Turbo Charger

EXHAUST GAS TURBO-CHARGER
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Technical Documentation :=#i?ii!BI*:'it$l<:tt
MITSUI ENGINEERING & SHIPBUILDING CO•. LTD.
Exhaust Gas Turbocharger
Operating Manual .................................................. ... C1

Work Cards .............................................................C2
Spare Parts Catalogue .............................................. C3
Turbocharger ....................................... TCA 55
Works No. of turbocharger .................. _ __
Engine ................................................ _ __
4C-09341 C1/2/3 1
Mitsui Engineering & Shipbuilding Co., Ltd.
All rights reserved, including the reproduction in any form or by photomechanical means (photocopy/microcopy), in
whole or in part, and the translation.
4C-09341 C1/2/3 2
Technical Documentation
Operating Manual C1
Exhaust Gas Turbocharger .................... TCA 55
4C-09341 C1 TCA55 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 .............................................................................................................................. 11
2.1 General Safety Instructions ........................................................................................................................... 11

2.2 Safety during Operation ................................................................................................................................. 13
2.3 Safety during Maintenance/Repairs ............................................................................................................... 19
3 Technical Data ............................................................................................................... 21
3.1 Exhaust Gas Turbocharger ............................................................................................................................ 21

3.2 Operating Media ............................................................................................................................................ 27
4 Description .................................................................................................................... 29
4.1 Exhaust Gas Turbocharger ............................................................................................................................ 29

4.2 Lube Oil System ............................................................................................................................................ 33
4.3 Sealing Air System ...................................................................................................................................... 38
5 Operation ........................................................................................................................ 41
5.1 Starting Operation/Putting Out of Operation .................................................................................................. 41

5.2 Emergency Operation of the Engine ............................................................................................................ 44
5.3 Malfunctions/Faults ........................................................................................................................................ 46
6 Maintenance ................................................................................................................... 51
6.1 General Remarks ......................................................................................................................................... 51

6.2 Tools ............................................................................................................................................................. 53
6.3 Maintenance Schedule .................................................................................................................................. 54
6.4 Remarks to the Maintenance Work ............................................................................................................... 57
6.5 Inspection of Individual Components ............................................................................................................ 59
6.6 Inspection Report ........................................................................................................................................... 63
4C-09341 C1 TCA55 4
Introduction 1
Product Liability 1.1
Safe and economic operation of the engine system including the turbo-
charger requires extensive knowledge. Also, the operatability can be main-
tained or regained only through maintenance and repair work when these
are carried out with expertise and skill by trained personnel. The rules of
proper craftsmanship are to be observed Negligence is to be prevented.
The technical documentation supplements this ability through specialized

information, draws attention to dangers and points out the safety regulations
to be observed. Mitsui Engineering & Shipbuilding Co., Ltd. asks you to
observe the following guidelines:
R 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 C1-0perating 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-Capter 6.3).
· Carry out maintenance on the turbocharger regularly and properly within the
specified intervals (see Maintenance Schedule, Section C1 -Chapter 6.3).
Perform any and all repair work exclusively with original Mitsui spare parts
(see Section C3 - S are Parts Catalo ue).
Important!
In the case of infringement of the before mentioned safety
instructions, the Mitsui Engineering & Shipbuilding Co., Ltd shall deny
any and all liability.
4C-09341 C1 1.1 TCA55 5

ln,_roduction
Scope of Supply 1.2
Scope of Supply
Each turbocharger is adapted especially to the engine system of a certain

customer. Due to this customization, a standardized scope of supply is not
given for the turbocharger.
The following scope of supply is effective only for the turbocharger with the
Works No.
Type Turbocharger type TCA55

Engine type
Built-in equipment Compressor diffuser 1>

Turbine nozzle ring 1>
Fig . 1-1. Compressordiffuser Fig. 1-2. Turbine nozzle ring
Auxiliary equipment 1[1 Silencer with air filter

0 Air intake casing
1) Flow cross-section punch-marked on face side of component
4C-09341 C11 .2 TCA55 6

Accessories (optional) D Counter flange and seal for gas outlet casing
D Counter flange and seal for air intake casing
IBJ Cleaning device for turbine (optional)
IBI Wet cleaning
IBJ Dry cleaning
D Cleaning device for compressor
IBJ Speed measuring device
Final speed of range 25000rpm
IBJ Speed indicator
~analogous
D digital
IBJ Emergency and post-lubrication system
IBI Tools
lEI Spare parts
D Special spares
D Jet assist
Documentation Inscriptions on the turbocharger , operating tags English

Inscription on labeling tags English
System of units metric
Operating manuals English
Inquiries
For inquiries on any parts delivered by Mitsui Engineering Shipbuilding

Co, Ltd is at yo ur disposal (for addresses, see Chapter 1.3).
4C-09341 C11 .2 TCA55 7

Introduction
Addresses 1.3
MES Technoservice Co., Ltd.
Addresses and contact persons Table 1-1 contains the addresses of MES Technoservice Co., Ltd. as well
as the telephone and fax numbers of the responsible departments, ready to
fully assist you if required.
Location Address Subject Contact person

T echnoservice division, 6-4, Tsukiji 5-chome, Chuo-ku,
Tokyo office Tokyo 104-8439, Japan
TEL. 81-3-3544 3421
FAX. 81-3-3544-3030
T echnoservice division, 1, Yawatakaigandori , lchihara,

Chiba office Chiba 290-8601, Japan
TEL. 81-436-43-6116
FAX. 81-436-43-1892
T echnoservice division, Matsuoka Shinagawa Bldg., 2F,

Keihin office 4-38, Konan 5-chome,
Minato-ku, Tokyo 108-0075,
Japan
TEL. 81-3-5460-5220
FAX. 81-3-5460-8413
T echnoservice division, Portplaza Bldg., 4F 9-27, Meiko
Nagoya office 2-chome, Minato-ku, Nagoya,
Aichi 455-0037, Japan
TEL. 81-52-654-9461
FAX. 81-52-654-8381
T echnoservice division, Kaigan Bldg., 5F 3, Kaigandori ,

Kobe office Chuo-ku, Kobe , Hyogo
650-0024, Japan
TEL. 81-78-321-2501
FAX. 81-78-331-5062
T echnoservice division, 1-1 , Tama 3-chome, Tamano,
T a ma no office Okayama 706-8651 , Japan
TEL. 81-863-23-2586
FAX. 81-863-23-2348,2085,2349
Table1-1 . Locattons and addresses of MES Technoservtce Co., Ltd.
4C-09341 C11 .3 TCA55 8

Service addresses
Country Address Contact person Telephone/Fax/e-mail

Mitsuizosen Technoservice TEL. 65- !! 71677
Singapore Pte. Ltd. FAX. 65-7733677
192, Pandan Loop, #04-29Pantech
Industrial Complex, Singapore
128381
Mitsuizosen Technoservice TEL. 852-2610-1282
Hongkong Limited FAX. 852-2610-1 220
Unit Nos. 1309-1312, Leve l1 3, Metro
Plaza Tower 1,223Hing Fong Road
Kwai Fong, New Territories ,
Hong Kong
Mitsuizosen Technoservice TEL. 886-r-33 1-280 1
Taiwan Co. , Ltd. FAX . 886-7-332-2218
8 Mingchuan 2nd Road , 14f-2
Chienchen District, Kaohsi ung,
R, O, C.
Table1-2: Service adresses
4C-09341 C1 1.3 TCA55 9

Safety 2
General Safety Instructions 2. 1
Safety Instructions Safety instructions are always noted down prior to the description of
any action. They are categor ized 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 da nger which will result in:
· Death or serious injury,

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

· Total damage to property or
· Serious environmental damage.
ATTENTION
When the respective caution measures are not complied with, a hazardous
situation wi ll be caused which can lead to:
· Personal injury,
· Possible damage to property.
A symbol appropriate to the hazard is always depicted in the marginal

column. It either indicates a hazard (hazard symbol) or the corresponding
protective measures (safety symbols):
4C-09341 C1 2.1 TCA55 11

Safety Symbols
vt)
Wear gloves •
(
~
Wear
v
eWear Wear hard
G
Wear safety
protective hearing hat gloves
goggles protection
:flt
~
Wear
~--/
i
eRead
protective manual
clothing
Danger Symbols
Wamingofa Danger of Tripping Danger of Corrosive

hazard slipping hazard electric materials
location shock
Crush
hazard
lnflammaple Hot surface
materials
Danger of
suspended
loads
•
Rotating
gear hazard
Bans
(9
I
---
'
I
I
®
1
'
' - ·-
.
\!
;
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
foll owi ng designations:
Important/
For pointing out fault sources/handling errors; material damage can
occur.
Note!
Additional notes. information and tips.
4C-09341 C1 2.1 TCA55 12

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 sim ulta neous high component temperatures.
A consequence of additional extraordinary influences might be - in
ext remely rare cases - a failure of the components.
Precautions
Mitsui Engineeri ng & Shipbuilding Co, Ltd. turbochargers correspond to the
req uired conta inment safety according to the rules stipulated by the
classification societies so that t he state of the art prevents fragments from
escaping. In extreme cases, particularly if the turbocharge r 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 ru les:
Important!
Persons are by no means allowed to stay without any reason near the
operating turbocharger.
·T urbine and compressor are to be cleaned at regular intervals as specified in the

operating manual.
· T he maintenance of the turbocharger must be carried out by trained personnel
as we ll as in the maintena nce 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 technica l docume ntation of the system, particularly the operating and
maintenance manuals for the engine, turbocharger and the accessories
required for engine operation, must be stored at a location where they are
accessible for the operating and maintenance personnel at all times.
Regulations for Prevention of When operating the system and for al l maintenance and repair work, the
Accidents relevant regulations for prevention of accidents are to be observed.
It is advisable to hang these regulations in the engine room and to
repeatedly point out the dangers of accide nts.
4C-09341 C1 2.2 TCA55 13

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:
9.
8G
Fig .2. Safety instruction sign - Engine room
Persons, who for operational reasons are to be withi n the danger area of 2.5
m around the engine, are to be instructed of the predominant hazards.
Access to th e danger area Is permitted when the turbocharge r is in prope r
ope rating conditio n and only when wearing suitable protective equipment. It
is prohibited to stay within the danger area without reason.
4C-09341 C1 2.2 TCA55 14

Hearing Protection
WARNING
Sound level exceeding 85dB(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!
Exhaust Gases In the engine room, exhaust gases with harmful components NO,, 80 2 , CO,
HC and soot can be set free.
Health risk due to exhaust gases !

The exhaust gases of the engine are harmful to one's health and
detrimental to the environment when exceeding the limit values.
• Carry out maintena nce in accordance with the maintenance schedule!
• Orient the operational management on behalf of the hazards!
• Observe operation results critically!
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 fue l and oil pipes (maintenance schedule)!
· Eliminate any leakages immediately!
Fire-extinguishing Equipment The engine room must be equipped with fire-extinguishing equipment.
The proper function of this equipment is to be checked regularly.
DANGER
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 rsons are in the en ine room .
4C-09341 C1 2.2 TCA55 15

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 insu lations mounted to the turbocharger
during operation of the engine.
ula check t he of all fue l and oil
After asse mbly work, ensure that all cove ri ngs and protective covers from
moving components as wel l as insulations from hot components are
reattached aga in. Engine operation w ith coverings removed is permitted
only in specia l cases, such as for functional tests.
Alarm System If important opera ting data are exceeded, an ala rm system will set off alarm,
reduction o r stop signa ls dependi ng on the da nger potential. The cause of
the signa ls is to be thoroughly investigated and the source of the
malfunction to be corrected. The signals may not be ignored or suppressed,
except when orde red by management or in cases 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
become very hot. Persons can burn sounds an alarm in case of
technical problems or malfunctions. Therefore, an alarm always has a
cause which must be rectified!
• Do not ignore o r suppress any ala rm , reduction or stop signa lsi
• Investigate t he cause of every alarm, reduction or stop signal or report
t hem!
• As fa r as possible, prov ide for swift rectifi cation of the ca use of alarms and
signals!
• Ignore or suppress alarms, reductio n a nd stop sig na ls only in cases of force
m re or whe n ordered
4C-09341 C1 2.2 T CA55 16

Operating Personnel The engine and the systems required for its operation may be started,
ope rated 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 System:
Operational management through the chief engineer on board or through a

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

certificate that corresponds with the national regulations and international
agreement (STCW). The number of required persons and their minimum
qualification are usua lly stipulated through the national regulations or the
international agreement (STCW).
For Stationary Systems (Power Plants):
The superintendent (engineer) must be available. Supervision/controlling of

the engine and the accompanyi ng supply system through a trained and
specially briefed machinist or mechanic.
4C-09341 C1 2.2 TCA55 17

Safety during Maintenance/Repairs 2.3
Qualification of Personnel Performed by machinists or mechanical fitters and their helpers. Briefing and
supervision of difficult work tasks through a technical officer or the chief en-
gineer.
Use of Cleaning Agents When using cleaning agents the manufacturer's notes for usage, possible
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 manufacture's notes for cleaning agents!
·Wea r 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 ired or make these aware thereof!
Use of High-pressure Cleaners When working with high-pressure cleaners ensure proper usage. Air filters,
shaft ends (also including such with lipped sealing rings), governors, splash-
proof monitoring systems, cable sockets as well as sound and heat insula-
tions 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 became very hot duri ng
operation and require ample time for cooling down afterwards.
· Prior to taking any action, allow the engine and turbocharger to cool down
sufficiently (1-2h)!
· 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{1-2h).
· Drain the system and check that it has been drained completely.
·Wear protective clothing!
4C-09341 C1 2.3 TCA55 19

On turbochargers with emergency and post-lubrication system, the lube oil
will continue to drain for up to 1.5h after shutting down the engine system.
Disassembly and Assembly of During any work on the pipe systems, especially for fuel , lubrication oil and
Pipes air, ensure utmost cleanness in order to avoid foreign objects or debris from
entering the system. Therefore, all pipes subject to reassembly should be
blocked with care upon disassembly.
New pipes being insta lled should be checked for cleanness and flushed, if
required
For extended storage, al l individual parts are to be preserved.
Removal/Disassembly of Heavy
Co nts
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 load ing capacity for the
heavy component (this is not always the case for galleries, half-landings or
grid-iron cover ings).
Spare Parts During operation, very high forces are applied to the components of the
turbocharger. Therefore , Mitsui has developed special materials that can
withstand these high forces. The use of these high-quality materials can be
guaranteed only when using Mitsui original spare parts.
spare parts can be manufactured from low-quality

materials that cannot 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 personne.
• Use only Mitsui original spare parts!

• Use bought-out spare parts only after these have been released by Mitsui!
Mitsui shall in no way be liable for any damage to persons or material,

caused by usage of bought-out spare parts. Furthermore, any and all
warranty claims on the turbocharger expire when using foreign spare parts.
4C-09341 C1 2.3 TCA55 20

Technical Data 3
Exhaust Gas Turbocharger 3.1
Classification Turbocharger/Engine
Turbocharger Engine
Type Works No. Type Power Speed
[kW) [rpm]
TCA55
Turbocharger Type Plate
c£ -1
s
MITSUI
w
EXHAUST GAS TURBOC HARGER
TY Pe I 1
I Se r 1 a I No . I 2
I
Nm ax .I 3
I m i n-I T max. I 4
I c
0
I 5
I
~M IT S UI ENG I NEERING & SH I PBUI L D I NG c0. LTD . 01._
f/ '-1
1 Turbocharger type 4 Admissible turbine inlet

2 Serial No temperature. maximum
3 Admissible rotor speed. 5 Year of ex-works delivery
maximum
Fig .3. Type plate
Note!
The type plate is mounted on the front wall of the silencer.
4C-09341 C1 3.1 TCA55 21

Weights, Classified according to Assemblies (approx. values)
500 Exhaust gas turbocharger, incl. Silencer .... ... ................... .. .................. ... .. .... .... ............... .approx. 3250 kg*
501 Gas-admission casing, complete . ... .. .. .. ... .... .. .. .... ... .. ..... .. .... .. ... .. ........ ... .. .... ... .. ... .. .... ...... . .. .......... 240 kg
506 Gas outlet casing, complete ... .... ..... .. .... .. ...... .. ..... .... .... ......... .................. ..... .. .. .. .... ..... .. .... ... ..... .. 790 kg
509 Gas outlet diffuser .... ....................... ......... ... .............. .... ....... ... .......... .. ........................ .... ................ . 140 kg
Shroud ring .......... ... . ...... .. ....... ... ...... ... ...... .... .... .... .... .. ............. .... .. .. ....... .... .. ... ......... ... ............ .. ... ...... 10 kg
513 Nozzle ring ............................................................... ......................... .. ... ............. ... .... ..... ...... ...... 20 kg*
517 Bearing casing, complete. ... 580 kg
518 Casing feet, complete .................................... .. ... ....... .. ... ......... ... .... .. ... ... ... ..... .... ......... .... .... ......... 280 kg
520 Rotor complete ............. ... ......... .................. ....... .......... .. .... .. ....... ... ... .. ... . ........................ ... 130 kg*
Turbine rotor ... .... .. ... .... ..... ........... 90 kg
Compressor wheel ..... .. ........ ....................... .. .... ........................... .......... . . ........ .... ............. .... 40 kg
540 Insert ... ..... ... .. .... .. .... ................ ....................... ... ........ .. .. ..... ... .... ... .. .. .... .. ... ... ..... ... .. ....... .............. ... .. . 130 kg
542 Diffuser ..... ... .. ........... .. .... ....................................... ... ... ..... .. ... .. .... .... ... ... ... ... ... .. ... ..... ....... ... .. .... ... .... 30 kg
544 Silencer, complete (if existing) .......... ....... .. .. .... ... ......... .... ......... .... .. ............. ... .. .... ............... .. ......... 370 kg*
546 Compressor casing. . ... ... ..... ... ... .... .. .... ... ....... .. ... ..... .. ... .... .. . .. . .. .. .... . .. ... . single socket, complete 500 kg
554 Post lubrication tank, complete .... .. ..... .. ............ .. .... ............. ...... ............ ........ ........... ...... ........ .... ... .... 200 kg
595 Spare parts with box .............. .. ..... ... .. .... .... ... .. ... .. .. . .................... .. .. .. . .... ... .......... ... .. ... ...... . .. . .. ... .. X kg
596 Tools with box ..... .. .. ......... ... . .... ... .... .. ... . .............. ..... .... .. ....... ...... ..... .. ... ..... ........ .. ... .... ... ........ 40 kg
*) In case of the application of the additional specification, refer to additional instraction manual.
- VT A (Variable Turbine Area)
- THS (Turbo Hydraulic System)
- AIC (Air Intake Casing)
4C-09341 C1 3.1 TCA55 22

Operating Characteristics
Speed Admissible speed(Tier1) ....................... .. ..... ..... ... ....... ... .... max. 19000 rpm
Admissible speed (Tier2) .. . ........ ... .......... .... ....... .. ......... .. .... max. 20100 rpm
Temperatures Admissible exhaust gas temperature ahead of turbine .... max. 500 ' C
Admissible inlet temperature of lubricating oil ......... ... . ... max. 70 'C
Pressures Lubricating oil:
At regular operation and full load of engine . .. ....... ... ... .. .......... .. .. 1.3-2.2 bar
Alarm ...................... .... .... .......... .. .. ............ ... ............................... .... ::; 1.0 bar
Slow down ..... ................... ............... ....... ... ... ... ................. .. ::; 0.8 bar
Engine stop (shut down) ................... .. ... . .::; 0.6ba r
Admissible lubricating oil pressure ....... ...... max. 2.2 bar
Lube oil throughput with SAE 30 at 60 ' Cor SAE 40 at 65 "C ... ..................... .. .... ... .. ..... 5.2m 3/h
Lubricating Oil Lube oil supply: 2 co nnections that can be used alternatively. The connection
not used is plugged with a dummy lid.
Post lubrication tank : 1 connectio n (filling , relubricating), 1 ove rfl ow connec-

tion.
Lube oil outlet: 1 connection
Venting Venting: 2 con nections that can be used alternatively The connection not
used is plugged with a dummy lid
4C-09341 C1 3 1 TCA55 23
Dimensions and Connections
737
)
X
< )
2888
1 Exhaust gas inlet 6 Charge air inlet

2 Exhaust gas outlet 7 Charge air outlet
3 Washing water outlet 8 Lube oil supply
4 Lube oil outlet x rotor removal space. 660 mm
5 Venting
Fig . 4: Main dimensions, TCA 55 with go• gas-admission casing
4C-09341 C1 3.1 TCA55 24

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
influe nce the operating abi lity of the exhaust gas turbocharger.
The fol lowing inclination angles can be handled by the exhaust

gas turbocharger without problems.
Inclination Continuous Short-tenn

a "" ±15 ±22.5
~0 ±15 ±22.5
Table 1-3: PermiSSible IIJC!mes tor mstal/at1on positions crossw1se to the
longitudinal axis
Fig 5-1 . Turbocharger side view. installation crosswise to the

longitudinal axis of the vessel
Fig . 5-2. Turbocharger front view. installation crosswise to the

longitudinal axis of the vessel
Wrth the insta llation position in longitudinal direction of the ship, these
limit values are not reached even under unfavorable exterior conditions.
4C-09341 C1 3.1 TCA55 25

4C-09341 C1 3.1 TCA55 26
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 compo-
quality sition of the exhaust gas that flows through the turbocharger. Impurities in
the fuel can lead to residues in the exhaust gas, which can affect the turbo-
charger in an abrasive or corrosive manner.
The fuels used must meet the fuel specification is accordance with the
engine manufacturer's recommendation .
Lubricating Oil
The specification of lubricating oil is to be complied with the engine

manufacturer's recommendation.
4C-093 41 C1 3.2 TCA55 27

4C-09341 C1 3.2 TCA55 28
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 produci ng units concerning efficiency and longevity are
being continuously increased under the aspects of fuel utilization and
envi ronmental load.
In this, the components of exhaust gas turbochargers are subject to extreme
operating conditions.
• Exhaust gases of up to 500 oc contin uously flow through the turbine and
heat up its components, without an own counteractive cooling system.
Especiall y 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 oc
• The high temperatures lead to extreme thermal loads of the material at
many loca tions.
• Speeds are extremely high The MITSUI-MAN B&W exhaust gas
turbochargers are operated w ith speeds ranging from 10000 to 35000
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 sou nd or 2000 kmlh .
• The ce ntrifugal 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
3
can amount to 24 m /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 ca n be fulfilled only with use of the most recent material
and manufacturi ng technologies, introduced into the series by MAN B&W
with use of the latest developmental results, and based on decades of
experience in buildi ng diesel engines and exhaust gas turbochargers.
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.
4C-09341 C1 4.1 TCA55 29

Subassemblies
1 2 3 4 5 6 7 8 9 10
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.compressed
6 Bearing bush. 12 Gas-admission casing fresh air
com pressor side 13 Turbine blades
7 Bearing body 14 Casing foot
Fig. 6: Cutaway view
Turbocha rgers consist mainly of a turbine and a compressor, which are seated on
the same shaft. The exhaust gas of the engine drives the turbine ; the co mpressor
draws in fresh air and compresses it.
4C-09341 C1 4.1 TCA55 30

The turbocharger consists of the following main subassemblies:
• Rotating element:
Turbine w heel 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 casi ng.
• 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-technicall y 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 exhaust gas drives the
turbine wheel ; in this process, the energy contained in the exhaust gas is
transformed into mechanical rotation energy at the turbine wheel. As the turbine
wheel and the compressor wheel are seated on the same shaft, the compressor
wheel is driven at the same time . The exhaust gas exits the turbocharger through
the gas-outlet diffuser and the gas outlet casing.
The compressor wheel draws in fresh air through the silencer or the intake casing
and the insert. The fresh air is compressed in the compressor 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 bearing 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.
4C-09341 C1 4.1 TCA55 31

Intended Use
The turbocharger is intended for use on diesel and heavy-fuel-oil engines. 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
turbocharger manufacturer, otherwise turbocharger manufacturer 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.
• 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 syste m; operation through unauthorized personnel is to be
prevented with suitable means. For operation, the operating instructions
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.
Turbocharger manufacturer shall not be held liable for any or all damages
resulting there from.
• Unauthorized changes/alteration on the turbocha rger.

• 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.
4C-09341 C1 4.1 TCA55 32

. .~ .~.
C~ ~Q. s··-. r" r~·r--J~·"l. L•.••
'"-"··~·
.... ·O·
Lube Oil System 4.2
Lube Oil Diagram
Level 2
Level1
12
5
.
•
__._
*Standard specifications turbocharger
2.2 --=r
I
2.1
•
a> max. irx:;lination of system: + 5o 1
1 Supply pipe 7 Bearing casing 13 Non-return valve with

2.1 Pressure reduction valve 8 Locating bearing Orifice
(4-stroke) 9 Bearing bush 14 Bore
2.2 Orifice (2-stroke) 10 Drain pipe 15 Supply/drain pipe
3 Turbocharger supply pipe 11 Service tank or crank- 77 Overflow pipe
4 Non-return valve case 78 Post lubrication tank
5 Pressure monitor 12 Venting
6 Manometer
Fig 7. Lube oil diagram, TCA
~~ 4C-09341 C1 4.2 TCA55 33

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 integrated
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 ). A pressure reduction va lve (2. 1)
(four-stroke engine) respectively an orifice (2.2) (two-stroke engine) adjusts the
required lube oil pressure. The lube oil pressure is controlled behind the
non-return va lve (4) by means of a pressure monitor (5) and a manometer (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 turbocharger
casing, from where it rea ches the thrust bearing (8) and the bearing bushes (9)
via passages in the bearing casing (7) and the bearing body. The lubricating oil
flows to the gap between bearing and shaft as we ll 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 bearing casi ng by the rotation of the shaft. The lubricating
oil ex its the bearing 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 a> max. possible system inclination + so.
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 turbocharger
System 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 post lubrication tank is filled
with lubricating oil via a small bypass bore in the valve plate of the non-return
valve (13 ). As soon as the lube oil level reaches the overflow pipe (level2) ,
lubricating oil flows back into the bearing casing through the overflow pipe.
4C-09341 C1 4.2 TCA55 34

If the engine is shut off, the pressure in the lube oil system is reduced.
This causes the non-return va lve (13) to open and the non-return valve (4) to shut.
The lubricating oil flows under gravity from the post lubrication tank back into the
turbocharger to the bearing bushes and thrust bearing. Once the height of the
supply/drain pipe (15) is reached (level 1 ), the vo lume 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 turbine side is post-lubricated 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
turbine side is post-lubricated.
Shaft Sealing The bearing casi ng is sealed with labyrinth sea lings 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 labyrinth
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 labyri nth 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 intentional 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.
Lube Oil Filtration The turbocharger does not require any separate lube oil filters . The filtration
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

• Accum ulation 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
For engine lube oil pressures~ 2.2 bar, we recommend installing an orifi ce (2.2).
The lube oil pressure is controlled via the measuring connection behind the
non-return valve .
lmporlant!
Level differences between indication instrument and center 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)
4C-09341 C1 4.2 TCA55 35

Lube oil pressure at full load of engine and lubrication oi l at operating
temperature:
=
Pmin 1.3 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:
• < 1.0 bar: Alarm
• < 0.8 bar: Engine power at half load
• < 0.6 bar: Engine stop
lmporlant!
When reaching the limit values, both the a/ann and the re action 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 temperature
of the lubrication oil. At 60 oc- 65 "C, the lube oil throughput is approx. 7. 0
3
m /h.
Pre- Iubrication Before starting the engine, the bearing points of the turbocharger must be
pre-lubricated. This is done automatically together with the pre-lubrication of
the engine, as the lube oi l 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 continuous pre-lubrication.
Pre-lubrication before starting:
• 10- 30 min utes, oil pressure of 0.6-2.2 bar
Interval pre-lubrication:
• 10 minutes max. per 2 hat oil pressure of 0.6- 2. 2 bar
Post Lubrication Occurs automatically via the post lubrication tank ; otherwise at an oil
pressure of 0.2 - 0.6 bar for a period of 10 - 30 minutes.
4C-093 41 C1 4.2 TCA55 36

Connecting Several Turbochargers to the Engine Lube Oil System
If an engine operates with several turbochargers, then these are connected

parallel to the lube oi l system of the engine (see Fig. @)
1 Supply pipe
2. 1 Pressure reduction
valve
3 Turbocharger supply pipe
4 Non-return valve
5 Pressure monitor
6 Manometer
7 Bearing casing
10 Drain pipe
11 Service tank or
crankcase
12 Venting
18 Post lubrication tank
a Maximum inclination of
system. + Y
t:=j11
1 2.1
Fig . 8: Lube Oil system- Connection of several turbochargers
4C-09341 C1 4.2 TCA55 37

Description
Sealing Air System 4.3
Sealing Air Diagram
1 Compressor casing 6 Compensation pipe 12 Gas outlet casing

2 Ring duct. compressor- 7 Non-return valve c Compressor wheel
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 . 9. Sealing air diagram
4C-09341 C1 4. 3 TCA55 38
Sealing Air System The sealing air prevents hot exhaust gas from entering the bearing casing
and the lubricating oil from seeping into the turbine (oil coke).
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) , w hereby an orifice (3) reduc-
es 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 sea ling air
emerges between shaft and turbine labyrinth.
• A small amount of the sealing air flows back into the bearing ca sing ,
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 lab-
yrinth seal on the turbine side, and into the gas outlet casing (12).
This develops a thrust-compensating piston between the Ia byrinths on the

turbine disk and bearing casing .
The sealing air pressure is factory set via the orifice (3) and must not be con-
trolled or readjusted by the user.
Measures in Case of Vacuum With two-stroke engines, a vacuum can develop on the compressor side at
redu ced partial load during auxiliary blower operation. In this case, a
compensation pipe (6) between sealing air pipe and ambient air prevents
lubricating oil and ex haust gas from being drawn into the compressor
casing.
A non-return valve (7) blocks the compensation pipe during regular opera-
tion. In case of a vacuum in the sealing air system, the spring-free non-return
valve opens and outside air is draw n in through the co mpensation pipe.
4C-09341 C1 4.3 TCA 55 39

4C-09341 C1 4.3 TCA55 40
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 casing
and compressor casing.
3. Remove preservation agents on the exhaust gas flange of the turbine
casing as wel l 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
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 1-Jm recommended) in the lube oil supply
ahead of t he 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 Co ntrol System

Important!
The indication of the pending alarm and the reaction from the engine
control system must occur at the same time.
4C-09341 C1 5.1 TCA55 41

Work prior to Starting the Engine
1. Pre-lubricate engine and bearing points of the turbocharger (engine

control system).
2. Set all shut-off devices of the engine system to the operating position.
3. C heck the lube oil pressure in front of the turbocharger .
Starting Operation
Start the engine. The eng ine exhaust gases drive the turbocharger and thus
begin to start the operation. If available, the "Jet assist'' acceleration 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 ca uses 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 • Turbocha rger speed

Turbocharger • Lube oil pressure in front of turbocharger
• Lube oil temperature in front of turbocharger
• Lube oil temperature behind turbocha rger
• Exhaust gas pressure in front of turbine
• Exhaust gas temperature in front of turbine
• Cha rge air pressure behind compressor
• Cha rge air temperature behind compressor
• Leakage of exhaust gas, charge air and oi l pipes
• Contamination/saturatio n 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 rotating
parts.
By auscultation the turbocharger (listening with e.g., a stethosco pe) ,
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 ca n be used for approximate speed
control.
4C-09341 C1 5.1 T CA55 42

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 I
• Ignore or suppress alarms, reduction and stop signals only in cases of for ce
ma ·or or when ordered b manaqeme nt!
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 53).
Important!
All malfunctions are to be corrected as soon as possible, as minor
malfunctions can a/so lead to increased subsequent damage of the
turbocharger or engine.
3. If the damage can not be corrected immediately, emergency operation 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 oi l runs out of the post lubrication tank to the

turbocharger bearings so that these are still continuously lubricated for
several minutes (post lubrication) .
4C-09341 C1 5.1 TCA55 43

Operation
Emergency Operation of the Engine 5.2
on Failure of a Turbocharger
If damage occurs to a turbocharger which can not be corrected immediately,

emergency operation is still possible.
Available Appliances Tu rbocharger (see work card [500 .11] and [500.1 2])
• 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.
4C-09341 C1 5.2 TCA55 44

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 w hen
remova l of the running equipment is not possible!
· Persons are by no means allowed to stay in the vicinity of the turbocharger
durin emer enc o ration unless absolute! necessar' .
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 earned out
for reasons of time. Subsequent damages possible.
Measure A:
Block rotor from the compressor side using securing fixture (intake cross-section re- 0-4
mains open). Afterwards, mount intake si lencer again (See work card [500.11] )
Measure B:
Disassemble rotating element including beari ngs; shut bearing casi ng on compres- 0-4
sor and turbine side with end covers. Reassemble silencer/i ntake casing and gas-
admission casing again. (See work card [500.12])
Table1-4: Ernergency operation for fa ilure of one or both turbochargers
Legend
Code Number Supplementary Measures/Precautions
0 Observe instructions of engine manufacturer !

1 Reduce engine power. The maximum exhaust gas temperatures behind
cyl inder and in front of turbocharger, and (for engines with two turbocharg-
ers) the maximum admissible turbocharger speed must not be exceeded.
2 Apply all suitable possibi lities to reduce subsequent damages.
3 W hen the rotating element is blocked or disassembled, stop lube oil supply
because of da nger of contamination or fire .
4 Engines with 2 or more tu rbocha rgers:
Separate the exhaust gas intake side of the defective turbocha rger from the
gas flow of the second turbocharger with blind flange.
4C-09341 C1 5.2 TCA55 45

Operatiort
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 Clea n (See separate vo lume)
Turbine wheel and/or nozzle Clean (See separate vo lume)
ring heavily contaminated
500.52
Rotating element grazes Contact Mitsui Techno Service
Foreign objects in front of/in Check turbi ne/compressor for 500.43
turbine or compressor damage ; contact Mitsui Techno 500.53
Service, if required
Turbine wheel. shroud ring. Exchange defective compo- 500.43
nozzle ring or compressor nents; co ntact Mitsui Techno 500.52
wheel damaged or eroded Service, if required 500.53
500.54
High air-intake temperature Reduce output Engine
Charge air cooler contaminated Clean, measure pressure differ- Engine
entia I
Charge air pipe leaks Sea l cha rge air pipe Engine
Charge air temperature too high Check charge air coo ler Engi ne
Exhaust valves. valve slots Clean Engi ne
of engine contaminated
Exhaust gas pipe leaks Sea l exha ust gas pipe Engine
Exhaust-gas back-pressure be- Clean boiler Plant
hind turbine too high
Fuel injection at engine faulty Repair fuel injection Engi ne
Tab le 1-5: Trouble Shooting
4C-09341 C1 5.3 TCA55 46

2 Charge air pressure too Turbine speed too low See malfunction No. 4
low Silencerconta minated Clean/replace 500.24
500.32
Compressor contaminated Clean (See separate vo lume)
Turbine wheel and/or nozzle Clean (See separate vo lume)
500.52
Defective bearings, imbalance Bearing inspection (noise and 500.43
of rotating element vi brations); contact 500.46
Mitsui Techno Service, 500.53
if required 500.56
Rotating element grazes Check parts; contact 500.53
if required 500.56
Foreign objects in front/in tur- Check turbine/compressor for 500.43
bine or compressor damage ; contact Mitsui Techno 500.53
Turbine wheel , shroud ring, Replace defective compo- 500.43
nozzle ring or compressor nents; contact Mitsui Techno 500.52
500.54
High air intake temperature Reduce output Eng ine
Charge air cooler contaminated Clean Engine
Charge air pipe leaks Seal charge air pipe Engine
Exhaust valves, valve slots Engine
Clean
of engine contaminated
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 injectio n Engine
3 Charge air pressure too Nozzle ring lightly Clean 500.52
high contaminated/restricted
Low air intake temperature Reduce output Engine
Table1-5. Trouble Shooting
4C-09341 C1 53 T CA55 47
4 Speed too low Silencer or air filter contaminat- Clean/replace 500.24
ed 500.32
Compressor contaminated Clean (See separate volume)
Turbine wheel and/or nozzle Clean (See separate volume)
500 .52
Defective bearings, imbalance Bearing inspection ; contact
500.46
of rotating element Mitsui Techno Service,
500.56
if reauired
Foreign objects in front/in Check turbine/compressor for 500.43
turbine or compressor damage ; contact Mitsui Techno 500.53
nozzle ring or compressor nents; contact Mitsui Techno 500.52
500.54
High air intake temperature Reduce output Engine
Charge air cooler contaminated Clean Engine
Charge air pipe leaks Seal charge air pipe Engine
Exha ust va lves, valve slots Clean Engine
of engine co ntaminated
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
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
Check parts; contact
7 Lube oi I loss Thrust ring, labyrinth ring dam- 500.45
Mitsui Techno Service,
aged 500.53
if required
Defective labyrinth seal 500 .44
500 55
if required
Seals damaged, connections
Mitsui Techno Service ,
untight
if required
Sealing air ineffective, oil coke
behind turbine whee l
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
Tab le 1-5: Trouble Shooting
4C-09341 C1 5.3 TCA55 48

8 Hesitant starting, short Compressor contaminated Clean (See separate volume)
run-down time Turbine wheel and/or nozzle Clean (See separate volume)
500.52
Thrust ring, labyrinth ring dam- 500.45
aged 500.53
if required
Defective bearings, imbalance Bearing inspection ; contact 500.43
of rotating element Mitsui Techno Service, 500.46
if required 500.53
500.56
Check turbine/compressor for
Foreign obJects in front/in 500.43
damage ; contact
turbine or compressor 500.53
if required
Turbine wheel, shroud ring, Replace defective compo- 500.43
nozzle ring or compressor nents ; contact 500.52
wheel damaged Mitsui Techno Service, 500.53
if required 500.54
Sealing air ineffective, oil coke 500.53
behind turbine wheel
if required
9 Unusual strong noise Thrust ring, labyrinth ring dam- 500.45
aged 500.53
if required
if required 500.53
500.56
if required 500.56
Foreign objects in front/in 500.43
damage ; contact
turbine or compressor 500.53
Mitsu i Techno Service,
if required
nozzle ring or compressor nents ; contact 500.52
if required 500.54
10 Turbocharger vibrates Turbine wheel heavily contami- Clean 500.21
nated 500.22
Thrust ring, labyrinth ring dam- 500.45
aged 500.53
if required
if required 500.53
500.56
if required 500.56
Foreign objects in front/in tur- 500.43
damage ; contact
bine or compressor 500.53
if required
nozzle ring or compressor nents; contact 500.52
if required 50054
Table 1-5: Trouble Shootmg
~~ 4C-09341 C1 5.3 TCA55 49

11 Compressor pumps Turbine wheel and/or nozzle Clean (See separate volume)
500.52
Foreign objects in fr ont/in tur- Check turbine/compressor for 500.43
bine or compressor damage ; conta ct Mitsui Techno 500.53
Charge air coo ler contaminated Clean Engine
Charge air temperature too high Reduce output Eng ine
Inlet/exhaust valves, valve slots Clea n Engine
of engine co ntaminated
Exhaust-gas back-pressure be- Check exhaust gas pipe Engine/Plant
hind turbine too high
Fuel injection at engine faulty Repair fuel injection Engine
Table 1-5: Trouble Shootmg
4C-09341 C1 5.3 TCA55 50

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 operationa l readiness and operational safety of
the system. They are to be ca rried out by competent personnel in
accordance with the time schedule for maintenance.
Maintenance work supports the operating personnel in their effort to detect

arising malfu nctions/fail ures 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 qua ntity of spares for unexpected outages.
Maintenance Schedule
The required tasks are listed in the maintenance schedule (C hapter 6.3). It
contains
• a brief description of the work ,

• the repea t interva Is,
• 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 tech nica l documentation.
They describe
• the aim and object of the work
and contain information about
• the req uired tools/appliances and

• detailed descriptions and graphical depictions of the necessary work
sequences and work steps.
4C-09341 C1 6.1 TCA55 51

Spare Parts
Ordinal numbers for spare parts
• Turbocharger: In the spare parts cata log in val. C3 of the technical docu-
mentation
• Tools: Table of conte nts for tools
can be found on the respective work cards in va l. C2 of the technical

documentation .
Ordinal numbers consist of the 3-digit assemblies number, a dot, and a 3-digit
position number.
4C-09341 C1 6.1 TCA55 52

Tools 6.2
Inventory tools Co nventional tools, usually included in the inventory of the engine system.
Inventory tools are not conta ined in the turbocharger's scope of supply.
Standard Tools Included as standard in the turbocharger's scope of supply.

Normally, one set of standard tools is sufficient for a system with several
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 ordi nal numbers of the
individual tools can also be taken from the table of contents.
Tools Requested by the Custome r Additional tools and appliances can be ordered at the Mitsui Engineering &
Shipbuilding Co , Ltd. as required.
4C-09341 C1 6.2 TCA55 53

Maintenance
Maintenance Schedule 6.3
Reliability and Adaptability
Validity of the Maintenance The maintenance schedule contains a summary of the maintenance and in-
Schedule spection 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 with two-stroke engines.
After each major overhaul, which best is carried out with a due engine
service, the maintenance schedule starts from the beginning again.
A major overhau l includes the disassembly of the complete turbocharger 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 and an
Schedule 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 qua lities,
• Attentive separation of fuel and lubrication oil.
The maintenance intervals must be shortened when the following operating

conditions are given
• Longer-term operation with peak loads or low loads, long idle periods,
frequent heavy load cycles,
• Frequent engine starts and repeated run-up phases without sufficient
warm ing-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 qua lities and insufficient separation,
• Insufficient filtration of the intake air (particularly with stationary engines) .
4C-09341 C1 6.3 TCA55 54

Maintenance Schedule (Turbocharger on the Two-stroke Engine)
1'
2,
3
,. rC ,. .c
lU =
X
y
I (E) per
""'
N
0
l()
0
l()
.,....
0
l()
N
0
0
l()
.,....
0
0
0
I'?
0
0
0
1.0
0
0
~
.,....
0
0
~ ~
0
0
.,.... N
0
0
~
I'?
Inspection (during operation)

901 Check turbocharger for unusual noise or vib rations. A 1 0.1 TCA X
()
__.
' 903 Check turbocharger and system pipes for leaks A 1 0.2 TCA
X
(charge air, exhaust gas, lubricating oil)
905 Check all th e fixing screws, casing screws and pipe con nection s for tight fit C2-2.1 1 1 TCA 2 X
Maintenance (during operation)
91 1 Clean turbine 1 0.3 TCA 1
-Dry clean , if available
913 Clean turbine 1 0.6 TCA 1
-j -Wet c lea n, if ava ilable
()
)> 915 Clean co mpressor (in operation) 1 0.3 TCA 1
<Jl
<Jl 917 Clean ai r filter (if available) 500.24 1 0.4 TCA 1
1.2.3 Serial number of the maintenance work Q) Required time in man hours
,.. .-< Brief description of the maintenance work
Pertaining work card with detailed instructions
per
24-24000
Size of ratio for the data of required time
Repetition intervals in operating hours
I X
A = No work card necessary/available
Cross -reference to tasks that are ideally carried out together.
X
1
Maintenance work due
As required/depending on condition
==
y 2 Checking of new or overhauled parts required(once
Required personnel after the mentioned time)
1:
<Jl
<Jl
;.::!
~~ Maintenance
Maintenance Schedule (Turbocharger on the Two-stroke Engine)
,,
• I
1, X
2, vC '">£ < =y Q) per ...,. 0
0
I()
0
I()
0
0
I()
0
0
0
0
0
0
80 80 80 80
~
N (I) It>
3 N I() ...- N ...- (") It> ...- ...- (")
Maintenance (in common with an engine maintenance)

0__. 931 Clean and check compressor casing , insert and compressor wheel 500.41 2 4 TCA X
I
(visually check and clean , as required) 500.42
Establish operational readiness of the turbocharger again 500.43
951 Major overhaul C2- 2 20 TCA X
24 000 - 30 000 operating hours: 3. 3 ..3.5
Dismantle, clean and check all components of the turbocharger.
Check gaps and clearances upon assembly C2-2.2
1,2.3 Serial number of the maintenance work Q) Required time in man hours
-l
0
):>
,.......c 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
i
(J1
(J1 A = No work card necessary/available X Maintenance work due
X Cross-reference to tasks that are ideally carried out together. 1 As required/depending on condition
<=
y 2 Checking of new or overhauled parts required (once
Required personnel after the mentioned time)
(J1
(J)
Remarks to the Maintenance Work 6.4
Disassembling the Turbocharger
Disassembly Turbocharger T he simplest method to go about the disassembly depends on the space
conditio ns in the engine room . When pe rforming 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 turbocha rge r or for repair work concerning major
components, it is recommended to record the condition of individual
subassemblies and make entries into the operating log. Inspection 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 bala ncing precision and thus the smooth running or rotating
pa rts, must be exchanged with orig inal spa re parts or repaired by an
authorized repair faci lity or the manufact urer.
For dispatch, components must be packed and protected against corrosion

in such a manner that they are not further damaged during transportation.
Screw Connections
Loose ning Seized or Snug Important! Never attempt to loosen seized or snug screw connec-
Co nnections tions with overly force. This can lead to screws being tom
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 disso lver (e.g. Caramba , Omnigliss,
WD 40) to the screw con nection and a Ilow to penetrate for at least 1/2 hour,
so that the dissolver can work its way through the threads. Observe the
applicational tips of the dissolver manufacturer. Afterwards , apply light
hammer blows to the screw/bolt head so that the threads run freely.
Tighteni ng Screw Co nnections All screw con nections 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 th ere will be no securing effect
4C-09341 C16.4 TCA55 57

Fig . 10. Assembly of wedge lock washers
Important/
Always tighten screws/bolts with the specified tightening torque/
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 All lock washer pairs on the turbocharger are made of non-scaling material
and are not marked.
In order to avoid the screws/bolts and nuts on the turbine side from 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 t hreads from studs are
not treated.
4C-09341 C1 6.4 TCA55 58

Inspection of Individual Components 6.5
General Information
T he 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 repla cement of individual components.
Inspection Work
Gaps and Clearances Admissible values, see C2 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 C2 chapter 2.2.
Streaks, locally on ci rcumference 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 dam-
aged or pre-lubrication pressure too high.
Erosion during HFO Operation During HFO operation, small , hard particles (e.g. "catfines") are contained in
the exhaust gas. These act particularly erosive where high gas velocities and
high concentrations of such particles occur. The highest flow rates are effec-
tive at the outlet of the turbine nozzle ring. Here, the flow is strongly deflected
towards the direction of the circumference. Besides this, the particles con-
tained in the exhaust gas are hurled towards the outside. For this reason ero-
sions ca n be noticed at the discharge of the nozzle ring , at the interior diam-
eter 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 (recogn izable through the AI and Si
content) as we ll as other abrasive contaminants, are contained in the heavy
fuel oil. Their amount can be reduced by means of well dimensioned, heated
settling tanks und through sufficient separation.
4C-09341 C1 6 .5 TCA55 59
Additions Adding used engine lube oil is of particular disadvantage , recognizable
through the increased amounts of Ca and Fe. Used engine oil not only con-
tains residues of wear, but above all "Detergent dispersing additives", which
bind fine particles and prevent "catfines" and other impurities from being
eliminated through separation. For operation with "waste oil" added, a sharp
increase of erosion damage is noticed.
Combustion residue caused by incomplete co mbustion can also have ero-
sive effects. Therefore, ensure clean combustion.
Silencer, if available How is the condition of the air filter mat? How is the condition of the absorp-
tion 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 casi ngs tight, particularly at the parting lines and the connection
flanges? Do the casings show signs of cracks?
Were screws/bolts torn? Were all screws/bolts and nuts firmly tightened 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 whee l and the carrier?
Are the seat fa ces bright or are there signs of fretting?
Do the blades show signs of cracks or heavy wea r? Are there traces
of streaks?
Do the leading edges of the blades show puncture notches caused
by drawn-in foreign objects?
Turbine Roto r 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 detecta-
ble? Do the blades have signs of cracks?
Do the blades, disk 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 disk with
play At the blade end. they can be moved several millimeters both in axial
and in circumferential direction. Due to deposits. this movability is limited
after extended periods of operation.
Shroud Ring Are there any traces of streaks from the turbi ne blades?
The radial gap betwee n shroud ring and turbine blade may not fall below the
minimum va lue at any position, in order to avoid grazing during operation.
The gap ca n become larger due to erosion. This considerably influences the
efficiency Therefore, the gap is measured at 41ocations around the circum-
ference (every 90°) during checking. Admissible va lues, see work card
[500.54]
4C-09341 C1 6.5 TCA55 60

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 play of the running equipment and the bearing play within the ad-
missible range?
Note!
When the axial bearing play 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 (Guide line)
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 val ues and are reached with turbochargers
that operate on engines powered with heavy fuel oil.
Continued use or replacement of components is decided upon at each major
overhaul of the turbocharger. It is imperative that major overhauls are
performed according to the periods specified in the maintenance schedule.
4C-09341 C1 6.5 TCA55 61

4C-09341 C1 6.5 TCA55 62
Inspection Report 6.6
Accompanying the installer report .. ... ... . ... ...... .... ... ...... .. ...... . Date ...... .. ... . ... ..... ... .... .
Name of customer .. ...... ........ ... .... . Turbocharger ......... .
Address .... Works No ................
Site ................... Engine type ...... .. ... .. ..
Name of vessel .... Works No ....... ...... .
Turbocha rger 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 0 Diffuser 0 Turbine rotor

0 checked
0 utilized 0 replaced 0 utilized D replaced
0 contaminated . reason .. . ... . ... .
0 Intake casing , if available 0 balanced
0 blades
0 contaminated 0 bent 0 torn 0 contaminated
0 damage from foreign objects
0 traces of streaks
0 Silencer. if available
0 Compressorwheel 0 axial 0 radial
D Air fitter mat 0 all around the
0 utilized D replaced circumference
0 utilized 0 replaced 0 locally on the
0 contaminated 0 cleaned Reason .... .. .. .... .
circumference
0 Speed transmitter. if available 0 contaminated.
Location .
0 defectiv·e.... .... .. .. . 0 traces of streaks
0 blades
D axial 0 radia l
0 bent
0 Insert 0 all around the circumference
0 torn
0 locally on the circumference 0 blade
0 utilized 0 replaced
Location .. .. ..... . 0 foot plate
0 contaminated.
0 foot
0 traces of streaks 0 blades 0 damage from foreign
0 axial O radial 0 bent 0 torn objects
0 all around the circumference 0 damage from foreign objects 0 erosion
0 locally on the circumference 0 bore 0 coverings
0 signs of frettin g 0 light
Location . ..... . ... . . .
0 heavy
D Compressor housing 0 Thrust ring 0 one-sided
D contaminated . D utilized D replaced 0 Bearing points
0 signs of scoring 0 wear 0 signs of scoring D wear
D cracks D signs of fretting
0 seatings
D damage from foreign objects 0 signs of fretting
Location .
0 labyrinth tips
0 oil coke D wear
4C-09341 C1 6.6 TCA55 63

D Bearing casing D End cover, turbine side D Shroud ring
D Contaminated . ....... . 0 utilized 0 replaced D utilized 0 replaced
D Cracks 0 abnormal ru n-in pattern reason.. . .... ... .... . .
0 wear
D Sealing air bores 0 Contaminated .. . ... . .
0 oil coke D cleaned
D clogged D cleaned
0 Erosion ... .... ..... .
D Labyrinth disk, turbine side
D Oil bores
0 Traces of streaks
D clogged D cleaned 0 utilized 0 repla ced
0 all around the
D Seals 0 Wea r circumference
D replaced 0 oil coke 0 cleaned 0 locally on the
D Sealing air valve , if available D Turbine nozzle ring circumference
Location.
D Valve plate 0 utilized 0 replaced
0 moves easily 0 replaced D Gas-admission casing
0 blades
0 Bearing disc 0 bent 0 torn 0 Contaminated . ...... .
0 utilized 0 replaced 0 damage from foreign objects 0 Cracks
0 signs of scoring 0 wear 0 puncture notches 0 Erosion
0 length(!) -compressor side 0 erosion .. .. .. . .. .. .. . 0 Damage from foreign objects
Taperface . .. ........... mm 0 Screw con nections
0 length (l) - turbine side 0 coverings ..
Taperface . . ....... .... .mm 0 light 0 loose 0 torn off
0 heavy 0 repla ced
D Counter-thrust bearing
0 one-sided
0 utilized 0 replaced D Gas-outlet casing
0 signs of scoring 0 wear 0 contaminated . . .. .. .. .
0 length(l)/taperface . . . .mm
0 Crac ks
D Labyrinth disk, compressor side
(sealing cover) 0 Damage from foreign objects
0 Screw connections
0 utilized 0 replaced 0 loose 0 torn off
0 abnormal run-in pattern 0 repla ced
0 wear
0 traces of streaks
Gaps and clearances (admissible values , see C2 chapter 2.2)
Pos. 6 Turbine blade/shroud ring (Radia l gap) ................... ......... ... ...... ...... ... ... ......... ............ ... mm
Pos. 10 Compressor w heel/insert (Axial gap) .. ......... .................. .. ............ .. .................... ....... ... mm
Pos. 11 Compresso r w heel/insert (Rad ial gap) .. .. ...... .... ... .. ........................... ................ ...... ..... mm
Remarks:
Date Sig nature
4C-09341 C1 6.6 T C A55 64

Service Report 6.7
Name of author:
Name of customer:
Name of plant/vessel:
Turbocharger:
..........
Engine type:
Works No.: Works No.:
Overview Length, Gaps and Clearances of Turbocharger TCA
Meas. Point 6a/mm

Turbine Rotor
Meas. Point 11/mm

Compressor Wheel
I I
'------'1 -$· ~I __j
Thrust bearing Counter -thrust bearing

(bearing disk)
Running Hours: [----·----------il--1

Clearance Clearance Clearance Meas. Point
3a/mm 3b/mm 3c/mm 10/mm
cs 1l ts 2l cs ts cs ts
Maintenance
Length 1/mm Length 1/mm COC-No. COC-No .

thrust bearing counter-thrust brg . turbine rotor compressor wheel
Maintenance
1) compressor side
2) turbine side
4C-09341 C1 6.7 TCA55 65

Bearing Point 01/mm
cs ts
Turbine rotor
Meas. Point 02 /mm
r-·--......................................,
I l
i' - -!
Meas. Point 02/mm
i""'-'"""""'"""'"'"-""""'""1
Il__________ _ji Labyrinth rings
Remarks:
Date Signature Owner's Representative Signature Service Engineer
4C-09341 C1 6.7 TCA55 66

Work Cards
C2
Exhaust Gas Turbocharger ................ TCA 55
4C-09341 C2 TCA55 67
page
1 Introduction ................................................................................................................... 69
1.1 Prefa ce .......... . . ............. ........ 69
1.2 Layout and Usage of the Work Cards ... ········ ······· ............. .... . ... .. .. .. ............... .. ......... .. ........... 70
2 Setting Data .......................... ... ...................................................................................... 73

2. 1 Bolted Connectio ns and Tightening Torques .. 73
2.2 Gaps and Clearances . ... 77
3 Work Cards ................................................................................................................... 81

3.1 Emergency Operation .. . 81
500.11 Operation with Holding Device . ................ .... . 83
500. 12 Operation without Rotating Element . ... .. .. ........ . .................. . ... .. .. .......... .. .. .. .. .... .... ... ..... . .... 87
3. 2 Cleaning . ........... .. ......... .. ... .. ........ 91

500.24 Cleaning the Air Filter ... ...... ..... ... .. . 93
3.3 Assembly of the Turbocharger and Au xilia ry Equipment ......... 95

500.31 Turbocharger to Engine ....... ........... ... ..... .. .. .. .................... 97
500.32 Silencer .... 103
500 34 Emergency and Post Lubri cation Tank .. .. 107
3.4 Assembly and Maintenance- Compressor Side ...... ......... .......................... . ... 109
500.41 Speed Transmitter and Insert . ... ... ..... . 111
50042 Compressor Casing and Diffuser ........ ............ .. ... . ..... ............. 11 7
50043 Compressor Wheel ... . .. . .. ... .... ...... .. ... ...... ..... . ..... .. ... .. .. ... .. .. .. .. . 121
50044 Labyrinth Disk ........ . ....... ....................... ... .... .......... ... ..... .. .. ..................... .. ... ...... .... .... .............. 131
50045 Ring Nut and Labyrinth Ring .. ... ... ......... .. .... ... .... ............ . ... ... ......... . ... 135
50046 Thrust Bearing, Counter-Thrust Beari ng and Bearing Disk ........... .. ... .. .. .. . .. .. .... .. ... .. ... ...... 139
3.5 Assembly and Maintenance- Tu rbine Side ... ..... ........... . .... .. 149
500.51 Gas-admission Casing . . .. ..... . ... . . . ... . ........ 151
500.52 Turbi ne Nozzle Ring .... .... .......... . ........ .... ... ..... ... ... ...... ....... ...... ...... .... .. .. .... ... ....... ...... ... ........ ............. 155
500.53 Turbine Rotor ... ... . ... .. . ..... ...... ... . ... .. ....... ....... . .. ... ... .... ... ... .. ............. ... .. ... ... .... .. . .. ... .. .. ... ..... ... .......... 157
500.54 Shroud Ring ............. . . .. .... ... .. . .. . .. .. .. .... ... .... . .... . . .. .. ... ... ... ... .. . .. ..... .... ... . .... .. 161
500.55 End Cover ... ..... ....... ......... ........... . ... ... .. ..... . .. ..... .... ...... ...... .................. ... ....... ........ .... .................. .... .. 165
500.56 Bea ring Bushes... . .................. .......... 167
500.57 Gas Outlet Diffuser . . . .. . ... .. . . . .. .. ... ... ... ...... .. ...... ... .... ... . ... ... ... . ... .. ... . 173
4C-09341 C2 TCA 55 68
Introduction 1
Preface 1.1
Work Cards and Maintenance Schedule
T he work cards supplement the mai ntenance schedule of the turbocharger

in Volume C1 (Operati ng Instructio n) of the technical documentation. There ,
the required maintenance work is listed only in key words, whereas in the work
ca rds the requi red 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 severa l work cards must be observed.
ATTENTION
Danger of burning from hot components!
Many engine and turbocharger components become very hot during
operation and required ample time for cooling down afterwards.
•
· Prior to taking any action, al low the engine and turbocharger to cool down
I
(
'\I sufficiently!
~r
• Wea r protective clothing!
ATTENTION
• .
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!
• Duri ng the work, secure the engine against starting I
· Set nsl
4C-09341 C21 .1 T CA55 69

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 represents the collec-
tive subassembly group number for turbochargers.
Example :
Subassembly group number (500 for turbocharger)
Count1ng number (work card No. 31) _ _ _ _ _ _ _ _ _ _ _ _____._

J J
Turbocharger on engine ................................................................... 500.31
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 neces-
sary 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) J

Position number - - - - - - - - - - - - - - - - - - - - - - - '
All assemblies and subassembly group numbers are listed in Section C3

Chapter 2.
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 qualifica-
tion of the required personneL The higher hour rate covers the time require-
4C-09341 C21 .2 TCA55 70

ment for the complete scope of the respective work ca rd Personnel with low-
er hour rate is required only at times, e. g., for operation of a lifting tackle.
Tools/ Appliances Numbers mentioned under the Designation col umn represent spanne r
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 incl uded in the scope of supply, turbochargers are equipped with a set of
standard tools.
Option Tools requested by the customer (with tool number)
Inve ntory Commercially available tools/appliances
These are not included in the supply scope of the turbocharger . It is as-
sumed that these tools/appliances are included in the inve ntory of the en-
gine system.
Special Tools Special tools, e. g. for service centers
4C-09341 C21.2 TCA55 71

Setting Data 2
Bolted Connections and Tightening Torques 2.1
Short Version
Tightening values for all important bolted con nections/tightening torques for
various friction coefficients 1-J.
Tightening Torques for Bolted Connections
T ightening of Bolted Connections Whenever possible, bolted connections should be tightened with torque
by Torque wrenches.
Particularly important bolted connections on the turbocharger are specified
in Table 2-3 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 2-2.
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 co mpletely observed.
• The tightening torques for the various threads, depending on thei r coeffi-
cient of friction IJ (meaning depending on the selected lubricant), are listed
in Table 2-2. The tightening torques apply for bo~ materia ls 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 2-2.
The property class is impressed on the bolt head
Table 2-1. Conversion factors for tightening torques depending on the property class
of the bolts
Friction coefficient IJ For the friction coefficient IJ use approximatel y:
1J = 0.08 for lubricants at temperatures

~ 200 ' C, e. g. Molykote G-n or Mol ykote P40
~ 200 ' C, e. g. Molykote HSC
IJ = 0.14 for lightly oiled surfaces without refinishing
4C-09341 C2 2.1 TCA55 73

Tightening Torques in General
Tightening torque Tightening torque
Thread, in Nm with friction Thread, in Nm with friction
Nominal coefficient J.l Nominal coefficient J.l
size size
0.08 014 0.08 0. 14
M5 4 6 M24 475 690
M6 7 10 M24x2 500 750
M8 17 25 M27 700 1020
M10 34 50 M27x2 730 1100
M12 60 85 M30 950 1380
M14 95 135 M30x2 1015 1540
M14x1 .5 100 145 M33 1270 1870
M 16 140 205 M33x2 1350 2060
M16x1.5 150 220 M36 1640 2400
M18 200 280 M36x3 1710 2550
M18x1.5 215 320 M39 2115 3120
M18x2 205 300 M39x3 2190 3300
M20 275 400 M42 2630 3860
M20x1.5 295 450 M42x3 2760 4170
M20x2 285 425 M45 3260 4820
M22 370 540 M45x3 3415 5180
M22x1.5 385 595 M48 3950 5820
M22x2 380 565 M48x3 4185 6370
Table 2-2. Tightening torques for bolts, property class 8.8
4C-09341 C2 2.1 TCA55 74

Tightening Torques, Turbocharger
Important!
The tightening torques in Table 2-3 apply to a friction coefficient
p=0.08;
Work Description Tightening

Card Torque in Nm
500.11 Undercut bolt (546.0t3) <*> 75
Cylindrical screw (596.023) for hub 34
500.12 Closing device(emergency operation) :
Hexagon bolt(517.093)/Hexagon nut 60
(596.032)
500.32
Silencer at compressor casing :
60
Hexagon nut (544.182)
500.34 Emergency and post lubrication system:
60
Hexago n bolts for flanges/oil hoses
Hexago n bolt (554.048) 59
Hexago n bolt (554.056) 59
50041 Insert Undercut bolt (546 073) <*> 75

50042 Diffuser: Hexagon bolt (546.04b) 60
Compressor casing:Hexagon nut (506.104) 250
50043 Thrust screw for superbolt-tension nut 14
50044 Labyri nth disk: Hexagon bolt (517.093) 60
500.46 Thrust bearing : Hexagon nut(517.1 02) 60
Co unter-thrust bearing :
17
Hexago n bolt (517.157)
500.51 Gas-admission casing
70
Hexago n bolt (506. 106)
500.52 Nozzle ring/shroud ring :
70
Hexagon bolt (513.013)
500.54 Shroud ring : Hexagon bolt (509 012) 70
500.55 Stud screws : Lock nut(517. 094) 60
500.56
Counter-thrust bearing:
17
Hexago n bolt (517.157)
Table 2-3. Special tightening torques at turbocharger- contact surfaces and threads
lubricated with Molykote HSC)
*) In case the insert piece is without IRC, the tightening torque is 40Nm.
4C-09341 C2 2.1 TCA55 75

4C-09341 C2 2.1 TCA55 76
Gaps and Clearances 2.2
Short Version
Gaps and clearances are to be measured and compared with the specified
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
509.008 Shroud ring 520044 Compressor wheel

517.161 Bean!Jg bush 540.001 /nsen
517.1 62 BeaniJg body 540.030 Balance ring
520.001 Turbine shaft
Fig. 11 : Overview, gaps and clearances
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).
4C-09341 C2 2.2 TCA55 77

Gaps and Clearances Measuring Condition as Replace Pans Work Card
Point Manufactured
Min. [mm) I Max. [mm) Min. [mm) I Max. [mm)
Radial Clearance Bearing Bush/Turbine Shaft
3a 0.04 0. 07 500.53
500.56
I
520 .001
Radial Clearance Bearing Body/Bearing Bush: Turbine Side
3b 0.22 0.26 500.56
517.161
Radial Clearance Bearing Body/Bearing Bush: Compressor Side
3b 0.22 0.26 500.56
Axial Clearance Bearing Bush/Bearing Body: Turbine Side
3c 0.23 0.3 1 0.35 500.56
517.161
4C-09341 C2 2.2 TCA55 78

Gaps and Clearances Measuring Condition as Replace Pans Work Card
Point Manufactured
Min . [mm} I Max. [mm} Min. {mm] I Max. [mm}
Axial Clearance Bearing Bush/Bearing Body: Compressor Side
3c 0.23 0.31 0.35 500.56
517.161
Radial Gap Turbine Blade/Shroud Ring
0.80 1.00 (0.70) 2 ) 1.20 500.54
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.
Axial Gap @) and Radial Gap @ Compressor Wheel/Insert
1.40 1.60 1.80 50041

0.95 1.05 (0.80)3 ) 1.20 500.4 1
1) Set rotor towards system in direction (A) Measure the axial gap at 3 locations on the circumference via soft-metal
marking, and ca lcu late 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 va lue.
3) The minimum value may not be fallen short of at an y location on the circumference.
Important! Gaps and clearances marked with(*) are to be recorded

in the inspection report (see Section C1, Page 63).
4C-09341 C2 2.2 TCA55 79

4C-09341 C2 2.2 TCA55 80
Work Cards 3
Emergency Operation 3.1
4C-09341 C2 3.1 T CA55 81

4C-09341 C2 3.1 TCA55 82
Operation with Holding Device 500.11
Short Version
Enable emergency ope rati on by blocking the rotating element
Required Personnel and Time
Amount Qualification Required Time [h]

1 Qualified mechanic 06
1 Assista nt 0.6

1 Open-jaw wrench 36 - Inventory
1 Hex key 14 - 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

500.12 500.32 500.41
4C-09341 C2500.1 1 TCA55 83

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 element
is not possible.
Note!
By using the closing mechanism further damage of the rotating element ca n
be avoided
Work Sequence- Assembly of the Holding Device
596.022
I 596.023
520.044 596.024
520.001 Turbine rotor 596.022 Hub

520.044 Compressor \Nheel 596.023 Cylindricql screw
546.073 Undercut bolt 596.024 Lock washer pair
596.018 Locking key
Fig . 12. Special tools for operation with holding device
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 install ing the securing fixture in the
turbocharger.
· During the wo rk, secure the engine against starting.
· Set up danger signs!
4C-09341 C2 500 .11 TCA55 84

Starting Condition Silencer [500.32] , insert [500.41] and balance ring (540.030) disassembled
Work Steps 1. Unscrew spinner from compressor wheel (520.044).

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 bo lts of the insert.
Important/
Use Lock washer pairs (546.074)1
4. Mount the silencer again .
Important!
Lubricate contact surface and thread (e.g. Molykote HSC)I
WARNING
Danger of fire caused by lube oil!
During emergency operation with the securing fixture, the danger of fire
Ia is given when lube oil gets into turbocharger.
~
·ln e shut the oils to the turbocha
Note/
Additional emergency operation notes. see Section C1 -Chapter 52
Important!
ObseNe tightening torque upon installation!
Undercut bolt (546 073): 75 Nm

*) In case the insert piece is without IRC, the tightening torque is 40Nm.
Cyl indrical screw (596.023) for hub 34Nm
4C-09341 C2 500.11 TCA55 85

4C-09341 C2 500.11 TCA55 86
Operation without Rotating Element 500.12
Short Version
Enabling emergency operation by disassembling the rotating element and

closing the bearing casing with closing covers.
Amount Qualification Required Time [h)

1 Qualified mechanic 3.5
1 Assistant 35
Requ ired Tools/Appliances

(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

500.11 500.32
500.41 500.43 500.44
500.51 500.53
Technical data
Designation Specification
Closing device 16 kg
Closing cover (compressor side) 11 kg
Closing cover (tu rbi ne side) 3.5 kg
4C-09341 C2 500.12 TCA55 87

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 remova I of the rotating element is not pos-
sible.
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 I
596.033~~~ ..
517.093(8x)-,~(O·
· •· ·~596.032
517.095 (Bx) ""-.... . 596 .031 596 029
·~- ~~ i
596.027
I -""-...._""·""-.....
" (. )·..· ·..
""-.... .
.. .
596.030
rn· 1 596.028
~"'-....LflJ 1 596.033
(lo-u~96.032
...(~
1
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
Fig. 13. Closing mechanism at emergency operation without rotating element
4C-09341 C2 500.12 TCA55 88

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 I
Sta rting Condition [500.32] , 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 St• 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 (596033) each into
the closing cover.
Fig . 14. Installed closing cover (compressor side and turbine side)
4. Mount gas-admission casing.

5. Mount silencer.
~--- ~
_. ---------=--~~W
__A_R_N~IN~G~~=-----------------~
~ Danger of fire caused by lube oil!
During emergency operation without running equipment, the danger of
fire is given when lube oil gets into the turbocharger.
· In emergency operation , always shut the oil suppl y pipe to the turbocharger.
4C-09341 C2 500. 12 TCA55 89

Important!
Lubricate contact sutfaces of thread (e.g. with Molykote HSC)f
Note!
Additional emergency operation notes. see Section C1 - Chapter 5.2.
Important/
Observe tightening torques upon installation!
Hexago n bolt (517.093): 60 Nm

Hexago n nut (596 032): 60 Nm
4C-09341 C2 500.12 TCA55 90

ork Cards
Cleaning 3.2
Concerning wet cleaning I dry cleaning of the turbine and cleaning of the compressor (if fitted), please see a
separate volume.
4C-09341 C2 3.2 TCA55 91

C2 3.2 TCA55 92
4C-09341
(;rk Carel
Cleaning the Air Filter 500.24
Short Version
Clean the air filter regularly in accordance with the maintenance schedule.
T he work can be carried out during operation.
t Before remove the air filter mat, dismantle the side cover of AIC
Afte r reinstall the air fi lter mat, mantle the side cover (if the silencer is
equipped with AIC).
Qualification Required Time [h]

Qualified mechanic 0.3

- Compressed air - Inventory
- Cleaning Agent (non-corrosive) - Inventory
Spare Parts
Amount Designation Number

1 Ai r fi lter mat 544150
3 Lashing strap with ratchet 544160
1 Cover strip 544.0 12
General The soi led air fi lte r mat (544.150) can be cleaned several times, or replaced
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 contam inated air filter mat.
should not be used as a refererce for the cleaning interval.
4C-09341 C2 500 .24 TCA55 93

DANGER
Danger to life from crush injuries or blows against ng
components!
When the inspection cover (see Fig.15) 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!
Cleaning Interval Every 250 operating hours.
The cleaning intervals depend on the contamination degree of the drawn-in

air and therefore ra nge 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.
Fig . 15.1nspection cover (1) Fig 16. 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.@ ).
2 Clean the soiled air fi lter mat with wa rm water and a clea ning agent
(no n-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.
3. Place the air fi lter 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.
4C-09341 C2 500.24 T CA55 94

Assembly of the Turbocharger and 3.3
Auxiliary Equipment
4C-09341 C2 3.3 TCA55 95

4C-09341 C2 3.3 TCA55 96
A..::::r.~~tHf~l1j'
...... ,. . . ~~~~\· of·
~
t·" ~1P
. ;;....
1 · ~;t·:t"'\,-. . t"' 1."~~
'U1 •""'"""'""' t~H
"'yg·· ,...,r
r.7
Turbocharger to Engine 500.31
Short Version
Removing and Refitting the Turbocharger from and to the Engine.

1 Qual ified mechanic 6.0
1 Assista nt 6.0

2 Shack le - Inve ntory
1 T orq ue wrench - Inventory
1 Open-j aw and ring wrenches (set) - Inventory
1 Socket w rench (set) - Inventory
1 Screwdriver - Inventory
1 Lifting tackle , ropes - Inve ntory
- Wood (for placing underneath) - Inventory
1 High-temperature lubrica nt - Inve ntory
(e.g Molykote HSC)
Work Cards

500.41
Technical data
Turbocharger 3370 kg
4C-09341 C2 500.31 T CA55 97

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 fists of tools [596.01] see Section C3.
For standard spare parts see a separate volume.
• Socket adjustments of the casings are fa ctory set.

• Connections are shut with sealing caps.
• Interior components are conserved with corrosion prevention agents that
are consistent with operating media.
• Protective coating aga inst corrosion on the outside.
Condition at time of supply with In order to achieve increased corrosion protection (e. g., overseas, tropics,
increased corrosion protection subtropics), the following measures are additionally carried out:
• Dryi ng agent (bag , block) at the inside of closi ng 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 ke rose ne.
2. Remove sealing caps/lids.
In case of increased co rrosion protection:
3. Remove all drying agents, if applicable.

4 Blow compressed air through turbocharger casing, in order to remove
vapor -phase co rrosion 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.
·Thoro ughly blow out the turbocharger casing before assembling the
turbocharger.
• Upon initial into operation, check if any co rrosion protection agent is on the
turbocha
4C-09341 C2 500.31 TCA55 98

Work Sequence 2- Assembly to the Engine, Connection of the Charge Air and Exhaust Pipes
General
1 Suspension device 544.000 Silencer

501 .001 Gas-admission casing 546.000 Compressor casing
506.001 Gas outlet casing
Fig . 17. Suspension device for turbocharger with axial gas-admission casing
Note!
Suspension device mounted to turbocharger (condition of delivery).
Work Steps 1. Insert shackle and tackle line to suspension device.
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 onl for the lifti individual """"r"''"'"'''"'""
4C-09341 C2 500 .31 TCA55 99

nger ury ed 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 casi ng (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 turbocha e room.
2. Lift turbocharger with lifting tackle and place onto bracket of engine.
3. Align ing 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.
lmporlant!
The turbocharger must be aligned parlicu/arly accurate when a sliding
sleeve is used between compressor casing (546.000) and air pipe
instead of a compensator.
4. Lightly tighten the cas ing feet on the engine bracket Use the fastening
bolts and the resil ient sleeves (delivery scope of engine) for this.
5. Connect the exhaust pipe of th e 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. Co nnect the pressure socket of the compresso r 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 co nnection of the casing feet on the engine bracket
with torq ue wrench (see engine docume ntation) .
lmporlant!
Lubricate contact surfaces and threads (e.g. Mo/ykote HSC).
lmporlant!
Observe tightening torques upon assembly/
Screw connection of the casing feet on the engine bracket: See engine
manual.
4C-09341 C2 500.31 TCA55 100

Work Sequence 3- Connection of the Lube Oil System
General Backi ng up in the lu be oil discharge can lead to oil-flooding of the tu rbo-
charger. In the process, oil ca n 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 co nnect the
lube oil supply and drai n 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 terminal box
(compresso r casi ng) according to the electrica l wiring diagram
Also see work ca rd [500.41].
4C-09341 C2 500 .31 TCA55 101

Work Sequence 5- Cleaning System Connection (Option)
• Connect the dry cleaning system for the turbine at the intended location
on the engine/turbocharger.
• Mount the wet clea ning equipment for the turbine to the connections of
the cleaning nozzles (gas-admission casing).
• Connect the wet cleaning equipment for the compressor to the
con nection of the injection pipe in the compressor casing.
Work Sequence 6- Removal of the Turbocharger
Removal of the tu rbocharger is carried out in reverse order of assembly.

Due to restricted space conditions, it may be necessary to remove the tur-
bocharger in partially disassembled condition (silencer, compressor and
admission casing, and rotating element disassembled) (see Chapter 3.4
and 3. 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 ope ning pipes, flanges, screwed connections or gauges, free the
system of pressure and check that it is pressure-free!
· Before opening oil pipes, wa it until the lube oil has cooled down sufficiently
(1-2h).
• Drain the system and check that it has been drained completely.
·Wear protective clothing !
4C-09341 C2 500.31 TCA55 102

Silencer 500.32
Short Version
Removal and installation of the silencer is carried out in completed condition.

Disassembly of the si lencer is required for all work that must be performed
from the compressor side (see Chapter 3.4).
t If the turbocharger is equipped with THS or AIC, refer to the additional
instruction manual.

1 Assistant 2.0

1 Torque wrench - Inventory
- Lifting tackle with ropes - Inventory
- Eye bo lts, shackles - Inventory
- Wood (for placing underneath) - Inve ntory
Spare Parts
Designation Number
Lock washe r pair 544.181

500.24
Technical data
Silencer 426 kg
4C-09341 C2 500.32 TCA55 103

General
544.000 Silencer 544. 182 Hexagon nut

544. 181 Lock washer pair 546.000 Compressor casing
Fig 18. Installation/removal of the silencer at the compressor casing
For clea ning of air fi lte r, see work card [500.24].
DANGER
Danger to life from crush injuries or blows against rotating
components!
Never remove the inspection cover (see Fig.18 in work card [500.24]) of
the silencer du ring operation. There is danger of becoming entangled
in or coming against rotating components of the silencer or
turbocharger and being seriously inju red.
• Shut down the engine before work ing on the silencer.
· During the work , secure the engi ne against starting!
· Set u ns!
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.
• For attachment of the lifting equipment, use only the lifting hooks on the
silencer which are intended for this purpose.
• Move the silencer from or towards the silencer.
4C-09341 C2 500.32 TCA55 104

Work Sequence 1 -Removing the Complete Silencer
Starting Condit ion Connection of the compressor washing equipment loosened (if available).
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 compressor

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 Insta llation is carried out in reverse orde r of removaL
Important!
Lubricate contact surfaces and threads (e. g. Molyl<ote HSC).
Important!
Mount hexagon bolts with lock washer pairs.
Important!
Hexago n nut (544.182): 60 Nm
4C-09341 C2 500.32 TCA55 105

4C-09341 C2 500.32 TCA55 106
Emergency and Post Lubrication Tank 500.34
Short Version
The post lubrication tank is removed only when the compressor casing is
disassembled
Qualification Required Time [h)


- Lifting tackle with ropes - Inventory
Spare Parts

1 Sealing ring 554 065
1 Sea ling ring 554.068
1 Sea ling ring 554.084
1 Sea ling ring 554.09 (
8 Spring washer 554.158
Technical data
Post Lubrication Tank 200 kg
4C-09341 C2 500 .34 TCA55 107

Work Sequence 1 -Removal of the Post Lubrication Tank
Starting Condition
554.001 Oil tank

554.027 Non-return valve
554.056 Hexagon bolt
554.001
(554 .A) 554.063 Hexagon bolt
554.065 Sealing ring
554 089 554 066 Pipe with connection
554.068 Sealing ring
554.084 554.081 Pipe with connection
554 .087 554.084 Sealing ring
554.081 554.087 Hexagon bolt
554 .09 5 554.096 Hexagon bolt
554.097 554097 Sealing ring
554 098 Sealing ring
554. 157 Plain washer
554 158 Spring washer
Fig. 19. Removal of the emergency and post lubrication tank (554.000)
Oil pipes (554.066 and 554.081 ) have been released from bearing casing
and oil tank , and oil drained. The openings at the emergency and post
lubrication tank (554.000) and the bearing casing have been provisionally
shut.
Check if the sealing rings (554.065, 554.068 , 554.084,554.097,554.098)
need to be replaced .
Work Steps 1. Fasten oil tank (554.001) to rope; use lifting device.
2. Loosen hexa gon bolts (554.056) of bracket.
3. Lift post lubrication tank (554 000) with lifting device and set down on
wooden support.
Work Sequence 2 -Installation of the Post Lubrication Tank
Work Steps Installation is carried out in reverse order of removal. Afterwards connect the
oil pipes (554066, 554.081) . Use new sealing rings, as required .
Important!
Lubricate contact surfaces and threads (e.g. Mo/ykote HSC)I
4C-09341 C2 500.34 TCA55 108

Assembly and Maintenance - Compressor Side 3.4
4C-09341 C23.4 TCA55 109

4C-09341 C23.4 TCA55 110
Speed Transmitter and Insert 500.41
Short Version
Installation and removal of the speed transmitter/insert required for assem-

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

1 Assistant 1.5

- Lifting tackle with ropes, chains - Inventory
- Eye bolts - Inventory
- Steel or straight-edge - Inventory
(1) (Removing and refitting tool for insert) (596 518) (Standard)
2 Guide bar 596.045 Standard
1 Shackle A1 596.046 Standard
Spare Parts

1 Seal disk 540.026
1 Seal disk 546.050

500.32 500.43
4C-09341 C2 500.41 TCA55 111

Technical data
Insert 130 kg
Prerequisites
596.045
520044 Compressor wheel 546. 000 Compressor casing

540001 Insert 596.045 Guide bar
540 030 Balance ring 596.046 Shackle
Fig. 20. Removal and Installation of the Insert in the Compressor Casing
General Disassembly of the insert (540.001) enables removal of the compressor

wheel (520.044) and a part of the bearings without having to disassemble
the compressor casi ng (546.000).
Important!
Prior to removal of the inserl, 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] disassembled
Work Steps 1. Disconnect the cable of the speed transmitter (562.040) in the junction
box (562.011 ), o~n cable socket (546 .049) and pull the cable to the
inside (see Fig. @ ).
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 (see
Fig@ ).
4. Carefull y place insert onto woode n supports and remove balance ring
(540.030).
4C-09341 C2 50041 TCA55 112

Work Sequence 2 -Installation of Insert and Balance Ring
Sta rting Condition Compressor wheel [500.43] installed.

Speed transmitter (562 040) assembled in insert (540.001) (see Work
Sequence 4).
Note!
Mount 0-ring seals ( 540 0 15) only for version with JET ASS/ SJI
1. Apply machine oil to 0-ring sea ls and mount into the ring grooves of the
insert (540.001).
Important!
0-ring seals must be tensed all around the circumferenc e and may
not be twisted upon mounting.
2. Screw two gu ide bars (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 inse rt to lifting tackle at upper mounting hole of lifting tackle
using shackle (596.046) (o bserve installation position of speed trans-
mitter)
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 mount-
ing 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 2.2).
Important!
If a new insert and/or compressor wheel is installed [500A3], measure
and check the axial play of the insert/compressor wheel (see Chapter
2.2 - 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 junction box (562.011 ).
Important!
Lubricate contact surfaces and thread (e. g. Molykote HSC).
Important!
Observe tightening torque upon installation/
Tightening torque Undercut bolt (546.073) for insert: 75 Nm

*)In case the insert piece is without IRC, the tightening torque is 40Nm.
4C-09341 C2 500.41 TCA55 113

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 trans-
mitter (562.040) to the inside.
2. Unscrew the speed transmitter from the insert.
Work Sequence 4 -Installing the Speed Transmitter
E
562.014
562.013
~/Frl8
562.011
562 01 5
562.016
562.01 7
540.001 Insert 562 011 Junction box

540.025 Cable socket 562 013 Operational equipment
540.026 Seal disk 562.014 Analog meter
546.000 Co mpressor casing 562.015 Screw
546.049 Cable socket 562.016 Nut
546.050 Seal disk 562 017 Spring washer
562.003 Loctite
562.010 Speed transmitter
Fig 21 . Overview, speed-measuring equipment
4C-09341 C2 500.41 T CA55 114

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
(562.010) and screw in to the insert until flush .
Turn the speed transmitter ba ck until a gap dimension of 0.1 mm
to the surface area of the insert is adjusted (check with steel or straight-
edge- see Fig . @).
3. Secure speed transmitter with lock nut.
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 wo rk 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 junction box (562.011)
according to the wiring diagram (see work sequence 5 and 6).
4C-09341 C2 500.41 TCA55 115

Work Sequence 5 - Connection Assignment of the Speed Measuring Equipment (with Speed Indicator)
ifl!'riffi ~~~P.~~
Sh 1p1 ard ;upJiy
,/;
/_,./ I
,-----"'c._
' ---, I
;~ntir.fi~tfr~
I
':> 11pnrd ~ Jpp.y + ~~.jH- -1 +
L:AIJl. flLUf;HR
7_) 1:7 :1. - ' ] -

.6.1\AI iJii t'FTH
0 4- 2G TtA
MAY.'JOO:J
";->
CJl
8
-1:>.
_.
l!LIBf.
OFCRA TIO I~AL CJL F'10JT
73RS-D
-l
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)>
CJl
CJl
i 3r. S- D B-IA\oi-OS-t~SIE
~HI'I II
0)
(~)
.v
I"""",._ 'I>AON II'
~I (I
>A I,
oc. A='Plf: u: ~otus CRP
I KtA Nth u~ t Jl\t :.;u ~" ..•
, .,.
1 /2~
06 I!..'JE,Hi!i~i~l:ii
1-10 1/ / 4
UH S . 'c'·'" Tt.CHOHEER •,;nih:i C.l.4((~t~
1t·1s: 06
YH IRE i .
auto
'" "'· .
1/L '• 5 1!£
!\ 2
CA L::
rf;.t.lffHG 'C
/ ...,
J sX: 0020
IIJIII!SHEET
•J
Qf
Fig. 22. Cable connection of speed measuring equipment

Carel
Compressor Casing and Diffuser 500.42
Short Version
Disassembling the compressor casing in order to check the diffuser.

1 Qual ified mechanic 2.0
1 Assista nt 2.0

1 Hex key 8 - Inventory
- Lifting tackle with ropes, chains - Inventory
2 Wood block - Inventory
2 Eye bolt M12 596.051 Standard
2 Eye bo lt M20x2 596.058 Standard
3 Jack bolt M16x50 596 280 Standard I
Spare Parts
Designation Number
0 -ri ng seal 517.063

500.32 500.34
500.41 500.53
Technical data
Compressor casing 500 kg
Diffuser 30 kg
4C-09341 C2 500.42 TCA55 117

WARNING
Danger of injury from suspend s!
A rocking compressor casing is difficult to maneuver and can
therefore seriously injure people and cause damage to material (i.e.
the compressor wheel)!
• Use tackle line/chains to guide the silence.
• For attachment of the lifting equipment, use only the lifting eye bolts
intended for this purpose, as described under "Required
Tools/ "
Work Sequence 1 -Compressor Casing Removal
Starting Condition Post lubrication tank [500.34], silencer [500.32] 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. Fasten eye bolts to the compressor casing (546.000) and insert rope of
lifting tackle. Make sure that the rope is tensioned
2. Loosen the hexagon nuts (506.104) alongside the circumference.
3. Screw in three forcing-off bolts (596.280) and evenly loosen the
compressor casing.
4. Move the compressor casing away in axial direction, and place it on a
woode n support
Important!
Secure the compressor casing against rolling off.
596.058
506.099
506.104
546.000
546.000 Compressor casing 506. 104 Hexagon nut

506.099 Undercut bolt 506.058 Eyebolt
Fig . 23. Disassembly of a single-stage compressor casing to the turbocharger
4C-09341 C2 500.42 TCA55 11 8

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 (596.051) to diffuser and attach lifting tckle.
2. Loosen the lock nut (546.047) of the countersunk bolt (546 .145) that
fastens the diffuser in the compressor casing.
3. Remove diffuser (542.001) in axial direction.
546.000
542.001
542.001 Diffuser 546000 Compressor casing

Fig . 24. Removing the diffuser from the compressor casing
Work Sequence 3- Compressor Casing Installation
Starting Condition Compressor wheel [500.43] mounted on turbine rotor [500.53].
lmporlant!
The inserl [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 (596.051 ), hang the diffuser (542.001 ) to
the lifting tackle.
2 Mount the diffuser (542.001) to the compressor casing (546.000) with
the countersunk bolt (546.045). Save the countersunk bolt with lock nut
(546.047).
3. Fasten eye bolts to the compressor casing and insert the rope of the
lifting tackle . Ensure that the rope is tensioned .
4. Control and inse rt 0-ring seal (517.063) between compressor casing
and bearing casing.
lmporlant!
Oil O..ring sea/ lightly!
5. Guide the compressor casing axially to the turbocharger, slide onto the
undercut bolts (506.099) and tighten hexagon nuts (506.104) with the
specified tightening torque.
4C-09341 C2 500.42 TCA55 119

Important!
Do not damage the compressor wheel with the compressor casing.
Important!
Lubricate contact surfaces and thread (e. g. Mo/ykote HSC).
lmporlant!
Observe tightening torques upon installation/
Countersunk bolt diffuser (546.045): 60 Nm

Hexagon nut compresso r casing (506. 104): 250 Nm
4C-09341 C2 500 .42 TCA55 120

Compressor Wheel 500.43
Short Version
Removal of the compressor wheel for checking of the bearings and the bear-
ing bushes.

1 Assistant 2.0

1 Open-jaw wrench 36 - Inve ntory
1 Torq ue wre nch 10-70 Nm 596.100 Standard
1 Socket wrench insert 6x10 596. 101 Standard
(1) (Dismantling/assembly compressor wheel) (596.510) (Standard)
1 Puller ring 596.001 Standard
1 Assemb ly rin g 596.002 Standard
1 Forcing-off bolt 596.003 Standard
4 Threaded bar 596.004 Standard
1 Turn pin A12 596.071 Standard
1 Sleeve 596.167 Standard
(1) (Suspension device for compressor wheel) (596.522) (Standard)
1 Turn pin A12 596 071 Standard
1 Pipe 596. 160 Standard
1 Sleeve 596. 16r Standard
1 Hexagon bo lt 596. 168 Standard
1 Support 596.170 Standard
1 Hexagon bo lt 596. 197 Standard
1 Shackle 596.208 Standard
1 Lever carrier 596.26r Standard
1 Pipe 596.270 Standard
1 Slide 596.271 Standard
4 Cyli ndrica l screw M10x40 596.272 Standard
1 Bolt 596.273 Standard
3 Cyli ndrica l screw M10x50 596.274 Standard
2 Hexagon bolt M12x120 596 033 Standard
2 Sleeve 596.310 Standard
1 Support 596.31 1 Standard
4C-09341 C2 500.43 TCA55 121

Spare Parts

- Superbolt lubrica nt -
- Mo lykote P40 -

500.32 500. 41
500.44 500.53
Technical Data
Compressor wheel 40 kg
Suspension device co mpressor wheel 24 kg
520 066 520.035
520.067
h
520.068
.
I
'-.~.
\(~ ,
520001 Turbine rotor 520.066 Undercut bolt

520028 Thrust ring 520 067 Spinner
520035 Labyrinth ring 520068 Tension nut
520044 Compressor wheel 596.033 Bolt
596.310 Sleeve 596.311 Support
Fig. 25. Assembly and disassembly of the compressor wheel
4C-09341 C2 500.43 TCA55 122

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 (500.32) as well as insert with speed transmitter (500.41] removed
Fig . 26. Compressor wheel and compressor casing
Note!
The compressor wheel can also be removed without disassembly
ofthe compressor casing (see Fig@)
Work Steps 1. Mount the Support (596.311) on the Turbine side in order not to fall
down the turbine rotor.
2. Unscrew spinner.
Important!!
The thrust screws of the tension nut must be loosened step by
step!
Do not fully loosen single scn;-ws under any circumstances.
3. 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. @ )
4. Repeat the procedure (1/4 turn per screw, one time through) until the
pressure on the thrust screws is completely released.
5. The tension nut (520.068) can now be loosened by hand.
6. Completely unscrew the tension nut and pressure disk (see Fig@
from the turbine rotor.
4C-09341 C2 500.43 TCA55 123

520.001 Turbine rotor 596004 Threaded bar
520. 044 Compressor wheel 596.005 Hexagon nut
596.001 Puller ring 596.167 Sleeve
596.003 Forcing-off bolt
Fig. 27. Pulling off the compressor wheel with disassembling device (596.510)
7. Mount the sleeve (596 167) and assembling/disassembling device

(596.51 0) to the turbine rotor (520.001 ), and mount the compressor
w heel (520.044).
8. Release the co mpressor wheel with the puller (see Fig. @).
9. Dismount the assembling/disassembling device; the sleeve remains
assembled to the turbine rotor .
10. Fast~the slide (596.27 1) of the suspension device (596 .522) (see
Fig. @ ) with 4 cylindrical screws (596.272) to the compressor
wheel.
11 . Fasten lever ca rrier (596.267) in front of slide with 3 cylindrical screws

and insert pipe (596.270).
12. Atta ch suspension device to crane.
13. Fasten suspension device to sleeve (596.167) with bolt (596.273 ) and
lightly tension the rope of the lifting tackle .
14. Pull off compressor wheel.
15. Fully slide the compressor w heel onto the pipe (596.1 60) of the
suspension device and secure with the turn pin (596.071 ).
16. Remove bo lt (596.273) from the sleeve (596.167).
17. Ca refully place dow n compressor wheel onto woode n support; remove
suspension device.
18. Remove the Support (596.311 ) on the Turbine side.
4C-09341 C2 500.43 TCA55 124

Work Sequence 2- Installing the Compressor Wheel
General For assembly of the compressor wheel, use the assembly ring {596.002) and
the suspensio n device (596.522).
Starting Condition Silencer [500.32) as we ll as insert with speed tra nsmitter [500.41] removed.
T urbine rotor [500.53] and labyrinth disk [500.44) mounted.
517.089 Labyrinth disk 596. 167 Sleeve

520001 Turbine rotor
Fig . 28. Starling condition before assembly of the compressor wheel
Work Steps 1. Mount the Support {596 311) on the Turbine side in order not to fall
down the turbine rotor.
2. Fasten the slide (596.271) of the suspension device (596.522) with

4 cylind rica l screws (596.272) to the compressor wheel (520 .044)
(see Fig @l
3. Fasten lever carrier (596.267) in front of slide with 3 cylindrical screws

(596.274) and insert pipe (596 270).
Important!
Mark the balancing mark "0 " of the compressor wheel on the
slide of the suspension device, as the slide would cover the mark
on the compressor wheel.
4. Screw sleeve (596.167) onto undercut bolt {520. 066) of the turbine
rotor (520.00 1) {see Fig. @).
5. After clea ning, apply a thin coat of special lubricant (e. g. Molykote
P40) to the compressor wheel/turbine shaft seats in order to protect
against fretti ng (see Fig.@).
4C-09341 C2 500.43 TCA55 125

(596. 522)
596.267
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 Hexagon socket bolt
596.170 Support 596.273 Bolt
596.197 bolt 596.274 Hexagon socket bolt
Fig. 29. Suspension device (596.522) for compressor wheel
6. Slide the pipe (596. 160) of the suspension device through the slide
(596.27 1) at the compressor w heel~ secure the compressor wheel
with the turn pin (596.07 1) (see Fig. ® ).
lmpottantl
Lubricate the suspension tube with machinery oil so that the
compressor wheel can glide.
7. Fasten lifti ng ta ckle to suspension device with the shackle (596.208)

and lift the co mpressor wheel.
lmpottant!
The compressor wheel on the suspension tube can now be
brought into a leve!J;_osition by adjusting the hexagon bolt
(596.168) (see Fig.®).
8. Fasten suspension device to the sleeve (596.167) on the turbine rotor,

and fasten the pipe of the suspension device to the sleeve using a bolt
(596.273).
9. Pull out the turn pin (596.071).
lmpottantl
Rotate the compressor wheel on the suspension tube in such a
manner that the balancing marks of the sleeve and the turbine
rotor match.
4C-09341 C2 500.43 TCA55 126

10 Slide the compressor wheel onto the rotor shaft
11. Remove the suspension device from the sleeve.
12. Remove the pressure disk (1) from the tension nut (520.068) and
attach onto assembly ring (596.002)
1 Pressure disk 520.068 Tens.ion n·ut

2 Thrust sere\•\•' 596.002 Assembly rh1g
Fig . 30. Pressure disk on tension nut and assembly ring
13. Screw assembly ring (596.002) onto the undercut bolt (520.066) of
the turbine rotor and tighten with turn pin (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.
14. Dismount assembly ring and pressure disk (1).
Work Sequence 3- Fastening the Compressor Wheel
General The thrust screws of the tension nut are delivered readily lubricated; oth-
erwise, lubricate with Superbolt lubricant
Starting Condition Compressor wheel slid onto the rotor shaft (compare with work sequence 2) .
Work Steps 1. Clean and lubricate the main thread and the contact surfaces of the
tension nut (520.068) and thrust screws (2).
Important!
The thrust scrows of the tension nut are fully scrowed back.
2. Attach pressure disk to tension nut (520.068) (see Fig.@ ).
4C-09341 C2 500.43 TCA55 127

2
1 Pressure, disk 520,068 Tensil:m nut

2 Thmst sc.rew
Fig . 31. 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 tor up to 10 tensioning procedures.
Fig . 32. Pressure disk (1)
3. Screw the tension nut and pressure disk onto the undercut bolt
(520. 066) of the turbine rotor by ha nd and then screw it back 1/4 turn.
(see Fig.@ )
4. Screw in 3 thrust screws all the way and then tighten over cross with
half of the tightening torque (approx.7 Nm).
Then tighten with the full tightening torque (14 Nm).
5. Tighten all 6 thrust screws in circular direction with the full tightening
torque.
6. Repeat the tightening in circular direction until the undercut bolts are
tightened (approx. 2-3 times over).
4C-09341 C2 500 .43 TCA55 128

1 Thrust screw 520. 044 Compressor wheel
520068 Tension nut
Fig . 33. Compressor wheel with mounted tension nut
7. Fasten spinner (520.067). (see Fig.@ )
Important!
Observe tightening torques!
Tightening Torques Thrust screw: 14Nm
8. Remove the Support (596.311) on the Turbine side
4C-09341 C2 500.43 TCA55 129

4C-09341 C2 50043 TCA55 130
.. 1\,. "
ri:d ivl;;untenance ~ Cornpressor Si(ie
Labyrinth Disk 500.44
Short Version
Removi ng and installing the labyrinth disk in order to assemble/disassemble

additional assemblies.


1 Spanner 19 - Inventory
1 Lifting tackle, ropes - Inventory
(1) (Suspension device for labyrinth disk) (596.521) (Standard)
3 Forcing-off bolt M12 596.041 Standard
2 Eye bolt 596.051 Standard
Spare Parts
Amount Designation Number I

1 0 -ring seal 517.085 I
8 Lock washer pair 517.095 J

500.43 500.45 500.53
Technical Data
Labyrinth disk 28 kg
4C-09341 C2 500.44 TCA55 131

Work Sequence 1 -Removal of the Labyrinth Disk
517 001
596.051
596.044
517 .089
517.001 Bearing casing 596.044 Guide bar

517.089 Labyrinth disk 596051 Eye bolt
Fig . 34. 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 whee l [500.43] removed.
Work Steps 1. Remove two hexagon bolts fastening the labyrinth disk (517089)
and substitute them with two 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 forcing-off
bolts (596.041 ).
4. Screw the eye bolt (596. 051) to the labyrinth disk .
5. Fit the shackle/hook to the suspension device (596.521) of the labyrinth
disk and tension the rope/chain of the lifting ta ckle.
6. Move the labyrinth disk awa y from the turbocharger using the lifting tackle.
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 0-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.
4C-09341 C2 500.44 TCA55 132

Work Sequence 2- Installation of the Labyrinth disk
Starting Condition Labyrinth disk mounted on turbine rotor [500.45] .
Work Steps 1. Insert two 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. Fit lifting tackle to suspension device (596.521) with shackle
(596.208) or hook.
5. Insert new 0 -ring seal (517.085) into labyrinth disk if required.
Important!
Apply machinery oil for assembly of the 0-ring seal.
5. Slide labyrinth disk in front of bearing body and fasten with 8 hexagon
bolts (517.093) and lock washer pa irs (517.095)
Important!
Ensure correct installation position of the labyrinth disk: Sealing
air grooves located side wards!
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!
T ightening Torq ues Hexagon bolt (517.093) : 60 Nm
4C-09341 C2 500.44 TCA55 133

4C-09341 C2 500.44 TCA55 134
Labyrinth Ring 500.45
Short Version
Installing and removing the labyrinth ring from the rotor in order to
assemble/disassemble further parts.


(1) (Fitting/unfitting tool) (596.51 3) (Standard)
2 Threaded bar 596.070 Standard
2 Hexagon nut 596.0/2 Standard
1 Puller ring 596.073 Standard
1 Plastic hammer - Inventory
- Molykote P40 - Inventory

500.43 500.44 500.46
500.53
4C-09341 C2 500.45 TCA55 135

4C-09341 C2 500.45 TCA55 13&
Work Sequence 1 -Removal of the Labyrinth Ring
Starting Condition Compressor wheel [500.43) and labyrinth disk [500.44) removed.
Work Steps 1. Fully screw puller ring (596.073) onto undercut bolt (520.066) of
the turbine rotor (520 001 ).
2. Insert two threaded bars (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 bars.
3. Pull the labyrinth ring from the turbine rotor by alternately
tightening the nuts of the puller ring.
Replace the labyrinth ring when the labyrinth tips are damaged or wo rn :
D ~ 110.6 mm
Wo rk 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.
4C-09341 C2 500.45 TCA55 137

4C-09341 C2 500.45 TCA55 138
\;1\in"'~t'
"'"'~ """"t r.. r '~~···{
-..~a;\.,.
A 1:~. c t:::nn h h.•

~ "'-""""'" ..,,.,.~ ~ ~ E I<~{ l )
;:':Ht rl
~"""!!. ~
1\il '"' ~~ ~·"" t ;,~ ~~..., ·:::l> •.., ,,~. r-t ~ (''
~~~ '~~a- 'i; ~ ~= ~~"'ar· m it,-~ l i ~.... ~.JI"
ii_ "·"'~~f!'
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

Qualified mechanic 2,0

1 Spanner 19 - 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 08 / Standard
Spare Parts

1 Bearing disk 517.0 r 5
6 Lock washer pair for thrust bearing 517.095
1 Counter-thrust bearing 517.154
6 Lock washer pair for counte r-thrust bearing 517.156

500.43 500.44 500.45
500.53 500.55 500.56
4C-09341 C2 500.46 TCA55 139

596.501 596.500 517 075
517.157
I 517. 156
., .•.I.
517.095
517.102
I
596.075
517.075 Bearing disk 517. 157 Hexagon bolt

517.095 Lock washer pair 517. 162 Bearing body
517.100 Stud 520001 Turbine rotor
517. 102 Lock nut 520028 Thrust ring
517.153 Thrust bearing 520066 Undercut bolt
517. 154 Counter-thrust bearing 596.040 Extension shaft
517. 156 Lock washer pair 596.075 Protecting sleeve
Fig. 37. 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 Compresso r whee l [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. Mount guide (596.500) onto thrust bearing (517.153)
by hexagon bolts (596.501)
3. Loosen six lock nuts (517. 102) of the thrust bearing (517.1 53).
4. Press off thrust bearing from the bearing body (517. 162) with the
four forcing-off bolts (596.041) and check it (see work sequence 2).
5. Unscrew protecting sleeve.
6. Remove bearing disk (517 075) from the thrust ring (520.028) and
check it (see work sequence 3).
7. Screw assembly ring (596.086) of removing tool (596.154) onto the
external thread of thrust ring (520.068) and loosen thrust ring with th ree
forcing-off bolts (596.087).
8. Remove thrust ring and check it(see work sequence 4).
9. Unscrew hexagon bolts (517.157) and remove counter-thrust bearing
(517. 154) from the beari ng body (517.162).
10. Check counter-thrust bea ring (see Work Sequence 5) .
Note!
Removal and inspection of the bearing bushes. see [500.56}.
4C-09341 C2 500.46 TCA55 140

Work sequence2- Checking the thrust bearing
517.153 Thrust bearing a Thrust surface for bearing disk (517075)
Figure 38. Checking the thrust surface of the thrust bearing
Starting co ndition Thrust bearing (517.153) has been removed and cleaned.
See Work card- Removi ng and refitting the thrust bearing and
counter thrust beari ng , bearing disk and thrust ring. [500.46]
Work Steps
1. Carry out visual inspection of the thrust bearing (517 153)
2. Exchange the thrust bearing if:
there is excessive deep scratching and scoring on the thrust surface,
resulting in perceptible roughness.
the thrust surface has wear> 0.05 mm in the axial direction (a).
(see fig ur~ )
Exchange the thrust bearing if the thrust surface has wear> 0.05 mm.
Note!
Determining wear of the thrust surface (a):
-Check the evenness using a hairline gauge at three points
on the thrust surface (a).
-The thrust surface must not be worn on the outer or inner edge!
4C-09341 C2 500 46 TCA55 141

Work Sequence 3 -Inspection of the Bearing Disk
a
v
b
a Wedge surface b Engagement surface v Edge 517.075 Bearing disk
Fig. 39. Bearing disk in new condition (left) and with clear traces of wear (right)
Starting Condition Bearing disk (51 7.075) has been removed and cleaned.
(see work sequence 1).
See Work card- Removing and refitting the thrust bearing and
counter thrust bearing, bearing disk and thrust ring. [500.46)
Work Steps
1. Carry out visual inspection of the thrust bearing (517.153).
2. Exchange the thrust bearing if:
- Flaking or pitting of the DLC layer is detected on the wedge surfaces
of the disk surfaces and bare metal is exposed.
- Excessive wear is detected on the inner diameter of the bearing disk
and bare metal is exposed.
See also I bearing seat for bearing disk (517.075).
-There is excessive deep scratching and scoring on the wedge and
engagement surfaces, indicating the passage of larger particles
from the lube oil.
This can be individual scratches and scoring or entire bands of wear
-consisting of many scratches and score marks- on one segment
of the beari99._ disk (wedge and engagement surfaces).
(see figure(@))
4C-09341 C2 500.46 TCA55 142

3. Measure the lengths (I) of the wedge surfaces (a) on both sides of the
bearing disk to assess the wear.
Tip! Length (I) starts at the edge of the oil groove and extends up to
the edge (v) on the engagement surface (b).
(see figure@)
Exchange the bearing disk if one of the measured lengths (I) reaches
or falls below the following va lue:
Exchange the bearing disk if I :::; 24 mm
Note/
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 (1).
c Individual scratches and scoring> 0.5 mm (left-hand figure)
d Band of wear> 5 mm (right-ha nd figure)
Figure 40: Impermissible signs of wear on the bearing disk (517.075)
Exchange the bearing disk if individual scratches and scoring > 0.5 mm
Exchange the bearing disk if who le bands of wear > 5.0 mm
Important/
Do not remachine the running surfaces of the bearing disk!
The bearing disk must not be remachined, as this would destroy the
surface coating!
The bearing disk must be exchanged if pitting and cracks in the
bearing disk material exceed the permissible size/
4C-09341 C2 500.46 TCA55 143

Work Sequence 4- Checking the thrust ring
Thrust surface and bearing seat for bearing disk

(517.075)
Thrust surface for counter thrust bearing

(517.153)
Figure 41 : Thrust surfaces on the thrust ring (520.028)
Starting condition Thrust ring (520.028) has been removed and cleaned
See Wo rk card- Removing and refitting the thrust bearing and

counter thrust bearing , bearing disk and thrust ring. [500.46]
Work steps
1. Carry out a visual inspection of the running surfaces on both sides of the
thrust ring (520.028).
2. Exchange the thrust ring if:
Pitting or cracks are detected in the thrust ring material and bare
metal is exposed.
There is excessive deep scratching and scoring on the running
surfaces and on the bearing seat.
These include scratches and scoring measured in the radial direction
(a) (see figure @ )
3. Check the thrust ring with a micrometer for wear on the radial bearing seats
and the thrust surface, and exchange if:
D ~ 67.98 mm
T ~ 22.65 mm
0 - -
4C-09341 C2 500.46 TCA55 144

A
520 028 Thrust ring a T hrust surface for bea ring disk (517 .075) individual scratches and scoring > 0 5 mm
Figure 42. Impermissible signs of scratches and scoring on the thrust ring (520.028)
Exchange the thrust ring if the depth of individual scratches and scoring > 0.5 mm
Exchange the thrust ring if the total bands of individual scratches and scoring > 5.0 mm
Important!
Do not remachine the running surfaces of the thrust ring!
The running surfaces on the thrust ring must not be remachined, as
this would destroy the surface!
The thrust ring must be exchanged if pitting and cracks in the thrust
ring material exceed the permissible size!
4C-09341 C2 500.46 TCA55 145

Work Sequence 5- Checking the Counter-thrust Bearing
517.154 517.154
a Taperface b Wing v Edge 517. 154 Counter-thrust bearing
Fig. 39. Counter-thrust bearing in new condition (left), and with clear traces of wear (right)
Starting Condition Counter-thrust beari ng (517. 154) removed (see work sequence 1).
Work Steps The length (I) of the taper faces (a) is measured for eva luation of the degree
of wear The length (I) ends at the edge (v) of the wea ring surfaces (b).
lmpottant/
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(/).
Replace counter-thrust beari ng in case one of the lengths (I) is below the
followi ng va lue:
1 ~ 4mm
4C-09341 C2 500.46 TCA55 146

Work Sequence 4- Removal 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 (5 17.154).

2 Slide the thrust ring (520.028) onto the shaft, in front of the co unter-
th rust bearing.
Important!
Apply Molykote P40 to the bearing location for the thrust ring on
the turbine rotor (protection against fretting).
3. Apply machinery oi l 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 (517153) onto stud screws of the end cover
(see [500.55] ) 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).
7. Remove assembly guide (596.500) from the thrust bearing (517.153)
by loosing hexagon bolts (596.501).
Important!
Lubricate contact surfaces and threads (e. g. Molykote HSC )I
Important!
Tightening Torques Lock nut thrust bearing (517.1 02): 60 Nm

Hexagon bolt counter-thrust bearing (517.157): 17 Nm
4C-09341 C2 500.46 TCA55 147

4C-09341 C2 500.46 TCA55 148
Assembly and Maintenance - Turbine Side 3.5
4C-09341 C2 3.5 TCA55 149

4C-09341 C2 3.5 TCA55 150
Gas-admission Casing 500.51
Short Version
Removal of the casing for inspection of replacement of the turbine nozzle

ring or for disassembly of parts inside.
t If the turbocharger is equipped with VTA, refer to the additional instruction
manual.

1 Assistant 2.0

1 Open-jaw wrench 24 - Inve ntory
1 Torque wrench - Inve ntory
- Lifting tackle, ropes, winches - Inventory
(1) (Suspension device) (596.520) (Standard)
1 Shackle A1 596.046 Standard
1 Suspension plate 596 055 Standard
1 Eye bolt 596.058 Standard
Spare Parts
Designation Number
Lock washer pair 506.107
Technical Data
Gas-admission casi ng (90 ") 240 kg
4C-09341 C2 500 .51 TCA55 151

Danger ury 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 I
Appliances".
• Move the crane
596.186 if\'!- 596 046

·~ ~~&__
·.
. "~~
~~- 596.055
I
506.106
501 001 Gas-admission casing 596. 055 Suspension plate

506. 106 Hexagon bolt 596.058 Eye bolt
596.046 Shackle
Fig 44. 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. G) in Section C1.
Chapter 3. 1.
Work Steps 1. Remove coverings (if ava ilable) .

2. Unscrew two hexagon bolts (506.1 06) from gas-admission casing
(501.001) (see Fig @ J.
3. Fasten suspension plate (596 055) with a hexagon bolt to the gas-
admission casing.
4C-09341 C2 500.51 TCA55 152

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. 1 06) along the outer circumference.
Note!
Mark bolt holes on the casing that are not occupied - these must be
kept free when assembling the gas-adm ission 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 remova l.
Important!
Fasten gas-admission casing with twenty hexagon bolts (506.1 06)
and lock washer pairs (506.1 07).
Important!
Lubricate contact surfaces and threads (e. g. with Molykote HSC)!
Important!
Tightening Torques Hexagon bolt (506.106): 70 Nm
4C-09341 C2 500 .51 TCA55 153

4C-09341 C2 500.51 TCA55 154
T
Turbine Nozzle Ring 500.52
Short Version
Removal of the turbine nozzle ring is carried out for inspection purposes in
accordance with the maintenance plan.
t If the turbocharger is equipped with VTA, refer to the additional instruction
manual.

1 Assistant 0.5
Requ ired Tools/Appliances

1 Torque w rench - Inventory
- Lifting tackle, ropes - Inventory
(1) (Fitting/unfitting tool) (596.525) (Standard)
2 Eye bo lt 596 .051 Standard
Spare Parts

21 Hexagon bolt 513.013
21 Lock washer pair 513.014

500.51
Technical Data
T urbine nozzle ring 20 kg
4C-09341 C2 500 .52 TCA55 155

Work Sequence 1 -Nozzle Ring Removal
501 .001
5 13.001
51 3.010
596.050
r \ " '513.021
51 3.013 513.014
501001 Gas-admission casing 513.013 Hexagon bolt

513001 Nozzle ring 513.014 Lock washer pair
513010 Clamping ring 596.021 Guide bolt
596050 Guide bar
Fig. 45. /nstaf/ationlremoval 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 clampi ng ri ng (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 pu ll off th e nozzle ring (513 001 ).
Position rope around nozzle ri ng and remove from the gas-admission
casing in axial direction.
Work Seq uen ce 2- Nozzle Ring Installation
Important!
Lubricate contact surfaces and threads (e. g. Molykote HSC) f
Important/
4C-09341 C2 500.52 TCA55 156

Turbine Rotor 500.53
Short Version
Removal of the turbine rotor for inspection of the bearing bushes and the
bearing points.

1 Assistant 1.0

2 Open-jaw wre nch 19 - Inve ntory
(1)(Fitting/unfitting tool) (596.515) (Standard)
1 Protecting sleeve 596.075 Standard
1 Clamping sleeve 596.504 Standard
1 Pipe (0 s; 35 mm, length approx. 1000 mm) - Inve ntory
1 Lifting tackle, ropes - Inve ntory
- Wood (for placi ng underneath) - Inventory

500.43 500.44 500.45
500.46 500.51
Technical Data
Turbine rotor 90 kg
4C-09341 C2 500 .53 TCA55 157

Fig. 42. Turbine side: View of gas outlet casing Fig. 43. 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. @ ).
Starting Condition Turbine Side Gas-admission casing [500.51) removed.
Note!
Disassembly measure tor rotor. see Fig . (f) section C1- Chapter 3.1.
Work Steps 1. Position clamping sleeve (596.504) onto shaft end of turbine disk and
secure with hexagon bolt and nut (see Fig. @ ).
2. Pull turbine rotor (520.001) as straight as possible out of the bearing
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 (0 s; 35 mm, length approx. 1000 mm) into the
clamping sleeve (596.504) to guide the rotor upon removal.
5. Ca refully 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.
Important!
The inserted pipe can be used to keep the free-hanging rotor in
balance.
4C-09341 C2 500.53 TCA55 158

6. Place down the turbine rotor on wood blocks (in horizontal position) or
on wooden support (i n 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 wo rk on the turbine blades performed
through Mitsui MAN B&W service personnel!
In cased of doubt, definitely ensure to contact Mitsui MAN B&W.
When maintaining turbine rotor and turbine blades, these are to be
handled with utmost care.
520001 Turbine rotor 596.075 Protecting sleeve 596 504 Clamping sleeve
Fig. 48. Check points, rotor shaft
Note!
In order to check the diameters (0 1) . the turbine rotor must not be
pulled completely out of the bearing bcxiy
8. Measure and record the bearing points. Replace rotor when falling short
of the diameter measure (D 1) :
D 1 ~ 67.97 mm.
Note!
For checking of the bearing play between bearing bush and turbine
shaft, see [500.56] work sequence 3.
4C-09341 C2 500 .53 TCA55 159

Fig . 49. Clamping sleeve mounted on shaft end
9. Measure la byrinth ring. Replace labyrinth ring when falling short of the
diameter measure (02):
0 2$96.5 mm.
520.018
~----i:~520.021
520001 Turbine rotor 520021 Ring nut

520 018 Labyrinth ring. turbine side 596.075 Protecting sleeve
Fig . 50. 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 ).
4C-09341 C2 500.53 TCA55 160

Shroud Ring 500.54
Short Version
Check shroud ring for wear; adjust gap to the turbine


(1) (Fitting/unfitting too l) (596.525) (Standard)
2 Guide bar 596 050 Standard
2 Eye bo lt 596 .051 Standard
1 Torque w rench - Inventory
1 Feeler ga uge - Inventory
- Molykote HSC - -
Spare Parts

12 Hexagon bolt 509 012
12 Lock washer pair 509.014

500.51 500.53
Technical Data
Shroud ring 10 kg
4C-09341 C2 500 54 TCA55 161

Work Sequence 1 -Shroud Ring Removal
Starting Condition Gas-admission casing [500.51) removed.
509.014
Fig. 51 . Shroud ring and turbine rotor mounted
Work Steps 1. Unscrew two hexagon bolts (509.012) and repla ce 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 @J
in order to loosen the shroud ring.
3. Remove shroud ring (509.008).

4. Remove guide bars (596.050).
Work Sequence 2- Shroud Ring Installation
Starting Condition Turbine rotor [500.53) installed, gas-admission casing [500.51] removed.
Work Steps 1. Screw two guide bars (596.050) into diffuser (509 .001) of the gas outlet
casing (506.001 ).
2. Slide the shroud ring (509.008) on the guide bars and secure with three
hexagon bolts and lock washer pairs. Unscrew the guide bars.
3. Screw in all hexagon bolts (509.012) with lock washer pairs (509.014)
around the circumference, and lightly tighten.
Important!
Always use new lock washer pairs when mounting!
4C-09341 C2 500 .54 TCA55 162

4. Measure gap dimension "S" between turbine blade/shroud ring at both
locatio ns ''A" with feeler gauge. Lightly loosen hexagon bolts (509.012)
and align shroud ring (509.008) horizo ntally to the center (gap dimen-
sions left and right must be equal).
5. Lightly tighten the hexagon bolts.
6. Measure gap dimension "S" at the vertical measuring points "8 " and '' C"
and align shroud ring (509.008).
lmpottantl
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 0.2 mm higher than the turbine rotor upon
mounting (in the neutral position).
509. 008 Shroud ring s Gap a1mension

509.012 Hexagon bolt A,B,C Measuring points
520001 Turbine rotor 1 Top recess
2 Turbine blade
Fig .52. Measuring poin ts for gap clearance of turbine blade/shroud ring
A B =A -0.2 mm C=A +0.2mm
0.9 0.7 1.1
1.0 0.8 1. 2
1.1 0.9 1.3

Table 2-4. Measuring points for gap dimensicns ci turbine blacJelshrou:J ring
lmpottant!
For maximum pennitted gap clearances of components that have been
in operation, see Chapter 2.2- Gaps and Clearances.
4C-09341 C2 500.54 TCA55 163

7. Compare all 4 measured va lues again w ith the permitted gap
clearances (see Chapter 2.2) and record in the inspection report
(Section C1 - Chapter 6.6).
8. Tighten all hexagon bolts (509.0 12) with the specified torque.
Important/
Lubricate contact surfaces and threads (e. g. with Molykote HSC)/
Important!
Observe tightening torque upon installation!
Tightening Torques Hexago n bolt (509.012): 70 Nm.
4C-09341 C2 500.54 T CA55 164

End Cover 500.55
Short Version
Removal of the end cover is required for inspection of the bearing bush
(turbine side).

Designation
Open-jaw wrench 19
Spare Parts
Designation Number
Seal, turbine side 517.070

500.44 50045 50046
500.53 500.56
Technical Data
End cover with sealing cover and stud screws 16 kg
4C-09341 C2 500 .55 TCA55 165

517.094
I -517.001
517 .070
1517.072
151 7.064
I
51 7.068
517.001 Bearing casing 517.072 Sealing cover. turbine side

517.064 End cover 517094 Lock nut
517 068 Stud screws 517. 159 Cover
517.070 Seal. turbine side 517161 Bearing bush
Fig. 53. 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 cas ing (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)/
Important!
Observe tightening torques upon installation/
Tightening Torques Lock nut (517.094) 60 Nm
4C-09341 C2 500 .55 TCA55 166

Bearing Bushes 500.56
Short Version
Remova l of the beari ngs for inspection purposes or repla cement

Qua lified mechanic 10

1 Micrometer (outside and inside) - Inventory
1 Depth gauge - Inventory
Spare Parts

12 Lock washer pai r 517.156
2 Bearing bush 517 161

500.46 500.53 500.54
500.55
4C-09341 C2 500.56 TCA55 167

517.157
"f~,"'\~-~
1 517.154 1
1 s11. 1ss ,. s1 7. i a1 ! r:
' I 2
""'~ .j·
517.001 Bearing casing

517. 154 Counter-thrust bearing
517.156 Lock washer pair
517. 159 Cover
517. 161 Bearing bush (2: pin)
517. 162 Bearing body
Fig .54.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 Clearance and Removing
Starting Condition Turbine rotor [500.53] as we ll as thrust and counter-thrust bearing [500.46]
are removed
Important/
When removing the bushes(517.161) the bearing body(517.162)
remains firmly installed in the bearing casing (517.001).
Work Steps 1. Slide the bush by hand co mpletely into the bearin9J2ody and take
measure "A" with the depth gauge (compa re Fi g.~).
2. Replace the bearing bush when
A ::::0.35 mm
4C-09341 C2 500 .56 TCA55 168

517.161 Bearing bush 517. 162 Bearing bcx:Jy
Fig . 55. Measuring the axial clearan;e of the bearing bushes - com pressor 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 3).
Work Sequence 2- Bearing Bush, Turbine Side: Checking the Axial Clearance 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)
remains firmly installed in the bearing casing (517.001).
Work Steps 1.Loosen hexagon bolt (517.157) and remove cover (517.159).
2.Siide the bush by hand into the bearing body and take measure "A'' with
depth gauge (compare Fig. @ )
3.Replace the bearing bush when
A :<::0.35 mm
517.161
517. 161 Bearing bush 517. 162 Bearing bcx:Jy

Fig . 56. Measuring the axial clearance of the bearing bushes- turbine side
4. Mark the bush (turbine side).

5. Remove bush from bearing body and inspect for wear
(see Work Sequence 3).
4C-09341 C2 500 .56 TCA55 169

Work sequence3 -Checking the bearing bushes
Starting condition The bearing bushes (517.161) have been removed and cleaned. lnsta llation
position of each bearing bush marked with a felt-tip marker (turbine side/
compressor side).
Work Steps 1. Carry out a visua l inspection of both bearing bushes.

Exchange the bearing bush if
The bore for the spring pin (2) in the bearing body (517.162)
is worn or the spring pin is seated loosely in the bearing bush
(517.161) due to a worn hole.
2. Measure the wear dimension (I) at four points on circ umference of each
bearing bush. (see Fig. @l )
Exc hange the bearing bush if:
One of the worn grooves, measured at the narrowest point of
the bearing (usually the bearing centre of the bearing bush), has
reached or exceeded width (1) .
Excha nge the bearing bush if I<:: 21 mm
1517.1611
517. 161 Bearing bush 1 Tapped hole 2 Spring pin I Wear dimension
Fig . 57. Bearing bush with MGF profile- front and rear view
can cause rger amage.

During operation, worn or defective bearing bushed 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 bushed do not have deep grooves or
scoring on the running surfaces.
Check the accuracy to measure of the bearing bushes!
In cased of do lace the bea bushes!
4C-09341 C2 500.56 TCA55 170

Work Sequence 4- Installation of the Bearing Bush
Starting Condition Cond rtion and accuracy to measure of the bearing bushes (517.161 ) and the
bearing body (517162) checked .
Work Steps Important!

Before inserting the bearing bushes, lubricate them with
machinery oil.
Insta llation of the bearing bushes in the bearing body is carried out in
reverse order of removal.
Important!
Important/
Observe tightening torques upon assembly!
4C-09341 C2 500 56 TCA55 171

4C-09341 C2 500.56 TCA55 172
\/'- l ~ !;~·' l~ ..- i··,- ~ '11'""'
tf \f 'lH !{
v
v
dl "-~ ~
Assernbl}1r and \ilaintenance - Turbine Sid(:;
Gas Outlet Diffuser 500.57
Short Version
Removing and refitting the gas outlet diffuser.
Required Personnel and Ti me


1 Lifting tackle, ropes - Inventory
1 Shackle A 0.6 596.208 Standard
4 Eye bolts M16 - Inventory
4 Forcing-off bolts M16 - Inventory
- Mol ykote HSC - Inventory
Spare Parts
Designation Number
Lock washer pair 506.107

500.51 500.53 500.54
Technical Data
Gas outlet diffuser 150 kg
4C-09341 C2 500 .57 TCA55 173

Work Sequence 1 -Removal of the Gas Outlet Diffuser
Starting Condition Gas-admission casi ng [500.51) , shroud ring [500.54) , turbine rotor [500.53)
removed.
Work Steps 1. Screw three guide bars (596.045) into the bolt hole circle (1 ), each
divided by 120".
2. Loosen all four hexagon bolts (506.1 08).
3. Press off gas outlet diffuser (509.001) with the forcing-off bolts (M16)
(approx. 120 mm long) from the gas outlet casing (506.001) and fasten
to lifting tackle with shackle or eye bolts (M16).
4. Move gas outlet diffuser away from the gas outlet casing using the
lifting tackle, and place down carefully.
506.107 - - - -
506.108
509.001 - - - -
506.001
506.00 1 Gas outlet casing 506. 108 Hexagon bolt

506.107 Lock washer pair 509.001 Gas outlet diffuser
1 Bolt hole circle
Fig . 58. Gas outlet diffuser. installed
4C-09341 C2 500.57 TCA55 174

Work Sequence 2 -Installation of the Gas Outlet Diffuser
Work Steps 1. Screw two guide bars (596.045) into the gas outlet casing (506.001)
2. Lift gas outlet diffuser (509.001) with lifting tackle and position into the
gas outlet casing.
3. Fasten gas outlet diffuser with four hexagon bolts (506.1 08) and lock
washer pairs (506.107).
Note!
Mount the shroud ring [500.54} after mounting the turbine rotor [500.53}.
Important!
Important!
Obsetve tightening torques upon assembly!
4C-09341 C2 500.57 TCA55 175

4C-09341 C2 500.56 TCA55 176
Spare Parts Catalogue C3
Exhaust Gas Turbocharger ..... ..... ..... . TCA 55
4C-09341 C3 TCA55 177

page
1 Introduction .................................................................................... ....... ... ... ... ... ......... .. 179
1.1 Preface . .... ..... ... .. . ... ........ . ... .. ... ... ... ... ... . ....... ... .. ......... ..... ...... ... ........... .. .... .. ............ ........ 179
1.2 Layout and Usage of the Spare Pa rts Catalogue ... .. ...................... . .... .. ...... .. ........... .. .......... ..... ........ 180
1.3 Orderi ng Spare Parts ............................................... ........ ......... ... ....... .. ................. ......... ......... .. ......... 182
2 List of Assemblies ..................................................................................................... .. 183
500 List of Assemblies .................... .................. ... ... ... .. ... ... .... ......... .. .. ....... .. ......................................... ..... 184
3 List of Components ................................................................................................... .. 187
501.02 Gas-admission casing .. .. .. .. ... .. .. .. ... .. . ... ... .. .. .... ..... .... .. .. 188
506 01 Gas outlet casing ... .... ........ ... .. . ..... . .... ... . ... .. .. .... . .... .. . ... . . .. .. . . .. ... ...... . ... . ... 190
509 01 Gas outlet diffuser .... ... .. . .. .... .... ... ... ... .. ... ... . .. . .. . .. ... .. . .. ... . .. .... ... 192
513.01 Turbine nozzle ring ... .. ... .. ... ........... .. .. ....... ....... .. .. ...... .. .. .. ....... .. .. .......... ............ ..... .. .......... .. .... .......... 194
51701 Bearing casing . . .. .. .. . .. .. . . . . . .. ... ... .... .... .. ... . .. .. ... ... . .. .. .. . .. ... ... ... ... . ..... .. 196
518.01 Casing feet .. . .... . ... .. . ... .... .. .. ... .... ... .. ... .. .. .. .. ............................ .................. .. .. .. ............ 200
520 01 Rotor, complete ..... .. ... ......... .. ... ... .................. . ............. ......... .... .. . .... ... .. .. .. ................. ... .... ................ 202
540 01 Insert, complete . . .. . .. . . . . ..... . ... ....... .. .. .... .. .... .. .. ..... .... ...... ..... 204
542 01 Diffuser ... ... .. .... .. .. . .... .. . . ..... .... .... .. . ...... ... ..... ... ... .. .. .... .. .. .. .... .. .. ... .... .. .. .... .. . ... . ... ... .... .. ....... . . ... 207
544 01 Silencer, complete . . ... . .. . .. ... ... . .. ... .... .. ...... ... ... . ... .. ... ... ... .. ...... ...... .. ... ..... ... .... .. ... .. .... ... .. .. .... ..... 209
546 01 Compressor casing (single outlet) . ... ......... .. . ... .. ... .. .......... .... .... . ....... .. .. ... .............. ........ . ..... ... 211
55401 Emergency and Post lubrication tank . ....... ...... .......... .... ........ .. ..... .. ... ................ .. ......... 213
578 01 Wet Clea ning of the Turbine (Gas-admission casing 90 ") ...... .. ....... ..................................... .. .... ...... 215
591.01 Annula r lagging Gas-admission casing ............ . . .... .. ........ .... ...... .. .... .. ...... 217
591.02 Sound insulation Compressor casing ...... ..... .. ......... .. .... . ........ .. ....... .... .. .. ........ .. .. .. ... ..... ........ 219
4 Tools ...................... .............................................................................................. ........ 222
596.01 List of Tools .. .... 223
4C-093 41 C3 TCA55 178

Introduction 1
Preface 1.1
Spare Parts/Spare Parts Catalogue
Maintenance and repair work can be carried out properly on ly when the
required spare parts are available.
T hey 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.
T he structural principle of this spare parts catalogue is explained in

Chapter 1.2.
Sincerely yours
MITSUI-MAN B&W
4C-09341 C31 .1 TCA55 179

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 cata logue are structured according to the
assemblies system of the turbocharger.
Assemblies The assemblies of the MIT SUI- MAN B&W turbocharger can easily be
determined with the List of Assemblies (see Chapter 2).
Subassembly group numbers given in brackets do not exist for all turbochar-
gers. 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 8-digit printing number ( 4C-09341) on the
bottom left and of the ordinal number (e. g. C3-520.01) 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 number are the-
reby separated with a dot
T
520.001 Stock Number (e.g. turbine rotor)
T,____ Position Number
Subassembly group number
4C-09341 C31 .2 TCA55 180

Validity
Validity Spare parts catalogues are specially adapted to the respective turbocharger
version. Therefore , the respecti ve spare parts catalogue is valid only for the
turbocharger or the turbocharger series with the works No. or factory-num-
ber group on the cover sheet.
. Important!
Spare parts catalogues may not be transferred from one
turbocharger to another.
Changes/Alterations on the If changes/a lterations are carried out to the turbocharger over the coarse of
Turbocharger the operating period for which no new drawings are drawn up and subse-
quently no new spare parts sheet is made out by the MITSUI - MAN B&W,
the operators of the engine themselves must enter a respective remark into
the spare parts catalog ue. 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
4C-09341 C31 .2 TCA55 181

Ordering Spare Parts 1.3
Overview
T he turbocharger is part of a system from which t he assemblies ca n be from

va rious manufacturers T he followi ng table gives an overview of the va rious
spare parts catalogues/info rmation aides from w hich the necessary data fo r
spare parts orders can be taken.
Component!Assemblies lnfonnation Aid Volume of the Techni-

cal Documentation
Turbocharger Spare pa rts cata logue, tu rbocharger C3
Data in wo rk ca rds C2
Tools (turbocharger) List in the turbocharger too l box C3
Data in wo rk ca rds C2
Table 3-1. Spare parts catalogues and comparable information aides
Ordering of Spare Parts
T o avoid questions whe n ordering spare parts, the foll owing information is
required:
Type of tu rbocharge r.. .. ... . .. . .. ... . ...... .... ............ xxx xx

Manufacturing number of the turbocharger .. ... ..... xxxx
(Type of engine) ....... .... .................. .. ................ .. ..... ... .. ..... xxxxxx
(Manufacturi ng number of the engine) .. .... .. .... .. ... ... ......... xxxx
Designation of the pa rt.. .. ......................... ..... ............ xxxxxxxxx
Ord ina l 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).
4C-09341 C31 .3 TCA55 182

List of Assemblies 2
4C-09341 C32 TCA55 183

List of Assemblies 500
540 542 554 517 509
506
0
(..)
I 513
01
0
0
501
-l
0
)>
01
01
520
List of Assemblies
Assembly De signation
500 Exhaust gas turbocha rg er
501 Gas-a dmission casing (axial/ 90' )

506 Gas outlet casing
509 Gas outlet diffuser
513 Turbine nozzle ring
517 Bearing casing
() 518 Casing feet
<f
()1 520 Rotor co mplete
0
0 540 Insert
542 Diffuse r
544 Silence r
546 Compressor casing
-l
() 554 Post lu brication tank
)>
()1
()1
562 Speed measuring device
578 Cleaning device for turbine
579 Clea ning device for co mpressor
591 Cove ring and Insulation
Assemblies not shown in the figures
():)
()1
4C-09341 C3- 500 TCA55 186
List of Components 3
4C-09341 C33 TCA55 187

Gas-admission casing 90°* 501.02
501.000
0
<fJ
U1
0
0
N
-l
0
}>
U1
U1 ·-....__
. . . __q:__- 501.028
t)---501.027
- - 501 .026
(f)..._ 501.025
~ 501.024
~-- 501.023
....
~ *) If the turbocharger is equipped with VTA, refer to the additional instruction manual.
Gas-admission casing 90°* 501.02
Order No. Number Designation Order No. Number Designation
501.000 (1) Gas-admission casing, complete
501 .001 1 Gas-admission casi ng with insulation

501 .023 1 Screw plug
501 .024 1 Sealing ring
501.028 1 Sea ling ring
0
<f
()1
0
-"
---1
0
)>
()1
()1
*) If the turbocharger is equipped with VTA, refer to the additional instruction manual.
-"
co
<D
Gas outlet casing 506.01
506.040
\'<'~
~506.039
506.040
"'@ B
E
E
~
~506058
D
c 506 .060
506.208
0
(..)
' 506.103
U1
0
(J)
0
--" I
L soo.207
---l
0
)>
U1
U1
506 .058
--"
<D
0
Gas outlet casing 506.01
506.000 {1) Gas outlet casing, complete
506.001 1 Gas outlet casing with insulation

506.058 28 Spring wasl1er
506.060 28 Hexago n bolt
506.099 24 Undercut bolt
506. 103 8 Hexago n nut
()
If 506 .1 04 28 Hexagon nut
(JI
0
Q)
0__.
506.207 28 Spring washer
506 .208 4 Stud
-l
()
)>
()l
()l
(()
__.
Gas outlet diffuser 509.01
509.000
- 509.001
()
0.>
I
01
0 (>.. 509.014
<D
0__. ' " l so9.012
~
-l
()
)>
01
01
__.
<0
N
Gas outlet diffuser 509.01
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
()
y>
CJ1
8
0
......
--1
()
):>
CJ1
CJ1
Turbine nozzle ring* 513.01
513.000
, __
513.001
0
<f>
_.
()1
------------513.013
(.,.)
0_.
-------513.014
fi.F.JL-(f------NI+----t'-H-- - - -51 3. 021
_.
<D *) If the turbocharger is equipped with VTA, refer to the additional instruction manual.
~
Turbine nozzle ring* 513.01
513.000 1 Turbine nozzle ring, complete
513 .001 1 Nozzle ring

513 .010 1 Clamping ring
513 .021 4 Guide bolt
()
y:>
01
__.
w
0__.
-l
()
)>
01
01
*) If the turbocharger is equipped with VTA, refer to the additional instruction manual.
__.
c.o
01
Bearing casing 517.01
517.161 ~u- 517.147

517.100
517.156 1
®----517.144
517.143 ---cl:,
~~I ~ ---e
517.161
517.157 517.142
517.141 ---cl)
r ~-fa. 517.001
(517AC)
!
. J
517.027
517.169
517.032
~17.154 't··,_ 517~.159 517.~,4 517.033
\\
\
I
517.094 517.034
517.156 .,_ /h 517.035
. , ,.!~~-~ .157 _/ff:::-
· ........ ~Y/ ~'=181.
517.169
-l
0
)>
()1
()1
Bearing casing 517.01
517.000 (1) Bearing casing, compl. 517. 102 6 Hexago n nut

517.001(517AC) 1 Bearing casi ng 517. 142 1 Non-return valve
.J:>,
() 517.026 3 Seal 517.143 1 Sealing ring
I
0
co
0) 517.027 12 Hexago n bolt 517. 144 1 Pipe socket
.J:>,
__.
517.032 6 Seal 517.147 4 Hexagon bolt
517.033 6 Cove r 517.153 1 Thrust bearing
517.034 24 Hexagon bolt 517. 154 1 Counter-thrust bearing
517.035 24 Lock washer pair 517. 156 12 Loci< washer pair
()
y> 517.054 1 Orifice 517. 157 12 Hexagon bolt
01
__. 517 063 1 0-ring seal 517.159 1 Cove r
:--J
0 517 064 1 End cover, turbine side 517. 161 2 Bearing bush
517 068 8 Stud 517.1 62 1 Bearing body
517.070 1 Seal, turbine side 517. 169 2 Blind flange
517.072(517AA) 1 Sealing cover, turbine side 517. 172 6 Countersunl< head screw
-j
() 517.075 1 Bearing disk 517.173 6 Loci< nut
p
01 517.085 1 0-ring seal 517. 185 1 Seal, compressor side
01
517 089 1 Labyrinth disk , compressor side 517. 197(517AB) 1 Sealing cover, compressor side
517 094 8 Loci< nut
517 .100 6 Stud
__.
co
:--J
Bearing casing (cut out A} 517.01
517.000
517.083
~~i 517.02C
517.027
4C-09341 C3-51701 TCA55 198

Bearing casing (cut out A) 517.01
517 .006 1 Pipe

517020 1 Pipe
517 026 3 Seal
517.027 12 Hexagon bo lt
517.106 1 Flange
517. 11 3 1 Sealing ring
517 114 1 Sealing ring
517.117 1 Non-return valve
517 .139 1 Sealing ring
-l
0
)>
CJl
CJl
....\
([)
([)
Casing feet 518.01
518 .126
~~ 518 .025
I
........~ 518.126
0
(..)
I
~
.....
C.J1
CD
0
-"
-I
0
)>
C.J1
C.J1
II *
... I ... 022
*
Casing feet 518.01
518.000 (1) Casing feet, complete
518 .001 2 Casing foot

518 025 16 Distance sleeve
518 .1 26 16 Undercut bolt
()
y:>
(Jl
-'
(XJ
0
-'
-l
()
)>
(Jl
(Jl
1\.)
0
-'
Rotor, complete* 520.01
520.035 520.000
520.067
0
'f
01
N
0
0
.....
-1
0
)>
01
01
520.044
N
0
N
*) If the turbocharger is equipped with THS , refer to the additional instruction manual.
Rotor, complete* 520.01
520.000 {1) Rotor, complete
520 .001 1 Turbine rotor with items 520.018 to 520.028

J::..
0I 520.018 ( 1) Labyrinth ring, turbine side
0
<D 520.021 (1) Ri ng nut
0.l
J::..
--" 520.028 (1) T hrust ring
520 .035 1 Labyrinth ring, compressor side
520.044 1 Compressor wheel
520.066 1 Undercut bolt
0 520 .067 1 Spinner
y>
()1
N 520 068 1 Tension nut
0
0
--"
-l
0
)>
()1
()1
*) If the turbocharger is equipped with THS, refer to the additional instruction manual.
Insert, complete (Without IRC) 540.01
540.000
(only for version with Jet- Assist (Four stroke Engine))
()
(.0
540001-
I
()l
t5
0__.
-4
()
)>
()l
()l
tv
0
~
Insert, complete (With IRC) 540.01
540.000
540.015 (only for version with Jet- Assist (Four stroke Engine))
540.002 -
540.030
I
-l
0
;p
CJ1
CJ1
N
0
CJ1
Insert, complete 540.01
540.000 (1) Insert, complete
540 .001 1 Insert

540 .002 1 Soc l~et( * 1)
540.005 6 Hexagon bolt(*1)

540.007 6 Lock washer pair(*1)
540 .015 1 0-ring sea l(*2)
540 .025 1 Cable socket
540 .026 1 Seal disk
540.029 1 Metal adhesive
540 .030 1 Balance ring
*1) Only for version with IRC

-l *2) Only for version with Jet-Assist (Four stroke Engine)
0
)>
()1
()1
Diffuser 542.01
542 001
I
-;
0
)>
~
Diffuser 542.01
542.001 1 Diffuser
--l
()
)>
()1
()1
1\..)
0
co
Silencer, complete* 544.01
544.000
544.032
.,.._~~lr--544.011
544.061
544.040 ~~--ll-;~..,- 544.016
544.013
544.031
544.036 A
544.170
l' ___ _ 544.001 (544.A)
0
y>
01 544.060
t__.
0
B
544.223
-l
0
t-~ (544.F)
-~
)>
01
544.214 544.213
·-- -. . ......... ~:::~~~ --- .. , ____ (JJ_ _
01
c c
-·: -__-t:J:- 544.181 /~
t-~
544.182
544.216 544.215
o[;r:
l.__ -
544.402 ___
544.403/: -~ ~- E
D
544.401
N
0
t-~ 544.403 E t-~
544.211544.210
<0 544.219 544.217 544.400
*) If the turbocharger is equi pped with THS or AIC, refer to the additio nal instruction manuaL
Silencer, complete* 544.01
544.000 (1) Radial type silencer, complete
544001{544.A) 1 Silencer casing 544.211 24 Hexago n nut

544011 1 Protecting cap 544213 12 Washer
544013 1 Screwed connection 544214 12 Hexagon nut
544016 1 Pipe 544215 4 Loci< washer pair
544031 41 Perforated sheet 544216 4 Hexago n nut
544.032 41 Perforated sheet 544.217 41 Loci< washer pair
544033 41 Inner guide rail 544.219 41 Hexagon nut
544036 41 Outer guide rail 544.223{544.F) 1 Cover
()
544.040 41 Damper cushion 544.307 1 Loctite 586
G.>
I 544.050{544C) 1 Front wall 544.400 1 Pressure gauge
(Jl
~
:1::>.
544.060 1 Perforated sheet 544.401 1 Hexagon bolt
0
--" 544.061 1 Perforated sheet 544.402 1 Hexago n bolt
544.062 1 Perforated sl1eet 544.403 2 Seal ring
544.150 1 Fleece mat
-t 544.160 3 Lashing strap
()
)> 544.170 1 Cover strip
(Jl
(Jl
544.180 24 Stud
544.181 24 Loci< washer pair
544.182 24 Hexagon nut
544.210 24 Washer
*) If the turbocharger is equipped with THS or AIC. refer to the additional instruction manual.
tv
--"
0
Compressor casing {single outlet) 546.01
546.000
546.D73
546 .001
()
<f
(Jl
.t:.
<J)
0
--"
546.025
-l
()
546.305 .--c
)> 546.308
(Jl
(Jl
N
--"
--"
Compressor casing (single outlet) 546.03
546.000 (1) Compressor casing, complete
546 .001 1 Volute cas ing

546 .024 1 Sealing ri ng
546.025 3 Screw plug
546 .047 1 Lock nut
546 .049 1 Cable socket
546.050 1 Sea l disk
()
<f 546 .073 16 Undercut bolt(*)
01
<§) 546 .145 1 Cou ntersunk bolt
0
--"
546.305 2 Screwed connection
546 .308 2 Closure plug
*) 12 pes for without IRC insert piece

-I
()
)>
01
01
N
--"
N
Emergency and Post lubrication tank 554.01
554.000
554 .195
554.014
\ ~
~
" '.
554.001
(554AA)
554.084
554 .158
554 081
554.066
554 095
554.063
554.071
554 .031
(554AC)
554 .052
'\
554 .200 -----------~ 0
554 047
554 .056
554 .158
4C-09341 C3-554.01 TCA55 213

Emergency and Post lubrication tank 554.01
554.000 (1) Post lubrication tank, complete

554.157 12 Washer
554.001 (554AA) 1 O il tank
554AC 1 Bracket 554.195 2 0 -ring seal
554 014 24 Hexagon bolt 554.196 2 Flange
554 027 1 Non-return va lve 554.200 9 Washer

554.040 4 Hexago n bo lt
554 041 4 Hexagon nut
554.047 1 Plate
()
y; 554 056 4 Hexagon bolt
(Jl
(Jl 554.063 4 Hexagon bolt
~
0_. 554 065 1 Seal ring
554.066 1 Pipe
554.068 1 Seal ring
--l
() 554.081 1 Pipe
)>
(Jl
(Jl 554.084 1 Sea l
554 097 1 Sea l ring
554 098 1 Seal ring
Wet Cleaning of the Turbine (Gas-admission casing 90°) 578.01
1578.ooo 1
578.019
578.011
578.016
.""'-.
I
'•
578.015 I ~578010 .
,/
578.019
578.011
4C-09341 C3-578.01 TCA55 215

Wet Cleaning of the Turbine (Gas-admission casing 90°) 578.01
578.000 (1) Cleaning device for turbine, complete
578 .001 4 Spray nozzle

578 .010 4 Sea l
578 .01 1 8 Hexagon bo lt
578 .015 2 Pipe union
578.019 2 Injection pipe
()
578 .020 2 Injecti on pipe
y;
(Jl
~
co
0__.
-1
()
)>
(Jl
(Jl
N
__.
(J)
Annular lagging Gas-admission casing 591.01
591.000
()
<f 5 9 I 8 I . 3 ·1~) -----<9
(]1
<D
__.
0__.
.::. Q
...../ '-I
I ,
L~l I t.
, I \
-1
()
)>
(]1
(]1
5 9 I . CI 0 I 0-----------------------
--------- //
~-----------59 I . 0 I . CI:)
r:: 0..1 I . l," I . .') L
. ~- [ . - - _ _______,.. ~~
.)
________ --/
------ - - - - - - 5'3 1. 0 ' 342
) 9 I . 8 I . 3 '1 I ----------
- - - - - - - : ) 9 . C I . 34 I
Annular lagging Gas-admission casing 591.01
591.01.000 (1) Ring covering, complete
591 .01 .A 2 Ring covering , half

591 .01 .010 2 Connecting Plate
591 .01 .340 8 Hexagon bolt
591.01.341 16 Hexagon bolt
591.01 .342 16 Lock washer pair
()
Cf
(Jl
co
__.
0__.
-l
()
)>
(Jl
(Jl
IV
__.
co
Sound insulation compressor casing 591.02
591.000
591.02. Il l ~
59 I . 0 2 . I I 2 - ----._
591.02.080-----\
()
YJ
<J1
co
__. 59 I . 0 2. 6 - - - - - - - ----t
~----59 1 .02 .C
59 I 02 E--------~ ~"-------------59 I . 02 . A
~~
---1
()
):>
<J1
59 1.02 .1 12
<J1
591.02. 11 1- - - - - ------
.,.__- - - - 5 9 1 .02.1 12
-.--- - -59 I . 0 2 . I I I
N
__.
co
Sound insulation Compressor casing 591.02
591.02.000 (1) Sound insulation, complete
591.02.A 1 Jacket sheet with insulation

591.02.8 1 Jacl~et sheet with insulati on
591 .02.C 1 Jacket sheet with insulation
591.020 1 Jacket sheet with insulation
591.02.E 1 Jacket sheet with insulation
591.02.080 1 Frame
591.02.090 1 Frame
()
w 591.02.111 9 Hexagon bolt
'
()1
({)
..... 591.02 11 2 9 Washer
0
1\.)
-l
()
)>
()1
()1
1\.)
1\.)
0
4C-09341 C3- 591.02 TCA55 221
Spare Parts
Tools 4
tIn case of the application of the additional specifications, refer to the additional instruction manual.
4C-09341 C34 TCA55 222

List of Tools 596.01
t3 Order No.
Num-
ber
Designation
Weight
[kg)
Design Order No.
Num-
ber
Designation
Weight
[kg]
Design
596.001 1 Puller ring, 0.9 596.018 1 Locking key 4.6

compressor wheel 0 0
(emergency ope- ~
0 0 ration)
0 0
~
~
0 0
6 0 0
(!)
(.,.)
~
..... 596.002 1 Assembl y ring , 1. 99 596.022 1 Hub, 0.8
compressor
wheel
{@
(emergency ope-
ration)
00
o
0
0
0
0
a
0
(.,.)
(Jl 596.003 1 Forcing-off bolt 0.3 596.023 4 Cylindrical screw 0.1
(!)
' ~
0)
0
.....
M20x2x 100 M10 X 25
-1 596.004 4 Threaded bar 0.1 596.024 4 Lock washer pair 0.01

0
)>
(Jl
IJ
(Jl
M10 X 155 dt = 10.7

596.005 4 Hexagon nut 0.01 596.027 1 Closing cover 11 .1
0.=4~
(compressor si-
de), emergency
® operation
M10
N
N
(.,.)
Num- Weight Num- Weight

Order No. Designation Design Order No. Designation Design
ber (kg] ber [kg]
596.028 1 Closing cover 1.1 596.033 2 Hexagon bolt 0.14

(turbine side),
~
emergency opera-
tion
0.=253 M12 X 120
596.029 1 Packing 0.5 596 .040 1 Extension shaft 0.4
~
(compressor side)
0
()) dl = 319
(.V
()1 596.030 1 Packing 0.2 596.041 4 Hexago n bolt 0.08
<D
(turbine side)
({)
(J)
~
0
--"
dl = 157 M1 2 X 80
--l 596.031 1 Stud screw 0.6 596.044 2 Guide bar 0.5

0
)>
()1
/
"
()1
(j) 12 X 600
M12 x 550
596.032 3 Hexagon nut 0.02 596.045 2 Guide bar 1.1
~
M12
/
(j) 16 X 700

ber [kg) ber [kg]
596.046 1 Shackle 0.4 596.070 2 Threaded bar 0.08
0~
~ M6~
596.050 2 Guide bar 0.15 596.071 1 Turn pin 0.2
0
w
CJl
co
596.051 2 Eye bolt 0.2
~70
596.072 2 Hexagon nut 0.01
-~
~
0>
0
-"
@
M12 M6
596.055 1 Suspension plate, 2.2 596.073 1 Puller ring 1.0
-l
0 gas-admission
~
CJl
casing
IP {(f) 0
0
0
<P 100
596.058 1 Eye bolt 0.28 596.075 1 Protection sleeve, 4.3
~
turbine rotor
I= 428
M16

ber [kg] ber [kg]
596.087 3 Hexagon bolt 0.1 596.168 1 Hexago n bo lt, 0.1
Suspension device
~ ~
for compressor
wheel
M8 x 90 M12 X 60
596.092 1 Clamping sleeve 0.74 596.170 1 Support 8.6
0
0.J
596.101 1 Surface drive 0.03
~ 596.197 1 Hexago n bolt 0.2
~
t
·~
~
(J1
<D
OJ
~
0
5x6.3 M1 6 X 80
--!
596.160 1 Pipe, 4.8 596.198 1 Hexago n nut 0.03
0 Suspension device
)>
(J1 for compressor
~
(J1
whee l
I= 670
M16
596.167 1 Sleeve 0.5 596.208 1 Shackle 0.2
~ll
d~ ~
N
N
OJ

ber [kg] ber [kg]
596.267 1 Lever carrier 1.1 596.274 3 Cylindrica l screw 0.03
c\{) ~ M10 x 40
596.270 1 Pipe 2.6 596.275 1 Spanner head 0.53
0
(.0
(Jl
<.0
596.271 1 Slide 1.5
cJ>
~
27.2 x'900
~~-,,
596.310 2 Sleeve 0.05
CJ
Q
(J) l 00 \.} \ \ \
0
-->. .a ~
\Oi
\-~
r\\})
r·. . ~"'· \\
~) . - \) 1
•\ ~·
\
86
cJ>
() ~() /J
' '-·..___../'
0=25
---l
596.272 1 Hexagon socket 0.036 596.311 1 Support 0.5
~
0 bolt
/
)>
(Jl
(Jl
M10 x 30 L=525
596.273 1 Bolt 0.01
06~

ber [kg] ber [kg]
()
w
(Jl
<0
(J)
0__.
--1
()
)>
(JI
(Jl
N
N
co
I OPER~-\TINC} MANlTAL FOR TURBINE DRY CLEANING DEVICE
1 . Outline of Cleaning Method by Solid Material
Fig. 1 shows the outline of the cleaning device.

Some amount of solid material poured into the filling tank (A) is blown
into exhaust gas pipe before turbine blades by compressed air and remo\·e
deposit on nozzle vanes and turbine blades by making impart on them .
2. Solid Material
(1) Formed carbon . crushed nutshells and grained activated carbon are
suitable for solid material.
Rice and grain are not recommended as a dry cleaning material. as it
may stick in the exhaust gas boiler .
(2) The eleaning effect depends on shape. size . hardness and specific
gravity of solid material. If they are improperly applied. nozzle vanes
and turbine blades will be damaged.
The suitable size of solid material is 1.0 "' 1.5 mm. It must not be
larger than 1.5 mm.
3 . Cleaning procedure
The cleaning procedure is described in the attached paper.
4. Cautions
(1) Do not use solid material mixed '"'·ith water.
(2) If grained activated carbon and crushed nut shells are used . crush them
into specified ·sized pieces (1.0 "' 1.5 mm).
(:3) Do not open any drain valves of exhaust system and turbocharger :
otherwise solid material "'-'ill be burst out through the opening.
(-!) Be careful whether sparks draw out through chimney or not .

If they are dangerous . stop the cleaning .
(:) ) Surging during cleaning has to be a\·oided .

If surging occurs . the air s uppl y has to be adjusted by vah·e CD .
1
CLEA::-JING·
AA) Cleaning conditions
1) Normal operating load of engine.

No load reduction is ne cessa ry.
2) quantity of solid material is shown in Table 1 .
Table 1
Turbocharger type (~uantity of solid material
(liter)
TCA44 0.5
* TCA55
TCAGG
TCA77
TCA88
1.0
1.5
2.0
2.5
BB) Int erva l of cleaning
Recommended cleaning interval: 24 "' 50 hours
CC) Cl eani ng procedure (See Fig. 1)
1) Co nfirm that the \'a lve @ is clo se d firmly.
2) Before pouring solid material into the filling tank (A) , open the
valve ~- and then open the valve CD for 5 "' 10 seconds.
Note: A pipe (C) and nozzl e (E) m ay ha\'e been clogged with the residual
solid material.
This operation makes it possible to clean them .
3) Close the valves in the order of (?.) - CD.

Confirm that the valves ~ and CD are clos e d .
4) Opening the valves @,po ur a specified amount of solid material into the
filling tank (A) from the hopper (B) and close the valve Q).
5) Open the valves in the order of CD - (?.), and then the solid material is
blown into the TIC inlet pipe through the pipe C and the nozzle (E) for
about 30 seconds.
6) Close the valves in the order of ® - CD.
2
~ 1
A r r a n g e me n t of t he
Fi g. 1
c I e a n i ng d e v i c e
(A) )1A9Y?
Filling tank
(B) tl\ ':1/\
HoPPer
(C) iU~'B
Pi De
(D) ~~~~~
Pi De
( B)
------
,// ,// ,/ /7 // // ,// //
.------+-___,¥ - - - -
Jl!ll~J\
Ai r
I
(0. 5"-'0. 8 MPal
"'....
l \
'·,
'-
"'
.....
0
'"'....
"'
.....
0
I
<>
....
..:
.....
<0
N

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EXHAUST GAS TURBO-CHARGER

Exhaust Gas Turbocharger

Operating Manual .................................................. ... C1

Turbocharger ....................................... TCA 55

Works No. of turbocharger .................. _ __

Exhaust Gas Turbocharger .................... TCA 55

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

2.1 General Safety Instructions ........................................................................................................................... 11

3 Technical Data ............................................................................................................... 21

3.1 Exhaust Gas Turbocharger ............................................................................................................................ 21

4.1 Exhaust Gas Turbocharger ............................................................................................................................ 29

5.1 Starting Operation/Putting Out of Operation .................................................................................................. 41

6.1 General Remarks ......................................................................................................................................... 51

Product Liability 1.1

The technical documentation supplements this ability through specialized

4C-09341 C1 1.1 TCA55 5

Scope of Supply 1.2

Each turbocharger is adapted especially to the engine system of a certain

Type Turbocharger type TCA55

Built-in equipment Compressor diffuser 1>

Fig . 1-1. Compressordiffuser Fig. 1-2. Turbine nozzle ring

Auxiliary equipment 1[1 Silencer with air filter

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

4C-09341 C11 .2 TCA55 6

Documentation Inscriptions on the turbocharger , operating tags English

For inquiries on any parts delivered by Mitsui Engineering Shipbuilding

4C-09341 C11 .2 TCA55 7

MES Technoservice Co., Ltd.

Location Address Subject Contact person

T echnoservice division, 1, Yawatakaigandori , lchihara,

T echnoservice division, Matsuoka Shinagawa Bldg., 2F,

T echnoservice division, Kaigan Bldg., 5F 3, Kaigandori ,

Table1-1 . Locattons and addresses of MES Technoservtce Co., Ltd.

4C-09341 C11 .3 TCA55 8

Country Address Contact person Telephone/Fax/e-mail

4C-09341 C1 1.3 TCA55 9

General Safety Instructions 2. 1

· Death or serious injury,

· Death or serious injury,

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

4C-09341 C1 2.1 TCA55 11

Wamingofa Danger of Tripping Danger of Corrosive

Fire, open No access

4C-09341 C1 2.1 TCA55 12

·T urbine and compressor are to be cleaned at regular intervals as specified in the

4C-09341 C1 2.2 TCA55 13

Fig .2. Safety instruction sign - Engine room

4C-09341 C1 2.2 TCA55 14

Health risk due to exhaust gases !

4C-09341 C1 2.2 TCA55 15

4C-09341 C1 2.2 T CA55 16

Qualification of Personnel For Ship System:

Operational management through the chief engineer on board or through a

Persons managing the operation must be in possession of a competence

For Stationary Systems (Power Plants):

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

4C-09341 C1 2.2 TCA55 17

Opening Pipes/Pressure Tanks

·Wear protective clothing!

4C-09341 C1 2.3 TCA55 19