TCR16 0287-1

MAN Diesel & Turbo
Technical Documentation
Turbocharger
Operating Instructions
Turbocharger type ............................. TCR16-40

2014-01-23 - de
Translation of the original instructions

0287-1 C1-01 EN-US 1 (2)
MAN Diesel & Turbo
MAN Diesel & Turbo SE

86224 Augsburg
Phone +49 (0) 821 322-0
2014-01-23 - de
Fax +49 (0) 821 322-49 4180

[email protected]
www.mandieselturbo.com/primeserv
Copyright © 2014 MAN Diesel & Turbo

All rights reserved, including reprinting, copying (Xerox/microfiche) and translation.
2 (2) 0287-1 C1-01 EN-US

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

6.2 Tools
6.3 Maintenance schedule
6.3.1 Maintenance schedule - turbocharger
0287-1 C1-01 EN-US 1 (3)

MAN Diesel & Turbo
6.4 Remarks on maintenance work

Table of contents
6.5 Inspection of components

6.6 Inspection report
6.7 Service report
7 Work cards
7.1 Preface
7.1.1 Organisation and use of the work cards
7.2 Setting data
7.2.1 Screw Connections and Tightening Torques
7.2.2 Gaps and clearances
7.2.3 Speed Measuring Device
7.3 Emergency operation
500.11 Emergency operation with closing device
7.4 Cleaning
500.21 Cleaning the turbine - Wet cleaning
500.22 Cleaning the turbine - Dry cleaning
500.23 Cleaning the compressor - Pressure sprayer
500.24 Cleaning the air filter
7.5 Assembly and maintenance
500.31 Complete turbocharger
500.32 Silencer - Option
500.33 Air intake casing - Option
500.41 Insert, compressor side
500.42 Covering on compressor casing - Option
500.43 Compressor casing
500.44 Cartridge
500.45 Cartridge Components – Major Overhaul
500.46 Turbine nozzle ring
500.47 Gas admission casing and turbine-side insert
8 Spare parts catalogue / tools

8.1 Preface
8.1.1 Organisation and use of the spare parts catalogue
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8.1.2 Ordering spare parts

8.2 Overview of subassemblies
500 Overview of subassemblies
8.3 Spare parts
2 (3) 0287-1 C1-01 EN-US

MAN Diesel & Turbo
501.01 Gas admission casing
Table of contents
506.01 Gas outlet casing
513.01 Turbine nozzle ring
517.02 Bearing casing
520.01 Rotor, complete
540.04 Insert, compressor side
541.01 Insert, turbine side
542.01 Diffuser
544.02 Chamber silencer - OPTION
545.01 Air intake casing, 90° - OPTION
545.02 Air intake casing, axial - OPTION
562.01 Speed measuring device - OPTION
578.01 Cleaning device for turbine - Wet cleaning
578.02 Cleaning device for turbine - Dry cleaning
579.02 Cleaning device for compressor - Pressure sprayer
591.01 Covering on Gas Admission Casing
591.04 Covering on Gas Outlet Casing
591.05 Covering on Bearing Casing
591.06 Sound Insulation on Compressor Casing
599.01 Cartridge
8.4 Spare parts for maintenance 11.59500-0198
595.01 Spare Parts for Maintenance – OPTION
8.5 Spare parts for major overhaul 11.59500-0225
595.02 Spare parts for major overhaul - OPTION
8.6 Tools 11.59600-0221
596.01 Tools - OPTION Turbocharger TCR16
9 Index
2014-01-23 - de
0287-1 C1-01 EN-US 3 (3)

MAN Diesel & Turbo
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
2014-01-23 - de
Safety
0287-1 1 C1-01 EN-US 1 (1)

MAN Diesel & Turbo 1.0
Organisation and use of the safety instructions
Safety
Safety instructions
Safety instructions are always situated before the description of a task. They
are divided into 4 hazard levels. The severity of the hazard for personnel or
equipment is evaluated, as is the probability of the hazard.
Hazard level
The safety instructions for hazard levels 1 – 4 have the following designa-
tions:
▪ Danger,
▪ Warning,
▪ Caution,
▪ Caution (material damage only)
are indicated as follows:
If the corresponding precautionary measures are not taken,

there is a risk of immediate danger.
The direct result of this is:
• Death or severe (irreversible) physical injury.
If the corresponding precautionary measures are not taken,

this will result in a potentially hazardous situation.
The possible result of this is:
• Death or severe (irreversible) physical injury.
A hazardous situation can occur if the corresponding

precautionary measures are not taken.
This can result in:
• Minor (reversible) physical injury.
Material damage to the product can occur if the corresponding

precautionary measures are not taken.
This can result in:
• Exclusively material damage; no physical injury expected.
2012-12-12 - de
Additionally, the element Notice is also used:

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

1.0 MAN Diesel & Turbo
Identification of special user tips.

Safety
Additional or important notes and information.

No injuries or material damage expected.
A symbol appropriate to the hazard is always depicted in the marginal col-

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

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

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

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

open flames unauthorized
2012-12-12 - de
and smoking persons!

prohibited!
General
Safety
2 (3) C1 6673 1.0-02 EN-US

Safety
Safety instruction sign – engine room
Figure 1: Safety instruction sign - engine room
To point out the most important regulations, bans and hazards during
operation and maintenance, the safety instruction sign enclosed with
each turbocharger must be posted at the entry of the engine room.
2012-12-12 - de
Persons, who for operational reasons are to be within the danger area of 2.5
m around the engine, are to be instructed of the predominant hazards.
General
Safety
Access to the danger area is permitted when the turbocharger is in proper

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

Responsibility of the user
Safety
Personnel requirements
Safe and economical operation of the engine plant including the turbo-
charger requires comprehensive knowledge. Furthermore, it is possible to
maintain or restore the functional capability through maintenance and repair
work only if this is carried out with expertise and skill by trained personnel.
The rules of proper craftsmanship are to be observed; negligence must be
prevented.
Technical documentation
The Technical Documentation supplements this skill with specific information,
draws attention to hazards and points out the safety regulations that have to
be observed. We thus ask you to comply with the following rules:
Risk of accidents resulting from improper use of the

turbocharger!
Improper use of the turbocharger is liable to result in damage to the
turbocharger or individual components. Damaged components
represent a considerable risk of injury to the operating and
maintenance personnel.
• Before starting operation for the first time, read the available Technical
Documentation including the safety regulations contained therein.
• Use the turbocharger only for the purpose intended by the
manufacturer.
• Never remain unnecessarily in the vicinity of the turbocharger. The
presence of personnel in the vicinity of the turbocharger is permitted for
maintenance work that expressly has to be performed during operation!
• Perform the maintenance work on the turbocharger regularly and
correctly within the specified intervals!
• Use only original spare parts from the manufacturer when performing
repair and maintenance work.
The manufacturer disclaims all liability if the above-mentioned safety

regulations are infringed.
Intended use
2013-02-22 - de
The turbocharger is intended for use on diesel-fuel, heavy-fuel and gas

engines. It draws in the fresh air or air/gas mixture required for engine opera-
TCR16-40
tion and compresses it. The exhaust gas temperature must not exceed
Safety
650°C (720°C only with special materials of turbine stage).
C1 0288 1.1-02 EN-US 1 (3)

Any application beyond this must be discussed with and approved by the
Safety
turbocharger manufacturer. The turbocharger is not designed for operation in

an explosive atmosphere, i.e. the engine room (room with the engine and tur-
bocharger) must be continuously vented.
Each turbocharger is specially adapted to the engine on which it is to be
operated. This means the turbocharger may be operated only on this engine
or one of identical design.
The turbocharger is considered as being implemented in accordance with its
intended use only if the following conditions are additionally fulfilled:
▪ by the engine manufacturer:

The engine manufacturer must ensure that the turbocharger is connected to
a supply of lubricating oil from the engine or plant. Any connection points
located within an explosive atmosphere must be appropriately sealed.
The engine manufacturer must design the engine control system so that the
limit values of the turbocharger (max. admissible rotor speed and exhaust
gas temperature, admissible lube oil temperature and lube oil pressure,
vibrations, use of the specified operating media) are not exceeded in the
anticipated operating conditions.
▪ by the installation contractor / manufacturer of the complete plant:

The installation location must afford sufficient space for maintenance and
installation/removal of the rotor assembly. The use of lifting equipment must
be possible.
Supply, measuring, control and regulating systems must enable troublefree
operation (design in accordance with the turbocharger manufacturer’s rec-
ommendations and state of the art).
It must be possible for operation to be monitored by means of suitable
measures.
▪ by the user:
The operating parameters (max. admissible rotor speed and exhaust gas
temperature, admissible lube oil temperature and lube oil pressure, use of
the specified operating media) must be observed and may not be exceeded
(see type plate, Chapter 3.1.1).
The turbocharger may be operated only when in perfect condition.
Work on the turbocharger may be carried out only by trained personnel. All
work is subject to compliance with the operating instructions and the statu-
tory occupational health and safety regulations.
Malfunctions that could influence safety must be remedied before starting or
resuming operation.
Service and maintenance work must be performed in accordance with the
maintenance schedule (see Chapter 6.3.1).
2013-02-22 - de
Corrosion must be prevented on components that come into contact with an

explosive gas mixture.
TCR16-40
Only original spare parts and fasteners of the specified quality (bolts, nuts,
Safety
washers, seals, etc.) may be used for repairs.
2 (3) C1 0288 1.1-02 EN-US

Safety
Foreseeable misuse, negligence, improper use
Foreseeable misuse The following operating conditions are considered as misuse:
▪ Operation at operating values resulting in engine shutdown or load
reduction.
▪ Operation without appropriate surveillance/supervision.
▪ Operation without sufficient maintenance.
▪ Operation when supply systems have failed (e.g. lubricating oil system).
▪ Use of other than original spare parts.
▪ Operation and maintenance without the required personal protective
equipment.
▪ Long-term shut-down without taking preservation measures.
▪ Operation and maintenance by unauthorized/unqualified staff.
Gross negligence, improper The following operating conditions are considered as improper use:
use ▪ Operation outside the defined operating parameters.
▪ Operation with unauthorised modifications.
▪ Operation with defective, deactivated or modified safety equipment.
▪ Operation without a suitable fire-extinguishing system.
2013-02-22 - de
TCR16-40
Safety
C1 0288 1.1-02 EN-US 3 (3)

MAN Diesel & Turbo
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
2014-01-23 - de
Addresses
0287-1 2 C1-01 EN-US 1 (1)

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

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

Spare parts Fax +49 821 322 3998
PrimeServ Academy Tel. +49 821 322 1397

Training courses for turbochargers Fax +49 821 322 1170
and engines
Internet www.mandieselturbo.com/primeserv-academies
Worldwide service addresses

2013-08-26 - de
Internet MAN Diesel & Turbo service addresses and authorized service partners
Addresses
(ASP) can be found on the Internet under MAN | PrimeServ Worldwide Net-
work:
General
www.mandieselturbo.com/primeserv
C1 6673 2.1-06 EN-US 1 (1)

MAN Diesel & Turbo
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
Technical data
2014-01-23 - de
0287-1 3 C1-01 EN-US 1 (1)

Turbocharger
3.1 Turbocharger
Technical data
2014-01-23 - de
0287-1 3.1-01 EN-US 1 (1)

MAN Diesel & Turbo 3.1.1
Operating data and alarm points
Turbocharger
Turbocharger type plate
1 Turbocharger type
2 Speed n Smax – short-time operation (for test operation only)
3 Speed n Cmax – max. permissible speed for continuous operation
4 Works number (serial number)
5 Max. permissible turbine inlet temperature
6 Year of ex-works delivery
The type plate is attached to the delivery socket of the compressor casing.
An additional type plate is located on the silencer or the intake casing.
Operating parameters
Speed Operating limit nCmax see
type plate
Speed indicator Indication range 0 to 60 000 rpm
Exhaust gas temperature upstream of Operating limit tmax see
turbine type plate
Lube oil temperature Inlet temperature at full engine load < 75 °C
Lube oil pressure in normal operation and at full engine load 1.3 – 2.2 bar
(reference height: turbocharger centre-
line)
Lube oil flow rate with SAE 30 at 60 °C and 1.3 bar operating pres- 1.0 m3/h
sure
Jet Assist (optional) Max. permissible inlet pressure in turbocharger 4 bar
Further specifications see also Lube oil system, Chapter [4.2]
Table 1: TCR16 operating parameters
Alarm points
An alarm must be triggered by the engine control system when the following
operating data are exceeded:
Lube oil pressure Alarm at < 1.0 bar
(reference height: turbocharger centre-
Technical data
2014-01-23 - de
line) Reduction to engine half load (slow-down) < 0.8 bar

Engine shut-down < 0.6 bar
Speed Alarm at 97% nCmax
TCR16
Exhaust gas temperature upstream of Alarm at tmax see

turbine type plate
Table 2: Alarm points
C1 0287 3.1.1-02 EN-US 1 (2)

3.1.1 MAN Diesel & Turbo
Turbocharger
When the lower limit values are reached, the alarm must be triggered
and the engine control must react at the same time (without delay) in
order to avoid damage to the turbocharger.
Technical data
2014-01-23 - de
TCR16
2 (2) C1 0287 3.1.1-02 EN-US

Weights, dimensions and connections
Turbocharger
Weights
Subassembly Designation Optional Weight
500.000 Turbocharger without optional subassemblies 175.2 kg
501.000 Gas admission casing (1-channel/2-channel) 45.0 kg / -
506.000 Gas outlet casing (without/with waste gate) X 56.7 kg / 60.7 kg
513.000 Turbine nozzle ring 3.0 kg
517.000 Bearing casing 38.8 kg
520.000 Rotor, complete 14.2 kg
540.000 Insert, compressor side 12.7 kg
541.000 Insert, turbine side 12.4 kg
542.000 Diffuser 3.1 kg
544.000 Silencer X 43.5 kg
545.000 Air intake casing (90°/axial) X 24.3 kg / 15.1 kg
546.000 Compressor casing 46.0 kg
591.1000 Covering on gas admission casing X 9.3 kg
591.4000 Covering on gas outlet casing X 15.7 kg
591.5000 Covering on bearing casing X 1.0 kg
591.6000 Sound insulation on compressor casing X 13.4 kg
599.000 Cartridge (517.000 + 520.000) 53.0 kg
Table 1: Subassemblies and weights TCR16 (approximate values)
Technical data
2014-01-23 - de
TCR16
C1 0287 3.1.2-02 EN-US 1 (2)

Turbocharger
Dimensions
Figure 1: Main dimensions (in mm)
Connections
Exhaust gas Entry at the gas admission casing (501.01) ∅ 134 mm
Exhaust gas Outlet at the gas outlet casing (506.01) ∅ 256 mm
or at the gas outlet casing (506.02 optional) ∅ 256 mm
with “WASTE GATE” connection ∅ 68 mm
Charge air Entry at the silencer (544.01 optional) ∅ 615 × 242 mm
or at the air intake casing (545.01/545.02 optional) ∅ 256 mm
Charge air Outlet at the compressor casing (546.01) ∅ 145 mm
Lube oil Inlet at the bearing casing (517.01) ∅ 16 mm
Lube oil Drain at the bearing casing (517.01) ∅ 37 mm
Jet Assist (optional) Entry at the compressor casing (546.01)
flange connection for pipe inside diameter min. ∅ 20 mm
Table 2: TCR16 connections
Different versions of the casing can be installed, depending on the engine

Technical data
2014-01-23 - de
type.
For further details, see drawing: turbocharger connection dimensions
TCR16
2 (2) C1 0287 3.1.2-02 EN-US

Operating media/ Quality requirements

3.1 Turbocharger
Technical data
2014-01-23 - de
0287-1 3.2-01 EN-US 1 (1)

Fuels for the Engine

Fuels for the Engine
Engine Fuel Affects Exhaust The quality of the fuel with which the engine is operated affects the composi-
Gas Quality tion of the exhaust gas that flows through the turbocharger. Impurities in the
fuel can lead to residues in the exhaust gas, which can effect the turbo-
charger in an abrasive or corrosive manner.
Quality Requirements for MDO is also known as diesel fuel oil, diesel oil, bunker diesel oil or marine
Marine Diesel Oil (MDO) diesel fuel.
MDO is offered exclusively for shipping as heavy distillate (ISO-F-DMB or as
a mixture of distillate and low amounts of residual oil (ISO-F- DMC). The term
“blended MDO” is common for the dark brown to black colored mixture.
MDO is produced from crude oil and must be free of organic acids.
The usability of the fuel depends on the design of the engine and the clean-
ing device as well as if the characteristics mentioned below, which are based
on the condition at the time of supply, are observed.
The characteristics determined were based on the ISO 8217‑1996 and
CIMAC‑2003 specifications. The characteristics refer to the mentioned test-
ing methods.
Properties/Characteristics Unit Testing Method Characteristic
ISO-F specification DMB DMC
Density at 15 °C kg/m 3
ISO 3675 900 920
Kinematic viscosity at 40 °C mm /s = cSt
2
ISO 3104 < 11 < 14
Pour point Winter quality °C ISO 3016 <0 <0
Summer quality °C ISO 3016 <6 <6
Flash point Pensky Martens °C ISO 2719 > 60 > 60
Total sediment content Wt.% ISO CD 10307 0.10 0.10
Water content Vol.% ISO 3733 < 0.3 < 0.3
Sulphur content Wt.% ISO 8754 < 2.0 < 2.0
Ash content Wt.% ISO 6245 < 0.01 < 0.03
Carbon residue (MCR) Wt.% ISO CD 10370 > 0.3 < 2.5
Cetane number – ISO 5165 > 35 > 35
Copper strip test – ISO 2160 <1 <1
Vanadium content mg/kg DIN 51790 T2 0 < 100
Aluminum and silicium content mg/kg ISO CD 10478 0 < 25
Visual check – * –
Other specifications:
British Standard BS MA 100-1987 Class M2 Class M3
Technical data
2012-08-30 - de
ASTM D 975 2D 4D
ASTM D 396 No. 2 No. 4
* In good light and at room temperature, the fuel should appear clear and transparent.
General
Table 1: Marine Diesel Oil (MDO) – Characteristics to be met
C1 6673 3.2.1-01 EN-US 1 (4)

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

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

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

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

installing a centrifugal separator in front of the fuel filter. This widely sepa-
rates solid particles (sand, rust, catalyst residue, catfines) and water, so
that the cleaning intervals for the filter inserts can also be prolonged.
Operting data:
▪ Separator admission 65%, with reference to the rated throughput
capacity,
▪ Separation temperature 40-50 °C.
Quality requirements for MAN Diesel turbochargers can be operated on engines that run on crude-oil
Heavy Fuel Oil (HFO) based heavy fuel oil, when the engine and the processing system are
designed accordingly.
The fuels used must meet the fuel specifications in accordance with the
Table "Fuel specifications and corresponding characteristics".
The respective limit values to be observed are listed in the Table "Fuel speci-
fications and corresponding characteristics". The limit values that influence
the engine operation are to be specified when ordering fuel, e. g. in the
bunker or charter clause.
Adding motor oil (waste oil), mineral-oil-foreign materials (e. g. coal oil)
and remainders from refining or other processes (e. g. solvent) is
prohibited! This ban is specifically to be pointed out in the fuel order,
as it is not yet part of the standard fuel specifications.
Technical data
2012-08-30 - de
Such additions lead to combustion with high residue and increased wear and
corrosion on components of the turbocharger. Adding motor oil (waste/old
General
oil) is particularly critical, as the lube oil additives cause emulsions to form
and keep debris, water and catalyst particles finely distributed in poise. This
impedes or avoids the required fuel cleaning.
2 (4) C1 6673 3.2.1-01 EN-US

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

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

free engine operation.
The following points are to be observed for this:
Technical data
2012-08-30 - de
▪ Heavily abrasive inorganic, solid foreign substances (catfines, rust, sand)

must be separated to the greatest possible extent.
General
▪ With an aluminum content >10 mg/kg, the abrasive wear in the turbo-
charger increases heavily.
C1 6673 3.2.1-01 EN-US 3 (4)

▪ Use only separators of the latest generation which are fully effective over
a large density range without any adjustment, and separate water with
an HFO density of 1.01 g/ml at 15 °C. The cleaning effect is controlled by

the separator itself.
▪ The HFO purification is to be designed in such a manner that the charac-
teristics in the Table "Achievable foreign matter and water content after
separation" are reached:
Characteristic Particle Size Amount
Inorganic, solid foreign < 5 µm < 20 mg/kg
substances (AlSi content < 15 mg/kg)
(incl. catfines)
Water – < 0.2 vol.%
Table 3: Achievable foreign matter and water content after separation
▪ With unfavorable vanadium-sodium ratio, the melting temperature of the
HFO ash drops to the range of the exhaust valve temperature, which
causes hot corrosion. By pre-cleaning the HFO in the settling tank and in
the centrifugal separators, the water and thus the water-soluble sodium
compounds can be removed to the largest extent.
With a sodium content exceeding 100 mg/kg, increasing salt deposits in
the turbine are to be expected. This jeopardizes the turbocharger opera-
tion (by pumping of the turbocharger, among other things). When using
PTG, the sodium content must be limited to 50 mg/kg.
Under certain conditions, hot corrosion can be avoided with a fuel addi-
tive that increases the melting temperature of the HFO ash.
▪ Heavy fuel oils with a high ash content in form of foreign substances, e.
g. sand, rust, catfines, increase the mechanical wear in the turbocharger.
Heavy fuel oils from catalytic cracking plants can contain catfines. Gener-
ally, these are aluminum silicate, which effects high wear in the turbo-
charger. The determined aluminum content multiplied by 5-8 (depending
on catalyst composition) approximately amounts to the content of cata-
lyst material in the HFO.
Technical data
2012-08-30 - de
General
4 (4) C1 6673 3.2.1-01 EN-US

Lube oil

General requirements on lube oil
The specific power achieved by modern diesel and gas engines and the use
of fuels that are increasingly reaching the very limits in terms of quality place
higher requirements on the lube oil and necessitate careful selection of the
lube oil.
Only lube oils that meet the following requirements may be used:
▪ They must be engine oils
(no turbine, cylinder or gear oils).
▪ They must have been approved for the engine by the engine manufac-
turer.
▪ They must meet the requirements of the engine manufacturer and the
lubricant supplier in every operating state.
Specifications
Viscosity To ensure reliable operation of the turbocharger, the dynamic oil viscosity
limits with a range of 0.03 Pa s – 0.13 Pa s defined by MAN Diesel & Turbo
must be adhered to. For engine oil of viscosity class SAE 40, these limit val-
ues correspond to lube oil inlet temperatures of 40 °C and 70 °C. The same
dynamic oil viscosity limit values also apply to oils of other viscosity classes.
Technical data
2013-07-24 - de
Figure 1: Dynamic viscosity SAE 30 and SAE 40

Base Oil The base oil (doped lube oil = base oil + additives) must have a narrow distil-
General
lation range and be refined using state-of-the-art methods. If paraffins are

contained, they must not have a detrimental effect on the thermal stability or
the oxidation stability.
C1 6673 3.2.2-01 EN-US 1 (2)

Additives The additives must be dissolved in the oil and their composition must be
such that they leave as little ash as possible on combustion, even if the
engine is temporarily operated with distillate fuel. The ash must be soft. If this
prerequisite is not met, greater deposits can be expected in the combustion
chamber, and thus also on the gas admission casing.
Detergency The detergency must be so great that neither tar nor coke residues pro-
duced by combustion of the fuel can be deposited.
The lube oil must not take up any deposits arising from the fuel.
Reserve alkalinity The reserve alkalinity (ASTM D2896) must be high enough to neutralise acidic
combustion products. The reaction time of the additives must match the
process in the combustion chamber.
Lube oil additives It is not permissible to add additives to lube oil or to mix different brands of
lube oil (oils from different manufacturers), as this could interfere with the per-
formance of the carefully coordinated mixture of additives tailored to the spe-
cific base oil.
Selection of lube oils/ Most mineral oil companies are in close, permanent contact with engine
warranty manufacturers and can thus specify which oil from their own product line is
approved by the engine manufacturer for the specific application. Irrespective
of this information, the lube oil manufacturers are liable for the quality and
properties of their products. If you have any questions, we would be happy
to provide you with further details.
Lube oil filtration The turbocharger does not require its own lube oil filter.
Filtration and conditioning of the lube oil are sufficient when the following val-
ues are observed:
▪ Mesh of lube oil filter < 0.050 mm.
▪ Water content < 0.2% by weight.
Technical data
2013-07-24 - de
General
2 (2) C1 6673 3.2.2-01 EN-US

Intake air

Intake air
The quality and condition of the intake air have a decisive influence on the
turbocharger performance. Not only is the atmospheric condition of great
importance but also the solid and gaseous impurities contained in the air.
Mineral dust particles in the intake air have the effect of increasing wear.
Chemical/gaseous constituents on the other hand promote corrosion.
For this reason, effective cleaning of the intake air and regular maintenance/
cleaning of the air filter mat on the silencer are required.
Characteristic values of the The intake air (combustion air) must always be cleaned with a class G3 filter
intake air (in accordance with EN 779), even if there is no silencer installed on the tur-
bocharger.
The following maximum concentrations of particles in the intake air upstream
of the compressor must not be exceeded:
Characteristics/properties Concentration Unit1)
Dust (sand, cement, CaO, Al2O3 etc.) max. 5
Chlorine max. 1.5

mg/m3 (SPC)
Sulphur dioxide (SO2) max. 1.25
Hydrogen sulphide (H2S) max. 15
Salt (NaCl) max. 1

Table 1: Maximum concentration of particles in the intake air
1)
m3 (SPC) = cubic metre at standard temperature and standard pressure
When designing the intake air system, it must be ensured that the total pres-
sure loss (filter, silencer, piping) does not exceed 20 mbar.
Technical data
2012-08-30 - de
General
C1 6673 3.2.3-01 EN-US 1 (1)

Cleaning agents for compressor and turbine

Wet cleaning of the compressor and the turbine
Use freshwater only.

Salt water causes corrosion on the turbocharger components.
Wet cleaning For wet cleaning of the compressor and turbine during operation, use only
freshwater without chemical additives.
Dry cleaning of the turbine

Dry cleaning Commercially available granulates that meet the following specifications are
used for dry cleaning of the turbine during operation:
Granulate made of:
▪ Nut shells
▪ Activated charcoal (soft).
Grain size:
▪ 1.0 mm (max. 1.5 mm).
Store and mark granulates in such a manner that they can not be
mistaken for other materials (salt, sand, etc.).
Technical data
2013-09-24 - de
General
C1 6673 3.2.4-01 EN-US 1 (1)

MAN Diesel & Turbo
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
2014-01-23 - de
Description
0287-1 4 C1-01 EN-US 1 (1)

Turbocharger
Description
Subassemblies
2013-01-14 - de
Description
501.000 Gas admission casing 540.000 Insert, compressor side 546.000 Compressor casing
506.000 Gas outlet casing 541.000 Insert, turbine side 562.000 Speed transmitter
513.000 Turbine nozzle ring 542.000 Diffuser 579.000 Cleaning device
TCR
520.000 Rotor, complete 545.000 Air intake casing 591.000 Coverings

-591.9000
C1 0288 4.1-01 EN-US 1 (3)

Figure 1: TCR turbocharger

Description
Turbochargers of the TCR series consist mainly of a radial turbine stage and
a radial compressor stage, which are seated on the same turbine shaft. The
exhaust gases of the engine drive the turbine. The compressor draws in fresh
air or pre-compressed air and compresses it. The compressed air is then
forced into the cylinders of the engine.
The turbocharger consists of the following main subassemblies:
▪ Gas admission casing (501.000):
The gas admission casing houses the turbine nozzle ring (513.000) and
the insert (541.000). These components enable optimum adaptation of
the turbocharger to the engine.
▪ Gas outlet casing (506.000):
Integrated into the gas outlet casing is the gas outlet diffuser, which opti-
mises the flow of the exhaust gas.
Optionally, a gas outlet casing with a “WASTE GATE” connection can be
supplied.
▪ Bearing casing (517.000):
The interior bearing of the rotor primarily consists of two bearing bushes
and a thrust bearing. The highly stressed bearing points are lubricated
and cooled by means of the turbocharger lube oil system, which is inte-
grated into the bearing casing. The turbocharger lube oil system is sup-
plied with oil from the engine lube oil system.
▪ Rotor, complete (520.000):
The turbine wheel and turbine shaft are firmly connected to each other as
the turbine rotor. The compressor wheel is mounted on the turbine rotor
and can be removed.
▪ Silencer (544.000) or air intake casing (545.000):
Choice is optional; generally, silencers are used for marine systems and
air intake casings for stationary systems (power plants).
▪ Compressor casing (546.000):
The compressor casing houses the insert (540.000) and the dif-
fuser (542.000). These components enable optimum adaptation of the
turbocharger to the engine. The insert additionally fulfils a burst protec-
tion function.
The compressor casing is equipped with an outlet socket. A flange for
connecting the optional acceleration system (Jet Assist) is provided on
the side of the compressor casing.
Functional Description
The engine exhaust gases flow through the gas admission casing (501.000)
and the turbine nozzle ring (513.001), and run radially onto the turbine wheel
of the rotor (520.000). The exhaust gases drive the turbine wheel; in this
process, the energy contained in the exhaust gas is transformed into
mechanical rotation energy at the turbine wheel. As the turbine wheel and
the compressor wheel are seated on the same shaft, the compressor wheel
2013-01-14 - de
is driven at the same time. The exhaust gas exits the turbocharger through
Description
the integrated gas outlet diffuser and the gas outlet casing (506.000).
TCR
2 (3) C1 0288 4.1-01 EN-US

The compressor wheel draws in fresh air through the silencer (544.000) or
Description
the air intake casing (545.000) and the insert (540.000). The fresh air is com-
pressed in the compressor wheel, diffuser (542.001) and compressor cas-
ing (546.000). The compressed fresh air is forced into the cylinders of the
engine via the charge air cooler and charge air pipe.
The rotor (520.000) of the turbocharger is guided in radial direction by two
bearing bushes situated in the bearing casing (517.000) between the turbine
wheel and the compressor wheel. The thrust bearing arranged centrally in
the bearing casing not only performs the function of axial guidance, but also
transfers the thrust in axial direction.
The highly stressed bearing points are lubricated and cooled by means of the
turbocharger lube oil system, which is integrated into the bearing casing. The
turbocharger lube oil system is supplied with oil from the engine lube oil sys-
tem.
2013-01-14 - de
Description
TCR
C1 0288 4.1-01 EN-US 3 (3)

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

2 Bracket (engine) 7 Pressure gauge
3 Ring duct * 8 Pressure controller
4 Bearing casing * 9 Lube oil drain
5 Thrust bearing * * Scope of supply of turbocharger
Figure 1: Lube oil diagram, TCR turbocharger
Functional description
Lube oil circuit The highly stressed bearing points in the turbocharger are lubricated and
cooled by means of a lube oil system integrated into the bearing casing of
the turbocharger.
The lubricating oil is fed from the lube oil system of the engine to the lube oil
system of the turbocharger via the lube oil feed pipe (1).
The lube oil flows to the radial and axial lubrication gaps of the turbocharger
via the ring duct (3) and various bores.
On top of the bearing casing (4) is a connection for a pressure gauge (7)
and/or a pressure controller (8) for checking/monitoring the lube oil pressure.
The lube oil flows back into the lube oil system of the engine via the lube oil
drain (9).
The pipe for lube oil drainage must be installed with a sufficient
2013-10-29 - de
gradient and diameter to ensure drainage of the lube oil at all times
Description
without any back pressure.

TCR
C1 0288 4.2-03 EN-US 1 (4)

Danger of fire caused by escaping lube oil!

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

Continuous priming is only possible if there is no chimney draught
effect. A chimney draught can cause lube oil to be drawn into exhaust
gas ducts, leading to coking or fire.
Operational lubrication
Lube oil temperature Inlet temperature into the turbocharger: max. 75 °C at full engine load.
2013-10-29 - de
Description
TCR
2 (4) C1 0288 4.2-03 EN-US

Lube oil pressure!
Description
Inadequate lube oil pressure will cause bearing damage.
• The lube oil pressure must be set by the engine manufacturer prior to
initial start-up.
• The lube oil pressure must be checked and/or monitored via the
measuring connection (7, 8) at the top of the bearing casing.
Lube oil pressure Lube oil pressure at full engine load and with lube oil at operating tempera-
ture:
Pmin = 1.3 bar
Pmax = 2.2 bar
Limit values for monitoring of the lube oil pressure:
▪ < 1.0 bar: Alarm
▪ < 0.8 bar: Engine power at half load and
▪ < 0.6 bar: Engine shut-down.
When the lower limit values are reached, the alarm must be triggered
and the engine control must react at the same time (without delay) in
order to avoid damage to the turbocharger.
Differences in height between the indicating instrument and the

turbocharger centreline are to be taken into account with ± 0.1 bar per
1 m height difference (indicator installed higher – lower pressure;
indicator installed lower – higher pressure).
Lube oil flow rate The lube oil flow rate depends on:
▪ the viscosity (SAE class) and temperature of the lube oil,
▪ the lubrication gaps of the turbocharger.
For flow rate values, see Chapter [3.1.1].
Post lubrication
After an engine shut-down, the bearing points of the turbocharger must be
post lubricated for 10 – 30 minutes at a lube oil pressure of 0.3 – 0.6 bar (ref-
erence height: turbocharger centreline) for cooling purposes. This is done
either by means of the engine lube oil pumps or using a separate auxiliary
lube oil pump.
2013-10-29 - de
Description
TCR
C1 0288 4.2-03 EN-US 3 (4)

If continuous priming is specified for engines (e.g. because of stand-by

Description
starting), post lubrication is not required.

In this case, the continuous priming must be activated as soon as the
engine lube oil pumps are switched off.
2013-10-29 - de
Description
TCR
4 (4) C1 0288 4.2-03 EN-US

Acceleration system - Jet Assist
Description
OPTION
Jet Assist diagram
A Starting air cylinder (30 bar) D Insert

B 2/2 way solenoid valve E Compressor wheel
C Orifice F Turbocharger
Figure 1: Jet Assist diagram
The Jet Assist acceleration system is used when special requirements have
to be met with regard to fast and soot-minimised acceleration and/or the
dynamic load response of the engine.
The engine control actuates the 2/2 way solenoid valve (B). Compressed air
at 30 bar now flows from the starting air cylinder (A) through the orifice (C),
where it is reduced to a maximum of 4 bar. The compressed air is now
blown at max. 4 bar onto the blades of the compressor wheel (E) via a ring
duct and the inclined bores in the insert (D). On the one hand, this provides
additional air to the compressor while on the other hand, the compressor
wheel is accelerated, thus increasing the charge air pressure for the engine.
2008-07-17 - de
Description
TCR
C1 0288 4.3-01 EN-US 1 (1)

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

2 Exhaust gas pipe upstream of A Three-way cock with
turbine sealing air connection
3 Gas admission casing B Pressure gauge *
4 Turbine nozzle ring
5 Turbine wheel * Scope of supply of engine
6 Sealing air
(extracted downstream of
charge air cooler)
Figure 1: Diagram, wet cleaning of the turbine
Operating conditions
2012-05-24 - de
For wet cleaning, use only fresh water without any additives.
Description
TCR
C1 0288 4.4-02 EN-US 1 (2)

Carry out wet cleaning at considerably reduced engine load and at a

Description
low operating temperature of the turbocharger.

At a high operating temperature of the turbocharger, water can cause
a thermal shock and possibly destroy turbine components.
The water is sprayed into the gas admission casing (3) or the exhaust gas
pipe (2) before the turbine at a pressure of 2 to 3 bar. The flow of exhaust
gas transports the water droplets and distributes them over the turbine noz-
zle ring and turbine wheel. Fouling and deposits are removed from the blades
of the turbine nozzle ring and turbine wheel by the impact of the water drop-
lets.
The washing water is entrained as steam due to the high flow velocity in the
gas outlet casing/elbow and is emitted from the turbine via the chimney
flange.
The sealing air (6) prevents clogging and corrosion of the piping. For this pur-
pose, a small amount of air is extracted downstream of the charge air cooler
and fed continuously through the corresponding piping system.
Maintenance interval, see Maintenance Schedule.
2012-05-24 - de
Description
TCR
2 (2) C1 0288 4.4-02 EN-US

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

2 Screw plug 9 Compressed air pipe
3 Pipe 10 Sealing air
charge air cooler)
4 Connection point 11 Plate with cleaning instructions
5 Exhaust gas pipe upstream of A Stop cock
turbine
6 Gas admission casing B Three-way cock with
sealing air connection
Figure 1: Diagram, dry cleaning of the turbine
Dry cleaning is performed at normal operating load of the engine. The engine
load need not be reduced. Do not perform dry cleaning with the power tur-
bine at a standstill!
Use only commercially available granulates from nut shells or activated char-
coal (soft) with a grain size of 1.0 mm (max. 1.5 mm).
Do not use water for cleaning the turbine by this method, as in this
case the cleaning is carried out at normal operating load of the engine.
At high operating temperatures, water can cause a thermal shock and
possibly destroy turbine components.
2013-02-21 - de
Description
TCR
C1 0288 4.5-02 EN-US 1 (2)

Description
The granulate from the tank (1) is blown in through the connecting pipe (4)
with compressed air. The flow of exhaust gas in the gas admission housing
transports the granulate and distributes it over the turbine nozzle ring and
turbine wheel. Fouling and deposits are removed from the blades of the tur-
bine nozzle ring and turbine wheel by the impact of the granulate particles.
The loosened dirt and the granulate are carried out by the exhaust gas flow
through the gas outlet casing/elbow.
The sealing air (10) prevents clogging of the piping. For this purpose, a small
amount of air is extracted downstream of the charge air cooler and fed con-
tinuously through the corresponding piping system.
Cleaning the turbine with granulates on ship systems can lead to

downfall on deck.
2013-02-21 - de
Description
TCR
2 (2) C1 0288 4.5-02 EN-US

Cleaning system – Wet cleaning of the compressor
Description
General
With the small dimensions of the TCR turbochargers, dirt deposits on the
compressor wheel and diffuser blades can lead to a measurable decrease in
efficiency. A wet cleaning facility with pressure sprayer is available for clean-
ing the compressor during operation.
Wet cleaning system for the compressor with pressure sprayer
1 Handle 5 Coupling
2 Pressure sprayer 6 Hand valve
3 Relief valve 7 Turbocharger (compressor)
4 Nipple 8 Plate with cleaning instructions
Figure 1: Diagram, wet cleaning of the compressor with pressure sprayer
Cleaning of the compressor during operation is required at regular intervals in
accordance with the maintenance schedule.
The cleaning intervals depend on the degree of contamination of the intake
air and range from 100 to 200 operating hours.
For cleaning, use only fresh water without any additives.
Carry out the cleaning only with the engine warmed up and in
full load operation.
Do not shut down the engine immediately after cleaning, but continue
2010-10-13 - de
to run it for several minutes until dry.

Description
TCR
C1 0288 4.6-02 EN-US 1 (2)

Description
The pressure sprayer (2) is filled with fresh water. Pumping with the han-
dle (1) generates an overpressure in the water tank of the pressure
sprayer (2). By pressing the pushbutton on the hand valve (6), water is
sprayed into the compressor (7) by the pressure sprayer (2). Due to the high
speed of the rotor, the injected water droplets hit the blades of the compres-
sor wheel and the diffuser at high velocity, thus removing the dirt deposits
mechanically.
2010-10-13 - de
Description
TCR
2 (2) C1 0288 4.6-02 EN-US

MAN Diesel & Turbo
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
2014-01-23 - de
Operation
0287-1 5 C1-01 EN-US 1 (1)

Safety during Operation
Operation
Containment Safety
The turbocharger is one of the most highly loaded components on state-of-
the-art diesel engines. The high rotor speeds of a turbocharger result in high
centrifugal force stresses at the same time as high component temperatures.
If exceptional influences are additionally experienced, it is possible - in very
rare cases - for component failure to occur.
Precautions MAN Diesel & Turbo turbochargers comply with the containment safety
requirements according to the rules of the classification societies, with the
effect that fragments are prevented from escaping by state-of-the-art meas-
ures.
In extreme cases, however, particularly if the turbocharger has not been suffi-
ciently or properly maintained, there may be a risk of personal injury or mate-
rial damage in the vicinity of the turbocharger.
To eliminate the residual risk to the greatest possible extent, the following
rules must be observed:
Risk of injury!
Under no circumstances are persons permitted to be near the
turbocharger without reason during operation.
▪ The turbine and compressor must be cleaned at regular intervals as

specified in the maintenance schedule.
▪ The maintenance of the turbocharger must only be performed by trained
personnel at the maintenance intervals specified in the operating manual.
▪ Inadmissible operating conditions, such as frequent load shedding, com-
pressor surging and excessive turbocharger speeds, must be avoided.
▪ Corrosive and erosive agents in the intake air must be avoided.
Technical documentation
The technical documentation of the system, particularly the operating and
maintenance manuals for the engine, turbocharger and the accessories
required for engine operation, must be stored at a location where they are
accessible for the operating and maintenance personnel at all times.
Accident prevention regulations

When operating the system and for all maintenance and repair work, the rel-
2013-12-09 - de
evant Regulations for Prevention of Accidents are to be observed. It is advis-

able to hang these regulations in the engine room and to repeatedly point out
Operation
the dangers of accidents.

General
Safety instructions concerning specific hazard sources

Hearing protection
C1 6673 5.0-01 EN-US 1 (4)

Sound levels exceeding 85 dB(A)!

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

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

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

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

When carbon dioxide fire-extinguishing systems are put into operation,
danger of life is given due to suffocation.
• Do not put carbon dioxide fire-extinguishing systems into operation
2013-12-09 - de
before it is ensured that no more persons are in the engine room!

Operation
General
Protective covers
2 (4) C1 6673 5.0-01 EN-US

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

signals out of operation can lead to operational malfunctions
which can result in serious personal injury and damage to
property!
Turbocharger and engine are fitted with an alarm system which sounds
an alarm in case of technical problems or malfunctions. Therefore, an
alarm always has a cause which must be rectified!
• Do not ignore or suppress any alarm, reduction or stop signals!
• Investigate the cause of every alarm, reduction or stop signal or report
them!
• As far as possible, provide for swift rectification of the cause of alarms
and signals!
• Ignore or suppress alarms, reduction and stop signals only in cases of
increased danger or when ordered by management!
Personnel/ Qualification of The engine and the systems required for its operation may be started, oper-
personnel ated and stopped only by authorized persons. The personnel must be edu-
cated, trained and familiar with the system and the occurring dangers.
All persons operating the system or carrying out maintenance or repair work
on the system must have read and understood all accompanying operating
and maintenance instructions.
For ship systems:
2013-12-09 - de
Operational management through the chief engineer on board or through a

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

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

qualification are usually stipulated through the national regulations or the
international agreement (STCW).
C1 6673 5.0-01 EN-US 3 (4)

For stationary systems (power plants):

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

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

In the case of turbochargers on gas-powered engines, insulated
mounting can cause electrostatic charging, resulting in ignition of the
air/gas mixture in the air intake.
• If the turbocharger is mounted on the engine in such a way that it is
electrically insulated, an earth connection must be installed for the
equipotential bonding between the turbocharger and the engine.
2013-12-09 - de
Operation
General
4 (4) C1 6673 5.0-01 EN-US

Starting operation/Shutting down
Operation
Initial starting of operation
Danger of poisoning from toxic vapours!

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

2. Remove closing covers on gas admission casing, gas outlet casing and
compressor casing.
3. Remove preservation agents from the exhaust gas flanges of the tur-
bine casing as well as from the delivery socket of the compressor cas-
ing with a suitable scraper and cleaning agent.
4. Flush the lube oil system. Plug the oil supply and oil drainage of the tur-
bocharger and join the supply and drain pipes on the engine side, or
use an intake filter with low filter rating (20 μm recommended) in the
lube oil supply. Measurement of the oil pressure after the intake filter.
5. Prior to initial start-up, the lube oil pressure must be set by the engine
manufacturer, see “Lube oil system”, Chapter 4.2.
Before shipment, the oil system of each turbocharger is factory-

checked for cleanliness, and the oil supply and oil drainage are
plugged. Therefore, when flushing the engine oil system, care must be
taken to prevent inadmissible contamination in the oil from entering the
turbocharger.
For additional information on flushing the lube oil system, please refer
to the engine manufacturer’s manual.
For mounting the turbocharger on the engine, see work card Complete
turbocharger.
Engine control
2011-09-28 - de
Indication of the pending alarm and the reaction of the engine control
system must occur at the same time. Therefore, the engine control
Operation
system must conform at least to category 3 in compliance with

DIN EN ISO 13849-1.
TCR
C1 0288 5.1-01 EN-US 1 (3)

Operation
Work prior to starting the engine

1. Before starting the engine, the bearing points of the turbocharger must
be primed. Depending on the engine system, this is done by
– Priming immediately before starting or
– Continuous priming.
2. Set all shut-off devices of the system pipes of the engine plant to the
operating position.
3. Check the lube oil pressure at the top of the turbocharger, see lube oil
diagram, Chapter [4.2], connection für pressure gauge.
Starting operation
Turbocharger Start the engine. The engine exhaust gases drive the turbocharger and thus
start it operating. If provided, the “Jet Assist” acceleration system is put into
operation via the control system.
Checks during operation

General Despite automatic control and regulation of the engine system, regular
checks of the turbocharger are required so that possible malfunctions can be
detected as early as possible and the causes corrected in time.
The checks listed below are part of the operator's maintenance

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

turbocharger ▪ Lube oil pressure at top of turbocharger
▪ Lube oil temperature upstream of turbocharger
▪ Lube oil temperature downstream of turbocharger
▪ Exhaust gas pressure upstream of turbine
▪ Exhaust gas temperature upstream of turbine
▪ Charge air pressure downstream of compressor
▪ Charge air temperature downstream of compressor
▪ Exhaust gas, charge air and oil pipes for tightness
▪ Turbocharger for smooth running
▪ Air filter mat on the silencer for fouling/saturation
Smooth running An early indication of damage to the rotor and bearings is usually given by
irregular running due to imbalance or contact of rotating parts of the rotor.
2011-09-28 - de
Listening to the running noise of the turbocharger often allows unsmooth

operation to be detected at an early stage.
Operation
Speed With clean air ducts of the compressor, a certain charge air pressure is
assigned to each speed of the turbocharger. The charge pressure thus gives
an indication of the speed and can be used for approximate speed monitor-
TCR
ing.
2 (3) C1 0288 5.1-01 EN-US

Operating faults Chapter [5.3] lists various operating faults, identifies possible causes and
Operation
specifies remedial action.
Shutting down, post lubrication

Shutting down Shutting down the engine also puts the turbocharger out of operation. Due
to the flywheel effect, the rotor of the turbocharger continues to rotate for
some time.
The run-down time of the turbocharger gives an indication of its

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

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

Continuous priming is only possible if there is no chimney draught
effect. A chimney draught can cause lube oil to be drawn into exhaust
gas ducts, leading to coking or fire.
2011-09-28 - de
Operation
TCR
C1 0288 5.1-01 EN-US 3 (3)

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

General emergency The following instruction is obligatory for all options of emergency engine
measures operation in the event of turbocharger failure.
▪ Reduce the engine power in accordance with the engine manufacturer’s
instructions to the degree that
– the maximum permissible exhaust gas temperature downstream of
the cylinders is not exceeded,
– the maximum permissible exhaust gas temperature upstream of the
turbocharger is not exceeded,
– the maximum permissible speed of the turbocharger that is still
operational (on engines with more than one turbocharger) is not
exceeded,
– increased exhaust gas density is minimised.
Emergency measure, option 1

Engine may not be stopped for urgent reasons.
Danger due to further damage of the turbocharger!

Fire or destruction of the turbocharger can occur!
• Do not stay in the area of the turbocharger. Danger to life!
• As a precaution, prepare fire-extinguishing measures!
2011-05-16 - de
Operation
1. Damaged turbocharger remains unchanged.

TCR16-40
2. Observe the paragraph “General emergency measures” and the engine

manufacturer’s instructions for emergency operation.
C1 0288 5.2-02 EN-US 1 (2)

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

Operation
essary minimum.
Emergency measure, option 2

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

1. Separate the exhaust gas inlet side of the defective turbocharger from
the gas flow of the second turbocharger by fitting a blind flange.
2. On V-type engines having a common charge air pipe, a blind flange is
to be mounted on the compressor outlet of the defective turbocharger
so as to avoid air losses.
Observe the paragraph “General emergency measures” and the engine man-
ufacturer’s instructions for emergency operation.
2011-05-16 - de
Operation
TCR16-40
2 (2) C1 0288 5.2-02 EN-US

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

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

malfunctions can also lead to increased subsequent damage of the
turbocharger or engine.
Countermeasures 1. Reduce the engine power or shut down the engine, depending on the
available options.
2. Identify and correct the cause of the malfunction, see Table “Trouble-
shooting”.
3. If the damage cannot be corrected immediately, emergency operation
is possible, see Chapter [5.2].
Trouble Shooting
No. Malfunction Possible cause Corrective action Work card
1 Exhaust gas temperature Air filter mat or silencer fouled Clean/replace [500.24]
upstream of the turbine is [500.32]
too high
Compressor fouled Clean [500.23]
2008-07-17 - de
Turbine wheel heavily fouled Clean [500.21]

[500.22]
Operation
Turbine nozzle ring heavily fouled/ Clean/replace [500.21]

constricted [500.22]
[500.46]
TCR
C1 0288 5.3-01 EN-US 1 (6)


Operation
Rotor rubbing Check inserts/rotor/bearing [500.41]

bushes and replace parts if nec- [500.45]
essary, balance check by MAN [500.47]
Diesel & Turbo Service
Foreign bodies before/in com- Check compressor wheel and/or [500.45]
pressor and/or turbine turbine rotor and replace if neces-
sary
Turbine or compressor wheel Replace compressor wheel [500.45]
damaged and/or turbine rotor
Substantial erosion on turbine Check turbine rotor/turbine nozzle [500.45]
wheel/turbine nozzle ring ring and replace if necessary [500.46]
High air intake temperature Reduce power Engine
Charge air cooler fouled Clean Engine
Charge air pipe leaking Seal charge air pipe, tighten con- Engine/
nections system
Charge air temperature too high Check charge air cooler Engine
Inlet/exhaust valves, valve slots of Clean Engine
engine fouled
Exhaust gas pipe leaking Seal exhaust gas pipe, tighten Engine/
connections system
Exhaust gas back-pressure Clean turbine, check exhaust gas [500.21]
downstream of turbine too high pipe [500.22]
Engine/
system
Fuel injection on engine faulty Repair fuel injection Engine
2 Charge air pressure too low Air filter mat or silencer fouled Clean/replace [500.24]
[500.32]
[500.22]
[500.46]
Defective bearings, imbalance of Check bearing parts and replace [500.45]
the rotor parts if necessary, balance check
by MAN Diesel & Turbo Service
2008-07-17 - de
sary
Operation

TCR
2 (6) C1 0288 5.3-01 EN-US

Operation
nections system
engine fouled
connections system
Engine/
system
3 Charge air pressure too Turbine nozzle ring lightly fouled/ Clean [500.21]
high constricted [500.22]
Low air intake temperature Reduce power Engine
4 Speed too low Air filter mat or silencer fouled Clean/replace [500.24]
[500.32]
[500.22]
[500.46]
sary
nections system
2008-07-17 - de

engine fouled
Operation
connections system
TCR
C1 0288 5.3-01 EN-US 3 (6)


Operation

Engine/
system
5 Speed too high Turbine nozzle ring lightly fouled/ Clean [500.21]
6 Lube oil pressure too low Lube oil inlet temperature too high Check/adjust lube oil cooling Engine/
system
Lube oil filter fouled Clean/replace lube oil filter Engine/
system
Lube oil pressure gauge defective Replace lube oil pressure gauge Engine/
system
7 Lube oil loss Piston ring seals defective Replace piston rings [500.45]
Seals damaged, connections Replace seals, check/tighten con- [500.31]
leaking nections Engine
Lube oil pressure too high Reduce oil pressure at operating Engine/
temperature system
Excessive pressure in oil dis- Check/enlarge dimension/inclina- Engine/
charge or in crankcase tion/venting of lube oil discharge system
8 Hesitant starting, short run- Compressor fouled Clean compressor [500.23]
down time
[500.22]
[500.46]
Retaining ring, thrust ring or coun- Check parts and replace them if [500.45]
ter-thrust ring damaged necessary
sary
2008-07-17 - de
Oil coke downstream of turbine Check/replace piston ring on tur- [500.45]

wheel bine side, observe upper limit of
Operation
lube oil pressure during priming

and operation
TCR
4 (6) C1 0288 5.3-01 EN-US

Operation
9 Abnormally high noise level Retaining ring, thrust ring or coun- Check parts and replace them if [500.45]
sary
10 Turbocharger vibrates Turbine wheel heavily fouled Clean [500.21]

[500.22]
Retaining ring, thrust ring or coun- Check parts and replace them if [500.45]
sary
11 Compressor surges Turbine wheel heavily fouled Clean [500.21]
[500.22]
[500.46]
sary
Charge air temperature too high Reduce power Engine
2008-07-17 - de

engine fouled
Operation

Engine/
TCR
system
C1 0288 5.3-01 EN-US 5 (6)

Table 1: Troubleshooting
Operation
2008-07-17 - de
Operation
TCR
6 (6) C1 0288 5.3-01 EN-US

MAN Diesel & Turbo
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
2014-01-23 - de
Maintenance
0287-1 6 C1-01 EN-US 1 (1)

Safety during Maintenance/Repair
Maintenance
Qualification of personnel
Performed by machinists or mechanical fitters and their assistants.
Briefing and supervision of difficult work tasks through a technical officer or
the chief engineer.
Shutting down the engine for assembly work
Danger to life from crush injuries or impact!

If the engine starts during the removal of parts of the turbocharger,
there is a risk of coming into contact with rotating components and
being seriously injured.
• Shut down the engine before starting the removal work!
• During the work, lock out the engine to prevent it from starting!
• Set up warning signs!
Only carry out maintenance and repair work after consultation with the
engineering officer or chief engineer and if instructed to do so.
Inform the persons responsible for the operation of the engine and
turbocharger about the commencement and completion of the work.
Opening pipes/pressure tanks
Danger of burns from hot components!

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

The lube oil is under pressure and very hot!
• Before opening pipes, flanges, screwed connections or fittings, release
the pressure in the system and check that it is depressurised!
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• Before opening oil pipes, wait until the lube oil has cooled down
Maintenance
sufficiently!
C1 0288 6.0-01 EN-US 1 (3)

Maintenance
Removing and refitting pipes

When working on the piping systems, especially for fuel, lube oil and air, par-
ticular cleanliness must be ensured in order to prevent foreign bodies or
impurities from entering the system. When they are removed, all pipes that
are to be refitted must therefore be carefully sealed.
New pipes to be fitted must be checked for cleanliness and flushed if neces-
sary.
Preservation measures must be taken on any components that are to be put
into prolonged storage. Preservation agents appropriate to the storage dura-
tion and storage environment must be used.
Risk of explosion and fire!

Pipes and lines may contain residues of combustible or flammable
liquids and gas-air mixtures.
Components may be treated against corrosion with combustible
substances, e.g. anti-corrosion oil!
• Do not smoke or use naked flames when working on the engine and
turbocharger.
• Remove anti-corrosion agents.
Removal/disassembly of heavy components
Risk of injury due to suspended loads!

Unsuitable or poorly maintained transporting devices as well as
unsuitable storage locations can result in severe personal injury and
severe material damages.
• Use only transporting devices in faultless condition!
• Check if the lifting capacity of the used transporting devices is sufficient.
• Only chose storage locations which have a load carrying capacity
sufficient for the weight of the component (this is not always true for
galeries, landings or grid covers).
Use of cleaning agents

When using cleaning agents, the manufacturer’s notes for usage, possible
dangers and disposal are to be observed.
2013-02-21 - de
Maintenance
2 (3) C1 0288 6.0-01 EN-US

Cleaning agents can be caustic!
Maintenance
Cleaning agents on the skin, in the eyes or being inhaled can lead to
serious damage to one’s health or to allergies.
• Always observe the manufacturer’s notes for cleaning agents!
• Wear protective clothing whenever required!
• Wear protective gloves whenever required!
• Wear safety goggles whenever required!
• Wear respiratory protection whenever required!
• Pay attention that other persons also wear the appropriate protective
equipment whenever required or make these persons aware thereof!
Use of high-pressure cleaners

When working with high-pressure cleaners, ensure that they are used cor-
rectly.
Air filters, shaft ends (including those with lip-type sealing rings), governors,
splash-proof monitoring systems, cable sockets as well as sound and heat
insulation under non-watertight coverings must be covered or not subjected
to high-pressure cleaning.
Spare Parts
During operation, the components of the turbocharger are subjected to very
high forces. MAN Diesel & Turbo has therefore developed special materials
that can withstand these high forces. Only by using MAN Diesel & Turbo
original spare parts can you be sure that these high-quality materials have
been employed.
Spare parts from other manufacturers may be manufactured

using inferior materials that cannot withstand the loads they
are subjected to during operation of the turbocharger!
This can result in severe damage to the turbocharger, engine room and
engine, and danger to life for the operating personnel.
• Use only original spare parts from MAN Diesel & Turbo!
• Only use spare parts from other manufacturers if they have been
approved by MAN Diesel & Turbo!
MAN Diesel & Turbo shall in no way be liable for any personal injury or mate-
rial damage caused by use of spare parts from other manufacturers. Further-
more, any and all warranty claims relating to the turbocharger expire when
2013-02-21 - de
using non-original spare parts.

Maintenance
C1 0288 6.0-01 EN-US 3 (3)

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

2010-10-13 - de
As a turbocharger manufacturer, we offer the following services:

Maintenance
▪ Delivery of spare parts

▪ Consultation and support on questions concerning operation, mainte-
nance and repairs
▪ Practice-oriented training for operating personnel
TCR
▪ Assessment and clarification of damage cases
C1 0288 6.1-01 EN-US 1 (2)

▪ Assignment of fitters and engineers

Maintenance
Addresses and contact persons can be found in Chapter [2.1]
2010-10-13 - de
Maintenance
TCR
2 (2) C1 0288 6.1-01 EN-US

Tools
Maintenance
Optional tools
For maintenance work and emergency operation, special tools are optionally
available for TCR turbochargers.
The optional supply scope of these special tools is listed in the spare parts
catalogue, Chapter “Tools”.
Standard tools
As standard, the special tool “hexagon pin (596.001)” is supplied with each
TCR turbocharger. This hexagon pin is required for removal of the compres-
sor wheel and is attached inside the silencer or air intake casing.
Inventory tools
Commercially available tools that are usually included in the inventory of the
engine system.
Inventory tools are not contained in the turbocharger’s scope of supply.
2008-12-11 - de
Maintenance
TCR
C1 0288 6.2-01 EN-US 1 (1)

Maintenance schedule
Maintenance
Bindingness and adaptability
Validity of the maintenance The maintenance schedule contains a summary of the maintenance and
schedule inspection work, down to the major overhaul of the turbocharger.
A major overhaul of the turbocharger must be carried out latest after
▪ 12 000 - 18 000 operating hours
After each major overhaul, which best is carried out with a due engine serv-
ice, the maintenance schedule starts from the beginning again.
A major overhaul includes the disassembly of the complete turbocharger for
inspection of the actual condition, thorough cleaning and a check of all parts/
components.
The maintenance must be scheduled well in advance, meaning that, for

example, sailing timetables or power plant inspections must be taken
into account. In order to ensure the operational safety of the
turbocharger and the engine, maintenance work is to be performed as
far as possible on schedule or beforehand.
Adaptation of the The maintenance schedule takes the following operating conditions and an
maintenance schedule annual operating period of approx. 6000 hours into account:
▪ Uniform loading within a range of 60 to 90% of the rated power,
▪ Observation of the specified operating media temperatures and pres-
sures,
▪ Usage of the specified lube oil and fuel qualities,
▪ Attentive separation of fuel and lubrication oil.
The maintenance intervals must be shortened when the following operating
conditions are given:
▪ Longer-term operation with peak loads or low loads, long idle periods,
frequent heavy load cycles,
▪ Frequent engine starts and repeated run-up phases without sufficient
warming-up,
▪ High stress on the engine before reaching the specified operating media
temperatures,
▪ Too low lube oil, cooling water and charge air temperatures,
▪ Use of problematic fuel qualities and insufficient separation,
▪ Insufficient filtration of the intake air (particularly with stationary engines).
2012-08-30 - de
Maintenance
General
C1 6673 6.3-03 EN-US 1 (1)

Maintenance schedule - turbocharger
Maintenance
Maintenance Schedule – Turbocharger on Four-Stroke Engine
1, per
2,
12000
3000
3
150
250
24
Inspection (during operation)
901 Check turbocharger for unusual noise and vibrations. A 1 0.1 Turbo X
903 Check turbocharger and system pipes for leaks (charge air, A 1 0.2 Turbo X
exhaust gas, lube oil, cooling water (if provided))
904 Check cooling water leakage drain (if provided) on 500.31 1 0.1 Turbo X
turbocharger for leaks. No cooling water may escape from
the cooling water leakage drain.
905 Check all fixing screws, casing screws and pipe 500.31 1 1 Turbo 2 X
connections for tight fit. 7.2.1
Maintenance (during operation)
911 Clean turbine - dry cleaning (if provided) 500.22 1 0.3 Turbo 1
913 Clean turbine - wet cleaning (if provided) 500.21 1 0.6 Turbo 1
915 Clean compressor (during operation) 500.23 1 0.3 Turbo 1
Maintenance (engine has been stopped)
917 Clean air filter (if provided) 500.24 1 0.4 Turbo 1
Maintenance (together with engine maintenance)
951 Major overhaul every 12,000 ... 18,000 operating hours: 7.2.1 2 15 Turbo X
Dismantle, clean and check all components of the 7.2.2
turbocharger. Check gaps and clearances on reassembly. 500.31
500.32
500.33
500.41
500.42
500.43
500.44
500.45
500.46
500.47
24 ... Repetition interval in operating hours
X Maintenance work due
1 As required/depending on condition
2 Checking of new or overhauled parts required (once after the mentioned time)
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Maintenance
TCR16-40
C1 0288 6.3.1-03 EN-US 1 (1)

Remarks on maintenance work
Maintenance
General remarks
Disassembling the The simplest method to use for disassembly is best chosen on the basis of
turbocharger the space available in the engine room. When performing maintenance and
inspection work, it is sufficient in most cases to dismount only subassemblies
of the turbocharger.
Inspection report For a major overhaul of the turbocharger or for repair work concerning major
components, it is recommended to record the condition of individual subas-
semblies and to include this information in the operating log. Inspection
report form, see Chapter [6.6].
In disassembly work, mark the position of the components relative to

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

excessive force.
This can lead to bolts being sheared off or parts being so badly
damaged that they must be replaced. Sheared-off bolts must be drilled
out and the threads retapped.
Loosening seized or tight Apply diesel fuel or special solvent (e.g. Caramba, Omnigliss, WD 40) liberally
screw connections to the screw connections and allow to penetrate for at least ½ hour so that
the solvent can work its way through the thread. Observe the instructions for
use supplied by the solvent manufacturer. Then apply light hammer blows to
the bolt head until the bolt turns freely in the thread.
Tightening screw All screw connections on the turbocharger must be in satisfactory condition
connections for assembly or be renewed.
2013-02-21 - de
Maintenance
Always tighten screws/bolts with the specified tightening

torque!
For reasons of safety, only bolts of the specified quality may be used!
TCR
See Technical Documentation, Work Cards.
C1 0288 6.4-01 EN-US 1 (2)

Maintenance
Figure 1: Lock washer pair

When assembling the lock washer pairs (one pair consisting of 2 identical
washers), make sure that the long wedge surfaces (B) contact each other (on
the inside), otherwise the locking effect will be lost.
Incorrectly tightened and locked bolts and nuts can become loose due to
vibrations and then be driven into the turbocharger by the air or exhaust gas
flow, thereby causing severe damage.
Screw connections on the Due to the high temperatures on the turbine side, bolts, nuts and tab wash-
turbine side ers made of non-scaling materials are used. These are marked on the face
side (SB, SD, SM, VM or 4923, Z1 or 4828) to avoid them from being mis-
taken for regular parts. When disassembling, the fasteners marked in this
manner are to be stored separately until being assembled.
All lock washer pairs on the turbocharger are made of non-scaling material
and are not marked.
In order to avoid the bolts and nuts on the turbine side from fusing together
through overheating, they must be treated with high-temperature lubricant
(e.g. Molykote HSC) prior to each new assembly. Before treating with lubri-
cant, the threads must be cleaned thoroughly.
Screw-in threads of studs are not treated.
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Maintenance
TCR
2 (2) C1 0288 6.4-01 EN-US

Inspection of components
Maintenance
General remarks
The following remarks and questions are intended as a guide, e.g. for
▪ Assessment of the turbocharger condition,
▪ Operating log and inspection report,
▪ Inspection, reusing, repair and replacement of individual components.
Inspection work
Gaps and clearances For permissible limits, see Chapter [7.2.2]
Crack detection test Crack detection test on turbine blades (turbine rotor, compressor wheel) by
means of acoustic testing or the fluorescent dye penetration method.
Streaks Streaks all around the circumference of the turbine rotor, compressor wheel
and insert are an indication of wear.
Inspection of gaps and clearances, see Chapter [7.2.2]
Inspection of bearing parts, see work card [500.45]
Streaks on parts of the circumference of the turbine rotor, compressor wheel
and insert are an indication of imbalance.
Oil coke downstream of Shaft seal on turbine side damaged or pre-lubrication pressure too high.
turbine wheel
Erosion in HFO operation Where heavy fuel oil is used, the exhaust gas contains small hard particles
(e.g. “cat fines”) which have an erosive effect especially at the outlet of the
turbine nozzle ring, where gas velocities and concentrations of these parti-
cles are high. Here, the flow is also very strongly deflected in circumferential
direction. Moreover, these particles are flung outwards due to the centrifugal
effect.
“Cat fines” As a result of the refinery process, “cat fines”, a fine-grained powder of great
hardness (recognizable by the Al and Si content), and other abrasive con-
taminants are contained in the heavy fuel oil, depending on its quality. Their
amount can be reduced by means of amply dimensioned, heated settling
tanks and by adequate separation.
Admixtures Particularly disadvantageous is the admixture of used engine lube oil, charac-
terized by increased concentrations of Ca and Fe. Used engine lube oil con-
tains not only wear residues, but above all “detergent/dispersant additives”,
which bind fine particles and prevent “cat fines” and other impurities from
being extracted through separation. Far more severe erosion damage results
from blending the fuel with “used oil”.
Combustion residue caused by incomplete combustion can also have ero-
sive effects. Clean combustion must therefore be ensured.
Silencer, What is the condition of the air filter mat?
if provided Are there cracks on any of the components?
Speed measuring device Is the speed transmitter or the speed indicator defective?
2010-10-13 - de
Maintenance
Casings Which casings are heavily fouled by soot, oil or oil coke?
Were the casings tight, particularly at the joints and connecting flanges?
Do the casings show signs of cracks?
Were oil bores in the bearing casing clogged?
Had bolts broken off?
TCR
C1 0288 6.5-01 EN-US 1 (2)

Were all bolts and nuts firmly tightened and locked?

Maintenance
Are all bolts made of the specified material?

Are the seals in order?
Compressor wheel Do the turbine blades show signs of cracks or heavy wear? Are any streaks
evident?
Do the leading edges of the turbine blades show impact notches caused by
drawn-in foreign objects?
Are the seat faces bright or are there signs of fretting corrosion?
Turbine rotor Do the turbine blades show signs of cracks, streaks, heavy wear or erosion
at the edges?
Do the leading edges of the turbine blades show impact notches caused by
foreign objects?
Is the shaft running true? What is the condition of the bearings?
Are the seat faces bright or are there signs of fretting corrosion?
Bearing parts of the Are the seat faces bright or are there signs of fretting corrosion?
cartridge Are there any signs of scoring or heavy wear?
Checking for wear, see work card [500.45].
Insert Are any streaks evident?
Are the slits for the IRC (internal recirculation) continuous?
Diffuser Are any blades bent? Are any cracks evident on the blades?
Have foreign objects become jammed in the ducts?
Are there traces indicating the presence of foreign objects?
Turbine nozzle ring Are any blades bent? Are any cracks evident on the blades?
Are the blades heavily worn due to erosion?
Checking for wear, see work card [500.46].
Have foreign objects become jammed in the ducts?
Are there traces indicating the presence of foreign objects?
2010-10-13 - de
Maintenance
TCR
2 (2) C1 0288 6.5-01 EN-US

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

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

Service report
Maintenance
Form
2012-02-01 - de
Maintenance
TCR
C1 0288 6.7-01 EN-US 1 (1)

MAN Diesel & Turbo
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
2014-01-23 - de
Work cards
0287-1 7 C1-01 EN-US 1 (1)

Preface
7.1 Preface
7.2 Setting data
7.4 Cleaning
2014-01-23 - de
Work cards
0287-1 7.1-01 EN-US 1 (1)

Organisation and use of the work cards
Preface
Numbering
The ordinal number of the work cards is located at the top right of the title. It
consists of a three-digit subassembly number and a two-digit counting num-
ber. The subassembly number 500 represents the collective subassembly
number for turbochargers.
Example - Turbocharger on engine: 500.31
▪ 500 = Subassembly number (500 for turbocharger)
▪ 31 = Counting number (work card No. 31)
Cross-references in work cards are enclosed in square brackets.
Layout of the work cards

Work cards generally contain the following information:
▪ Brief description,
▪ Personnel and time requirements,
▪ Required tools and appliances,
▪ Related work cards, i.e. those work cards containing further necessary or
useful information,
▪ Possibly additional information/technical data and,
▪ The individual work sequences, always beginning with the starting condi-
tion, and followed by the individual work steps.
Parts and tools in the figures and text are each designated with their order
number.
Example - Hexagon bolt in bearing casing: 546.005
▪ 546 = Subassembly number (546 for bearing casing)
▪ 005 = Item number
All subassemblies and subassembly numbers are listed in the spare parts
catalogue.
Order numbers for tools are (generally) identical with the tool number affixed
to the tool.
Personnel and time required

The required time is mentioned in hours, both for the amount and qualifica-
tion of the required personnel. The higher hour rate covers the time require-
ment for the complete scope of the respective work card. Pesonnel with
lower hour rate is required only at times, e.g., for operation of a lifting tackle.
Tools/appliances required
2013-02-21 - de
The numbers in the Designation column refer to width across flats, given in
mm, e.g. socket wrench 10 = socket wrench width across flats 10 mm.
Work cards
The availability codes in the Status column have the following meaning:
Standard Included in the scope of supply of the turbocharger.
TCR
Optional Tools are supplied by special order.
C2 0288 7.1.1-01 EN-US 1 (2)

Inventory Commercially available tools/appliances

Preface
These are not included in the scope of supply of the turbo-

charger. It is assumed that these tools/appliances are included
in the inventory of the engine system.
Special Special tools, e.g. for service centers.
Tips and pictographs
For notes concerning fault sources/handling errors; material damage

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

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

lock washers tightening torques!
2013-02-21 - de
Work cards
TCR
2 (2) C2 0288 7.1.1-01 EN-US

Setting data
7.1 Preface
7.2 Setting data
7.4 Cleaning
2014-01-23 - de
Work cards
0287-1 7.2-01 EN-US 1 (1)

Screw Connections and Tightening Torques
Setting data
Brief description
Tightening values for all major screw connections, tightening torques for dif-
ferent friction coefficients µ.
Tightening torques for screw connections

Tightening of screw Whenever possible, screw connections should be tightened with torque
connections by torque wrenches.
For particularly important screw connections on the turbocharger, the tight-
ening torques are prescribed in the relevant work cards.
For all other screw connections that are to be tightened with torque
wrenches, the approximate values for the tightening torques may be noted
from Table 2 “Tightening torques for bolts of strength class 8.8”.
When tightening screw connections the following must be observed:
▪ Apart from the applied tightening torque, the clamping force of a screw
connection depends on the lubricant being used, the condition of the
contact surface and thread, as well as on the material combination. It is
therefore very important that all these conditions are satisfied.
▪ Table 2 “Tightening torques for bolts of strength class 8.8” gives the
tightening torques for the various screw threads depending on their coef-
ficient of friction µ, i.e. depending on the selected lubricant. The tighten-
ing torques apply for bolt materials of strength class 8.8 under utilization
of approx. 70% of their yield strength.
▪ For other strength classes, the conversion factors given in Table 1 are to
be used and multiplied by the tightening torque from Table 2. The
strength class is stamped on the bolt head.
Strength class 5.6 6.8 8.8 10.9 12.9
Conversion factor x 0.47 0.75 1.0 1.40 1.70
Table 1: Conversion factors for tightening torques depending on the strength class of
the bolts
Friction coefficient µ For the friction coefficient µ use approximately:
µ = 0.08 with lubricants for temperatures
≤ 200 °C, e.g. Molykote G-n or Molykote P40
≥ 200 °C, e.g. Molykote HSC
µ = 0.14 for lightly oiled surfaces without refinishing
Tightening torques in general

Thread, nominal size Tightening torque in Nm
2014-01-23 - de
for coefficient of friction µ

Work cards
TCR16-40
0.08 0.14
M5 4.1 5.8
M6 7 10
C2 0287 7.2.1-03 EN-US 1 (4)

Thread, nominal size Tightening torque in Nm

Setting data
for coefficient of friction µ
0.08 0.14
M8 17 24
M 10 34 49
M 12 59 84
M 14 93 134
M 14×1.5 99 145
M 16 141 205
M 16×1.5 148 220
M 18 196 282
M 18×1.5 213 319
M 18×2 205 300
M 20 275 398
M 20×1.5 295 445
M 20×2 285 422
M 22 368 538
M 22×1.5 393 594
M 22×2 381 566
M 24 473 686
M 24×2 503 753
M 27 694 1017
M 27×2 731 1103
M 30 945 1379
M 30×2 1014 1537
M 33 1271 1870
M 33×2 1353 2061
M 36 1640 2403
M 36×3 1707 2554
M 39 2113 3117
M 39×3 2190 3295
M 42 2623 3856
M 42×3 2757 4166
Table 2: Tightening torques for bolts, strength class 8.8
2014-01-23 - de
Work cards
TCR16-40
2 (4) C2 0287 7.2.1-03 EN-US

Setting data
Tightening torques for TCR16 turbocharger
Figure 1: Items for special tightening torques on TCR16
The special tightening torques given in the table are valid for a friction
coefficient µ=0.08
with lubricants for temperatures
• ≤ 200 °C, e.g. Molykote G-n or Molykote P40
• ≥ 200 °C, e.g. Molykote HSC.
Work Part Designation Nm WAF °C

card Order No.
[500.32] 546.004 Hexagon bolt 12 6 ≤ 200
[500.33] 546.004 Hexagon bolt 12 6 ≤ 200
[500.41] 546.020 Hexagon bolt 17 13 ≤ 200
[500.43] 546.005 Hexagon bolt 58 17 ≤ 200
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[500.44] 501.008 Hexagon nut 34 17 ≥ 200

Work cards
[500.45] 517.029 Cylindrical screw 29 6 ≤ 200

TCR16-40
[500.45] 517.051 Hexagon bolt 7 10 ≤ 200
C2 0287 7.2.1-03 EN-US 3 (4)

Work Part Designation Nm WAF °C

Setting data
card Order No.

[500.45] 520.005 Compressor wheel 120 24 ≤ 200
[500.47] 501.008 Hexagon nut 34 17 ≥ 200
Table 3: Special tightening torques for TCR16
2014-01-23 - de
Work cards
TCR16-40
4 (4) C2 0287 7.2.1-03 EN-US

Gaps and clearances
Setting data
Values and measurement
Figure 1: Gaps and clearances
Item Designations of parts Order No. When new Replace or remachine

parts
min. in mm max. in mm min. in mm max. in mm
1 a) Compressor wheel (520.005) Axial gap 0.50 0.60 0.50 0.60
b) Insert (540.001)
2 c) Turbine rotor (520.001) Axial gap 0.30 0.60 0.25 0.70
Insert (541.001)
3 d) Thrust bearing (517.002) Axial clear- 0.18 0.22 0.13 *) 0.28
Counter-thrust ring (520.028) ance
4 Compressor wheel (520.005) Permissible axial runout 0.06
5 e) Compressor wheel (520.005) Radial gap B 0.35 0.50 0.35 0.50
Insert (540.001) T 0.40 0.55 0.40 0.55
L/R 0.40 0.50 0.40 0.50
6 e) Turbine rotor (520.001) Radial gap B 0,65 0,80 0,65 0,80
Insert (541.001) T 0,70 0,85 0,70 0,85
L/R 0,70 0,80 0,70 0,80
The following instructions must be observed in order to ensure that

2013-01-14 - de
clearances and gaps are measured correctly.

Work cards
TCR16
C2 0287 7.2.2-01 EN-US 1 (2)

a) Measure by means of soft metal imprint (lead wire) at 3 points on the circumference and calculate the mean
Setting data
value. Deduct the measured axial clearance (3) from the calculated mean value with the rotor pushed in direc-
tion (B).
b) Adjustable using Laminum spacer ring (540.050) in steps of 0.1 mm.
c) Measure by means of soft metal imprint (lead wire) at 3 points on the circumference and calculate the mean
value. Deduct the measured axial clearance (3) from the calculated mean value with the rotor pushed in direc-
tion (A).
d) Measure with a dial gauge while vigorously moving the rotor in directions (A) and (B).
e)
Using a feeler gauge, measure at 4 points on the circumference. Different values are a result of the rotor being
supported at the bearing points at standstill.
*) The axial play in installed condition may be equal to or no more than 0.05 mm less than the individual compo-
nent measurement.
2013-01-14 - de
Work cards
TCR16
2 (2) C2 0287 7.2.2-01 EN-US

Speed Measuring Device
Setting data
Brief Description
Description and connection of the speed measuring device.
Speed Measuring Device TCR14 – TCR22
562.040 562.040
black -0 V black -0 V
red red
562.083
562.083
2 x 0.75 mm 2
2 x 0.75 mm2
562.310
T411
562.200 Sh 0V Sign
Sh 0V Sign I+ I- 0V 24V
+V
ON
T401 - +
RS232 24 V DC
2 x 0.75 mm 2
I+
24V 0V I-
+ -
2 x 0.75 mm 2
562.100
+ -
24 V DC
- +
562.100
562.040 Speed transmitter 562.200 Frequency-current converter T401

562.083 Terminal box 562.310 Frequency-current converter T411
562.100 Speed indicator, analogue with speed indication, digital
Figure 1: Cable connection of the speed measuring device TCR14 – TCR22
Version Designation
T401 Frequency-current converter (562.200)
Option: additional speed indicator, analogue (562.100) and/or measured data transmission
T411 Frequency-current converter with speed indication, digital (562.310)
2011-08-03 - de
Option: additional speed indicator, analogue (562.100) and/or measured data transmission
Work cards
Function
For all turbochargers of the TCR Series, the turbocharger manufacturer pro-
TCR
vides a speed transmitter for measuring the rotor speed as standard.
C2 0288 7.2.3-01 EN-US 1 (3)

The speed transmitter (562.040) is installed in the bearing casing and delivers
Setting data
speed pulses. The alternating pulses are conducted via a 2-wire cable to the
terminal box (562.083).
From the terminal box, the pulse signal is forwarded to a frequency-current
converter (562.200) or digital speed indicator (562.310).
The signal can additionally be indicated on a suitable analogue measuring
instrument. A transmission system for the measured values can be con-
nected to both variants of the speed measuring device.
The turbocharger manufacturer provides the measuring device and transmis-
sion system for the measured values on request.
Components
517.001
562.040
520.031
562.083
517.001 Bearing casing 562.040 Speed transmitter

520.031 Retaining ring 563.083 Terminal box
Figure 2: Speed measuring device

Speed transmitter The speed transmitter (562.040) is screwed radially into the bearing cas-
ing (517.001). Mounted on the rotor shaft is a retaining ring (520.031) with
two slots on the circumference for generating the speed pulses.
Two slots on the circumference of the retaining ring generate two

speed pulses per revolution.
The speed transmitter is screwed into position and locked with a defined gap
relative to the retaining ring.
Gap: 0.5 +0.8 mm
2011-08-03 - de
Read-Out Units The read-out units can be housed in the switch cabinet or operating cabinet,
for example.
Work cards
The following measuring transducers can be connected:

▪ Frequency-current converter (562.200)
▪ Frequency-current converter with speed indication, digital (562.310)
TCR
2 (3) C2 0288 7.2.3-01 EN-US

If a frequency-current converter or a digital tachometer is used, the number
Setting data
of slots on the retaining ring (number of pulses per revolution), the maximum
rotor speed and the alarm points must be taken into consideration when pro-
gramming the devices.
If original components from the turbocharger manufacturer are used, this
parameter is factory-set.
The speed sensing and speed indication must be exactly matched to

one another. It is therefore recommended that the sensing and
indication system should be purchased completely from the
turbocharger manufacturer.
Analogue speed indicator/measured value transmitter

Both variants of the speed measuring device have a power output (4-20 mA)
for connection of an additional analogue speed measuring device and/or
measured value transmitter.
2011-08-03 - de
Work cards
TCR
C2 0288 7.2.3-01 EN-US 3 (3)

Emergency operation
7.1 Preface
7.2 Setting data
7.4 Cleaning
2014-01-23 - de
Work cards
0287-1 7.3-01 EN-US 1 (1)

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

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

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

If the engine starts during the removal of parts of the turbocharger,
there is a risk of coming into contact with rotating components and
being seriously injured.
2008-12-11 - de
• Shut down the engine before starting the removal work!

Work cards
• During the work, lock out the engine to prevent it from starting!
• Set up warning signs!
TCR
C2 0288 500.11-01 EN-US 1 (2)

Emergency operation
Work sequence - Emergency operation with closing device
501.000 Gas admission casing 596.006 Closing cover

501.007 Lock washer pair 596.012 Pipe
501.008 Hexagon nut 596.028 Foot
506.000 Gas outlet casing 596.030 Hexagon nut
Figure 1: Closing device
Starting condition Coverings are removed to the extent necessary.

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

Work cards
– information in the engine operating manual.

TCR
2 (2) C2 0288 500.11-01 EN-US

Cleaning
7.1 Preface
7.2 Setting data
7.4 Cleaning
2014-01-23 - de
Work cards
0287-1 7.4-01 EN-US 1 (1)

Cleaning the turbine - Wet cleaning
Cleaning
Brief description
Wet cleaning of the turbine during operation in the case of significantly
reduced engine performance. Carry out the cleaning in time, in accordance
with the maintenance schedule.

1 Technician 0,6
Preliminary remarks
Cleaning agent Use exclusively fresh water for cleaning.
Cleaning interval Every 150 operating hours (or less, depending on the operating conditions),
at reduced engine load.
The wet cleaning of the turbine may only be carried out at

heavily reduced engine load (max. exhaust-gas temperature
ahead of turbine ≤ 320° C)!
When the exhaust-gas temperature is too high, the washing water can
trigger a thermoshock and cause damage to the turbine.
Type Max. exhaust gas temperature Max. turbocharger speed

upstream of turbine in °C in rpm
TCR10 ≤ 320 ≤ 38 000
TCR12 ≤ 320 ≤ 32 000
TCR14 ≤ 320 ≤ 26 000
TCR16 ≤ 320 ≤ 22 000
TCR18 ≤ 320 ≤ 18 000
TCR20 ≤ 320 ≤ 15 000
TCR22 ≤ 320 ≤ 12 000
In order to save time, carry out the cleaning shortly after engine start-
2010-10-13 - de
up, provided the components to be cleaned are not yet too hot.
Work cards
This allows step 2 of the work sequence to be omitted.
General The layout of the cleaning device depends on the engine type and can vary
TCR
from the illustration.
C2 0288 500.21-02 EN-US 1 (2)

Cleaning
1 Water supply 6 Sealing air

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

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

Should vibrations occur on the turbocharger that were not evident
2010-10-13 - de
before, repeat the washing procedure.

Work cards
If these vibrations, caused by irregular dirt accumulations, cannot be

eliminated by washing, the turbocharger must be dismantled and the
parts involved must be subjected to mechanical cleaning.
TCR
2 (2) C2 0288 500.21-02 EN-US

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

1 Technician 0,3
Preliminary remarks
Cleaning agent Use only commercially available granulates from nut shells or activated char-
coal (soft) with a grain size of 1.0 mm (max. 1.5 mm).
Do not use water for cleaning the turbine by this method, as in this
case the cleaning is carried out at normal operating load of the engine.
Cleaning interval Every 24 operating hours, at normal operating load of the engine.
Assembly instructions ▪ The tank (1) must be installed in a suitable location, not lower than 1.0 m
below the connection point (4).
▪ The pipe (3) may not be longer than 6.0 m and must be supported
against vibrations. An unobstructed flow must be ensured.
▪ The connection point (4) can be provided on the exhaust gas pipe just
before the gas admission casing (5) or on the inlet socket of the gas
admission casing.
▪ Maximum operating temperature of the three-way cock (B): ≤ 150 °C.
2013-06-18 - de
Work cards
TCR
C2 0288 500.22-02 EN-US 1 (2)

Cleaning
1 Tank 8 Turbine wheel

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

Steps 1. Stop cock (A) must be closed.
2. Three-way cock (B) must be in position “0”.
3. Unscrew the screw plug (2).
Fill the prescribed quantity of granulate into the tank (1) and close
it with the screw plug (2). See Table “Filling volume”.
4. Open the stop cock (A).
Slowly turn the stop cock (B) to position “I” until a whistling sound
is heard indicating introduction of the granulate.
Granulate injection time approx. 30 seconds.
5. Close the stop cock (A).
6. Switch the three-way cock (B) to position “0” (sealing air).
The sealing air prevents clogging of the piping.
Type Filling volume
2013-06-18 - de
TCR10, TCR12 0.2 litres

Work cards

TCR22 0.5 litres
TCR
Table 1: Filling volume
2 (2) C2 0288 500.22-02 EN-US

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

1 Technician 0,3
Preliminary remarks
Cleaning agent Use exclusively fresh water for cleaning.
Cleaning interval Every 150 operating hours.
Carry out the cleaning only with the engine warmed up and in
full load operation.
Do not shut down the engine immediately after cleaning, but continue
to run it for several minutes until dry.
2010-10-13 - de
Work cards
TCR
C2 0287 500.23-01 EN-US 1 (2)

Cleaning
1 Handle 5 Coupling
2 Pressure sprayer 6 Hand valve
3 Relief valve 7 Turbocharger (compressor)
4 Nipple 8 Plate with cleaning instructions
Figure 1: Diagram, wet cleaning of the compressor with pressure sprayer
Work sequence - Compressor cleaning (during operation)

Steps 1. Operate engine at full load.
2. Turn handle (1) on pressure sprayer tank (2) in counter-clockwise direc-
tion and take out the pump.
3. Fill fresh water into the tank, filling volume 0.5 litres.
4. Screw in the pump and operate it until the relief valve (3) blows off.
5. Connect hose with nipple (4) to the coupling (5).
6. Depress pushbutton (see large arrow in figure) on the hand valve (6)
until the water is completely injected into the compressor (7) (for
approx. 30 seconds).
7. Release plug-in connection and vent the tank. For venting, pull spindle
on the relief valve (3) outwards (see small arrow in figure).
2010-10-13 - de
Work cards
TCR
2 (2) C2 0287 500.23-01 EN-US

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

1 Technician 0,4
Tools/Appliances Required
– Compressed air – Inventory
– Cleaning agent (non-corrosive) – Inventory
Spare parts
Quantity Designation Number
1 Air filter mat 544.201
2 Clamp 544.202
1 Cover sheet 544.205
Preliminary remarks
Replace the air filter mat only when the engine is at standstill!
The air filter mat may be replaced only when the engine is at standstill.
The entry of dirt and foreign objects must be prevented.
General The dirty air filter mat (544.201) can be cleaned several times or replaced
with a new mat.
Replacement is required if the air filter mat is considerably stretched, tattered
or perforated.
Cleaning agent Warm water to which a non-corrosive cleaning agent has been added
Cleaning interval Every 250 operating hours.
2009-10-28 - de
Cleaning is necessary when the air filter mat starts to discolour, turning grey.
Work cards
The air filter is then saturated and the contamination starts to advance
TCR16-40
towards the compressor and the charge air cooler.
C2 0288 500.24-02 EN-US 1 (3)

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

Cleaning
should not be used as a reference for the cleaning interval.
Figure 1: Air filter on the silencer
Work sequence - Removal, cleaning/replacement, refitting

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

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

Work cards
TCR16-40
2 (3) C2 0288 500.24-02 EN-US

Cleaning
Position of the clamps
Figure 2: Position of the clamps

Correct position of the The clamps must be attached as close as possible to the outer edges of the
clamps silencer in order to prevent dirt and foreign objects from entering the com-
pressor through the silencer.
2009-10-28 - de
Work cards
TCR16-40
C2 0288 500.24-02 EN-US 3 (3)

Assembly and maintenance

7.1 Preface
7.2 Setting data
7.4 Cleaning
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Work cards
0287-1 7.5-01 EN-US 1 (1)

Complete turbocharger

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

1 Technician 4,5
1 Assistant 1,0
1 Set of ring or socket wrenches - Inventory
1 Screwdriver - Inventory
- Torque wrench - Inventory
- Round sling (min. load capacity 6 kN) - Inventory
- Lifting tackle, ropes - Inventory
- Wood as a support - Inventory
- High-temperature lubricant (e.g. Molykote - Inventory
HSC)
Related work cards

7.2.1
Technical data
Designation Information
Turbocharger (without silencer, gas outlet casing and 175.2 kg
accessories)
Silencer 43.5 kg
Air intake casing 90° 24.3 kg
Air intake casing axial 15.1 kg
Gas outlet casing (with/without waste gate) 56.7 kg / 60.7 kg
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Work cards
Preliminary remarks
Removal/refitting of the complete turbocharger only in case of major overhaul
TCR16
or replacement. Figure Removing turbocharger from engine bracket and

refitting it shows the turbocharger with a silencer. The same work steps are
required for turbochargers with an air intake casing.
C2 0287 500.31-01 EN-US 1 (4)

For maintenance work on the turbocharger, subassemblies/

components are removed in succession. Please refer to the following

work cards 500.32 to 500.47.
501.000 Gas admission casing 544.000 Silencer

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

No persons may be present in the area of danger around and
underneath a suspended load.
• Do not use shackles or chains for attaching the lifting tackle to the
bearing casing of the turbocharger.
• Lifting tackle, ropes and attachment points must be able to take the
load safely and be in perfect condition.
• All lifting, moving and setting down of the load must be carried out
slowly.
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Work cards
TCR16
2 (4) C2 0287 500.31-01 EN-US


Work sequence - Removing the complete turbocharger
Danger of burns from hot components!

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

The lube oil is under pressure and very hot!
• Before opening pipes, flanges, screwed connections or fittings, release
the pressure in the system and check that it is depressurised!
• Before opening oil pipes, wait until the lube oil has cooled down
sufficiently!
Starting condition The engine is shut down. Components of the turbocharger have cooled
down far enough to allow maintenance work to be carried out. Tools and
appliances are at hand and ready. The turbocharger can be accessed safely.
Coverings are removed to the extent necessary.
Steps 1. Detach or remove any connecting pipes installed for exhaust gas,
charge air, Jet Assist, turbine cleaning, compressor cleaning, lube oil
pressure/temperature, speed measurement and other special connec-
tions.
2. Attach lifting tackle to the turbocharger at the bearing casing (517.000)
using a round sling of adequate capacity.
Carefully tension the round sling. Attach secondary ropes at
appropriate points to assist in balancing.
3. Undo the screw connections between the turbocharger and the engine
bracket.
See engine manual for instructions.
4. Carefully lift off the turbocharger using the lifting tackle and set it down
on a wooden support.
With the turbocharger removed, seal the openings for air, exhaust gas
and lube oil to prevent foreign objects or water from entering.
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Work cards
TCR16
C2 0287 500.31-01 EN-US 3 (4)

Work sequence - Refitting the complete turbocharger
Observe the following procedures when refitting the

turbocharger on the engine.
• Remove protective caps from pipe connections/pipes.

• Use only flawless seals and screw locking elements.
• Insert sealing elements for lube oil in the engine bracket (see engine
manual).
• Apply high-temperature lubricant (e.g. Molykote HSC) to the threads of
heat-resistant screws and nuts on the turbine side.
Steps 1. Attach lifting tackle to the turbocharger at the bearing casing (517.000)
using a round sling of adequate capacity.
Carefully tension the round sling. Attach secondary ropes at appropriate
points to assist in balancing.
2. Insert sealing elements for lube oil in the engine bracket; seals are
included in the scope of supply of the engine (see engine manual).
3. Carefully lift the turbocharger using the lifting tackle and set it down on
the engine bracket.
4. At first, only lightly bolt the turbocharger to the engine bracket.
5. Align and fasten the connections for exhaust gas and charge air on the
engine and the turbocharger. See engine manual for instructions.
6. Tighten the bolts fastening the turbocharger to the engine bracket.
See engine manual for instructions.
7. Refit the coverings.
8. Re-establish all connections required for Jet Assist, turbine cleaning,
compressor cleaning, lube oil pressure/temperature, speed measure-
ment and other special connections.
Refitting the turbocharger on a gas-powered engine
Danger of fire caused by electrostatic charging

In the case of turbochargers on gas-powered engines, insulated
mounting can cause electrostatic charging, resulting in ignition of the
air/gas mixture in the air intake.
• If the turbocharger is mounted on the engine in such a way that it is
electrically insulated, an earth connection must be installed for the
equipotential bonding between the turbocharger and the engine.
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Work cards
TCR16
4 (4) C2 0287 500.31-01 EN-US

Silencer - Option

Brief description
The silencer is removed and refitted in the fully assembled state. The silencer
has to be removed for all work that is to be performed from the compressor
side.

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

500.31
Technical Data
Silencer 43.5 kg
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Work cards
TCR16
C2 0287 500.32-01 EN-US 1 (2)

Preliminary remarks
544.000 Silencer 546.004 V-profile clamp

Figure 1: Removing and refitting the silencer
Work sequence - Removing the complete silencer

Starting condition Connecting pipe for compressor cleaning is released, if provided.
Steps 1. Attach lifting tackle to the silencer (544.000) using a rope.
2. Loosen the V-profile clamp (546.004) on both sides of the circumfer-
ence.
3. Move the silencer away from the compressor casing (546.000) in axial
direction and place it on a wooden support with the flange face down.
Work sequence - Refitting the complete silencer

Steps 1. Attach lifting tackle to the silencer (544.000) using a rope.
2. Move the silencer towards the compressor casing (546.000) in axial
direction.
3. Fasten the silencer to the compressor casing with V-profile
clamp (546.004).
Observe tightening torques during refitting!
• Apply oil to the threads and contact surfaces.

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• Tightening torque for the V-profile clamp (546.004) on both sides of the
Work cards
circumference: 12 Nm
TCR16
2 (2) C2 0287 500.32-01 EN-US

Air intake casing - Option

Brief description
The air intake casing is removed and refitted in the fully assembled state. The
air intake casing has to be removed for all work that is to be performed from
the compressor side.
- Wood (for placing underneath) - Inventory

1 Technician 0,4
1 Assistant 0,4
Related work cards

500.31
Technical Data
Air intake casing 90° 24.3 kg
Air intake casing axial 15.1 kg
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Work cards
TCR16
C2 0287 500.33-01 EN-US 1 (3)

Preliminary remarks
545.001 Air intake casing 546.004 V-profile clamp

Figure 1: Removing and refitting the air intake casing (545.01 or 545.02)
Work sequence - Removing the complete air intake casing

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

Steps 1. Attach lifting tackle to the air intake casing (545.01 or 545.02) using a
rope.
2. Move the air intake casing towards the compressor casing (546.000) in
axial direction.
3. Fasten the air intake casing to the compressor casing with V-profile
clamp (546.004).
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Work cards
TCR16
2 (3) C2 0287 500.33-01 EN-US


• Apply oil to the threads and contact surfaces.
• Tightening torque for the V-profile clamp (546.004) on both sides of the
circumference: 12 Nm
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Work cards
TCR16
C2 0287 500.33-01 EN-US 3 (3)

Insert, compressor side

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

1 Technician 0,4
1 Torque wrench 13 - Inventory
- Special lubricant (e.g. Molykote G-n or Moly- - Inventory
kote P40)
Spare Parts
1 O-ring seal 540.015
Related work cards

500.31 500.32 500.33
Technical data
Insert, compressor side 12.7 kg
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Work cards
TCR16
C2 0287 500.41-03 EN-US 1 (3)

Preliminary remarks
540.001 Insert 540.030 Spacer ring

540.010 Holding ring 546.001 Compressor casing
540.015 O-ring seal 546.020 Hexagon bolt
Figure 1: Removing and refitting the compressor-side insert
Work sequence - Removing the insert

Starting condition Silencer or air intake casing is removed.
Steps 1. Unscrew the hexagon bolts (546.020).
2. Evenly force off the insert (540.001) and the retaining ring bolted to it
(540.010) using 3 hexagon bolts (546.020), remove in axial direction
and place it on a wooden support.
Risk of material damage to the compressor wheel!

The blades of the compressor wheel must not be damaged during
removal.
Work sequence - Installing the insert

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Work cards
The O-ring seal must be tensioned around its full circumference and
TCR16
must not be twisted during installation.
2 (3) C2 0287 500.41-03 EN-US

Steps 1. Apply clean lubricating oil to the O-ring seal (540.015) and insert it into

the ring grooves of the insert (540.001).
2. Install the complete insert together with the balance ring (540.030) into
the compressor casing (546.001) and fasten it with hexagon
bolts (546.020).
Observe tightening torques during installation!

• Apply special lubricant (e.g. Molykote G-n or Molykote P40) to the
threads and contact surfaces.
• Tightening torque for hexagon bolts (546.020): 17 Nm
Inspection of gaps (items 2 and 6), see Chapter [7.2.2]

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Work cards
TCR16
C2 0287 500.41-03 EN-US 3 (3)

Covering on compressor casing - Option

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

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

500.31 500.32 500.33
500.41
Technical data
Covering, complete 13.4 kg
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Work cards
TCR16
C2 0287 500.42-01 EN-US 1 (2)

Preliminary remarks
546.001 Compressor casing 591.000 Covering
Figure 1: Removing and refitting the covering on the compressor casing
Work sequence - Removing the covering on the compressor casing

Starting condition Silencer or air intake casing, and compressor-side insert are removed.
Steps 1. Undo the connecting elements on the covering halves.
2. Lift off covering (591.6000) and set it down on a wooden support.
Work sequence - Refitting the covering on the compressor casing

Steps 1. Mount the covering halves on the compressor casing and fasten them
with the connecting elements.
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Work cards
TCR16
2 (2) C2 0287 500.42-01 EN-US

Compressor casing

Brief description
Remove and refit the compressor casing. Maintenance work is due/required.
Beginning from the compressor side.
Personnel and Time Required

1 Technician 1,0
Tools/Appliances Required
1 Torque wrench - Inventory
- Lifting tackle, rope - Inventory
- Special lubricant (e.g. Molykote G-n or Moly- - Inventory
kote P40)
Spare Parts
Related work cards

500.31 500.32 500.33
500.41 500.42
Technical Data
Compressor casing (single outlet/double outlet) 46.0 kg
Diffuser 3.1 kg
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Work cards
TCR16-40
C2 0287 500.43-03 EN-US 1 (3)

Preliminary remarks
517.001 Bearing casing 546.006 Clamping claw

542.001 Diffuser 546.008 Countersunk bolt
546.001 Compressor casing 546.029 O-ring seal
546.005 Hexagon bolt
Figure 1: Removing and refitting the compressor casing
Work sequence - Removing the compressor casing

Starting condition Coverings are removed to the extent necessary.
Silencer or air intake casing, compressor-side insert and connection for Jet
Assist (if provided) are removed.
The insert must be disassembled before removal of the compressor

casing!
Steps 1. Attach lifting tackle to the compressor casing (546.001) using a rope.
2. Unscrew the hexagon bolts (546.005) and take off the clamping
claws (546.006).
3. Remove the compressor casing in axial direction, place it on a wooden
support and take measures to prevent it from rolling off.
4. If the diffuser (542.001) is to be removed:
Unscrew the cylindrical screw (546.008) and remove the diffuser
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in axial direction.
Work cards
Work sequence - Refitting the compressor casing

TCR16-40
Steps 1. Install the diffuser (542.001).

2. Apply clean lubricating oil to the O-ring seal (546.029) and insert it into
the ring groove of the compressor casing (546.001).
2 (3) C2 0287 500.43-03 EN-US

The O-ring seal must be tensioned around its full circumference and

must not be twisted during installation.
3. Using the lifting tackle, place the compressor casing (546.001) against
the bearing casing (517.001) in axial direction.
4. Fasten the compressor casing (546.001) to the bearing cas-
ing (517.001) with clamping claws (546.006) and hexagon
bolts (546.005).

• Apply special lubricant (e.g. Molykote G-n or Molykote P40) to the
threads and contact surfaces.
• For safety reasons, only the hexagon bolts (546.005) originally installed
by MAN Diesel &Turbo may be used.
• Tightening torque for hexagon bolts (546.005): 58 Nm
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Work cards
TCR16-40
C2 0287 500.43-03 EN-US 3 (3)

Cartridge

Brief description
Remove and refit the cartridge for inspection. Maintenance work is due/
required. Beginning from the compressor side.

1 Technician 0,6
3 Forcing-off bolt 596.018 Option
3 Forcing-off sleeve 596.019 Option
2 Open-jaw wrench 19 - Inventory
HSC)
Related work cards

500.31 500.32 500.33
500.41 500.42 500.43
Technical data
Cartridge 53.0 kg
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Work cards
TCR16
C2 0287 500.44-01 EN-US 1 (3)

Preliminary remarks
501.001 Gas admission casing 513.001 Turbine nozzle ring

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

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

wheels.
Pay attention to the turbine nozzle ring (513.001) when removing the
TCR16
cartridge.
2 (3) C2 0287 500.44-01 EN-US


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

contact surfaces.
• Tightening torque for hexagon nuts (501.008): 34 Nm
Observe the correct use of lock washer pairs!

Long wedge surfaces to contact each other (on the inside), otherwise there will be no
locking effect.
For checking the gaps (items 2 and 6), see Chapter [7.2.2].
For checking the gap (item 6), the front closures/connections of the
gas outlet casing (506.000) must first be removed.
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Work cards
TCR16
C2 0287 500.44-01 EN-US 3 (3)

Cartridge Components – Major Overhaul

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

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

500.31 500.32 500.33
500.41 500.42 500.43
500.44
Technical data
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Work cards
Bearing casing 38.8 kg

TCR16-40
Turbine rotor 10.0 kg

Compressor wheel 3.7 kg
C2 0287 500.45-03 EN-US 1 (8)

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

1 Thrust bearing 517.002
2 Bearing bush 517.003
2 Retaining ring 517.038
6 Hexagon bolt 517.051
1 Piston ring 520.132
1 Piston ring 520.133
Work sequence - Mounting the arresting device for the turbine rotor
Starting condition Coverings, silencer or air intake casing, compressor-side insert and com-
pressor casing are removed.
506.001 Gas outlet casing 596.002 Retainer

506.034 Hexagon bolt 596.003 Hexagon pin
520.001 Turbine rotor 596.004 Spring plug
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Figure 1: Arresting device for turbine rotor

Work cards
Steps 1. Before removing the cartridge, fasten the arresting device for the tur-
TCR16-40
bine rotor (596.002, 596.003 and 596.004) to the gas outlet casing or
gas admission casing with hexagon bolts (506.034).
2 (8) C2 0287 500.45-03 EN-US


Work sequence - Removing the compressor wheel, compressor-side cover and retaining
ring
517.001 Bearing casing 520.005 Compressor wheel

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

The hexagon pin (596.001) is located inside the silencer or air intake
casing.
Steps 1. After mounting the arresting device, first just slightly loosen the com-
pressor wheel (520.005) with the hexagon pin (596.001) (right-hand
thread).
2. Disconnect the speed transmitter (562.040) and unscrew it from the
bearing casing (517.001).
3. Remove the cartridge, see work card [500.44].
4. Block the turbine rotor (520.001) on the face side in circumferential
direction using a hexagon screw driver and unscrew the compressor
wheel (520.005) with the hexagon pin (596.001) (right-hand thread).
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5. Unscrew the hexagon bolts (517.029) and evenly force off the
Work cards
cover (517.087) with 2 hexagon bolts (M8, thread length ≥ 40 mm).

TCR16-40
6. Remove the cover together with the piston ring (520.133) in axial direc-
tion.
C2 0287 500.45-03 EN-US 3 (8)

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

7. Pull the retaining ring (520.031) off the turbine rotor in axial direction.
Work sequence - Removing bearing parts, turbine rotor and turbine-side cover
517.001 Bearing casing 517.051 Hexagon bolt

517.002 Thrust bearing 520.001 Turbine rotor
517.003 Bearing bush 520.027 Thrust ring
517.005 Bearing body, compressor side 520.028 Counter-thrust ring
517.006 Bearing body, turbine side 520.132 Piston ring
517.009 Cover 596.036 Guide rod
517.038 Retaining ring
Figure 3: Removing and refitting bearing parts, turbine rotor and turbine-side cover
Steps 1. Unscrew two hexagon bolts (517.051) and replace them with guide
rods (596.036).
2. Unscrew the remaining hexagon bolts (517.051) and evenly force off
the bearing body (517.005).
3. Remove the counter-thrust ring (520.028), thrust bearing (517.002) and
thrust ring (520.027) in axial direction.
4. Remove the turbine rotor (520.001), fitted piston ring (520.132) and
cover (517.009) in axial direction.
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Work cards
Mark the axial installation position of the piston ring (520.132).

TCR16-40
4 (8) C2 0287 500.45-03 EN-US

5. Remove the bearing body (517.006) in axial direction.

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

Steps 1. Measure the lengths (b) of the wedge surfaces (V) on the compressor
and turbine sides.
Length (b) extends up to the edge (K) on the bearing contact face
(A). Depending on the angle of light incidence, a dark band may
appear in front of the edge (K) on the wedge surface (V). This
band is to be included in the measurement of length (b).
2. Replace the thrust bearing (517.002) when
– on the compressor side (VS) one of the lengths (b) ≤ 2.2 mm,
– on the turbine side (TS) one of the lengths (b) ≤ 2.9 mm.
Work sequence - Checking the bearing bush on the turbine and compressor sides
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Figure 5: Checking the bearing bush

Work cards
Steps 1. The bore of the two bearing bushes (517.003) with MGF profile is not
TCR16-40
absolutely circular. Wear becomes evident as a mirror-bright recess of

band width (W) caused by embedding of the turbine rotor.
2. Replace the bearing bush (517.003) when
– band width (W) ≥ 14.0 mm.
C2 0287 500.45-03 EN-US 5 (8)

Work sequence - Checking the retaining ring, turbine rotor, piston ring
Steps 1. Replace the retaining ring (520.031) when
– D1 ≤ ∅ 28.94 mm.
2. Replace the turbine rotor (520.001) when
– D2 ≤ ∅ 28.94 mm.
3. Replace the piston ring (520.132) when
– the axial width of 2.5 mm has worn down to less than 2.0 mm.
4. Replace the piston ring (520.133) when
– the axial width of 3.0 mm has worn down to less than 2.5 mm.
Work sequence - Assembly
Imbalance after installation of a new compressor wheel or

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

during assembly as protection against fretting (contact corrosion).
1. Screw two guide rods (596.036) into the bearing casing (517.001) as an
assembly aid.
2. Insert the bearing body (517.006) together with the fitted bearing
bush (517.003) into the bearing casing (517.001) in axial direction.
3. Install the turbine-side cover (517.009) and the turbine rotor (520.001)
with fitted piston ring (520.132) in axial direction.
Observe the marked axial installation position of the piston ring or fit a
new piston ring (520.132).
4. Install the thrust ring (520.027), thrust bearing (517.002) and counter-
thrust ring (520.027) in axial direction.
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The balancing marks (0) of the turbine shaft, thrust ring and counter-
Work cards
thrust ring must coincide radially.

TCR16-40
5. Install the bearing body (517.005) together with the fitted bearing
bush (517.003) and fasten with hexagon bolts (517.051).
6. Remove the guide rods and screw in the remaining hexagon bolts.
6 (8) C2 0287 500.45-03 EN-US

7. Push the retaining ring (520.031) onto the turbine shaft.

The balancing marks (0) of the turbine shaft and retaining ring must
coincide radially.
Observe tightening torques during assembly!

Apply special preservative (Molykote P40) to the threads and contact
surfaces.
Tightening torque for hexagon bolts (517.051): 7 Nm
8. Apply clean lubricating oil to the O-ring seal (517.031) and insert it into
the ring groove of the cover (517.087). The O-ring seal must be ten-
sioned around its full circumference and must not be twisted during
installation.
9. Install the cover (517.087) together with the fitted piston ring (520.133)
in axial direction.
Observe the marked axial installation position of the piston ring or fit a
new piston ring (520.133).
10. Fasten cover (517.087) with hexagon bolts (517.029) and tighten with
specified torque 29 Nm.
11. Block the turbine rotor (520.001) in circumferential direction. At first just
lightly fasten the compressor wheel (520.005) with the hexagon
pin (596.001) (right-hand thread).
12. Install the cartridge, see work card [500.44].
13. Mount the arresting device for the turbine rotor (596.002, 596.003 and
596.004) on the gas outlet casing with hexagon bolts (506.034) (see
Figure Arresting device for turbine rotor).
14. Fasten the compressor wheel (520.005) with the hexagon pin (596.001)
and torque wrench (right-hand thread).
Observe tightening torques during assembly!

Apply special preservative (Molykote P40) to the threads and contact
surfaces.
Tightening torque for compressor wheel (520.005): 120 Nm
Tightening torque for hexagon bolts (517.029): 29 Nm
2013-01-14 - de
Work cards
TCR16-40
15. Screw the speed transmitter (562.040) into the bore on the side of the
bearing casing (517.001). Connect the cable ends in the terminal box.
16. Remove the arresting device.
C2 0287 500.45-03 EN-US 7 (8)

Work cards Assembly and maintenance
8 (8)
TCR16-40 500.45
C2 0287 500.45-03 EN-US

MAN Diesel & Turbo
2013-01-14 - de
Turbine nozzle ring

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

1 Technician 0,2
Related work cards

500.31 500.32 500.33
500.41 500.42 500.43
500.44
Technical data
Turbine nozzle ring 3.0 kg
Preliminary remarks
2013-01-14 - de
Work cards
501.001 Gas admission casing 513.001 Turbine nozzle ring

TCR16
501.009 Parallel pin
Figure 1: Removing and refitting the turbine nozzle ring
C2 0287 500.46-01 EN-US 1 (2)

Work sequence - Removing the turbine nozzle ring

Starting condition Coverings, silencer or air intake casing, compressor-side insert, compressor
casing and cartridge are removed.
Steps Work Sequence – Removing and Checking the Turbine Nozzle Ring
1. Take the turbine nozzle ring (513.001) out of the gas admission cas-
ing (501.001) in axial direction.
2. Check the turbine nozzle ring for erosive wear.
The erosive wear of the guide vanes (A) is caused by the outlet
flow mainly in the area of the trailing edges (B). The original posi-
tion of the trailing edges (B) can be recognised at the roots (G) of
the guide vanes (A).
Since the guide vanes do not wear evenly, the mean value of the
guide vane reduction (Lm) is calculated as follows:
(L1 + L2 + L3 + … + Ln)
Lm = ____________________ n = number of guide vanes (A)
n
Replace the turbine nozzle ring when Lm ≥ 10 mm.
A Guide vanes E Negative areas (to the left of D)

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

2013-01-14 - de
Work cards
Insert the turbine nozzle ring (513.001) into the gas admission cas-
ing (501.001) in axial direction. Make sure that it is in the correct circumferen-
tial position in relation to the parallel pin (501.009).
TCR16
2 (2) C2 0287 500.46-01 EN-US

Gas admission casing and turbine-side insert

Brief description
Remove and refit the gas admission casing and turbine-side insert. Mainte-
nance work is due/required.

1 Technician 1,0
HSC)
Related work cards

500.31 500.32 500.33
500.41 500.42 500.43
500.44 500.46
Technical data
Gas admission casing 45.0 kg
Covering on gas admission casing 9.3 kg
Insert, turbine side 12.4 kg
2014-01-09 - de
Work cards
TCR16
C2 0287 500.47-01 EN-US 1 (3)

Preliminary remarks
501.001 Gas admission casing 541.001 Insert, turbine side

501.007 Lock washer pair 541.021 Countersunk bolt
501.008 Hexagon nut 596.020 Suspension device
501.011 Clamping claw 596.025 Shackle
Figure 1: Removing and refitting the gas admission casing and turbine-side insert
Work sequence - Removing the gas admission casing

Starting condition Coverings, silencer or air intake casing, compressor-side insert, compressor
casing, cartridge and turbine nozzle ring are removed.
Steps 1. Attach lifting tackle to the gas admission casing (501.001) using a rope.
Carefully tension the rope.
2. Unscrew the hexagon nuts (501.008), take off the lock washer
pairs (501.007) and the clamping claws (501.011).
3. Remove the gas admission casing (501.001) in axial direction and place
it on a wooden support.
Work sequence - Removing the turbine-side insert

Steps 1. Unscrew the countersunk bolts (541.021).
2. Remove the turbine-side insert (541.001) in axial direction and place it
on a wooden support.
Work sequence - Refitting the turbine-side insert and gas admission casing
2014-01-09 - de
Steps 1. Insert the insert (541.001) into the gas admission casing (501.001) in
Work cards
axial direction and fasten it with countersunk bolts (541.021).

2. Using the lifting tackle, place the gas admission casing (501.001)
against the gas outlet casing (506.001) in axial direction.
TCR16
2 (3) C2 0287 500.47-01 EN-US

3. Fasten the gas admission casing (501.001) to the gas outlet cas-

ing (506.001) with the clamping claws (501.011), lock washer
pairs (501.007) and hexagon nuts (501.008).
4. Refit the covering parts between the gas admission casing (501.001)
and the gas outlet casing (506.001).

Consequences
• Apply high-temperature lubricant (e.g. Molykote HSC) to the threads and
contact surfaces.
• Tightening torque for hexagon nuts (501.008): 34 Nm
Observe the correct use of lock washer pairs!

Long wedge surfaces to contact each other (on the inside), otherwise there will be no
locking effect.
2014-01-09 - de
Work cards
TCR16
C2 0287 500.47-01 EN-US 3 (3)

MAN Diesel & Turbo
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
Spare parts catalogue / tools
2014-01-23 - de
0287-1 8 C1-01 EN-US 1 (1)

Preface
8.1 Preface
8.3 Spare parts
8.4 Spare parts for maintenance
8.5 Spare parts for major overhaul
8.6 Tools

2014-01-23 - de
0287-1 8.1-01 EN-US 1 (1)

Organisation and use of the spare parts catalogue
Preface
General
Maintenance and repair work on the turbocharger can be carried out prop-
erly only if the required spare parts and tools are available.
It is thus advisable to order spare parts for the turbocharger in time, keeping
spare parts for maintenance and major overhaul in stock and having the
required tools available.
Contents of the spare parts catalogue

The spare parts catalogue covers
▪ all essential components of the turbocharger.
The spare parts catalogue does not contain
▪ subordinate or plant-specific insulations/coverings.
▪ subordinate cabling, or cabling leading away from the turbocharger/
cabling and pipes installed out by other manufacturers.
Validity
Scope of supply The spare parts catalogue is valid for the specified turbocharger type. To
identify parts, the individual pages of the spare parts catalogue must be
selected in accordance with the scope of supply of the turbocharger.
Modified components Since our turbochargers undergo upgrading development, it may happen
that when spare parts are ordered later on the parts supplied differ from the
ones supplied originally, which, however, serve the same purpose as the lat-
ter. In such cases, the identity card of the part supplied will contain a corre-
sponding reference.
Organisation
Overview of subassemblies MAN Diesel & Turbo SE turbochargers are assembled from a number of sub-
assemblies. Standard subassemblies form a basis to which other applica-
tion-specific subassemblies can be added. The overview of the subassem-
blies illustrates the layout of the individual subassemblies.
Spare parts The spare parts sheets are ordered by subassembly from 500 to 599.
The ordinal number at the top of the spare parts sheets consists of the 3-
digit subassembly number and a 2-digit variant number corresponding to the
design variant.
The order numbers for spare parts consist of a 3-digit subassembly number
and a 3-digit item number. The subassembly number and the item number
are separated by a dot.
Spare parts for maintenance The list of spare parts for maintenance or major overhaul of the turbocharger
and major overhaul contains a selection of spare parts. This list is also included in the spare parts
box for identification of the parts.
2012-12-19 - de
All spare parts that are not packed in plastic bags must be stored well
coated in grease. Please re-order immediate replacements for spare parts
that have been used.
TCR16-40
Tools The list of tools includes special tools for maintenance and major overhaul of
a turbocharger. This list is also included in the tool box for identification of the
tools.
C3 0288 8.1.1-01 EN-US 1 (2)

Order numbers for tools consist of the subassembly number for tools and a
Preface
3-digit item number.

2012-12-19 - de
TCR16-40
2 (2) C3 0288 8.1.1-01 EN-US

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

PrimeServ Augsburg Fax +49 821 322 49 4180
86224 Augsburg
Germany
PrimeServ Turbocharger Tel. +49 821 322 4010 Axial turbochargers (24 hours)
Technical service Tel. +49 821 322 4020 Radial turbochargers (24 hours)
Fax +49 821 322 3998

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

Spare parts
2013-09-06 - de
Fax +49 821 322 3998

TCR16-40
C3 0288 8.1.2-01 EN-US 1 (2)


Preface
Headquarters
PrimeServ Academy Tel. +49 821 322 1397
Training courses for turbochargers Fax +49 821 322 1170
and engines
Internet www.mandieselturbo.com/primeserv-academies
If parts have to be ordered which the spare parts catalogue does not
contain or that are not found, the component and the installation
location should be described as precisely as possible, with a photo
possibly attached.
2013-09-06 - de
TCR16-40
2 (2) C3 0288 8.1.2-01 EN-US

Overview of subassemblies
8.1 Preface
8.3 Spare parts
8.6 Tools

2014-01-23 - de
0287-1 8.2-01 EN-US 1 (1)

MAN Diesel & Turbo 500
Subassemblies

2014-01-23 - de
TCR16-40
C3 0287 500-01 EN-US 1 (2)

500 MAN Diesel & Turbo
Subassembly Designation Optional Weight

500.000 Turbocharger without optional subassemblies 175.2 kg

501.000 Gas admission casing (1-channel/2-channel) 45.0 kg / -
506.000 Gas outlet casing (without/with waste gate) X 56.7 kg / 60.7 kg
513.000 Turbine nozzle ring 3.0 kg
517.000 Bearing casing 38.8 kg
520.000 Rotor, complete 14.2 kg
540.000 Insert, compressor side 12.7 kg
541.000 Insert, turbine side 12.4 kg
542.000 Diffuser 3.1 kg
544.000 Silencer X 43.5 kg
545.000 Air intake casing (90°/axial) X 24.3 kg / 15.1 kg
546.000 Compressor casing 46.0 kg
591.1000 Covering on gas admission casing X 9.3 kg
591.4000 Covering on gas outlet casing X 15.7 kg
591.5000 Covering on bearing casing X 1.0 kg
591.6000 Sound insulation on compressor casing X 13.4 kg
599.000 Cartridge (517.000 + 520.000) 53.0 kg
Table 1: Subassemblies and weights TCR16 (approximate values)
2014-01-23 - de
TCR16-40
2 (2) C3 0287 500-01 EN-US

Spare parts
8.1 Preface
8.3 Spare parts
8.6 Tools

2014-01-23 - de
0287-1 8.3-01 EN-US 1 (1)

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

501.000 Gas admission casing, complete 1
2009-11-25 - de
501.001 Gas admission casing 1

501.005 Clamping claw 8
TCR16-40
501.006 Stud 24
501.007 Lock washer pair 24
501.008 Hexagon nut 24
C3 0287 501.01-02 EN-US 1 (2)


Spare parts
501.009 Parallel pin 1

501.026 Screw plug 2
501.027 Sealing ring 2
2009-11-25 - de
TCR16-40
2 (2) C3 0287 501.01-02 EN-US

Gas outlet casing
Spare parts
Spare parts 506.01

506.000 Gas outlet casing, complete 1
506.001 Gas outlet casing 1
506.003 Cover 1
506.034 Hexagon bolt 8
2009-02-06 - de
506.038 Seal 1
506.047 Supporting sheet 1
TCR16-40
506.048 Washer 5
C3 0287 506.01-01 EN-US 1 (2)


Spare parts

2009-02-06 - de
TCR16-40
2 (2) C3 0287 506.01-01 EN-US

Turbine nozzle ring
Spare parts
Spare parts 513.01

513.001 Turbine nozzle ring 1

2009-02-06 - de
TCR16-40
C3 0287 513.01-01 EN-US 1 (1)

Bearing casing
Spare parts
Spare parts 517.02

517.000 Bearing casing, complete 1
517.001 Bearing casing 1
517.002 Thrust bearing 1
517.003 Bearing bush 2
517.005 Bearing body, compressor side 1
517.006 Bearing body, turbine side 1

517.009 Cover, turbine side 1
517.029 Cylindrical screw 8
2012-05-11 - de
517.031 O-ring seal 1

517.038 Retaining ring 2
TCR16
517.087 Cover, compressor side 1
C3 0287 517.02-01 EN-US 1 (1)

Rotor, complete
Spare parts
Spare parts 520.01

520.000 Rotor, complete 1
520.001 Turbine rotor 1
520.005 Compressor wheel 1
520.027 Thrust ring 1
520.028 Counter-thrust ring 1
520.031 Retaining ring 1
520.132 Piston ring 1

520.133 Piston ring 1
2009-11-25 - de
TCR16-40
C3 0287 520.01-01 EN-US 1 (1)

Insert, compressor side
Spare parts
Spare parts 540.04

540.000 Insert, compressor side, complete 1
540.001 Insert 1
540.010 Holding ring 1
540.030 Spacer ring 1

2012-05-11 - de
TCR16
C3 0287 540.04-01 EN-US 1 (1)

Insert, turbine side
Spare parts
Spare parts 541.01

541.000 Insert, turbine side, complete 1
541.001 Insert 1
541.021 Countersunk bolt 3
2011-04-12 - de
TCR16-40
C3 0287 541.01-01 EN-US 1 (1)

Diffuser
Spare parts
Spare parts 542.01

542.001 Diffuser 1
2009-02-06 - de
TCR16-40
C3 0287 542.01-01 EN-US 1 (1)

Chamber silencer - OPTION
Spare parts
Spare parts 544.02

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

2008-07-17 - de
544.063 Hexagon pin 1

TCR16-40
544.201 Air filter mat 1

544.202 Clamp 2
C3 0288 544.02-01 EN-US 1 (2)


Spare parts
544.203 Clamp 1
544.205 Cover strip 1
2008-07-17 - de
TCR16-40
2 (2) C3 0288 544.02-01 EN-US

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

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

545.026 Notched nail 4
2012-11-28 - de

TCR16-40
C3 0287 545.01-01 EN-US 1 (1)

Air intake casing, axial - OPTION
Spare parts
Spare parts 545.02
Designation Quantity
545.000 Air intake casing axial, complete 1
545.001 Air intake pipe 1

2010-05-19 - de

545.188 Sealing compound 1
TCR16-40
545.189 Activator 1
C3 0287 545.02-01 EN-US 1 (1)

Compressor casing
Spare parts
Spare parts 546.02
Order no. Designation Quantity

546.000 Compressor casing, complete 1
546.001 Compressor casing 1
546.004 V-profile clamp 1

546.008 Countersunk bolt 1
2014-01-23 - de

546.026 Notched nail 4
TCR16

C3 0287 546.02-01 EN-US 1 (2)

Order no. Designation Quantity

Spare parts

546.050 Flange 1
2014-01-23 - de
TCR16
2 (2) C3 0287 546.02-01 EN-US

Speed measuring device - OPTION
Spare parts
Spare parts 562.01

562.000 Speed measuring device, complete 1
562.040 Speed transmitter 1
562.083 Terminal box 1
2012-03-15 - de
562.100 Speed indicator 1

562.135 Teflon-armoured cable *m
* Specify length in m when ordering

TCR
C3 0288 562.01-01 EN-US 1 (1)

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

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

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

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

578.000 Cleaning device for turbine – Dry cleaning, complete 1
578.001 Tank 1
578.005 Plate 1
578.025 Screw connection 1
2008-12-11 - de

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


Spare parts

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

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

579.029 Pressure sprayer 1
579.090 Hose (length 1.5 m) 1
579.091 Hose clamp 2

579.095 Coupling 1
579.096 Nipple 1
579.100 Support 1
2008-12-11 - de

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

Covering on Gas Admission Casing
Spare parts
Spare parts 591.01

2011-04-12 - de
591.1000 Covering on gas admission casing, complete 1

TCR16-40
C3 0287 591.01-02 EN-US 1 (1)

Covering on Gas Outlet Casing
Spare parts
Spare Parts 591.04

2011-04-12 - de
591.4000 Covering on gas outlet casing, complete 1

TCR16-40
C3 0287 591.04-01 EN-US 1 (1)

Covering on Bearing Casing
Spare parts
Spare parts 591.05

591.5000 Covering on bearing casing, complete 1
2011-04-12 - de
TCR16-40
C3 0287 591.05-01 EN-US 1 (1)

Sound Insulation on Compressor Casing
Spare parts
Spare Parts 591.06

2011-04-12 - de
591.6000 Sound insulation on compressor casing, complete 1

TCR16-40
C3 0287 591.06-01 EN-US 1 (1)

Cartridge
Spare parts
Spare parts 599.01

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

2009-02-06 - de
TCR16-40
C3 0287 599.01-01 EN-US 1 (1)

Spare parts for maintenance

11.59500-0198
8.1 Preface
8.3 Spare parts
8.6 Tools

2014-01-23 - de
0287-1 8.4-01 EN-US 1 (1)

Spare Parts for Maintenance – OPTION
Spare parts for maintenance

11.59500-0198
11.59500-0322
Order No. Designation Sketch Data Quantity
501.006 Stud D = M10 6
L = 34 mm
0.017 kg
501.007 Lock washer pair d = 10.7 mm 6
0.005 kg
501.008 Hexagon nut d = M10 6
0.012 kg
506.038 Seal D = 245 mm 2
0.040 kg
540.015 O-ring seal D = 210 mm 1
0.030 kg
546.018 O-ring seal D = 355 mm 1
0.035 kg
2012-07-12 - de
TCR16-40
0287 595.01-02 EN-US 1 (1)

Spare parts for major overhaul

11.59500-0225
8.1 Preface
8.3 Spare parts
8.6 Tools

2014-01-23 - de
0287-1 8.5-01 EN-US 1 (1)

Spare parts for major overhaul - OPTION

11.59500-0225
11.59500-0323
501.006 Stud D = M10 6
L = 34 mm
0.017 kg
501.007 Lock washer pair d = 10.7 mm 6
0.005 kg
501.008 Hexagon nut d = M10 mm 6
0.012 kg
506.038 Seal D = 245 mm 2
0.040 kg
517.002 Thrust bearing D = 117 mm 1
0.851 kg
517.003 Bearing bush D = 42 mm 2
0.126 kg
2012-08-16 - de
TCR16-40
0287 595.02-03 EN-US 1 (2)


11.59500-0225
517.031 O-ring seal D = 172 mm 1
0.006 kg
517.038 Retaining ring D = 45.5 mm 2
0.005 kg
517.051 Hexagon bolt D = M6 6

L = 39 mm
0.008 kg
520.132 Piston ring D = 38 mm 1
0.003 kg
520.133 Piston ring D = 55 mm 1
0.007 kg
540.015 O-ring seal D = 220 mm 1

0.018 kg
517.018 O-ring seal D = 363 mm 1

2012-08-16 - de
0.030 kg
TCR16-40
2 (2) 0287 595.02-03 EN-US

Tools
11.59600-0221
8.1 Preface
8.3 Spare parts
8.6 Tools

2014-01-23 - de
0287-1 8.6-01 EN-US 1 (1)

Tools - OPTION
Tools
11.59600-0221
Turbocharger TCR16
11.59600-0221
Order no. Designation Sketch Data Quantity
(596.001) Hexagon pin L = 55 mm 1
544.063 Is located on the silencer or air 0.174 kg

or intake casing
545.063
596.002 Retainer L = 280 mm 1
0.940 kg
596.003 Hexagon pin L = 334 mm 1
0.440 kg
596.004 Spring plug L = 72.5 mm 1
0.020 kg
596.006 Closing cover D = 329 mm 1
4.200 kg
596.012 Pipe L = 172 mm 2

D = 38 mm
2014-01-21 - de
0.930 kg
TCR16
0287 596.01-01 EN-US 1 (2)

Order no. Designation Sketch Data Quantity

Tools
11.59600-0221
596.018 Forcing-off bolt L = 82 mm 3
0.084 kg
596.019 Forcing-off sleeve L = 70 mm 3
0.100 kg
596.025 Shackle D = 16 mm 2
0.310 kg
596.028 Foot H = 190 mm 1

W = 223 mm
3.700 kg
596.030 Hexagon nut d = M20 1
0.054 kg
596.036 Guide rod L = 80 mm 2

D = M6
0.017 kg
2014-01-21 - de
TCR16
2 (2) 0287 596.01-01 EN-US

MAN Diesel & Turbo
1 Safety
2 Addresses
3 Technical data
4 Description
5 Operation
6 Maintenance
7 Work cards
9 Index
2014-01-23 - de
Index
0287-1 9 C1-01 EN-US 1 (1)

MAN Diesel & Turbo
Index
A D
Addresses and contact persons 2.1 (1) Danger of Fire/Fire-extinguishing 5.0 (2)
Air intake casing 500.33 (2) Systems
Air intake casing, 90° 545.01 (1) Danger symbols 1.0 (2)
Air intake casing, axial 545.02 (1) Differences in height 4.2 (3)
Alarm points 3.1.1 (1) Diffuser 542.01 (1)
Alarm System 5.0 (3)
Arresting device for turbine rotor 500.45 (2) E
Emergency measures (in the event 5.2 (1)
B
of turbocharger failure)
Bans (symbols) 1.0 (2) Emergency operation with closing 500.11 (2)
Bearing casing 517.02 (1) device
Bearing parts 500.45 (4) Exhaust Gases 5.0 (2)
C F
Cartridge 500.44 (2) Fire-extinguishing Equipment 5.0 (2)
599.01 (1) Friction coefficient µ 7.2.1 (1)
Chamber silencer 544.02 (1) Fuel specifications 3.2.1 (2)
Characteristics (fuels) 3.2.1 (1) Fuels 3.2.1 (1)
Check Functional description
Bearing bush 500.45 (5) Lube oil system 4.2 (1)
Thrust bearing 500.45 (5) Functional description (turbo- 4.1 (2)
Checks during operation 5.1 (2) charger)
Cleaning
High-pressure 6.0 (3) G
Cleaning agents for compressor 3.2.4 (1) Gaps and clearances 7.2.2 (1)
and turbine Gas admission casing 500.47 (2)
Cleaning device for compressor
Pressure sprayer 579.02 (1) 500.47 (2)
Cleaning device for turbine 501.01 (1)
Dry cleaning 578.02 (1) Gas outlet casing 506.01 (1)
Wet cleaning 578.01 (1)
Cleaning system H
Dry cleaning of turbine 500.22 (2)
Hazard levels
Wet cleaning of compressor 500.23 (2)
Stufe 1 – 4 1.0 (1)
Wet cleaning of turbine 500.21 (2)
Hearing Protection 5.0 (1)
Cleaning the air filter 500.24 (1)
High-pressure cleaner 6.0 (3)
Compressor casing 546.02 (1)
Compressor wheel 500.45 (3)
Connections 3.1.2 (2) I
Containment safety 5.0 (1) Inclination
Cover Lube oil drain 4.2 (2)
compressor side 500.45 (3) Initial Starting of Operation (first) 5.1 (1)
Turbine side 500.45 (4) Insert
Covering compressor side 540.04 (1)
2014-01-23 - de
Bearing casing 591.05 (1) Turbine side 500.47 (2)

Compressor casing 591.06 (1)
541.01 (1)
Gas admission casing 591.01 (1)
Inspection of components (general) 6.5 (1)
Gas outlet casing 591.04 (1)
Inspection of individual compo- 6.5 (1)
Covering on the compressor cas- 500.42 (2)
nents (general)
ing
Intended Use 1.1 (2)
0287-1 C1-01 EN-US 1 (3)

MAN Diesel & Turbo
J R
Jet Assist acceleration system 4.3 (1) Read-out unit
Speed measuring 7.2.3 (2)
L Regulations for Prevention of Acci- 5.0 (1)
dents
Lock washer pairs Retaining ring 500.45 (3)
Assembly, general 6.4 (2) Rotor 520.01 (1)
Lube oil drain
Inclination 4.2 (2)
S
Lube oil system
Functional description 4.2 (1) Safety
Inclination of drain pipe 4.2 (2) during Maintenance/Repair 6.0 (1)
Venting 4.2 (2) during Operation 5.0 (1)
General safety instructions 1.0 (1)
M Safety Instruction
Caution 1.0 (1)
Maintenance Schedule 6.3 (1) Caution (material damage only) 1.0 (1)
Maintenance Work Danger 1.0 (1)
General Remarks 6.1 (1) Warning 1.0 (1)
Maintenance work Safety symbols 1.0 (2)
Remarks 6.4 (1) Screw connections
Loosening 6.4 (1)
N Lubricant 6.4 (2)
Numbering Special materials 6.4 (2)
Work cards 7.1.1 (1) Table of values 7.2.1 (1)
Tightening torques 7.2.1 (1)
Shutting down 5.1 (3)
O
Silencer 500.32 (2)
Operating faults (what to do in case 5.3 (1) Spare parts
of) General 6.0 (3)
Operating Media 3.2.1 (1) Order numbers 6.1 (1)
Operating parameters 3.1.1 (1) Special services/Repair work 6.1 (1)
Order numbers 7.1.1 (1) Speed measurement 7.2.3 (1)
Ordering spare parts 8.1.2 (1) Speed measuring device 562.01 (1)
Outlet casing 506.01 (1) Speed transmitter 7.2.3 (2)
Starting operation 5.1 (2)
P Starting the engine (preparatory 5.1 (2)
work)
Personnel
Qualification 1.1 (1)
T
General 7.1.1 (1) Tool number 7.1.1 (1)
Post lubrication 4.2 (3) Tools
Pressure sprayer 579.02 (1) Availability 7.1.1 (1)
Priming 4.2 (2) Inventory 7.1.1 (2)
Protective Covers 5.0 (2) Optional 7.1.1 (1)
Special 7.1.1 (2)
Q Standard 7.1.1 (1)
Torques
Qualification
2014-01-23 - de
Table of values 7.2.1 (1)

Personnel 1.1 (1) Turbine nozzle ring 513.01 (1)
Qualification of Personnel Turbine rotor 500.45 (4)
Maintenance/Repair 6.0 (1) Turbocharger
Ship systems 5.0 (3) Removal and refitting 500.31 (2)
Stationary systems 5.0 (4) Subassemblies 4.1 (2)
Type plate 3.1.1 (1)
2 (3) 0287-1 C1-01 EN-US

MAN Diesel & Turbo
V W
Venting Weights of subassemblies 3.1.2 (1)
Lube oil system 4.2 (2) 500 (2)
Work cards 6.1 (1)
2014-01-23 - de
0287-1 C1-01 EN-US 3 (3)

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MAN Diesel & Turbo

Turbocharger type ............................. TCR16-40

Translation of the original instructions

MAN Diesel & Turbo SE

Fax +49 (0) 821 322-49 4180

Copyright © 2014 MAN Diesel & Turbo

2 (2) 0287-1 C1-01 EN-US

6.1 General remarks

0287-1 C1-01 EN-US 1 (3)

6.4 Remarks on maintenance work

6.5 Inspection of components

8 Spare parts catalogue / tools

8.1.2 Ordering spare parts

2 (3) 0287-1 C1-01 EN-US

501.01 Gas admission casing

0287-1 C1-01 EN-US 3 (3)

0287-1 1 C1-01 EN-US 1 (1)

Organisation and use of the safety instructions

If the corresponding precautionary measures are not taken,

If the corresponding precautionary measures are not taken,

A hazardous situation can occur if the corresponding

Material damage to the product can occur if the corresponding

Additionally, the element Notice is also used:

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

Identification of special user tips.

Additional or important notes and information.

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

Wear Wear Wear Wear Wear

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

Crush hazard Inflammable Hot Danger of sus- Rotating

Fire, No access for

and smoking persons!

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

Figure 1: Safety instruction sign - engine room

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

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

Responsibility of the user

Risk of accidents resulting from improper use of the

The manufacturer disclaims all liability if the above-mentioned safety

The turbocharger is intended for use on diesel-fuel, heavy-fuel and gas

650°C (720°C only with special materials of turbine stage).

C1 0288 1.1-02 EN-US 1 (3)

turbocharger manufacturer. The turbocharger is not designed for operation in

▪ by the engine manufacturer:

▪ by the installation contractor / manufacturer of the complete plant:

Corrosion must be prevented on components that come into contact with an

washers, seals, etc.) may be used for repairs.

2 (3) C1 0288 1.1-02 EN-US

C1 0288 1.1-02 EN-US 3 (3)

0287-1 2 C1-01 EN-US 1 (1)

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

Fax +49 821 322 3998

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

PrimeServ Academy Tel. +49 821 322 1397

Worldwide service addresses

C1 6673 2.1-06 EN-US 1 (1)

0287-1 3 C1-01 EN-US 1 (1)

0287-1 3.1-01 EN-US 1 (1)

Operating data and alarm points

line) Reduction to engine half load (slow-down) < 0.8 bar