409-0, Telefax: +49 40-74 09-104
http://www.mandieselturbo.com, E-Mail: PrimeServ-ham@mandiesel.com
MAN Diesel & Turbo

MAN | PrimeServ Hamburg

Page 3 of 4

Introduce cartridge assembly into the gas admission casing ensuring the nozzle ring is in the
correct position, place 4 claws/hex nuts evenly spaced and tighten, release the 4 claws/hex nuts
and press out the cartridge, remove the lead wire and record the axial clearance.

Reassemble the cartridge assembly into the gas admission casing aligning the bolt holes were the
cartridge connects/positions on the foot, position all fixation bolts to the foot by hand.

Check that the lube oil inlet/outlet pipe work/bores in the bearing housing are in the correct position

Assemble the claws, lock washer pairs and nuts, progressively tighten nuts turning the compressor
wheel slightly to the left and right to ensure the turbine rotor enters the turbine side insert correctly.
Observe the relevant toque value for these nuts.

Tighten the fixation bolts for the cartridge/foot observing tightening torque

Assemble the lube oil inlet/outlet pipework, re-assemble the previously set aside orifice if this
design is applicable

The radial clearance of the turbine rotor/turbine side insert can only be recorded if the gas outlet
casing has been removed

Work Card 500.14

Assemble the o ring on the bearing casing, apply lube oil to the connecting surfaces , assemble the
compressor casing on the cartridge
Beware of contact of the compressor casing with the compressor wheel

Assemble the V Clamp with the bolt fixation at this point do not apply the given torque

Rotate the compressor casing flange to the cooler connection and install the bolts by hand but do
not tighten at this point

Apply the required torque to the V Clamp ensuring an equal spacing between the 2 halves of the
clamps.Tap the V Clamp with a suitable hammer (plastic/copper) recheck final torque
Position the locking plates to the V Clamp if applicable and apply required torque

Tighten fixation bolts to the compressor casing flange/cooler

Prepare cartridge for axial gap (compressor wheel/insert) position lead wire to at least 3 of the
compressor wheel vanes at an axial position

MAN Diesel &Turbo SE PrimeServ Hamburg , Postadresse:Postfach 11 09 09, 20409 Hamburg, Germany, Hausadresse:Rossweg 6, 20457 Hamburg, Germany
Telefon: +49 40-7409-0, Telefax: +49 40-74 09-104
http://www.mandieselturbo.com, E-Mail: PrimeServ-ham@mandiesel.com
MAN Diesel & Turbo

MAN | PrimeServ Hamburg

Page 4 of 4

Check balance ring for deformation (load point were the bolts make contact when pressing out) re-
dress to a flatten surface before assembly

Assemble the insert piece with balance ring, using four bolts tighten into position.(lube oil applied
to the seating surfaces assists the assembly)

Release the four bolts and press out the insert piece, remove lead wire and record axial clearance.

Reassemble the insert piece with balance ring and O Rings (jet assist application) fixing in
position with all bolts on required torque
Record radial clearance (compressor wheel/insert) with a feeler gauge
Reassemble the speed pick up as per design refer to the manual
Reassemble the silencer, position the V clamp and apply the required torque to the V clamp
ensuring an equal spacing between the 2 halves of the clamps.
Tap the V clamp with a suitable hammer (plastic/copper) recheck final torque

Carry out a test run observing as a minimum the data below, if any deficiencies are observed
investigate the reason before putting the engine into full operation

Load %
Engine Speed RPM
Turbocharger speed RPM
Gas temp. Before turbine ˚C
Gas temp. After turbine ˚C
Charger air pressure bar
Lube oil inlet pressure bar
Lube oil inlet temp. ˚C
Lube oil outlet temp ˚C

MAN Diesel &Turbo SE PrimeServ Hamburg , Postadresse:Postfach 11 09 09, 20409 Hamburg, Germany, Hausadresse:Rossweg 6, 20457 Hamburg, Germany
Telefon: +49 40-7409-0, Telefax: +49 40-74 09-104
http://www.mandieselturbo.com, E-Mail: PrimeServ-ham@mandiesel.com