NJS

06.05.00
TURBOCHARGE R I
Mainten ance 135

MaK Mak Engines

turbocharger
principle, the mainten an ce of the BBC ins truct 1ons
In the BBC
out according to Appendix
13 to be carried mainten an ce included in the
Tor operation and
File. done withín
nce work to be operating
of the mainten an índicated
The fo ll owing is a lists che dule and after the
work
the scope of the
hours.

Operating hours
Work to be done

Cle aning the compress Or 25

to fuel
250-1000 according
quality and operating
Cle aning the turbine (only for
heavy fuel operation ) conditions.

500
Cle aning the air filter
be exten de d
E00. T.is perod can i t has
Be aring oil change (turbine and to 1000 hours if
compressor sides ) che cks that
been prove d by
the l uboil quality meets
the BBC requirement s .
Bearbeitet:

2500
Cle aning the cooling Water spaces
Gepruft: Cle an ing the luboil spaces 2500

Che cking the ge ar pumps

Sprache: (on ly for VTR 400-501) 16 ,000

Exchanging the rolling be arings See te chn ical data in

Engl. paragraph 01 of the BBC
instructions.

Nol Except ncleaning the turbine" (see 06.13.01) the instructions

BBC manual.
have to be taken from the

Instruct ions for emergen cy engine opertion with a defective

turbocharger can be found under 2.9.1 of the engine operating
instructions.

Ausgabe:
1-2.77

Druc

D6.05.00
 gas turbo-the
Changing riven supercharget
Hours of operation: 500

MaK Mak Engines

ings. After
roller be aroperation.
of the
SERVICING
operation change the luboilafter l00 hours of
of changed
Every S00 hours
bearing the luboil
must be
renewing a
according
oil chambers
Note an the
discoloured, clefollowing tities are
is oil quan
If the oil No. 06.06,02. The chambers (litres ) :
to job card both bearing
required for filling VTR 320/321
VTR 400/401
VTR 250/251
VTR 200/201 3.8
VTR 160 3.6
1.5
0.7 0.8

Sequence of operations
Lubricating isk on
and let
Unscrew oil drain plugs (1)
fine sieve
through a
the oil run off turbine side
through a clean
or, 1f necessary, the
cloth. Any sludge is caught in 3
sieve or cloth.
the bear ing
It is advisable to remove
cap (2) and examine it for any 2
loosen
adher ing sluage. To do this,
Srews (3). When replacing the cap,
Bearbeitet. ensure that the sealing (4) is not
amaged. Tighten up rain plugs T
fimly with new sealing ring. Through
the filler opening (5) pour in new oil
with a funnel until the maximum level
Geprúft:
is exactly between the markings (6)
(Red and white line). Then close the 6
filler opening tightly.
Sprache.
Engl. Caution
It is advisable to use a mineral acid
Thanes free turbine o1l. Bowever, 1t is
possible to use a good engine oil
wh ich has a kinematic viscosity at 5O°C Hollow shaft pump
of 0.3 to l.06 cu²s-l (30 to 106 cSt),
corresponding to an o1l with SAE 20, on compressor side
30, 40 for superchargers fitted with 3
a lubricating isk (WE), or of 0.3 to
o.76 cm²s-l (30 - 76 cSt), correspond
ing to an oil with SAE 20, 3o for
superchargers with a hollow shaft
pnp (WP).
Ausgabe 2
2-10.75

6
Fe

Druck NI,

alle Mot
06.0S.01
 chanbers 6f
drLyen superchaxger operation: 2,500
MaK Hours of

INSPECTION the coolfhg

ion inspect and clean, 1f necessary ,
2,500 hours of operat
Bvery chambers of the turbine housing.
water

the
Note
lock cap or screw and 1inspect
To carry out the inspection, r emove top necessarY"
chamber for sca les and clean, 1f
water
walls of the cooling
Sequence of operations
lows :
cleaning be undertaken as fol Technical
BBC recommends that should be used for cleaning and escal ing.kg£/cm has
50 hydrochloric acid2o/21° B with a specific gravity of 1.16 volume
comnercial acid of and must be d1luted with 6 parts by
36% by volume must be added to
a concentration of 1ron,an immunising agent
of water. TO protect the cast volume of Polyrad 110 A
(product of
O.l - o.2% by
this mixture, e.g. or 0.58 by volume of bone
glue.
Hercules Powder, Wilmington, USA)should be open so that any gas can escape.
top
The water outlet (N) at the to take effect for 2 - 6 hours depending on
The solution should be left to
the scales.Light tapping helps the scales
the nature and thickness of
rop off. chambers must be washed
socon as the acid is remov ed, the cooling water solution.
Bearbeitet: As rinse out with 5% soa
thoroughly with fresh water. Finally,

Caution
open, if possible, because of
Geprüft: Cleaning work should be carried out in the
For the same reason, there should be no open
the anger of explosion.
fire in enclosed spaces.
Sprache:
Engl.
Thames

N
N

Ausgabe:
2-10.75

N
Exhaust gas intake cap
Druck-Nr,:
Exhaust gas outlet cap
1l!e
.0tOrn
O6.06.01
 Checking the Luboil Chambers 138
Job Card No.: 06.06. 02
MaK of the Turbocharger
MaK Engines Hours of 0perat ion: 2500
See also j ob card No. 06.05.01.
INSPECTION
Check the lubo i l chambers for fouling every
It becomes necessary to cle an the oil 2,500 hours of operation.
severe ly discoloured. chambers if the luboil is

Note
Luboil chambers are cle aned with
mineral oil is adde d. Do not use paraffin
petrole um
oil to which 20 % cle an
risk of rusting and the spirit because of the
completely dry running. possibility of pitting as a r e s u l t of
Sequence of Operat ions
Drain off luboil to job card
and wash out the inside with No. 06.05.01. Remove bearing cover (4)
the seal air pass age 'X*, the paraffin oil, check the cle anness of
(1). The s ame checks must be balance ch amber 'z! an d the end screen
carried out on the compressor side.
Caution!
Fill up with luboil after cle an ing
is completed (see
06.05.01). job card No .
Note: The periods for changing the
presSure: bearings depend on the charging
BeloW 550 mm. Hg (740
Below 900 mm.Hg (1200 mbar): 16,000 hours
Over 900 mm. Hg (1200 mbar): 12,000 hours
The job card for mbar): 8,000 hours
renewing the
10,000 hours for all bearings, No. 06.07.01, indicates
engines.

2 3
21 3
 Removing the bearing mount ings
MaK WE, WP 2 (turbine side)

Mak Engines
Job card no. : 06.07.01

Hours of operation: l0,000

See also job cards no.:
06.05.0l, 06.06.02 , O6.07.o2
SERVICING
Change bearing mountings every 10, 000 hours of
operation.
Tools: BBC tool kit for
turbocharger

Note
Ensure absolute cleanliness.
Sequence of operations
Drain off oil at plug 5861.
screws 5037 and take Remove bearing cap 58. Remove locking wire on
out
bolt 5024 as it deteminesscrews
the
and cover plate 34. Do not take out quide
inlet under the oil correct position of the oil
level. Secure holding device l042 on scoop with the oi1
Loosen lock nut 2084 and shaft nut lubr icating isk 33.
extractor l020. Take out 2081. Remove lubricating disk with
zemove housing insert 5O9. bearing mounting with extractOr l020. Do not

Caution Ensure that the

must be wrapped in paraffinbearing mounting 38 does not
The BBC servicing paper in order to protect it fall
from
apart. It
contamination.
further work on thedepartments
Bearbeitet: are at your disposal for
turbo-driven technical advice and
supercharger.

Gepruft:
5024 1042 1130

Sprache
Engi.
Thanes 2081 2094
ham

5861
S037

Ausgabe:
2-10. 75

1042 10 20
1020

Druck-Nr.:

alle Mot
O6. 07.ol
 Fitting bearing mountings WE, WP2
(turbine side) Job card no. : 06.07.02
MaK Mak Engines Hors of operation: l0,000

See also job cards no. : 06.07.Ol, 06.05.Ol, 06. 1l.01

SERVICING

Tools: BBC tool kit for turbocharger

Note

The bearing cage must be cleaned with paraffin oil, to which 208 clean mineral
oil is added, before inserting the new bearing mounting. Do not use
petroleum spirit because of the risk of rusting.

Sequence of operations
Insert bearing Dounting 38. Mount lubrication disk 33 and firstly fizmly
tighten shaft nut 2081 until the bearing mounting rests against the shoulder
of the shaft. Then loosen and tighten slightly. Tighten lock nut 2084 firnly
Replace cover plate 34, tighten screws 5037 and secure with locking wire.
Fasten bearing cap 58. Fill up with oil.
Caution: Ensure that plug 5861 closes firnly. Fill up with oil to
specified mark.
Bearbeitet:

Geprüft:
33
33

1042
Sprache: 1042
Engl.
36
Thames

58
1042 1130

Ausgabe: 2081 2084

2-10.75

5861

Druck-Nr,:
s037
alle Mot
O6.07. 02
 Remov ing bearing mount ings WP 2, 06. 08.01
(compres sor side) Job card no.:
WP 21
MaK Mak Eng ines Hours of operation: 10,O00

06.05.0l, O6.08.02
See also job cards no. :

SERVICING
l0,000 hors of operation.
The bearing nount ings must be changed every
Tools: BBC tool kit for turbocharger

Note
Ensure absolute cleanliness.

Sequence of operations
l00sen
plugs 5681 and drain off oil. Remove bearing cap 78011,
Open oil rain intake
hexagonal-head screws 3306 and remove o1l COrrect
locking wire 3307, unscrew determines the
bolt 5024 because it
pipe 370. Do not take out quide hexagonal-head screws 3303, take
position of the oil intake pipe. Remove Place holding device l042P upside
3301.
away locking plate 3302 and nozzle Remove lock nut
bolt S024 and screw onto lubr icating disk 330.
down over guide Pull off lubricating disk 330
2084 and shaft nut 20811 with spanner l130. and extractor socket 1022P.
extractor l020
and insert ring 331 with bearing Do not unscrewW
out bearing nounting 32 with bearing extractor l020.
Take determines the axial play.
taper sleeve 7228 because it
E Bearbeitet: paper for protection against
Caution: Wrap removed parts in paraffin
contamination.
are at your isposal for technical
The BBC servicing departments turbo- riven supercharger.
adyice and further work on the
( Geprüt:
7801
3306 1130 3307
5891
! Sprache:
Engl. 3712 3T1
3302
20811
Thames

-3710

3303 2084 R
3301 1042P 5861
370

True-running check

Ausgabe: VTR l60 VYR 284 VTR 250 VTR 251 VTR 320/321 VTR 400/401
Type
)-10. 75 O-0.04 O-0.05 O-0.O5 O- O.06 0- 0.02
O- 0.03
R (m)

1022 P 330 331

1020 32 1020 1042 P E

Druck-Nr.

lle Mot.
o6.08.01
 Fitting bearing mountings WP 2,
WP 21 (compressor side) Job card no. : 06. 08.02
MaK Mak Engines Bours of operation: l0,000
See also job cards no. : O6.08.0l, O6.05.Ol, O6.11.Ol

SERVICING

Tools: BBC tool kit for turbocharger

Note

Clean bearing cage with paraffin oil, to which 2o% clean mineral oil is
added, before inserting the new bear ing mounting. Do not use petroleum spirit
because of the risk of rusting.
In the case of the bearing nounting which can only be
delivered with spare parts, the play in the axial and obtained
radial
complete and 1s
spring blocks and
the axial position of the double-row ball bearing
have been correctly adjusted
(aimension of the plate on the oil side in the bearing cap).
Sequence of operations:
Assembly takes place in the reverse
First, fimly tighten shaft nut 2081lsequence (see job card no.:06.O8.01) .
until the bearing mounting rests
against the shoulder. Then loosen and tighten
lock screws and nuts.
Measure
slightly. Finally, carefully
whether it cOresponds to the distance onon the
K compressOr side and compare
Tighten lock nut 2084 firmly. specification the plate in the bearing cap.
Mount bearing cap and fill up with clean oil.
Bearbeitet:
Caution: When fitting a replacement rotor the
as per job card no.06.11.01. imension K must be re-determined
Geprkft:

Sprache: 330
330
Engl. 1042P
104,2P 331
Thames
True-running check 331 32
Type VTR 160 VTR 200
VTR 250 VTR 321
VITR 251
320 VTR 401
R (mm) O-0.03 O-0.04 400
O-0.05 O-0.O5 0-0.06 0-0.02
3306 1130 78011
5891 3307
Ausgabe: 3712 3711 3302 "20811
2-10. 75
-3710

3303 2084
3301 1042P E R
370 5861

Druck-Nr,:
alle Mot.
06.08.02
 Removing and fitting
Job card no.: 06.10.0l
the rotor
MaK Hour s of operat ion: as
requ ired
Mak Engines

See also job card no.: 06.1l0.02 (11lustrations),

06.07.Ol, 06. 08.Ol, 06.11.ol

RECONDITIONING
As required, e.g. when shutting down the exhaust-gas turbo-dr iven suparchargar
the rotor must be removed.

Tools: BBC tool kit for turbocharger

Note
To renove the rotor the supercharger oes not have to be taken away fron the
engine. In the case of superchargers VIR 160, 200, 250 and 251, guide parts
are not necessar 1ly required because of the lower weights; the sequence of
operations is the same, however.
Sequence of operations
Removing
Remove exhaust silencer and air intake pipe. Remove bearing according to
job card no.06.07.01 and 06.O8.01. Push guide piece 1063 on to extension l054.
Connect extensions 1053 and l054 and screw on to the shaft end, compressor
side. Support extension l053 and push guide piece 1063 1nto the air intake
box and secure.
Bearbeitet:
Loosen air intake box (76) with forcing screws, take out and suspend from a
Crane. Unscrew extensions l053 and 1054 from the shaft and remove air intake
box. Tightly screw bush 1055 on the compressor side of the shaft end with
nut 2081 and suspend from a crane. Screw guide tube l052 on to the turbine
Geprkft: side of the shaft end. Fasten guide plate l062 on the bOx flange and attach
extension 1053.
Push rotor on to compressor side until 1t rests against the
bush 704. If the baffle (702) oes not go along with 1t, shaft quard
Sprache: 1t must be loosened
from the gas exhaust box (60) by forcing screws.
Push out rotor
Engl. and support shaft end on compressor side. Suspend rotor on the completely
bush (704), unscrew guide tubes l052 and 1053 and move out shaft guard
Cheek cut-off alr passage X (see rotor.
Thames
Aluminum liners 2 and 3must fit 11lustration 1n O6.06.02); it shoula be clean.
tightly 1n the casing and the sealing grooves
mMst be undamaged and free of dirt.

Fitting
Serew on guide tubes l052 and l053 and
bush (704). Push in rotor suspend rotor on the sha ft nara
completely.
tube 1052 on the turbine side of the Remove extension l053 anâ uia
box. Replace air intake box.
shaft end and guide plate l062 on
tho
Replace exhaust silencer and air intake
Caution pipe.
Ausgabe: A
Cy1indrincal
intake box (60O).
pin is used to fix the
position of the
2-10. 75 baffle (702) in the gas

Druck Nr.
Ille Mot .
I6. 10.01
 Removing and f1tting 06. l0.02
14/
the rotor Job card no. :
MaK ror Hak Engines
as
Hours of operation: required

See also job card no. : 06.10.0l

~ 50kg
1062 1055
1063 76 77 1054 702 704

Dermontage 1053

Disnantling

Montage
Fitting
~ 40kg

30 60 50 1052 1062 1053

1055

25
26
2081 20

Bearbeitet:
1042A07143
10745

Geprüft:
~80 kg

1055 1052 1062 1053

Sprache:
Engl.
Th¡mes
Dernontage
Dismantling
K
Montage
Fitting
1055 1063
Ausgabe: 1052
2-10.75
1451

1053

1062
Druck-Nr,: 1054

..0tuen
O6.10.02
O6.08.OZ
 06.11.01
Turbocharger Clearance S No.:
Mak (VTR 320)
Mak M 451 /452/4 53 AK
Jot card
Operating Hoursi 44
as required
See also job cards o.
IN SPECTION 06.07.022, 06.08.02, 06.10.01.

Cneck 1ng t he cle arances is

rene wed. necessar only when parts have Dee

VTR 320

071-130
013-112.

Bearbeitet:

-K
K2
Geprüt:
M

Sprache:
Engl.
Nolte

Rie0355
49,9s-os
a5-0s
556 T-0.30
a375
S"03-44

1026 102 R-O6-07

Q-030-035

5563
Ausgabe: N
625-0.725
1-8.72
O" 0,5-06

Druck-Nr.:
M 451/
a52 / 5 3
06.11.01
 Turbocharger Cle arances Job Card No.: O6.11.11
(VTR 250/251)
MaK Mak 45 1/452 /453 AK
Operating Hours:
as required

See also job cards No. 06.07.02, 06.08.02, 06.10.01.

INSPECTION
Checking the cle arances is necessary only when parts have been
rene wed.

VIR 250/251

6-10

Bearbeitet: 5mm
ca

LoK-K1 MeK2-K
Geprkft:

Sprache:
Engl.
Nolte
4128
40204
50+&os
84,4:os
D45-060,
T030035
S-as0-435
RaO,48-055
42,6:006
42os
Ausgabe:
1-8.72
4010) 35-04 P0,30-0.35
41:9 Nneastat
O045-0,60

Druck-Nr,:
M 45 1/
452 /453
O6,11.11
 Stopping the exhaust-gas turbo
MaK driven super charger
or Ln,:ines
Job card no, : 06.12.01
Hours of operation: as
required
See al so job cards no.: 06.07.Ol, O6.08.0l, o6.10. Ol

RECONDITIONING (emergency operation)

In certain circumstances the Diesel engine must continue to oper ate despite a
damaged turbo-driven supercharger . For this, the rotor must be changed.
Tools: See job card no. 06.l0.01. The closing tool is supplied
as a special-purpose tool on the customer's request,
although it can be made with equipment on board.

Note
To renove the rotor the engine 9106 9107 9117 9100
must be stopped.

Sequence of operations
Removíng the bearing on the
compressor and turbine sides
(see job cards 06.07.01 and
06.08.Ol). Removing the rotor
(see job card o6.10.01).
The openings produced must be
closed with the closing tool.
The two pull rods 9100 and 910l
are sCrewed together with the
Bearbeitet: inner cover plate 9102 and
fastened to the cover 9106 on
the turbine side.
Tighten
mt 9l07 until the clamping
Geprkft: iscs 9117 are pressed flat.
P1t cover plate 9l105 on
cOmpressor side and tighten
nut 9107 until the 4
Sprache:
iscs 9103 are pressed clamping
Bngl. £lat.
The cooling water must be shut
Thames off only 1f severe
should appear in theleakage
casing on the gas sideturbine
which
could endanger operation of
the engine.
The rotor oes not need to be
renOved 1f
ava1lable. blocking evices are
Pirstly, the rotor
Rust be blocked on
s1de after removing thethecompressOr 9102 9101 9107 9103 9105
DOuntings. I£ higher nan bear ing
Ausgabe: effective
5 bars (5 pressur es than around
kg/ cn) are
operation,anticipated
2-10.75 in nrgency
POSBible on engines which is
with
be blocked on to
also,st
r iven the turbo-iven
turbine side. superchargers, the damaged
superchargers,
be sealed the
with a blank 21ange
On engines with
conpr essor outlet of the 2 supercharger,
exchaust-gas turbo
£ron ascaping. After
each
to prevent damaged
the charge air supercharger must also
on th turblne
side must beblocking operation on the from other super
Bupercharger , Sect on 2 9 of replaced. CAUION In the compressor chargers
side the bearing
of the
Druck-Nr,: the
engine ia operat lon) Part engine operating case of a damaged
alle
must be followed implicitly. lnstructlons
"Energency operation with (supervision
damaged
Iiotoren
06.12.0l
supercharger" ,
 06.13.01
TURBO CHARGER
Side and
Cleaning the Turbine |250-1000 h, to fuel quality
operating conditions.
MaK Mak Engines

SERVICING

Note
running on he avy fue l, deposi ts will forn on the
If the engine isdecreasing the charger effi ciency and in cre asing the
turbine blades inject -
dep os its must be removed by
bearing loads by unbal an ce. These of detergents or solvents ).
ing fresh water (without ad dition
The washing intervals de pend on the fue l quality and operat ing condi
tions, and they can be fixed on ly be experien ce in operation .
Sequence of Operations
1. Connect the clean ing pipes (5) with the water s upply by the
disconnect ab le hose (2) and cock (3).
2. Reduce the engine output until the turbocharger speed isS as
indicated below . If there is no tach ome ter at h and, set the
engine at minimum speed. The exhaust gas temperature before
turbine must be below 300°C.

Rater pressure:
1 bar (1 kg/cm)
Type VTR
R.P.M. 250/25S1
5000
320/321 400/401 500/501 630/631
Water 4000 3200
eitet: 5 2500 2000
8
1itres/minute 12 19 30
3. Open drain valve (4) and
sft:
If the
the exhpipiag is clogge d, make sure that the piping is
aust manifold. water might pass into the free.
che: 4. Open the
cocks (1)
engine by
re ducer) and and (3)
gl. (30-40 % of theche ck the water(water
quan pressure set at 1
minutes. injected quant ity tity bar by a
). flowing out of the dpain
Washing time approx. 10
lte 5. After
inject ing
minutes at the samethe water run
load untilthe
allengine
Caution parts for
are about
dry, three
It must be
the avoided at any r ate that
Removeexhaust
hose manifold
(2) alw aysbetween the water
after W Washing enters
Auspabe: ashing. operat ions,
2-2.77 5 2
3

Dri
6.13.O1
 Cle aning the Blower Side
Job Card No.: 06. 14.01
MaK of the Turbocharger
MaK Eng ines Hours of 0peration: 24
449

SERVICING
The blower side of the turbocharger should be clean ed
every day.
Tools: Clean ing in jector No. 1.9171
Note
A fine sticky dust settles on the interior parts of
the turbocharger
Which are in contact with the air, and this great ly reduces the
Output of the blower.
Sequence of Operat ions
l. Cle an ing injector: Fill the iniector with water and hold it at
cleaning pipe of the charger. Open the stop cock and inject the the
contents continuous ly (see table ). Then close the stop cock again .
2 . Me asuring cup (installed ) : Fill the cup with
water an d
Pres the button, which opens a valve so that the chargeclose it.
presSure
air
forces the water on to the impeller.
Caution!
The water should be injected when the engine has
its
rature an d operates under full load, this means, the running tempe
turbocharger
speed is high. After cleaning the blower side , the engine
continue to run under load for about 10 should
minutes at least.
Bearbeitet: The success of clean ing can be seen by the
exhaust gas te mperatures. If no success can charge air pressure or
be detected, cle aning
should not be repeated earlier than after 10 minutes.
Admissible quantity of water:
Gepruft: For VTR 160, 200 0.25 litre
For VTR 250, 251, 320, 321 0.5 1itre
For VTR 400, 401 500, 501 1.0 1itre
Sprache: For VTR 630, 631 2.5 1itres
G
Engl.
E
37°30
VTR
160,200,250,
25T.
G
80631
VTR400,401 201
VTR
630.
250,251 VTR
321
VTR
3

Ausgabe:
2-10. 75
VIR 200,
321
320,
160
22°30
VT EF GH VTR
160 7 150
200 10175
250 15 213 1.9171
75337
90 578
500 95 a
Druck-Nr.:
alle Mot
O6.14.01