Technical Documentation

Exhaust Gas Turbocharger

Operating Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . C1
Work Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2
Spare Parts Catalogue . . . . . . . . . . . . . . . . . . . . . . . . C3
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I

Turbocharger . . . . . . . . . . . . . . . . . . . TCA88 - 20 ...

Works No. of turbocharger . . . . . . . . . Only for Information

Engine . . . . . . . . . . . . . . . . . . . . . . . . ________
TCA 88 Title Page-Basis.fm

D36 6673-1 E

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

6673 C1/2/3/I–01 E 06.05 1

 TCA 88 Title Page-Basis.fm

© 2005 MAN B&W Diesel AG

All rights reserved, including the reproduction in any form or by photomechanical means (photocopy/micro-
copy), in whole or in part, and the translation.

6673 C1/2/3/I–01 E 06.05 2

 Technical Documentation
Exhaust Gas Turbocharger
Operating Manual C1

Exhaust Gas Turbocharger . . . . . . . . . TCA88

D36 6673-1 E
TCA88_Title_C1.fm

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

6673 C1–01 E 06.05 TCA88 3

Table of contents C1

page

1 Introduction ...............................................................................................................5

1.1 Product Liability...................................................................................................................................... 5

1.2 Scope of Supply..................................................................................................................................... 6
1.3 Addresses .............................................................................................................................................. 8

2 Safety........................................................................................................................ 13

2.1 General Safety Instructions.................................................................................................................. 13

2.2 Safety during Operation ....................................................................................................................... 15
2.3 Safety during Maintenance/Repairs..................................................................................................... 20

3 Technical Data ......................................................................................................... 23

3.1 Exhaust Gas Turbocharger.................................................................................................................. 23

Operating Characteristics .................................................................................................................... 24
Alarm Points ......................................................................................................................................... 24
Weights ................................................................................................................................................ 25
Dimensions and Connections .............................................................................................................. 26
Allowable Inclinations ........................................................................................................................... 27
3.2 Operating Media .................................................................................................................................. 29

4 Description............................................................................................................... 35

4.1 Exhaust Gas Turbocharger.................................................................................................................. 35

4.2 Lube Oil System................................................................................................................................... 39
4.3 Sealing Air System............................................................................................................................... 44
4.4 Acceleration System ............................................................................................................................ 46
4.5 Cleaning System – Dry Cleaning ......................................................................................................... 48
4.6 Cleaning System – Wet Cleaning of the Turbine ................................................................................. 50
4.7 Cleaning System – Wet Cleaning, Compressor................................................................................... 52

5 Operation ................................................................................................................. 53

5.1 Starting Operation/Putting Out of Operation ........................................................................................ 53

5.2 Emergency Operation of the Engine.................................................................................................... 56
5.3 Malfunctions/Faults .............................................................................................................................. 58

6 Maintenance............................................................................................................. 63

6.1 General Remarks................................................................................................................................. 63

6.2 Tools/Special Tools.............................................................................................................................. 65
6.3 Maintenance Schedule ........................................................................................................................ 66
6.3.1 Maintenance Schedule (Turbocharger on the Two-stroke Engine) ..................................................... 67
6.4 Remarks to the Maintenance Work...................................................................................................... 69
6.5 Inspection of Individual Components ................................................................................................... 71
TCA 88 englischIVZ.fm

6.6 Inspection Report................................................................................................................................. 75

Index I ............................................................................................................................. 273

6673 C1–01 E 06.05 TCA88 4

 Introduction 1

Product Liability 1.1

Personnel Requirements Safe and economic operation of the engine system including the turbo-
charger requires extensive knowledge. Also, the operatability can be
maintained or regained only through maintenance and repair work
when these are carried out with expertise and skill by trained person-
nel. The rules of proper craftsmanship are to be observed. Negligence
is to be prevented.

Technical Documentation The technical documentation supplements this ability through special-
ized information, draws attention to dangers and points out the safety
regulations to be observed. The MAN B&W Diesel AG asks you to ob-
serve the following guidelines:

WARNING
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, especially the sections C1 –
Operating Manual and Work Cards 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 (see Maintenance Schedule, Section C1 -
Chapter 6.3.1).
 Carry out maintenance on the turbocharger regularly and
properly within the specified intervals (see Maintenance
Schedule, Section C1 - Chapter 6.3.1).
 Perform any and all repair work exclusively with original MAN
B&W Diesel spare parts (see Section C3 - Spare Parts
Catalogue).

Important!
In the case of infringement of the before mentioned safety
instructions, the MAN B&W Diesel AG shall deny any and all
liability.
xx
TCA88_I_ProdLiability.fm

6673 C1 1.1–01 E 06.05 TCA88 5

Introduction

Scope of Supply 1.2

Scope of Supply

Each turbocharger is adapted especially to the engine system of a cer-

tain customer. Due to this customization, a standardized scope of sup-
ply is not given for the turbocharger.

The following scope of supply is effective only for the turbocharger with
the Works No. _________.

Type Turbocharger type TCA88

Motor type _________

Built-in equipment Compressor diffuser1)

Turbine nozzle ring1)

Fig. 1: Compressor diffuser Fig. 2. Turbine nozzle ring

Auxiliary equipment  Silencer with air filter

 Air intake casing TCA88_I_SocpeofSupply.fm

1) Flow cross-section punch-marked on face side of component

6673 C1 1.2–02 E 06.05 TCA88 6

 Accessories (optional)  Counter flange and seal for gas outlet casing

 Counter flange and seal for air intake casing

 Cleaning device for turbine

 Wet cleaning
 Dry cleaning

 Cleaning device for compressor

 Speed measuring device

Final speed of range 15 000 rpm

 Speed indicator
 analogous
 digital

 Emergency and post-lubrication system

 Tools for Works No. _________

 Spare parts for Works No. _________

 Special spares for Works No. _________

 Jet assist

 IMO certification

Documentation Inscriptions on the turbocharger, operating tags English

Inscription on labeling tags English
System of units metric
Operating manuals English
Quantity: 4

Anti-corrosion packaging AN 400

Inquiries

For inquiries on any parts delivered by MAN B&W, the MAN B&W Die-
sel AG is at your disposal (for addresses, see Chapter 1.3).
TCA88_I_SocpeofSupply.fm

6673 C1 1.2–02 E 06.05 TCA88 7

Introduction

Addresses 1.3

MAN B&W Diesel AG, Works

Addresses and contact persons Table 1 contains the addresses of the MAN B&W Diesel AG Works and
of the technical office in Hamburg, as well as the telephone and fax
numbers of the responsible departments, ready to fully assist you if re-
quired.

Location Address Subject Contact person

Augsburg Works MAN B&W Diesel AG Service Phone: +49 821-322-3994
86224 Augsburg turbocharger
Germany Fax: +49 821-322-3998
Phone: +49 821-322-0 E-Mail: [email protected]
Fax: +49 821-322-3382 Web: www.manbw.com
Hamburg Works MAN B&W Diesel AG
Service Center, Hamburg Works
Rossweg 6
20457 Hamburg
Germany
Phone: +49 40-7409-0
Fax: +49 40-7409-104
Technical Office MAN B&W Diesel AG
Hamburg Sales Office, Hamburg
Admiralitätsstraße
20459 Hamburg
Germany
Phone: +49 40-378515-0
Fax: +49 40-378515-10
Web: www.manbw.com
Table 1: Locations and addresses of the MAN B&W Diesel AG
TCA88_I_Addr.fm

6673 C1 1.3–01 E 06.05 TCA88 8

 Service addresses

Country Address Telephone/Fax/E-Mail

Argentina Turbogen Phone +54 11 4521-5667
Lugones 1855 Phone +54 11 4521-1914
1430 Buenos Aires Phone +54 11 4522-5632
Argentina Fax +54 11 4521-8283
E-Mail [email protected]
Australia MAN B&W Diesel Australia Pty Ltd. Phone +61 2 8874-0700
396 Lane Cove Road Fax +61 2 9889-5337
North Ryde NSW 2113 E-Mail [email protected]
Web www.manbw.com.au
Mailing address:
P.O. Box 734
North Ryde NSW 1670, Australia
Belgium TRS Rollo Belgium N.V. Phone +32 3 543-8500
Norderlaan 181 Phone +32 3 543-8502
2030 Antwerpen, Belgium Fax +32 3 544-7254
E-Mail [email protected]
Brazil MAN B&W do Brasil Indústria e Comércio Ltda. Phone +55 21 2290-9393
Service Center Rio Fax +55 21 2290-9144 (Spares)
Rua Olga, 84 Bonsucesso Fax +55 21 2290-8749
Rio de Janeiro, RJ 21041 140, Brazil E-Mail [email protected]
E-Mail [email protected]
Canada Dynamic Engineering Inc. Phone +1 604 253-4427
1270 Frances Street Fax +1 604 253-3553
Vancouver E-Mail
B. C. V6A 1Z5 [email protected]
Canada Web www.dynamicengineering.com
China MAN B&W Diesel Technical Services Phone +86 21 5866-2108
(Shanghai) Co., Ltd. Fax +86 21 5866-2109
Wai Gao Qiao Free Trade Zone E-Mail [email protected]
Ao Na Road, No. 151 Web www.mbd-china.com
Pudong, Shanghai 200131
Kemklen Technical Service Ltd. Phone +852 2861-2812
17/F. East Town Building Fax +852 2861-2465/1168
41, Lockhart Road E-Mail [email protected]
Wanchai Web www.turbokts.com
Hong Kong
Denmark MAN B&W Diesel A/S, Holeby Phone +45 5469-3100
Oestervej 2 Fax +45 5469-3033
4960 Holeby E-Mail service/[email protected]
Denmark Web www.manbw.com
MAN B&W Diesel A/S, Alpha Diesel Phone +45 9620-4100
Service Center Denmark Phone +45 2040-6059
Langerak 74 Fax +45 9620-4041
9900 Fredrikshavn E-Mail [email protected]
Web www.manbw.com
Mailing address:
Niels Juels Vej 15
9900 Frederikshavn
Denmark
MAN B&W Diesel A/S Phone +45 3385-1100
Teglholmsgade 41 Fax +45 3385-1049
2450 Copenhagen SV E-Mail [email protected]
TCA88_I_Addr.fm

Denmark Web http://www.manbw.dk

Table 2: Service addresses

6673 C1 1.3–01 E 06.05 TCA88 9

Country Address Telephone/Fax/E-Mail
Germany MAN B&W Diesel AG Phone +49 40-7409-0
Service Center Werk Hamburg Fax +49 40-7409-104
Hachmannkai E-Mail [email protected]
Rossweg 6 Web http://www.manbw-service.com
20457 Hamburg
Germany
Great Marine Turbo Engineering Ltd. Phone +44 151-647-8141
Britain The Turbocharger Centre Fax +44 151-666-2143
Abbey House - Abbey Street E-Mail [email protected]
Priory Trading Estate Web http://www.marineturbo.co.uk
Birkenhead L41 5JU
Great Britain
Turbo Service International Ltd. Phone +44 8086-1000
190 Commercial Road Fax +44 8086-3000
Totton E-Mail [email protected]
Southhampton SO40 3AA Web http://www.turbosi.com
Great Britain
Greece Turbotechniki Ltd. Phone +30 10 4002 585
2, Ilias 8 Tripoles Str. Fax +30 10 4009 290
18863 Perema Piraeus E-Mail [email protected]
Greece
Italy La Meccanica Turbo Diesel S.R.L Phone +39 010 246-1111/7499
Calata Gadda Fax +39 010 246-1144
16126 Genova Porto E-Mail [email protected]
Italy Web www.mtd.it
Netherlands Turbo Blower Service B. V. Phone +31 10-426-7383/2679
17, Nieuwe Waterwegstraat Fax +31 10-473-3050
3115 HE Schiedam E-Mail [email protected]
Netherlands Web http://www.turbo.nl
Philippines MAN B&W Diesel Technical Service Phone +63 2 776-3369
(Philippines) Inc. Phone +63 2 776-3347
Km. 17, West Service Road Fax +63 2 776-3384
Brgy. Marcelo Green E-Mail [email protected]
South Super Highway Web www.manbw.com.ph
Parañaque City
Philippines
Singapore MAN B&W Diesel (Singapore) Pte. Ltd. Phone +65 6349-1600
Tuas Avenue 2 Fax +65 6862-1409
Singapore 639460 Fax +65 6861-3314 (Spares)
Fax +65 6861-8590 (Service)
E-Mail [email protected]
Web [email protected]
South Africa IMS Engineering (Pty) Ltd. Phone +27 21 511 8201
124 Marine Drive Service Road Fax +27 21 511 8238
Paarden Eiland 7420 E-Mail [email protected]
Cape Town, 7405
South Africa
Spain Premenasa-Turbos Preccion Mananica Naval Phone +34 91 778-1262
(Central) S. A. Fax +34 91 778-1285
C/Luis I, num. 26 E-Mail [email protected]
Poligono Industrial de Vallecas Web www.premenasa.es
28031 Madrid
Spain
(South) Turbo Cádiz S. L. Phone +34 95 688-9204
Pol. Ind. Fadricas Phone +34 95 688-9205
c/Hilladores, 3 Fax +34 95 688-9206
TCA88_I_Addr.fm

11100 San Fernando (Cádiz) E-Mail [email protected]

Spain Web www.turbocadiz.com
Table 2: Service addresses

6673 C1 1.3–01 E 06.05 TCA88 10

 Country Address Telephone/Fax/E-Mail
(North) MINDASA Phone +34 942-558-600
Mecanizacion Industrial Astillereo S. A. Fax +34 942-558-360
Poligono Industrial de Guarnizo
Aparto de Correos No. 37
39610 Astrillereo-Cantabria
Spain
Turkey GTS Turbo Dizel Service Phone +90 216 392-1082
Aydintepe Mah. G-50 Fax +90 216 392-1067
Sokak E-Mail [email protected]
Gemdok Sani Sitese No. 10
Tuzla, Istanbul
Turkey
United Arab Dubai Drydocks Phone +971 4 345-0626
Emirates Jumeriah Beach Road Fax +971 4 345-0116
P.O. Box 8988 E-Mail [email protected]
Dubai Web www.drydocks.gov.ae
UAE
USA Dresser Rand Company - Phone +1 713 827-0542
(South central) Service Division Fax +1 713 827-0353
Turbocharger Business Unit E-Mail
1415 Lumpkin Road [email protected]
Houston TX. 77043
USA
USA H. W. Ramberg Inc. Phone +1 718 625-3960
(North east) 37 Van Dyke Street Fax +1 718 875-1239
Brooklyn E-Mail [email protected]
N. Y. 11231-1590 Web www.ramberg.com
USA
USA Motor Services Hugo Stamp Inc. Phone +1 954 763-3660
(South east) 3190 S. W. 4th Avenue Fax +1 954 763-2872
Fort Lauderdale E-Mail [email protected]
Florida 33315 E-Mail [email protected]
USA Web www.mshs.com
Table 2: Service addresses

Note!
For the current list of service addresses contact:
Ms. Barbara Weidner
Turbocharger Service Office

Phone: +49 821-322-1198

Fax.: +49 821-322-3998
E-mail: [email protected]
xxx
TCA88_I_Addr.fm

6673 C1 1.3–01 E 06.05 TCA88 11

 TCA88_I_Addr.fm

6673 C1 1.3–01 E 06.05 TCA88 12

 Safety 2

General Safety Instructions 2.1

Safety Instructions Safety instructions are always noted down prior to the description of
any action. They are categorized in 4 hazard levels and differentiated
by the degree of hazard seriousness for personnel or equipment.

Danger Levels 1-3 Generally, the safety instructions of the hazard levels 1-3

 Danger,
 Warning,
 Attention

are indicated as follows:

DANGER
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.
xx

WARNING
When the respective caution measures are not complied with, a poten-
tially hazardous situation will be caused which can lead to:

 Death or serious injury,

 Serious damage to property or
 Serious environmental damage.
xxxx

ATTENTION
When the respective caution measures are not complied with, a haz-
ardous situation could be caused which can lead to:

 Personal injury,
 Possible damage to property.
xx

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

column. It either indicates a hazard (hazard symbol) or the correspond-
TCA88_S_general.fm

ing protective measures (safety symbols):

6673 C1 2.1–02 E 06.05 TCA88 13

Safety Symbols

Wear gloves Wear Wear Wear hard Wear safety

protective hearing hat gloves
goggles protection

Wear Read
protective manual
clothing

Danger Symbols

Warning of a Danger of Tripping Danger of Corrosive

hazard slipping hazard electric materials
location shock

Crush Inflammable Hot surface Danger of Rotating

hazard materials suspended gear hazard
loads

Bans

Fire, open No access

flames and for
smoking are unauthorized
prohibited! persons!

Danger Level 4 The safety instructions of danger level 4 are indicated by means of the
following designations:

Important!
For pointing out fault sources/handling errors; material damage
can occur.

Note!
Additional notes, information and tips.
TCA88_S_general.fm

6673 C1 2.1–02 E 06.05 TCA88 14

 Safety

Safety during Operation 2.2

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 tempera-
tures.
A consequence of additional extraordinary influences might be - in ex-
tremely rare cases - a failure of the components.

Precautions
MAN B&W turbochargers correspond to the required containment safe-
ty according to the rules stipulated by the classification societies so that
the state of the art prevents fragments from escaping. In extreme cas-
es, 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:

Important!
Persons are by no means allowed to stay without any reason near
the operating turbocharger.

 Turbine and compressor are to be cleaned at regular intervals as

specified in the operating manual.
 The maintenance of the turbocharger must be carried out by trained
personnel as well as in the maintenance intervals as stipulated in
the operating manuals.
 Inadmissible operating conditions, such as frequent load releases,
compressor surging, excessive turbocharger speeds, must be
avoided.
 Corrosive and erosive media in the intake air are to be avoided.

Technical Documentation The technical documentation of the system, particularly the operating
and maintenance manuals for the engine, turbocharger and the acces-
sories 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 When operating the system and for all maintenance and repair work,
Accidents the relevant regulations for prevention of accidents are to be observed.
It is advisable to hang these regulations in the engine room and to re-
peatedly point out the dangers of accidents.
TCA88_S_duringopera.fm

6673 C1 2.2–01 E 06.05 TCA88 15

Safety Instruction Sign – Engine Room

Important!
To point out the most important regulations, bans and hazards
during operation and maintenance the following safety
instruction sign must be posted at the entry of the engine room:
xx

Fig. 3. Safety instruction sign – engine room

Persons, who for operational reasons are to be within the danger area
of 2.5 m around the engine, are to be instructed of the predominant
hazards. Access to the danger area is permitted when the turbocharger
is in proper operating condition and only when wearing suitable protec-
tive equipment. It is prohibited to stay within the danger area without
reason.

Important!
TCA88_S_duringopera.fm

Explanations of instruction sign see Chapter 2.1.

6673 C1 2.2–01 E 06.05 TCA88 16

 Hearing Protection

WARNING
Sound level exceeding 85 dB (A)!
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!
xx

Exhaust Gases In the engine room, exhaust gases with the harmful components NOx,
SO2, CO, HC and soot can be set free.

WARNING
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!
xx

Danger of Fire

WARNING
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!
xx

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
Danger to life through suffocation!
When a carbon dioxide fire-extinguishing system is 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.
TCA88_S_duringopera.fm

xx

6673 C1 2.2–01 E 06.05 TCA88 17

Protective Covers

WARNING
Danger of burns and fire hazard from hot system
components!
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!
xx

After assembly work, ensure that all coverings and protective covers
from moving components as well as all insulations from hot compo-
nents 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 malfunction to be corrected. The signals may not be ig-
nored or suppressed, except when ordered by management or in cas-
es of increased danger.

WARNING
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 force majeure or when ordered by management!
xx
TCA88_S_duringopera.fm

6673 C1 2.2–01 E 06.05 TCA88 18

 Operating Personnel The engine and the systems required for its operation may be started,
operated and stopped only by authorized persons. The personnel must
be educated, 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.

Qualification of Personnel 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 compe-

tence certificate that corresponds with the national regulations and in-
ternational agreement (STCW). The number of required persons and
their minimum qualification are usually stipulated through the national
regulations or the international agreement (STCW).

For Stationary Systems (Power Plants):

The superintendent (engineer) must be available. Supervision/control-

ling of 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

furnished in accordance with the energy economy law (EnWG) that the
technical operation management is guaranteed by qualified and suffi-
ciently numbered personnel. In other countries, comparable laws/
guidelines are to be observed.
TCA88_S_duringopera.fm

6673 C1 2.2–01 E 06.05 TCA88 19

Safety

Safety during Maintenance/Repairs 2.3

Qualification of Personnel Performed by machinists or mechanical fitters and their assistants.

Briefing and supervision of difficult work tasks through a technical offic-

er or the chief engineer.

Use of Cleaning Agents When using cleaning agents the manufacturer’s notes for usage, pos-
sible dangers and disposal are to be observed.

WARNING
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!
xx

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),
governors, 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.

Opening Pipes/Pressure Tanks

ATTENTION
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!
xx
TCA88_S_duringmaint.fm

6673 C1 2.3–01 E 06.05 TCA88 20

 ATTENTION
Danger of burning/scalding from running-out lube oil!
The lube oil is under pressure and very hot!

 Before opening pipes, flanges, screwed connections or gauges,

free the system of pressure and check that it is pressure-free!

 Before opening oil pipes, wait until the lube oil has cooled down
sufficiently (1-2 h).

 Drain the system and check that it has been drained completely.

 Wear protective clothing!

xx

On turbochargers with emergency and post-lubrication system, the

lube oil will continue to drain for up to 1.5 h after shutting down the en-
gine system.

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 de-
bris from entering the system. Therefore, all pipes subject to reassem-
bly 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

WARNING
Danger of injury from suspended loads!
Unsuitable or poorly maintained transport equipment as well as
unsuitable set-down locations can lead to serious injury of
people and to major damage.
 Use only transport equipment which is in perfect condition.
 Check if the transport equipment being used has the required
carrying capacity.
 Choose only set-down locations that have sufficient loading
capacity for the heavy component (this is not always the case for
galleries, half-landings or grid-iron coverings).
xx
TCA88_S_duringmaint.fm

6673 C1 2.3–01 E 06.05 TCA88 21

Spare Parts During operation, very high forces are applied to the components of the
turbocharger. Therefore, MAN B&W has developed special materials
that can withstand these high forces. The use of these high-quality ma-
terials can be guaranteed only when using MAN B&W original spare
parts.

DANGER
Bought-out spare parts can be manufactured from low-
quality materials that can not withstand the forces
occurring during operation of the turbocharger!
This can result in serious damage to the turbocharger, engine
room and engine, as well as danger to life for the operating
personnel.
 Use only MAN B&W original spare parts!
 Use bought-out spare parts only after these have been released
by MAN B&W!
xx

MAN B&W shall in no way be liable for any damage to persons or ma-
terial, caused by usage of bought-out spare parts. Furthermore, any
and all warranty claims on the turbocharger expire when using foreign
spare parts.

TCA88_S_duringmaint.fm

6673 C1 2.3–01 E 06.05 TCA88 22

 Technical Data 3

Exhaust Gas Turbocharger 3.1

Classification Turbocharger/Engine

Turbocharger Engine
Type Works No. Type Power/kW Speed/rpm
TCA88 _ ___ ___ ________ _____ ___

Turbocharger Type Plate

exhaust gas turbocharger

type 1 W/No. 2
n max 3 RPM max. temp 4 ° 5
type-tested 6 year 7

1 Turbocharger type
2 Works No. (Serial No.)
3 Admissible rotor speed, maximum
4 Admissible turbine inlet temperature, maximum
5 Unit of temperature
6 Type approval
7 Year of ex-works delivery

Fig. 4. Type plate

Note!
The type plate is mounted on the pressure socket of the compressor
casing or on the 90° air intake casing (if provided).

xx
TCA 88 TD-Turbocharger.fm

6673 C1 3.1–02 E 06.05 TCA88 23

Operating Characteristics

Speed Operating limit nmax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see type plate

Exhaust gas temperature ahead of Operating limit tmax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see type plate
turbine

Lube oil temperature Inlet temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 - 70 °C

Outlet temperature, max. . . . . . . . . . . . . see engine start-up record 1)

∆ Inlet temperature/Outlet temperature. . . . . . . . . . . . . . . . . ≤ 40 °C 2)

Lube oil pressure At regular operation and full load of engine . . . . . . . . . . . 1.2 - 2.2 bar

Admissible lubricating oil pressure, max. . . . . . . . . . . . . 2.2 (6.0)3) bar

Lube oil throughput with SAE 30 at 60 °C and 1.3 bar pressure in operation . . . 12.6 m3/h

Noise development up to 105 dB (A) at a distance of 1 m from the turbocharger

Alarm Points

When exceeding the following operating data, an alarm is to be actuat-

ed by the engine control system:

Speed Alarm actuation at . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97% nmax

Exhaust gas temperature ahead of Alarm actuation at tmax . . . . . . . . . . . . . . . . . . . . . . . . . . see type plate
turbine

Lube oil temperature Alarm actuates

at max. outlet temperature . . . . . . . . . . . see engine start-up record 1)

Alarm actuates when ∆ inlet temperature/outlet temperature . . . ≥ 40 °C 2)

Lube oil pressure Alarm actuates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < 1.2 bar

Reduction to engine half load (slow down) . . . . . . . . . . . . . . . < 1.0 bar

Engine shut-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < 0.8 bar

TCA 88 TD-Turbocharger.fm

1) Start-up record = IBN-Protokoll

2) Only for turbocharger retrofits
3) For engine lube oil pressures > 2.2 bar, an orifice or a pressure reducing valve
is to be provided for in the oil supply to the turbocharger. See Chapter 4.2.

6673 C1 3.1–02 E 06.05 TCA88 24

 Weights1)

500 Exhaust gas turbocharger, incl. silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 500 kg

501 Gas-admission casing, complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 000 kg

506 Gas outlet casing, complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 300 kg

509 Gas outlet diffuser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .655 kg

Shroud ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 kg

513 Nozzle ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 kg

517 Bearing casing, complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 500 kg

518 Casing feet, complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .740 kg

520 Rotor gear, complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601 kg

Turbine rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 kg
Compressor wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 kg

540 Insert. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400 kg

542 Diffuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165 kg

544 Silencer, complete (if existing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2010 kg

545 Intake casing, complete (if existing)

axial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .629 kg
90° . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1032 kg

546 Compressor casing, complete

single outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 250 kg
double outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 500 kg

554 Emergency and post-lubrication system, complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285 kg

595 Spare parts with box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 kg

596 Tools with box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 kg

TCA 88 TD-Turbocharger.fm

1) approx. values

6673 C1 3.1–02 E 06.05 TCA88 25

Dimensions and Connections

1040 1264

1076 2

X
7 5
6
2970

1135
8
3
4
9 1500 3788
2286

1 Exhaust gas inlet 6 Charge air inlet

2 Exhaust gas outlet 7 Charge air outlet
3 Washing water outlet 8 Jet assist
4 Lube oil outlet 9 Lube oil supply
5 Venting x rotor removal size: 890 mm

Fig. 5: Main dimensions, TCA88 with 90° gas-admission casing

TCA 88 TD-Turbocharger.fm

6673 C1 3.1–02 E 06.05 TCA88 26

 Allowable Inclinations

Installation position The exhaust gas turbochargers of the TCA Series require horizontal
assembly with respect to the axis of the running equipment.

Ship applications For operation in ships, however, where the installation position is
crosswise to the longitudinal axis, inclination angles occur that can
influence the operating ability of the exhaust gas turbocharger.

The following inclination angles can be handled by the exhaust gas tur-
bocharger without problems.

Inclination Continuous Short-term

α/° ±15 ±22.5
β/° ±15 ±22.5
Table 3: Permissible inclines for installation positions crosswise to the
longitudinal axis

Fig. 6. Turbocharger side view, installation crosswise to the

longitudinal axis of the vessel

β
TCA 88 TD-Turbocharger.fm

Fig. 7. Turbocharger front view, installation crosswise to the

longitudinal axis of the vessel

With the installation position in longitudinal direction of the ship, these

limit values are not reached even under unfavorable exterior conditions.

6673 C1 3.1–02 E 06.05 TCA88 27

 TCA 88 TD-Turbocharger.fm

6673 C1 3.1–02 E 06.05 TCA88 28

 Technical Data

Operating Media 3.2

Fuels for the Engine

Engine fuel affects exhaust gas The quality or the fuel with which the engine is operated affects the
quality composition of the exhaust gas that flows through the turbocharger. Im-
purities in the fuel can lead to residues in the exhaust gas, which can
effect the turbocharger in an abrasive or corrosive manner.

Quality Requirement for MDO is also known as diesel fuel oil, diesel oil, bunker diesel oil or ma-
Marine Diesel Oil (MDO) rine 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 mixture. 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
cleaning 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
testing methods.

Properties/Characteristic Unit Testing Method Parameter

ISO-F specification DMB DMC
Density at 15 °C kg/m3 ISO 3675 0.900 0.920
Kinematic viscosity at 40 °C mm2/s =ˆ cSt ISO 3104 <11 <14
Pour point Winter quality °C ISO 3016 <0 <0
Summer quality °C <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
Sulfur 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 con- mg/kg ISO CD 10478 0 <25
tent
Visual check – * –
Other specifications:
TCA 88 TD-Operating Media.fm

British Standard BS MA 100-1987 Class M2 Class M3

ASTM D 975 2D 4D
ASTM D 396 No. 2 No. 4
* In good light and at room temperature, the fuel should appear clear and transparent.
Table 4: Marine Diesel Oil (MDO) – Characteristics to be met

6673 C1 3.2–01 E 06.05 TCA88 29

 Important!
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
incompatible and therefore should not be mixed. For this reason, the
respective fuel tank should be emptied to the greatest possible
extent before a new batch is filled up.

Important!
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 wa-
ter, so that the cleaning intervals for the filter inserts can also be pro-
longed.

Operating data:

 Separator admission 65%, with reference to the rated throughput

capacity
 Separation temperature 40 – 50 °C.

Quality Requirements for Heavy MAN B&W turbochargers can be operated on engines that run on
Fuel Oil (HFO) crude-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
Table 5.
Table 5 lists each of the limit values to be observed. The limit values
that influence the engine operation are to be specified when ordering
fuel, e. g. in the bunker or charter clause.

Important!
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.

Such additions lead to combustion with high residue and increased

wear and corrosion on components of the turbocharger. Adding motor
oil (waste/old oil) is particularly critical, as the lube oil additives cause
TCA 88 TD-Operating Media.fm

emulsions to form and keep debris, water and catalyst particles finely
distributed in poise. This impedes or avoids the required fuel cleaning.

6673 C1 3.2–01 E 06.05 TCA88 30

 Important!
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.
xx

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 max. 40 40 80 180 380 500 700
Viscosity (at 100 °C) (cSt) 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)
Sulfur Wt.% max. 3.5 3.5 4 5 5
Ash Wt.% max. 0.10 0.15 0.20
Vanadium mg/kg max. 150 150/ 350 200/ 300/ 600
300 500 600
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 5: Fuel specifications and corresponding characteristics

Important!
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.
 With an aluminum content >10 mg/kg, the abrasive wear in the
turbocharger increases heavily.
 Use only separators of the latest generation which are fully effective
over a large density range without any adjustment, and separate
water with 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
characteristics in Table 6 are reached:
Characteristic Particle size Amount
TCA 88 TD-Operating Media.fm

Inorganic, solid foreign < 5 µm < 20 mg/kg

substances (incl. catfines) (AlSi content
< 15 mg/kg)
Water – < 0.2 Vol.%
Table 6: Achievable foreign matter and water content after separation

6673 C1 3.2–01 E 06.05 TCA88 31

  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
additive 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 turbocharger. Heavy fuel oils from catalytic cracking plants
can contain catfines. 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 content of catalyst material in the
HFO.

Lubricating Oil

Base Oil The base oil must fulfill the following limit values, particularly concern-
ing the aging stability.

Properties/Characteristic Unit Testing Method Parameter

Structure – – Preferably paraffin-based
Behavior 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 < 0.05
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 resin-
ous and asphaltic aging products.
Table 7: 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 enables increased mechanical wear.

Additives may not aid a clogging of the filter inserts, neither in the active
or processed condition.

Viscosity
Turbocharger SAE class Viscosity mm2/s at 40 °C resp.
TCA 88 TD-Operating Media.fm

100 °C
TCA33 to TCA99 30 Preferred in the upper range of
40 the SAE class assigned to the tur-
bocharger
Table 8: Viscosity (SAE class) of lubricating oils

6673 C1 3.2–01 E 06.05 TCA88 32

 Lubricating Oil Additives We urgently advise against the later addition of additives to the lubricat-
ing oil or mixing different lube oil brands together, as this can destroy
the function of the additive package matched for the base oil. Such ac-
tion also annuls the supplier’s responsibility for the lubricating oil.

Intake Air

The state as well as the condition of the intake air has a decisive influ-
ence on the performance of the turbocharger. Not only is the atmo-
spheric condition of great importance, but also the degree of solid and
gaseous impurities.

Mineral dust particles in the intake air have a wear-increasing effect,

whereas chemical/ gaseous ingredients increase corrosion.

For this reason, effective cleaning of the intake air and regular mainte-
nance/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 silenc-
er/air intake casing or ahead of the compressor inlet.

The following maximum concentrations in the intake air may not be exceeded:

Properties/Characteristics Concentration/
mg/Nm3 1)
Dust (sand, cement, CaO, Al203 etc.) 5
Chlorine 1.5
Sulphur dioxide (SO2) 1.25
Hydrogensulphide (H2S) 15
Table 9: Maximum concentration of particles in the intake air
1) Standard cubic meter/Nm3

When dimensioning the intake air system, pay attention not to exceed
a total pressure loss (filter, silencer, pipe) of 20 mbar.
TCA 88 TD-Operating Media.fm

6673 C1 3.2–01 E 06.05 TCA88 33

Compressed Air

Jet Assist Connection to starting-air cylinders

Cleaning Agent for Turbine

Dry Cleaning For dry cleaning of the turbine during operation, commercial granules
are used that must meet the following specifications:

Granulates of:

 Nutshells,
 Activated charcoal (soft).

Particle size:

 1.0 mm (max. 1.5 mm).

 Filling capacity of container, approx. 2.5 l.

Wet Cleaning Fresh water without chemical additives

Water pressure:

 2-3 bar (at 4 washing lances).

Important!
Use fresh water only. Salt water causes corrosion on the
turbocharger components.
xx

TCA 88 TD-Operating Media.fm

6673 C1 3.2–01 E 06.05 TCA88 34

 ◊

Description 4

Exhaust Gas Turbocharger 4.1

General

Economical operation of modern large-scale engines is not imaginable

without exhaust gas turbochargers. The already high requirements for
propulsion systems and energy producing units concerning efficiency
and longevity are being continuously increased under the aspects of
fuel utilization and environmental load.

In this, the components of exhaust gas turbochargers are subject to ex-

treme operating conditions.

 Exhaust gases of up to 650 °C continuously flow through the turbine

and heat up its components, without an own counteractive cooling
system. Especially the shaft bearing must withstand the high
operating temperatures without the lubricating film ever breaking.
 On the compressor side, the air is heated to over 200 °C.
 The high temperatures lead to extreme thermal loads of the material
at many locations.
 Speeds are extremely high: The MAN B&W exhaust gas
turbochargers are operated with speeds ranging from 10 000 to
35 000 rpm, depending on size. In this, circumferential velocities of
560 m/s and more are reached at the compressor wheel, which
amounts to 1.7 times the speed of sound or 2 000 km/h.
 The centrifugal forces are extremely high: Forces of several
hundred kN can easily apply at the foot of the turbine blade.
 The complete gas exchange of the engine is performed by the
exhaust gas turbocharger. For this machine, the throughput of
combustion air can amount to 48 m3/s.
 Simplified, it can be said that approx. 1/3 of the power produced by
the engine is converted on minute space within the exhaust gas
turbocharger.

These requirements can be fulfilled only with use of the most recent
material and manufacturing technologies, introduced into the series by
MAN B&W with use of the latest developmental results, and based on
decades of experience in building diesel engines and exhaust gas tur-
bochargers.

Important!
Prescribed maintenance must be carried out precisely and in time
using the prescribed tools, in order to keep the turbocharger in
good condition and not damage it.

Maintenance Schedule see Chapter 6.3.

TCA 88 D-Turbocharger.fm

6673 C1 4.1–01 E 06.05 TCA88 35

Subassemblies

1 2 3 4 5 6 7 8 9 10

11

12

13

19 18 17 16 15 14

1 Silencer 8 Turbine rotor 15 Gas-outlet diffuser

2 Insert 9 Gas outlet casing 16 Outlet, washing water
3 Compressor casing 10 Bearing bush, 17 Thrust bearing
4 Diffuser turbine side 18 Compressor wheel
5 Bearing casing 11 Nozzle ring 19 Discharge, com-
6 Bearing bush, 12 Gas-admission casing pressed fresh air
compressor side 13 Turbine blades
7 Bearing body 14 Casing foot

Fig. 8: Cutaway view, TCA88

Turbochargers consist mainly of a turbine and a compressor, which are

seated on the same shaft. The exhaust gas of the engine drives the tur-
bine; the compressor draws in fresh air and compresses it.
TCA 88 D-Turbocharger.fm

6673 C1 4.1–01 E 06.05 TCA88 36

 The turbocharger consists of the following main subassemblies:

 Rotating element:
Turbine wheel and shaft are firmly connected together; the turbine
blades are individually set into the turbine wheel. The compressor
wheel is mounted on the shaft and can be removed.
 Bearing casing:
The interior bearing of the running equipment consists of two
bearing bushes and a thrust bearing. Lubrication of the bearing is
carried out via the lube oil circuit of the engine. Lubricating oil pipes,
lube oil venting and sealing air pipes are integrated in the bearing
casing.
 Gas-admission casing:
The nozzle ring is built into the gas-admission casing. It enables
optimum adaptation of the turbocharger to the engine.
 Gas outlet casing:
The gas-outlet diffuser in the outlet casing is flow-technically
optimized. The outlet casing is fitted with 5 offset connections for the
washing water outlet. Depending on the build-in position of the
turbocharger, the connection positioned lowest is used.
The outlet casing is designed so that together with the flanged-on
gas-admission casing, it offers optimum burst protection for the
turbine wheel.
 Silencer or air intake casing
 Compressor casing optional with one or two discharge connections.
The compressor casing houses the diffuser, which allows for
optimum adaptation of the turbocharger to the engine. Additionally,
the diffuser functions as burst protection.

Functional Description

The exhaust gas of the engine flows through the gas-admission casing
and the nozzle ring, and runs axially onto the turbine wheel. The ex-
haust gas drives the turbine wheel; in this process, the energy con-
tained in the exhaust gas is transformed into mechanical rotation ener-
gy 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 gas-
outlet diffuser and the gas outlet casing.

The compressor wheel draws in fresh air through the silencer or the in-
take casing and the insert. The fresh air is compressed in the compres-
sor wheel, diffuser and compressor casing. The compressed fresh air
is forced into the cylinders of the engine via charge air cooler and
charge air pipe.

The running equipment of the turbocharger is led radially by two bear-

ing bushes, which are situated in the bearing casing between turbine
wheel and compressor wheel. The thrust bearing positioned on the
compressor side not only handles the axial guidance, but also transfers
the thrust in axial direction. A bearing body holds the bearing seat and
at the same time is used as insulation against the hot exhaust-gas side
of the turbocharger.
TCA 88 D-Turbocharger.fm

6673 C1 4.1–01 E 06.05 TCA88 37

Intended Use

The turbocharger is intended for use on diesel and heavy-fuel-oil en-

gines. It produces the required amount of air for engine operation and
the charge pressure. Any application beyond this must be discussed
with and approved by MAN B&W, otherwise MAN B&W will refuse any
and all liability.

Each turbocharger is specially adapted to the engine with which it will

be operated. This means the turbocharger may be operated only on
this engine or one that is absolutely comparable (Also see scope of
supply, technical specifications and order confirmation).

In addition to this, the intended use includes as follows:

 The build-in location must afford sufficient space for maintenance

and assembly/disassembly of the turbocharger. Usage of lifting
equipment must be possible.
 Supply, measuring, control and regulating systems must enable
trouble-free operation (design/lay-out in accordance with
MAN B&W recommendation, resp. state of art).
 Observing the operating parameters (admissible exhaust gas
temperature, admissible lube oil temperature and lube oil pressure,
use of the specified operating materials, see Chapter 3).
 The turbocharger may be put into operation only when in perfect
condition.
 Operation may be carried out only by trained personnel which is
familiar with the system; operation through unauthorized personnel
is to be prevented with suitable means. For operation, the operating
manuals and the general safety and operational regulations are to
be observed.
 The operation must be controlled by means of suitable measures.
 Malfunctions that could influence the safety are to be corrected
immediately.
 Performing the service and maintenance in accordance with the
maintenance schedule.
 For repairs, use original spare part only.

Not Intended Use The following points specifically do no comply with the intended use.
MAN B&W shall not be held liable for any or all damages resulting
therefrom.

 Unauthorized changes/alteration on the turbocharger.

 Installation of foreign (non-original) parts.
 Operation not within the defined operating parameters.
 Bridging/shutting off alarm systems, and thereby enabling
operation in spite of limiting values being exceeded.
 Operation when supply systems have failed (e. g. lubricating oil
system).
 Insufficient maintenance.
 Longer-term shut downs without preservation measures.
TCA 88 D-Turbocharger.fm

6673 C1 4.1–01 E 06.05 TCA88 38

 Description

Lube Oil System 4.2

Lube Oil Diagram

18*
Level 2
16*

17*
Level 1 15*
12
14*
13*

9*

8* 7*

6 T
PI

5 4*
PSL
3 10

* Delivery scope, turbocharger 2

α > max. inclination of system: + 5° 1 11

1 Supply pipe 7 Bearing casing 13 Non-return valve with

2 Orifice 8 Locating bearing bypass
3 Turbocharger supply 9 Bearing bush 14 Bore
pipe 10 Drain pipe 15 Supply/drain pipe
4 Non-return valve 11 Service tank or crank- 16 Orifice
5 Pressure monitor case 17 Overflow pipe
TCA 88 D-Lube Oil System.fm

6 Pressure gauge 12 Venting 18 Emergency and post-

lubrication system

Fig. 9. Lube oil diagram TCA88

6673 C1 4.2–01 E 06.05 TCA88 39

Functional Description

Lube Oil Circuit The lubrication and cooling of the high-stressed bearing bushes in the
turbocharger takes place by means of a lube oil system, which is inte-
grated mainly in the bearing casing.

The lubricating oil is supplied from the lube oil system of the engine to
the lube oil system of the turbocharger via a supply pipe (1). An orifice
(2) adjusts the required lube oil pressure. The lube oil pressure is con-
trolled behind the non-return valve (4) by means of a pressure monitor
(5) and a pressure gauge (6).

Important!
Air bubbles may not be contained in the oil being supplied. This
could lead to bearing damage at post lubrication of the
turbocharger.

The lubrication oil flows through the non-return valve (4) into the turbo-
charger casing, from where it reaches the thrust bearing (8) and the
bearing bushes (9) via passages in the bearing casing (7) and the bear-
ing body. The lubricating oil flows to the gap between bearing and shaft
as well as to the face-sided lubrication point of the thrust bearing via
bores in the bearing bushes. The lubricating oil leaves the gap between
the bearing and the shaft and is splashed against the wall of the bear-
ing casing by the rotation of the shaft. The lubricating oil exits the bear-
ing casing through the drain pipe (10) and flows back into the lube oil
system of the engine (11).

Important!
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.

A backup in the lube oil drain 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.

For this reason the lube oil drain must be installed with an inclination,
which is calculated as follows:

Inclination α > max. possible system inclination + 5°.

Venting Due to constructive measures, this turbocharger does not require a

separate venting tank. Lubricating oil and air are separated from each
other within the bearing casing. The connection for the venting pipe
(12) is attached directly at the bearing casing.

Emergency and Post-lubrication The emergency and post-lubrication system (18) above the turbo-
System charger ensures the lubrication of the bearings after the engine is
switched off, as long as the rotating element runs out and the bearings
still must cool down.

During operation the non-return valve (13) is shut. The emergency and
post-lubrication system is filled with lubricating oil via a small bypass
TCA 88 D-Lube Oil System.fm

bore in the valve plate of the non-return valve (13). As long as the lube
oil level is below the overflow (17), the emergency and post-lubrication
system is pressure-free. As soon as the lube oil level reaches the over-
flow pipe (level 2), lubricating oil flows back into the bearing casing
through the overflow pipe. An orifice (16) is installed in the overflow
pipe. It effects that less lubricating oil runs off than enters, until the

6673 C1 4.2–01 E 06.05 TCA88 40

 emergency and post-lubrication system is filled. This leads to compres-
sion of the air in the upper part of the tank.

If the engine is shut off, the pressure in the lube oil system is reduced.
This causes the non-return valve (13) to open and the non-return valve
(4) to shut. At first the lubricating oil flows under pressure from the
emergency and post-lubrication system back into the turbocharger to
the bearing bushes. As soon as the lube oil level sinks below the over-
flow (level 2), the emergency and post-lubrication system becomes
pressure-free again. The lubrication oil is now fed back to the bearing
bushes at reduced flow rate by means of gravity. Once the height of the
supply/drain pipe (15) is reached (level 1), the volume remaining in the
tank flows through a small bore (14) in the supply/drain pipe near the
bottom passage. The size of the bore is dimensioned in such a manner
that due to the geodetic pressure, only the bearing bush (9) on the tur-
bine side is post-lubricated.

Shaft Sealing The bearing casing is sealed with labyrinth sealings on the rotor shaft,
both on the turbine and compressor side. The radial labyrinth clearance
is dimensioned so that during the first operating phase, the rotating lab-
yrinth tips lightly embed into the softer layer of the cover seal. At higher
speeds, the running equipment is lightly elevated according to the
thickness of the lubricating film. The labyrinth tips run freely then. When
standing still, the running equipment is lowered again. The labyrinth
tips embed into the grooves of the cover seal, through which a better
sealing effect is achieved during pre and post lubrication. Run-in
grooves at the circumference of the sealing cover bores are thus inten-
tional and not a reason for replacement of the parts.

On the turbine side, the shaft is additionally sealed by means of sealing

air (see Chapter 4.3).

Operating Conditions

Lube Oil Quality Commercial engine lubricating oils SAE 30 and SAE 40.
High-alkaline cylinder oils are not suitable (See Chapter 3.1).

Lube Oil Filtration The turbocharger does not require any separate lube oil filters. The fil-
tration and processing of the lubrication oil through the engine system
is generally sufficient. The following values must be observed:

 Lube oil filter ≤ 0.050 mm

 Accumulation with water < 0.2% amount of weight
 No accumulation with residue > 0.020 mm

Lube Oil Temperature Inlet temperature in the turbocharger: max. 70 °C.

Lube Oil Pressure For engine lube oil pressures > 2.2 bar to 6.0 bar max., we recommend
installing an orifice (2).
For this, the measuring connection for control of the lube oil pressure
must be provided for behind the non-return valve (see Fig. 9 ).

Important!
Level differences between indication instrument and center
TCA 88 D-Lube Oil System.fm

turbocharger are to be taken into account with ± 0.1 bar per 1 m

level difference. (Indicator positioned higher – lower pressure;
indicator positioned lower – higher pressure)

6673 C1 4.2–01 E 06.05 TCA88 41

 Lube oil pressure at full load of engine and lubrication oil at operating
temperature:

Pmin = 1.2 bar Pmax = 2.2 bar

Lube oil pressure at engine start and cold lube oil: For a short time up to
4 bar.

Limit values for alarm in case of too low lube oil pressure:
 < 1.2 bar: Alarm
 < 1.0 bar Engine power at half load
 < 0.8 bar: Engine stop.

Important!
When reaching the limit values, both the alarm and the reaction of
the engine control must go off at the same time (without delay), in
order to avoid damage to the turbocharger.

Lube Oil Consumption The required lube oil throughput depends on the viscosity and temper-
ature of the lubrication oil. At 60– 65 °C, the lube oil throughput is ap-
prox. 9 m3/h.

Pre-lubrication Before starting the engine, the bearing points of the turbocharger must
be pre-lubricated. This is done automatically together with the pre-lu-
brication of the engine, as the lube oil system of the turbocharger is
connected to that of the engine. Depending on the engine system, pre-
lubrication occurs directly before starting, either through interval or con-
tinuous pre-lubrication.

Pre-lubrication before starting:

 10 - 30 minutes max. at an oil pressure of 0.6 - 2.2 bar.

Interval pre-lubrication:

 10 minutes max. per 2 h, oil pressure of 0.6 - 2.2 bar.

Post Lubrication Occurs automatically via the emergency and post-lubrication system;
otherwise at an oil pressure of 0.2-0.6 bar for a period of 10-30 minutes.

TCA 88 D-Lube Oil System.fm

6673 C1 4.2–01 E 06.05 TCA88 42

 Connecting Several Turbochargers to the Engine Lube Oil System

If an engine operates with several turbochargers, then these are con-

nected parallel to the lube oil system of the engine (see Fig. 10 ).

12 18 18 12 1 Supply pipe
2.1 Pressure reduction
valve
7 7
3 Turbocharger supply
valve
4 Non-return valve
5 Pressure monitor
6 6 6 Pressure gauge
PI PI 7 Bearing casing
10 Drain pipe
PSL
4 4 PSL 11 Service tank or
10 10 crankcase
5 5
12 Venting
3 3 18 Emergency and post-
lubrication system
α Maximum inclination
of system: + 5°
11

1 2.1

Fig. 10: Lube oil system – Connection of several turbochargers

TCA 88 D-Lube Oil System.fm

6673 C1 4.2–01 E 06.05 TCA88 43

Description

Sealing Air System 4.3

Sealing Air Diagram

12
1 2 3 6

4
T
C 5

10 9

11

1 Compressor casing 6 Compensation pipe 12 Gas outlet casing

2 Ring duct, 7 Non-return valve C Compressor wheel
compressor-side 8 Pipe bend T Turbine wheel
3 Orifice 9 Bearing bush
4 Sealing air pipe 10 Locating bearing
5 Ring duct, turbine-side 11 Bearing casing

Fig. 11: Sealing air diagram, TCA88

TCA 88 D-Sealing Air System.fm

6673 C1 4.3–01 E 06.05 TCA88 44

 Functional Description

Sealing Air System The sealing air prevents hot exhaust gas from entering the bearing cas-
ing and the lubricating oil from seeping into the turbine (oil coke). Addi-
tionally, undesirable axial thrust on the bearing bushes is reduced.

The sealing air system is fully integrated in the bearing casing (11). A
part of the air compressed by the compressor wheel (C) is diverted and
flows out of the compressor casing (1) into a ring duct (2) in the bearing
casing. From there, the air is led into the sealing air pipe (4), whereby
an orifice (3) reduces the pressure to the required sealing air pressure.
The air is led to a ring duct (5) on the turbine side of the bearing casing.
There, the sealing air emerges between shaft and turbine labyrinth.

 A small amount of the sealing air flows back into the bearing casing,
presses against the turbine-sided bearing bush (9), and thus holds
back the lubricating oil.
 The other part of the sealing air is led past the rotor shaft, through the
labyrinth seal on the turbine side, and into the gas outlet casing (12).

This develops a thrust-compensating piston between the labyrinths on

the turbine disc and bearing casing.

The sealing air pressure is factory set via the orifice (3) and must not
be controlled or readjusted by the user.

Measures in Case of Vacuum With four-stroke engines, a vacuum can develop on the compressor
side at reduced partial load (suction operation). In this case, a
compensation pipe (6) between sealing air pipe and ambient air
prevents lubricating oil and exhaust gas from being drawn into the
compressor casing.

A non-return valve (7) blocks the compensation pipe during regular op-
eration. In case of a vacuum in the sealing air system, the spring-free
non-return valve opens and outside air is drawn in through the compen-
sation pipe.
TCA 88 D-Sealing Air System.fm

6673 C1 4.3–01 E 06.05 TCA88 45

Description
Acceleration System 4.4
“Jet Assist” (Auxiliary Air Drive)

Diagram “Jet Assist”

6*
7*

C*

5*

4*

1 2 3
A * Delivery scope, turbocharger

1 Pressure reducing sta- 4 Ring duct A Starting-air cylinder

tion or orifice 5 Insert (30 bar)
2 Solenoid valve 6 Bore C Compressor wheel
3 Non-return valve 7 Compressor casing

Fig. 12: Jet assist diagram, TCA88

TCA 88 D-Jet Assist.fm

6673 C1 4.4–01 E 06.05 TCA88 46

 Functional Description

“Jet Assist” The “Jet Assist” acceleration system is used when special require-
ments are made towards swift and possibly soot-free acceleration, and/
or towards the load applications of the engine.

The engine control actuates the solenoid valve (2). Compressed air of
30 bar now flows from the starting-air cylinder through the pressure re-
ducing station or orifice (1), where it is reduced to a maximum of 4 bar.
The compressed air reaches the compressor casing (7) via a non-re-
turn valve (3) at a maximum of 4 bar, from where it is led to the insert
(5) via the ring duct (4). The compressed air is blown onto the compres-
sor wheel (C) through several inclined bores in the insert. On the one
hand this provides additional air to the compressor, while on the other
hand the compressor wheel is accelerated, thus increasing the charge
air pressure.
TCA 88 D-Jet Assist.fm

6673 C1 4.4–01 E 06.05 TCA88 47

Description

Cleaning System – Dry Cleaning 4.5

Diagram Dry cleaning of the turbine

2
1 Compressed air pipe
(5 – 8 bar)
3 A
2 Screw plug
8
3 Granulate container
B
4 Pipes
4 (25 x 2,0 mm)
9 1

5 5 Connection flange

6 Adapter

7 Gas-admission cas-
ing

7 8 Gas-outlet casing
6 9 Turbine wheel
10
10 Nozzle ring

A Stop cock
(compressed air)

B Stop cock (exhaust

gas)

Fig. 13: Diagram, turbine dry cleaning

TCA 88 D-Dry Cleaning.fm

6673 C1 4.5–01 E 06.05 TCA88 48

 Functional Description

The dry cleaning of the turbine is performed during operation at normal

load of the engine.

The granulate container (3) is equipped with a filling opening, a com-

pressed-air pipe (1) and a pipe (4) leading to the gas-admission casing
(7). The pipes for compressed air are fitted with stop cocks (A) and (B).

The granulate container is filled with cleaning granulates and shut tight.
The stop cock (A) in the compressed-air supply pipe is opened and
compressed air flows into the granulate container. Afterwards, the stop
cock (B) in the pipe leading to the gas-admission casing is opened. The
compressed air blows the granulates out of the granulate container into
the gas-admission casing, from where the exhaust gas flow transports
the granulates to the turbine wheel. The granulates bounce against the
nozzle ring and turbine wheel, thus removing deposits and contamina-
tion. The exhaust gas flow carries the granulates and contamination
particles out of the system.

Important!
Cleaning the turbine with granulates on ship systems can lead to
downfall on deck.

Note!
Maintenance interval, see Chapter 6.3.1 – Maintenance Schedule

Operating Conditions

 The granulate container (3) must be fastened at a suitable location.

It may not be not be positioned lower than 1 m below the connection
flange (5).
 The pipe (4) may not be longer than 6 m and must be supported
against vibrations. Ensure unobstructed flow.
 Maximum operating temperature of the stop cock (B) (exhaust gas):
≤150 °C.
 The connection flange (5) can be attached either at the adapter (6)
of the exhaust gas pipe or directly at the gas-admission casing (7).

Important!
Store and mark granulates in such a manner that they can not be
mistaken for other materials (salt, sand, etc.).

Note!
Granulates to be used for cleaning: See Chapter 3.2/Technical Data –
Operating Media.
TCA 88 D-Dry Cleaning.fm

6673 C1 4.5–01 E 06.05 TCA88 49

Description

Cleaning System – Wet Cleaning of the Turbine 4.6

Diagram Wet cleaning of the turbine

E 2 1

5 4

1 Washing water 6 Turbine wheel

2 Pressure gauge 7 Drain, washing water
3 Nozzles 8 Drain funnel
4 Gas-admission casing B Drain valve
TCA 88 D-Wet Cleaning T.fm

5 Nozzle ring E Shut off valve water supply

Fig. 14: Diagram, turbine wet cleaning

6673 C1 4.6–01 E 06.05 TCA88 50

 Functional Description

The wet cleaning is performed during operation with heavily reduced

engine load, in order to avoid overload of the turbine blades (ther-
moshock).

Note!
Wet cleaning, see work card [500.21] in section C2.

The advantages of wet cleaning in comparison to dry cleaning are:

 The better cleaning effect and thus longer cleaning intervals,

 Control of the cleaning effect via the contamination degree of the
drained washing water.

The washing water flows through the stop cock (E).

The washing lances spray the washing water in the exhaust gas pipe in
front of the turbine. The washing water droplets bounce against the
nozzle ring and the turbine, where they wear off the contamination. The
washing water collects in the turbine casing and runs off through the
washing water drain (7) and the drain valve (B). The washing water is
led via a funnel (8) to a sediment tank, where it is collected.

The funnel enables visual control of the washing water. The cleaning
process is finished when the washing water remains clean.

Note!
Maintenance interval, see Chapter 6.3.1 – Maintenance Schedule.
TCA 88 D-Wet Cleaning T.fm

6673 C1 4.6–01 E 06.05 TCA88 51

Description

Cleaning System – Wet Cleaning, Compressor 4.7

Wet Cleaning System of the Compressor with Pressure Sprayer

1
1 Handle

4 3 2 Pressure sprayer
3 Relief Valve
4 Hand valve
5 Turbocharger (compressor)

5 2

Fig. 15. Wet cleaning system (pressure sprayer), compressor

Functional Description

The wet cleaning of the compressor is performed during operation at

full load.

The water container of the pressure sprayer (2) is filled with freshwater.
An overpressure is created in the water container by means of the
pump. By actuating the pushbutton on the hand valve (4), water is
sprayed into the compressor casing (5) ahead of the compressor
wheel. The water drops bounce against the compressor wheel where
they wear off contamination.
TCA88_D_WetCleanCom_E.fm

6673 C1 4.7–02 E 06.05 TCA88 52

 Operation 5

Starting Operation/Putting Out of Operation 5.1

Initial Starting of Operation

1. Unpack the turbocharger.

2. Remove closing covers on gas-admission casing, gas outlet cas-
ing and compressor casing.
3. Remove preservation agents on the exhaust gas flange of the tur-
bine casing as well as on the pressure neck of the compressor
casing with suitable scraper and cold cleaner.

WARNING
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.
xx

Note!
For assembly of the turbocharger to the engine, see Technical
Documentation/Section C2.

Important!
Upon delivery, 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 that inadmissible contamination in the oil does not
get into the turbocharger.

4. Flush the lube oil system. Plug the oil supply and oil drainage of
the turbocharger and connect the supply and drain pipe on the
engine side, or use an intake filter with low filter rating (20 µm
recommended) in the lube oil supply ahead of the turbocharger.
Measurement of the oil pressure after the intake filter.

Note!
For additional information on flushing the oil lubrication system, please
refer to the engine manufacturers’ manual.

Engine Control System

Important!
The indication of the pending alarm and the reaction from the
TCA88_OperaStart.fm

engine control system must occur at the same time. Therefore,

the engine control system must at least correspond with category
3 according to DIN EN 954-1.

6673 C1 5.1–02 E 06.05 TCA88 53

Work prior to Starting the Engine

1. Pre-lubricate engine and bearing points of the turbocharger (en-

gine control system).
2. Set all shut-off devices of the engine system to the operating po-
sition.
3. Check the lube oil pressure in front of the turbocharger.

Starting Operation

Start the engine. The engine exhaust gases drive the turbocharger and
thus begin to start the operation. If available, the “Jet assist” accelera-
tion system is put into operation via the control system.

Checks during Operation

General Despite automatic activation and control of the engine system, regular
checks of the turbocharger are required so that possible malfunctions
are detected as early as possible and the causes can be corrected in
time.

Important!
The following listed checks are at the operators duty of care.
Results, observations and activities of such control measures are
to be recorded in an engine log book. Reference values are to be
defined in order to enable an objective evaluation of the results.

Continuous Checks on the  Turbocharger speed

Turbocharger  Lube oil pressure in front of turbocharger
 Lube oil temperature in front of turbocharger
 Lube oil temperature behind turbocharger
 Exhaust gas pressure in front of turbine
 Exhaust gas temperature in front of turbine
 Charge air pressure behind compressor
 Charge air temperature behind compressor
 Leakage of exhaust gas, charge air and oil pipes
 Contamination/saturation of air filter mat at silencer
 Smooth running of turbocharger

Smooth Running Damage to the rotating element and bearings usually gives notice of
appearance by unsmooth running, owing to imbalance or grazing of ro-
tating parts. By auscultating the turbocharger (listening with e.g., a
stethoscope), unsmooth running can often be detected at an early
stage.

Speed For clean air ducts of the compressor, a certain charge air pressure is
assigned to each speed of the turbocharger. Thus, the charge pressure
gives information about the speed and can be used for approximate
speed control.
TCA88_OperaStart.fm

6673 C1 5.1–02 E 06.05 TCA88 54

 What to do in Case of Operating Faults

WARNING
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 or report every alarm, reduction or stop
signal!
 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 force majeure or when ordered by management!
xx

1. Either reduce the engine load or shut off engine, depending on the
situation.
2. Determine and correct the cause of the malfunction (see
Chapter 5.3).

Important!
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.

3. If the damage can not be corrected immediately, emergency op-

eration is possible (see Chapter 5.2).
4. When the damage has been corrected, start the engine operation
again as usual.

Putting Out of Operation

1. Shut off engine. The turbocharger gradually comes to a stop.

Important!
The run-down time of the turbocharger permits to draw
conclusions about its mechanical condition. Sudden stopping is
an indicator for mechanical damage to the bearing, grazing of the
compressor or turbine wheel, foreign objects that have become
obstructed or heavy contamination.

2. The lubrication oil runs out of the emergency and post-lubrication

system to the turbocharger bearings so that these are still contin-
uously lubricated for several minutes (post lubrication).
TCA88_OperaStart.fm

6673 C1 5.1–02 E 06.05 TCA88 55

Operation
Emergency Operation of the Engine 5.2
on Failure of a Turbocharger

If damage occurs to a turbocharger which can not be corrected imme-

diately, emergency operation is still possible.

Available Appliances Turbocharger (see work card [500.11] and [500.12])

 Securing fixture for blocking of the rotating element from the

compressor side (intake cross-section remains open).
 End cover, for closing of the compressor and turbine back side when
the rotating element is disassembled.

All appliances are designed in such a manner that continuous flow

through the air and exhaust gas side of the turbocharger is possible.

Appliances for use on the engine:

 Screen (grid) for the side of the charge air pipe that faces away from
the turbocharger. The screen is supposed to ease the suction
operation of the engine.
 Blind flange/s for blocking of the partially mounted charge-air
bypass pipe (if given).

Achievable Outputs/Speeds for Four-stroke Engines

The following criteria restrict the achievable engine load in engine-

emergency operation

 Maximum exhaust gas temperature after cylinder,

 Maximum exhaust gas temperature before turbocharger,
 Density of exhaust gas.

The following rating data apply only as reference values:

Turbocharger failed L-Engine V-Engine

Engine operation with variable speed 15% 15%
Engine operation with constant speed 20% 20%
Table 10: Emergency operation for failure of one turbocharger – Achievable
outputs
TCA88_OperaEmerg.fm

6673 C1 5.2–01 E 06.05 TCA88 56

 Emergency Operation on Failure of One Turbocharger

WARNING
Despite compliance of the following measures, the danger of
turbocharger destruction is still given!
For this case, there is imminent danger of personal injury or damage
to property!
 Limit the duration of emergency operation to the absolute
necessary minimum.
 Use the securing fixture (measure A) for emergency operation
only when removal of the running equipment is not possible!
 Persons are by no means allowed to stay in the vicinity of the
turbocharger during emergency operation unless absolutely
necessary.
xx

Emergency Measures Supplementary

Measures/
Precautions
(see code number)
Engine may not be stopped for reasons of urgency

Turbocharger remains unchanged 0–3

Engine may be stopped (short-term)
Important!
Carry out measure A only when measure B can not be carried out for reasons
of time. Subsequent damages possible

Measure A:
Block rotor from the compressor side using securing fixture (intake cross-section re- 0–5
mains open). Afterwards, mount intake silencer again. (See work card [500.11])
Measure B:
Disassemble rotating element including bearings; shut bearing casing on compres- 0–5
sor and turbine side with end covers. Reassemble silencer/intake casing and gas-
admission casing again. (See work card [500.12])
Table 11: Emergency operation for failure of one turbocharger

Legend

Code Number Supplementary Measures/Precautions

0 Observe instructions of engine manufacturer!
1 Reduce engine power. The maximum exhaust gas temperatures behind
cylinder and in front of turbocharger, and (for engines with two or more tur-
bochargers) the maximum admissible turbocharger speed must not be ex-
ceeded. Pay attention to density of exhaust gas.
2 As a precaution prepare fire-extinguishing measures!
3 When the rotating element is blocked or disassembled, stop lube oil supply
because of danger of contamination or fire.
4 For suction operation (or with two or more turbochargers), the engine must
TCA88_OperaEmerg.fm

be driven with reduced charge.

5 Engines with two or more turbochargers:
Separate the exhaust gas intake side of the defective turbocharger from the
gas flow of the second turbocharger with blind flange.

6673 C1 5.2–01 E 06.05 TCA88 57

Operation
Malfunctions/Faults 5.3
and their Causes (Trouble Shooting)

Important!
In case of turbocharger irregularities upon or during engine
operation, determine and correct the cause of the malfunction as
soon as possible. Otherwise the danger is given that minor
malfunctions can lead to increased subsequent damage on the
turbocharger or engine.

No. Malfunction Possible Cause Corrective Action Work

Card
1 Exhaust gas temperature Silencer contaminated Clean/replace 500.24
in front of turbine too high 500.32
Compressor contaminated Clean 500.23
Turbine wheel and/or nozzle Clean 500.21
ring heavily contaminated 500.22
500.52
Rotating element grazes Contact MAN B&W Service
Foreign objects in front of/in tur- Check turbine/compressor for 500.43
bine or compressor damage; contact MAN B&W 500.53
Service, if required
Turbine wheel, shroud ring, noz- Exchange defective compo- 500.43
zle ring or compressor wheel nents; contact MAN B&W Ser- 500.52
damaged or eroded vice, if required 500.53
500.54
High air-intake temperature Reduce output Engine
Charge air cooler contaminated Clean, measure pressure differ- Engine
ential
Charge air pipe leaks Seal charge air pipe Engine
Charge air temperature too high Check charge air cooler Engine
Inlet/exhaust valves, valve slots Clean Engine
of engine contaminated
Exhaust gas pipe leaks Seal exhaust gas pipe Engine
Exhaust-gas back-pressure be- Clean boiler Plant
hind turbine too high
Fuel injection at engine faulty Repair fuel injection Engine
Table 12: Trouble Shooting
TCA88_OperaFaults.fm

6673 C1 5.3–01 E 06.05 TCA88 58

 No. Malfunction Possible Cause Corrective Action Work
Card
2 Charge air pressure too Turbine speed too low See malfunction No. 4
low Silencer contaminated Clean/replace 500.24
500.32
Compressor contaminated Clean 500.23
Turbine wheel and/or nozzle Clean 500.21
ring heavily contaminated 500.22
500.52
Defective bearings, imbalance Bearing inspection (noise and 500.43
of rotating element vibrations); contact MAN B&W 500.46
Service, if required 500.53
500.56
Rotating element grazes Check parts; contact MAN B&W 500.53
Service, if required 500.54
500.56
Foreign objects in front/in tur- Check turbine/compressor for 500.43
bine or compressor damage; contact MAN B&W 500.53
Service, if required
Turbine wheel, shroud ring, noz- Replace defective components; 500.43
zle ring or compressor wheel contact MAN B&W Service, if 500.52
damaged or eroded required 500.53
500.54
High air intake temperature Reduce output Engine
Charge air cooler contaminated Clean Engine
Charge air pipe leaks Seal charge air pipe Engine
Inlet/exhaust valves, valve slots Clean, measure pressure differ- Engine
of engine contaminated ential
Exhaust gas pipe leaks Seal exhaust gas pipe Engine
Exhaust gas pressure after tur- Clean turbine; check for dam- 500.21
bine too high age, if required 500.22
500.53
Fuel injection at engine faulty Repair fuel injection Engine
3 Charge air pressure too Nozzle ring lightly Clean 500.52
high contaminated/restricted
Low air intake temperature Reduce output Engine
Table 12: Trouble Shooting
TCA88_OperaFaults.fm

6673 C1 5.3–01 E 06.05 TCA88 59

No. Malfunction Possible Cause Corrective Action Work
Card
4 Speed too low Silencer or air filter Clean/replace 500.24
contaminated 500.32
Compressor contaminated Clean 500.23
Turbine wheel and/or nozzle Clean 500.21
ring heavily contaminated 500.22
500.52
Defective bearings, imbalance Bearing inspection; contact 500.46
of rotating element MAN B&W Service, if required 500.56
Rotating element grazes Contact MAN B&W Service
Foreign objects in front/in Check turbine/compressor for 500.43
turbine or compressor damage; contact MAN B&W 500.53
Service, if required
Turbine wheel, shroud ring, noz- Replace defective components; 500.43
zle ring or compressor wheel contact MAN B&W Service, if 500.52
damaged or eroded required 500.53
500.54
High air intake temperature Reduce output Engine
Charge air cooler contaminated Clean Engine
Charge air pipe leaks Seal charge air pipe Engine
Inlet/exhaust valves, valve slots Clean Engine
of engine contaminated
Exhaust gas pipe leaks Seal exhaust gas pipe Engine
Exhaust-gas back-pressure Clean turbine; check for 500.21
behind turbine too high damage as required 500.22
500.53
Engine fuel injection faulty Repair fuel injection Engine
5 Speed too high Nozzle ring lightly Clean 500.52
contaminated/restricted
Low air intake temperature Reduce output Engine
6 Lube oil pressure too low Flow temperature of lube oil too Engine
high
Lube oil filter contaminated Replace lube oil filter Engine
Lube oil manometer defective Replace lube oil manometer Engine
7 Lube oil loss Thrust ring, labyrinth ring dam- Check parts; contact MAN B&W 500.45
aged Service, if required 500.53
Defective labyrinth seal Check parts; contact MAN B&W 500.44
Service, if required 500.55
Seals damaged, connections Check parts; contact MAN B&W
untight Service, if required
Sealing air ineffective, oil coke Check parts; contact MAN B&W
behind turbine wheel Service, if required
Lube oil pressure too high Reduce oil pressure Engine/
Plant
Overpressure in oil drain or in Drain oil as described in
crankcase Chapter 4.2
Table 12: Trouble Shooting
TCA88_OperaFaults.fm

6673 C1 5.3–01 E 06.05 TCA88 60

 No. Malfunction Possible Cause Corrective Action Work
Card
8 Hesitant starting, short Compressor contaminated Clean 500.23
run-down time Turbine wheel and/or nozzle Clean 500.21
ring heavily contaminated 500.22
500.52
Thrust ring, labyrinth ring dam- Check parts; contact MAN B&W 500.45
aged Service, if required 500.53
Defective bearings, imbalance Bearing inspection; contact 500.43
of rotating element MAN B&W Service, if required 500.46
500.53
500.56
Rotating element grazes Contact MAN B&W Service
Foreign objects in front/in Check turbine/compressor for 500.43
turbine or compressor damage; contact MAN B&W 500.53
Service, if required
Turbine wheel, shroud ring, noz- Replace defective components; 500.43
zle ring or compressor wheel contact MAN B&W Service, if 500.52
damaged required 500.53
500.54
Sealing air ineffective, oil coke Check parts; contact MAN B&W 500.53
behind turbine wheel Service, if required
9 Unusual strong noise Thrust ring, labyrinth ring dam- Check parts; contact MAN B&W 500.45
aged Service, if required 500.53
Defective bearings, imbalance Bearing inspection; contact 500.43
of rotating element MAN B&W Service, if required 500.46
500.53
500.56
Rotating element grazes Check parts; contact MAN B&W 500.53
Service, if required 500.54
500.56
Foreign objects in front/in Check turbine/compressor for 500.43
turbine or compressor damage; contact MAN B&W 500.53
Service, if required
Turbine wheel, shroud ring, noz- Replace defective components; 500.43
zle ring or compressor wheel contact MAN B&W Service, if 500.52
damaged required 500.53
500.54
10 Turbocharger vibrates Turbine wheel heavily contami- Clean 500.21
nated 500.22
Thrust ring, labyrinth ring dam- Check parts; contact MAN B&W 500.45
aged Service, if required 500.53
Defective bearings, imbalance Bearing inspection; contact 500.43
of rotating element MAN B&W Service, if required 500.46
500.53
500.56
Rotating element grazes Check parts; contact MAN B&W 500.53
Service, if required 500.54
500.56
Foreign objects in front/in tur- Check turbine/compressor for 500.43
bine or compressor damage; contact MAN B&W 500.53
Service, if required
Turbine wheel, shroud ring, noz- Replace defective components; 500.43
zle ring or compressor wheel contact MAN B&W Service, if 500.52
damaged required 500.53
TCA88_OperaFaults.fm

500.54
Table 12: Trouble Shooting

6673 C1 5.3–01 E 06.05 TCA88 61

No. Malfunction Possible Cause Corrective Action Work
Card
11 Compressor pumps Turbine wheel and/or nozzle Clean 500.21
ring heavily contaminated 500.22
500.52
Foreign objects in front/in tur- Check turbine/compressor for 500.43
bine or compressor damage; contact MAN B&W 500.53
Service, if required
Low air intake temperature Reduce output Engine
Charge air cooler contaminated Clean Engine
Charge air temperature too high Reduce output Engine
Inlet/exhaust valves, valve slots Clean Engine
of engine contaminated
Exhaust-gas back-pressure be- Check exhaust gas pipe Engine/
hind turbine too high Plant
Fuel injection at engine faulty Repair fuel injection Engine
Table 12: Trouble Shooting

TCA88_OperaFaults.fm

6673 C1 5.3–01 E 06.05 TCA88 62

 Maintenance 6

General Remarks 6.1

Maintenance Work

Maintenance work belongs to the duties of the user, just as regular

checks do. Their purpose is to retain operational readiness and opera-
tional safety of the system. They are to be carried out by competent per-
sonnel in accordance 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

(Chapter 6.3.1). It contains

 a brief description of the work,

 the repeat intervals,
 the personnel and time requirements,
 references to the respective work cards/working instructions.

Work Cards

The work cards are comprised in Part C2 of the technical documenta-

tion. They 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.
TCA 88 Maintenance.fm

6673 C1 6.1–01 E 06.05 TCA88 63

Spare Parts

Ordinal numbers for spare parts

 Turbocharger: In the spare parts catalog in Part C3 of the technical

documentation
 Tools: Table of contents for tools
 can be found on the respective work cards in Part C2 of the
technical documentation.

Ordinal numbers consist of the 3-digit assemblies number, a dot, and a

3-digit position number.

Special Services/Repair Work

MAN B&W offers the following special services:

 Delivery of spare parts

 Consultation and support on questions concerning operation,
maintenance and repairs
 Field-experienced training for operating personnel of MAN B&W
exhaust gas turbochargers
 Assessment and clarification of damage cases
 Dispatch of fitters and engineers

In case of requests please contact us at

 MAN B&W Diesel AG, Augsburg Works

 MAN B&W Diesel AG, Service Center Hamburg
 MAN B&W Diesel Pte. Ltd., Service Center Singapore
 Other Service Centers and authorized repair shops

Addresses in Chapter 1.3.

TCA 88 Maintenance.fm

6673 C1 6.1–01 E 06.05 TCA88 64

 Maintenance

Tools/Special Tools 6.2

Inventory tools Conventional tools, usually included in the inventory of the engine sys-
tem.
Inventory tools are not contained in the turbocharger’s scope of supply.

Standard Tools Included as standard in the turbocharger’s scope of supply.

Normally, one set of standard tools is sufficient for a system with sev-
eral turbochargers. The usual maintenance work can be carried out
with these standard tools and the inventory tools.
The standard tool kit for the turbocharger(s) is combined in one or more
boxes and supplied with a table of contents. The ordinal numbers of the
individual tools can also be taken from the table of contents.

Tools Requested by the Customer Additional tools and appliances can be ordered at the MAN B&W Die-
sel AG, as required.

Special Tools Available only at the Service Centers; these tools are not required by
the user of the turbocharger.
Some jobs, -more repair work than maintenance-, require special
knowledge, experience and auxiliary equipment/appliances. For jobs
like this, additional specialty tools are available to our Service Centers
and possibly to some authorized repair shops. Therefore, we recom-
mend that you always consult these Partners or commission work to
them when your own time schedule, or the professional or personnel
capacities are not sufficient.
TCA 88 Maintenance.fm

6673 C1 6.2–01 E 06.05 TCA88 65

Maintenance

Maintenance Schedule 6.3

Reliability and Adaptability

Validity of the Maintenance The maintenance schedule contains a summary of the maintenance
Schedule and inspection work, down to the major overhaul of the turbocharger.

A major overhaul of the turbocharger must be carried out latest after

 24 000–30 000 operating hours.

After each major overhaul, which best is carried out with a due engine
service, the maintenance schedule starts from the beginning again.

A major overhaul includes the disassembly of the complete turbocharg-

er for inspection of the actual condition, thorough cleaning and a check
of all parts/components.

Important!
The maintenance must be scheduled ahead of time, meaning that
e. g. ship timetables or auditioning periods of power plants must
be planned. 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 Maintenance The maintenance schedule takes the following operating conditions
Schedule and an annual operating period of approx. 6000 h into account:

 Uniform loading within a range of 60 to 90% of the rated power,

 Observation of the specified operating media temperatures and
pressures,
 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 op-

erating 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).
TCA 88 Maintenance.fm

6673 C1 6.3–01 E 06.05 TCA88 66

 TCA88_MaintSched.fm

Maintenance

Maintenance Schedule (Turbocharger on the Two-stroke Engine) 6.3.1

6673
C1 6.3.1–03 E

1,

12000
18000
24000
36000
1500
3000
6000
2, per

150
250
24
50
3,
Inspection (during operation)
901 Check turbocharger for unusual noise and vibrations. A 1 0.1 TCA X
903 Check turbocharger and system pipes for leaks A 1 0.2 TCA X
(charge air, exhaust gas, lubrication oil)
905 905 Check all the fixing screws, casing screws and pipe connections for tight fit C2-3.1 1 1 TCA 2 X
06.05

Maintenance (during operation)

911 Clean turbine 500.22 1 0.3 TCA 1
– Dry clean, if available
913 Clean turbine 500.21 1 0.6 TCA 1
– Wet clean, if available
915 Clean compressor (in operation) 500.23 1 0.3 TCA 1
917 Clean air filter (if available) 500.24 1 0.4 TCA 1
1,2,3 Serial number of the maintenance work
Required time in man hours
Brief description of the maintenance work per Size of ratio for the data of required time
TCA88

Pertaining work card with detailed instructions 24 . . . 24000 Repetition intervals in operating hours
A = No work card necessary/available X Maintenance work due
Cross-reference to tasks that are ideally carried out together. 1 As required/depending on condition
2 Checking of new or overhauled parts required (once
Required personnel after the mentioned time)
67
 Maintenance

Maintenance Schedule (Turbocharger on the Two-stroke Engine) 6.3.1

6673
C1 6.3.1–03 E

1,

12000
18000
24000
36000
1500
3000
6000
2, per

150
250
24
50
3,
Maintenance (in common with an engine maintenance)
931 Clean and check compressor casing, insert, diffuser and compressor wheel 500.41 2 4 TCA X
(visually check and clean, as required). 500.42
Establish operational readiness of the turbocharger again 500.43
941 Check thrust bearing, counter-thrust bearing, bearing disk 500.46 931 1 2.0 TCA X
951 Major overhaul C2- 2 20 TCA X
06.05

24 000 - 30 000 operating hours: 4.3. .4.5

Dismantle, clean and check all components of the turbocharger.
Check gaps and clearances upon assembly C2-3.2
1,2,3 Serial number of the maintenance work
Required time in man hours
Brief description of the maintenance work per Size of ratio for the data of required time
Pertaining work card with detailed instructions 24 . . . 24000 Repetition intervals in operating hours
A = No work card necessary/available X Maintenance work due
Cross-reference to tasks that are ideally carried out together. 1 As required/depending on condition
2 Checking of new or overhauled parts required (once
Required personnel after the mentioned time)
TCA88
68

TCA88_MaintSched.fm
 Maintenance

Remarks to the Maintenance Work 6.4

Disassembling the Turbocharger

Disassembly Turbocharger The simplest method to go about the disassembly depends on the
space conditions in the engine room. When performing maintenance
and inspection work, it is sufficient in most cases to disassemble only
subassemblies of the turbocharger.

Inspection Report For a major overhaul of the turbocharger or for repair work concerning
major components, it is recommended to record the condition of indi-
vidual subassemblies and make entries into the operating log. Inspec-
tion report form, see Chapter 6.6.

Important!
For disassembly work, mark the position of the components to
each other using a felt 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
or rotating parts, must be exchanged with original spare parts or re-
paired by an authorized repair facility or the manufacturer.

For dispatch, components must be packed and protected against cor-

rosion in such a manner that they are not further damaged during trans-
portation.

Screw Connections

Loosening Seized or Snug Important!

Connections Never attempt to loosen seized or snug screw connections with
overly force. This can lead to screws being torn off or parts being
so heavily damaged that they must be replaced. Torn off screws
must be drilled out; the threads must be reworked.

Apply plenty of diesel fuel or special dissolver (e. g. Caramba, Omnig-

liss, WD 40) to the screw connection and allow to penetrate for at least
1/2 hour, so that the dissolver can work its way through the threads. Ob-
serve the applicational tips of the dissolver manufacturer. Afterwards,
apply light hammer blows to the screw/bolt head so that the threads run
freely.
TCA 88 Maintenance Remarks.fm

Tightening Screw Connections All screw connections on the turbocharger must be in perfect condition
upon assembly or be renewed. When assembling lock washer pairs (1
pair consists of 2 equal washers), the long wedge surfaces (inside)
must face each other, otherwise there will be no securing effect.

6673 C1 6.4–01 E 06.05 TCA88 69

 Fig. 16: Assembly of wedge lock washers

Important!
Always tighten screws/bolts with the specified tightening torque
(see Technical Documentation Section C2 Work Cards)!

Improper tightened and secured screws/bolts and nuts can become

loose due to vibrations and then be driven into the turbocharger by the
air or exhaust gas flow, and cause severe damage.

Screw Connections on the Turbine Due to the high temperatures on the turbine side, screws/bolts, nuts
Side and tab washers of non-scaling materials are used. These are marked
on the face side (SM, VM or 4923, Z1 or 4828), to avoid them from be-
ing mistaken with regular parts. When disassembling, the fasteners
marked in this manner are to be stored separately until being assem-
bled.
All lock washer pairs on the turbocharger are made of non-scaling ma-
terial and are not marked.

In order to avoid the screws/bolts and nuts on the turbine side from
heating together, 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
from studs are not treated.

TCA 88 Maintenance Remarks.fm

6673 C1 6.4–01 E 06.05 TCA88 70

 Maintenance

Inspection of Individual Components 6.5

General Information

The following remarks and questions are intended as a guide, e. g. for

 Assessment of the turbocharger condition,

 Operating log and inspection report,
 Checking, reusing, repair and replacement of individual
components.

Inspection Work

Gaps and Clearances Admissible values, see Chapter 2.2.

Crack Test Crack test on turbine blades (turbine rotor, compressor wheel) via
acoustic testing or penetration testing with fluorescent color.

Streaks Streaks all around the circumference of the turbine rotor, compressor
wheel, insert: Check gaps and clearances, see Chapter 2.2.

Streaks, locally on circumference of turbine rotor, compressor wheel,

insert: Indication of imbalance.

Oil Coke behind Turbine Wheel Sealing air not effective (e. g., pipe clogged), shaft seal on turbine side
damaged or pre-lubrication pressure too high.

Erosion during HFO Operation During HFO operation, small, hard particles (e.g. “catfines”) are con-
tained in the exhaust gas. These act particularly erosive where high
gas velocities and high concentrations of such particles occur. The
highest flow rates are effective at the outlet of the turbine nozzle ring.
Here, the flow is strongly deflected towards the direction of the circum-
ference. Besides this, the particles contained in the exhaust gas are
hurled towards the outside. For this reason erosions can be noticed at
the discharge of the nozzle ring, at the interior diameter of the shroud
ring and at the exterior of the turbine blades.

“Catfines” As a result of the refinery process and the achieved quality, “catfines”,
a fine grained powder with great hardness (recognizable through the Al
and Si content) as well as other abrasive contaminants, are contained
in the heavy fuel oil. Their amount can be reduced by means of well di-
mensioned, heated settling tanks and through sufficient separation.
TCA 88 Maintenance Remarks.fm

6673 C1 6.5–01 E 06.05 TCA88 71

Additions Adding used engine lube oil is of particular disadvantage, recognizable
through the increased amounts of Ca and Fe. Used engine oil not only
contains residues of wear, but above all “Detergent dispersing addi-
tives”, which bind fine particles and prevent “catfines” and other impu-
rities from being eliminated through separation. For operation with
“waste oil” added, a sharp increase of erosion damage is noticed.
Combustion residue caused by incomplete combustion can also have
erosive effects. Therefore, ensure clean combustion.

Silencer, if available How is the condition of the air filter mat? How is the condition of the ab-
sorption plates? Are cracks on any of the components?

Insert Are there any traces of streaks?

Control Unit for Speed Is the speed transmitter or the speed indicator defective?

Casing Which casings are strongly contaminated from soot, oil or oil coke?
Were the casings tight, particularly at the parting lines and the connec-
tion flanges? Do the casings show signs of cracks?
Were screws/bolts torn? Were all screws/bolts and nuts firmly tight-
ened and secured?
Was the seal air or were oil bores in the bearing casing clogged?
Are all seals O.K.?

Compressor Wheel How is the seat of the compressor wheel and the carrier?
Are the seat faces bright or are there signs of fretting?
Do the turbine blades show signs of cracks or heavy wear? Are there
traces of streaks?
Do the leading edges of the turbine blades show puncture notches
caused by drawn-in foreign objects?

Turbine Rotor How is the run-out of the shaft? How is the condition of the bearing
points?
Are the labyrinth rings strongly worn?
Are the seating faces bright or are there signs of fretting?
Are the blades damaged or is heavy wear or erosion at the edges de-
tectable? Do the blades have signs of cracks?
Do the blades, disc or shaft show any traces of streaks?
Are the fastenings at the foot of the blade O.K.?

Note!
In new condition, the blades are not fastened but inserted into the disc
with clearance. At the blade end, they can be moved several
millimeters both in axial and in radial direction. Due to deposits, this
movability is limited after extended periods of operation.

Shroud Ring Are there any traces of streaks from the turbine blades?
The radial gap between shroud ring and turbine blade may not fall be-
low the minimum value at any position, in order to avoid grazing during
operation. The gap can become larger due to erosion. This consider-
ably influences the efficiency. Therefore, the gap is measured at 4 loca-
tions around the circumference (every 90°) during checking. Admissi-
ble values, see work card [500.54].
TCA 88 Maintenance Remarks.fm

6673 C1 6.5–01 E 06.05 TCA88 72

 Turbine Nozzle Ring Are the blades bent? Are the blades heavily worn due to erosion?
Are foreign objects obstructed in the ducts? Can traces be detected
that point out to foreign objects?
Can any cracks be detected at the blades?

Thrust Ring Are the die seating faces bright or are there signs of fretting?
Are there any signs of scoring or heavy wear?

Bearings For checking of the bearings and bearing bushes, see work card
[500.46] and [500.56]. Any wear across corners on both bearings is an
indicator for imbalance of the running equipment.
How is the seat of the bearing in the casing bore?
Is the axial clearance of the running equipment and the bearing clear-
ance within the admissible range?

Note!
When the axial bearing clearance is determined by axial displacement
of the running equipment, then the running equipment is to be lifted
lightly so that the labyrinth tips come free, out of the grooves in the
cover seal.

Labyrinth Disk, End Cover Is the run-in pattern of the labyrinth tips normal?

Operating Life, Assemblies

Bearing Up to 50 000 operating hours

Turbine rotor Up to 100 000 operating hours

Compressor wheel Up to 80 000 operating hours

The operating life of the compressor wheel depends on the intake air
temperature, the charge pressure and the load profile of the engine. It
can be considerably reduced by unfavorable conditions.

Casing Practically unlimited

These periods are empirical values and are reached with turbocharg-
ers that operate on engines powered with heavy fuel oil.
Continued use or replacement of components is decided upon at each ma-
jor overhaul of the turbocharger. It is imperative that major overhauls are per-
formed according to the periods specified in the maintenance schedule.
TCA 88 Maintenance Remarks.fm

6673 C1 6.5–01 E 06.05 TCA88 73

6673
C1 6.5–01 E
06.05
TCA88
74
TCA 88 Maintenance Remarks.fm
 Maintenance

Inspection Report 6.6

Accompanying the installer report . . . . . . . . . . . . . . . . . . . . . Date. . . . . . . . . . . . . . . . . . . . .

Name of customer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger . . . . . . . . . . . . . .

Address. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Works No. . . . . . . . . . . . . . . . .

Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine type . . . . . . . . . . . . . . .

Name of vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Works No. . . . . . . . . . . . . . . . .

Turbocharger inspected/overhauled on . . . . . . . . . . . . . . . . . . . . . . . . . . by. . . . . . . . . . . . . . . . . . . . . . . .

Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Last inspection/Overhauled on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by. . . . . . . . . . . . . . . . . . . . . . . .

Operating hours since last inspection/overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . h

Operating hours since start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . h


 Please mark where applicable Diffuser Turbine rotor

 checked
 utilized  replaced  utilized  replaced
Intake casing, if available . .  contaminated ......... reason . . . . . . . . . . . . . .
 contaminated . . . . . . . . .  blades  balanced
 bent  torn  contaminated. . . . . . . . .
Silencer, if available
 damage from foreign ob-  traces of streaks
 Air filter mat jects  axial  radial
 utilized  replaced Compressor wheel  all around the
 contaminated  cleaned circumference
 utilized  replaced
 locally on the
Speed transmitter, if available Reason . . . . . . . . . . . . . circumference
 defective . . . . . . . . . . . . .  contaminated . . . . . . . . . Location. . . . . . . . . . . . .
 traces of streaks  blades
Insert
 axial  radial  bent
 utilized  replaced  torn
 all around the circumfer-
 contaminated ence  blade
 traces of streaks  locally on the circumfer-  foot plate
ence  foot
 axial  radial  damage from foreign
 all around the circumfer- Location . . . . . . . . . . objects
ence  blades  erosion
 locally on the circumfer-  bent  torn  coverings
 light
ence  damage from foreign ob-
 heavy
Location . . . . . . . . . . . . . jects
 one-sided
 bore
Compressor housing  Bearing points
 signs of fretting
 contaminated . . . . . . . . .  signs of scoring  wear
TCA 88 Maintenance Report.fm

Thrust ring
 cracks  seatings
 utilized  replaced  signs of fretting
 damage from foreign objects  signs of scoring  wear
Location. . . . . . . . . . . . .
 signs of fretting
 labyrinth tips
 oil coke  wear

6673 C1 6.6–01 E 06.05 TCA88 75

 Bearing casing Labyrinth disk, compressor Shroud ring
side(sealing cover)
 Contaminated . . . . . . . . .  utilized  replaced
 Cracks  utilized  replaced
reason. . . . . . . . . . . . . . . . .
 Sealing air bores  abnormal run-in pattern
 Contaminated . . . . . . . .
 clogged  cleaned  wear
 traces of streaks  Erosion . . . . . . . . . . . . .
 Oil bores
 clogged  cleaned End cover, turbine side  Traces of streaks
 all around the
 Seals  utilized  replaced
circumference
 replaced  abnormal run-in pattern  locally on the
Sealing air valve, if available  wear circumference
 oil coke  cleaned
 Valve plater Location . . . . . . . . . . . . .
Labyrinth disk, turbine side
 moves easily Gas-admission casing
 replaced  utilized  replaced
 Contaminated . . . . . . . .
Bearing disk  wear
 Cracks
 oil coke  cleaned
 utilized  replaced  Erosion
Turbine nozzle ring  Damage from foreign objects
 signs of scoring
 utilized  replaced  Screw connections
 wear
 loose  torn off
 blades
 length (l) - compressor side  replaced
 bent  torn
Taperface .......................mm Gas outlet casing
 damage from foreign objects
 length (l) - turbine side  puncture notches  contaminated . . . . . . . . .
 erosion . . . . . . . . . . . . . .
Taperface .......................mm  Cracks
 Damage from foreign objects
Counter-thrust bearing  coverings . . . . . . . . . . . .
 light  Screw connections
 utilized  replaced  heavy  loose  torn off
 signs of scoring  one-sided  replaced
 wear
 length (l), taperface ...... mm
Gaps and clearances (admissible values, see C2 Chapter 3.2)

Pos. 6 Turbine blade/shroud ring (Radial gap)............................................. mm

Pos. 10 Compressor wheel/insert (Axial clearance)...................................... mm

Pos. 11 Compressor wheel/insert (Radial gap)............................................. mm

Remarks:
TCA 88 Maintenance Report.fm

Date Signature

6673 C1 6.6–01 E 06.05 TCA88 76

 Technical Documentation
Exhaust Gas Turbocharger
Work Cards C2

Exhaust Gas Turbocharger . . . . . . . . . TCA88

D36 6673-1 E
TCA88_Title_C2.fm

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

6673 C2–01 E 06.05 TCA88 77

Table of contents C2

page

1 Introduction ............................................................................................................. 79

1.1 Preface................................................................................................................................................. 79
1.2 Layout and Usage of the Work Cards.................................................................................................. 80

2 Safety Instructions .................................................................................................. 83

2.1 Symbols and Designations .................................................................................................................. 83

2.2 Safety Instruction Sign Engine Room .................................................................................................. 84

3 Setting Data ............................................................................................................. 87

3.1 Bolted Connections and Tightening Torques....................................................................................... 87

3.2 Gaps and Clearances .......................................................................................................................... 91

4 Work Cards .............................................................................................................. 95

4.1 Emergency Operation .......................................................................................................................... 95

500.11 Operation with Holding Device .............................................................................................97
500.12 Operation without Rotating Element ...................................................................................101
4.2 Cleaning............................................................................................................................................. 105
500.21 Cleaning the Turbine (Wet Cleaning) .................................................................................107
500.22 Cleaning the Turbine (Dry Cleaning) ..................................................................................111
500.23 Cleaning the Compressor (Pressure Sprayer) ...................................................................113
500.24 Cleaning the Air Filter .........................................................................................................115
4.3 Assembly of the Turbocharger and Auxiliary Equipment ................................................................... 117
500.31 Turbocharger to Engine ......................................................................................................119
500.32 Silencer ...............................................................................................................................125
500.33 Air Intake Casing ................................................................................................................129
500.34 Emergency and Post-lubrication System ............................................................................133
4.4 Assembly and Maintenance - Compressor Side................................................................................ 137
500.41 Speed Transmitter and Insert .............................................................................................139
500.42 Compressor Casing and Diffuser .......................................................................................145
500.43 Compressor Wheel .............................................................................................................149
500.44 Labyrinth Disk .....................................................................................................................159
500.45 Ring Nut and Labyrinth Ring ..............................................................................................163
500.46 Thrust Bearing, Counter-Thrust Bearing ............................................................................167
4.5 Assembly and Maintenance - Turbine Side ....................................................................................... 173
500.51 Gas-admission Casing .......................................................................................................175
500.52 Turbine Nozzle Ring ...........................................................................................................179
500.53 Turbine Rotor ......................................................................................................................181
500.54 Shroud Ring ........................................................................................................................185
500.55 End Cover ...........................................................................................................................189
TCA 88 englischIVZ2.fm

500.56 Bearing Bushes ..................................................................................................................191

Index I..............................................................................................................................273

6673 C2–01 E 06.05 TCA88 78

 Introduction 1

Preface 1.1

Work Cards and Maintenance Schedule

The work cards supplement the maintenance schedule of the turbo-

charger in Volume C1 (operating manual) of the technical documenta-
tion. There, the required maintenance work is listed only in key words,
whereas in the work cards the required work sequences are described
step by step.

At first the aim and object of the work is described. Then, among other
things, information is given on the required tools and appliances.
For most jobs several work cards must be observed.

ATTENTION
Danger of burning 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!

 Wear protective clothing!

xx

WARNING
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!
xx
TCA88_I_Preface_C2.fm

6673 C2 1.1–01 E 06.05 TCA88 79

Introduction

Layout and Usage of the Work Cards 1.2

Numbering The ordinal number of the work cards is located in the top right of the
title. It consists of a 3-digit subassembly group number and a 2-digit
counting number. The subassembly group number 500 hereby repre-
sents the collective subassembly group number for turbochargers.

Example:
Turbocharger on engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500.31
Subassembly group number (500 for turbocharger)
Counting number (work card No. 31)

On the work cards, cross-references to affiliated work cards are printed

in square brackets.

Example:
Cross-reference to work card 500.43 . . . . . . . . . . . . . . . . . . . [500.43]
In work card 500.44 (labyrinth disk) reference is made to work card
500.43 (compressor wheel).

Layout of the Work Cards Work cards generally contain the following information:

 Required personnel and time,

 affiliated work cards, meaning work cards that contain additional
necessary or other useful information,
 required tools and appliances,
 possibly additional information/technical data and
 the individual work sequences, always beginning with the initial
position, and followed by the individual work steps.

Parts and tools in the figures and text are each designated with their
stock number.

Example:
Non-return valve in bearing casing . . . . . . . . . . . . . . . . . . . .517.142
Subassembly group number (517 for bearing casing)
Position number

All assemblies and subassembly group numbers are listed in

Section C3 Chapter 2.
TCA88_I_LayoutUsage_C2.fm

Stock numbers for tools are (generally) identical with the tool number
affixed on the tool.

Required Personnel and Time The required time is mentioned in hours, both for the amount and qual-
ification of the required personnel. The higher hour rate covers the time
requirement for the complete scope of the respective work card. Per-

6673 C2 1.2–01 E 06.05 TCA88 80

 sonnel with lower hour rate is required only at times, e. g., for operation
of a lifting tackle.

Tools/Appliances Numbers mentioned under the Designation column represent span-

ner widths in mm, e. g. socket wrench 22 = socket wrench, size 22 mm.

Availability-codes under the Status column have the following meaning:

Standard Standard tools (with tool number)

If included in the scope of supply, turbochargers are equipped with a
set of standard tools.
Option Tools requested by the customer (with tool number)
Inventory Commercially available tools/appliances
These are not included in the supply scope of the turbocharger. It is
assumed that these tools/appliances are included in the inventory of
the engine system.
Special Tools Special tools, e. g. for service centers
TCA88_I_LayoutUsage_C2.fm

6673 C2 1.2–01 E 06.05 TCA88 81

 TCA88_I_LayoutUsage_C2.fm

6673 C2 1.2–01 E 06.05 TCA88 82

 Safety Instructions 2

Symbols and Designations 2.1

In the work cards, the safety instructions are indicated by means of the
following symbols and designations:

DANGER
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.
xx

WARNING
When the respective caution measures are not complied with, a poten-
tially hazardous situation will be caused which can lead to:

 Death or serious injury,

 Serious damage to property or
 Serious environmental damage.

ATTENTION
When the respective caution measures are not complied with, a haz-
ardous situation could be caused which can lead to:

 Personal injury,
 Possible damage to property.

A safety or danger symbol appropriate to the hazard is always depicted

in the marginal column (see C1-Operating Manual, Section 2.1 - Gen-
eral Safety Instructions).

Important!
For pointing out fault sources/handling errors; material damage
can occur.

Note!
Additional notes, information and tips.

The instructions “Lubricate contact surfaces and threads”, “Observe

tightening torques” and “Use lock washer pairs” are additionally indicat-
ed by means of symbols in the marginal column:
TCA88_Sa_SymDes_C2.fm

Grease, lubricate and Use lock washers Observe tightening

oil torques

6673 C2 2.1–02 E 06.05 TCA88 83

Safety Instructions

Safety Instruction Sign Engine Room 2.2

Important!
To point out the most important regulations, bans and hazards
during operation and maintenance the following safety
instruction sign must be posted at the entry of the engine room:
xxx:

Fig. 1. Safety instruction sign – engine room

Persons, who for operational reasons are to be within the danger area
of 2.5 m around the engine, are to be instructed of the predominant
hazards. Access to the danger area is permitted when the turbocharger
TCA88_Sa_SymDes_C2.fm

is in proper operating condition and only when wearing suitable protec-

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

6673 C2 2.2–02 E 06.05 TCA88 84

 Explanations to the Safety Instruction Sign

Important!
The regulations, bans and hazards on the safety instruction sign
apply at all times and therefore especially for the maintenance
work described in the work cards.

Safety Symbols

Wear gloves Wear Wear Wear hard Wear safety

protective hearing hat gloves
goggles protection

Wear Read
protective manual
clothing

Danger Symbols

Warning of a Danger of Tripping Danger of Corrosive

hazard slipping hazard electric materials
location shock

Crush Inflammable Hot surface Danger of Rotating

hazard materials suspended gear hazard
loads

Bans

Fire, open No access

flames and for
smoking are unauthorized
prohibited! persons!
TCA88_Sa_SymDes_C2.fm

6673 C2 2.2–02 E 06.05 TCA88 85

 TCA88_Sa_SymDes_C2.fm

6673 C2 2.2–02 E 06.05 TCA88 86

 x

Setting Data 3

Bolted Connections and Tightening Torques 3.1

Short Version

Tightening values for all important bolted connections/tightening

torques for various friction coefficients µ.

Tightening Torques for Bolted Connections

Tightening of Bolted Connections Whenever possible, bolted connections should be tightened with
by Torque torque wrenches.
Particularly important bolted connections on the turbocharger are
specified in Table 3 and additionally on the respective work cards.
For all other bolted connections that are to be tightened with torque
wrenches, the approximate values for the tightening torques are
specified in Table 2.

When tightening bolted connections observe as follows:

 Apart from the applied tightening torque, the tension force of a

bolted connection depends on the lubricant being used, the surface
condition of support and thread, as well as on the material
combination. It is therefore very important that these conditions are
completely observed.
 The tightening torques for the various threads, depending on their
coefficient of friction µ (meaning depending on the selected
lubricant), are listed in Table 2. The tightening torques apply for bolt
materials of the 8.8 property class under utilization of approx. 70 % of
their yield strength. For other property classes, conversion factors are
to be used and multiplied with the tightening torques from Table 2.
The property class is impressed on the bolt head.
Property 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 property
class of the bolts
TCA88_S_BoltCon.fm

6673 C2 3.1–01 E 06.05 TCA88 87

Coefficient µ For the friction coefficient µ use approximately:

µ = 0.08 for lubricants at temperatures

≤ 200 °C, e. g. Molykote G-n or Molykote P40
≥ 200 °C, e. g. Molykote HSC

µ = 0.14 for lightly oiled surfaces without refinishing

Tightening Torques in General

Tightening torque
Thread, nominal size in Nm with friction coefficient µ
0.08 0.14
M5 4 6
M6 7 10
M8 17 25
M 10 34 50
M 12 60 85
M 14 95 135
M 14x1.5 100 145
M 16 140 205
M 16x1.5 150 220
M 18 200 280
M 18x1.5 215 320
M 18x2 205 300
M 20 275 400
M 20x1.5 295 450
M 20x2 285 425
M 22 370 540
M 22x1.5 385 595
M 22x2 380 565
M 24 475 690
M 24x2 500 750
M 27 700 1020
M 27x2 730 1100
M 30 950 1380
M 30x2 1015 1540
M 33 1270 1870
M 33x2 1350 2060
M 36 1640 2400
M 36x3 1710 2550
M 39 2115 3120
M 39x3 2190 3300
M 42 2630 3860
M 42x3 2760 4170
M 45 3260 4820
M 45x3 3415 5180
M 48 3950 5820
M 48x3 4185 6370
TCA88_S_BoltCon.fm

Table 2. Tightening torques for bolts, property class 8.8

6673 C2 3.1–01 E 06.05 TCA88 88

 Tightening Torques, Turbocharger

Important!
The tightening torques in Table 3 apply to a friction coefficient
µ=0.08;

Work Description Tightening

Card Torque in Nm
500.11 Undercut bolt (546.073) 210
Cylindrical screw (596.023) for hub 140
500.12 Closing device (emergency operation):
Hexagon bolt (517.093)/hexagon nut 140
(596.032)
500.32 Silencer at compressor casing:
Hexagon nut (544.182) 275
500.33 Air intake casing at compressor casing:
Hexagon nut (545.427) 275
500.34 Emergency and post-lubrication system:
Hexagon bolts for flanges/oil hoses 60
Hexagon bolt (554.048) 60
Hexagon bolt (554.056) 140
500.41 Insert: Undercut bolt (546.073) 210
500.42 Diffuser: Hexagon bolt (546.045) 60
Compressor casing:
Hexagon nut (506.104) 450
500.43 Thrust screw for superbolt-tension nut 63
500.44 Labyrinth disk: Hexagon bolt (517.093) 140
500.46 Thrust bearing: Hexagon nut (517.102) 140
Counter-thrust bearing:
Hexagon bolt (517.157) 34
500.51 Gas-admission casing:
Hexagon bolt (506.106) 335
500.52 Nozzle ring/clamp ring:
Hexagon bolt (513.013) 165
500.54 Shroud ring: Hexagon bolt (509.012) 165
500.55 Stud screws: Lock nut (517.094) 140
500.56 Counter-thrust bearing:
Hexagon bolt (517.157) 34
Locating disc:
Countersunk screw (517.067) 34
Table 3. Special tightening torques at turbocharger - contact surfaces and
threads lubricated with Molykote HSC)
TCA88_S_BoltCon.fm

6673 C2 3.1–01 E 06.05 TCA88 89

 TCA88_S_BoltCon.fm

6673 C2 3.1–01 E 06.05 TCA88 90

 Setting Data

Gaps and Clearances 3.2

Short Version

Gaps and clearances are to be measured and compared with the spec-
ified tolerances; the results are to be recorded and appropriate action
is to be taken.

Required Tools/Appliances

Amount Designation Number Status

1 Feeler gauge – Inventory
1 Sliding caliper – Inventory
1 Dial gauge – Inventory

Overview

540.001 509.008
540.030

10
517.162 6a

520.044 520.001

517.161
3c 3c
3a 3a
3b

11

509.008 Shroud ring 520.044 Compressor wheel

517.161 Bearing bush 540.001 Insert
517.162 Bearing body 540.030 Balance ring
520.001 Turbine rotor

Fig. 2. Overview, gaps and clearances

TCA88_S_GapsClearances.fm

Important!
When tolerances are not met, the causes must be corrected, e. g.,
imbalance, malfunctions with the lube oil system (debris, pressure,
volume, temperature, pre-lubrication and post lubrication).

6673 C2 3.2–01 E 06.05 TCA88 91

Radial Clearance Bearing Bush/Turbine Shaft

Condition as
Measuring Replace Parts Work
Gaps and Clearances Manufactured
Point Card
Min./mm Max./mm Min./mm Max./mm

517.161
3a 3a – 0.07 0.11 – 0.14 500.53
500.56

520.001

Radial Clearance Bearing Body/Bearing Bush: Turbine Side

Condition as
Measuring Replace Parts Work
Gaps and Clearances Manufactured
Point Card
Min./mm Max./mm Min./mm Max./mm

517.162 3b – 0.33 0.37 – 0.42 500.56

3b

517.161

Radial Clearance Bearing Body/Bearing Bush: Compressor Side

Condition as
Measuring Replace Parts Work
Gaps and Clearances Manufactured
Point Card
Min./mm Max./mm Min./mm Max./mm

517.162 3b – 0.33 0.37 – 0.42 500.56

3b

517.161
TCA88_S_GapsClearances.fm

6673 C2 3.2–01 E 06.05 TCA88 92

 Axial Clearance Bearing Bush/Bearing Body: Turbine Side

Condition as
Measuring Replace Parts Work
Gaps and Clearances Manufactured
Point Card
Min./mm Max./mm Min./mm Max./mm

517.162 3c – 0.34 0.42 – 0.50 500.56

3c

517.161

Axial Clearance Bearing Bush/Bearing Body: Compressor Side

Condition as
Measuring Replace Parts Work
Gaps and Clearances Manufactured
Point Card
Min./mm Max./mm Min./mm Max./mm

517.162 3c – 0.34 0.42 – 0.50 500.56

3c

517.161

Radial Gap Turbine Blade/Shroud Ring

Condition as
Measuring Replace Parts Work
Gaps and Clearances Manufactured
Point Card
Min./mm Max./mm Min./mm Max./mm

520.001 6a 1) * 1.20 1.40 (0.80) 2) 1.80 500.54

509.008

6a
TCA88_S_GapsClearances.fm

1) Setting specification for shroud ring, see Work card [500.54].

2) The minimum value may not be fallen short of at any location on the circumference.

6673 C2 3.2–01 E 06.05 TCA88 93

Axial Gap (10) and Radial Gap (11) Compressor Wheel/Insert

Condition as
Measuring Replace Parts Work
Gaps and Clearances Manufactured
Point Card
Min./mm Max./mm Min./mm Max./mm

546.001 10 1) * 2.70 3.00 – 3.30 500.41

540.001 11 2) * 1.60 1.70 (1.30) 3) 2.00 500.41
A 10

11

520.044

1) Set rotor towards system in direction (A). Measure the axial gap at 3 locations on the circumference via soft-metal marking,
and calculate the mean value (determined value corresponds with the largest given (max.) axial gap).
2) Take measurement at 4 locations of the circumference with a feeler gauge and calculate the average value.
3) The minimum value may not be fallen short of at any location on the circumference.

Important!
Gaps and clearances marked with (*) are to be recorded in the
inspection report (see Section C1, Page 75).

TCA88_S_GapsClearances.fm

6673 C2 3.2–01 E 06.05 TCA88 94

 Work Cards 4

Emergency Operation 4.1

TCA 88 AK Emergency (C2).fm

6673 C2 4.1–01 E 06.05 TCA88 95

 TCA 88 AK Emergency (C2).fm

6673 C2 4.1–01 E 06.05 TCA88 96

 Work Cards
Emergency Operation
Operation with Holding Device 500.11

Short Version

Enable emergency operation by blocking the rotating element.

Required Personnel and Time

Amount Qualification Required Time/h

1 Qualified mechanic 0.6
1 Assistant 0.6

Required Tools/Appliances

Amount Designation Number Status

1 Open-jaw wrench 95 – Inventory
1 Open-jaw wrench 27 – Inventory
1 Hex key – Inventory
1 Holding device 596.511 Standard
1 Arresting wrench 596.018 Standard
1 Hub 596.022 Standard
4 Cylindrical screw 596.023 Standard
1 Lock washer pair 596.024 Standard

Corresponding Work Cards

Work Card Work Card Work Card

500.12 500.32 500.33
500.41
TCA 88 AK 500.11.fm

6673 C2 500.11–01 E 06.05 TCA88 97

Introductory Remarks

The damaged turbocharger can be shut down either with the holding
device [500.11] or with the closing mechanism [500.12].

Use the holding device (596.511) only when removal of the rotating el-
ement is not possible.

Note!
By using the closing mechanism (see work card [500.12] Operation
without Rotating Element) further damage of the rotating element can
be avoided.

Work Sequence – Assembly of the Holding Device

596.022
596.018

520.001

2 x 546.073

596.023
520.044 596.024

520.001 Turbine rotor 596.022 Hub

520.044 Compressor wheel 596.023 Cylindrical screw
546.073 Undercut bolt 596.024 Lock washer pair
596.018 Locking key

Fig. 3. Holding device for emergency operation with rotating element

DANGER
Danger to life from crush injuries or blows!
When the engine starts during assembly of the securing fixtures,
there is danger of becoming entangled in or coming against
rotating components and being seriously injured.
 Shut down the engine before installing the securing fixture in the
turbocharger.
 During the work, secure the engine against starting.
 Set up danger signs!
TCA 88 AK 500.11.fm

xx

6673 C2 500.11–01 E 06.05 TCA88 98

 Starting Condition Silencer [500.32]/air intake casing [500.33], insert [500.41] and bal-
ance ring (540.030) disassembled.

Work Steps 1. Unscrew spinner from compressor (520.044) wheel.

2. Fasten hub (596.022) on compressor wheel with four cylindrical
screws (596.023) and lock washer pair (596.024).

Note!
The hub is formed accordingly so that the tension nut does not have to
be loosened.

3. Attach arresting wrench (596.018) on hub and tighten with two

undercut bolts (546.073) of the insert.

Important!
Use Lock washer pairs (546.074)!

4. Mount the silencer of air intake casing again.

Important!
Lubricate contact surfaces and threads (e. g. Molykote HSC)!
xx

WARNING
Danger of fire caused by lube oil!
During emergency operation with the securing fixture, the danger
of fire is given when lube oil gets into the turbocharger.
 In emergency operation, always shut the oil supply pipe to the
turbocharger.
xx

Note!
Additional emergency operation notes, see Section C1 - Chapter 5.2 of
operating manuals.

Important!
Observe tightening torques upon installation!

Undercut bolts (546.073): 210 Nm

Cylindrical screw (596.023) for hub: 140 Nm
TCA 88 AK 500.11.fm

6673 C2 500.11–01 E 06.05 TCA88 99

 TCA 88 AK 500.11.fm

6673 C2 500.11–01 E 06.05 TCA88 100

 Work Card
Emergency Operation
Operation without Rotating Element 500.12

Short Version

Enabling emergency operation by disassembling the rotating element

and closing the bearing casing with closing covers.

Required Personnel and Time

Amount Qualification Required Time/h

1 Qualified mechanic 3.5
1 Assistant 3.5

Required Tools/Appliances

Amount Designation Number Status

1 Open-jaw wrench 24 – Inventory
1 Closing mechanism 596.512 Standard
1 Closing cover (compressor side) 596.027 Standard
1 Closing cover (turbine side) 596.028 Standard
1 Gasket (compressor side) 596.029 Standard
1 Gasket (turbine side) 596.030 Standard
1 Stud screw 596.031 Standard
2 Hexagon nut 596.032 Standard
2 Hexagon bolt 596.033 Standard

Corresponding Work Cards

Work Card Work Card Work Card

500.11 500.32 500.33
500.41 500.43 500.44
500.51 500.53
TCA 88 AK 500.12.fm

6673 C2 500.12–01 E 06.05 TCA88 101

 Technical Data

Designation Specification
Closing device 60 kg
Closing cover (compressor side) 44 kg
Closing cover (turbine side) 12 kg

Introductory Remarks

The damaged turbocharger can be shut down either with the holding
device [500.11] or with the closing mechanism [500.12].

Use the holding device only when removal of the rotating element is not
possible.

Note!
By using the closing mechanism (596.512) further damage of the
rotating element can be avoided.

Work Sequence – Assembly of the Closing Covers

596.033
596.032

596.033
517.093 (8x) 596.032
517.095 (8x) 596.031 517.001
596.029

596.027

596.030
596.028
596.033
596.032

596.033

517.001 Bearing casing 596.029 Gasket (compressor side)

517.093 Hexagon bolt 596.030 Gasket (turbine side)
517.095 Lock washer pair 596.031 Stud screw
596.027 Closing cover (compressor side) 596.032 Hexagon nut
596.028 Closing cover (turbine side) 596.033 Hexagon bolt
TCA 88 AK 500.12.fm

Fig. 4. Closing mechanism at emergency operation without rotating element

6673 C2 500.12–01 E 06.05 TCA88 102

 DANGER
Danger to life from crush injuries or blows!
When the engine starts during removal of the running gear or
during assembly of the closing mechanism, there is danger of
becoming entangled in or coming against rotating components.
 Shut down the engine before removal of the running gear as well
as before installing the closing mechanism in the turbocharger.
 During the work, secure the engine against starting!
 Set up danger signs!
xx

Starting Condition Silencer [500.32]/air intake casing [500.33], insert [500.41] and gas-
admission casing [500.51] disassembled.
Compressor wheel [500.43], labyrinth disk [500.44] and turbine rotor
[500.53] disassembled.

Note!
Bearing bushes and counter-thrust bearing can remain assembled.

Work Steps 1. Fasten stud (596.031) to closing cover (596.027) with two nuts
(596.032).
2. Fasten closing cover and seal (596.029) to the bearing casing
(517.000) with eight hexagon bolts (517.093) and lock washer
pairs (517.095) of the disassembled labyrinth disk (517.089).
3. Mount closing cover (596.028) and sealing (596.030) on turbine
side and fasten to stud with nut (596.032).

Note!
For easier installing, screw two hexagon bolts (596.033) each into the
closing cover.

Fig. 5. Installed closing cover (compressor side and turbine side)

4. Mount gas-admission casing.

5. Mount silencer or air intake casing.

WARNING
Danger of fire caused by lube oil!
During emergency operation without running equipment, the
TCA 88 AK 500.12.fm

danger of fire is given when lube oil gets into the turbocharger.
 In emergency operation, always shut the oil supply pipe to the
turbocharger.
xx

6673 C2 500.12–01 E 06.05 TCA88 103

 Important!
Lubricate contact surfaces and threads (e. g. Molykote HSC)!
xx

Note!
Additional emergency operation notes, see Section C1 - Chapter 5.2.

Important!
Observe tightening torques upon installation!

Hexagon nut (596.032): 140 Nm

Hexagon bolt (517.093): 140 Nm

TCA 88 AK 500.12.fm

6673 C2 500.12–01 E 06.05 TCA88 104

 Work Cards

Cleaning 4.2
TCA 88 Cover Cleaning (C2).fm

6673 C2 4.2–01 E 06.05 TCA88 105

6673
C2 4.2–01 E
06.05
TCA88
106
TCA 88 Cover Cleaning (C2).fm
 Work Card
Cleaning
Cleaning the Turbine (Wet Cleaning) 500.21

Short Version

Carry out the wet cleaning in time according to the maintenance plan;
clean components from debris/residue.

Required Personnel and Time

Amount Qualification Required Time/h

1 Qualified mechanic 0.6

Introductory Remarks

General Amount and layout of the washing lances (4) depends on the engine
type and can vary from the illustration.

Cleaning Agent Use only fresh water for cleaning.

Cleaning Interval Every 250 operating hours (depending on the operating conditions the
intervals can be shorter).

Also see the plate on the engine with the cleaning specification.

Note!
In order to save time, carry out the cleaning briefly after putting the
engine into operation, as long as the components subject to cleaning
are not too hot yet.
In this case, work step 2 of work sequence can be skipped.

Technical Data

Designation Specification
Washing lances
Gas-admission casing 4
Water pressure 2 bar
Exhaust gas temperature at turbine ≤ 320 °C
Turbocharger speed 7000 rpm
TCA 88 AK 500.21.fm

6673 C2 500.21–01 E 06.05 TCA88 107

 E 2 1

6
4
5

1 Washing water 6 Turbine wheel

2 Pressure gauge 7 Washing water outlet
3 Nozzles 8 Drain funnel
4 Gas-admission casing B Drainage cock
5 Nozzle ring E Stop cock water supply

Fig. 6. Diagram for water washing of turbine

TCA 88 AK 500.21.fm

6673 C2 500.21–01 E 06.05 TCA88 108

 Work Sequence 1 – Water Washing of Turbine (during Operation)

General Water washing of the turbine is carried out at reduced engine power.
Washing is carried out in “intervals”, otherwise the turbine could graze.
The size of the nozzle slot and the water pressure are matched to the
exhaust amount and temperature (quantity of heat) of the charger.

Work Steps 1. Run the engine at reduced engine power (1/4 load) for approx.
10 minutes (cooling down to the stabilizing condition).
2. Check the operating parameters for the washing of the turbine:
Exhaust gas temperature ≤ 320 °C
Turbocharger speed 7000 rpm
Water pressure 2 bar

Important!
The exhaust gas temperature of 320 °C must not be exceeded
under any circumstances, otherwise the turbine can graze during
washing.

3. Open drainage cock (B). Check the outflow of exhaust gas at the
opened cock; free opening, if required.
4. Open stop cock (E): Water is sprayed through the nozzles (3).
5. Washing duration 1 minute.

Note!
The water running out of the washing water outlet (7) gives information
about the washing effect or about the contamination degree of the
turbine. The water can be checked at the drain funnel (8).

6. Shut the stop cock (E).

7. Run the turbocharger dry for 1 minute at reduced engine capacity.
8. Repeat the washing procedure and the running dry
(work steps 4-7) 3-5 times.
9. Shut drainage cock (B).
10. Run the turbocharger dry for 8 minutes at reduced engine power,
then slowly increase the load.

Note!
In case vibrations of the turbocharger occur that were previously not
existent, repeat the washing procedure.

Important!
If vibrations due to irregular heavy deposits of debris can not be
corrected through the washing, the turbocharger must be
dismantled and the respective parts must be cleaned
mechanically.
xx
TCA 88 AK 500.21.fm

6673 C2 500.21–01 E 06.05 TCA88 109

 TCA 88 AK 500.21.fm

6673 C2 500.21–01 E 06.05 TCA88 110

 Work Card
Cleaning
Cleaning the Turbine (Dry Cleaning) 500.22

Short Version

Dry cleaning of the turbocharger (if available) is carried out in HFO op-
eration. Carry out the cleaning in time according to the maintenance
plan; clean components from debris/residue.

Required Personnel and Time

Amount Qualification Required Time/h

1 Qualified mechanic 0.6

Technical Data

Designation Specification
Granulates: Particle size:
Nutshells or activated charcoal (soft) 1 mm (max. 1.5 mm)
Filling volume approx. 2.5 l

Introductory Remarks

General The exact layout of the components depends on the engine type and
can vary from the illustration.

Note!
For turbine cleaning with this setup, do not use water, as in this case
the cleaning is carried out at normal operating load of the engine.

Cleaning Interval At normal operating load of the engine, every 24 operating hours.
TCA 88 AK 500.22.fm

6673 C2 500.22–01 E 06.05 TCA88 111

 8 2 1 Compressed-air pipe
(5 - 8 bar)
3 A 2 Screw plug

3 Tank

B 4 Pipes (25 x 2.0 mm)

9
5 Connection flange
4 1
6 Adapter
5
7 Gas-admission casing

8 Gas outlet casing

9 Turbine wheel
7
10 Nozzle ring
6
A Stop cock
10
(compressed air)

B Stop cock (exhaust gas)

Fig. 7. Diagram dry cleaning of turbine

Work Sequence – Dry Cleaning of Turbine (during Operation)

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

2. Unscrew screw plug (2), fill cleaning agent (granulates, active car-
bon) into the tank (3) and then shut again.
3. Open stop cock (A) (compressed air).
4. Slowly open stop cock (B) (exhaust gas) until a whistling sound indi-
cates that the granulates are being blown in. Blow-in duration approx.
30 seconds.
5. Shut stop cock (A) and (B).
TCA 88 AK 500.22.fm

6673 C2 500.22–01 E 06.05 TCA88 112

 Work Card
Cleaning
Cleaning the Compressor (Pressure Sprayer) 500.23

Short Version

The cleaning of the compressor is carried out during operation.

Carry out the work in time according to the maintenance schedule.
Clean the components from debris/residue.

Required Personnel and Time

Amount Qualification Required Time /h

1 Qualified mechanic 0.3

Introductory Remarks

General The layout of the components depends on the engine type and can
vary from the illustration.

See plate with the cleaning specifications (see Fig. 8 ) on pressure

sprayer.

Cleaning Agent Use fresh water only for cleaning.

Cleaning Interval Every 150 operating hours.

The cleaning intervals depend on the contamination degree of the

drawn-in air and range between 100 and 200 operating hours.

Note!
Carry out the cleaning only with the engine warmed up and at full load
operation. Do not shut down the engine immediately after the cleaning,
but continue to run for several minutes dry.
TCA 88 AK 500.23.fm

6673 C2 500.23–02 E 06.05 TCA88 113

 1 Plate (cleaning specification)
4 2 Pressure sprayer
3
7 3 Relief Valve
6 4 Handle
2 5 Hand valve
6 Nipple
8
1 7 Coupling
5
6
8 Silencer/Compressor

Fig. 8. Wet cleaning system (pressure sprayer), compressor

Work Sequence – Compressor Cleaning (during Operation)

Work Steps 1. Operate engine at full load.

2. Turn the handle (4) on the container of the pressure sprayer (2) to
the left and take out the pump.
3. Fill a maximum of 2 l of freshwater into the container (to the 2 L
mark on the container).
4. Screw in the pump and operate it until the relief valve (3) blows off.
5. Connect hose with nipple (6) to the coupling (7).
6. Operate the pushbutton (see large arrow in figure 8 ) on the hand
valve (5) until water is blown into the compressor (8) (approx. 30
seconds).
7. Release the plug connection and vent the container; for this, pull
the spindle at the relief valve (3) outward (see small arrow in
figure 8 ).
TCA 88 AK 500.23.fm

6673 C2 500.23–02 E 06.05 TCA88 114

 Work Card
Cleaning
Cleaning the Air Filter 500.24

Short Version

Clean the air filter regularly in accordance with the maintenance schedule.
The work can be carried out during operation.

Required Personnel and Time

Amount Qualification Required Time/h

1 Qualified mechanic 0.3

Required Tools/Appliances

Amount Designation Number Status

- Compressed air – Inventory
- Cleaning Agent (non-corrosive) – Inventory

Spare Parts

Amount Designation Number

1 Air filter mat 544.150
3 Lashing strap with ratchet 544.160
1 Cover strip 544.170

Introductory Remarks

General The soiled air filter mat (544.150) can be cleaned several times, or re-
placed by a new mat.
Replacement is necessary when the air filter mat is strongly deformed,
frayed out or perforated.

Note!
An increase in pressure loss, due to a contaminated air filter mat,
should not be used as a reference for the cleaning interval.
xx
TCA 88 AK 500.24.fm

6673 C2 500.24–01 E 06.05 TCA88 115

 DANGER
Danger to life from crush injuries or blows against rotating
components!
When the inspection cover (see Fig. 9 ) of the silencer is
removed during operation, there is danger of becoming
entangled in or coming against rotating components in the
silencer or turbocharger and being seriously injured.
 Open the inspection cover for visual checks only when the engine
is shut down!
 Change only the air filter mat during operation (see work sequence).

Cleaning Interval Every 250 operating hours.

The cleaning intervals depend on the contamination degree of the
drawn-in air and therefore range between 250 and 500 operating hours.

Note!
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.
xx

Fig. 9. Inspection cover (1) Fig. 10. Air filter mat with lashing strap and silencer

Work Sequence – Removal/Cleaning/Reinstallation of the Air Filter Mat

1. Loosen lashing straps and remove air filter mat (see Fig. 10 ).

2. Clean the soiled air filter mat with warm water and a cleaning
agent (non-corrosive).

Important!
Avoid overly mechanical stress (such as wringing out or intensive
water jet). After the cleaning, blow out the air filter mat with
compressed air.
TCA 88 AK 500.24.fm

3. Place the air filter mat over the perforated sheet of the silencer.
4. Place the cover strip over the butt joint of the air filter mat and then
fasten the air filter mat with lashing straps.
5. Firmly tighten the ratchets of the lashing straps.

6673 C2 500.24–01 E 06.05 TCA88 116

 Work Cards

Assembly of the Turbocharger and Auxiliary Equipment 4.3

TCA 88 Cover Assembly (C2).fm

6673 C2 4.3–01 E 06.05 TCA88 117

6673
C2 4.3–01 E
06.05
TCA88
118
TCA 88 Cover Assembly (C2).fm
 Work Card
Assembly of the Turbocharger and Auxiliary Equipment
Turbocharger to Engine 500.31

Short Version

Removing and Refitting the Turbocharger from and to the Engine.

Required Personnel and Time

Amount Qualification Required Time/h

1 Qualified mechanic 6.0
1 Assistant 6.0

Required Tools/Appliances

Amount Designation Number Status

2 Shackle – Inventory
1 Torque wrench – Inventory
1 Open-jaw and ring wrenches – Inventory
(set)
1 Socket wrench (set) – Inventory
1 Screwdriver – Inventory
1 Lifting tackle, ropes – Inventory
– Wood (for placing underneath) – Inventory
1 High-temperature lubricant – Inventory
(e. g. Molykote HSC)

Work Cards

Work Card Work Card Work Card

500.21 500.22 500.23
500.41

Technical Data

Designation Specification
TCA 88 AK 500.31.fm

Turbocharger 15500 kg

6673 C2 500.31–01 E 06.05 TCA88 119

 Work Sequence 1 – Deconserving

Condition at time of supply  Packed in wooden box.

(as a rule)  Accessories, spare parts and tool box are enclosed.

For lists of spare parts [595.01] and tools [596.01] see Section C3 in
the spare parts catalogue.

 Socket adjustments of the casings are factory set.

 Connections are shut with sealing caps.
 Interior components are conserved with corrosion prevention
agents that are consistent with operating media.
 Protective coating against corrosion on the outside.

Condition at time of supply with in- In order to achieve increased corrosion protection (e. g., overseas,
creased corrosion protection tropics, subtropics), the following measures are additionally carried out:

 Drying agent (bag, block) at the inside of closing caps/lids.

 Prior to closing the opening, a vapor-phase corrosion agent is
sprayed into the gas intake, gas discharge and air-discharge
connections.

Work Steps 1. Remove the protective coating against corrosion on the outside
using diesel or kerosene.
2. Remove sealing caps/lids.

In case of increased corrosion protection:

3. Remove all drying agents, if applicable.

4. Blow compressed air through turbocharger casing, in order to
remove vapor-phase corrosion agent.

WARNING
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
xx
TCA 88 AK 500.31.fm

6673 C2 500.31–01 E 06.05 TCA88 120

 Work Sequence 2 – Assembly to the Engine, Connection of the Charge Air and Exhaust Pipes

General

506.001

501.001

544.000

546.000

1 Suspension device 544.000 Silencer

501.001 Gas-admission casing 546.000 Compressor casing
506.001 Gas outlet casing
Fig. 11. Suspension device for turbocharger with 90° gas-admission casing

Note!
Suspension device welded to turbocharger (condition of delivery).
xx

Work Steps 1. Insert shackle and tackle line to suspension device

(see Fig. 11 ).

WARNING
Danger of the turbocharger falling down!
Improvised or incorrectly attached suspension devices can
result in the falling down of the turbocharger and can seriously
injure or kill persons located below.
 Lift the complete turbocharger only with the suspension device!
 Never use other or self-designed suspension devices!
 Never use the lifting eye bolts to lift up the complete turbocharger,
as these are intended only for the lifting individual components.
xx
TCA 88 AK 500.31.fm

6673 C2 500.31–01 E 06.05 TCA88 121

 WARNING
Danger of injury from suspended loads!
A rocking turbocharger is difficult to maneuver and can therefore
seriously injure or kill people.
 Hang turbochargers with the axial gas-admission casing
onto the two lifting hooks between the compressor casing
(546.000) and the gas outlet casing (506.001) and additionally
onto the silencer (544.000) so that the turbocharger is in balance.
 Hang turbochargers with the radial gas-admission casing
only onto the two lifting hooks between the compressor casing
(546.000) and the gas outlet casing (506.001). The turbocharger
is then in balance.
 Use tackle line/chains and adjust these to the appropriate lengths
in order to guide the turbocharger.
 Move the turbocharger slowly in the engine room.
xx

2. Lift turbocharger with lifting tackle and place onto bracket of engine.
3. Aligning the turbocharger:
The exhaust pipe must be in alignment with the gas-admission
casing (501.001) and the compressor socket must be in alignment
with the charge-air pipe of the engine.

Important!
The turbocharger must be aligned particularly accurate when a
sliding sleeve is used between compressor casing (546.000) and
air pipe instead of a compensator.

4. Lightly tighten the casing feet on the engine bracket. Use the fasten-
ing bolts and the resilient sleeves (delivery scope of engine) for this.
5. Connect the exhaust pipe of the engine and gas-admission casing
(501.001) with the compensator (delivery scope of engine).
Lightly stretch the compensator forward for this and use heat-
resistant bolts.
6. Connect the pressure socket of the compressor casing (546.000)
and the charge air pipe with the compensator or with the sliding
sleeve (both in delivery scope of engine).
7. Tighten screwed connection of the casing feet on the engine
bracket with torque wrench.

Important!
Lubricate contact surfaces and threads (e. g. Molykote HSC)!
xx

Wichtig!
Observe tightening torques upon assembly!

Screw connection of the casing feet on the engine bracket: See engine
manual.
TCA 88 AK 500.31.fm

6673 C2 500.31–01 E 06.05 TCA88 122

 Work Sequence 3 – Connection of the Lube Oil System

General Backing up in the lube oil discharge can lead to oil-flooding of the tur-
bocharger. In the process, oil can seep out of the turbine side and
cause a fire in the exhaust pipe.

Important!
The lube oil discharge must be installed sloped:
Gradient > maximum possible system inclination +5°.
(See Section C1 - Chapter 4.2)

Work Steps 1. Remove the closures at the bearing casing (517.000) and connect
the lube oil supply and drain pipes to the turbocharger.

Important!
After fitting the lube oil pipes to size and prior to the final
assembly, treat all pipes in acid bath and thoroughly clean them.

2. Mount and connect lube oil pipes, gauges and pressure controllers.

Important!
Use only seals that are in proper condition.

Work Sequence 4 – Connecting the Speed Transmitter

Work Steps Connect the read-out unit of the speed measuring device to the termi-
nal box (compressor casing) according to the electrical wiring diagram.

Also see work card [500.41].

TCA 88 AK 500.31.fm

6673 C2 500.31–01 E 06.05 TCA88 123

Work Sequence 5 – Jet Assist Connection (Option)

Work Steps 1. Check if the O-ring seals (540.015) are in the insert (540.001).
2. Fit air-supply pipe (delivery scope of engine) with pressure
reducer, solenoid valve and non-return valve to the connection at
the compressor casing and bolt together.

Work Sequence 6 – Cleaning System Connection (Option)

 Connect the dry cleaning system for the turbine at the intended
location on the engine/turbocharger [500.22].
 Mount the wet cleaning equipment for the turbine to the connections
of the cleaning nozzles (gas-admission casing) and the dirty water
drain [500.21].
 Connect the wet cleaning equipment for the compressor to the
connection of the injection pipe in the compressor casing [500.23].

Work Sequence 7 – Removal of the Turbocharger

Removal of the turbocharger is carried out in reverse order of assembly.

Due to restricted space conditions, it may be necessary to remove the
turbocharger in partially disassembled condition (silencer, compressor
and admission casing, and rotating element disassembled) (see
Chapter 4.4 and4.5).

ATTENTION
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!
 Wear protective clothing!

ATTENTION
Danger of burning/scalding from running-out lube oil!
The lube oil is under pressure and very hot!

 Before opening pipes, flanges, screwed connections or gauges,

free the system of pressure and check that it is pressure-free!

 Before opening oil pipes, wait until the lube oil has cooled down
sufficiently (1-2 h).

 Drain the system and check that it has been drained completely.

 Wear protective clothing!

TCA 88 AK 500.31.fm

6673 C2 500.31–01 E 06.05 TCA88 124

 Work Card
Assembly of the Turbocharger and Auxiliary Equipment
Silencer 500.32

Short Version

Removal and installation of the silencer is carried out in completed con-

dition.
Disassembly of the silencer is required for all work that must be per-
formed from the compressor side (see Chapter 4.4).

Required Personnel and Time

Amount Qualification Required Time/h

1 Qualified mechanic 2.0
1 Assistant 2.0

Required Tools/Appliances

Amount Designation Number Status

1 Open-jaw wrench 30 – Inventory
1 Torque wrench – Inventory
- Lifting tackle with ropes – Inventory
- Eye bolts, shackles – Inventory
- Wood (for placing underneath) – Inventory

Spare Parts

Amount Designation Number

24 Lock washer pair 544.181

Corresponding Work Cards

Work Card Work Card Work Card

500.24

Technical Data
TCA 88 AK 500.32.fm

Designation Specification
Silencer 2010 kg

6673 C2 500.32–01 E 06.05 TCA88 125

Introductory Remarks

General

546.000

544.000

544.181
544.182

544.000 Silencer 544.182 Hexagon nut

544.181 Lock washer pair 546.000 Compressor casing
Fig. 12. Installation/removal of the silencer at the compressor casing

For cleaning of air filter, see work card [500.24].

DANGER
Danger to life from crush injuries or blows against rotating
components!
Never remove the inspection cover (see Fig. 9 in work card
[500.24]) of the silencer during operation. There is danger of
becoming entangled in or coming against rotating components
of the silencer or turbocharger and being seriously injured.
 Shut down the engine before working on the silencer.
 During the work, secure the engine against starting!
 Set up danger signs!

WARNING
Danger of injury from suspended loads!
A rocking silencer is difficult to maneuver and can therefore
seriously injure people and cause damage to material.
TCA 88 AK 500.32.fm

 For attachment of the lifting equipment, use only the lifting hooks
on the silencer which are intended for this purpose.
 Move the silencer slowly away from or towards the silencer.
xx

6673 C2 500.32–01 E 06.05 TCA88 126

 Work Sequence 1 – Removing the Complete Silencer

Starting Condition Connection of the compressor washing equipment loosened (if avail-
able).

Work Steps 1. Fasten silencer to lifting equipment using ropes.

Important!
The studs on the silencer casing are secured with Loctite 586.
Therefore do not heat them upon disassembly.

2. Loosen hexagon nuts (544.182) at intermediate flange of com-

pressor casing/silencer from the stud bolts of the silencer casing,
preceding in circumferential direction.
3. Move silencer in axial direction away from the compressor casing and
place it on wooden support with the flange surface down.

Work Sequence 2 – Installation of the Complete Silencer

Work Steps Installation is carried out in reverse order of removal.

Important!
Lubricate contact surfaces and threads (e. g. Molykote HSC)!
xx

Important!
Mount hexagon bolts with lock washer pairs!

Important!
Observe tightening torques upon installation!

Hexagon nut (544.182): 275 Nm

TCA 88 AK 500.32.fm

6673 C2 500.32–01 E 06.05 TCA88 127

 TCA 88 AK 500.32.fm

6673 C2 500.32–01 E 06.05 TCA88 128

 Work Card
Assembly of the Turbocharger and Auxiliary Equipment
Air Intake Casing 500.33

Short Version

Removal and refitting of the air intake casing is carried out in complete
condition. Dismantling of the air intake casing is necessary for all jobs
that must be performed from the compressor side (Chapter 4.4).

Required Personnel and Time

Amount Qualification Required Time/h

1 Qualified mechanic 2.0
1 Assistant 2.0

Required Tools/Appliances

Amount Designation Number Status

2 Open-jaw wrench 30 – Inventory
1 Torque spanner – Inventory
- Lifting tackle with ropes – Inventory
- Wood (for placing underneath) – Inventory
1 Shackles 596.046 Standard
1 Eye bolt 596.051 Standard

Spare Parts

Amount Designation Number

48 Lock washer pair 545.428

Technical Data

Designation Specification
Air intake casing axial 629 kg
Air intake casing 90° 1032 kg
TCA88 WK-500.33.fm

6673 C2 500.33–01 E 06.05 TCA88 129

Introductory Remarks

General

546.046 546.051
545.401

546.000

545.425
545.428

545.428
545.427

545.401 Air intake casing

545.425 Hexagon bolt
545.427 Hexagon nut
545.428 Lock washer pair
546.000 Compressor casing
596.046 Shackles
596.051 Eye bolt
Fig. 13. Installation/removal of the air intake casing at the compressor casing

Work Sequence 1 – Removing

Starting Condition Connection of the compressor washing equipment loosened (if avail-
able).

Work Steps 1. Screw eye bolt (596.051) into air intake casing (545.401).
2. Hang air intake casing via shackle (596.046) to lifting device; ten-
sion the rope.
3. Loosen hexagon nuts (545.427), hexagon bolts (545.425), lock
washer pairs (545.428) in circumferential direction.
4. Move air intake casing away from compressor casing in axial di-
rection and place down on wooden supports.
TCA88 WK-500.33.fm

6673 C2 500.33–01 E 06.05 TCA88 130

 Work Sequence 2 – Installation

Work Steps Refitting is carried out in reverse order of removal.

Important!
Lubricate contact surfaces and threads (e. g. Molykote HSC)!
xx

Important!
Mount hexagon bolts and hexagon nuts each with lock washer
pairs.

Important!
Observe tightening torques upon installation!

Hexagon nut (545.427): 275 Nm

TCA88 WK-500.33.fm

6673 C2 500.33–01 E 06.05 TCA88 131

 TCA88 WK-500.33.fm

6673 C2 500.33–01 E 06.05 TCA88 132

 Work Card
Assembly of the Turbocharger and Auxiliary Equipment
Emergency and Post-lubrication System 500.34

Short Version

The emergency and post-lubrication system is removed only when the

compressor casing is disassembled.

Required Personnel and Time

Amount Qualification Required Time/h

1 Qualified mechanic 1.5

Required Tools/Appliances

Amount Designation Number Status

1 Open-jaw wrench 19 – Inventory
1 Open-jaw wrench 24 – Inventory
- Lifting tackle with ropes – Inventory
- Wood (for placing underneath) – Inventory

Spare Parts

Amount Designation Number

8 Lock washer pair 554.049
1 Sealing ring 554.061
1 Seal 554.062
1 Sealing ring 554.083

Technical Data

Designation Specification
Emergency and Post-lubrication System 285 kg
TCA 88 AK 500.34.fm

6673 C2 500.34–01 E 06.05 TCA88 133

 Work Sequence 1 – Removal of the Emergency and Post-lubrication System

Starting Condition

554.001 Oil tank

554.048 Hexagon bolt

554.049 Lock washer pair

554.001 554.050 Hexagon nut

554.055 Resilient sleeve

554.056 Hexagon bolt

554.083
554.049 554.061 Sealing ring
554.087
554.080 554.062 Sealing ring
554.056
554.048 554.096 554.063 Hexagon bolt
554.055
554.064 Non-return valve
554.031
554.049 554.056 554.066 Hose pipe with
554.061 connection
554.064 554.055
554.062 554.080 Hose pipe with
554.050 connection

554.063 554.066 554.083 Sealing ring

554.096
554.087 Hexagon bolt

554.096 Hexagon bolt

Fig. 14. Removal of the emergency and post-lubrication system (554.000)

Oil hoses (554.066 and 554.080) have been released from bearing
casing and oil tank, and oil drained. The openings at the emergency
and post-lubrication system (554.000) and the bearing casing have
been provisionally shut.
Check if the sealing rings (554.061, 554.062, 554.083) need to be re-
placed.

Work Steps 1. Fasten oil tank (554.001) to rope; use lifting device.
2. Loosen hexagon bolt (554.048) of plate (554.047).
3. Loosen hexagon bolts (554.056) of bracket (554.031).
4. Lift emergency and post-lubrication system (554.000) with lifting
device and set down on wooden support.
TCA 88 AK 500.34.fm

6673 C2 500.34–01 E 06.05 TCA88 134

 Work Sequence 2 – Installation of the Emergency and Post-lubrication System

Work Steps Installation is carried out in reverse order of removal. Afterwards con-
nect the oil hoses (554.066, 554.080). Use new sealing rings, as re-
quired.

Important!
Lubricate contact surfaces and threads (e. g. Molykote HSC)!
xx

Important!
Observe tightening torques upon installation!

Hexagon bolts flanges/oil hoses: 60 Nm

Hexagon bolt (554.048): 60 Nm
Hexagon bolt (554.056): 140 Nm
TCA 88 AK 500.34.fm

6673 C2 500.34–01 E 06.05 TCA88 135

 TCA 88 AK 500.34.fm

6673 C2 500.34–01 E 06.05 TCA88 136

 Work Cards

Assembly and Maintenance - Compressor Side 4.4

TCA 88 Cover C-Side (C2).fm

6673 C2 4.4–01 E 06.05 TCA88 137

 TCA 88 Cover C-Side (C2).fm

6673 C2 4.4–01 E 06.05 TCA88 138

 Work Card
Assembly and Maintenance - Compressor Side
Speed Transmitter and Insert 500.41

Short Version

Installation and removal of the speed transmitter/insert required for as-

sembly/disassembly of other assemblies/components and for control
purposes or replacement.

Required Personnel and Time

Amount Qualification Required Time/h

1 Qualified mechanic 1.5
1 Assistant 1.5

Required Tools/Appliances

Amount Designation Number Status

1 Open-jaw wrench 27 – Inventory
1 Torque wrench – Inventory
1 Screwdriver – Inventory
- Lifting tackle with ropes, chains – Inventory
- Eye bolts – Inventory
- Wood (for placing underneath) – Inventory
- Steel or straight-edge – Inventory
1 Removing and refitting tool for insert 596.518 Standard
3 Guide bar 596.045 Standard
1 Shackle A1 596.046 Standard

Spare Parts

Amount Designation Number

2 O-ring seal 540.015
1 Seal disk 540.026
1 Seal disk 546.050

Corresponding Work Cards

TCA 88 AK 500.41.fm

Work Card Work Card Work Card

500.32 500.33 500.43

6673 C2 500.41–02 E 06.05 TCA88 139

 Technical Data

Designation Specification
Insert 400 kg

Prerequisites

596.046

540.030
546.000

596.045

540.001
520.044

520.044 Compressor wheel 546.000 Compressor casing

540.001 Insert 596.045 Guide bar
540.030 Balance ring 596.046 Shackle

Fig. 15. Removal and Installation of the Insert in the Compressor Casing

General Disassembly of the insert (540.001) enables removal of the compres-

sor wheel (520.044) and a part of the bearings without having to disas-
semble the compressor casing (546.000).

Important!
Prior to removal of the insert, the connection of the speed
transmitter must always be released from the terminal box at the
compressor casing.

Work Sequence 1 – Removing the Insert

Starting Condition Silencer [500.32]/intake casing [500.33] disassembled.

Work Steps 1. Disconnect the cable of the speed transmitter (562.040) in the ter-
minal box (562.083), open cable socket (546.049) and pull the
cable to the inside (see Fig. 16 ).
2. Loosen two undercut bolts (546.073) from the compressor casing
(546.000) and replace them with guide bars (596.045).
3. Loosen the other undercut bolts and remove insert with lifting tackle.
For this, fasten insert to shackle (596.046) and attach lifting tackle
TCA 88 AK 500.41.fm

(see Fig. 15 ).
4. Carefully place insert onto wooden supports and remove balance
ring (540.030).

6673 C2 500.41–02 E 06.05 TCA88 140

 Work Sequence 2 – Installation of Insert and Balance Ring

Starting Condition Compressor wheel [500.43] installed.

Speed transmitter (562.040) assembled in insert (540.001) (see Work
Sequence 4).

Note!
Mount O-ring seals (540.015) only for version with JET ASSIST!

1. Apply machine oil to O-ring seals and mount into the ring grooves
of the insert (540.001).

Important!
O-ring seals must be tensed all around the circumference and
may not be twisted upon mounting.

2. Screw two assembly rods (596.045) (every second mounting

thread, starting from the top center) into the compressor casing
(546.000).
3. Place on balance ring (540.030).
4. Fasten insert to lifting tackle at upper mounting hole of lifting
tackle using shackle (596.046) (observe installation position of
speed transmitter).
5. Lift insert, place on compressor casing and carefully slide over the
compressor wheel (520.044).
6. Fasten insert with 2 undercut bolts (546.073) and disassemble
mounting rods.
7. Mount all undercut bolts and tighten with specified tightening
torque.
8. Measure radial gap between compressor wheel/insert with feeler
gauge and record (see Chapter 3.2).

Important!
If a new insert and/or compressor wheel is installed [500.32],
measure and check the axial gap of the insert/compressor wheel
(see Chapter 3.2 - Gaps and Clearance).

9. Guide the cable of the speed transmitter (562.040) through the

cable socket (546.049) and seal disk (546.050) in the compressor
casing and tighten the cable socket.
10. Connect the cable of the speed transmitter in the terminal box
(562.083).

Important!
Lubricate contact surfaces and threads (e. g. Molykote HSC)!
xx

Important!
Observe tightening torques upon installation!
TCA 88 AK 500.41.fm

Undercut bolt (546.073) for insert: 210 Nm

6673 C2 500.41–02 E 06.05 TCA88 141

Work Sequence 3 – Disassembling the Speed Transmitter

Starting Condition Insert (540.001) is removed and placed on a firm support.

1. Open cable socket (540.025) and pull the cable end of the speed
transmitter (562.040) to the inside.
2. Unscrew the speed transmitter from the insert.

Work Sequence 4 – Installing the Speed Transmitter

X Y
562.077 562.040
Y
562.003
562.086 540.001
0...0,1 mm

562.087 562.040
540.025
540.026
546.073

546.000
546.049 562.083
P 562.019
X P
546.050
562.086
562.020
SI 562.100 SI 562.100
562.083 ST 562.200 SI 562.310
562.086
X
A B

540.001 Insert 562.020 Lock washer

540.025 Cable socket 562.040 Speed transmitter
540.026 Seal disk 562.077 Sealing material
546.000 Compressor casing 562.083 Terminal box
546.049 Cable socket 562.086 Cable socket
546.050 Seal disk 562.087 Seal disk
546.073 Undercut bolt 562.100 Speed indicator, analog
562.003 Loctite 222 562.200 Frequency-current converter
562.019 Cylindrical screw 562.310 Speed indicator, digital

A,B Variants for speed indicators (compare Fig. 18 )

Fig. 16. Overview, speed-measuring equipment

Starting Condition Insert (540.001) is removed and placed on a firm support.

Work Steps 1. Degrease the bolt hole and the locating face in the insert (e. g.
with Loctite Cleaner 7061).
2. Apply Loctite 222 (562.003) to the thread of the speed transmitter
(562.040) and screw in to the insert until flush.
Turn the speed transmitter back sofar until a gap dimension of
0.1 mm to the surface area of the insert is adjusted (check with
TCA 88 AK 500.41.fm

steel or straight-edge - see Fig. 16 ).

6673 C2 500.41–02 E 06.05 TCA88 142

 3. Secure speed transmitter with lock nut.

540.001

562.040

540.001 Insert 562.040 Speed transmitter

Fig. 17. Installing speed transmitter

4. Guide cable through cable socket (540.025) and seal disk

(540.026) at insert to the outside and tighten cable socket.
5. Assemble insert (see work sequence 2).
6. Guide cable through cable socket (546.049) and seal disk
(546.050) in compressor casing (546.000) and tighten cable
socket.
7. Connect cable of the speed transmitter in the terminal box
(562.083) according to the wiring diagram (see work sequence 5).
TCA 88 AK 500.41.fm

6673 C2 500.41–02 E 06.05 TCA88 143

 Work Sequence 5 – Connection Assignment of the Speed Measuring Equipment

562.040 562.040

bl = GND bl = GND
ye = TTL ye = TTL
re = 12 V DC re = 12 V DC

562.083 562.083

A B
3 x 0,75 mm 2
3 x 0,75 mm2
ISO
ISO

Rel-COM
562.200

Rel-NO
24 V DC 562.310
+-

12 11 10 9
12 2 1 3 8 10 13 14 15 22 16
1 2 3 7 8
2 x 0,75 mm2
2 x 0,75 mm 2 ISO (4...20 mA)
+ - ISO (4...20 mA)
24 V DC
+ -
+ -
562.100
562.100

562.040 Speed transmitter 562.200 Frequency-current converter

562.083 Terminal box 562.310 Digital speed indicator
562.100 Analog speed indicator
Fig. 18. Cable connection of speed measuring equipment (bl=black, ye=yellow, re=red)

Connection Designation
A Frequency-current converter (562.200)

Option: Additional analog speed indicator (562.100)

and/or transmission of measured values.
B Digital speed indicator (562.310)

Option: Additional analog speed indicator (562.100)

and/or transmission of measured values.
TCA 88 AK 500.41.fm

6673 C2 500.41–02 E 06.05 TCA88 144

 Work Card
Assembly and Maintenance - Compressor Side
Compressor Casing and Diffuser 500.42

Short Version

Disassembling the compressor casing in order to check the diffuser.

Required Personnel and Time

Amount Qualification Required Time/h

1 Qualified mechanic 2.0
1 Assistant 2.0

Required Tools/Appliances

Amount Designation Number Status

1 Open-jaw wrench 36 – Inventory
1 Open-jaw wrench 19 – Inventory
1 Torque wrench – Inventory
1 Screwdriver – Inventory
- Lifting tackle with ropes, chains – Inventory
- Wood (for placing underneath) – Inventory
2 Wood blocks – Inventory
2 Eye bolts M30 x 2 596.058 Standard
2 Eye bolt M12 596.180 Standard
3 Jack bolts M20 x 70 596.280 Standard

Spare Parts

Amount Designation Number

1 O-ring seal 517.063

Corresponding Work Cards

Work Card Work Card Work Card

TCA 88 AK 500.42.fm

500.32 500.33 500.34

500.41 500.53

6673 C2 500.42–01 E 06.05 TCA88 145

Technical Data

Designation Specification
Compressor casing (single outlet) 2250 kg
Compressor casing (double outlet) 2500 kg
Diffuser 165 kg

WARNING
Danger of injury from suspended loads!
A rocking compressor casing is difficult to maneuver and can
therefore seriously injure people and damage material (i.e. the
compressor wheel)!
 Use tackle line/chains to guide the silencer.
 For attachment of the lifting equipment, use only the lifting eye
bolts intended for this purpose, as described under „Required
Tools/Appliances“.
xx

Work Sequence 1 – Compressor Casing Removal

Starting Condition Emergency and post-lubrication system [500.34], silencer [500.32] or

air intake casing [500.33] as well as insert with speed transmitter
[500.41] removed.

Important!
The insert must be disassembled before removal of the
compressor casing.

Work Steps 1. Depending on the position of the compressor casing, fasten 1 or 2 lift-
ing eye bolts (596.058) to the compressor casing (546.000) and insert
the wire rope of the lifting tackle. Make sure that the rope is tensioned.
2. Loosen the hexagon nuts (546.104) alongside the circumference.
3. Screw in three forcing-off bolts and evenly loosen the compressor
casing.
4. Move the compressor casing away in axial direction, and place it
on a wooden support.
TCA 88 AK 500.42.fm

6673 C2 500.42–01 E 06.05 TCA88 146

 Important!
Secure the compressor casing against rolling off.

546.058

506.099
506.104

546.000

546.000 Compressor casing 546.104 Hexagon nut

506.099 Undercut bolt 596.058 Eye bolt
Fig. 19. Assembly of a single-stage compressor casing to the turbocharger

Work Sequence 2 – Diffuser Removal

Starting Condition Compressor casing (546.000) disassembled and positioned on a

wooden support (e. g. two wood blocks) while properly secured against
rolling off.

Work Steps 1. Fasten lifting eye bolt (596.180) to diffuser and attach lifting tackle.
2. Loosen the hexagon bolt (546.045) that fastens the diffuser in the
compressor casing.
3. Remove diffuser (542.001) in axial direction.

596.180

546.045

546.000

542.001

542.001 Diffuser 546.045 Hexagon bolt

TCA 88 AK 500.42.fm

546.000 Compressor casing 596.180 Eye bolt

Fig. 20. Removing the diffuser from the compressor casing

6673 C2 500.42–01 E 06.05 TCA88 147

Work Sequence 3 – Compressor Casing Installation

Starting Condition Compressor wheel [500.43] mounted on turbine rotor [500.53].

Important!
The insert [500.41] must not be mounted for assembly of the
compressor casing, otherwise the compressor wheel may
become damaged upon assembly of the compressor casing.

Work Steps 1. With the lifting eye bolt (596.180), hang the diffuser (542.001) to
the lifting tackle.
2. Mount the diffuser to the compressor casing (546.000) with the
hexagon bolt (546.045). Use the lock washer pair (546.046) for
this.
3. Dependent on the position of the compressor casing (546.000),
fasten 1 or 2 lifting eye bolts (596.058) to the compressor casing.
4. Insert the rope of the lifting tackle. Ensure that the rope is ten-
sioned.
5. Control and insert O-ring seal (517.063) between compressor
casing and bearing casing.

Important!
Oil O-ring seal lightly!

6. Guide the compressor casing axially to the turbocharger, slide

onto the undercut bolts (506.099) and tighten hexagon nuts
(546.104) with the specified tightening torque.

Important!
Do not damage the compressor wheel with the compressor
casing.

Important!
Lubricate contact surfaces and threads (e. g. Molykote HSC)!
xx

Important!
Observe tightening torques upon installation!

Hexagon bolt diffuser (546.045): 60 Nm

Hexagon nut compressor casing (506.104): 450 Nm
TCA 88 AK 500.42.fm

6673 C2 500.42–01 E 06.05 TCA88 148

 Work Card
Assembly and Maintenance - Compressor Side
Compressor Wheel 500.43

Short Version

Removal of the compressor wheel for checking of the bearings and the
bearing bushes.

Required Personnel and Time

Amount Qualification Required Time/h

1 Qualified mechanic 2.0
1 Assistant 2.0

Required Tools/Appliances

Amount Designation Number Status

1 Open-jaw wrench 55 – Inventory
1 Torque wrench 8-70 Nm 596.100 Standard
1 Socket wrench insert 8x10 596.101 Standard
– Wood (for placing underneath) – Inventory
1 Dismantling/assembly 596.510 Standard
compressor wheel
1 Puller ring 596.001 Standard
1 Assembly ring 596.002 Standard
1 Forcing-off bolt 596.003 Standard
4 Threaded rod 596.004 Standard
4 Hexagon nut 596.005 Standard
1 Turn pin A12 596.071 Standard
1 Sleeve 596.167 Standard
1 Suspension device for 596.522 Standard
compressor wheel
1 Turn pin A12 596.071 Standard
1 Pipe 596.160 Standard
1 Sleeve 596.167 Standard
1 Hexagon bolt 596.168 Standard
1 Support 596.170 Standard
1 Hexagon bolt 596.197 Standard
1 Hexagon nut 596.198 Standard
1 Shackle 596.208 Standard
1 Lever carrier 596.267 Standard
1 Pipe 596.270 Standard
TCA 88 AK 500.43.fm

1 Slide 596.271 Standard

1 Cylindrical screw M16 x 40 596.272 Standard
1 Bolt 596.273 Standard
3 Cylindrical screw M16 x 55 596.274 Standard

6673 C2 500.43–01 E 06.05 TCA88 149

Spare Parts

Amount Designation Number

– Superbolt lubricant –
– Molykote P40 –

Corresponding Work Cards

Work Card Work Card Work Card

500.32 500.33 500.41
500.44 500.53

Technical Data

Designation Specification
Compressor wheel 200 kg
Suspension device compressor wheel 40 kg

520.066
520.067 520.035

520.044 520.028

520.068 520.001

520.001 Turbine rotor 520.066 Undercut bolt

520.028 Thrust ring 520.067 Spinner
520.035 Labyrinth ring 520.068 Tension nut
520.044 Compressor wheel
Fig. 21. Assembly and disassembly of the compressor wheel
TCA 88 AK 500.43.fm

6673 C2 500.43–01 E 06.05 TCA88 150

 Work Sequence 1 – Removing the Compressor Wheel

General For disassembly of the compressor wheel, use the puller ring (596.001)
and the suspension device (596.522).

Starting Condition Silencer [500.52]/air intake casing [500.33] as well as insert with
speed transmitter [500.41] removed.

520.044

520.067

520.044 Compressor wheel 520.067 Spinner

Fig. 22. Compressor wheel and compressor casing

Note!
The compressor wheel can also be removed without disassembly of
the compressor casing (see Fig. 22 ).

Work Steps 1. Unscrew (520.067) spinner.

Important!
The thrust screws of the tension nut must be loosened step by
step!
Do not fully loosen single screws under any circumstances.

2. Release all thrust screws, one after the other, approx. 1/4 turn
(one time through) in circular order beginning with the top thrust
screw (see Fig. 30 ).
3. Repeat the procedure (1/4 turn per screw, one time through) until
the pressure on the thrust screws is completely released.
4. The tension nut (520.068) can now be loosened by hand.
5. Completely unscrew the tension nut and pressure disk (Fig. 28 /1)
from the turbine rotor.
TCA 88 AK 500.43.fm

6673 C2 500.43–01 E 06.05 TCA88 151

 520.044
W
596.167

596.001

596.001

596.004

596.005

520.044 Compressor wheel 596.004 Threaded rod

596.001 Puller ring 596.005 Hexagon nut
596.003 Forcing-off bolt 596.167 Sleeve
W Balancing mark
Fig. 23. Pulling off the compressor wheel with disassembling device (596.510)

6. Mount the sleeve (596.167) and assembling/disassembling

device (596.510) to the turbine rotor (520.001), and mount the
compressor wheel (520.044).

7. Release the compressor wheel with the puller (see Fig. 23 ).

8. Dismount the assembling/disassembling device (see Fig. 24 ); the

sleeve remains assembled to the turbine rotor.

520.001 596.167

596.001
596.003

520.044
596.004 (4x)

596.005 (4x)
520.001 Turbine rotor 596.004 Threaded rod
520.044 Compressor wheel 596.005 Hexagon nut
596.001 Puller ring 596.167 Sleeve
596.003 Forcing-off bolt
TCA 88 AK 500.43.fm

Fig. 24. Pulling off the compressor wheel with disassembling device
(596.510)

6673 C2 500.43–01 E 06.05 TCA88 152

 9. Fix the slide (596.271) of the suspension device (596.522) (see
Fig. 26 ) with cylindrical screw (596.272) to the compressor wheel.

10. Fasten the lever carrier (596.267) with 3 additional cylindrical

screws (596.274) to the slide and compressor wheel and insert the
pipe (596.270).

11. Attach suspension device to crane.

12. Fasten suspension device to sleeve (596.167) using bolt

(596.273) and lightly tension the rope of the lifting tackle.

13. Pull off compressor wheel.

14. Fully slide the compressor wheel onto the pipe (596.160) of the
suspension device and secure with the turn pin (596.071).

15. Remove bolt (596.273) from the sleeve (596.167).

16. Carefully place down compressor-wheel lifting tackle onto

wooden support; remove suspension device.

Work Sequence 2 – Installing the Compressor Wheel

General For assembly of the compressor wheel, use the assembly ring
(596.002) and the suspension device (596.522).

Starting Condition Silencer [500.32]/intake casing [500.33] as well as insert with speed
transmitter [500.41] removed.
Turbine rotor [500.53] and labyrinth disk [500.44] mounted.

520.089

520.001

596.167

517.089 Labyrinth disk 596.167 Sleeve

520.001 Turbine rotor
Fig. 25. Starting condition before assembly of the compressor wheel

Work Steps 1. Fix the slide (596.271) of the suspension device (596.522) with
cylindrical screw (596.272) to the compressor wheel (520.044) (see
Fig. 26 ).
2. Fasten the lever carrier (596.267) with 3 additional cylindrical
TCA 88 AK 500.43.fm

screws (596.274) to the slide and compressor wheel and insert the
pipe (596.270).

6673 C2 500.43–01 E 06.05 TCA88 153

 Important!
Mark the balancing mark “O” of the compressor wheel on the
slide of the suspension device, as the slide would cover the mark
on the compressor wheel after assembling (see Fig. 23 ).

3. Screw sleeve (596.167) onto undercut bolt (520.066) of the tur-

bine rotor (520.001) (see Fig. 26 ).
4. After cleaning, apply a thin coat of special lubricant (e. g. Molykote
P40) to the compressor wheel/turbine shaft seats in order to pro-
tect against fretting (see Fig. 25 ).

596.208

596.170

596.168
596.160
520.044
596.270
596.273
596.197, 596.198
596.071
596.267
596.167
520.044 596.272 596.197 520.001
596.271

520.001 Turbine rotor 596.198 Hexagon nut

520.044 Compressor wheel 596.208 Shackle
596.071 Turn pin 596.267 Lever carrier
596.160 Pipe 596.270 Pipe
596.167 Sleeve 596.271 Slide
596.168 Hexagon bolt 596.272 Cylindrical screw
596.170 Support 596.273 Bolt
596.197 Hexagon bolt 596.274 Cylindrical screw
Fig. 26. Suspension device (596.522) for compressor wheel
5. Slide the pipe (596.160) of the suspension device through the
slide (596.271) at the compressor wheel and secure the compres-
sor wheel with the turn pin (596.071) (see Fig. 26 ).

Important!
Lubricate the suspension tube with machinery oil so that the
compressor wheel can glide.

6. Fasten lifting tackle to suspension device with the shackle

(596.208) and lift the compressor wheel.

Important!
The compressor wheel on the suspension tube can now be
brought into a level position by adjusting the hexagon bolt
(596.168) (see Fig. 26 ).

7. Fasten suspension device to the sleeve (596.167) on the turbine

TCA 88 AK 500.43.fm

rotor, and fasten the pipe of the suspension device to the sleeve
using a bolt (596.273).
8. Pull out the turn pin (596.071).

6673 C2 500.43–01 E 06.05 TCA88 154

 Important!
Rotate the compressor wheel on the suspension tube in such a
manner that the balancing marks of the slide (596.271) and the
turbine rotor match.

9. Slide the compressor wheel onto the rotor shaft.

10. Remove the suspension device from the sleeve.
11. Remove the pressure disk (1) from the tension nut (520.068) and
attach onto assembly ring (596.002).

520.068 596.002
2 1

1 Pressure disk 520.068 Tension nut

2 Thrust screw 596.002 Assembly ring

Fig. 27. Pressure disk on tension nut and assembly ring

12. Screw assembly ring (596.002) onto the undercut bolt (520.066)
of the turbine rotor and tighten with tommy bar (596.071) until
compressor wheel is flush.

Important!
In the area of the compressor outlet, the hub collar of the
compressor wheel must be flush with the bearing casing.

13. Dismount assembly ring and pressure disk (1).

Work Sequence 3 – Fastening the Compressor Wheel

General The thrust screws of the clamping nut are delivered readily lubricated;
otherwise, lubricate with Superbolt lubricant.

Starting Condition Compressor wheel slid onto the rotor shaft (compare with work se-
quence 2).

Work Steps 1. Clean and lubricate the main thread and the contact surfaces of
the clamping nut (520.068) and thrust screws (2).

Important!
The thrust screws (2) are fully screwed back.

2. Attach pressure disk (1) to tension nut (520.068) (see Fig. 28 ).

TCA 88 AK 500.43.fm

6673 C2 500.43–01 E 06.05 TCA88 155

 520.068

1
2

1 Pressure disk 520.068 Tension nut

2 Thrust screw

Fig. 28. Attach pressure disk to tension nut

Note!
Markings on pressure disks that have already been in operation are
normal and do not inevitably require the pressure disk to be replaced.
The pressure disk can be used for up to 10 tensioning procedures.

Fig. 29. Pressure disk (1)

3. Screw the clamping nut and pressure disk onto the undercut bolt
(520.066) of the turbine rotor by hand and then screw it back 1/4
turn (see Fig. 30 ).
4. Screw in 4 thrust screws all the way and then tighten over cross
with half of the tightening torque (approx. 32 Nm).
Then tighten with the full tightening torque (63 Nm).
5. Tighten all 8 thrust screws in circular direction with the full tighten-
ing torque.
6. Repeat the tightening in circular direction until the thrust screws
are tightened (approx. 2-3 times over).
TCA 88 AK 500.43.fm

6673 C2 500.43–01 E 06.05 TCA88 156

 520.044
1

520.068
1

520.066
2

520.044 Compressor wheel 1 Pressure disk

520.066 Undercut bolt 2 Thrust screw
520.068 Tension nut
Fig. 30. Compressor wheel with mounted tension nut
7. Fasten spinner (520.067) (see Fig. 22 ).

Important!
Observe tightening torques upon installation!

Thrust screw (tension nut): 63 Nm

TCA 88 AK 500.43.fm

6673 C2 500.43–01 E 06.05 TCA88 157

 TCA 88 AK 500.43.fm

6673 C2 500.43–01 E 06.05 TCA88 158

 Work Card
Assembly and Maintenance - Compressor Side
Labyrinth Disk 500.44

Short Version

Removing and installing the labyrinth disk in order to assemble/disas-

semble additional assemblies.

Required Personnel and Time

Amount Qualification Required Time/h

1 Qualified mechanic 1.0

Required Tools/Appliances

Amount Designation Number Status

1 Spanner 24 – Inventory
1 Torque wrench – Inventory
1 Lifting tackle, ropes – Inventory
3 Forcing-off bolt M12 596.041 Standard
1 Suspension device for labyrinth 596.521 Standard
disk
3 Guide bar 596.044 Standard
2 Eye bolt 596.180 Standard

Spare Parts

Amount Designation Number

1 O-ring seal 517.085
8 Lock washer pair 517.095

Corresponding Work Cards

Work Card Work Card Work Card

500.43 500.45 500.53
TCA 88 AK 500.44.fm

6673 C2 500.44–01 E 06.05 TCA88 159

 Technical Data

Designation Specification
Labyrinth disk 140 kg

Work Sequence 1 – Removal of the Labyrinth Disk

517.001

596.180

596.044

517.089

517.001 Bearing casing 596.044 Guide bar

517.089 Labyrinth disk 596.180 Eye bolt
Fig. 31. Removing and refitting the labyrinth disk with disassembled compressor casing

Note!
The labyrinth disk can also be removed and refitted without
disassembly of the compressor casing.

Starting Condition Compressor wheel [500.43] removed.

Work Steps 1. Remove two hexagon bolts fastening the labyrinth disk (517.089)
and substitute them with three guide bars (596.044).

Note!
Unscrew the second hexagon bolt each from the center/top.

2. Release the hexagon bolts around the circumference of the labyrinth

disk.
3. Loosen the labyrinth disk from the bearing casing using the forc-
ing-off bolts (596.041).
4. Screw the eye bolt (596.180) to the labyrinth disk.
5. Screw shackle/hook to the suspension device (596.521) of the
TCA 88 AK 500.44.fm

labyrinth disk and tension the rope/chain of the lifting tackle.

6. Move the labyrinth disk away from the turbocharger using the lifting
tackle.

6673 C2 500.44–01 E 06.05 TCA88 160

 7. Dismantle the guide bars.
8. Check for marks of wear on the labyrinth disk and on the sealing
cover (517.197) assembled to the labyrinth disk.
Check the O-ring seal (517.085).

Note!
Slight grooves in the bore of the sealing cover, which have developed
through the tips of the labyrinth ring, increase the sealing effect and are
no reason for replacing the part.
xx

Installation of the Labyrinth disk

Starting Condition Labyrinth disk mounted on turbine rotor [500.45].

Work Steps 1. Insert three guide bars (596.044) (second mounting thread each
from center/top) in the bearing casing (517.001).
2. Screw eye bolt (596.180) into labyrinth disk (517.089).
3. Fasten lifting tackle to suspension device (596.521) with shackle
(596.208) or hook.
4. Insert new O-ring seal (517.085) into labyrinth disk if required.

Important!
Apply machinery oil for assembly of the O-ring seal.

5. Slide labyrinth disk in front of bearing body and fasten with

8 hexagon bolts (517.093) and lock washer pairs (517.095).

Important!
Ensure correct installation position of the labyrinth disk: Sealing
air grooves located sidewards!

6. Unscrew eye bolt from labyrinth disk.

7. Disassemble guide bars.
8. Screw in the rest of the hexagon bolts (517.093) and lock washer
pairs (517.095), and tighten all 8 hexagon bolts with the specified
tightening torque.

Important!
Lubricate/oil contact surfaces, threads and sealing rings (e. g.
with Molykote HSC).

Important!
Observe tightening torques upon installation!

Hexagon bolt (517.093): 140 Nm

TCA 88 AK 500.44.fm

6673 C2 500.44–01 E 06.05 TCA88 161

 TCA 88 AK 500.44.fm

6673 C2 500.44–01 E 06.05 TCA88 162

 Work Card
Assembly and Maintenance - Compressor Side
Ring Nut and Labyrinth Ring 500.45

Short Version

Installing and removing the labyrinth ring from the rotor in order to as-
semble/disassemble further parts.

Required Personnel and Time

Amount Qualification Required Time/h

1 Qualified mechanic 1.0

Required Tools/Appliances

Amount Designation Number Status

1 Fitting/unfitting tool 596.513 Standard
1 Spanner for ring nut 596.065 Standard
2 Threaded rod 596.070 Standard
2 Hexagon nut 596.072 Standard
1 Puller ring 596.073 Standard
1 Plastic hammer – Inventory
– Molykote P40 – Inventory

Corresponding Work Cards

Work Card Work Card Work Card

500.43 500.44 500.46
500.53
TCA 88 AK 500.45.fm

6673 C2 500.45–01 E 06.05 TCA88 163

 596.072

596.070

596.073
520.035
517.075
520.028 520.001
520.066

517.153

520.038
D 517.075
520.028 520.001
520.035

520.066

517.153

517.075 Bearing disk 520.038 Ring nut

517.153 Thrust bearing 520.066 Undercut bolt
520.001 Turbine rotor 596.070 Threaded rod
TCA 88 AK 500.45.fm

520.028 Thrust ring 596.072 Hexagon nut

520.035 Labyrinth ring 596.073 Puller ring
Fig. 32. Assembly/disassembly of the labyrinth ring

6673 C2 500.45–01 E 06.05 TCA88 164

 Work Sequence 1 – Removal of the Labyrinth Ring

596.065

596.065 Spanner for ring nut

Fig. 33.

Starting Condition Compressor wheel [500.43] and labyrinth disk [500.44] removed.

Work Steps 1. Loosen ring nut (520.038) with mounting wrench (596.065).
2. Fully screw puller ring (596.073) onto undercut bolt (520.066) of
the turbine rotor (520.001).
3. Insert two threaded rods (596.070) through the holes in the puller
ring and screw them into the labyrinth ring (520.035). Mount nuts
(596.072) to the threaded rods.
4. Pull the labyrinth ring from the turbine rotor by alternately tighten-
ing the nuts of the puller ring.

Replace the labyrinth ring when the labyrinth tips are damaged or worn:

D ≤ 185.4 mm

Work Sequence 2 – Assembly of the Labyrinth Ring

Starting Condition Thrust ring (520.028), bearing disk (517.075) and thrust bearing
(517.153) are mounted on the turbine rotor (520.001) [500.46].

Work Steps 1. Lubricate the seat of the labyrinth ring (520.035) on the turbine
rotor with Molykote P40.
2. Slide labyrinth ring in front of thrust bearing onto the turbine rotor.
3. Secure labyrinth ring with ring nut (520.038). Tighten ring nut with
mounting wrench (596.065) (slight hammer blow).
TCA 88 AK 500.45.fm

6673 C2 500.45–01 E 06.05 TCA88 165

 TCA 88 AK 500.45.fm

6673 C2 500.45–01 E 06.05 TCA88 166

 K

Work Card
Assembly and Maintenance - Compressor Side
Thrust Bearing, Counter-Thrust Bearing 500.46
and Bearing Disk
Short Version

Carry out tasks regularly according to the maintenance plan and check
condition/degree of wear of the parts.
Removal of the bearings for inspection purposes or replacement.

Required Personnel and Time

Amount Qualification Required Time/h

1 Qualified mechanic 2.0

Required Tools/Appliances

Amount Designation Number Status

1 Spanner 17 – Inventory
1 Spanner 19 – Inventory
1 Spanner 24 – Inventory
1 Rubber hammer – Inventory
1 Punch wood – Inventory
1 Removing tool thrust bearing 596.524 Standard
1 Extension shaft 596.040 Standard
3 Forcing-off bolts 596.041 Standard
1 Protecting sleeve 596.075 Standard
1 Removing tool thrust ring 596.514 Standard
1 Assembly ring 596.086 Standard
3 Hexagon bolt 596.087 Standard

Spare Parts

Amount Designation Number

1 Bearing disk 517.075
6 Lock washer pair for thrust bearing 517.095
1 Counter-thrust bearing 517.154
6 Lock washer pair for counter-thrust bearing 517.156

Corresponding Work Cards

TCA 88 AK 500.46.fm

Work Card Work Card Work Card

500.43 500.44 500.45
500.53 500.55 500.56

6673 C2 500.46–01 E 06.05 TCA88 167

 517.157
517.153 517.156
517.075

520.028
517.154

517.095
520.066
517.102 517.162

520.001

517.100
596.040

596.075

517.075 Bearing disk 517.157 Hexagon bolt

517.095 Lock washer pair 517.162 Bearing body
517.100 Stud 520.001 Turbine rotor
517.102 Lock nut 520.028 Thrust ring
517.153 Thrust bearing 520.066 Undercut bolt
517.154 Counter-thrust bearing 596.040 Extension shaft
517.156 Lock washer pair 596.075 Protecting sleeve
Fig. 34. Assembly/disassembly of counter-thrust bearing, thrust ring, bearing disk and thrust bearing

Work Sequence 1 – Removal of Thrust Bearing, Bearing Disk and Counter-thrust Bearing

Starting Condition Compressor wheel [500.43], labyrinth disk [500.44] and labyrinth ring
[500.45] removed.
Work Steps 1. Mount protecting sleeve (596.075) with extension shaft (596.040)
onto undercut bolt (520.066) of the turbine rotor (520.001).
2. Loosen 8 hexagon nuts (517.102) of the thrust bearing (517.153).
3. Press off thrust bearing from the bearing body (517.162) with the
three forcing-off bolts (596.041) and remove.
4. Unscrew protecting sleeve.
5. Remove bearing disk (517.075) from the thrust ring (520.028) and
check it (see work sequence 2).
6. Screw the assembly ring (596.086) of the removing tool (596.514)
onto the external thread of the thrust ring (520.028) and loosen
the thrust ring with three forcing-off bolts (596.087).
7. Remove thrust ring.
8. Unscrew hexagon bolts (517.157) and remove counter-thrust
bearing (517.154) from the bearing body (517.162).
9. Check counter-thrust bearing (see Work Sequence 3).
TCA 88 AK 500.46.fm

Note!
Removal and inspection of the bearing bushes, see [500.56].

6673 C2 500.46–01 E 06.05 TCA88 168

 Work Sequence 2 – Inspection of the Bearing Disk

517.075 517.075
l
l
(b) (b)

(a) (a)

(v)
(v)

a Taper face b Wing v Edge 517.075 Bearing disk

Fig. 35. Bearing disk in new condition (left) and with clear traces of wear (right)

Starting Condition Bearing disk (517.075) removed (see work sequence 1).

Work Steps The length (l) of the taper faces (a) is measured for evaluation of the
degree of wear. The length (l) begins at the edge of the oil groove and
ends at the edge (v) of the wearing surfaces (b).

Important!
Depending on the incidence of light, a dark band can be seen in
front of the edge (v) on the taper face (a). This is also to be
included in the length measurement (l).

The bering disk can be reused again when one of the lengths (l) is not
below the following value:

l = 15 mm.
TCA 88 AK 500.46.fm

6673 C2 500.46–01 E 06.05 TCA88 169

 Work Sequence 3 – Checking the Counter-thrust Bearing

517.154 517.154

l
l

(b) (b)
(v)
(v)
(a) (a)

a Taper face b Wing v Edge 517.154 Counter-thrust bearing

Fig. 36. Counter-thrust bearing in new condition (left), and with clear traces of wear (right)

Starting Condition Counter-thrust bearing (517.154) removed (see work sequence 1).

Work Steps The length (l) of the taper faces (a) is measured for evaluation of the
degree of wear. The length (l) ends at the edge (v) of the wearing sur-
faces (b).

Important!
Depending on the incidence of light, a dark band can be seen in
front of the edge (v) on the taper face (a). This is also to be
included in the length measurement (l).

Replace counter-thrust bearing in case one of the lengths (l) is below

the following value:

l ≤ 7 mm
TCA 88 AK 500.46.fm

6673 C2 500.46–01 E 06.05 TCA88 170

 Work Sequence 4 – Installation of Thrust Bearing, Bearing disk and Counter-thrust Bearing

Starting Condition Bearing bushes [500.56] and turbine rotor [500.53] mounted.
The protecting sleeve (596.075) is not mounted.

Work Steps 1. Mount the counter-thrust bearing (517.154).

2. Slide the thrust ring (520.028) onto the shaft, in front of the
counter-thrust bearing.

Important!
Apply Molykote P40 to the bearing location for the thrust ring on
the turbine rotor (protection against fretting).

3. Apply machinery oil to both sides of the bearing disk (517.075)

and place bearing disk on thrust ring.
4. Screw protecting sleeve with extension shaft (596.040) onto
undercut bolt.

Important!
Check if the studs (517.068) are completely screwed into the end
cover (517.064) (see work card [500.55]) and do not project out of
the bearing body (517.162)!

5. Slide thrust bearing (517.153) onto stud screws until these can be
fully seen, and the thrust bearing completely faces against the
bearing body (517.162).

Important!
Do not misalign the thrust bearing upon assembly.

6. Secure the thrust bearing with lock nuts (517.102) and lock
washer pairs (517.095).

Important!
Lubricate contact surfaces and threads (e. g. Molykote HSC)!
xx

Important!
Observe tightening torques upon installation!

Lock nut thrust bearing (517.102): 140 Nm

Hexagon bolt counter-thrust bearing (517.157): 34 Nm
TCA 88 AK 500.46.fm

6673 C2 500.46–01 E 06.05 TCA88 171

 TCA 88 AK 500.46.fm

6673 C2 500.46–01 E 06.05 TCA88 172

 Work Cards

Assembly and Maintenance - Turbine Side 4.5

TCA 88 Cover T-Side (C2).fm

6673 C2 4.5–01 E 06.05 TCA88 173

 TCA 88 Cover T-Side (C2).fm

6673 C2 4.5–01 E 06.05 TCA88 174

 Work Card
Assembly and Maintenance - Turbine Side
Gas-admission Casing 500.51

Short Version

Removal of the casing for inspection of replacement of the turbine noz-

zle ring or for disassembly of parts inside.

Required Personnel and Time

Amount Qualification Required Time/h

1 Qualified mechanic 2.0
1 Assistant 2.0

Required Tools/Appliances

Amount Designation Number Status

1 Open-jaw wrench 30 – Inventory
1 Torque wrench – Inventory
– Lifting tackle, ropes, winches – Inventory
– Wood (for placing underneath) – Inventory
1 Suspension device 596.520 Standard
1 Shackle A1.6 596.046 Standard
1 Suspension plate 596.055 Standard
1 Eye bolt 596.058 Standard

Spare Parts

Amount Designation Number

20 Lock washer pair 506.107

Technical Data

Designation Specification
Gas-admission casing (axial) 650 kg
TCA 88 AK 500.51.fm

6673 C2 500.51–01 E 06.05 TCA88 175

 WARNING
Danger of injury from suspended loads!
The gas-admission casing must not rock, or else it could fall
down and seriously injure people and cause damage to material.
 Use tackle line/chains to guide the gas-admission casing.
 For attachment of the lifting equipment, use only the suspension
device intended for this purpose as described under “Required
Tools/Appliances”.
 Move the crane slowly.

501.001
596.186
596.046

596.055

506.106
596.058
506.106

501.001 Gas-admission casing 596.055 Suspension plate

506.106 Hexagon bolt 596.058 Eye bolt
596.046 Shackle
Fig. 37. Mounting of the gas-admission casing

Work Sequence 1 – Removal of the Gas-admission Casing

Starting Condition Connection and exhaust gas lines are disconnected.

Note!
Main dimensions/disassembly measures, see Fig. 5 in Section C1,
Chapter 3.1.

Work Steps 1. Remove coverings (if available).

2. Unscrew two hexagon bolts (506.106) from gas-admission casing
(501.001) (see Fig 37 ).
3. Fasten suspension plate (596.055) with a hexagon bolt to the gas-
TCA 88 AK 500.51.fm

admission casing.

6673 C2 500.51–01 E 06.05 TCA88 176

 Important!
Both bolts of the suspension plate must be inserted into the
fastening holes of the gas-admission casing.

4. Hang the gas-admission casing to the lifting device, and tension

rope.
5. Remove all hexagon bolts (506.106) along the outer circumfer-
ence.

Note!
Mark bolt holes on the casing that are not occupied – these must be
kept free when assembling the gas-admission casing.

6. Move the casing away from the gas outlet casing (506.001) in
axial direction.
7. Carefully place the gas-admission casing onto a wooden support.

Work Sequence 2 – Installation of the Gas-admission Casing

Work Steps Installation is carried out in reverse order of removal.

Important!
Fasten gas-admission casing with twenty hexagon bolts (506.106)
and lock washer pairs (506.107).

Important!
Lubricate contact surfaces and threads (e. g. Molykote HSC)!
xx

Important!
Observe tightening torques upon installation!
xx

Hexagon bolt (506.106): 335 Nm

TCA 88 AK 500.51.fm

6673 C2 500.51–01 E 06.05 TCA88 177

 TCA 88 AK 500.51.fm

6673 C2 500.51–01 E 06.05 TCA88 178

 Work Card
Assembly and Maintenance - Turbine Side
Turbine Nozzle Ring 500.52

Short Version

Removal of the turbine nozzle ring is carried out for inspection purpos-
es in accordance with the maintenance plan.

Required Personnel and Time

Amount Qualification Required Time/h

1 Qualified mechanic 0.5
1 Assistant 0.5

Required Tools/Appliances

Amount Designation Number Status

1 Open-jaw wrench 24 – Inventory
1 Torque wrench – Inventory
– Lifting tackle, ropes – Inventory
1 Fitting/unfitting tool 596.525 Standard
2 Guide bar 596.050 Standard
2 Eye bolt 596.051 Standard

Spare Parts

Amount Designation Number

23 Hexagon bolts 513.013
23 Lock washer pair 513.014

Corresponding Work Cards

Work Card Work Card Work Card

500.51

Technical Data
TCA 88 AK 500.52.fm

Designation Specification
Turbine nozzle ring 99 kg

6673 C2 500.52–01 E 06.05 TCA88 179

 Work Sequence 1 – Nozzle Ring Removal

501.001

513.001
513.010

513.014
513.013 596.050

513.014
513.013

501.001 Gas-admission casing 513.013 Hexagon bolt

513.001 Nozzle ring 513.014 Lock washer pair
513.010 Clamping ring 596.050 Guide bar

Fig. 38. Installation/removal of the turbine nozzle ring (90° gas-admission casing)

Starting Condition Gas-admission casing [500.51] removed and placed on firm support.

Work Steps 1. Loosen outer hexagon bolts (513.013) from gas-admission casing
(501.001). Remove clamping ring (513.010) by hand.
2. Unscrew two hexagon bolts (513.013) on the inside and replace
them with guide bars (596.050). Loosen the other hexagon bolts.
3. Slightly pull off the nozzle ring (513.001).
Position rope around nozzle ring and remove from the gas-admis-
sion casing in axial direction.

Work Sequence 2 – Nozzle Ring Installation

Work Steps Installation is carried out in reverse order of removal.

Important!
Lubricate contact surfaces and threads (e. g. Molykote HSC)!
xx

Important!
Observe tightening torques upon installation!
TCA 88 AK 500.52.fm

Hexagon bolt (513.013): 165 Nm

6673 C2 500.52–01 E 06.05 TCA88 180

 Work Cards
Assembly and Maintenance - Turbine Side
Turbine Rotor 500.53

Short Version

Removal of the turbine rotor for inspection of the bearing bushes and
the bearing points.

Required Personnel and Time

Amount Qualification Required Time/h

1 Qualified mechanic 1.0
1 Assistant 1.0

Required Tools/Appliances

Amount Designation Number Status

2 Open-jaw wrench 19 – Inventory
1 Fitting/unfitting tool 596.515 Standard
1 Protecting sleeve 596.075 Standard
1 Clamping sleeve 596.504 Standard
1 Pipe (Ø ≤ 40mm, length approx. – Inventory
1000 mm)
1 Lifting tackle, ropes – Inventory
– Wood (for placing underneath) – Inventory

Corresponding Work Cards

Work Card Work Card Work Card

500.43 500.44 500.45
500.46 500.51

Technical Data

Designation Specification
Turbine rotor 370 kg
TCA 88 AK 500.53.fm

6673 C2 500.53–01 E 06.05 TCA88 181

 1

1 Turbine blade

Fig. 39. Turbine side: View of gas outlet casing Fig. 40. Compressor side: View of bearing casing

Work Sequence 1 – Removal/Inspection of Turbine Rotor and Labyrinth Ring

Starting Condition Compressor Side Compressor wheel [500.43], labyrinth disk [500.44], labyrinth ring
[500.45], thrust bearing and bearing disk [500.46] removed.
Protecting sleeve (596.075) screwed onto turbine rotor (520.001)
(see Fig. 41 ).

Starting Condition Turbine Side Gas-admission casing [500.51] removed.

Note!
Disassembly measure for rotor, see Fig. 5 Section C1 - Chapter 3.1.

Work Steps 1. Position clamping sleeve (596.504) onto shaft end of turbine disc
and secure with hexagon bolt and nut (see Fig. 41 ).
2. Pull turbine rotor (520.001) as straight as possible out of the bear-
ing casing.
3. Hang turbine rotor with the rope to the lifting tackle as close as
possible to the turbine. Lightly tension rope.
4. Insert a suitable pipe (Ø ≤ 40 mm, length approx. 1000 mm) into
the clamping sleeve (596.504) to guide the rotor upon removal.
5. Carefully pull out the turbine rotor all the way, guiding the crane
along.

Important!
Do not misalign the rotor upon pulling out, otherwise the bearing
of the rotor could be damaged.
TCA 88 AK 500.53.fm

Important!
The inserted pipe can be used to keep the free-hanging rotor in
balance.

6673 C2 500.53–01 E 06.05 TCA88 182

 6. Place down the turbine rotor on wood blocks (in horizontal posi-
tion) or on wooden support (in vertical position).

Important!
Do not set down the rotor on the turbine blades. Do not damage
the bearing locations.

7. Check the turbine rotor (520.001) (visual check):

 Do the blades show traces of thrust?
 Do the bearing locations show traces of scoring?

WARNING
There is a substantial accident risk when operating a
turbocharger with improperly mounted turbine blades!
Incorrect fastening and securing of replaced turbine blades can
lead from loosening of the blades to the total loss of the
turbocharger.
 Have all maintenance work on the turbine blades performed
through MAN B&W service personnel!
 In cases of doubt, definitely ensure to contact MAN B&W.
 When maintaining turbine rotor and turbine blades, these are to
be handled with utmost care.
xx

596.075
520.001

D1 D1

520.001

520.001 Turbine rotor 596.075 Protecting sleeve 596.504 Clamping sleeve

Fig. 41. Check points, rotor shaft

Note!
In order to check the diameters (D1), the turbine rotor must not be
pulled completely out of the bearing body.
TCA 88 AK 500.53.fm

8. Measure and record the bearing points. Replace rotor when falling
short of the diameter measure (D1):
D1 ≤ 113.97 mm.

6673 C2 500.53–01 E 06.05 TCA88 183

 Important!
For checking of the bearing clearance between bearing bush and
turbine shaft, see [500.56] work sequence 3.

9. Measure labyrinth ring. Replace labyrinth ring when falling short

of the diameter measure (D2):
D2 ≤ 161.40 mm.

520.001

520.018
520.021
596.075

D2

520.001 Turbine rotor 520.021 Ring nut

520.018 Labyrinth ring, turbine side 596.075 Protecting
sleeve
Fig. 42. Check points, labyrinth ring

Work Sequence 2 – Turbine Rotor Installation

Starting Condition Condition and accuracy to measure of the bearings [500.56] and the
turbine rotor checked (see work sequence 1).

Work Steps Installation is carried out in reverse order of removal.

TCA 88 AK 500.53.fm

6673 C2 500.53–01 E 06.05 TCA88 184

 Work Cards
Assembly and Maintenance - Turbine Side
Shroud Ring 500.54

Short Version

Check shroud ring for wear; adjust gap to the turbine.

Required Personnel and Time

Amount Qualification Required Time/h

1 Qualified mechanic 1.0
1 Assistant 1.0

Required Tools/Appliances

Amount Designation Number Status

1 Fitting/unfitting tool 596.525 Standard
2 Guide bar 596.050 Standard
2 Eye bolt 596.051 Standard
1 Open-jaw wrench 24 – Inventory
1 Torque wrench – Inventory
1 Feeler gauge – Inventory
– Molykote HSC – –

Spare Parts

Amount Designation Number

12 Hexagon bolt 509.012
12 Lock washer pair 509.014

Corresponding Work Cards

Work Card Work Card Work Card

500.51 500.53

Technical Data
TCA 88 AK 500.54.fm

Designation Specification
Shroud ring 53 kg

6673 C2 500.54–01 E 06.05 TCA88 185

Work Sequence 1 – Shroud Ring Removal

Starting Condition Gas-admission casing [500.51] removed.

509.001

509.008

509.012

509.014

509.001 Diffuser outside wall 509.012 Hexagon bolt

509.008 Shroud ring 509.014 Lock washer pair
Fig. 43. Shroud ring and turbine rotor mounted

Work Steps 1. Unscrew two hexagon bolts (509.012) and replace them with two
guide bars (596.280).
2. Unscrew all hexagon bolts around the circumference.

Note!
A screwdriver can be applied to the top and bottom recess (see
Figure 44 )) in order to loosen the shroud ring.

3. Remove shroud ring (509.008).

4. Remove guide bars.

Work Sequence 2 – Shroud Ring Installation

Starting Condition Turbine rotor [500.53] installed, gas-admission casing [500.51] re-
moved.

Work Steps 1. Screw two guide bars (596.050) into diffuser (509.001) of the gas-
outlet casing (506.001).
2. Place on the shroud ring (509.008) and secure with three hexa-
gon bolts and lock washer pairs. Unscrew the guide bars.
3. Screw in all hexagon bolts (509.012) with lock washer pairs
TCA 88 AK 500.54.fm

(509.014) around the circumference, and lightly tighten.

6673 C2 500.54–01 E 06.05 TCA88 186

 Important!
Always use new lock washer pairs when mounting!

4. Measure gap dimension S between turbine blade/shroud ring at

both locations A with feeler gauge. Lightly loosen hexagon bolts
(509.012) and align shroud ring (509.008) horizontally to the center
(gap dimensions left and right must be equal).
5. Lightly tighten the hexagon bolts.
6. Measure gap dimension S at the vertical measuring points B and
C and align shroud ring (509.008).

Important!
Due to the floating bearing of the turbine, the turbine rotor is
lightly elevated during operation by the oil. Therefore, the shroud
ring must be fastened 0.3 mm higher than the turbine rotor upon
mounting (in the neutral position).

C
520.001 s

A A

2 509.012

B 509.008

509.008 Shroud ring S Gap dimension

509.012 Hexagon bolt A,B,C Measuring points
520.001 Turbine rotor 1 Top recess
2 Turbine blade
Fig. 44. Measuring points for gap dimension of turbine blade/shroud ring

A B = A - 0.3 mm C = A + 0.3 mm
1.2 0.9 1.5
1.3 1.0 1.6
TCA 88 AK 500.54.fm

1.4 1.1 1.7

Table 4. Gap dimensions at measuring points B and C are dependent of A in
new condition

6673 C2 500.54–01 E 06.05 TCA88 187

 Important!
For maximum permitted gap dimensions of components that have
been in operation, see Chapter 3.2 – Gaps and Clearances.

7. Compare all 4 measured values again with the permitted gap

dimensions (see Chapter 3.2) and record in the inspection report
(Section C1 - Chapter 6.6).
8. Tighten all hexagon bolts (509.012) with the specified torque.

Important!
Lubricate contact surfaces and threads (e. g. Molykote HSC)!
xx

Important!
Observe tightening torques upon installation!
xx

Hexagon bolt (509.012): 165 Nm

TCA 88 AK 500.54.fm

6673 C2 500.54–01 E 06.05 TCA88 188

 Work Cards
Assembly and Maintenance - Turbine Side
End Cover 500.55

Short Version

Removal of the end cover is required for inspection of the bearing bush
(turbine side).

Required Personnel and Time

Amount Qualification Required Time/h

1 Qualified mechanic 0.5

Required Tools/Appliances

Amount Designation Number Status

1 Open-jaw wrench 24 – Inventory

Spare Parts

Amount Designation Number

1 Seal, turbine side 517.070

Corresponding Work Cards

Work Card Work Card Work Card

500.44 500.45 500.46
500.53 500.56

Technical Data

Designation Specification
End cover with sealing cover and stud screws 55 kg
TCA 88 AK 500.55.fm

6673 C2 500.55–01 E 06.05 TCA88 189

 517.094

517.001

517.161
517.070
517.072
517.064 517.159

517.064
517.068

517.001 Bearing casing 517.072 Sealing cover, turbine side

517.064 End cover 517.094 Lock nut
517.068 Stud screws 517.159 Cover
517.070 Seal, turbine side 517.161 Bearing bush
Fig. 45. Installation of end cover in the bearing casing

Work Sequence 1 – Removal of the End Cover

Starting Condition Turbine rotor [500.53] and thrust bearing [500.46] removed.

Work Steps 1. Unscrew the eight lock nuts (517.094) for attachment of the studs
(517.068).
2. Pull off the end cover (517.064) from the bearing casing.

Work Sequence 2 – Installation of the End Cover

Starting Condition Bearing bushes [500.56] mounted.

Turbine rotor [500.53] not mounted.

Work Steps 1. Slide sealing cover (517.072) and seal (517.070) on stud screws
(517.068) of the end cover (517.064).

Important!
Check if the studs (517.068) are completely screwed into the end
cover (517.064)!
2. Slide end cover with stud screws into bearing casing (517.001) -
turbine side.
3. Fasten the end cover with the lock nuts (517.094).

Important!
Lubricate contact surfaces and threads (e. g. Molykote HSC)!
xx
TCA 88 AK 500.55.fm

Important!
Observe tightening torques upon installation!
xx

Lock nut (517.094): 140 Nm

6673 C2 500.55–01 E 06.05 TCA88 190

 Work Cards
Assembly and Maintenance - Turbine Side
Bearing Bushes 500.56

Short Version

Removal of the bearings for inspection purposes or replacement.

Required Personnel and Time

Amount Qualification Required Time/h

1 Qualified mechanic 1.0

Required Tools/Appliances

Amount Designation Number Status

1 Open-jaw wrench 17 – Inventory
1 Micrometer (outside and inside) – Inventory
1 Depth gauge – Inventory

Spare Parts

Amount Designation Number

12 Lock washer pair 517.156
2 Bearing bush 517.161

Corresponding Work Cards

Work Card Work Card Work Card

500.46 500.53 500.54
500.55
TCA88_AK_50056_57.fm

6673 C2 500.56–01 E 06.05 TCA88 191

 517.157 517.001 517.066
517.156 517.067
517.162

517.156
517.157
517.089
517.153
517.075
517.154 517.064
517.161
517.161
517.159
517.068

517.001 Bearing casing 517.153 Thrust bearing

517.064 End cover 517.154 Counter-thrust bearing
517.066 Locating disc 517.156 Lock washer pair
517.067 Countersunk screw 517.157 Hexagon bolt
517.068 Stud 517.159 Cover
517.075 Bearing disk 517.161 Bearing bush
517.089 Labyrinth disk 517.162 Bearing body
Fig. 46. Bearing casing

Note!
Before disassembly: Mark the installation position of the bearing
bushes on the bushes in the bearing body with a felt pen (compressor
side/turbine side), so that these can not be mixed up.

Work Sequence 1 – Bearing Bush, Compressor Side: Checking the Axial Gap and Removing

Starting Condition Turbine rotor [500.53] as well as thrust and counter-thrust bearing
[500.46] are removed.

Important!
When removing the bushes (517.161) the bearing body (517.162)
and the locating disc (517.066) remains firmly installed in the
bearing casing (517.001).

Work Steps 1. Slide the bush by hand completely into the bearing body and take
measure A with the depth gauge (compare Fig. 47 ).
2. Replace the bearing bush when

A ≥ 0.50 mm.
TCA88_AK_50056_57.fm

6673 C2 500.56–01 E 06.05 TCA88 192

 517.162

517.161

517.161 Bearing bush 517.162 Bearing body

Fig. 47. Measuring the axial clearance of the bearing bushes - compressor side

3. Mark the bush with a felt pen (compressor side).

4. Remove the bush from the bearing body and check for wear
(see Work Sequence 4).

Work Sequence 2 – Bearing Bush, Turbine Side: Checking the Axial Gap and Removing

Starting Condition Turbine rotor [500.53] and end cover [500.55] removed from the bearing
casing.

Important!
When removing the bushes (517.161) the bearing body (517.162)
and the locating disc (517.066) remains firmly installed in the
bearing casing (517.001).

Work Steps 1. Loosen hexagon bolt (517.157) and remove cover (517.159).
2. Slide the bush by hand into the bearing body and take measure A
with depth gauge (compare Fig. 48 ).
3. Replace the bearing bush when

A ≥ 0.50 mm.

517.162

517.161

517.161 Bearing bush 517.162 Bearing body

Fig. 48. Measuring the axial clearance of the bearing bushes - turbine side
TCA88_AK_50056_57.fm

4. Mark the bush (turbine side).

5. Remove bush from bearing body and inspect for wear (see
Work Sequence 4).

6673 C2 500.56–01 E 06.05 TCA88 193

Work Sequence 3 – Checking the Bearing Body

Starting Condition Bearing bushes (517.161) are removed out of bearing body (517.162)
(see Work Sequence 1 and 2). Bearing body remains installed in the
bearing casing (517.001)!

Work Steps 1. Clean the bearing locations in the bearing body.

2. Measure both location bores (inside-diameter D5 - see Fig. 49 ) in
the bearing body for the bearing bushes (turbine and compressor
side) and record the measured values.

Replace the bearing when

D5 ≥ 165.04 mm.

D3 D4

517.162
517.161

D4

D3
D5

517.161 Bearing bush 517.162 Bearing body

Fig. 49. Checking the bearing body and bearing bushes

Work Sequence 4 – Checking the Bearing Bushes/Radial Clearances of Bearing Bush

Starting Condition The diameter measures (D1) of the bearing locations on the turbine
shaft for both bearing bushes (517.161) have been determined (com-
pare [500.53] Work Sequence 1).
Measures for both location bores (inside diameter D5) of bearing bush-
es taken (compare Work Sequence 3).
Marked bearing bushes (turbine side/compressor side) removed from
bearing body.

WARNING
Defective bearing bushes can cause major turbocharger
damage.
During operation, worn or defective bearing bushes can lead to
breakdown of components in the turbocharger. This can lead to
the injury of persons and cause damage in the engine room.
 Carry out checks and maintenance work regularly!
 Pay attention that the bearing bushes do not have deep grooves
or scoring on the running surfaces.
TCA88_AK_50056_57.fm

 Check the accuracy to measure of the bearing bushes!

 In cases of doubt, replace the bearing bushes!
xx

Work Steps 1. Thoroughly clean the bearing bushes.

6673 C2 500.56–01 E 06.05 TCA88 194

 2. Measure the inside diameter (D3) and the outside diameter (D4)
of the bearing bushes and record (see Fig. 49 ).
3. Replace the bearing bush when

D3 ≥ 114.11 mm,

D4 ≤ 164.62 mm.

4. Calculating the radial clearances (see Chapter 3.2. – Gaps and

Clearances).

Important!
The radial clearance between bearing bush/turbine shaft is
calculated out of the difference between the interior diameter of
the bearing bush (D3) and the respective diameter dimension (D1)
of the turbine rotor as follows: R(3a) = D3 - D1 (compare [500.53]).

Important!
The radial clearance between bearing body/bearing bush is
calculated out of the difference between the exterior diameter of
the bearing bush (D4) and the respective location bore (inside
diameter D5) in the bearing body as follows: R(3b) = D5 - D4

5. Replace the bearing bush when

R(3a) ≥ 0.14 mm

R(3b) ≥ 0.42 mm.

Work Sequence 5 – Installation of the Bearing Bush

Starting Condition Condition and accuracy to measure of the bearing bushes (517.161)
and the bearing body (517.162) checked.

Work Steps Important!

Before inserting the bearing bushes, lubricate them with
machinery oil.

Installation of the bearing bushes in the bearing casing is carried out in

reverse order of removal.

Important!
Lubricate contact surfaces and threads (e. g. Molykote HSC)!
xx

Important!
Control tightening torques of countersunk screw (517.067) of
locating disc!
Observe tightening torques upon assembly!
TCA88_AK_50056_57.fm

Hexagon bolt (517.157): 34 Nm

Countersunk screw (517.067): 34 Nm

6673 C2 500.56–01 E 06.05 TCA88 195

 TCA88_AK_50056_57.fm

6673 C2 500.56–01 E 06.05 TCA88 196

 Technical Documentation
Exhaust Gas Turbocharger
Spare Parts Catalogue C3

Exhaust Gas Turbocharger . . . . . . . . . TCA88

D36 6673-1 E
TCA88_Title_C3.fm

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

6673 C3–01 E 06.05 TCA88 197

Table of contents C3

page

1 Introduction ...........................................................................................................199

1.1 Preface ............................................................................................................................................... 199

1.2 Layout and Usage of the Spare Parts Catalogue .............................................................................. 200
1.3 Ordering Spare Parts ......................................................................................................................... 202

2 List of Assemblies .................................................................................................205

500 List of Assemblies ......................................................................................................................... 206

3 Spare Parts ............................................................................................................209

501.02 Gas-admission casing .................................................................................................................. 210

506.01 Gas outlet casing .......................................................................................................................... 212
509.01 Gas outlet diffuser ......................................................................................................................... 214
513.01 Turbine nozzle ring ....................................................................................................................... 216
517.01 Bearing casing .............................................................................................................................. 218
518.01 Casing feet .................................................................................................................................... 222
520.01 Rotor, complete ............................................................................................................................ 224
540.01 Insert, complete ............................................................................................................................ 226
542.01 Diffuser ......................................................................................................................................... 228
544.01 Silencer, complete ........................................................................................................................ 230
545.01 Air intake casing axial ................................................................................................................... 232
545.02 Air intake casing 90° ..................................................................................................................... 234
546.01 Compressor casing (single outlet) ................................................................................................ 236
546.02 Compressor casing (double outlet) ............................................................................................... 238
554.02 Emergency and post-lubrication system ....................................................................................... 240
578.03 Dry Cleaning of the Turbine .......................................................................................................... 244
578.04 Wet Cleaning of the Turbine ......................................................................................................... 246
579.03 Wet Cleaning of the Compressor (pressure sprayer) ................................................................... 248
579.04 Wet Cleaning of the Compressor (pipe connection) ..................................................................... 250
591.01 Annular lagging Gas-admission casing ........................................................................................ 252
591.02 Sound insulation compressor casing (single outlet) ..................................................................... 254
591.03 Sound insulation compressor casing (double outlet) .................................................................... 256

4 Reserve Parts ........................................................................................................259

595.01 List of Reserve Parts .................................................................................................................... 261

5 Tools .......................................................................................................................265

596.01 List of Tools .................................................................................................................................. 267

Index I..............................................................................................................................273
TCA 88 englischIVZ3.fm

6673 C3–01 E 06.05 TCA88 198

 Introduction 1

Preface 1.1

Spare Parts/Spare Parts Catalogue

Maintenance and repair work can be carried out properly only when the
required spare parts are available.
They are to be kept in stock or to be ordered in good time. The stock
numbers required for ordering can be found in spare parts catalogues.
The spare parts catalogue for the exhaust gas turbocharger is avail-
able.

The structural principle of this spare parts catalogue is explained in

Chapter 1.2. Stock numbers for engine components, measurement
and control equipment as well as for system accessories of the engine
can be found in other modules of the technical documentation. See the
enclosed Notes in Chapter 1.3.

Sincerely yours

MAN B&W Diesel AG

TCA88_Intro_C3.fm

6673 C3 1.1–01 E 06.05 TCA88 199

Introduction

Layout and Usage of the Spare Parts Catalogue 1.2

Layout

Contents The spare parts catalogue includes

 all essential components of the turbocharger.

The spare parts catalogue does not include

 secondary or system-specific insulations/coverings and

 subordinate cablings and pipes that lead away from the
turbocharger or are carried out by other manufacturers.

Structural Principle The pages of the spare parts catalogue are structured according to the
assemblies system of the turbocharger.

Assemblies The assemblies of the MAN turbocharger can easily be determined

with the List of Assemblies (see Chapter 2).
Subassembly group numbers given in brackets do not exist for all tur-
bochargers. Subassembly group numbers marked with * can not be
viewed in the List of Assemblies.

Ordinal number The ordinal number located at the top right of the spare parts sheets
consists of the 3-digit subassembly group number and a 2-digit version
number, which complies with the design.

Sheet Number The sheet number consists of the 4-digit printing number (6673) on the
bottom left and of the ordinal number (e. g. C3 520.01 E) next to it on
the right.

Stock Number Stock numbers consist of a 3-digit subassembly group number and a
3-digit position number. Subassembly group number and position num-
ber are thereby separated with a dot.

520.001 Stock Number (e.g. turbine rotor)

Position Number
Subassembly group number
TCA88_Intro_C3.fm

6673 C3 1.2–01 E 06.05 TCA88 200

 Validity

Validity Spare parts catalogues are specially adapted to the respective turbo-
charger version. Therefore, the respective spare parts catalogue is val-
id only for the turbocharger or the turbocharger series with the works
No. or factory-number group on the cover sheet.

Important!
Spare parts catalogues may not be transferred from one
turbocharger to another.

Spare parts catalogues which are handed out in advance for informa-
tion purposes are marked with a red note sheet as “Informational Is-
sue”.

Important!
Informational issues are
not suitable for ordering spare parts,
not suitable for the planning of inventory,
not suitable to be taken over into electronic data
processing systems!

Replacement Sheets In case of changes at a later point of time, the respective auxiliary or
replacement sheets will be sent to you.

Important!
Please ensure that such auxiliary or replacement sheets, as have
been assigned to you, are properly filed into all corresponding
spare parts catalogues.

Changes/Alterations on the If changes/alterations are carried out to the turbocharger over the
Turbocharger coarse of the operating period for which no new drawings are drawn up
and subsequently no new spare parts sheet is made out by the MAN
B&W Diesel AG, the operators of the engine themselves must enter a
respective remark into the spare parts catalogue. This will help to avoid
false orders.

Delivery of Changed Parts Due to continuous development on the turbochargers, future spare
parts for orders might be delivered that are changed in comparison to
the original components, which nonetheless fulfill the same function. In
such cases, the identifying card of the delivered part will contain an ap-
propriate note.
TCA88_Intro_C3.fm

6673 C3 1.2–01 E 06.05 TCA88 201

Introduction

Ordering Spare Parts 1.3

Overview

The turbocharger is part of a system from which the assemblies can be

from various manufacturers. The following table gives an overview of
the various spare parts catalogues/information aides from which the
necessary data for spare parts orders can be taken.

Component/Assemblies Information Aid Section of the Techni-

cal Documentation
Turbocharger Spare parts catalogue, turbocharger C3
Data in work cards C2
Tools (turbocharger) List in the turbocharger tool box C3
Data in work cards C2

Engine Spare parts catalogue, engine See technical documen-

Measurement and control equip- List of measurement and control equipment tation of engine and
ment system
Engine and system accessories Spare parts catalogue/Spare parts sheet
depending on manufacturer and product
Table 1. Spare parts catalogues and comparable information aides

Ordering of Spare Parts

To avoid questions when ordering spare parts, the following information

is required:

Type of turbocharger xxx xx

Factory number of the turbocharger x xxx xxx
(Type of engine) xxxxxx
(Factory number of the engine) xxx
Designation of the part xxxxxxxxx
Ordinal number xxx.xxx
Quantity xx
Shipping address xxxxxxxxx
Shipping method xxxxxxxxx

Important!
If parts must be ordered that are not contained or can not be found
in the spare parts catalogue, describe the part and the build-in
location as precisely as possible (send photo along). For parts of
subsuppliers which can not be found in their records, the
information on the type plate must be quoted.
TCA88_Intro_C3.fm

6673 C3 1.3–01 E 06.05 TCA88 202

 Address

Please direct your order to:

MAN B&W Diesel Aktiengesellschaft

86224 Augsburg

Telephone +49 821 322 3994

Telefax +49 821 322 3998
TCA88_Intro_C3.fm

6673 C3 1.3–01 E 06.05 TCA88 203

 TCA88_Intro_C3.fm

6673 C3 1.3–01 E 06.05 TCA88 204

 Spare Parts Catalogue

List of Assemblies 2
TCA88_ListAssem.fm

6673 C3 2–01 E 06.05 TCA88 205

 List of Assemblies 500

540 542 554 517 509 501

506

513

501

545

544
520

546
518
206

6673 C3 500–02 E 06.05 TCA88 TCA 88 500 - Assemblies.fm 206

 TCA 88 500 - Assemblies.fm

List of Assemblies

Assembly Designation

500 Exhaust gas turbocharger

501 Gas-admission casing

506 Gas outlet casing
509 Gas outlet diffuser
513 Turbine nozzle ring
517 Bearing casing
518 Casing feet
520 Rotor complete
540 Insert
542 Diffuser
(544) Silencer
(545) Air intake casing (axial, 90°)
546 Compressor casing (single outlet, double outlet)
554 Emergency and post-lubrication system
562* Speed measuring device
578* Cleaning device for turbine
579* Cleaning device for compressor
591* Covering and Insulation

* Assemblies not shown in the figures

(...) if available
207

6673 C3 500–02 E 06.05 TCA88 207

208

6673 C3 500–02 E 06.05 TCA88 TCA 88 500 - Assemblies.fm 208

 Spare Parts Catalogue

Spare Parts 3
TCA 88 Spare Parts.fm

6673 C3 3–01 E 06.05 TCA88 209

 Gas-admission casing 501.02

501.000
501.001

501.028
501.027
501.026
501.025
501.024
501.023
210

6673 C3 501.02–01 E 06.05 TCA88 TCA88_501.fm 210

 TCA88_501.fm

Gas-admission casing 501.02

Order No. Number Designation Order No. Number Designation

501.000 1 Gas-admission casing, compl.

501.001 1 Gas-admission casing with insulation
501.023 1 Screw plug
501.024 1 Sealing ring
501.025 1 Screw plug
501.026 1 Sealing ring
501.027 1 Sealing ring
501.028 1 Screw plug
211

6673 C3 501.02–01 E 06.05 TCA88 211

 Gas outlet casing 506.01

506.000
506.039
506.001 506.040

506.102

506.105 B 506.066
506.056
506.040
506.039 506.068
506.027 506.107
506.108

506.104
506.099 506.027
506.068
A 506.066

506.027
506.068 506.106
506.066
A 506.107
506.056 506.027
506.027
506.068
506.056 B
506.066 506.068
506.068 506.027 506.056
506.058
506.058 506.056 506.066 506.058
506.060 506.060 506.068
506.066
506.027 506.056 506.060
506.066
212

6673 C3 506.01–01 E 06.05 TCA88 TCA 88 506.01.fm 212

 TCA 88 506.01.fm

Gas outlet casing 506.01

Order No. Number Designation Order No. Number Designation

506.000 1 Gas outlet casing, compl.

506.001 1 Gas outlet casing with insulation
506.027 7 Seal
506.039 2 Screw plug
506.040 2 Sealing ring
506.056 56 Lock washer pair
506.058 36 Lock washer pair
506.060 36 Hexagon bolt
506.066 56 Hexagon bolt
506.068 7 Flange
506.099 24 Undercut bolt
506.102 28 Hexagon bolt
506.104 28 Hexagon nut
506.105 28 Hexagon nut
506.106 24 Hexagon bolt
506.107 28 Lock washer pair
506.108 4 Hexagon bolt
213

6673 C3 506.01–01 E 06.05 TCA88 213

 Gas outlet diffuser 509.01

509.000

509.001

509.008

509.014
509.012
214

6673 C3 509.01 E 06.05 TCA88 TCA 88 509.01.fm 214

 TCA 88 509.01.fm

Gas outlet diffuser 509.01

Order No. Number Designation Order No. Number Designation

509.000 1 Diffuser, complete

509.001 1 Diffuser outside wall
509.008 1 Shroud ring
509.012 12 Hexagon bolt
509.014 12 Lock washer pair
215

6673 C3 509.01 E 06.05 TCA88 215

 Turbine nozzle ring 513.01

513.014 513.000
513.013

513.001
513.014

513.013

513.010
216

6673 C3 513.01 E 06.05 TCA88 TCA 88 513.01.fm 216

 TCA 88 513.01.fm

Turbine nozzle ring 513.01

Order No. Number Designation Order No. Number Designation

513.000 1 Turbine nozzle ring, compl.

513.001 1 Nozzle ring
513.010 1 Clamping ring
513.013 23 Hexagon bolt
513.014 23 Lock washer pair
217

6673 C3 513.01 E 06.05 TCA88 217

 Bearing casing 517.01

517.147 517.000
517.156
517.157 517.161
517.144
517.100
517.143
517.142 517.214
517.141
517.224
517.214
517.154 517.223
517.162 517.221 517.027
517.169
517.172 517.220
517.094 517.161
517.054
517.159
517.185
517.001
517.156

517.026
517.157

517.197
517.173
517.093 517.063

517.095 517.026

517.169

517.066

517.085 517.067

517.089
517.070
517.102 517.027
517.153 517.072
517.095 517.075

517.064

517.068
218

6673 C3 517.01 E 06.05 TCA88 TCA 88 517.01.fm 218

 TCA 88 517.01.fm

Bearing casing 517.01

Order No. Number Designation Order No. Number Designation

517.000 1 Bearing casing, compl. 517.153 1 Thrust bearing

517.001 1 Bearing casing with items 517.100 and 517.162 517.154 1 Counter-thrust bearing
517.026 3 Seal 517.156 12 Lock washer pair
517.027 12 Hexagon bolt 517.157 12 Hexagon bolt
517.054 1 Orifice 517.159 1 Cover
517.063 1 O-ring seal 517.161 2 Bearing bush
517.064 1 End cover, turbine side 517.162 1 Bearing body
517.066 1 Locating disc 517.169 2 Blind flange
517.067 2 Countersunk screw 517.172 6 Countersunk head srew
517.068 8 Stud 517.173 6 Lock nut
517.070 1 Seal, turbine side 517.185 1 Seal, compressor side
517.072 1 Sealing cover, turbine side 517.197 1 Sealing cover, compressor side
517.075 1 Bearing disk 517.214 20 Hexagon bolt
517.085 1 O-ring seal 517.220 1 Sealing ring
517.089 1 Labyrinth disk, compressor side 517.221 1 Flange
517.093 8 Hexagon bolt 517.223 1 Sealing ring
517.094 8 Lock nut 517.224 1 Flange
517.095 14 Lock washer pair
517.100 6 Stud
517.102 6 Hexagon nut
517.141 1 Sealing ring
517.142 1 Non-return valve
517.143 1 Sealing ring
517.144 1 Pipe socket
517.147 4 Hexagon bolt
219

6673 C3 517.01 E 06.05 TCA88 219

 Bearing casing (cut out A) 517.01

517.000
A

517.211

517.211 517.214
517.212
517.214
517.006 517.026
517.139 517.083 517.071
517.138

517.020
517.106 517.074
517.113
517.074
517.027
517.109 517.117 517.071
517.219

517.115 517.114
517.216 517.217

517.214
517.218
220

6673 C3 517.01 E 06.05 TCA88 TCA 88 517.01.fm 220

 TCA 88 517.01.fm

Bearing casing (cut out A) 517.01

Order No. Number Designation Order No. Number Designation

517.000 1 Bearing casing, compl.

517.006 1 Pipe bend
517.020 1 Pipe adapter
517.026 3 Seal
517.027 12 Hexagon bolt
517.071 2 Screw plug
517.074 2 Sealing ring
517.083 4 Hexagon bolt
517.106 1 Flange
517.109 1 Seal
517.113 1 Sealing ring
517.114 1 Sealing ring
517.115 1 Flange
517.117 1 Non-return valve
517.138 2 Screw plug
517.139 2 Sealing ring
517.211 2 Sealing ring
517.212 1 Flange
517.214 20 Hexagon bolt
517.216 1 Sealing ring
517.217 1 Flange
517.218 6 Hexagon bolt
517.219 6 Hexagon nut
221

6673 C3 517.01 E 06.05 TCA88 221

 Casing feet 518.01

518.000

518.126

518.025
518.001 518.025

518.126

518.001

Ø28
222

6673 C3 518.01 E 06.05 TCA88 TCA88_518.fm 222

 TCA88_518.fm

Casing feet 518.01

Order No. Number Designation Order No. Number Designation

518.000 1 Casing feet, compl.*

518.001 2 Casing foot
518.025 16 Distance sleeve
518.126 16 Undercut bolt

* Fixing elements see spare parts (engine)

223

6673 C3 518.01 E 06.05 TCA88 223

 Rotor, complete 520.01

520.035 520.000

520.028

520.021

520.018

520.067

520.068

520.001
520.066

520.044

520.038
224

6673 C3 520.01 E 06.05 TCA88 TCA 88 520.01.fm 224

 TCA 88 520.01.fm

Rotor, complete 520.01

Order No. Number Designation Order No. Number Designation

520.000 1 Rotor, complete

520.001 1 Turbine rotor with items 520.018 to 520.028
520.018 1 Labyrinth ring, turbine side
520.021 1 Ring nut
520.028 1 Thrust ring
520.035 1 Labyrinth ring, compressor side
520.038 1 Ring nut, compressor side
520.044 1 Compressor wheel
520.066 1 Undercut bolt
520.067 1 Spinner
520.068 1 Tension nut
225

6673 C3 520.01 E 06.05 TCA88 225

 Insert, complete 540.01

540.025 540.000
540.026 540.015
540.029

540.001
540.030

(546.073)
226

6673 C3 540.01 E 06.05 TCA88 TCA 88 540.01.fm 226

 TCA 88 540.01.fm

Insert, complete 540.01

Order No. Number Designation Order No. Number Designation

540.000 1 Insert, complete

540.001 1 Insert
540.015 1 O-ring seal*
540.025 1 Cable socket
540.026 1 Seal disk
540.029 1 Metal adhesive
540.030 1 Balance ring

* Only for version with Jet-Assist

227

6673 C3 540.01 E 06.05 TCA88 227

 Diffuser 542.01

542.001
542.001
228

6673 C3 542.01 E 06.05 TCA88 TCA 88 542.01.fm 228

 TCA 88 542.01.fm

Diffuser 542.01

Order No. Number Designation Order No. Number Designation

542.001 1 Diffuser
229

6673 C3 542.01 E 06.05 TCA88 229

 Silencer, complete 544.01

544.000
544.160
544.170 544.150

544.060
A

544.011

544.016

544.030
544.600

544.013

544.222 A

544.111

544.112

544.050

544.211

544.210
544.115
544.307
544.116 544.180
544.181

544.182

544.211

544.210
230

6673 C3 544.01 E 06.05 TCA88 TCA 88 544.01.fm 230

 TCA 88 544.01.fm

Silencer, complete 544.01

Order No. Number Designation Order No. Number Designation

544.000 1 Radial type silencer, complete

544.011 1 Protecting cap
544.013 1 Screwed connection
544.016 1 Pipe
544.030 64 Damping pad
544.050 1 Front wall
544.060 1 Perforated sheet
544.111 4 Screw plug
544.112 4 Sealing ring
544.115 1 Screw plug
544.116 1 Sealing ring
544.150 1 Fleece mat
544.160 3 Lashing strap
544.170 1 Cover strip
544.180 24 Stud
544.181 24 Lock washer pair
544.182 24 Hexagon nut
544.210 58 Washer
544.211 58 Hexagon nut
544.222 1 Cover
544.307 1 Loctite 586
544.600 1 Transport cover
231

6673 C3 544.01 E 06.05 TCA88 231

 Air intake casing axial 545.01

545.000

545.409

545.408
545.404

545.418

545.412

545.413

545.401

545.425

545.428

545.428

545.427
232

6673 C3 545.01 E 06.05 TCA88 TCA88 545.01.fm 232

 TCA88 545.01.fm

Air intake casing axial 545.01

Order No. Number Designation Order No. Number Designation

545.000 1 Air intake casing, complete

545.401 1 Air intake pipe
545.404 1 Gasket
545.408 1 Injection pipe
545.409 1 Screw connection
545.412 1 Screw plug
545.413 1 Sealing ring
545.418 1 Hexagon bolt
545.425 24 Hexagon bolt
545.427 24 Hexagon nut
545.428 48 Lock washer pair
233

6673 C3 545.01 E 06.05 TCA88 233

 Air intake casing 90° 545.02

545.427 545.000
545.428

545.406

545.405

545.428

545.425

545.462

545.408
545.401 545.404

545.412

545.413
234

6673 C3 545.02 E 06.05 TCA88 A88_54502.fm 234

 A88_54502.fm

Air intake casing 90° 545.02

Order No. Number Designation Order No. Number Designation

545.000 1 Air intake casing, complete

545.401 1 Air intake pipe
545.404 1 Gasket
545.408 1 Injection pipe
545.409 1 Screw connection
545.412 1 Screw plug
545.413 1 Sealing ring
545.418 1 Hexagon bolt
545.425 24 Hexagon bolt
545.427 24 Hexagon nut
545.428 48 Lock washer pair
235

6673 C3 545.02 E 06.05 TCA88 235

 Compressor casing (single outlet) 546.01

546.000
A
546.049
546.050
546.020 B
546.022 546.021 546.305
546.308
546.305
546.308
546.001
A

546.073

B
546.023
546.045
546.025 546.024
546.026 546.046

546.093

546.091
236

6673 C3 546.01 E 06.05 TCA88 TCA 88 546.01.fm 236

 TCA 88 546.01.fm

Compressor casing (single outlet) 546.01

Order No. Number Designation Order No. Number Designation

546.000 1 Compressor casing, compl.

546.001 1 Volute casing
546.020 1 Flange
546.021 1 Sealing ring
546.022 6 Hexagon bolt
546.023 1 Screw plug
546.024 1 Sealing ring
546.025 3 Screw plug
546.026 3 Sealing ring
546.045 1 Hexagon bolt
546.046 1 Lock washer pair
546.049 1 Cable socket
546.050 1 Seal disk
546.073 12 Undercut bolt
546.091 1 Type plate
546.093 4 Notched nail
546.305 2 Screwed connection
546.308 2 Closure plug
546.309 Metal adhesive
237

6673 C3 546.01 E 06.05 TCA88 237

 Compressor casing (double outlet) 546.02

546.000
A
546.049
546.050
546.020 B
546.022 546.021 546.305
546.308
546.305
546.308
546.001
A

546.073

B
546.023
546.045
546.025 546.024
546.026 546.046

546.093

546.091
238

6673 C3 546.02 E 06.05 TCA88 TCA 88 546.02.fm 238

 TCA 88 546.02.fm

Compressor casing (double outlet) 546.02

Order No. Number Designation Order No. Number Designation

546.000 1 Compressor casing, compl.

546.001 1 Volute casing
546.020 1 Flange
546.021 1 Sealing ring
546.022 6 Hexagon bolt
546.023 2 Screw plug
546.024 2 Sealing ring
546.025 6 Screw plug
546.026 6 Sealing ring
546.045 1 Hexagon bolt
546.046 1 Lock washer pair
546.049 1 Cable socket
546.050 1 Seal disk
546.073 12 Undercut bolt
546.091 1 Type plate
546.093 4 Notched nail
546.305 4 Screwed connection
546.308 4 Closure plug
546.309 Metal adhesive
239

6673 C3 546.02 E 06.05 TCA88 239

 Emergency and post-lubrication system 554.02

554.000
554.061

554.064

554.062

554.063
554.066

554.096

554.047

554.049
554.056

554.048
554.055
554.051

554.056
554.052

554.055

554.031

554.049

554.050
240

6673 C3 554.02 E 06.05 TCA88 TCA88_554_02.fm 240

 TCA88_554_02.fm

Emergency and post-lubrication system 554.02

Order No. Number Designation Order No. Number Designation

554.000 1 Emergency and post-lubrication system, complete

554.001 1 Oil tank
554.040 4 Hexagon bolt
554.041 8 Lock washer pair
554.042 4 Hexagon nut
554.080 1 Hose with connection
554.083 1 Sealing ring
554.087 4 Hexagon bolt
554.093 2 Plate
554.094 8 Notched nail
554.096 4 Hexagon bolt
241

6673 C3 554.02 E 06.05 TCA88 241

 Emergency and post-lubrication system 554.02

554.000
554.061

554.064

554.062

554.063
554.066

554.096

554.047

554.049
554.056

554.048
554.055
554.051

554.056
554.052

554.055

554.031

554.049

554.050
242

6673 C3 554.02 E 06.05 TCA88 TCA88_554_02.fm 242

 TCA88_554_02.fm

Emergency and post-lubrication system 554.02

Order No. Number Designation Order No. Number Designation

554.031 1 Bracket
554.047 1 Plate
554.048 5 Hexagon bolt
554.049 10 Lock washer pair
554.050 5 Hexagon nut
554.051 4 Lock washer pair
554.052 4 Hexagon nut
554.055 4 Resilient sleeve
554.056 4 Hexagon bolt
554.061 1 Sealing ring
554.062 1 Sealing ring
554.063 4 Hexagon bolt
554.064 1 Non-return valve
554.066 1 Hose with connection
554.096 4 Hexagon bolt
243

6673 C3 554.02 E 06.05 TCA88 243

 Dry Cleaning of the Turbine 578.03

578.03.000

578.03.025

578.03.026
578.03.020
578.03.028

578.03.030 578.03.027
578.03.029

578.03.035
578.03.001
578.03.029

578.03.032
578.03.032
578.03.033
578.03.033
578.03.034 578.03.031
578.03.038
578.03.037 578.03.033
578.03.032
578.03.039
578.03.041
244

6673 C3 578.03 E 06.05 TCA88 TCA88_578.fm 244

 TCA88_578.fm

Dry Cleaning of the Turbine 578.03

Order No. Number Designation Order No. Number Designation

578.03.000 1 Washing equipment turbine, compl.

578.03.001 1 Container
578.03.020 1 Screw plug
578.03.025 1 Angular screw connection
578.03.026 1 Pipe
578.03.027 1 Threaded socket
578.03.028 1 Reducing connection
578.03.029 1 U-bolt
578.03.030 1 Ball cock
578.03.031 1 Ball cock
578.03.032 3 Cap nut
578.03.033 3 Self-tapping ring
578.03.034 1 Threaded socket
578.03.035 1 Plate (cleaning instructions)
578.03.037 2 Stud
578.03.038 2 Hexagon nut
578.03.039 1 Flange
578.03.041 1 Sealing cement, heat-resistant
245

6673 C3 578.03 E 06.05 TCA88 245

 Wet Cleaning of the Turbine 578.04

578.04.000

578.04.019
578.04.017

578.04.011

578.04.001
578.04.010

578.04.017
578.04.021
578.04.001
578.04.010

578.04.011
578.04.001
578.04.010

578.04.016
**
593.022 593.030

*
578.04.011

593.003
578.04.019
578.04.001
578.04.010

578.04.019 578.04.011

578.04.017
246

6673 C3 578.04 E 06.05 TCA88 TCA88_578.fm 246

 TCA88_578.fm

Wet Cleaning of the Turbine 578.04

Order No. Number Designation Order No. Number Designation

578.04.000 1 Cleaning device for turbine, compl.

578.04.001 4 Spray nozzle
578.04.010 1 Sealing cement, heat-resistant
578.04.011 8 Hexagon bolt
578.04.016 1 Angular screw connection
578.04.017 3 T-screw connection
578.04.019 3 Pipe
578.04.021 1 Pipe
593.003 1 Ball cock
593.022 4 Blind rivet
593.030 1 Plate (cleaning specification)
* 1 Water supply connection
** 1 Sealing air
247

6673 C3 578.04 E 06.05 TCA88 247

 Wet Cleaning of the Compressor (pressure sprayer) 579.03

579.03.000

Compressor cleaning
with clean water (no sea water)
charge .................... 2 l
operating overpressure 3 bar
Cleaning only when the engine is
hot and at full load operation
Do not stop the engine
immediately after cleaning

Admission
579.03.091
Press the pump slightly down and turn
left. Remove the pump. Each time before
loosening the pump, discharge the
overpressure by drawing out the safety 579.03.090
valve.
Fill in water up to the 2 liter marking
at the container scale.
Screw in the pump in the container,
acute the pump untill an operatingpressure
of 3 is reached in the container.
>> Red colour range at the piston
pressure gauge <<
Overpressure discharged through the
safety valve.
COMPRESSURE CLEANING
move the quick-acting clutch in the
wash-up connection for compressure.
Press the push button of the hand valve
to initiate the cleaning process. By
releasing the push button of the
spray procedure is interrupted.
Wash up time approx. 30 seconds.

579.03.029
579.03.179

579.03.091
579.03.096
248

6673 C3 579.03 E 06.05 TCA88 TCA88_579.fm 248

 TCA88_579.fm

Wet Cleaning of the Compressor (pressure sprayer) 579.03

Order-No. Number Designation Order-No. Number Designation

579.03.000 1 Pressure sprayer, compl.

579.03.029 1 Container
579.03.090 1 Hose
579.03.091 2 Hose clamp
579.03.096 1 Socket
579.03.179 1 Plate (cleaning instructions)
249

6673 C3 579.03 E 06.05 TCA88 249

 Wet Cleaning of the Compressor (pipe connection) 579.04

579.04.000
(544.01)
(545.01)

578.04.054

578.04.053

578.04.050

578.04.058
578.04.057

578.04.033

578.04.032
578.04.034
250

6673 C3 579.04 E 06.05 TCA88 TCA88_579.fm 250

 TCA88_579.fm

Wet Cleaning of the Compressor (pipe connection) 579.04

Order No. Number Designation Order No. Number Designation

579.04.000 1 Pipe for compressor-washing unit, complete

578.04.032 1 Screwed connection
578.04.033 1 Socket
578.04.034 1 Nipple plug
578.04.050 1 Pipe
578.04.053 1 Pipe clip
578.04.054 1 Hexagon bolt
578.04.057 1 Plate (cleaning specification)
578.04.058 4 Blind rivet
251

6673 C3 579.04 E 06.05 TCA88 251

 Annular lagging Gas-admission casing 591.01

591.000

591.330
591.020

591.340

591.330

591.340

591.330

591.030

591.340

591.010

591.330
591.340
252

6673 C3 591.01 E 06.05 TCA88 TCA88_591_01.fm 252

 TCA88_591_01.fm

Annular lagging Gas-admission casing 591.01

Order No. Number Designation Order No. Number Designation

591.000 1 Ring covering, complete

591.010 1 Ring covering half
591.020 1 Ring covering half
591.030 1 Jacket sheet
591.330 8 Lock washer pair
591.340 8 Hexagon bolt
253

6673 C3 591.01 E 06.05 TCA88 253

 Sound insulation compressor casing (single outlet) 591.02

591.000
591.02.060
591.02.153

591.02.152

591.02.066 591.02.052

591.02.040
591.02.154

591.02.146

591.02.145

591.02.042

591.02.048 591.02.050

591.02.111

591.02.112

591.02.080

591.02.038

591.02.070

591.02.112

591.02.111
591.02.030
591.02.100

591.02.330
591.02.111
591.02.111
591.02.090

591.02.112
591.02.112
254

6673 C3 591.02 E 06.05 TCA88 TCA88_591_02.fm 254

 TCA88_591_02.fm

Sound insulation compressor casing (single outlet) 591.02

Order No. Number Designation Order No. Number Designation

591.02.000 1 Sound insulation, complete

591.02.030 1 Jacket sheet with insulation
591.02.038 2 Turnbuckle
591.02.040 1 Jacket sheet with insulation
591.02.042 1 Cover
591.02.048 1 Insulation
591.02.050 1 Jacket sheet with insulation
591.02.052 1 Cover
591.02.060 1 Jacket sheet with insulation
591.02.066 2 Turnbuckle
591.02.070 1 Jacket sheet with insulation
591.02.080 1 Frame
591.02.090 1 Frame
591.02.100 1 Type plate
591.02.111 9 Hexagon bolt
591.02.112 9 Washer
591.02.145 4 Washer
591.02.146 4 Hexagon bolt
591.02.152 4 Washer
591.02.153 4 Hexagon bolt
591.02.154 2 Turnbuckle
591.02.330 4 Blind rivet
255

6673 C3 591.02 E 06.05 TCA88 255

 Sound insulation compressor casing (double outlet) 591.03

591.03.330
591.03.304 591.000
591.03.305
591.03.100 591.03.305
591.03.306 591.03.304

591.03.050
591.03.060

591.03.030 591.03.305
591.03.304
591.03.060

591.03.304

591.03.040 591.03.305
591.03.010

591.03.305 591.03.030
591.03.304

591.03.060

591.03.305 591.03.050 591.03.060

591.03.304 591.03.330
591.03.100 591.03.304 591.03.305
591.03.305
256

6673 C3 591.03 E 06.05 TCA88 TCA88_591_03.fm 256

 TCA88_591_03.fm

Sound insulation compressor casing (double outlet) 591.03

Order No. Number Designation Order No. Number Designation

591.02.000 1 Sound insulation, complete

591.02.030 2 Jacket sheet with insulation
591.02.040 1 Jacket sheet with insulation
591.02.050 2 Jacket sheet with insulation
591.03.060 4 Frame
591.02.100 1 Type plate
591.03.304 24 Washer
591.03.305 24 Hexagon bolt
591.03.306 4 Turnbuckle
591.03.330 4 Blind rivet
257

6673 C3 591.03 E 06.05 TCA88 257

258

6673 C3 591.03 E 06.05 TCA88 TCA88_591_03.fm 258

 Spare Parts Catalogue

Reserve Parts 4
TCA88_ReserveParts.fm

6673 C3 4–01 E 06.05 TCA88 259

 TCA88_ReserveParts.fm

6673 C3 4–01 E 06.05 TCA88 260

 TCA88_595_ReserveParts.fm

List of Reserve Parts 595.01

Weight/ Weight/
Order No. Number Designation Design Order No. Number Designation Design
kg kg

506.027 1 Gasket 0.1 509.012 4 Hexagon bolt 0.2

di = 146
da = 240 M16 x 100 SM
506.066 2 Hexagon bolt 0.2 509.014 12 Lock washer pair 0.01

M16 x 45 SM di = 17
506.106 6 Hexagon bolt 0.6 513.013 10 Hexagon bolt 0.1

M20 x 2 x 105 SM M16 x 45 SM

506.107 28 Lock washer pair 0.02 513.014 21 Lock washer pair 0.01

di = 21.4 di = 17
506.108 1 Hexagon bolt 0.2 517.026 1 Gasket 0.07

M20 x 2 x 55 SM di = 135
261

6673 C3 595.01–01 E 06.05 TCA88 261

 List of Reserve Parts 595.01

Weight/ Weight/
Order No. Number Designation Design Order No. Number Designation Design
kg kg

517.063 1 O-ring seal 0.2 517.102 2 Hexagon nut 0.03

di = 1400 M16
517.070 1 Gasket, 0.4 517.109 1 Gasket 0.1
turbine side

di = 65
di = 263 da = 140
517.075 1 Bearing disk 2.6 517.154 1 Counter-thrust 4.1
bearing

517.085 1 O-ring seal 0.1 517.156 12 Lock washer pair 0.01

di = 492 di = 10.7
517.095 14 Lock washer pair 0.01 517.157 3 Hexagon bolt 0.05

di = 17 M10 x 28
262

6673 C3 595.01–01 E 06.05 TCA88 TCA88_595_ReserveParts.fm 262

 TCA88_595_ReserveParts.fm

List of Reserve Parts 595.01

Weight/ Weight/
Order No. Number Designation Design Order No. Number Designation Design
kg kg

517.161 2 Bearing bush 7.7 540.015 2 O-ring seal 0.2

di = 885
517.172 2 Countersunk bolt 0.04 546.073 1 Undercut bolt 0.7

M10 x 40 M20 x 360

517.173 2 Lock nut 0.01 554.013 1 O-ring seal 0.1

VM10 di = 507
517.185 1 Gasket, 0.1
compressor side

di = 250
da = 329
517.211 1 Seal ring 0.1

di = 60
da = 128
263

6673 C3 595.01–01 E 06.05 TCA88 263

264

6673 C3 595.01–01 E 06.05 TCA88 TCA88_595_ReserveParts.fm 264

 Spare Parts Catalogue

Tools 5
TCA88_Tools.fm

6673 C3 5–01 E 06.05 TCA88 265

 TCA88_Tools.fm

6673 C3 5–01 E 06.05 TCA88 266

 TCA88_596_Tools.fm

List of Tools 596.01

Number Number
Weight/ Weight/
Order No. Designation Design Order No. Designation Design
kg kg

596.001 1 Puller ring, 3.2 596.018 1 Locking key 9.2

compressor wheel (emergency
operation)

596.002 1 Assembly ring, 4.1 596.022 1 Hub, 3.9

compressor wheel (emergency
operation)

596.003 1 Jack bolt 0.3 596.023 4 Cylindrical screw 0.1

M20 x 2 x 100 M16 x 45

596.004 4 Threaded bar 0.2 596.024 4 Lock washer pair 0.01

M16 x 232 di = 17

596.005 4 Hexagon nut 0.1 596.027 1 Closing cover 43.9

(compressor side),
emergency opera-
tion

M12 o =720
267

6673 C3 596.01–01 E 06.05 TCA88 267

 List of Tools 596.01

Weight/ Weight/
Order No. Number Designation Design Order No. Number Designation Design
kg kg

596.028 1 Closing cover 11.7 596.033 2 Hexagon bolt 0.2

(turbine side),
emergency
operation
o =423 M16 x 120

596.029 1 Gasket 1.1 596.040 1 Extension shaft 1.3

(compressor side)

di = 534
da = 724
596.030 1 Gasket 0.4 596.041 3 Hexagon bolt 0.12
(turbine side)

di = 264
da = 410 M12 x 100
596.031 1 Stud screw 1.4 596.044 3 Guide bar 1.1

M16 x 900 M16 x 700

596.032 3 Hexagon nut 0.03 596.045 3 Guide bar 2

M16 M20 x 830

268

6673 C3 596.01–01 E 06.05 TCA88 TCA88_596_Tools.fm 268

 TCA88_596_Tools.fm

List of Tools 596.01

Weight/ Weight/
Order No. Number Designation Design Order No. Number Designation Design
kg kg

596.046 1 Shackle 0.4 596.058 2 Eye bolt 1.7

A 1.6 M30 x 2
596.050 2 Guide bar 0.3 596.065 1 Spanner for ring 5.5
nut

M16 x 200
596.051 2 Eye bolt 0.3 596.070 2 Threaded bar 0.3

M10 x 517
M16
596.052 1 Eye bolt 0.7 596.071 1 Turn spin 0.2

o 12
M24 x 2
596.055 1 Suspension plate, 5.3 596.072 2 Hexagon nut 0.01
gas-admission
casing

M10
269

6673 C3 596.01–01 E 06.05 TCA88 269

 List of Tools 596.01

Weight/ Weight/
Order No. Number Designation Design Order No. Number Designation Design
kg kg

596.073 1 Puller ring 1.8 596.100 1 Torque spanner 1.5

o 130 8-70 Nm

596.075 1 Protection sleeve, 14.8 596.101 1 Surface drive

turbine rotor

8 x 10
596.086 1 Assembly ring 6.7 596.160 1 Pipe, 10.4
suspension device
for compressor
wheel

o 265
596.087 3 Hexagon bolt 0.2 596.167 1 Sleeve 2.5

M12 x 170 da = 63
596.504 1 Clamping sleeve 2.3 596.168 1 Hexagon bolt, 0.06
• 596.092 1 • Clamping sleeve suspension device
• 596.124 1 • Hexagon bolt for compressor
wheel
• 596.125 1 • Hexagon nut
BM12 x 60
270

6673 C3 596.01–01 E 06.05 TCA88 TCA88_596_Tools.fm 270

 TCA88_596_Tools.fm

List of Tools 596.01

Weight/ Weight/
Order No. Number Designation Design Order No. Number Designation Design
kg kg

596.170 1 Support 10.5 596.248 8 Hexagon bolt 0,1

M16 x 50
596.180 2 Eye bolt 0.2 596.267 1 Lever carrier 2.9

M12

596.197 1 Hexagon bolt 0.2 596.270 1 Pipe 2.8

M16 x 90
35 x 4 x 900
596.198 1 Hexagon nut 0.03 596.271 1 Slide 7.3

M16

596.208 1 Shackle 0.2 596.272 1 Cylindrical screw 0.09

A 0.6 M16 x 40
271

6673 C3 596.01–01 E 06.05 TCA88 271

 List of Tools 596.01

Weight/ Weight/
Order No. Number Designation Design Order No. Number Designation Design
kg kg

596.273 1 Bolt 0.01

o8
596.274 3 Cylindrical screw 0.1

M16 x 55
596.280 3 Hexagon bolt 0,2

M20 x 70
272

6673 C3 596.01–01 E 06.05 TCA88 TCA88_596_Tools.fm 272

 Index I

A spare parts
sound insulation 254–255
accessories 7 compressor wheel 153
accleration system “Jet Assist” 46–47 connection
address charge air and exhaust pipes 121
MAN B&W Diesel AG 203 several turbocharger 43
addresses and contact persons the lube oil system 123
MAN B&W Diesel AG 8 containment safety 15
air intake casing 130 counter-thrust bearing 168
spare parts cutaway view, TCA88 36
90° 234–235
axial 232–233 D
alarm system 18 danger of fire/ fire fighting equipment 17
allowable inclinations 27 deconserving of turbocharger 120
appliances (emergency operation) 56 diffuser 147
auxiliary equipment 6 spare parts 228–229
availability-codes 81 dimensions and connections 26
B documentation 7
dry cleaning
balancing mark turbine 111–112
marking 154 dry cleaning turbine
bearing spare parts 244–245
bearing bush 193
bearing disk 168 E
counter-thrust bearing 168 emergency and post-lubrication system 40, 134
thrust bearing 168 spare parts 240–243
bearing body 193–194 emergency operation 56
bearing casing operation without rotating element 101
spare parts 218–221 with holding device 97–99
built-in equipment 6 emergency operation of the engine
C failure of turbocharger 57
end cover 190
casing feet exhaust gases 17
spare parts 222–223
characteristics (fuels) 31 F
checks during operation 54 fuel specification 31
cleaning agent, turbine 34 fuels 29
cleaning system functional description (exhaust gas turbocharger) 37
dry cleaning 48–49
wet cleaning compressor 52 G
wet cleaning of the turbine 50–51 gaps and clearances 91–94
Coefficient µ 88 gas outlet casing 182
compressed air connection 33, 34 spare parts 212–213
compressor gas outlet diffuser
cleaning 113 spare parts 214–215
compressor casing gas-admission casing 176
spare parts spare parts 210–211
double outlet 238–239 annular lagging 252–253
single outlet 236–237 general
TCA 88 englischMIX.fm

compressor casing (double outlet) exhaust gas turbocharger 35

spare parts
sound insulation 256–257
H
compressor casing (single outlet) hearing protection 17

6673 I–01 E 06.05 TCA88 273

holding device 97 putting out of operation 55
I Q
insert 140 qualification of personnel
spare parts 226–227 maintenance/repairs 20
inspection ship systems 19
bearing bush 193 stationary systems 19
bearing disk 169 R
counter-thrust bearing 170
turbine rotor 183 replacement sheets 201
inspection cover of silencer 116 required personnel and time
inspection of individual components(general) 71 general 80
inspection report 75 reserve parts
inspection turbocharger list 261–263
during operation 67 ring nut 165
rotor
J
spare parts 224–225
jet assist 46 rotor shaft 183
L S
labyrinth disk 160 safety
labyrinth ring 164 during maintenance/repairs 20
labyrinth ring, measurement points 184 during operation 15
layout safety instruction
spare parts catalogue 200 attention 13
list of assemblies 206–207 danger 13
locations and addresses warning 13
MAN B&W Diesel AG 8 safety instruction sign 84
lube oil diagram 39 safety instructions 13
lubricating oil 32 safety instructions (symbols) 83
M scope of supply 6
screw connections 69
maintenance sealing air system 44–??
remarks 69 service
maintenance schedule 63, 66 addresses 9–11
maintenance turbocharger bearing disk 169
during operation 67 counter-thrust bearing 170
in common with an engine maintenance 68 turbine rotor 182, 183
maintenance work service addresses 9
general hints 63 shaft sealing 41
measuring points sheet number 200
gaps and clearances 95 shroud ring 186
N silencer 125
spare parts 230–231
numbering spanner
work cards 80 for ring nut 165
O spare parts
general 22
operating characteristics 24 order numbers 64
operating conditions (lube oil) 41 spare parts catalogue
operating faults (what to do) 55 assemblies 200
operating life, assemblies 73 informational issues 201
operating media 29–34 structural principle 200
ordering spare parts 202 validity 201
ordinal number 200 special services / repair work 64
outputs/speed (failure of a turbocharger) 56 special tools 65
P speed measuring equipment
TCA 88 englischMIX.fm

with speed indicator 144

preface speed transmitter
work cards 79 cable connection 144
product liability 5 installing 142
protective covers 18

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 speed-measuring equipment 142
starting of operation (initial) 53
starting operation 54
status
inventory 81
option 81
special tools 81
standard 81
stock number 80, 200
T
thrust bearing 168
thrust ring 168
tightening torques
bolted connections 87
general 88
turbocharger TCA88 89
tools 65
list 267–272
tools/fixtures
general 81
trouble shooting 58
turbine cleaning
dry cleaning 111
wet cleaning 107
turbine nozzle ring 180
spare parts 216–217
turbocharger
classification/engine 23
connecting several to engine 43
general 35
type 6
type plate 23
V
venting 40
W
weights of assemblies 25
wet cleaning
spare parts
compressor (pipe connection) 250–251
compressor (pressure sprayer) 248–249
turbine 107–108
spare parts 246–247
wet cleaning system
compressor 114
work cards 63
work prior to starting the engine 54
works number 6
TCA 88 englischMIX.fm

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 TCA 88 englischMIX.fm

6673 I–01 E 06.05 TCA88 276