TCR18 0288-2

MAN Diesel & Turbo
Technical Documentation
Turbocharger
Operating Instructions
Turbocharger type....................... TCR18-41
Works No. of turbocharger..........

2010-05-12
Translation of the original instructions
0288-2 C1-2 EN 1 (2)

MAN Diesel & Turbo
MAN Diesel & Turbo SE

86224 Augsburg
Germany
Phone +49 (0) 821 322-0
2010-05-12
Fax +49 (0) 821 322-49 4180

[email protected]
www.mandieselturbo.com/primeserv
Copyright © MAN Diesel & Turbo

All rights reserved, including reprinting, copying (Xerox/microfiche) and translation.
2 (2) 0288-2 C1-2 EN

MAN Diesel & Turbo
Table of contents
Table of contents
1 Safety
1.0 General Safety Instructions
1.1 Product Liability
2 Addresses
2.1 MAN Diesel | PrimeServ
3 Technical data
3.1 Turbocharger
3.1.1 Operating data and alarm points
3.1.2 Weights, dimensions and connections
3.2 Operating media/ Quality requirements
3.2.1 Fuels for the Engine
3.2.2 Lubricating Oil
3.2.3 Intake Air
3.2.4 Cleaning Agents for Compressor and Turbine
4 Description
4.1 Turbocharger
4.2 Lube oil system
4.3 Acceleration system - Jet Assist OPTION
4.4 Cleaning system – Wet cleaning of the turbine
4.5 Cleaning system – Dry cleaning of the turbine
4.6 Cleaning system – Wet cleaning of the compressor
5 Operation
5.0 Safety during Operation
5.1 Starting operation/Shutting down
5.2 Emergency operation of the engine on failure of a turbocharger
5.3 Malfunctions/faults and their causes
6 Maintenance
6.0 Safety during Maintenance/Repair
6.1 General remarks
6.2 Tools
2010-05-12
6.3 Maintenance Schedule

6.3.1 Maintenance schedule - turbocharger
6.4 Remarks on maintenance work
6.5 Inspection of components
6.6 Inspection report
0288-2 C1-2 EN 1 (3)

MAN Diesel & Turbo
6.7 Service report

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

8.1 Preface
8.1.1 Organisation and use of the spare parts catalogue
8.1.2 Ordering spare parts
8.2 Overview of subassemblies
500 Overview of subassemblies
8.3 Spare parts
501.01 Gas admission casing
506.01 Gas outlet casing
506.02 Gas outlet casing with waste gate - OPTION
513.01 Turbine nozzle ring
517.01 Bearing casing
2010-05-12
520.01 Rotor complete

540.01 Insert, compressor side
541.01 Insert, turbine side
542.01 Diffuser
544.02 Chamber silencer - OPTION
2 (3) 0288-2 C1-2 EN

MAN Diesel & Turbo
545.01 Air intake casing, 90° - OPTION
Table of contents
545.02 Air intake casing, axial - OPTION
562.01 Speed measuring device - OPTION
578.01 Cleaning device for turbine - Wet cleaning
578.02 Cleaning device for turbine - Dry cleaning
579.02 Cleaning device for compressor - Pressure sprayer
591.01 Covering on gas admission casing
591.02 Covering on gas outlet casing
591.03 Covering on compressor casing - OPTION
599.01 Cartridge
8.4 Spare parts for maintenance 11.59500-0246
595.01 Spare parts for maintenance - OPTION Turbocharger TCR18
8.5 Spare parts for major overhaul 11.59500-0257
595.02 Spare parts for major overhaul - OPTION Turbocharger TCR18
8.6 Tools - OPTION 11.59600-0219
596.01 Tools Turbocharger TCR18
9 Index
2010-05-12
0288-2 C1-2 EN 3 (3)

MAN Diesel & Turbo
Safety
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
2010-05-12
0288-2 1-2 EN 1 (1)

MAN Diesel & Turbo 1.0
General Safety Instructions
Safety
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.
For notes concerning fault sources/handling errors; material damage can

occur.
Additional notes, information and tips.
2009-01-15
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-
General
Safety
tective measure (safety symbols):
C1 6673 1.0-02 EN 1 (3)

1.0 MAN Diesel & Turbo
Safety Symbols
Safety
Wear Wear Wear Wear Wear

gloves protective hearing pro- hard hat safety boots
goggles tection
Wear Read
protective manual
clothing
Danger Symbols
Warning of a Danger of slip- Tripping haz- Danger of Corrosive

hazard loca- ping ard electric shock materials
tion
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!
2009-01-15
General
Safety
2 (3) C1 6673 1.0-02 EN

Safety Instruction Sign - Engine Room
Safety
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.
Persons, who for operational reasons are to be within the danger area of 2.5
2009-01-15
m around the engine, are to be instructed of the predominant hazards.

Access to the danger area is permitted when the turbocharger is in proper
operating condition and only when wearing suitable protective equipment.
General
Safety
It is prohibited to stay within the danger area without reason.
C1 6673 1.0-02 EN 3 (3)

Product Liability
Safety
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 regula-
tions to be observed. The MAN Diesel & Turbo SE asks you to observe the
following 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.
2009-01-15
General
Safety
C1 6673 1.1-02 EN 1 (1)

MAN Diesel & Turbo
Addresses
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
2010-05-12
0288-2 2-2 EN 1 (1)

MAN Diesel | PrimeServ
Addresses
Works in Germany
Contact persons The following tables contain addresses for MAN Diesel & Turbo 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 (switchboard)
MAN Diesel & Turbo | PrimeServ Fax +49 821 322-49 4180
Augsburg
86224 Augsburg e-mail [email protected]
Germany Internet http:// www.mandiesel.com
PrimeServ Turbocharger Tel. +49 821 322 4010 (axial turbochargers)
Technical service Tel. +49 821 322 4020 (radial turbochargers)
Fax +49 821 322-3998
e-mail [email protected]
Internet http:// www.mandiesel.com/primeserv
PrimeServ Turbocharger e-mail [email protected]
Retrofits Internet http:// www.mandiesel.com/primeserv
PrimeServ Turbocharger Tel. +49 821 322-4030
Spare parts Fax +49 821 322-3998
PrimeServ Academy Tel. +49 821 322-1397
Training courses for turbochargers Fax +49 821 322-1170
and engines
Internet http://www.mandiesel.com/psa-augsburg
Hamburg plant
(servicing, repairs, maintenance)
MAN Diesel & Turbo SE Tel. +49 40 7409-0
MAN Diesel & Turbo | PrimeServ Fax +49 40 7409-104
Hamburg
Hachmannkai e-mail [email protected]
Rossweg 6 Internet http:// www.mandiesel.com/primeserv
20457 Hamburg
Germany
Worldwide Service Addresses

Internet MAN Diesel & Turbo service addresses and authorized service partners
(ASP) can be found on the Internet at:
2010-02-17
http:// www.mandiesel.com/primeserv
PrimeServ Worldwide A brochure with the worldwide service addresses can be obtained from:
Addresses
General
C1 6673 2.1-06 EN 1 (2)

administrative office(administrative office)

Addresses
Tel. +49 821 322-1198

Fax +49 821 322-3998
e-Mail [email protected]
2010-02-17
Addresses
General
2 (2) C1 6673 2.1-06 EN

MAN Diesel & Turbo
Technical data
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
2010-05-12
0288-2 3-2 EN 1 (1)

Turbocharger
3.1 Turbocharger
0288-2 3.1-2 EN 1 (1)

MAN Diesel & Turbo 3.1.1
Operating data and alarm points
Turbocharger
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. An additional type plate is located on the silencer or the intake
casing.
Operating parameters
Speed Operating limit nmax see
type plate
Speed indicator Indication range 0 to 50 000 rpm
Exhaust gas temperature upstream of Operating limit tmax see
turbine type plate
Lube oil temperature Inlet temperature at full engine load < 75 °C
Lube oil pressure in normal operation and at full engine load 1.3 – 2.2 bar
(reference height: turbocharger centre-
line)
Lube oil flow rate with SAE 30 at 60 °C and 1.3 bar operating pres- 1.3 m3/h
sure
Jet Assist (optional) Max. permissible inlet pressure in turbocharger 4 bar
Further specifications see also Lube oil system, Chapter [4.2]
Table 1: TCR18 operating parameters
Alarm points
An alarm must be triggered by the engine control system when the following
Technical data
operating data are exceeded:

2010-05-12
Speed Alarm at 97% nmax

Exhaust gas temperature upstream of Alarm at tmax see
TCR18
turbine type plate
C1 0288 3.1.1-02 EN 1 (2)

3.1.1 MAN Diesel & Turbo
Lube oil temperature Alarm at max. outlet temperature see

Turbocharger
engine commission-
ing log
Lube oil temperature in the case of tur- Alarm at Δ inlet temperature/outlet temperature > 30°C
bocharger retrofits
Lube oil pressure Alarm at < 1.0 bar
(reference height: turbocharger centre-
line) Reduction to engine half load (slow-down) < 0.8 bar
Engine shut-down < 0.6 bar
Table 2: Alarm points
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.
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
Technical data
2010-05-12
TCR18
2 (2) C1 0288 3.1.1-02 EN

Weights, dimensions and connections
Turbocharger
Weights
Subassembly Designation Optional Weight
500 Turbocharger, complete, incl. silencer 451 kg
500 Turbocharger, complete, with air intake casing, 90° 424 kg
500 Turbocharger, complete, with air intake casing, axial 408 kg
501 Gas admission casing 62 kg
506 Gas outlet casing 87 kg
506 Gas outlet casing, with waste gate X 93 kg
513 Turbine nozzle ring 4 kg
517 Bearing casing 66 kg
520 Rotor, complete 22 kg
540 Insert, compressor side 18 kg
541 Insert, turbine side 8 kg
542 Diffuser 5 kg
544 Silencer X 68 kg
545 Air intake casing, 90° X 41 kg
545 Air intake casing, axial X 25 kg
546 Compressor casing 70 kg
591 Covering, on gas admission casing 18 kg
591 Covering, on gas outlet casing 23 kg
591 Covering, on compressor casing X 10 kg
599 Cartridge (517 + 520) 88 kg
Table 1: TCR18 subassemblies and weights (approximate values)
Technical data
2009-02-02
TCR18
C1 0288 3.1.2-03 EN 1 (2)

Dimensions
Turbocharger
Figure 1: Main dimensions (in mm)
Connections
Exhaust gas Entry at the gas admission casing (501.01) ∅ 162 mm
Exhaust gas Outlet at the gas outlet casing (506.01) ∅ 310 mm
or at the gas outlet casing (506.02 optional) ∅ 310 mm
with “WASTE GATE” connection ∅ 68 mm
Charge air Entry at the silencer (544.01 optional) ∅ 741 × 290 mm
or at the air intake casing (545.01/545.02 optional) ∅ 310 mm
Charge air Outlet at the compressor casing (546.01) ∅ 176 mm
Lube oil Inlet at the bearing casing (517.01) ∅ 18 mm
Lube oil Drain at the bearing casing (517.01) ∅ 45 mm
Jet Assist (optional) Entry at the compressor casing (546.01)
flange connection for pipe inside diameter min. ∅ 40 mm
Table 2: TCR18 connections
Different versions of the casing can be installed, depending on the engine

type.
Technical data
For further details, see drawing: turbocharger connection dimensions

2009-02-02
TCR18
2 (2) C1 0288 3.1.2-03 EN

Operating media/ Quality requirements

3.1 Turbocharger
0288-2 3.2-2 EN 1 (1)

Fuels for the Engine

Fuels for the Engine
Engine Fuel Affects Exhaust The quality of the fuel with which the engine is operated affects the com-
Gas Quality position of the exhaust gas that flows through the turbocharger. Impurities
in the fuel can lead to residues in the exhaust gas, which can effect the
turbocharger in an abrasive or corrosive manner.
Quality Requirements for MDO is also known as diesel fuel oil, diesel oil, bunker diesel oil or marine
Marine Diesel Oil (MDO) diesel fuel.
MDO is offered exclusively for shipping as heavy distillate (ISO-F-DMB or

as a mixture of distillate and low amounts of residual oil (ISO-F- DMC). The
term “blended MDO” is common for the dark brown to black colored mix-
ture. MDO is produced from crude oil and must be free of organic acids.
The usability of the fuel depends on the design of the engine and the clean-
ing device as well as if the characteristics mentioned below, which are
based on the condition at the time of supply, are observed.
The characteristics determined were based on the ISO 8217‑1996 and
CIMAC‑2003 specifications. The characteristics refer to the mentioned test-
ing methods.
Properties/Characteristics Unit Testing Method Characteristic
ISO-F specification DMB DMC
Density at 15 °C kg/m 3
ISO 3675 900 920
Kinematic viscosity at 40 °C mm /s = cSt
2
ISO 3104 < 11 < 14
Pour point Winter quality °C ISO 3016 < 0 < 0
Summer quality °C ISO 3016 < 6 < 6
Flash point Pensky Martens °C ISO 2719 > 60 > 60
Total sediment content Wt.% ISO CD 10307 0.10 0.10
Water content Vol.% ISO 3733 < 0.3 < 0.3
Sulphur content Wt.% ISO 8754 < 2.0 < 2.0
Ash content Wt.% ISO 6245 < 0.01 < 0.03
Carbon residue (MCR) Wt.% ISO CD 10370 > 0.3 < 2.5
Cetane number – ISO 5165 > 35 > 35
Copper strip test – ISO 2160 < 1 < 1
Vanadium content mg/kg DIN 51790 T2 0 < 100
Aluminum and silicium content mg/kg ISO CD 10478 0 < 25
Visual check – * –
Other specifications:
British Standard BS MA 100-1987 Class M2 Class M3
Technical data
2009-01-15
ASTM D 975 2D 4D
ASTM D 396 No. 2 No. 4
General
* In good light and at room temperature, the fuel should appear clear and transparent.
Table 1: Marine Diesel Oil (MDO) – Characteristics to be met
C1 6673 3.2.1-01 EN 1 (4)

Mixing fuels can lead to a reduction of quality. This can result in

combustion with a high degree of residuals, which can cause heavy

contamination of the turbocharger. Extreme contamination can damage
the turbocharger.
Therefore the following points are to be observed:
▪ In loading plants and during transportation, MDO is treated as residual

oil. Mixing with, e. g. high-viscous fuel oil or Interfuel remaining in a
bunker vessel is possible and can lead to a considerable reduction in
quality.
▪ Different bunker batches of blended MDO (ISO-F DMC) can be incom-
patible and therefore should not be mixed. For this reason, the respec-
tive fuel tank should be emptied to the greatest possible extent before
a new batch is filled up.
Ocean water in the fuel aides corrosion in the turbocharger and leads to
high-residual combustion. Solid foreign matter increases the mechanical
wear in the nozzle ring and the turbine of the turbocharger.
Therefore the following is to be observed:
▪ If blended MDO (ISO-F DMC) is primarily being used, we recommend

installing a centrifugal separator in front of the fuel filter. This widely
separates solid particles (sand, rust, catalyst residue, catfines) and
water, so that the cleaning intervals for the filter inserts can also be pro-
longed.
Operting data:
▪ Separator admission 65%, with reference to the rated throughput
capacity,
▪ Separation temperature 40-50 °C.
Quality requirements for MAN Diesel turbochargers can be operated on engines that run on crude-
Heavy Fuel Oil (HFO) oil based heavy fuel oil, when the engine and the processing system are
designed accordingly.
The fuels used must meet the fuel specifications in accordance with the
Table "Fuel specifications and corresponding characteristics".
The respective limit values to be observed are listed in the Table "Fuel
specifications and corresponding characteristics". The limit values that
influence the engine operation are to be specified when ordering fuel, e. g.
in the bunker or charter clause.
Adding motor oil (waste oil), mineral-oil-foreign materials (e. g. coal oil)
and remainders from refining or other processes (e. g. solvent) is
prohibited! This ban is specifically to be pointed out in the fuel order, as
it is not yet part of the standard fuel specifications.
Technical data
Such additions lead to combustion with high residue and increased wear
2009-01-15
and corrosion on components of the turbocharger. Adding motor oil (waste/

old oil) is particularly critical, as the lube oil additives cause emulsions to
General
form and keep debris, water and catalyst particles finely distributed in poise.
This impedes or avoids the required fuel cleaning.
2 (4) C1 6673 3.2.1-01 EN

The heavy fuel oils ISO F-RMK 35/45/55, with a maximum density of

1010 kg/m3, can be used only when respectively modern separators are
available.
Fuel Specification
CIMAC 2003 A10 B/C10 D15 E/F25 G/H35 H45 H55
BS MA-100 M4 M5 M7 8/9 M8/ – M9/ –
ISO F-RM A10 B/C10 D15 E/F25 G/H35 H45 H55
System-relevant Characteristics
Viscosity (at 50 °C) mm2/s (cSt) max. 40 40 80 180 380 500 700
Viscosity (at 100 °C) mm /s (cSt)
2
max. 10 10 15 25 35 45 55
Density (at 15 °C) g/ml max. 0.975 0.981 0.985 0.991
Flash point °C min. 60
Pour point (summer) °C max. 6 24 30 30
Pour point (winter) °C min. 0 24 30 30
Engine-relevant Characteristics
Carbon residue (Conrad- Wt.% max. 10 10/14 14 15/20 18/22 22 22
son)
Sulphur Wt.% max. 3.5 3.5 4 5 5
Ash Wt.% max. 0.10 0.15 0.20
Vanadium mg/kg max. 150 150/30 350 200/50 300/60 600
0 0 0
Water Vol.% max. 0.5 0.5 0.8 1 1 1 1
Sediment (potential) Wt.% max. 0.1
Supplementary Characteristics
Aluminum + silicium mg/kg max. 80
Asphaltenes Wt.% max. 2/3 of the carbon residue (Conradson)
Sodium mg/kg Sodium< 1/3 vanadium, sodium< 100
Cetane number of the fluid mixing component: min. 35
Fuel to be free of mineral-oil-foreign additives such as coal oil or vegetable oil.
Free of creosol and lubricating oil (waste oil)
Table 2: Fuel specifications and corresponding characteristics (HFO)
Thorough processing of heavy fuel oil is required for trouble-free

engine operation.
The following points are to be observed for this:
▪ Heavily abrasive inorganic, solid foreign substances (catfines, rust,

sand) must be separated to the greatest possible extent.
Technical data
2009-01-15
▪ With an aluminum content >10 mg/kg, the abrasive wear in the turbo-
charger increases heavily.
General
▪ Use only separators of the latest generation which are fully effective over
a large density range without any adjustment, and separate water with
C1 6673 3.2.1-01 EN 3 (4)

an HFO density of 1.01 g/ml at 15 °C. The cleaning effect is controlled

by the separator itself.

▪ The HFO purification is to be designed in such a manner that the char-
acteristics in the Table "Achievable foreign matter and water content
after separation" are reached:
Characteristic Particle Size Amount
Inorganic, solid foreign < 5 µm < 20 mg/kg
substances (AlSi content < 15 mg/kg)
(incl. catfines)
Water – < 0.2 vol.%
Table 3: Achievable foreign matter and water content after separation
▪ With unfavorable vanadium-sodium ratio, the melting temperature of the
HFO ash drops to the range of the exhaust valve temperature, which
causes hot corrosion. By pre-cleaning the HFO in the settling tank and
in the centrifugal separators, the water and thus the water-soluble
sodium compounds can be removed to the largest extent.
With a sodium content exceeding 100 mg/kg, increasing salt deposits
in the turbine are to be expected. This jeopardizes the turbocharger
operation (by pumping of the turbocharger, among other things). When
using PTG, the sodium content must be limited to 50 mg/kg.
Under certain conditions, hot corrosion can be avoided with a fuel addi-
tive that increases the melting temperature of the HFO ash.
▪ Heavy fuel oils with a high ash content in form of foreign substances, e.
g. sand, rust, catfines, increase the mechanical wear in the turbo-
charger. Heavy fuel oils from catalytic cracking plants can contain cat-
fines. Generally, these are aluminum silicate, which effects high wear in
the turbocharger. The determined aluminum content multiplied by 5-8
(depending on catalyst composition) approximately amounts to the con-
tent of catalyst material in the HFO.
Technical data
2009-01-15
General
4 (4) C1 6673 3.2.1-01 EN

Lubricating Oil

Lubricating Oil
Base Oil The base oil must fulfil the following limit values, particularly concerning the
aging stability:
Properties/Characteristics Unit Testing Method Characteristic
Structure – – Preferably paraffin-based
Behaviour in cold - still fluid °C ASTM-D2500 -15
Flash point acc. to Cleveland °C ASTM-D92 > 200
Ash content (oxide ash) Wt.% ASTM-D482 < 0.02
Carbon residue acc. to Conradson Wt.% ASTM-D189 < 0.50
Aging tendency after 100 h of heating – MAN aging cabinet –
to 135 °C
n-heptane insoluble Wt.% ASTM-D4055 resp. < 0.2
DIN 51592
Evaporation loss Wt.% – < 2
Drop test (filter paper) – MAN test Must not show separation of resinous
and asphaltic aging products.
Table 1: Lubricating oil – Characteristics to be met
Additives Additives must be dissolved in oil and of such a structure that as little ash
as possible results during combustion. The ash must have a soft structure.
If this is not the case, increased formation of residue in the bearing casing
of the turbocharger must be taken into account. Hard additive ash aides
increased mechanical wear.
Additives may not aid a clogging of the filter inserts, neither in the active or
processed condition.
Viscosity SAE Class Viscosity mm2/s at 40 °C resp. 100°C
30 Preferred in the upper range of the SAE class assigned to the
40 turbocharger
Table 2: Viscosity (SAE class) of lubricating oils
Lubricating Oil Additives We urgently advise against the later addition of additives to the lubricating
oil or mixing different lube oil brands together, as this can destroy the func-
tion of the additive package matched for the base oil. Such action also
annuls the supplier’s responsibility for the lubricating oil.
Technical data
2009-01-15
General
C1 6673 3.2.2-01 EN 1 (1)

Intake Air

Intake Air
The state as well as the condition of the intake air has a decisive influence
on the performance of the turbocharger. Not only is the atmospheric con-
dition of great importance, but also the degree of solid and gaseous impur-
ities.
Mineral dust particles in the intake air have a wear-aiding effect. Chemical/
gaseous components, on the other hand, have a corrosion-aiding effect.
For this reason, effective cleaning of the intake air and regular maintenance/
cleaning of the silencer air filter mat is required.
Intake Air Characteristics The particle size in the intake air must not exceed 5 μm after the silencer/
air intake casing or ahead of the compressor inlet.
The following maximum concentrations in the intake air may not be
exceeded:
Concentration
Properties/Characteristics
in mg/Nm3 1)
Dust (sand, cement, CaO, Al2O3 etc.) 5
Chlorine 1.5
Sulphur dioxide (SO2) 1.25
Hydrogen sulphide (H2S) 15
1) Standard cubic meter in Nm 3
Table 1: Maximum concentration of particles in the intake air

When dimensioning the intake air system, pay attention not to exceed a total
pressure loss (filter, silencer, piping) of 20 mbar.
Technical data
2009-04-30
General
C1 6673 3.2.3-01 EN 1 (1)

Cleaning Agents for Compressor and Turbine

Wet Cleaning of the Compressor and Turbine
Use freshwater only.

Salt water causes corrosion on the turbocharger components.
Wet Cleaning For wet cleaning of the compressor and turbine during operation, use only
freshwater without chemical additives.
Dry Cleaning of the Turbine
Dry Cleaning For dry cleaning of the turbine during operation, commercial granules are
used that must meet the following specifications:
Granulate of:
▪ Nutshells,
▪ Activated charcoal (soft).
Particle size:
▪ 1.0 mm (max. 1.5 mm).
Store and mark granulates in such a manner that they can not be
mistaken for other materials (salt, sand, etc.).
Technical data
2009-01-15
General
C1 6673 3.2.4-01 EN 1 (1)

MAN Diesel & Turbo
Description
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
2010-05-12
0288-2 4-2 EN 1 (1)

Turbocharger
Description
Subassemblies
2008-12-11
501 Gas admission casing 520 Rotor, complete 544 Silencer

506 Gas outlet casing 540 Insert, compressor side 545 Air intake casing
Description
513 Turbine nozzle ring 541 Insert, turbine side 546 Compressor casing
517 Bearing casing 542 Diffuser
Figure 1: TCR turbocharger
TCR
C1 0288 4.1-01 EN 1 (3)

Turbochargers of the TCR series consist mainly of a radial turbine stage and
Description
a radial compressor stage, which are seated on the same turbine shaft. The
exhaust gases of the engine drive the turbine. The compressor draws in
fresh air and compresses it. The compressed fresh air is then forced into
the cylinders of the engine.
The turbocharger consists of the following main subassemblies:
▪ Gas admission casing (501):
The turbine nozzle ring (513) and the insert (541) are installed in the gas
admission casing. These components enable optimum adaptation of
the turbocharger to the engine.
▪ Gas outlet casing (506):
Integrated into the gas outlet housing is the gas outlet diffuser, which
optimises the flow of the exhaust gas.
Optionally, a gas outlet casing with a “WASTE GATE” connection can
be supplied.
▪ Bearing casing (517):
The interior bearing of the rotor primarily consists of two bearing bushes
and a thrust bearing. The highly stressed bearing points are lubricated
and cooled by means of the turbocharger lube oil system, which is inte-
grated into the bearing casing. The turbocharger lube oil system is sup-
plied with oil from the engine lube oil system.
▪ Rotor, complete (520):
The turbine wheel and turbine shaft are firmly connected to each other
as the turbine rotor. The compressor wheel is mounted on the turbine
rotor and can be removed.
▪ Silencer (544) or air intake casing (545):
Choice is optional; generally, silencers are used for marine systems and
air intake casings for stationary systems (power plants).
▪ Compressor casing (546):
The compressor casing houses the insert (540) and the diffuser (542).
These components enable optimum adaptation of the turbocharger to
the engine. The insert additionally fulfils a burst protection function.
The compressor casing is equipped with an outlet socket. A flange for
connecting the optional acceleration system (Jet Assist) is provided on
the side of the compressor casing.
Functional Description
The engine exhaust gases flow through the gas admission casing (501) and
the turbine nozzle ring (513), and run radially onto the turbine wheel of the
rotor (520). The exhaust gases drive the turbine wheel; in this process, the
energy contained in the exhaust gas is transformed into mechanical rotation
energy at the turbine wheel. As the turbine wheel and the compressor wheel
are seated on the same shaft, the compressor wheel is driven at the same
time. The exhaust gas exits the turbocharger through the integrated gas
outlet diffuser and the gas outlet casing (506).
2008-12-11
The compressor wheel draws in fresh air through the silencer (544) or the
Description
air intake casing (545) and the insert (540). The fresh air is compressed in
the compressor wheel, diffuser (542) and compressor casing (546). The
compressed fresh air is forced into the cylinders of the engine via the charge
TCR
air cooler and charge air pipe.
2 (3) C1 0288 4.1-01 EN

The rotor (520) of the turbocharger is guided in radial direction by two bear-
Description
ing bushes situated in the bearing casing (517) between the turbine wheel
and the compressor wheel. The thrust bearing arranged centrally in the
bearing casing not only performs the function of axial guidance, but also
transfers the thrust in axial direction.
The highly stressed bearing points are lubricated and cooled by means of
the turbocharger lube oil system, which is integrated into the bearing casing.
The turbocharger lube oil system is supplied with oil from the engine lube
oil system.
2008-12-11
Description
TCR
C1 0288 4.1-01 EN 3 (3)

Lube oil system
Description
Lube oil diagram
1 Lube oil supply 6 Bearing bushes *

2 Bracket (engine) 7 Pressure gauge
3 Ring duct * 8 Pressure controller
4 Bearing casing * 9 Lube oil drain
5 Thrust bearing * * Scope of supply of turbocharger
Figure 1: Lube oil diagram, TCR turbocharger
Functional description
Lube oil circuit The highly stressed bearing points in the turbocharger are lubricated and
cooled by means of a lube oil system integrated into the bearing casing of
the turbocharger.
The lubricating oil is fed from the lube oil system of the engine to the lube
oil system of the turbocharger via the lube oil supply (1).
The lube oil flows to the radial and axial lubrication gaps of the turbocharger
via the ring duct (3) and various bores.
On top of the bearing casing (4) is a connection for a pressure gauge (7)
and/or a pressure controller (8) for checking/monitoring the lube oil pres-
sure.
The lube oil flows back into the lube oil system of the engine via the lube oil
2008-12-11
drain (9).
Description
The pipe for the lube oil drain must be installed with sufficient large
diameter and inclination, so that drainage of the lube oil is readily
possible without backing up.
TCR
C1 0288 4.2-03 EN 1 (3)

Danger of fire from running-out lube oil!

Description
A backup in the lube oil outlet can lead to an oil-flood in the turbocharger.
In the worst case, the oil can come out of the turbine-side and cause a
fire in the exhaust pipe.
The lube oil drain must therefore be installed with an inclination, which is
calculated as follows:
Inclination α > max. possible system inclination + 5°.
Venting The oil drain must have a venting facility from a sufficiently large compart-
ment permitting the oil to settle down, e.g. a venting box. The cross section
of the venting pipe should be approximately that of the oil discharge pipe.
Priming
Prior to engine start-up, the bearings of the turbocharger must be primed.
Depending on the engine system, this may take the form of priming imme-
diately before start-up, or continuous priming. The following values are to
be observed in this connection:
Priming before start-up:
▪ Oil pressure 1.3 – 2.2 bar, duration < 10 minutes.
Continuous priming:
▪ Oil pressure 0.3 – 0.6 bar.
Danger of fire caused by lube oil!

Continuous priming is only possible if there is no chimney draught effect.
A chimney draught can cause lube oil to be drawn into exhaust gas ducts,
leading to coking or fire.
Operational lubrication
Lube oil quality Commercial engine lubricating oils SAE 30 or SAE 40.
High-alkaline cylinder oils are not suitable. See Chapter Lube oil
Lube oil filtration The turbocharger does not require its own lube oil filter.
Filtration and conditioning of the lube oil is sufficient when the following
values are observed:
2008-12-11
▪ Lube oil filter < 0.050 mm,

Description
▪ Water content < 0.2% by weight,

Lube oil temperature Inlet temperature into the turbocharger: max. 75 °C at full engine load.
TCR
2 (3) C1 0288 4.2-03 EN

Lube oil pressure!
Description
Inadequate lube oil pressure will cause bearing damage.
▪ The lube oil pressure must be set by the engine manufacturer prior to
initial start-up.
▪ The lube oil pressure must be checked and/or monitored via the
measuring connection (7, 8) at the top of the bearing casing.
Lube oil pressure Lube oil pressure at full engine load and with lube oil at operating temper-
ature:
Pmin = 1.3 bar
Pmax = 2.2 bar
Limit values for monitoring of the lube oil pressure:
▪ < 1.0 bar: Alarm
▪ < 0.8 bar: Engine power at half load and
▪ < 0.6 bar: 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.
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).
Lube oil flow rate The lube oil flow rate depends on:
▪ the viscosity (SAE class) and temperature of the lube oil,

▪ the lubrication gaps of the turbocharger.
For flow rate values, see Chapter [3.1.1].
Post lubrication
After an engine shut-down, the bearing points of the turbocharger must be
post lubricated for 10 – 30 minutes at a lube oil pressure of 0.3 – 0.6 bar
(reference height: turbocharger centreline) for cooling purposes. This is
done either by means of the engine lube oil pumps or using a separate aux-
iliary lube oil pump.
If continuous priming is specified for engines (e.g. because of stand-by

starting), post lubrication is not required.
In this case, the continuous priming must be activated as soon as the
2008-12-11
engine lube oil pumps are switched off.

Description
TCR
C1 0288 4.2-03 EN 3 (3)

Acceleration system - Jet Assist
Description
OPTION
Jet Assist diagram
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
The Jet Assist acceleration system is used when special requirements have
to be met 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 addi-
tional air to the compressor while on the other hand, the compressor wheel
is accelerated, thus increasing the charge air pressure for the engine.
2009-01-15
Description
TCR
C1 0288 4.3-01 EN 1 (1)

Cleaning system – Wet cleaning of the turbine
Description
General
Depending on the fuel oil grade and the engine operating mode, residues
from combustion may accumulate in the turbine. In this case, the turbine
has to be cleaned during operation at regular intervals after initial start-up,
as specified in the maintenance schedule. Optionally, wet cleaning or dry
cleaning can be carried out separately or alternately. Wet cleaning is more
effective and has longer intervals, but can be carried out only at reduced
operating speed and temperature. Dry cleaning can be performed at normal
load, but is required more frequently.
Diagram, wet cleaning of the turbine
1 Water supply 7 Plate with cleaning instructions

2 Exhaust gas pipe upstream of tur- A Three-way cock with
bine sealing air connection
3 Gas admission casing B Pressure gauge *
4 Turbine nozzle ring
5 Turbine wheel * Scope of supply of engine
6 Sealing air
(extracted downstream of charge
air cooler)
Figure 1: Diagram, wet cleaning of the turbine
Operating conditions
2009-01-15
For wet cleaning, use only fresh water without any additives.
Description
Carry out wet cleaning at considerably reduced engine load and at a low
operating temperature of the turbocharger.
At a high operating temperature of the turbocharger, water can cause a
TCR
thermal shock and possibly destroy turbine components.
C1 0288 4.4-02 EN 1 (2)

Description
The water is sprayed into the gas admission casing (3) or the exhaust gas
pipe (2) before the turbine at a pressure of 2 to 3 bar. The flow of exhaust
gas transports the water droplets and distributes them over the turbine
nozzle ring and turbine wheel. Fouling and deposits are removed from the
blades of the turbine nozzle ring and turbine wheel by the impact of the water
droplets.
The washing water is entrained as steam due to the high flow velocity in the
gas outlet casing/elbow and is emitted from the turbine via the chimney
flange.
The sealing air (6) prevents clogging and corrosion of the piping. For this
purpose, a small amount of air is extracted downstream of the charge air
cooler and fed continuously through the corresponding piping system.
Maintenance interval, see Maintenance Schedule.
2009-01-15
Description
TCR
2 (2) C1 0288 4.4-02 EN

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

2 Screw plug 9 Compressed air pipe
3 Pipe 10 Sealing air
(extracted downstream of charge air
cooler)
4 Connection point 11 Plate with cleaning instructions
5 Exhaust gas pipe A Stop cock
upstream of turbine
6 Gas admission casing B Three-way cock with
sealing air connection
Figure 1: Diagram, dry cleaning of the turbine
Dry cleaning is performed at normal operating load of the engine. The engine
load need not be reduced. Use only commercially available 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. At high
operating temperatures, water can cause a thermal shock and possibly
destroy turbine components.
2009-01-15
Description
Assembly instructions ▪ The tank (1) must be installed in a suitable location, not lower than 1.0 m
below the connection point (4).
▪ The pipe (3) may not be longer than 6.0 m and must be supported
TCR
against vibrations. An unobstructed flow must be ensured.
C1 0288 4.5-02 EN 1 (2)

▪ The connection point (4) can be provided on the exhaust gas pipe just
Description
before the gas admission casing (5) or on the inlet socket of the gas
admission casing.
▪ Maximum operating temperature of the three-way cock (B): ≤ 150 °C.
The granulate from the tank (1) is blown in through the connecting pipe (4)
with compressed air. The flow of exhaust gas in the gas admission housing
transports the granulate and distributes it over the turbine nozzle ring and
turbine wheel. Fouling and deposits are removed from the blades of the
turbine nozzle ring and turbine wheel by the impact of the granulate parti-
cles. The loosened dirt and the granulate are carried out by the exhaust gas
flow through the gas outlet casing/elbow.
The sealing air (10) prevents clogging of the piping. For this purpose, a small
amount of air is extracted downstream of the charge air cooler and fed con-
tinuously through the corresponding piping system.
Cleaning the turbine with granulates on ship systems can lead to

downfall on deck.
2009-01-15
Description
TCR
2 (2) C1 0288 4.5-02 EN

Cleaning system – Wet cleaning of the compressor
Description
General
With the small dimensions of the TCR turbochargers, dirt deposits on the
compressor wheel and diffuser blades can lead to a measurable decrease
in efficiency. A wet cleaning facility with pressure sprayer is available for
cleaning the compressor during operation.
Wet cleaning system for the compressor with pressure sprayer
1 Handle 5 Coupling
2 Pressure sprayer 6 Hand valve
3 Relief valve 7 Turbocharger (compressor)
4 Nipple 8 Plate with cleaning instructions
Figure 1: Diagram, wet cleaning of the compressor with pressure sprayer
Cleaning of the compressor during operation is required at regular intervals
in accordance with the maintenance schedule.
The cleaning intervals depend on the degree of contamination of the intake
air and range from 100 to 200 operating hours.
For cleaning, use only fresh water without any additives.
Carry out the cleaning only with the engine warmed up and in full
load operation.
Do not shut down the engine immediately after cleaning, but continue to
run it for several minutes until dry.
2009-01-15
Description
The pressure sprayer (2) is filled with 2 litres of fresh water. Pumping with
TCR
the handle (1) generates an overpressure in the water tank of the pressure
sprayer (2). By pressing the pushbutton on the hand valve (6), water is
C1 0288 4.6-02 EN 1 (2)

sprayed into the compressor (7) by the pressure sprayer (2). Due to the high
Description
speed of the rotor, the injected water droplets hit the blades of the com-
pressor wheel and the diffuser at high velocity, thus removing the dirt
deposits mechanically.
2009-01-15
Description
TCR
2 (2) C1 0288 4.6-02 EN

MAN Diesel & Turbo
Operation
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
2010-05-12
0288-2 5-2 EN 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
property 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
relevant Regulations for Prevention of Accidents are to be observed. It is
2009-01-15
advisable to hang these regulations in the engine room and to repeatedly

point out the dangers of accidents.
Operation
Safety Instructions Concerning Specific Danger Sources

General
Hearing Protection
C1 6673 5.0-01 EN 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 Equipment The engine room must be equipped with fire-extinguishing equipment. The
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
before it is ensured that no more persons are in the engine room!
Protective Covers
2009-01-15
Operation
General
2 (4) C1 6673 5.0-01 EN

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
reattached 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 malfunc-
tion 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:
Operational management through the chief engineer on board or through a
technical officer.
Persons managing the operation must be in possession of a competence
certificate that corresponds with the national regulations and international
agreement (STCW). The number of required persons and their minimum
2009-01-15
qualification are usually stipulated through the national regulations or the

Operation
international agreement (STCW).

General
For stationary systems (power plants):
C1 6673 5.0-01 EN 3 (4)

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

Operation
the engine and the accompanying supply system through a trained and
specially 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 tech-
nical operation management is guaranteed by qualified and sufficiently
numbered 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.
2009-01-15
Operation
General
4 (4) C1 6673 5.0-01 EN

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 turbine
casing as well as from the delivery socket of the compressor casing with
a suitable scraper and cleaning agent.
4. Flush the lube oil system. Plug the oil supply and oil drainage of the
turbocharger and join the supply and drain pipes on the engine side, or
use an intake filter with low filter rating (20 µm recommended) in the lube
oil supply. Measurement of the oil pressure after the intake filter.
5. Prior to initial start-up, the lube oil pressure must be set by the engine
manufacturer, see “Lube oil system”, Chapter [4.2].
Before shipment, the oil system of each turbocharger is factory-checked

for cleanliness, and the oil supply and oil drainage are plugged.
Therefore, when flushing the engine oil system, care must be taken to
prevent inadmissible contamination in the oil from entering the
turbocharger.
For additional information on flushing the lube oil system, please refer to
the engine manufacturer’s manual.
For mounting the turbocharger on the engine, see work card [500.31].
Indication of the pending alarm and the reaction of the engine control
system must occur at the same time. Therefore, the engine control
system must conform at least to category 3 in compliance with
2009-01-15
DIN EN 954-1.
Operation
TCR
C1 0288 5.1-01 EN 1 (3)

Work prior to starting the engine

Operation
1. Before starting the engine, the bearing points of the turbocharger must
be primed. Depending on the engine system, this is done by
˗ Priming immediately before starting or
˗ Continuous priming.
2. Set all shut-off devices of the system pipes of the engine plant to the
operating position.
3. Check the lube oil pressure at the top of the turbocharger, see lube oil
diagram, Chapter [4.2], connection für pressure gauge.
Starting Operation
Turbocharger Start the engine. The engine exhaust gases drive the turbocharger and thus
start it operating. If provided, the “Jet Assist” acceleration system is put into
operation via the control system.
Checks during operation
General Despite automatic control and regulation of the engine system, regular
checks of the turbocharger are required so that possible malfunctions can
be detected as early as possible and the causes corrected in time.
The checks listed below are part of the operator's maintenance

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

bocharger
▪ Lube oil pressure at top 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
▪ Turbocharger for smooth running
▪ Air filter mat on the silencer for fouling/saturation
Smooth running An early indication of damage to the rotor and bearings is usually given by
irregular running due to imbalance or contact of rotating parts of the rotor.
2009-01-15
Listening to the running noise of the turbocharger often allows unsmooth

Operation
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
TCR
2 (3) C1 0288 5.1-01 EN

an indication of the speed and can be used for approximate speed moni-
Operation
toring.
Operating faults Chapter [5.3] lists various operating faults, identifies possible causes and
specifies remedial action.
Shutting down, post lubrication
Shutting down Shutting down the engine also puts the turbocharger out of operation. Due
to the flywheel effect, the rotor of the turbocharger continues to rotate for
some time.
The run-down time of the turbocharger gives an indication of its

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

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

Continuous priming is only possible if there is no chimney draught effect.
A chimney draught can cause lube oil to be drawn into exhaust gas ducts,
leading to coking or fire.
2009-01-15
Operation
TCR
C1 0288 5.1-01 EN 3 (3)

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

General emergency meas- The following instruction is obligatory for all options of emergency engine
ures operation in the event of turbocharger failure.
▪ Reduce the engine power in accordance with the engine manufacturer’s

instructions to the degree that
˗ the maximum permissible exhaust gas temperature downstream of
the cylinders is not exceeded,
˗ the maximum permissible exhaust gas temperature upstream of the
turbocharger is not exceeded,
˗ the maximum permissible speed of the turbocharger that is still
operational (on engines with more than one turbocharger) is not
exceeded,
˗ increased exhaust gas density is minimised.
Emergency measure, option 1 Engine may not be stopped for urgent reasons.
Danger due to further damage of the turbocharger!

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

2009-10-28
2. Observe the paragraph “General emergency measures” and the engine

Operation
manufacturer’s instructions for emergency operation.

TCR18
3. Limit the duration of emergency engine operation to the absolutely nec-

essary minimum.
C1 0288 5.2-02 EN 1 (2)

Emergency measure, option 2 Emergency operation with closing device

Operation
Engine with one turbocharger may be stopped (short-term).

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

1. Separate the exhaust gas inlet side of the defective turbocharger from
the gas flow of the second turbocharger by fitting a blind flange.
2. On V-type engines having a common charge air pipe, a blind flange is
to be mounted on the compressor outlet of the defective turbocharger
so as to avoid air losses.
Observe the paragraph “General emergency measures” and the engine
2009-10-28
Operation
TCR18
2 (2) C1 0288 5.2-02 EN

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

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

malfunctions can also lead to increased subsequent damage of the
turbocharger or engine.
Countermeasures 1. Reduce the engine power or shut down the engine, depending on the
available options.
2. Identify and correct the cause of the malfunction, see Table “Trouble-
shooting”.
3. If the damage cannot be corrected immediately, emergency operation
is possible, see Chapter [5.2].
2009-01-15
Operation
TCR
C1 0288 5.3-01 EN 1 (6)

Trouble Shooting
Operation
No. Malfunction Possible cause Corrective action Work card

1 Exhaust gas temperature Air filter mat or silencer fouled Clean/replace [500.24]
upstream of the turbine is [500.32]
too high
Compressor fouled Clean [500.23]
Turbine wheel heavily fouled Clean [500.21]
[500.22]
Turbine nozzle ring heavily Clean/replace [500.21]
fouled/constricted [500.22]
[500.46]
Rotor rubbing Check inserts/rotor/bearing [500.41]
bushes and replace parts if nec- [500.45]
essary, balance check by MAN [500.47]
Diesel & Turbo Service
Foreign bodies before/in com- Check compressor wheel and/or [500.45]
pressor and/or turbine turbine rotor and replace if nec-
essary
Turbine or compressor wheel Replace compressor wheel and/ [500.45]
damaged or turbine rotor
Substantial erosion on turbine Check turbine rotor/turbine noz- [500.45]
wheel/turbine nozzle ring zle ring and replace if necessary [500.46]
High air intake temperature Reduce power Engine
Charge air cooler fouled Clean Engine
Charge air pipe leaking Seal charge air pipe, tighten con- Engine/
nections system
Charge air temperature too high Check charge air cooler Engine
Inlet/exhaust valves, valve slots Clean Engine
of engine fouled
Exhaust gas pipe leaking Seal exhaust gas pipe, tighten Engine/
connections system
Exhaust gas back-pressure Clean turbine, check exhaust gas [500.21]
downstream of turbine too high pipe [500.22]
Engine/
system
Fuel injection on engine faulty Repair fuel injection Engine
2009-01-15
Operation
TCR
2 (6) C1 0288 5.3-01 EN

Operation
2 Charge air pressure too low Air filter mat or silencer fouled Clean/replace [500.24]
[500.32]
[500.22]
[500.46]
Defective bearings, imbalance of Check bearing parts and replace [500.45]
the rotor parts if necessary, balance check
by MAN Diesel & Turbo Service
essary
nections system
of engine fouled
connections system
Engine/
system
3 Charge air pressure too Turbine nozzle ring lightly fouled/ Clean [500.21]
high constricted [500.22]
Low air intake temperature Reduce power Engine
2009-01-15
Operation
TCR
C1 0288 5.3-01 EN 3 (6)


Operation
4 Speed too low Air filter mat or silencer fouled Clean/replace [500.24]
[500.32]
[500.22]
[500.46]
essary
nections system
of engine fouled
connections system
Engine/
system
5 Speed too high Turbine nozzle ring lightly fouled/ Clean [500.21]
constricted [500.22]
6 Lube oil pressure too low Lube oil inlet temperature too Check/adjust lube oil cooling Engine/
high system
Lube oil filter fouled Clean/replace lube oil filter Engine/
system
Lube oil pressure gauge defective Replace lube oil pressure gauge Engine/
system
2009-01-15
Operation
TCR
4 (6) C1 0288 5.3-01 EN

Operation
7 Lube oil loss Piston ring seals defective Replace piston rings [500.45]
Seals damaged, connections Replace seals, check/tighten [500.31]
leaking connections Engine
Lube oil pressure too high Reduce oil pressure at operating Engine/
temperature system
Excessive pressure in oil dis- Check/enlarge dimension/incli- Engine/
charge or in crankcase nation/venting of lube oil dis- system
charge
8 Hesitant starting, short run- Compressor fouled Clean compressor [500.23]
down time
[500.22]
[500.46]
Retaining ring, thrust ring or Check parts and replace them if [500.45]
counter-thrust ring damaged necessary
essary
Oil coke downstream of turbine Check/replace piston ring on tur- [500.45]
wheel bine side, observe upper limit of
lube oil pressure during priming
and operation
9 Abnormally high noise level Retaining ring, thrust ring or Check parts and replace them if [500.45]
essary
2009-01-15
Operation
TCR
C1 0288 5.3-01 EN 5 (6)


Operation
10 Turbocharger vibrates Turbine wheel heavily fouled Clean [500.21]

[500.22]
Retaining ring, thrust ring or Check parts and replace them if [500.45]
essary
11 Compressor surges Turbine wheel heavily fouled Clean [500.21]
[500.22]
[500.46]
essary
Charge air temperature too high Reduce power Engine
of engine fouled
Engine/
system
Table 1: Troubleshooting
2009-01-15
Operation
TCR
6 (6) C1 0288 5.3-01 EN

MAN Diesel & Turbo
Maintenance
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
2010-05-12
0288-2 6-2 EN 1 (1)

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

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

The lube oil is under pressure and very hot!
▪ Before opening pipes, flanges, screwed connections or fittings, release
the pressure in the system and check that it is depressurised!
▪ Before opening oil pipes, wait until the lube oil has cooled down
sufficiently!
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.
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!
2009-01-15
Maintenance
▪ Check if the transport equipment being used has the required carrying
capacity!
▪ Choose only set-down locations that have sufficient loading capacity
TCR18
for the heavy component (this is not always the case for galleries, half-
landings or grid-iron coverings)!
C1 0288 6.0-01 EN 1 (3)

Danger of Crush Injuries from Rotating Components

Maintenance
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!
▪ Wear protective gloves whenever required!
▪ Wear safety goggles whenever required!
▪ Wear respiratory protection whenever required!
▪ Pay attention that other persons also wear the appropriate protective
equipment whenever required or make these persons aware thereof!
Use of High-pressure Cleaners

When working with high-pressure cleaners ensure 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!
2009-01-15
Maintenance
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!
TCR18
▪ Only use spare parts from other manufacturers if they have been
approved by MAN Diesel!
2 (3) C1 0288 6.0-01 EN

MAN Diesel shall in no way be liable for any personal injury or material dam-
Maintenance
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.
2009-01-15
Maintenance
TCR18
C1 0288 6.0-01 EN 3 (3)

General remarks
Maintenance
Maintenance Work
Maintenance work belongs to the duties of the user, just as regular checks
do. Their purpose is to retain operational readiness and operational safety
of the system. They are to be carried out by competent personnel in accord-
ance with the time schedule for maintenance.
Maintenance work supports the operating personnel in their effort to detect
arising malfunctions/failures in time. They deliver hints towards necessary
maintenance work or repairs to the persons responsible, and influence the
planning of downtimes.
Maintenance and repair work can be carried out properly only when the
required spare parts are available. In addition to these spare parts, it is
advisable to stock a certain quantity of spares for unexpected outages.
Maintenance Schedule
The required tasks are listed in the maintenance schedule, sheet [6.3.1]. The
schedule contains
▪ a brief description of the work,
▪ the repetition intervals,
▪ the personnel and time requirements,
▪ references to the respective work cards.
Work Cards
The work cards describe
▪ the aim and object of the work
and contain information about
▪ the required tools/appliances and
▪ detailed descriptions and graphical depictions of the necessary work
sequences and work steps.
See work card [7.1.1]
Spare Parts
Order numbers for spare parts can be found
▪ in the spare parts catalogue of the technical documentation and
▪ on the respective work cards of the technical documentation.
Order numbers consist of the three-digit subassembly number and a three-
digit item number, separated by a dot.
2009-01-15
Special Services/Repair Work

Maintenance
MAN Diesel offers the following services:

▪ Delivery of spare parts
TCR
C1 0288 6.1-01 EN 1 (2)

▪ Consultation and support on questions concerning operation, mainte-

Maintenance
nance and repairs

▪ Practice-oriented training for operating personnel of MAN Die-
sel exhaust gas turbochargers
▪ Assessment and clarification of damage cases
▪ Assignment of fitters and engineers
If you require any of these services please contact us at
▪ MAN Diesel SE, Augsburg Works
▪ MAN Diesel SE, Hamburg Service Center,
▪ Other Service Centers and authorized repair shops
Service Centers and authorized repair shops of MAN Diesel & Turbo SE can
be found in the chapter [2.1] “MAN Diesel & Turbo SE in Germany” and
“Worldwide service addresses”.
2009-01-15
Maintenance
TCR
2 (2) C1 0288 6.1-01 EN

Tools
Maintenance
Optional tools
For maintenance work and emergency operation, special tools are option-
ally available for TCR turbochargers.
The optional supply scope of these special tools is listed in the spare parts
catalogue, Chapter “Tools”.
Standard tools
As standard, the special tool “hexagon pin (596.001)” is supplied with each
TCR turbocharger. This hexagon pin is required for removal of the com-
pressor wheel and is attached inside the silencer or air intake casing.
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.
2008-12-11
Maintenance
TCR
C1 0288 6.2-01 EN 1 (1)

Maintenance Schedule
Maintenance
Reliability and Adaptability
Validity of the Maintenance The maintenance schedule contains a summary of the maintenance and
Schedule inspection work, down to the major overhaul of the turbocharger.
A major overhaul of the turbocharger must be carried out latest after

▪ 12 000 - 18 000 operating hours
After each major overhaul, which best is carried out with a due engine serv-
ice, 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 Mainte- The maintenance schedule takes the following operating conditions and an
nance Schedule annual operating period of approx. 6000 hours into account:
▪ Uniform loading within a range of 60 to 90% of the rated power,

▪ Observation of the specified operating media temperatures and pres-
sures,
▪ Usage of the specified lube oil and fuel qualities,
▪ Attentive separation of fuel and lubrication oil.
The maintenance intervals must be shortened when the following operating
conditions are given:
▪ Longer-term operation with peak loads or low loads, long idle periods,
frequent heavy load cycles,
▪ Frequent engine starts and repeated run-up phases without sufficient
warming-up,
▪ High stress on the engine before reaching the specified operating media
temperatures,
▪ Too low lube oil, cooling water and charge air temperatures,
▪ Use of problematic fuel qualities and insufficient separation,
▪ Insufficient filtration of the intake air (particularly with stationary
engines).
2009-01-15
Maintenance
General
C1 6673 6.3-03 EN 1 (1)

Maintenance schedule - turbocharger
Maintenance
Maintenance schedule - turbocharger on four-stroke engine
1, per
2,
12000
3
3000
150
250
24
Inspection (during operation)
901 Check turbocharger for unusual noise and vibrations. A 1 0,1 Turbo X
903 Check turbocharger and system pipes for leaks (charge A 1 0,2 Turbo X
air, exhaust gas, lube oil)
905 Check all fixing screws, casing screws and pipe connec- 500.31 1 1 Turbo 2 X
tions for tight fit. 7.2.1
Maintenance (during operation)
911 Clean turbine - dry cleaning (if provided) 500.22 1 0,3 Turbo 1
913 Clean turbine - wet cleaning (if provided) 500.21 1 0,6 Turbo 1
915 Clean compressor (during operation) 500.23 1 0,3 Turbo 1
Maintenance (engine has been stopped)
917 Clean air filter (if provided) 500.24 1 0,4 Turbo 1
Maintenance (together with engine maintenance)
951 Major overhaul every 12,000 ... 18,000 operating hours: 7.2.1 2 15 Turbo X
Dismantle, clean and check all components of the turbo- 7.2.2
charger. Check gaps and clearances on reassembly. 500.31
500.32
500.33
500.41
500.42
500.43
500.44
500.45
500.46
500.47
Maintenance Schedule, Legend

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
A No work card required/available
2009-10-28
Maintenance
TCR18
C1 0288 6.3.1-03 EN 1 (1)

Remarks on maintenance work
Maintenance
General Remarks
Disassembling the turbo- The simplest method to use for disassembly is best chosen on the basis of
charger the space available in the engine room. When performing maintenance and
inspection work, it is sufficient in most cases to dismount only subassem-
blies 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 sub-
assemblies and to include this information in the operating log. Inspection
report form, see Chapter [6.6].
In disassembly work, mark the position of the components relative to

each other using a felt-tip marker pen. If required, document the
disassembly/assembly with a camera.
Exchanging Components
Components with traces of wear or damage that influence especially the
strength and the balancing precision and thus the smooth running of rotat-
ing parts, must be exchanged with original spare parts or repaired by an
authorized 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) lib-
screw connections erally to the screw connections and allow to penetrate for at least ½ hour
so that the solvent can work its way through the thread. Observe the instruc-
tions for use supplied by the solvent manufacturer. Then apply light hammer
blows to the screw head until the screw turns freely in the thread.
Tightening screw connec- All screw connections on the turbocharger must be in satisfactory condition
tions for assembly or be renewed.
Always tighten screws/bolts with the specified tightening

torque!
See Technical Documentation, Work Cards.
2009-01-15
Maintenance
TCR
C1 0288 6.4-01 EN 1 (2)

Maintenance
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 tur- Due to the high temperatures on the turbine side, screws/bolts, nuts and
bine side tab washers made of non-scaling materials are used. These are marked on
the face side (SM, VM or 4923, Z1 or 4828) to avoid them from being mis-
taken for regular parts. When disassembling, the fasteners marked in this
manner are to be stored separately until being assembled.
All lock washer pairs on the turbocharger are made of non-scaling material
and are not marked.
In order to avoid the 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.
2009-01-15
Maintenance
TCR
2 (2) C1 0288 6.4-01 EN

Inspection of components
Maintenance
General Remarks
The following remarks and questions are intended as a guide, e. g. for
▪ Assessment of the turbocharger condition,
▪ Operating log and inspection report,
▪ Inspection, reusing, repair and replacement of individual components.
Inspection Work
Gaps and clearances For permissible limits, see Chapter [7.2.2]
Crack detection test Crack detection test on turbine blades (turbine rotor, compressor wheel) by
means of acoustic testing or the fluorescent dye penetration method.
Streaks Streaks all around the circumference of the turbine rotor, compressor wheel
and insert are an indication of wear.
Inspection of gaps and clearances, see Chapter [7.2.2]
Inspection of bearing parts, see work card [500.45]
Streaks on parts of the circumference of the turbine rotor, compressor wheel
and insert are an indication of imbalance.
Oil coke downstream of tur- Shaft seal on turbine side damaged or priming pressure too high.
bine wheel
Erosion in HFO operation Where heavy fuel oil is used, the exhaust gas contains small hard particles
(e.g. “cat fines”) which have an erosive effect especially at the outlet of the
turbine nozzle ring, where gas velocities and concentrations of these parti-
cles are high. Here, the flow is also very strongly deflected in circumferential
direction. Moreover, these particles are flung outwards due to the centrifu-
gal effect.
“Cat fines” As a result of the refinery process, “cat fines”, a fine-grained powder of great
hardness (recognizable by the Al and Si content), and other abrasive con-
taminants are contained in the heavy fuel oil, depending on its quality. Their
amount can be reduced by means of amply dimensioned, heated settling
tanks and by adequate separation.
Admixtures Particularly disadvantageous is the admixture of used engine lube oil, char-
acterized by increased concentrations of Ca and Fe. Used engine lube oil
contains not only wear residues, but above all “detergent/dispersant addi-
tives”, which bind fine particles and prevent “cat fines” and other impurities
from being extracted through separation. Far more severe erosion damage
results from blending the fuel with “used oil”.
Combustion residue caused by incomplete combustion can also have ero-
sive effects. Clean combustion must therefore be ensured.
Silencer, What is the condition of the air filter mat?
2009-01-15
Maintenance
if provided Are there cracks on any of the components?
Speed measuring device Is the speed transmitter or the speed indicator defective?
TCR
C1 0288 6.5-01 EN 1 (2)

Casings Which casings are heavily fouled by soot, oil or oil coke?
Maintenance
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 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? Are any streaks
evident?
Do the leading edges of the turbine blades show impact notches caused by
drawn-in foreign objects?
Are the seat faces bright or are there signs of fretting corrosion?
Turbine rotor Do the turbine blades show signs of cracks, streaks, heavy wear or erosion
at the edges?
Do the leading edges of the turbine blades show impact notches caused by
foreign objects?
Is the shaft running true? What is the condition of the bearings?
Are the seat faces bright or are there signs of fretting corrosion?
Bearing parts of the cartridge Are the seat faces bright or are there signs of fretting corrosion?
Are there any signs of scoring or heavy wear?
Checking for wear, see work card [500.45].
Insert Are any streaks evident?
Diffuser Are any blades bent? Are any cracks evident on the blades?
Have foreign objects become jammed in the ducts?
Are there traces indicating the presence of foreign objects?
Turbine nozzle ring Are any blades bent? Are any cracks evident on the blades?
Are the blades heavily worn due to erosion?
Checking for wear, see work card [500.46].
Have foreign objects become jammed in the ducts?
Are there traces indicating the presence of foreign objects?
2009-01-15
Maintenance
TCR
2 (2) C1 0288 6.5-01 EN

Inspection report
Maintenance
Form
2010-05-05
Maintenance
TCR
C1 0288 6.6-01 EN 1 (2)

Maintenance
2010-05-05
Maintenance
TCR
2 (2) C1 0288 6.6-01 EN

Service report
Maintenance
Form
2009-10-28
Maintenance
TCR18
C1 0288 6.7-01 EN 1 (1)

MAN Diesel & Turbo
Work cards
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
2010-05-12
0288-2 7-2 EN 1 (1)

Preface
7.1 Preface
7.2 Setting data
7.4 Cleaning
0288-2 7.1-2 EN 1 (1)

Organisation and use of the work cards
Preface
Numbering
The ordinal number of the work cards is located at the top right of the title.
It consists of a three-digit subassembly number and a two-digit counting
number. The subassembly number 500 represents the collective subas-
sembly number for turbochargers.
Example - Turbocharger on engine: 500.31
▪ 500 = Subassembly number (500 for turbocharger)
▪ 31 = Counting number (work card No. 31)
Cross-references in work cards are enclosed in square brackets.
Layout of the Work Cards
Work cards generally contain the following information:
▪ Brief description,
▪ Personnel and time requirements,
▪ Required tools and appliances,
▪ Related work cards, i.e. those work cards containing further necessary
or useful information,
▪ Possibly additional information/technical data and,
▪ The individual work sequences, always beginning with the starting con-
dition, and followed by the individual work steps.
Parts and tools in the figures and text are each designated with their order
number.
Example - Hexagon bolt in bearing casing: 546.005
▪ 546 = Subassembly number (546 for bearing casing)
▪ 005 = Item number
All subassemblies and subassembly numbers are listed in the spare parts
catalogue.
Order numbers for tools are (generally) identical with the tool number affixed
to the tool.
Required Personnel and Time

The required time is mentioned in hours, both for the amount and qualifi-
cation of the required personnel. The higher hour rate covers the time
requirement 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
2009-01-15
tackle.
Work cards
Tools / Appliances
The numbers in the Designation column refer to width across flats, given in
TCR
mm, e.g. socket wrench 10 = socket wrench width across flats 10 mm.
C2 0288 7.1.1-01 EN 1 (2)

Availability codes in the Status column have the following meaning:

Preface
Standard Included in the scope of supply of the turbocharger.

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 tight-

ening 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!
2009-01-15
Work cards
TCR
2 (2) C2 0288 7.1.1-01 EN

Setting data
7.1 Preface
7.2 Setting data
7.4 Cleaning
0288-2 7.2-2 EN 1 (1)

Screw connections and tightening torques
Setting data
Brief description
Tightening values for all important bolted connections/tightening torques
for various friction coefficients μ.
Tightening Torques for Bolted Connections

Tightening of screw connec- Whenever possible, screw connections should be tightened with torque
tions by torque wrenches.
For particularly important screw connections on the turbocharger, the tight-

ening torques are specified in Table 3 “Special tightening torques for
TCR18” and additionally on the respective work cards.
For all other screw connections that are to be tightened with torque
wrenches, the approximate values for the tightening torques may be noted
from Table 2 “Tightening torques for bolts of strength class 8.8”.
When tightening screw connections the following must be observed:
▪ Apart from the applied tightening torque, the clamping force of a screw
connection depends on the lubricant being used, the condition of the
contact surface and thread, as well as on the material combination. It is
therefore very important that all these conditions are satisfied.
▪ Table 2 “Tightening torques for bolts of strength class 8.8” gives the
tightening torques for the various screw threads depending on their
coefficient of friction µ, i.e. depending on the selected lubricant. The
tightening torques apply for bolt materials of strength class 8.8 under
utilization of approx. 70% of their yield strength.
▪ For other strength classes, the conversion factors given in Table 1 are
to be used and multiplied by the tightening torque from Table 2. The
strength class is stamped on the bolt head.
Strength class 5.6 6.8 8.8 10.9 12.9
Conversion factor x 0.47 0.75 1.0 1.40 1.70
Table 1: Conversion factors for tightening torques depending on the strength
class of the bolts
Friction coefficient µ For the friction coefficient µ use approximately:
µ = 0.08 with lubricants for temperatures

≤ 200 °C, e.g. Molykote G-n or Molykote P40
≥ 200 °C, e.g. Molykote HSC
µ = 0.14 for lightly oiled surfaces without refinishing
2010-05-12
Work cards
TCR18
C2 0288 7.2.1-03 EN 1 (3)

Tightening torques in general

Setting data
Tightening torque in Nm
Thread, nominal size for coefficient of friction µ
0.08 0.14
M5 4.1 5.8
M6 7 10
M8 17 24
M 10 34 49
M 12 59 84
M 14 93 134
M 14×1,5 99 145
M 16 141 205
M 16×1,5 148 220
M 18 196 282
M 18×1,5 213 319
M 18×2 205 300
M 20 275 398
M 20×1,5 295 445
M 20×2 285 422
M 22 368 538
M 22×1,5 393 594
M 22×2 381 566
M 24 473 686
M 24×2 503 753
M 27 694 1017
M 27×2 731 1103
M 30 945 1379
M 30×2 1014 1537
M 33 1271 1870
M 33×2 1353 2061
M 36 1640 2403
M 36×3 1707 2554
M 39 2113 3117
M 39×3 2190 3295
M 42 2623 3856
M 42×3 2757 4166
2010-05-12
M 45 3262 4821
Work cards
M 45×3 3414 5178

M 48 3952 5823
TCR18
M 48×3 4184 6367

Table 2: Tightening torques for bolts, strength class 8.8
2 (3) C2 0288 7.2.1-03 EN

Tightening torques for TCR18 turbocharger
Setting data
Figure 1: Items for special tightening torques on TCR18
The special tightening torques given in the table are valid for a friction
coefficient µ=0.08
with lubricants for temperatures
▪ ≤ 200 °C, e.g. Molykote G-n or Molykote P40
▪ ≥ 200 °C, e.g. Molykote HSC.
Work Part
Designation Nm WAF °C
card Order No.
[500.32] 546.004 Hexagon bolt 12 6 ≤ 200
[500.33] 546.004 Hexagon bolt 12 6 ≤ 200
[500.41] 546.020 Hexagon bolt 34 17 ≤ 200
[500.43] 546.005 Hexagon bolt 59 19 ≤ 200
[500.44] 501.008 Hexagon nut 34 17 ≥ 200
[500.45] 517.051 Hexagon bolt 7 10 ≤ 200
[500.45] 520.005 Compressor wheel 220 30 ≤ 200
[500.47] 501.008 Hexagon nut 34 17 ≥ 200
2010-05-12
Work cards
Table 3: Special tightening torques for TCR18

TCR18
C2 0288 7.2.1-03 EN 3 (3)

Gaps and clearances
Setting data
Values and measurement
Figure 1: Gaps and clearances

Replace or remachine
When new
Item Designations of parts Order No. parts
min. in mm max. in mm min. in mm max. in mm
1 a) Compressor wheel (520.005) Axial gap 0.30 0.60 0.25 0.70
b) Insert (540.001)
2 c) Turbine rotor (520.001) Axial gap 0.30 0.80 0.25 0.90
Insert (541.001)
3 d) Thrust bearing (517.002) Axial clear- 0.18 0.22 0.13 *) 0.28
Counter-thrust ring (520.027) ance
5 e) Compressor wheel (520.005) Radial gap 0.50 0.60 0.40 0.70
Insert (540.001)
6 e) Turbine rotor (520.001) Radial gap 0.70 0.80 0.60 0.90
Insert (541.001)
4 Compressor wheel (520.005) Permissible axial runout 0.06
a) Measure by means of soft metal imprint (lead wire) at 3 points on the circumference and calculate the mean
value. Deduct the measured axial clearance (3) from the calculated mean value with the rotor pushed in
direction (B).
b) Adjustable by means of balance ring (540.030), t = 1.25 mm or t = 1.50 mm.
c) Measure by means of soft metal imprint (lead wire) at 3 points on the circumference and calculate the mean
value. Deduct the measured axial clearance (3) from the calculated mean value with the rotor pushed in
direction (A).
2009-10-28
d) Measure with a dial gauge while vigorously moving the rotor in directions (A) and (B).
Work cards
e) Using a feeler gauge, measure at 4 points on the circumference and calculate the mean value.
TCR18
*) The axial play in installed condition may be the same or no more than 0.05 mm less than the individual
component measurement.
C2 0288 7.2.2-02 EN 1 (2)

Setting data
2009-10-28
Work cards
TCR18
2 (2) C2 0288 7.2.2-02 EN

Emergency operation
7.1 Preface
7.2 Setting data
7.4 Cleaning
0288-2 7.3-2 EN 1 (1)

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

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

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

If the engine starts during the removal of parts of the turbocharger, there
is a risk of coming into contact with rotating components and being
seriously injured.
▪ 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!
2008-12-11
Work cards
TCR
C2 0288 500.11-01 EN 1 (2)

Work sequence - Emergency operation with closing device

Emergency operation
501.000 Gas admission casing 596.006 Closing cover

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

Work cards
˗ information in the engine operating manual.

TCR
2 (2) C2 0288 500.11-01 EN

Cleaning
7.1 Preface
7.2 Setting data
7.4 Cleaning
0288-2 7.4-2 EN 1 (1)

Cleaning the turbine - Wet cleaning
Cleaning
Brief description
Wet cleaning of the turbine during operation in the case of significantly
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 (or less, depending on the operating conditions),
at reduced engine load.
The wet cleaning of the turbine may only be carried out at heavily
reduced engine load (max. exhaust-gas temperature ahead of
turbine ≤ 320° C)!
When the exhaust-gas temperature is too high, the washing water can
trigger a thermoshock and cause damage to the turbine.
Max. exhaust gas temperature Max. turbocharger speed

Type
upstream of turbine in °C in rpm
TCR14 ≤ 320 ≤ 26 000
TCR16 ≤ 320 ≤ 22 000
TCR18 ≤ 320 ≤ 18 000
TCR20 ≤ 320 ≤ 15 000
TCR22 ≤ 320 ≤ 12 000
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.
General The layout of the cleaning device depends on the engine type and can vary
from the illustration.
2009-02-02
Work cards
TCR
C2 0288 500.21-02 EN 1 (2)

Cleaning
1 Water supply 6 Sealing air

cooler)
2 Exhaust gas pipe 7 Plate with cleaning instructions
upstream of turbine
3 Gas admission casing A Three-way cock with sealing air connection
4 Turbine nozzle ring B Pressure gauge *
5 Turbine wheel * Scope of supply of engine
Figure 1: Diagram, wet cleaning of the turbine
Work sequence - Wet cleaning of the turbine (during operation)

Steps 1. Reduce engine load to a maximum exhaust gas temperature upstream
of turbine ≤ 320 °C, observe turbocharger speed.
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. Switch the three-way cock (A) to position “I” (washing)
Water pressure approx. 2 - 3 bar.
4. Washing duration approx. 30 seconds, then repeat the washing proce-
dure 10 times with an interval of 1 minute after each procedure.
5. Switch the three-way cock (A) to position “0” (sealing air).
The sealing air prevents clogging and corrosion of the piping.
6. Continue to run the engine at reduced engine load for 10 minutes (until
the washing water has dried), then slowly increase the engine load.
Vibrations caused by dirt accumulations

2009-02-02
Should vibrations occur on the turbocharger that were not evident

Work cards
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.
TCR
2 (2) C2 0288 500.21-02 EN

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

1 Technician 0,3
Preliminary remarks
Cleaning agent Use only commercially available granulates from nut shells or activated
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 operating load of the engine.
Assembly instructions ▪ The tank (1) must be installed in a suitable location, not lower than 1.0 m
below the connection point (4).
▪ The pipe (3) may not be longer than 6.0 m and must be supported
against vibrations. An unobstructed flow must be ensured.
▪ The connection point (4) can be provided on the exhaust gas pipe just
before the gas admission casing (5) or on the inlet socket of the gas
admission casing.
▪ Maximum operating temperature of the three-way cock (B): ≤ 150 °C.
2009-01-15
Work cards
TCR
C2 0288 500.22-02 EN 1 (3)

Cleaning
1 Tank 8 Turbine wheel

2 Screw plug 9 Compressed air pipe
3 Pipe 10 Sealing air
cooler)
4 Connection point 11 Plate with cleaning instructions
5 Exhaust gas pipe upstream A Stop cock
of turbine
6 Gas admission casing B Three-way cock with sealing air con-
nection
Figure 1: Diagram, dry cleaning of the turbine
Work Sequence – Dry Cleaning of Turbine (during Operation)

Steps 1. Stop cock (A) must be closed.
2. Three-way cock (B) must be in position “0”.

3. Unscrew the screw plug (2).
Fill the prescribed quantity of granulate into the tank (1) and close it with
the screw plug (2). See Table “Filling volume”.
4. Open the stop cock (A).
Slowly turn the stop cock (B) to position “I” until a whistling sound is
heard indicating introduction of the granulate.
Granulate injection time approx. 30 seconds.
5. Close the stop cock (A).
6. Switch the three-way cock (B) to position “0” (sealing air).
The sealing air prevents clogging of the piping.
2009-01-15
Work cards
TCR
2 (3) C2 0288 500.22-02 EN

Type Filling volume
Cleaning
TCR12, TCR14, TCR16 0.3 litres
TCR18, TCR20 0.4 litres
TCR22 0.5 litres
Table 1: Filling volume
2009-01-15
Work cards
TCR
C2 0288 500.22-02 EN 3 (3)

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

1 Technician 0,3
Introductory Remarks
Cleaning agent Use exclusively fresh water for cleaning.
Cleaning interval Every 150 operating hours.

Carry out the cleaning only with the engine warmed up and in full
load operation.
Do not shut down the engine immediately after cleaning, but continue to
run it for several minutes until dry.
2009-01-15
Work cards
1 Handle 5 Coupling
2 Pressure sprayer 6 Hand valve
3 Relief valve 7 Turbocharger (compressor)
4 Nipple 8 Plate with cleaning instructions
TCR
Figure 1: Diagram, wet cleaning of the compressor with pressure sprayer
C2 0288 500.23-02 EN 1 (2)

Cleaning
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).
2009-01-15
Work cards
TCR
2 (2) C2 0288 500.23-02 EN

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

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

Cleaning is necessary when the air filter mat starts to discolour, turning grey.
The air filter is then saturated and the contamination starts to advance
2009-10-28
towards the compressor and the charge air cooler.

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

not be used as a reference for the cleaning interval.
TCR18
C2 0288 500.24-02 EN 1 (3)

Cleaning
Figure 1: Air filter on the silencer
Work sequence - Removal, cleaning/replacement, refitting

Starting condition Engine has been stopped.
Steps 1. Loosen the clamps (544.202), remove cover sheet (544.205) and air filter
mat (544.201).
2. Clean the air filter mat by flushing with warm water to which a non-cor-
rosive cleaning agent has been added.
Avoid excessive mechanical stress (e.g. wringing, sharp water jet). After
cleaning, blow compressed air through the air filter mat.
In case of heavy contamination, it may be necessary to immerse the air

filter mat into a cleaning agent for several hours. Therefore it is
recommended to have a second air filter mat in stock at all times.
3. Place air filter mat (544.201) over the perforated plate of the silencer.
The perforated plate must be completely covered by the air filter mat.
4. Place cover sheet (544.205) over the hem of the air filter mat and then
fasten the air filter mat using the clamps (544.202).
2009-10-28
Work cards
TCR18
2 (3) C2 0288 500.24-02 EN

Position of the clamps
Cleaning
Figure 2: Position of the clamps
Correct position of the clamps The clamps must be attached as close as possible to the outer edges of the
silencer in order to prevent dirt and foreign objects from entering the com-
pressor through the silencer.
2009-10-28
Work cards
TCR18
C2 0288 500.24-02 EN 3 (3)

Assembly and maintenance

7.1 Preface
7.2 Setting data
7.4 Cleaning
0288-2 7.5-2 EN 1 (1)

Complete turbocharger

Brief description
Remove and refit the turbocharger in complete condition. Major overhaul/
maintenance of the turbocharger is due.

1 Technician 4,5
1 Assistant 1,0
1 Set of ring or socket wrenches - Inventory
1 Screwdriver - Inventory
- Torque wrench - Inventory
- Round sling (min. load capacity 10 kN) - Inventory
- Lifting tackle, ropes - Inventory
- Wood as a support - Inventory
- High-temperature lubricant (e.g. Molykote HSC) - Inventory
Related work cards

7.2.1
Technical data
Designation Information
Turbocharger, complete with silencer 451 kg
Preliminary remarks
Removal/refitting of the complete turbocharger only in case of major over-
haul or replacement. Figure Removing turbocharger from engine bracket
and refitting it shows the turbocharger with a silencer. The same work steps
are required for turbochargers with an air intake casing.
For maintenance work on the turbocharger, subassemblies/components

are removed in succession. Please refer to the following work cards
2009-10-28
500.32 to 500.47.
Work cards
TCR18
C2 0288 500.31-01 EN 1 (4)

501.000 Gas admission casing 544.000 Silencer

506.000 Gas outlet casing 546.000 Compressor casing
517.000 Bearing casing
Figure 1: Removing turbocharger from engine bracket and refitting it
Risk of serious or fatal injury when lifting and moving loads!

No persons may be present in the area of danger around and underneath
a suspended load.
▪ Do not use shackles or chains for attaching the lifting tackle to the
bearing casing of the turbocharger.
▪ Lifting tackle, ropes and attachment points must be able to take the
load safely and be in perfect condition.
▪ All lifting, moving and setting down of the load must be carried out
slowly.
Work sequence - Removing the complete turbocharger
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)!
2009-10-28
Work cards
TCR18
2 (4) C2 0288 500.31-01 EN

Danger of burning/scalding from escaping lube oil!

The lube oil is under pressure and very hot!
▪ Before opening pipes, flanges, screwed connections or fittings, release
the pressure in the system and check that it is depressurised!
▪ Before opening oil pipes, wait until the lube oil has cooled down
sufficiently!
Starting condition The engine is shut down. Components of the turbocharger have cooled
down far enough to allow maintenance work to be carried out. Tools and
appliances are at hand and ready. The turbocharger can be accessed safely.
Coverings are removed to the extent necessary.
Steps 1. Detach or remove any connecting pipes installed for exhaust gas,
charge air, Jet Assist, turbine cleaning, compressor cleaning, lube oil
pressure/temperature, speed measurement and other special connec-
tions.
2. Attach lifting tackle to the turbocharger at the bearing casing (517.000)
using a round sling of adequate capacity.
Carefully tension the round sling. Attach secondary ropes at appropriate
points to assist in balancing.
3. Undo the screw connections between the turbocharger and the engine
bracket.
See engine manual for instructions.
4. Carefully lift off the turbocharger using the lifting tackle and set it down
on a wooden support.
With the turbocharger removed, seal the openings for air, exhaust gas
and lube oil to prevent foreign objects or water from entering.
Work sequence - Refitting the complete turbocharger
Observe the following procedures when refitting the

turbocharger on the engine.
▪ Remove protective caps from pipe connections/pipes.
▪ Use only flawless seals and screw locking elements.
▪ Insert sealing elements for lube oil in the engine bracket (see engine
manual).
▪ Apply high-temperature lubricant (e.g. Molykote HSC) to the threads of
heat-resistant screws and nuts on the turbine side.
Steps 1. Attach lifting tackle to the turbocharger at the bearing casing (517.000)
using a round sling of adequate capacity.
2009-10-28
Carefully tension the round sling. Attach secondary ropes at appropriate

Work cards
points to assist in balancing.

2. Insert sealing elements for lube oil in the engine bracket; seals are
TCR18
included in the scope of supply of the engine (see engine manual).
C2 0288 500.31-01 EN 3 (4)

3. Carefully lift the turbocharger using the lifting tackle and set it down on
the engine bracket.

4. At first, only lightly bolt the turbocharger to the engine bracket.
5. Align and fasten the connections for exhaust gas and charge air on the
engine and the turbocharger. See engine manual for instructions.
6. Tighten the bolts fastening the turbocharger to the engine bracket.
See engine manual for instructions.
7. Refit the coverings.
8. Re-establish all connections required for Jet Assist, turbine cleaning,
compressor cleaning, lube oil pressure/temperature, speed measure-
ment and other special connections.
Refitting the turbocharger on a 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.
2009-10-28
Work cards
TCR18
4 (4) C2 0288 500.31-01 EN

Silencer - Option

Brief description
Removal and installation of the silencer is carried out in completed condi-
tion. Disassembly of the silencer is required for all work that must be per-
formed from the compressor side.

1 Technician 0,4
1 Assistant 0,4
1 Hexagon screw driver 6 - Inventory
- Wood (for placing underneath) - Inventory
Related work cards

500.31
Technical Data
Silencer 68 kg
2009-02-02
Work cards
TCR18
C2 0288 500.32-01 EN 1 (2)

Preliminary remarks
544.000 Silencer 546.004 V-profile clamp

Figure 1: Removing and refitting the silencer
Work sequence - Removing the complete silencer
Starting condition Connecting pipe for compressor cleaning is released, if provided.
Steps 1. Attach lifting tackle to the silencer (544.000) using a rope.
2. Loosen the V-profile clamp (546.004) on both sides of the circumfer-

ence.
3. Move the silencer away from the compressor casing (546.000) in axial
direction and place it on a wooden support with the flange face down.
Work sequence - Refitting the complete silencer

Steps 1. Attach lifting tackle to the silencer (544.000) using a rope.
2. Move the silencer towards the compressor casing (546.000) in axial

direction.
3. Fasten the silencer to the compressor casing with V-profile
clamp (546.004).
Observe tightening torques during refitting!

▪ Apply oil to the threads and contact surfaces.
▪ Tightening torque for the V-profile clamp (546.004) on both sides of the
circumference: 12 Nm
2009-02-02
Work cards
TCR18
2 (2) C2 0288 500.32-01 EN

Air intake casing - Option

Brief description
Removal and refitting of the air intake casing is carried out in complete con-
dition. Dismantling of the air intake casing is necessary for all jobs that must
be performed from the compressor side.

1 Technician 0,4
1 Assistant 0,4
- Wood (for placing underneath) - Inventory
Related work cards

500.31
Technical Data
Air intake casing 90° 41 kg
Air intake casing axial 25 kg
2009-02-02
Work cards
TCR18
C2 0288 500.33-01 EN 1 (2)

Preliminary remarks
545.001 Air intake casing 546.004 V-profile clamp

Figure 1: Removing and refitting the air intake casing (545.01 or 545.02)
Work sequence - Removing the complete air intake casing
Starting condition Connecting pipe for compressor cleaning is released, if provided.
Steps 1. Attach lifting tackle to the air intake casing (545.01 or 545.02) using a
rope.
2. Loosen the V-profile clamp (546.004) on both sides of the circumfer-
ence.
3. Move the air intake casing away from the compressor casing (546.000)
in axial direction and place it on a wooden support.
Work sequence - Refitting the complete air intake casing

Steps 1. Attach lifting tackle to the air intake casing (545.01 or 545.02) using a
rope.
2. Move the air intake casing towards the compressor casing (546.000) in
axial direction.
3. Fasten the air intake casing to the compressor casing with V-profile
clamp (546.004).

▪ Apply oil to the threads and contact surfaces.
2009-02-02
▪ Tightening torque for the V-profile clamp (546.004) on both sides of the
Work cards
circumference: 12 Nm
TCR18
2 (2) C2 0288 500.33-01 EN

Insert, compressor side

Brief description
Remove and refit the compressor-side insert. Maintenance work is due/
required. Beginning from the compressor side.

1 Technician 0,4
2 Guide rod 596.035 Option
1 Socket wrench 10 - Inventory
1 Torque wrench 17 - Inventory
- Lifting tackle, rope - Inventory
- Special lubricant (e.g. Molykote G-n or Molykote - Inventory
P40)
Spare Parts
2 O-ring seal 540.015
Related work cards

500.31 500.32 500.33
Technical data
Insert, compressor side 18 kg
2009-02-02
Work cards
TCR18
C2 0288 500.41-01 EN 1 (3)

Preliminary remarks
540.001 Insert 540.030 Balance ring

540.010 Retaining ring 546.001 Compressor casing
540.015 O-ring seal 546.020 Hexagon bolt
540.020 Hexagon bolt 596.035 Guide rod
Figure 1: Removing and refitting the compressor-side insert
Work sequence - Removing the insert
Starting condition Silencer or air intake casing is removed.
Steps 1. Loosen two hexagon bolts (546.020) from the compressor cas-
ing (546.001) and replace with guide rods (596.035).
Unscrew the remaining hexagon bolts (546.020).
2. Evenly force off the insert (540.001) and the retaining ring bolted to it
(540.010) using 3 hexagon bolts (546.020).
3. Attach lifting tackle to the insert using a rope, remove the insert in axial
direction and place it on a wooden support.
Take care not to damage blades of the compressor wheel.
Work sequence - Installing the insert
O-ring seals must be tensed all around the circumference and may not
2009-02-02
be twisted upon mounting.

Work cards
TCR18
Steps 1. Apply clean lubricating oil to the O-ring seals (540.015) and insert them
into the ring grooves of the insert (540.001).
2 (3) C2 0288 500.41-01 EN

2. Screw two guide rods (596.035) into the compressor casing (546.001)

as an assembly aid.
3. Install the complete insert together with the balance ring (540.030) into
the compressor casing (546.001) and fasten it with hexagon
bolts (546.020).
4. Remove the guide rods and screw in the remaining hexagon bolts.
Observe tightening torques during installation!

▪ Apply special lubricant (e.g. Molykote G-n or Molykote P40) to the
threads and contact surfaces.
▪ Tightening torque for hexagon bolts (546.020): 34 Nm
For checking the gaps (items 1 and 5), see Chapter [7.2.2].
2009-02-02
Work cards
TCR18
C2 0288 500.41-01 EN 3 (3)

Covering on compressor casing - Option

Brief description
Remove and refit the covering on the compressor casing. Maintenance work
is due/required. Beginning from the compressor side.

1 Technician 0,4
1 Open-jaw wrenches (set) - Inventory
Related work cards

500.31 500.32 500.33
500.41
Technical data
Covering, complete 10 kg
2009-02-02
Work cards
TCR18
C2 0288 500.42-01 EN 1 (2)

Preliminary remarks
546.001 Compressor casing 591.000 Covering

Figure 1: Removing and refitting the covering on the compressor casing
Work sequence - Removing the covering on the compressor casing
Starting condition Silencer or air intake casing, and compressor-side insert are removed.
Steps 1. Undo the connecting elements on the covering halves.
2. Lift off the covering (591.000/591.03) and place it on a wooden support.
Work sequence - Refitting the covering on the compressor casing

Steps 1. Mount the covering halves on the compressor casing and fasten them
with the connecting elements.
2009-02-02
Work cards
TCR18
2 (2) C2 0288 500.42-01 EN

Compressor casing

Brief description
Remove and refit the compressor casing. Maintenance work is due/

1 Technician 0,6
1 Suspension device 596.020 Option
1 Shackle 596.025 Option
- Lifting tackle, rope - Inventory
- Special lubricant (e.g. Molykote G-n or Molykote - Inventory
P40)
Spare Parts
Related work cards

500.31 500.32 500.33
500.41 500.42
2010-05-12
Work cards
TCR18
C2 0288 500.43-03 EN 1 (3)

500.43
Preliminary remarks
Compressor casing
517.001 Bearing casing 546.010 Clamping claw

517.018 O-ring seal 546.008 Countersunk bolt
542.001 Diffuser 596.020 Suspension device
546.001 Compressor casing 596.025 Shackle
546.005 Hexagon bolt
Figure 1: Removing and refitting the compressor casing
Work sequence - Removing the compressor casing
Starting condition Coverings are removed to the extent necessary.
Silencer or air intake casing, compressor-side insert and connection for Jet
Assist (if provided) are removed.
The insert must be disassembled before removal of the compressor

casing!
Steps 1. Unscrew the hexagon bolts (546.005) and take off the clamping claws
(546.010).
2. Screw the suspension device (596.020) onto the compressor casing
(546.001) with two hexagon bolts (546.005).
3. Attach lifting tackle to the compressor casing using shackle (596.025)
and rope, and remove the casing in axial direction.
4. Place it on a wooden support and take measures to prevent it from roll-
2010-05-12
ing off.
5. If the diffuser (542.001) is to be removed:
Unscrew the countersunk bolt (546.008) and remove the diffuser in axial
direction.
2 (3) C2 0288 500.43-03 EN

Work sequence - Refitting the compressor casing

Steps 1. Install the diffuser (542.001).
2. Apply clean lubricating oil to the O-ring seal (517.018) and insert it into
the ring groove of the bearing casing (517.001).
The O-ring seal must be tensioned around its full circumference and must
not be twisted during installation.
3. Using the lifting tackle, place the compressor casing (546.001) against
the bearing casing (517.001) in axial direction.
4. Fasten the compressor casing (546.001) to the bearing casing (517.001)
with clamping claws (546.010) and hexagon bolts (546.005).

▪ Apply special lubricant (e.g. Molykote G-n or Molykote P40) to the
threads and contact surfaces.
▪ For safety reasons, only the hexagon bolts (546.005) originally installed
by MAN Diesel &Turbo, made of a special material, may be used.
▪ Tightening torque for hexagon bolts (546.005): 59 Nm
2010-05-12
Work cards
TCR18
C2 0288 500.43-03 EN 3 (3)

Cartridge

Brief description
Remove and refit the cartridge for inspection. Maintenance work is due/

1 Technician 0,6
3 Forcing-off bolt 596.018 Option
3 Forcing-off sleeve 596.019 Option
2 Open-jaw wrench 22 - Inventory
Related work cards

500.31 500.32 500.33
500.41 500.42 500.43
Technical data
Cartridge 88 kg
2009-10-28
Work cards
TCR18
C2 0288 500.44-01 EN 1 (3)

Preliminary remarks
501.001 Gas admission casing 506.000 Gas outlet casing

501.004 Clamping claw 513.001 Turbine nozzle ring
501.005 Clamping claw 596.018 Forcing-off bolt
501.007 Lock washer pair 596.019 Forcing-off sleeve
501.008 Hexagon nut 599.000 Cartridge
Figure 1: Removing and refitting the cartridge
Work sequence - Removing the cartridge

Starting condition Coverings, silencer or air intake casing, compressor-side insert and com-
pressor casing are removed.
Steps 1. Disconnect the connection for speed measurement, if provided.
2. Remove the front covering from the gas admission casing (501.001).
3. Attach lifting tackle to the cartridge (599.000) using a rope. Carefully
tension the rope.
When removing the cartridge from the engine bracket:
release the engine-side fastening elements between the cartridge and
the engine bracket. See engine manual for instructions.
4. Unscrew the hexagon nuts (501.008), take off the lock washer
pairs (501.007) and the clamping claws (501.004, 501.005).
5. Evenly force off the cartridge at 3 points on the circumference using
tools (596.018 and 596.019), remove it in axial direction and place it on
2009-10-28
a wooden support.
Work cards
Take care not to damage blades of the compressor and turbine

wheels.
TCR18
Pay attention to the turbine nozzle ring (513.001) when removing the
cartridge.
2 (3) C2 0288 500.44-01 EN

Work sequence - Installing the cartridge

Steps 1. Attach lifting tackle to the cartridge (599.000) using a rope and carefully
move the cartridge up against the gas admission casing in axial direc-
tion.
2. Fasten the cartridge to the gas admission casing (501.001) with clamp-
ing claws (501.004, 501.005), lock washer pairs (501.007) and hexagon
nuts (501.008).
When mounting the cartridge on the engine bracket:
install sealing elements for lube oil between the cartridge and the engine
bracket; seals are included in the scope of supply of the engine.
Fasten the cartridge to the gas admission casing with clamping claws,
lock washer pairs and hexagon nuts.
Install the cartridge on the engine bracket using the engine-side fasten-
ing elements. See engine manual for instructions.
3. Refit the front covering to the gas admission casing (501.001).
Observe tightening torques during installation!

▪ Apply high-temperature lubricant (e.g. Molykote HSC) to the threads
and contact surfaces.
▪ Tightening torque for hexagon nuts (501.008): 34 Nm
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.
For checking the gaps (items 2 and 6), see Chapter [7.2.2].
For checking the gap (item 6), the front closures/connections of the gas
outlet casing (506.000) must first be removed.
2009-10-28
Work cards
TCR18
C2 0288 500.44-01 EN 3 (3)

Cartridge components - Major overhaul

Brief description
Dismantle the cartridge, inspect the components, reassemble the cartridge.
Major overhaul is due/required.

1 Technician 4,0
1 Hexagon pin 596.001 Standard
1 Retainer 596.002 Option
1 Hexagon pin 596.003 Option
1 Spring plug 596.004 Option
2 Guide rod 596.036 Option
1 Torque wrench 30 (220 Nm) - Inventory
1 Socket wrench 10 - Inventory
1 Pliers for retaining ring - Inventory
- Special preservative (Molykote P40) - Inventory
Related work cards

500.31 500.32 500.33
500.41 500.42 500.43
500.44
Technical data
2010-05-12
Work cards
Bearing casing 66 kg
TCR18
Turbine rotor 16 kg
Compressor wheel 6 kg
C2 0288 500.45-03 EN 1 (7)

Spare Parts
Tools and spare parts for a major overhaul must be available.

1 Thrust bearing 517.002
2 Bearing bush 517.003
2 Retaining ring 517.038
6 Hexagon bolt 517.051
1 Piston ring 520.132
1 Piston ring 520.133
Work sequence - Mounting the arresting device
506.001 Gas outlet casing 596.002 Retainer

506.034 Hexagon bolt 596.003 Hexagon pin
520.001 Turbine rotor 596.004 Spring plug
Figure 1: Arresting device for turbine rotor
Starting condition Coverings, silencer or air intake casing, compressor-side insert and com-
pressor casing are removed.
2010-05-12
Steps 1. Before removing the cartridge, fasten the arresting device for the turbine
Work cards
rotor (596.002, 596.003 and 596.004) to the gas outlet casing (506.001)
with hexagon bolts (506.034).
TCR18
2 (7) C2 0288 500.45-03 EN

Work sequence - Removing the compressor wheel, compressor-side cover and retaining

ring
517.001 Bearing casing 520.005 Compressor wheel

517.029 Cylindrical screw 520.031 Retaining ring
517.031 O-ring seal 520.133 Piston ring
517.087 Cover, compressor side 562.040 Speed transmitter
520.001 Turbine rotor 596.001 Hexagon pin
Figure 2: Removing and refitting the compressor wheel, compressor-side cover and retaining ring
Special tool for removing the compressor wheel!

The hexagon pin (596.001) is located inside the silencer or air intake
casing.
Steps 1. After mounting the arresting device, first just slightly loosen the com-
pressor wheel (520.005) with the hexagon pin (596.001) (right-hand
thread).
2. Disconnect the speed transmitter (562.040) and unscrew it from the
bearing casing (517.001).
3. Remove the cartridge, see work card [500.44].
4. Block the turbine rotor (520.001) on the face side in circumferential
direction using a hexagon screw driver and unscrew the compressor
wheel (520.005) with the hexagon pin (596.001) (right-hand thread).
2010-05-12
5. Unscrew the cylindrical screws (517.029) and evenly force off the
Work cards
cover (517.087) with 2 hexagon bolts (M10, thread length ≥ 40 mm).

6. Remove the cover together with the piston ring (520.133) in axial direc-
TCR18
tion.
C2 0288 500.45-03 EN 3 (7)

Mark the axial installation position of the piston ring (520.133).

7. Pull the retaining ring (520.031) off the turbine rotor in axial direction.
Work sequence - Removing bearing parts, turbine rotor and turbine-side cover
517.001 Bearing casing 517.038 Retaining ring

517.002 Thrust bearing 517.051 Hexagon bolt
517.003 Bearing bush 520.001 Turbine rotor
517.005 Bearing body, compressor side 520.027 Thrust ring / counter-thrust ring
517.006 Bearing body, turbine side 520.132 Piston ring
517.009 Cover, turbine side 596.036 Guide rod
Figure 3: Removing and refitting bearing parts, turbine rotor and turbine-side cover
Steps 1. Unscrew two hexagon bolts (517.051) and replace them with guide rods
(596.036).
2. Unscrew the remaining hexagon bolts (517.051) and evenly force off the
bearing body (517.005).
3. Remove the counter-thrust ring (520.027), thrust bearing (517.002) and
thrust ring (520.027) in axial direction.
4. Carefully remove the turbine rotor (520.001), fitted piston ring (520.132)
and cover (517.009) in axial direction.
2010-05-12
Work cards
Mark the axial installation position of the piston ring (520.132).

TCR18
4 (7) C2 0288 500.45-03 EN

5. Evenly force off the bearing body (517.006).

Remove the bearing bushes (517.003) only if they are to be replaced.
See work sequence - checking the bearing bushes
Work sequence - Checking the thrust bearing
Figure 4: Checking the thrust bearing

Steps 1. Measure the lengths (b) of the wedge surfaces (V) on the compressor
and turbine sides.
Length (b) extends up to the edge (K) on the bearing contact face (A).
Depending on the angle of light incidence, a dark band may appear in
front of the edge (K) on the wedge surface (V). This band is to be included
in the measurement of length (b).
2. Replace the thrust bearing (517.002) when
˗ on the compressor side (VS) one of the lengths (b) ≤ 2.7 mm,
˗ on the turbine side (TS) one of the lengths (b) ≤ 3.5 mm.
Work sequence - Checking the bearing bushes
Figure 5: Checking the bearing bush

Steps 1. The bore of the two bearing bushes (517.003) with MGF profile is not
absolutely circular. Wear becomes evident as a mirror-bright recess of
2010-05-12
band width (W) caused by embedding of the turbine rotor.

Work cards
2. Replace the bearing bush (517.003) when

˗ band width (W) ≥ 16.0 mm.
TCR18
C2 0288 500.45-03 EN 5 (7)

Work sequence - Checking the retaining ring, turbine rotor, piston rings
Steps 1. Replace the retaining ring (520.031) when

˗ D1 ≤ ∅ 34.94 mm.
2. Replace the turbine rotor (520.001) when
˗ D2 ≤ ∅ 34.94 mm.
3. Replace the piston ring on the turbine side (520.132) when
˗ the axial width of 2.5 mm has worn down to less than 2.0 mm.
4. Replace the piston ring on the compressor side (520.133) when
˗ the axial width of 2.5 mm has worn down to less than 2.0 mm.
Work sequence - Assembly
Imbalance after installation of a new compressor wheel or

turbine rotor!
▪ Before installing a new compressor wheel or a new turbine rotor, the
complete rotor assembly must be balanced.
▪ Balancing can only be carried out by a service center authorised by
MAN Diesel & Turbo.
Apply special preservative (e.g. Molykote P40) to all fitting surfaces

during assembly as protection against fretting (contact corrosion).
1. Screw two guide rods (596.036) into the bearing casing (517.001) as an
assembly aid.
2. Insert the bearing body (517.006) together with the fitted bearing
bush (517.003) into the bearing casing (517.001) in axial direction.
3. Install the turbine-side cover (517.009) and the turbine rotor (520.001)
with fitted piston ring (520.132) in axial direction.
Observe the marked axial installation position of the piston ring or fit a
new piston ring (520.132).
4. Install the thrust ring (520.027), thrust bearing (517.002) and counter-
thrust ring in axial direction.
The balancing marks (0) of the turbine shaft, thrust ring and counter-
thrust ring must coincide radially.
5. Install the bearing body (517.005) together with the fitted bearing
bush (517.003) in axial direction and fasten with hexagon
bolts (517.051).
2010-05-12
6. Remove the guide rods and screw in the remaining hexagon bolts.
Work cards
TCR18
6 (7) C2 0288 500.45-03 EN

Observe tightening torques during assembly!

Apply special preservative (Molykote P40) to the threads and contact
surfaces.
Tightening torque for hexagon bolts (517.051): 7 Nm
7. Push the retaining ring (520.031) onto the turbine shaft.

The balancing marks (0) of the turbine shaft and retaining ring must
coincide radially.
8. Apply clean lubricating oil to the O-ring seal (517.031) and insert it into
the ring groove of the cover (517.087). The O-ring seal must be ten-
sioned around its full circumference and must not be twisted during
installation.
9. Install the cover (517.087) together with the fitted piston ring (520.133)
in axial direction.
Observe the marked axial installation position of the piston ring or fit a
new piston ring (520.133).
10. Fasten cover (517.087) with cylindrical screws (517.029).

11. Block the turbine rotor (520.001) in circumferential direction. At first just
lightly fasten the compressor wheel (520.005) with the hexagon
pin (596.001) (right-hand thread).
12. Install the cartridge, see work card [500.44].
13. Mount the arresting device for the turbine rotor (596.002, 596.003 and
596.004) on the gas outlet casing with hexagon bolts (506.034) (see
Figure Arresting device for turbine rotor).
14. Fasten the compressor wheel (520.005) with the hexagon pin (596.001)
and torque wrench/torque amplifier (right-hand thread).
Observe tightening torques during assembly!

Apply special preservative (Molykote P40) to the threads and contact
surfaces.
Tightening torque for compressor wheel (520.005): 220 Nm
15. Screw the speed transmitter (562.040) into the bore on the side of the
bearing casing (517.001). Connect the cable ends in the terminal box.
2010-05-12
16. Remove the arresting device.

Work cards
TCR18
C2 0288 500.45-03 EN 7 (7)

Turbine nozzle ring

Brief description
Remove and refit the turbine nozzle ring for inspection. Check the state and
wear condition.

1 Technician 0,2
Related work cards

500.31 500.32 500.33
500.41 500.42 500.43
500.44
Technical data
Turbine nozzle ring 4 kg
2009-02-02
Work cards
TCR18
C2 0288 500.46-01 EN 1 (3)

Preliminary remarks
501.001 Gas admission casing 513.001 Turbine nozzle ring

501.009 Parallel pin
Figure 1: Removing and refitting the turbine nozzle ring
Work sequence - Removing the turbine nozzle ring
Starting condition Coverings, silencer or air intake casing, compressor-side insert, compres-
sor casing and cartridge are removed.
Steps 1. Take the turbine nozzle ring (513.001) out of the gas admission cas-
ing (501.001) in axial direction.
2. Check the turbine nozzle ring for erosive wear.
The erosive wear of the guide vanes (A) is caused by the outlet flow
mainly in the area of the trailing edges (B). The original position of the
trailing edges (B) can be recognised at the roots (G) of the guide
vanes (A).
Since the guide vanes do not wear evenly, the mean value of the guide
vane reduction (Lm) is calculated as follows:
(L1 + L2 + L3 + … + Ln)
Lm = ____________________ n = number of guide vanes (A)
n
Replace the turbine nozzle ring when Lm ≥ 10 mm.
2009-02-02
Work cards
TCR18
2 (3) C2 0288 500.46-01 EN


A Guide vanes E Negative areas (to the left of D)
B Trailing edge (original) F Positive area (to the right of D)
C Contour of the reduction G Root of the guide vane
D Mean reduction
(area F = Σ areas E)
Figure 2: Erosive wear on the turbine nozzle ring
Work sequence - Installing the turbine nozzle ring

Insert the turbine nozzle ring (513.001) into the gas admission cas-
ing (501.001) in axial direction. Make sure that it is in the correct circumfer-
ential position in relation to the parallel pin (501.009).
2009-02-02
Work cards
TCR18
C2 0288 500.46-01 EN 3 (3)

Gas admission casing and turbine-side insert

Brief description
Remove and refit the insert. Maintenance work is due/required.

1 Technician 1,0
1 Suspension device 596.020 Option
1 Shackle 596.025 Option
Related work cards

500.31 500.32 500.33
500.41 500.42 500.43
500.44 500.46
Technical data
Gas admission casing 62 kg
Covering on gas admission casing 18 kg
Insert, turbine side 8 kg
2009-02-02
Work cards
TCR18
C2 0288 500.47-01 EN 1 (3)

Preliminary remarks
501.001 Gas admission casing 541.001 Insert, turbine side

501.007 Lock washer pair 541.021 Cylindrical screw
501.008 Hexagon nut 596.020 Suspension device
501.011 Clamping claw 596.025 Shackle
506.001 Gas outlet casing
Figure 1: Removing and refitting the gas admission casing and turbine-side insert
Work sequence - Removing the gas admission casing
Starting condition Coverings, silencer or air intake casing, compressor-side insert, compres-
sor casing, cartridge and turbine nozzle ring are removed.
Steps 1. Remove the covering parts between the gas admission casing (501.001)
and the gas outlet casing (506.001).
2. Screw the suspension device (596.020) onto the gas admission cas-
ing (501.001) with 2 hexagon nuts (501.008).
3. Attach lifting tackle to the gas admission casing (501.001) using
shackle (596.025) and rope. Carefully tension the rope.
4. Unscrew the hexagon nuts (501.008), take off the lock washer
pairs (501.007) and the clamping claws (501.011).
5. Remove the gas admission casing (501.001) in axial direction and place
it on a wooden support.
Work sequence - Removing the turbine-side insert

2009-02-02
Work cards
Steps 1. Unscrew the cylindrical screws (541.021).

TCR18
2. Remove the turbine-side insert (541.001) in axial direction and place it

on a wooden support.
2 (3) C2 0288 500.47-01 EN

Work sequence - Refitting the turbine-side insert and gas admission casing

Steps 1. Insert the insert (541.001) into the gas admission casing (501.001) in
axial direction and fasten it with cylindrical screws (541.021).
2. Using the lifting tackle, place the gas admission casing (501.001) against
the gas outlet casing (506.001) in axial direction.
3. Fasten the gas admission casing (501.001) to the gas outlet cas-
ing (506.001) with the clamping claws (501.011), lock washer
pairs (501.007) and hexagon nuts (501.008).
4. Refit the covering parts between the gas admission casing (501.001)
and the gas outlet casing (506.001).

▪ Apply high-temperature lubricant (e.g. Molykote HSC) to the threads
and contact surfaces.
▪ Tightening torque for hexagon nuts (501.008): 34 Nm
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.
2009-02-02
Work cards
TCR18
C2 0288 500.47-01 EN 3 (3)

MAN Diesel & Turbo
Spare parts catalogue / tools

1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
2010-05-12
0288-2 8-2 EN 1 (1)

Preface
8.1 Preface
8.3 Spare parts
8.4 Spare parts for maintenance
8.5 Spare parts for major overhaul
8.6 Tools - OPTION
0288-2 8.1-2 EN 1 (1)

Organisation and use of the spare parts catalogue
Preface
General
Maintenance and repair work on the turbocharger can be carried out prop-
erly only if the required spare parts and tools are available.
We thus recommend ordering spare parts for the turbocharger in time,
keeping spare parts for maintenance and major overhaul in stock and having
the required tools available.
Yours sincerely,
MAN Diesel & Turbo SE
Contents of the spare parts catalogue

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.
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 scope of supply of the turbocharger.
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
latter. In such cases, the identity card of the part supplied will contain a
corresponding reference.
Organisation
Overview of subassemblies MAN Diesel & Turbo SE turbochargers are assembled from a number of
subassemblies. Standard subassemblies form a basis to which other appli-
cation-specific subassemblies can be added. The overview of the subas-

semblies illustrates the layout of the individual subassemblies.
Spare parts The spare parts sheets are ordered by subassembly from 500 to 599.
The ordinal number at the top of the spare parts sheets consists of the 3-
digit subassembly number and a 2-digit variant number corresponding to
the design variant.
2008-12-11
The order numbers for spare parts consist of a 3-digit subassembly number
and a 3-digit item number. The subassembly number and the item number
are separated by a dot.
TCR18
C3 0288 8.1.1-01 EN 1 (2)

Spare parts for maintenance The list of spare parts for maintenance or major overhaul of the turbocharger
Preface
and major overhaul contains a selection of spare parts. This list is also included in the spare
parts box for identification of the parts.
All spare parts that are not packed in plastic bags must be stored well
coated in grease. Please re-order immediate replacements for spare parts
that have been used.
Tools The list of tools includes special tools for maintenance and major overhaul
of a turbocharger. This list is also included in the tool box for identification
of the tools.
Order numbers for tools consist of the subassembly number for tools and
a 3-digit item number.
2008-12-11
TCR18
2 (2) C3 0288 8.1.1-01 EN

Ordering spare parts
Preface
Information required
To avoid queries, the following information should be provided when order-
ing spare parts:
Turbocharger type xxxxxxxxx
Works number of turbocharger x xxx xxx
Order number xxx.xxx
Designation of part xxxxxxxxx
Quantity xx
Shipping address xxxxxxxxx
Mode of shipment xxxxxxxxx
Table 1: Information required in the order
Addresses
Augsburg plant
(headquarters)
MAN Diesel & Turbo SE Tel. +49 821 322 0 (switchboard)
MAN Diesel & Turbo | PrimeServ Fax +49 821 322-49 4180
Augsburg
86224 Augsburg e-mail [email protected]
Germany Internet http:// www.mandiesel.com
PrimeServ Turbocharger Tel. +49 821 322 4010 (axial turbochargers)
Technical service Tel. +49 821 322 4020 (radial turbochargers)
Fax +49 821 322-3998
PrimeServ Turbocharger e-mail [email protected]
Retrofits Internet http:// www.mandiesel.com/primeserv
PrimeServ Turbocharger Tel. +49 821 322-4030
Spare parts Fax +49 821 322-3998
PrimeServ Academy Tel. +49 821 322-1397
Training courses for turbochargers Fax +49 821 322-1170
and engines
Internet http://www.mandiesel.com/psa-augsburg
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
2010-01-19
attached.
TCR18
C3 0288 8.1.2-01 EN 1 (1)

Overview of subassemblies
8.1 Preface
8.3 Spare parts
8.6 Tools - OPTION
0288-2 8.2-2 EN 1 (1)

MAN Diesel & Turbo 500
Subassemblies

2009-02-02
TCR18
C3 0288 500-01 EN 1 (2)

500 MAN Diesel & Turbo
Subassembly Designation Optional Weight

500 Turbocharger, complete, incl. silencer 451 kg

500 Turbocharger, complete, with air intake casing, 90° 424 kg
500 Turbocharger, complete, with air intake casing, axial 408 kg
501 Gas admission casing 62 kg
506 Gas outlet casing 87 kg
506 Gas outlet casing, with waste gate X 93 kg
513 Turbine nozzle ring 4 kg
517 Bearing casing 66 kg
520 Rotor, complete 22 kg
540 Insert, compressor side 18 kg
541 Insert, turbine side 8 kg
542 Diffuser 5 kg
544 Silencer X 68 kg
545 Air intake casing, 90° X 41 kg
545 Air intake casing, axial X 25 kg
546 Compressor casing 70 kg
591 Covering, on gas admission casing 18 kg
591 Covering, on gas outlet casing 23 kg
591 Covering, on compressor casing X 10 kg
599 Cartridge (517 + 520) 88 kg
Table 1: TCR18 subassemblies and weights (approximate values)
2009-02-02
TCR18
2 (2) C3 0288 500-01 EN

Spare parts
8.1 Preface
8.3 Spare parts
8.6 Tools - OPTION
0288-2 8.3-2 EN 1 (1)

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

501.000 Gas admission casing, complete 1
501.001 Gas admission casing 1
501.004 Clamping claw 1
2009-10-28

501.006 Stud 22
501.007 Lock washer pair 22
TCR18
501.008 Hexagon nut 22

501.009 Parallel pin 1
C3 0288 501.01-02 EN 1 (2)


Spare parts

501.026 Screw plug 2
501.027 Sealing ring 2
2009-10-28
TCR18
2 (2) C3 0288 501.01-02 EN

Gas outlet casing
Spare parts
Spare parts 506.01

506.000 Gas outlet casing, complete 1
506.001 Gas outlet casing 1
506.003 Cover 1
2009-01-30
506.034 Hexagon bolt 8

506.038 Seal 1
506.047 Supporting sheet 1
TCR18
506.048 Washer 5
C3 0288 506.01-01 EN 1 (2)


Spare parts

2009-01-30
TCR18
2 (2) C3 0288 506.01-01 EN

Gas outlet casing with waste gate - OPTION
Spare parts
Spare parts 506.02

506.000 Gas outlet casing, complete 1
506.001 Gas outlet casing 1
506.003 Cover 1
506.038 Seal 2
2009-01-30
506.047 Supporting sheet 1

506.048 Washer 5
TCR18
506.053 Waste gate connection 1

C3 0288 506.02-01 EN 1 (2)


Spare parts

2009-01-30
TCR18
2 (2) C3 0288 506.02-01 EN

Turbine nozzle ring
Spare parts
Spare parts 513.01

513.001 Turbine nozzle ring 1
2009-01-30
TCR18
C3 0288 513.01-01 EN 1 (1)

Bearing casing
Spare parts
Spare parts 517.01

517.000 Bearing casing, complete 1
517.001 Bearing casing 1
517.002 Thrust bearing 1
2009-01-30
517.003 Bearing bush 2

517.005 Bearing body, compressor side 1
517.006 Bearing body, turbine side 1
TCR18
517.009 Cover, turbine side 1

517.018 O-ring seal 1
C3 0288 517.01-01 EN 1 (2)


Spare parts

517.029 Cylindrical screw 4
517.038 Retaining ring 2
517.087 Cover, compressor side 1
2009-01-30
TCR18
2 (2) C3 0288 517.01-01 EN

Rotor complete
Spare parts
Spare parts 520.01

520.000 Rotor complete 1
520.001 Turbine rotor 1
520.005 Compressor wheel 1
520.027 Thrust ring / Counter-thrust ring 2
520.132 Piston ring 1

520.133 Piston ring 1
2010-05-12
TCR18
C3 0288 520.01-02 EN 1 (1)

Insert, compressor side
Spare parts
Spare parts 540.01

540.000 Insert, compressor side, complete 1
540.001 Insert 1
540.030 Balance ring 1
2009-10-28
TCR18
C3 0288 540.01-01 EN 1 (1)

Insert, turbine side
Spare parts
Spare parts 541.01

541.000 Insert, turbine side, complete 1
541.001 Insert 1
541.021 Cylindrical screw 3
2009-01-30
TCR18
C3 0288 541.01-01 EN 1 (1)

Diffuser
Spare parts
Spare parts 542.01

542.001 Diffuser 1
2009-01-30
TCR18
C3 0288 542.01-01 EN 1 (1)

Chamber silencer - OPTION
Spare parts
Spare parts 544.02

544.000 Chamber silencer, complete 1
544.006 Stud 6
544.007 Washer 12
544.025 Type plate 1
544.034 Perforated plate 1

2009-01-15
544.063 Hexagon pin 1

544.201 Air filter mat 1
TCR18
544.202 Clamp 2
544.203 Clamp 1
C3 0288 544.02-01 EN 1 (2)


Spare parts
544.205 Cover strip 1

2009-01-15
TCR18
2 (2) C3 0288 544.02-01 EN

Air intake casing, 90° - OPTION
Spare parts
Spare parts 545.01

545.000 Air intake casing 90°, complete 1
545.001 Air intake bend 1

2010-05-12

TCR18
545.188 Sealing compound 1

545.189 Activator 1
C3 0288 545.01-01 EN 1 (2)

Spare parts
2010-05-12
TCR18
2 (2) C3 0288 545.01-01 EN

Air intake casing, axial - OPTION
Spare parts
Spare parts 545.02

545.000 Air intake casing axial, complete 1
545.001 Air intake pipe 1

2010-05-12

TCR18
545.188 Sealing compound 1

545.189 Activator 1
C3 0288 545.02-01 EN 1 (2)

Spare parts
2010-05-12
TCR18
2 (2) C3 0288 545.02-01 EN

Compressor casing
Spare parts
Spare parts 546.01

546.000 Compressor casing, complete 1
546.001 Compressor casing 1
546.004 V-profile clamp 1
2010-05-12
546.008 Countersunk bolt 1

TCR18

546.026 Notched nail 4
C3 0288 546.01-03 EN 1 (2)


Spare parts

546.050 Flange 1
2010-05-12
TCR18
2 (2) C3 0288 546.01-03 EN

Speed measuring device - OPTION
Spare parts
Spare parts 562.01

562.000 Speed measuring device, complete 1
562.040 Speed transmitter 1
562.083 Terminal box 1
2008-12-11
562.100 Speed indicator 1

562.135 Teflon-armoured cable *m
TCR
* Specify length in m when ordering
C3 0288 562.01-01 EN 1 (1)

Cleaning device for turbine - Wet cleaning
Spare parts
Spare parts 578.01

578.000 Cleaning device for turbine – Wet cleaning, complete 1
578.005 Plate 1
578.104 Ball cock 1
578.122 Union nut 1
578.123 Cutting ring 1
578.136 Plate (with cleaning instructions) 1

2008-12-11
TCR
C3 0288 578.01-03 EN 1 (1)

Cleaning device for turbine - Dry cleaning
Spare parts
Spare parts 578.02

578.000 Cleaning device for turbine – Dry cleaning, complete 1

578.001 Tank 1
578.005 Plate 1
578.025 Screw connection 1
2008-12-11

578.028 Pipe 1
578.030 Ball cock 1
TCR
578.031 Ball cock 1
C3 0288 578.02-02 EN 1 (2)


Spare parts

578.042 Union nut 1
578.043 Cutting ring 1
578.067 Pipe clip 1
578.143 Spacer pipe 2
578.146 Washer 2
578.164 Spacer block 1
2008-12-11
TCR
2 (2) C3 0288 578.02-02 EN

Cleaning device for compressor - Pressure sprayer
Spare parts
Spare parts 579.02

579.029 Pressure sprayer 1
579.090 Hose (length 1.5 m) 1

579.091 Hose clamp 2
579.095 Coupling 1
579.096 Nipple 1
579.100 Support 1
2008-12-11

579.130 Retainer 1
579.178 Plate 1
TCR
C3 0288 579.02-01 EN 1 (1)

Covering on gas admission casing
Spare parts
Spare parts 591.01

591.01.000 Covering with insulation on gas admission casing, complete 1
2009-01-30
TCR18
C3 0288 591.01-01 EN 1 (1)

Covering on gas outlet casing
Spare parts
Spare parts 591.02

591.02.000 Covering with insulation on gas outlet casing, complete 1
2009-01-30
TCR18
C3 0288 591.02-01 EN 1 (1)

Covering on compressor casing - OPTION
Spare parts
Spare parts 591.03

591.03.000 Covering with insulation on compressor casing, complete 1

2009-01-30
TCR18
C3 0288 591.03-01 EN 1 (1)

Cartridge
Spare parts
Spare parts 599.01

599.000 * Cartridge 1
* 599.000 = (517.000) and (520.000) assembled

2009-01-30
TCR18
C3 0288 599.01-01 EN 1 (1)

11.59500-0246
Spare parts for maintenance
8.1 Preface
8.3 Spare parts
8.6 Tools - OPTION
0288-2 8.4-2 EN 1 (1)

Spare parts for maintenance - OPTION
11.59500-0246
Turbocharger TCR18
11.59500-0246
Order No. Designation Sketch Data Quantity
501.006 Stud D = M10 6

L = 34 mm
0.017 kg
501.007 Lock washer pair d = 10.7 mm 6
0.005 kg
501.008 Hexagon nut d = M10 6
0.012 kg
506.038 Seal D = 295 mm 2
0.056 kg
517.018 O-ring seal D = 428 mm 1
0.050 kg
2009-01-30
TCR18
0288 595.01-01 EN 1 (2)


11.59500-0246
540.015 O-ring seal D = 263 mm 2
0.030 kg
2009-01-30
TCR18
2 (2) 0288 595.01-01 EN

11.59500-0257
Spare parts for major overhaul
8.1 Preface
8.3 Spare parts
8.6 Tools - OPTION
0288-2 8.5-2 EN 1 (1)

Spare parts for major overhaul - OPTION
11.59500-0257
Turbocharger TCR18
11.59500-0257
501.006 Stud D = M10 6

L = 34 mm
501.007 Lock washer pair d = 10.7 mm 6
501.008 Hexagon nut d = M10 mm 6
506.038 Seal D = 295 mm 2
517.002 Thrust bearing D = 140 mm 1
1.520 kg
2009-10-28
TCR18
0288 595.02-02 EN 1 (3)


11.59500-0257
517.003 Bearing bush D = 51 mm 2
0.218 kg
517.018 O-ring seal D = 428 mm 1
517.031 O-ring seal D = 210 mm 1
517.038 Retaining ring D = 56.2 mm 2
517.051 Hexagon bolt D = M6 6

L = 44 mm
520.132 Piston ring D = 46 mm 1

2009-10-28
TCR18
2 (3) 0288 595.02-02 EN

11.59500-0257
520.133 Piston ring D = 65 mm 1
540.015 O-ring seal D = 263 mm 2

2009-10-28
TCR18
0288 595.02-02 EN 3 (3)

11.59600-0219
Tools - OPTION
8.1 Preface
8.3 Spare parts
8.6 Tools - OPTION
0288-2 8.6-2 EN 1 (1)

Tools
11.59600-0219
Tools - OPTION
Turbocharger TCR18
11.59600-0219
(596.001) Hexagon pin L = 60 mm 1
544.063 Is located inside the silencer 0.294 kg

or or air intake casing
545.063
596.002 Retainer L = 336 mm 1
1.091 kg
596.003 Hexagon pin L = 380 mm 1
0.730 kg
596.004 Spring plug L = 105.5 mm 1
0.034 kg
596.006 Closing cover D = 399 mm 1

6.100 kg
2009-12-11
TCR18
0288 596.01-02 EN 1 (4)


Tools - OPTION
11.59600-0219
596.012 Pipe L = 167 mm 2

D = 38 mm
0.904 kg
596.018 Forcing-off bolt L = 97 mm 3
0.152 kg
596.019 Forcing-off sleeve L = 85 mm 3
0.154 kg
596.020 Suspension device H = 334 mm 1

L = 200 mm
1.828 kg
596.025 Shackle D = 16 mm 1
0.310 kg
596.028 Foot H = 210 mm 1

W = 270 mm
4.922 kg
2009-12-11
TCR18
2 (4) 0288 596.01-02 EN

11.59600-0219
Tools - OPTION
0.054 kg
596.035 Guide rod L = 300 mm 2

D = M10
0.180 kg
596.036 Guide rod L = 80 mm 2

D = M6
0.017 kg
596.037 Guide rod L = 100 mm 2

D = M8
0.040 kg
596.050 Hexagon bolt L = 43 mm 2

D = M12
0.041 kg
596.051 Hexagon bolt L = 70 mm 2

D = M8
0.031 kg
2009-12-11
TCR18
0288 596.01-02 EN 3 (4)


Tools - OPTION
11.59600-0219
0.005 kg
2009-12-11
TCR18
4 (4) 0288 596.01-02 EN

MAN Diesel & Turbo
Index
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
2010-05-12
0288-2 9-2 EN 1 (1)

MAN Diesel & Turbo
Covering 591.01 (1)

Index
Index
591.02 (1)
591.03 (1)
A Covering on the compressor cas- 500.42 (2)
Admission casing 501.01 (1) ing
Adresses 2.1 (1)
Service 2.1 (1) D
Adresses and contact persons 2.1 (1) Danger of Fire/Fire-extinguishing Sys- 5.0 (2)
MAN Diesel SE 2.1 (1) tems
Air intake casing 500.33 (2) Danger Symbols 1.0 (2)
Air intake casing, 90° 545.01 (1) Differences in height 4.2 (3)
Air intake casing, axial 545.02 (1) Diffuser 542.01 (1)
Alarm points 3.1.1 (2)
Alarm System 5.0 (3) E
Arresting device for turbine rotor 500.45 (2) Emergency measures (in the event of 5.2 (1)
Availability code 7.1.1 (2) turbocharger failure)
Emergency operation with closing 500.11 (2)
B device
Bans (symbols) 1.0 (2) Exhaust Gases 5.0 (2)
Bearing casing 517.01 (1)
Bearing parts 500.45 (4) F
Fire-extinguishing Equipment 5.0 (2)
C Friction coefficient µ 7.2.1 (1)
Cartridge 500.44 (2) Fuel specifications 3.2.1 (2)
599.01 (1) Fuels 3.2.1 (1)
Chamber silencer 544.02 (1) Functional description (turbocharger) 4.1 (2)
Characteristics (fuels) 3.2.1 (1)
Check 500.45 (5) G
Bearing bush 500.45 (5) Gaps and clearances 7.2.2 (1)
Thrust bearing 500.45 (5) Gas admission casing 500.47 (2)
Checks during operation 5.1 (2) 501.01 (1)
Cleaning agents for compressor and 3.2.4 (1) Gas outlet casing 506.01 (1)
turbine 506.02 (1)
Cleaning device for compressor 579.02 (1)
Pressure sprayer 579.02 (1) H
Cleaning device for turbine 578.01 (1) Hazard levels 1.0 (1)
578.02 (1) Level 1 - 3 1.0 (1)
Dry cleaning 578.02 (1) Hearing Protection 5.0 (1)
Wet cleaning 578.01 (1)
Cleaning system 500.21 (2) I
500.22 (2) Inclination, permissible 4.2 (2)
500.23 (1) Insert 500.41 (2)
Dry cleaning of turbine 500.22 (2) 500.47 (2)
Wet cleaning of compressor 500.23 (1) 540.01 (1)
Wet cleaning of turbine 500.21 (2) 541.01 (1)
Cleaning the air filter 500.24 (1) Compressor side 500.41 (2, 3, 1)
Compressor casing 500.43 (2) 500.45 (2, 3, 1)
546.01 (1) 540.01 (2, 3, 1)
2010-05-12
Compressor wheel 500.45 (3) Inspection of components (general) 6.5 (1)

Connections 3.1.2 (2) Inspection of Individual Components 6.5 (1)
Containment Safety 5.0 (1) (General)
Cover 500.45 (3, 4)
Turbine side 500.45 (4, 2, 1) J
500.47 (4, 2, 1) Jet Assist acceleration system 4.3 (1)
541.01 (4, 2, 1)
0288-2 C1-2 EN 1 (2)

MAN Diesel & Turbo
6.0 (1)
L
Index
during Maintenance/Repair 6.0 (1)

Lubricating oil 3.2.2 (1) during operation 5.0 (1)
General Safety Instructions 1.0 (1)
M Safety instruction 1.0 (1)
Maintenance schedule 6.3.1 (1) Caution 1.0 (1)
Maintenance Schedule 6.3 (1) Danger 1.0 (1)
Maintenance work 6.4 (1) Warning 1.0 (1)
General Remarks 6.1 (1) Safety Symbols 1.0 (2)
Remarks 6.4 (1) Screw connections 6.4 (1)
Maintenance Work 6.1 (1) Shutting down 5.1 (3)
General Remarks 6.1 (1) Silencer 500.32 (2)
Remarks 6.4 (1) Spare parts 6.1 (1)
Order numbers 6.1 (1)
N Spare parts 6.0 (3)
Numbering 7.1.1 (1) General 6.0 (3)
Work cards 7.1.1 (1) Special services/Repair work 6.1 (1)
Speed measuring device 562.01 (1)
O Starting operation 5.1 (2)
Operating faults (what to do in case of) 5.3 (1) Starting operation (first time) 5.1 (1)
Operating Media 3.2.1 (1) Starting the engine (preparatory work) 5.1 (2)
Operating parameters 3.1.1 (1) Status 7.1.1 (2)
Operational lubrication 4.2 (2) Inventory 7.1.1 (2)
Order numbers 7.1.1 (1) Optional 7.1.1 (2)
Ordering spare parts 8.1.2 (1) Special 7.1.1 (2)
Outlet casing 506.01 (1) Standard 7.1.1 (2)
506.02 (1)
T
P Tightening torques for screw con- 7.2.1 (1)
Post lubrication 4.2 (3) nections, general
Pressure sprayer 579.02 (1) Tool number 7.1.1 (1)
Priming 4.2 (2) Tools 6.2 (1)
Product Liability 1.1 (1) Turbine nozzle ring 500.46 (2)
Protective Covers 5.0 (2) 513.01 (1)
Turbine rotor 500.45 (4)
Q Turbocharger 4.1 (1)
Qualification of Personnel 5.0 (3) 500.31 (2)
6.0 (1) Removal and refitting 500.31 (2)
Maintenance/Repair 6.0 (1) Subassemblies 4.1 (1)
Ship systems 5.0 (3) Type plate 3.1.1 (1)
Stationary systems 5.0 (3)
V
R Venting 4.2 (2)
Regulations for Prevention of Acci- 5.0 (1)
dents W
Required Personnel and Time 7.1.1 (1) Weights of subassemblies 3.1.2 (1)
general 7.1.1 (1) 500 (2)
Retaining ring 500.45 (3) Work cards 6.1 (1)
2010-05-12
Rotor 520.01 (1)
S
Safety 1.0 (1)
5.0 (1)
2 (2) 0288-2 C1-2 EN

TCR18 0288-2

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MAN Diesel & Turbo

Turbocharger type....................... TCR18-41

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

Translation of the original instructions

0288-2 C1-2 EN 1 (2)

MAN Diesel & Turbo SE

Fax +49 (0) 821 322-49 4180

Copyright © MAN Diesel & Turbo

2 (2) 0288-2 C1-2 EN

6.3 Maintenance Schedule

0288-2 C1-2 EN 1 (3)

6.7 Service report

8 Spare parts catalogue / tools

520.01 Rotor complete

2 (3) 0288-2 C1-2 EN

545.01 Air intake casing, 90° - OPTION

0288-2 C1-2 EN 3 (3)

0288-2 1-2 EN 1 (1)

General Safety Instructions

When the respective caution measures are not complied with,

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 can

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

tective measure (safety symbols):

C1 6673 1.0-02 EN 1 (3)

Wear Wear Wear Wear Wear

Warning of a Danger of slip- Tripping haz- Danger of Corrosive

Crush hazard Inflammable Hot Danger of sus- Rotating

Fire, No access for

2 (3) C1 6673 1.0-02 EN

Safety Instruction Sign - Engine Room

Figure 1: Safety Instruction Sign - Engine Room

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

It is prohibited to stay within the danger area without reason.

C1 6673 1.0-02 EN 3 (3)

For improper usage of the turbocharger, the danger of accidents

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

C1 6673 1.1-02 EN 1 (1)

0288-2 2-2 EN 1 (1)

MAN Diesel | PrimeServ

Worldwide Service Addresses

C1 6673 2.1-06 EN 1 (2)

administrative office(administrative office)

Tel. +49 821 322-1198

2 (2) C1 6673 2.1-06 EN

0288-2 3-2 EN 1 (1)

0288-2 3.1-2 EN 1 (1)

Operating data and alarm points

1 Turbocharger type 5 Unit of temperature

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

operating data are exceeded:

Speed Alarm at 97% nmax

turbine type plate

C1 0288 3.1.1-02 EN 1 (2)

Lube oil temperature Alarm at max. outlet temperature see

Lube oil requirements

2 (2) C1 0288 3.1.1-02 EN

Weights, dimensions and connections

C1 0288 3.1.2-03 EN 1 (2)