Operating Instructions

ST3 Exhaust Gas Turbocharger

OPERATING and
MOUNTING INSTRUCTIONS
for
EXHAUST GAS
TURBOCHARGER

ST3

Kompressorenbau Bannewitz GmbH

Windbergstraße 45
01728 Bannewitz
Federal Republic of Germany

Phone: +49 (351) 40 85 603 (Sales)

+49 (351) 40 85 669 (Service)
+49 (172) 35 16 045 (24-hour phone)
Fax: +49 (351) 40 85 648 (Service)

E-Mail: service-24/[email protected]
Homepage: www.kbb-turbo.de

(In the appendix, you can find a list of service stations.)

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Issued: 06/2015 Scholze Checked: S. Käseberg Released: K. Buchmann
 Operating Instructions
ST3 Exhaust Gas Turbocharger

Name plate

Each exhaust gas turbocharger is characterized by specifying the type, the specification
number and the serial number. This can be taken from the name plate. The name plate is
affixed at the side of the bearing casing of the exhaust gas turbocharger.
For all spare part inquiries, requests and orders the:
• TC type (Type)
• Specification No. (Spec.)
• Serial No. (Serial)

must be specified. Only if these data are known, the request can be handled properly and
promptly.

Exclusion of warranty claims

Any damage which results from
• poor maintenance,
• improper handling and/or the disregard of the operating instructions in this
instruction manual,
• the attachment of additional parts to the exhaust-gas turbocharger by third party or,
• the usage of non-original spare parts is excluded from warranty and liability.

Furthermore, the warranty and liability is excluded in any kind of interventions by

unauthorized persons during the warranty period.
These include particularly:
• the disassembly of any exhaust-gas turbocharger components,
• repair and maintenance work which requires the disassembly of exhaust-gas
turbocharger components,
• the replacement of parts which requires the disassembly of exhaust-gas
turbocharger components.

Exceptions
Exceptions apply to the replacement / removal of the entire exhaust-gas turbocharger, the
speed sensor, silencer filter mats, the entire silencer and the exhaust-gas elbow.
The manufacturer of the exhaust-gas turbocharger may give its consent to other exceptions
on request but these are always subject to the written approval of Kompressorenbau
Bannewitz GmbH.
Authorised persons
Authorised persons are employees of Kompressorenbau Bannewitz GmbH as well as
employees of authorised service workshops (see Appendix / Chapter 9) who have been
trained by Kompressorenbau Bannewitz GmbH.

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 Operating Instructions
ST3 Exhaust Gas Turbocharger Contents

Table of Contents
Chapter Title Page

1 TECHNICAL DATA ...................................................................... 5

1.1 Operating data ...............................................................................................5
1.2 Alarm values ..................................................................................................6
1.3 Dimensions ....................................................................................................6
1.4 Test connections ...........................................................................................7
1.5 Weights of important components ...............................................................7
1.6 Vibrations .......................................................................................................8
2 SAFETY ....................................................................................... 9
2.1 Built-in safety systems ..................................................................................9
2.2 Safety measures (to be taken by user) ........................................................9
2.3 Declaration of incorporation ....................................................................... 10
3 GENERAL INFORMATION ABOUT DANGER .......................... 11
3.1 Danger zone ................................................................................................. 11
3.2 Operators and maintenance personnel ..................................................... 11
3.3 Installation of spare and wear parts ........................................................... 12
4 DESIGN ...................................................................................... 13
4.1 Brief description .......................................................................................... 13
4.2 Construction ................................................................................................ 13
4.3 Function........................................................................................................ 13
4.4 Usage to the intended purpose .................................................................. 13
5 OPERATION .............................................................................. 14
5.1 Commissioning ............................................................................................ 14
5.2 Starting-up.................................................................................................... 14
5.3 Stopping ....................................................................................................... 15
5.4 Failures ......................................................................................................... 15
5.5 Emergency operation of the exhaust gas turbocharger........................... 15
5.6 Measures for extended period without operation ..................................... 16
6 MAINTENANCE ......................................................................... 17
6.1 General ......................................................................................................... 17
6.2 Maintenance work ........................................................................................ 17
6.3 Cleaning........................................................................................................ 18
6.4 Maintenance schedule................................................................................. 19
6.4.1 Maintenance for operation with Marine Diesel Oil (MDO) .............................. 19
6.4.2 Maintenance for operation with Heavy Fuel Oil (HFO) .................................. 20
6.5 Trouble-shooting table ................................................................................ 22

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 Operating Instructions
Contents ST3 Exhaust Gas Turbocharger
7 DISASSEMBLY AND ASSEMBLY ............................................ 23
7.1 Introduction ................................................................................................. 23
7.2 Checking the components ......................................................................... 23
7.3 Checking the clearances ............................................................................ 24
7.4 Work sheets................................................................................................. 26
7.4.1 Compressor washing .................................................................................... 26
7.4.2 Turbine washing............................................................................................ 27
7.4.3 Cleaning the silencer .................................................................................... 30
7.4.4 Shutting down the exhaust gas turbocharger ................................................ 31
7.4.5 Disassembly of the complete turbocharger ................................................... 32
7.4.6 Assembly of the complete turbocharger ........................................................ 33
7.4.7 Assembly and disassembly of the silencer or air-intake bend ....................... 34
7.4.8 Assembly and disassembly of the compressor casing .................................. 35
7.4.9 Disassembly and assembly of the cartridge .................................................. 36
7.4.10 Disassembly of the exhaust-gas elbow ......................................................... 37
8 SPARE PARTS AND TOOLS .................................................... 38
8.1 General......................................................................................................... 38
8.2 Spare parts .................................................................................................. 39
8.2.1 Exhaust gas turbocharger, complete (1000) ................................................. 39
8.2.2 Exhaust gas turbocharger, basic unit (1100)................................................. 40
8.2.3 Turbine casing complete ............................................................................... 41
8.2.4 Compressor casing complete........................................................................ 42
8.2.5 Gaskets and shims (9910) ............................................................................ 43
8.2.6 Connection elements (9921) ......................................................................... 44
8.2.7 Connection elements (9930) ......................................................................... 45
8.2.8 Connection elements (9931) ......................................................................... 46
8.3 Tools ............................................................................................................ 46
8.3.1 Tool set (9700) .............................................................................................. 46
8.3.2 Optional Tools ............................................................................................... 48
9 APPENDIX ................................................................................. 49

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 Operating Instructions
ST3 Exhaust Gas Turbocharger Chapter 1

1 TECHNICAL DATA

1.1 Operating data

Specification 730xxxx
see name
Max. speed (n max)
plate
Max. exhaust gas temperature upstream of turbine (t max)

Lubricating oil
Types of lubricating oil: engine oil with a kinematic viscosity of 110 ... 140 mm²/s
at 40 °C, e.g. SAE30, SAE40
Nominal oil filter fineness upstream of TC max. 25 µm
Lubricating oil pressure upstream of TC 300 + 150 kPa
Admissible lubricating oil pressures for special operating states
at start-up min. 50 kPa
from start-up to idle running min. 50 kPa
at standstill (prelubrication or relubrication/standby mode) see diagram below
Lubricating oil temperature upstream of TC 40 ... 105 °C
Lubricating oil temperature downstream of TC max. 120 °C
Lubricating oil flow (60°C, 300kPa) max. 28 l/min
Sound pressure level (measured by the silencer/compressor 106 dB(A)
casing, at 1m distance, 92% of max. speed accordingly 100%
engine power)
Counter-pressure downstream of turbine max. 2.5 kPa(g)
Underpressure upstream of compressor max. 1.5 kPa(g)

p oil
(kPa)

t oil (oC)
Admissible lubricating oil pressure for continuous pre- and re-
lubrication (standby operation)

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 Operating Instructions
Chapter 1 ST3 Exhaust Gas Turbocharger

1.2 Alarm values

Measurement Alarm value

TC speed 0.97 * n max
Exhaust gas temperature before turbine t max – 15K
Lubricating oil outlet temperature of TC < 120 °C
Lubricating oil pressure before TC > 125 kPa (1.25 bar)

If alarm values are adapted accordingly to the engine data, the values specified above
are not to be exceeded and/or be fallen below in the case of lubricating oil pressure!
The maximum speed and the maximum exhaust gas temperature before turbine are
indicated on the name plate and the test certificate!

1.3 Dimensions

F All dimensions are specified in mm!

Length max. 930mm

Width (depend on the casing position) max. 425mm
Height (depend on the casing position) max. 449mm

Exhaust gas Inlet single-nozzle casing 1x Ø 105 mm

Inlet double-nozzle casing 2x Ø 70 mm
Outlet Ø 205 mm
Charge air Outlet Ø 120 mm
Cooling compressor * Inlet 2 x M18 x 1.5
Jet Assist * Inlet 1 x M26 x 1.5
Lubricating oil Inlet at bearing casing Ø 10 mm
Outlet at bearing casing Ø 32 mm
Compressor washing Air piping M18 x 1.5
Water piping M16 x 1.5
Turbine washing Water piping M18x1.5
Drainage G1”

* It might vary depending on turbo specification

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 Operating Instructions
ST3 Exhaust Gas Turbocharger Chapter 1

F The piping for the pipe connections listed is not included in the scope of supply of
Kompressorenbau Bannewitz GmbH.

Pipes have always to be laid free of stress.

1.4 Test connections

The turbocharger (TC) is equipped with the following test connections which can be used as
required.
• There are two threads each (M18x1.5) provided at the intake bend, compressor
casing and turbine-inlet casing and at the exhaust-gas elbow for measuring the
temperature and pressure.
• For measuring the speed, the bearing casing can be equipped with a speed sensor.

1.5 Weights of important components

(The indicated masses vary according to the turbocharged variants and provide guidance
for any necessary installation tools)
Designation Part No. Mass
Exhaust gas Turbocharger, complete * (1000) approx. 161 kg
(=1100+9100+9010)
Exhaust gas turbocharger, basic unit (1100) approx. 114 kg
Cartridge (1200) approx. 39 kg
Turbine casing complete approx. 38 kg
Turbine casing (5010) approx. 29 kg
Insert, turbine casing (5020) approx. 6 kg
Containment ring (5220) approx. 2 kg
Compressor casing complete approx. 34 kg
Compressor casing (6010) approx. 24 kg
Insert, compressor casing (6040) approx. 8 kg
Turbine nozzle ring (7010) approx. 3 kg
Compressor diffuser (8010) approx. 2 kg
Exhaust gas elbow (9100) approx. 22 kg
Sealing device (9704) approx. 8 kg
Silencer (9010) approx. 22 kg
Air intake bend (9020) approx. 7 kg
Air inlet flange (9025) approx. 4 kg
Containment shield (5210) approx. 6 kg

* Basic unit including silencer and exhaust-gas elbow (see name plate) without insulation.

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 Operating Instructions
Chapter 1 ST3 Exhaust Gas Turbocharger

1.6 Vibrations

Maximum admissible vibration load at engine for 10 ... 250 Hz :

Admissible value at TC (at place LG) at silencer (at place SD)

Velocity VRMS (mm/s) max. 45 mm/s max. 71 mm/s
Amplitude SRMS mm max. 0,7 mm max. 1,1 mm
Acceleration aRMS (m/s²) max. 70 m/s² max. 111 m/s²

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 Operating Instructions
ST3 Exhaust Gas Turbocharger Chapter 2

2 SAFETY
The exhaust gas turbocharger is an incomplete machine and has been designed on the
basis of the following standards and regulations:
1. Machinery directive 2006/42/EC
2. Risk assessment and evaluation for ISO 14121-1

2.1 Built-in safety systems

• A safety system for the turbocharger is not necessary as its design and connection
with the engine to which it is attached require an inherent safety.
• For general speed monitoring, the turbocharger can be equipped with a tachometer.

Assembly and disassembly work must not be done during operation.

See chapters 7.4.1 and 7.4.2 for maintenance and cleaning jobs which may be done
while the engine is running.

2.2 Safety measures (to be taken by user)

• These operating instructions are part of the exhaust gas turbocharger and shall be
always accessible for the operators and maintenance personnel.
• The operating instructions should be read before commissioning the turbocharger.
Particular attention should be paid to directions and information relating to dangers.
The user is required:
• to make his operators and maintenance personnel familiar with safe working
methods
• to supervise the observance of the safety regulations.

The individual jobs in these instructions are described such that they can be understood by
skilled workers.
The necessary tools and testing/inspection means must be made available to these
workers.
The user must obtain permission to operate the unit from the local authorities and observe
the following:
1. labour safety
2. cleaning and maintenance of the machines
3. product disposal
4. environmental protection

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 Operating Instructions
Chapter 2 ST3 Exhaust Gas Turbocharger

2.3 Declaration of incorporation

In accordance with Directive 2006/42/EC, Annex II, part 1, section B
Manufacturer : Kompressorenbau Bannewitz GmbH
Windbergstraße 45
01728 Bannewitz,
Federal Republic of Germany
Product : Exhaust turbocharger
Type, specification , serial no. see name plate
The head of the engineering department, Klaus Buchmann, Windbergstraße 45, 01728
Bannewitz, is authorized to compile all the special documents in accordance with Annex VII
B.
The exhaust turbocharger is defined as a partly completed machinery in accordance with
article 2g and intended to be assembled to a combustion engine only. The special technical
documents in accordance with Annex II B were compiled and in response to a reasonable
request of a national authority transmitted on an electronic base.
The exhaust turbocharger must not put into service until the final machinery into which is it
to be incorporated has been declared in conformity with the provisions of this Directive.
Ingolf Ulbricht
Corporate Quality

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 Operating Instructions
ST3 Exhaust Gas Turbocharger Chapter 3

3 GENERAL INFORMATION ABOUT DANGER

3.1 Danger zone

The danger zone is defined by the engine as the turbocharger is an integral part of the
engine.

F During turbocharger operation, the user must keep the danger zone free of any
objects so to ensure unhindered access to the unit.

Ear muffs should be worn as the sound level is high!

Care should also be taken when approaching the hot casings!

• The exhaust gas turbocharger is mounted on the engine. It may not be interfered
with when the engine is running.
• Make sure the exhaust gas pipes at the turbine side cannot come loose during
operation since exhaust gas might escape at this point.
• As the exhaust gas turbocharger is an integral part of the engine, its operation is
described in connection with the engine. However, its maintenance is described
separately in the operating instructions.

3.2 Operators and maintenance personnel

Operators and maintenance personnel are persons who are responsible for transport,
installation, operation, maintenance, cleaning and troubleshooting.
Make sure to observe the following accident prevention regulations:
• winches, hoisting and drawing gear (BGV D 8)
• load take-up devices for hoisting operations (BGR 500 chapter 2.8)
If these regulations are not observed, your life and limb may be endangered!
1. The turbocharger may only be maintained by duly qualified and authorised persons.
2. In maintaining the turbocharger, the responsibilities shall be clearly defined and
must be adhered to so as to prevent confusing competences with respect to the
safety aspect.
3. The operating instructions shall be followed irrespective of what kind of work
(operation, maintenance, etc.) is concerned.
4. In order to ensure a long service life, the exhaust gas turbocharger has to be
operated in accordance with the technical specification.
5. Operators are not allowed to interfere with the unit in a way that would affect
machine safety.
6. It is also within the responsibility of the operator to see to it that no unauthorized
person works on the turbocharger.
7. The operator must inform the owner without delay of any safety-affecting changes to
the turbocharger.
8. The cleaning, maintenance described in these instructions are easy to understand
by persons skilled in mechanical, cleaning and maintenance work. The necessary
tools and testing/inspection means must be available to these persons.

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 Operating Instructions
Chapter 3 ST3 Exhaust Gas Turbocharger
3.3 Installation of spare and wear parts
It is emphasised that spare parts and accessories not supplied by us are not
tested/inspected and approved by us. The installation and use of such products may
negatively affect the performance of your turbocharger. We assume no liability for damage
caused by the use of components and accessories not made by us.
For ordering spare parts and tools, please refer to the
• spare parts list
• tools list.

The spare parts lists attached (see chapter 8.2) contain all spare parts for the turbocharger.
For the maintenance and commissioning of the turbocharger, refer to the respective
chapters in these operating instructions.

Before doing any maintenance, cleaning or repair work, the engine must have come to
a standstill. Therefore turn the engine off and secure it against unintentional re-
starting.
See chapters 7.4.1 and 7.4.2 for maintenance jobs which can be done during engine
operation.
Make sure to observe the following accident prevention regulations:
• winches, hoisting and drawing gear (BGV D 8)
• load take-up devices for hoisting operations (BGR 500 chapter 2.8).
If these regulations are not observed, your life and limb may be endangered!

F See the inspection schedule (see chapter 6.4) for the maintenance intervals.

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 Operating Instructions
ST3 Exhaust Gas Turbocharger Chapter 4

4 DESIGN

4.1 Brief description

Exhaust gas turbocharger (TC): Type ST3
Specification number: 730xxxx
Mass : 161 kg

4.2 Construction
The exhaust gas turbocharger (TC) ST3 is equipped with a single-stage radial flow turbine
and a single-stage radial flow compressor.
The turbine wheel and the shaft consist of one part, the compressor impeller is mounted on
the shaft. The rotor has a bearing consisting of two plain bearings in a bearing casing. The
compressor casing and the turbine casing are flanged to the bearing casing. You can use a
silencer or alternatively an intake bend (intake elbow) at the entrance of the compressor
casing.
The plain bearings are lubricated by the lubricating oil system of the engine. The lubricating
oil flow depends on the oil temperature, oil pressure and TC speed.

4.3 Function
The rotor is driven by the exhaust-gas energy of the diesel engine. The exhaust gases
reach the turbine wheel via the turbine casing and the turbine nozzle ring.
The compressor impeller mounted on the same shaft takes in the required combustion air
via a silencer, compresses the air to a higher pressure and transports the compressed air to
the engine via a charge air cooler.
The TC is not equipped with a special control device. The TC speed is adjusted depending
on the operating conditions of the engine.

4.4 Usage to the intended purpose

The exhaust gas turbocharger is intended for supercharging combustion engines. Any other
usage is not permitted and has to be cleared up with Kompressorenbau Bannewitz GmbH
(KBB) in advance.
The TC specification attached to the engine is thermodynamically adjusted and is binding
for this engine variant, i.e. if the TC has to be replaced, use the same TC specification
again.
Modifications and additional attachments to the TC are subject to a written consent of
Kompressorenbau Bannewitz GmbH, non-observance of the aforementioned invalidates
any rights of warranty claim.
The usage to the intended purpose also includes that the specified maintenance and
inspection work is carried out regularly and to the full extent (see Chapter 6.4).

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 Operating Instructions
Chapter 5 ST3 Exhaust Gas Turbocharger

5 OPERATION

5.1 Commissioning
Prior to commissioning, it is imperative to make sure that the plain bearings of the TC are
supplied with oil. The plain bearings are lubricated by the lubricating oil system of the
engine. The lubricating oil flow depends on the oil temperature, oil pressure and TC speed.
The lubricating oil pressures required for special operating conditions are listed in chapter
1.1.
Ensure and check the free return flow of the lubricating oil.
The following has to be checked :
• lubricating oil pressure upstream of TC,
• lubricating oil temperature upstream of TC.

Ensure the lubricating oil supply of the plain bearings (see chapter 1.1).
Lubrication has to be started prior to start-up processes.
Pay special attention to prevent leakages in the oil supply and return pipes to prevent
oil from flowing onto the hot, gas-carrying casings in order to prevent the formation of
hazardous oil vapours (and fire risk).

5.2 Starting-up
The exhaust gas turbocharger is driven by the exhaust gases of the engine and is started
together with the engine.
The TC speed is adjusted depending on the operating conditions of the engine. The charge
air pressure required for the engine is fixed by adjusting the turbine nozzle ring and the
compressor diffuser during the TC tuning.
If the corresponding meters are available, enter the following measured values into the
engine log during engine operation (at least once every 24 operating hours):
• Speed of exhaust gas turbocharger
• Exhaust gas temperature upstream of turbine or downstream of cylinder
• Charge air temperature downstream of compressor or downstream of charge air
cooler
• Charge air pressure downstream of compressor
• Lubricating oil temperature upstream of TC
• Lubricating oil pressure upstream of TC
The engine has to be stopped immediately when the oil pressure falls below the
minimum value.
Lubrication has to be started prior to start-up processes.
Pay special attention to prevent leakages in the oil supply and return pipes to prevent
oil from flowing onto the hot, gas-carrying casings in order to prevent the formation of
hazardous oil vapours (and fire risk).

Additionally perform the following checks at regular intervals :

• Tightness of the exhaust gas, charge air and oil piping
• Smooth running of the exhaust gas turbocharger

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 Operating Instructions
ST3 Exhaust Gas Turbocharger Chapter 5

The charge air pressure is utilised as a parameter for the exhaust gas turbocharger speed.
Unsteady operation (vibration of TC) indicates an increased unbalance of rotating parts
possibly resulting in the rotor or bearing being damaged (see chapter 6.5).

5.3 Stopping
After the engine has been stopped, the exhaust gas turbocharger continues to run for some
time.
The run out period depends on the installation.
If the rotor comes to an immediate standstill, this can be caused by one of the following
reasons:
• damaged bearings
• compressor impeller or turbine blades come in contact with the casing as the
clearance is compensated due to extensive forces caused by thermal distortion
• clamped foreign matters

F
The turbocharger must be lubricated 15 minutes after the engine is turned off.
The lubricating time is to be extended in case of engines with a turbine inlet
temperature >580°C (at full load) or oil inlet temperature >80°C.
Pay attention to the operating instructions of the engine manufacturer.

5.4 Failures
Failures can be detected by abnormal measured values (exhaust gas temperature, charge
air pressure, speed), heavy noise or leakages of pipes.
In case of irregularities on the TC, reduce the engine load or stop the engine.
Since even minor failures may cause heavy consequential damage, determine and
immediately eliminate the cause of failure (see chapter 6.5)

5.5 Emergency operation of the exhaust gas turbocharger

If the exhaust gas turbocharger has to be shut down due to a defect and the engine has to
run in emergency operating mode, perform the work according to chapter 7.4.4.
After shutting down the exhaust gas turbocharger, limit the engine output in order to
prevent the exhaust gas temperature from exceeding admissible values downstream
of the outlet cylinder.
Pay attention to the operating instructions of the engine manufacturer.

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 Operating Instructions
Chapter 5 ST3 Exhaust Gas Turbocharger

5.6 Measures for extended period without operation

When shutting down an exhaust gas turbocharger, which was operated with an engine
before, for more than twelve month, it has to be dismounted from the engine.
An inspection should be carried by authorized service centres out in accordance with the
maintenance schedule in chapter 6.4.
It is necessary to completely dismantle the exhaust gas turbocharger. All components are to
be cleaned and slightly rubbed with oil. Then the exhaust gas turbocharger can be
reassembled. All machined surfaces and flanges are to be evenly coated with an
anticorrosive agent (such as Tectyl). All openings should be sealed. Additionally, a
hygroscopic drying agent can be put into the interior spaces of the compressor casing and
the turbine inlet.
The preserved exhaust gas turbochargers and spare parts should be kept in a dry room
(humidity of 60 % max.) and protected from moisture, aggressive gases and vapours. At
rest, the exhaust gas turbocharger should be protected against steady vibration which may
damage the bearings.
The state of the preserved parts and exhaust gas turbochargers should be checked every
twelve months.
Before re-operating the exhaust gas turbocharger, it is necessary to clean off the
anticorrosive agent.

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 Operating Instructions
ST3 Exhaust Gas Turbocharger Chapter 6

6 MAINTENANCE

6.1 General
Maintenance and monitoring work is summarised in the maintenance schedule in chapter
6.4.
Proper maintenance work enables failures to be detected in time. Maintenance work also
indicates necessary overhauls as well as work to be scheduled during yard or harbour times
or on interruptions.
The operating hours specified in the maintenance schedule are to be considered as
benchmarks. They can be shortened according to existing operating conditions as well as
adjusted to the maintenance intervals of the engine.
It is important to eliminate even minor, apparently insignificant defects immediately and to
determine and eliminate their causes in order to prevent consequential damage at the
engine or exhaust gas turbocharger.
If the engine is not equipped with an automatic monitoring system with data recording,
entries into the engine log are required at least once every 24 operating hours. Thereby,
deviations can be detected in time.

6.2 Maintenance work

In order to keep the exhaust gas turbocharger in a safe condition, perform the inspection
and check of various subassemblies and components according to the maintenance
schedule in chapter 6.4.
The chapter 7.4 includes detailed instructions on the work sequence for assembly and
disassembly work., which may be carried out by the cabin crew. Inspections may be
conducted only by KBB-authorized workshops.
Make sure to observe the following accident prevention regulations:
• winches, hoisting and drawing gear (BGV D 8)
• load take-up devices for hoisting operations (BGR 500 chapter 2.8).

F For a basic overhaul or repairs affecting essential parts of the exhaust gas
turbocharger, it is recommended to document their condition.

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 Operating Instructions
Chapter 6 ST3 Exhaust Gas Turbocharger

6.3 Cleaning
Cleaning the silencer
• see chapter 7.4.3

Cleaning the compressor

Cleaning during operation:
• see chapter 7.4.1

Mechanical cleaning:
• Remove the compressor casing and silencer (see chapters 7.4.7 and 7.4.8). (The
compressor impeller remains on the shaft.)
• Remove all deposits with diesel fuel or another admissible liquid cleansing agent.

Make sure to observe the accident prevention regulations!

While washing, make sure to prevent the cleaning agent from entering the charge air
piping or the interior of the turbocharger.
The compressor impeller must not be cleaned with caustic liquids!

Cleaning the turbine

Cleaning the turbine must not affect the dimensions of the functional surfaces. The surfaces
must not be roughened. The blades must not be bent. The following cleaning methods are
allowed:
Cleaning during operation:
• see chapter 7.4.2 (for heavy fuel oil operation only)

Mechanical cleaning:
• Remove the compressor casing and silencer (see chapters 7.4.7 and 7.4.8). (The
compressor impeller remains on the shaft.) The cartridge must be removed from the
turbine casing. The turbine wheel, the turbine nozzle ring and the turbine casing
must be cleaned mechanically.
• Cleaning with an alkaline aqueous detergent solution and subsequent drying
• Cleaning with diesel oil (if lightly soiled)
• In case of heavily soiled, insert the components in diesel or an alkaline aqueous
detergent solution. The parts can be cleaned with a wire brush after that.

Take care not to remove the anti-wear layer from the blades (never use a hammer or
chisel).
Sandblasting is not permitted!
A crack test may show incorrect results after sandblasting!

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 Operating Instructions
ST3 Exhaust Gas Turbocharger Chapter 6

6.4 Maintenance schedule

6.4.1 Maintenance for operation with Marine Diesel Oil (MDO)

F The operating hours given in the table are guidelines, which can be reduced for
adjustment to the maintenance intervals of the engine.

The inspections (I to III) must be performed only by authorized service centres!

Item Chapter Maintenance work Recommen- Maintenance interval

ded parts (operating hours)
1. Check for abnormal noise every 24
2. 7.4.1 Compressor washing during every 24 - 48
operation, actuate compressor
washing system
3. 7.4.3 Replace filter mat at silencer (9012) approx. every 500
or on demand
4. Check fastening bolts at the feet, once after
tighten all casing bolts and piping commissioning, then
joints every 1,000 hours
5. Inspection I (9910) max. every 12,500
• disassembly (9921)
• cleaning (9931)
• checking of rotor & bearings
• checking of casings
• assembly
6. Inspection II (9921) max. every 25,000
• like inspection I (9931)
• replacement of the bearings
7. Inspection III (9910) max. every 50,000
• like inspection II (9921)
• replacement of the rotor (9931)

(9012) Filter mat (9910) Gaskets and shims

(9931) Connecting elements (9921) Connecting elements

F Bearings and rotor are made available by service centre and may be changed only by
these!

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 Operating Instructions
Chapter 6 ST3 Exhaust Gas Turbocharger

6.4.2 Maintenance for operation with Heavy Fuel Oil (HFO)

F
The operating hours given in the table are guidelines, which can be reduced for
adjustment to the maintenance intervals of the engine.
The interval of the inspection “0” is depending on the fuel quality.

The inspections (I to III) must be performed only by authorized service centres!

Item Chapter Maintenance work Recommen- Maintenance

ded parts interval
(operating hours)
1. Check for abnormal noise every 24
2. 7.4.1 Compressor washing during every 24 - 48
operation, actuate compressor
washing system
3. 7.4.2 Turbine washing during operation, Approx. every 300,
actuate turbine washing system according to
Cleaning with water requirements
depending on HFO
quality
4. 7.4.3 Replaced filter mat at silencer (9012) Approx. every 500
or on demand
5. Check fastening bolts at the feet, once after
tighten all casing bolts and piping commissioning, then
joints every 1,000 hours
6. 7.4.9 Inspection 0 (9910) approx. every 6000
• disassembly cartridge (9921)
• turbine cleaning (9931)
• assembly
7. Inspection I (9910) max. every 12,500
• disassembly (9921)
• cleaning (9931)
• checking rotor and bearings
• checking casing
• assembly
8. Inspection II (9910) max. every 25,000
• like inspection I (9921)
• replacement of bearings (9931)
9. Inspection III (9910) max. every 50,000
• like inspection II (9921)
• replacement of the rotor (9931)

(9012) Filter mat (9910) Gaskets and shims

(9931) Connecting elements (9921) Connecting elements

F Bearings and rotor are made available by service centre and may be changed only by
these!

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 Operating Instructions
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The nozzle ring is subject to an increased wear for heavy fuel oil operation. Therefore
it is a wear part.
The lifetime of the nozzle ring is at least 12,500 hours, but it depends on HFO quality
and operating conditions.
The nozzle ring has to be replaced with appropriate wear and fundamental change of
performance data (as charge air pressure and exhaust temperature).

F However, other factors can also be responsible for a change in the exhaust gas
temperature and charge air pressure!

Irrespective of the foregoing, the exhaust gas temperature limit values (after the cylinder)
specified by the engine manufacturer may not be exceeded.
Wear mostly affects the guide blades and can progress as follows:

Can still be used Replace

Wear pattern 1 Wear pattern 2 Wear pattern 1

Original
state

Wear pattern 1
• The guide blades display a slot alongside one of the disks.
• The nozzle ring can still be used if the slot length is < 15 mm and the slot width < 4
mm.
Under the above-mentioned conditions the nozzle ring is not considered to be worn to such
an extent that it needs replacement and can thus continue to be used.

Wear pattern 2
• The guide blades display slots alongside both disks.
• The nozzle ring can still be used if the slot length is < 15 mm and the slot width < 3
mm.
Under the above-mentioned conditions the nozzle ring is not considered to be worn to such
an extent that it needs replacement and can thus continue to be used.

Wear pattern 3
• The guide blades show deep slots alongside both disks and the outlet edge of more
than two of the guide blades is completely worn.
The nozzle ring must be replaced.

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 Operating Instructions
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6.5 Trouble-shooting table

Charge air pressure and/or speed too high

Charge air pressure and/or speed too low
Temp. upstream of turbine too high

Lubricating oil pressure too low

Delayed start, short coasting
Fault

Lubricating oil leakage

Turbocharger vibrates
Turbocharger pumps
Heavy noise
Causes Chapter
Silencer or air filter contaminated 7.4.3
Compressor contaminated 7.4.8
Charge air cooler contaminated Engine
Leaking exhaust gas piping Engine
Exhaust gas counter pressure too high
Engine
downstream of turbine
Turbine wheel or compressor impeller Service
damaged (unbalanced) centre
Service
Defective bearing
centre
Service
Rotor in contact with casing
centre
Foreign matter in turbine or compressor Service
(unbalanced) centre
Turbine contaminated 7.4.2
Turbine nozzle ring contaminated 7.4.2
Failure of fuel injection at engine Engine
Leaking charge air piping Engine
High air intake temperature Engine
Inlet or outlet valves of the engine
Engine
contaminated
Low air intake temperature Engine
Lubricating oil filter contaminated Engine
Lubricating oil pressure gauge defective Engine
Lubricating oil inlet temperature too high Engine
Excessive pressure in oil return Engine
Service
Sealing air ineffective
centre
Gaskets damaged, connections leaking Engine
Service
Plain compression rings damaged
centre

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 Operating Instructions
ST3 Exhaust Gas Turbocharger Chapter 7

7 DISASSEMBLY AND ASSEMBLY

7.1 Introduction
The chapter 7.4 shall enable the user to perform simple maintenance work by himself.
It is assumed that the staff is familiar with the work and that the tools required are ready at
hand. Furthermore, the exhaust gas turbocharger has to be accessible and corresponding
hoists have to be available.
Make sure to observe the following accident prevention regulations:
• winches, hoisting and drawing gear (BGV D 8)
• load take-up devices for hoisting operations (BGR 500 Kap.2.8)

7.2 Checking the components

The check list shown below can be used as instruction for checking the condition of the
exhaust gas turbocharger and its major components. Damage effecting rigidity, balance and
smooth running of rotating components should be eliminated by the manufacturer or an
authorized workshop. If damaged parts are returned for repair, ensure an appropriate
protection against transportation damage.
After having disassembled the casings, perform the following checks at the cleaned parts.

Rotor, complete
• Are contact traces visible at the casing?
• Are contact traces visible at the rotor?

If re-working is performed or if rotor parts are replaced, rebalancing has to be

executed!

Compressor impeller/turbine wheel

• Can you detect any sliding traces or cracks at the compressor impeller?

Compressor diffuser/Turbine nozzle ring

• Are the guide vanes twisted or worn out?
• Is foreign matter clamped into the ducts?
• Can you detect traces of foreign matter?

Casing
• Are the casings heavily contaminated by oil, dust or soot?
• Is there any leakage at the casing? (Main items: connection flanges, charge air,
exhaust gas and oil connections)
• Are all bolts and nuts tight?

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7.3 Checking the clearances

The clearances have to be observed to ensure a safe turbocharger operation and achieve
the required efficiency.
The clearances have to be checked if:
• parts have been replaced (turbine casing or turbine casing insert, compressor or
compressor casing insert ,cartridge),
• the engine or turbocharger operating parameters deviate from the norm
• there are score marks on rotor parts or casings
• during overhauls and inspections
• heavy contamination

Checking the clearances:

• Radial clearance S1 (compressor) and S12 (turbine)
• Axial bearing clearance S15

clearance new limit

S1 0.5±0.05 0.8
S12 0.5±0.05 0.8
+0.14
S15 0.21 -

S1 and S12:
The clearance S1 is determined simultaneously at the opposite positions C1 and C2
(horizontal and vertical) between the compressor impeller and the compressor casing insert
using two feeler gauges (measuring range 0.05 to 0.1mm).
The clearance S12 is determined simultaneously at the opposite positions T1 and T2
(horizontal and vertical) between the turbine wheel and the turbine casing insert using two
feeler gauges (measuring range 0.05 to 0.1mm).

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S15:
The clearance S15 is determined on the compressor side of the rotor end. Push the rotor
towards the turbine side and set the dial gauge (measuring range 0 to 1mm, precision min.
±0.001) to "0". Pull the rotor to the compressor side and read out the clearance S15 from
the dial gauge.

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7.4 Work sheets

7.4.1 Compressor washing

(Every 24 - 48 operating hours)

Legend
1. Ball valve
2. Water tank
3. Water piping
4. Air piping

Work sequence:
1. Operate the engine at 50 - 85 % of nominal output.
2. Open the water tank (2), fill with clean water (no sea water and no additives)
(approx. 0,5 l), close the water tank.
3. Open the ball valve (1), wait for approx. 20 sec., close valve (1). The compressed air
flows through the air piping (4) via the ball valve (1) into the water tank. The water is
pressed through the water piping (3) into the injection pipe, atomised by the air
taken in and hits the compressor blades at high speed.

Perform cleaning only with warm engine at 50 - 85 % of nominal output.

If compressor surging occurs during or after water injection then the engine output
needs to be reduced further.
Continue to operate the engine for at least 10 to 15 min. after cleaning.
Do not wash before a pause of operation. Corrosion risk!
Washing is ineffective in case of hardened deposits, thus perform washing at regular
intervals.
Do not use any chemical additives!

F
If the negative pressure upstream of the compressor is too high, water is already
taken in when the water is filled into the water tank and the cleaning effect is reduced.
In order to avoid this, you can:
• install the water tank at a lower level
(min. 1000 mm below the turbocharger center)
or
• include a second stop valve, which is opened after the water tank has been
closed, into the water piping.

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7.4.2 Turbine washing

(For heavy fuel oil operation only, every 300 operating hours respective depending on HFO
quality)

F
Heavy fuel oil operation results in contamination and deposits on nozzle ring and
turbine wheel reducing the efficiency. Due to these deposits the charge air pressure
will be increased.
The washing intervals depend on the fuel quality and operating conditions. That's why
they must be adjusted based on the experience gained during engine operation if
necessary later on.
The increase of charge air pressure by for e.g. more than 0.1 bar (at same engine
power) could be used for adjusting the washing interval, which could be adjusted
within 25 to 600 hours.
Read and take down the charge air pressure and exhaust gas temperatures at a
reference point (at 75 % or 100 % of the output) before and after washing to check the
washing effect.
Hot exhaust gas can escape from the drain - Risk of burning!
Continue to operate the engine for at least 60 minutes after water injection. Do not
wash before a stop of operation. Corrosion risk!
Washing is ineffective in case of hardened deposits, thus perform washing at regular
intervals from the beginning.
In the case of ineffective washing the turbine is to be cleaned mechanically. For this
purpose the turbine casings are to be dismantled.
Pay attention also to instruction of the engine’s operating manual!

Legend
1 Sanitary fresh water 5 3-way valve 9 Valve (optional)
2 Regulating valve 6 Wash-water piping 10 Escape funnel or sight glass
3 Fresh-water piping 7 Injector 11 Manometer
4 Removable flexible tube 8 Connection for drain 12 Sealing air (charge
(optional) air / optional)
5010 Turbine casing 9100 Exhaust gas elbow

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Turbine washing is possible by 2 different procedures as following:

• Interval washing at reduced engine output
• 10 min turbine washing at engine idle

7.4.2.1 Interval washing

Work sequence:

1. Check the injection nozzle/valve (7) for free passage!

2. Connect the removable flexible tube section (4) to the fresh water piping (3).
3. Reduce the engine output until the temperature before the turbine drops to its
specified value (see Table).
4. Wait for approx. 10 minutes!
5. Open valve (9) (if available) for drainage (8).
6. Open valve (2) and set the water pressure (see Table).
7. Open stop valve (5) for approx. 30 seconds, if necessary readjust water pressure by
means of valve (2).
8. Close stop valve (5).
9. Wait approx. 3 minutes to allow the injected water to evaporate.
10. Repeat steps 7 and 9 twice or three times.
11. Close valve (2) and valve (9) for drainage!
12. Run dry the exhaust-gas turbocharger for approx. 10 minutes and at the same time
increase engine load slowly!
13. Repeat the washing if previously absent vibrations occur at the exhaust-gas
turbocharger.
14. Remove the flexible tube (4).

F
The effect of the turbine washing could be controlled by changing of charge air
pressure and exhaust temperature!
Water pressure and washing period could be increased for improvement of washing
effect, if necessary!

Operating values for turbine washing

Exhaust-gas temperature Water pressure Total

before turbine (gauge) washing time
350 – 430 °C 2.5 – 4.5 bar 3-4 x 30 sec

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7.4.2.2 Turbine washing at engine idle

Turbine washing at engine idle is allowed only if a drain is connected!

Drain must be opened, otherwise risk of flooding of turbine!

Work sequence:

1. Check injection nozzle/ valve (7) for free passage!

2. Connect the flexible tube (4) to fresh-water piping (3).
3. Reduce the engine output (see table), run engine at idle.

F Warm up the engine if turbine washing is done after engine start!

4. Wait for approx. 10 minutes!

5. Open the valve (9) of the drain (8).
6. Open stop valve (5).
7. Open valve (2) and adjust the water pressure (see table).
8. Check water outlet at the drain.
9. Close the stop valve (5) after at least 10 minutes.
10. Close the valve (2) and the valve (9) of the drain.
11. Run dry the exhaust gas turbocharger for approx. 10 minutes and at the same time
increase engine load slowly!
12. Repeat the washing process if the exhaust gas turbocharger is affected by
vibrations which did not occur before.
13. Remove the flexible tube (4).

F
The exhaust temperature before turbine could increase during washing procedure,
but should not exceed max. 350 °C!
The effect of the turbine washing could be controlled by changing of charge air
pressure and exhaust temperature!
Water pressure and washing period could be increased for improvement of washing
effect, if necessary!

Operating values for turbine washing

Engine output Exhaust gas temperature Water pressure Total

before turbine (gauge) washing period

< 10% Max. 350 °C 2.5 – 4.5 bar Min. 10 min

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 Operating Instructions
Chapter 7 ST3 Exhaust Gas Turbocharger
7.4.3 Cleaning the silencer

(Every 500 operating hours) Related chapter 7.4.7

General
In most cases merely the filter mat has to be replace. For this purpose the silencer may stay
at the exhaust gas turbocharger.
The given maintenance interval of 500 operating hours is just a mean guide value, since the
accumulation of dirt in the filter mat and the pressure drop resulting there from are largely
dependent on the environment. For operation under extreme conditions, it is recommended
to add a maintenance indicator (water gauge) signalling the right moment for cleaning. This
indicator shall be adjusted so as to give the cleaning signal when a vacuum of app. 100 mm
w.g. is reached at point A intended for mounting (e.g. a MANN maintenance indicator for air
filters, max. 200 mm w.g. = 20 mbar).
Work sequence: Replacing the filter mat
1. Open and remove the tension tapes (9014)
2. Pull the filter mat (9012) from the silencer (9010) .
3. Install the new filter mat (9012) and tension tapes (9014).

Work sequence: Cleaning the silencer

F If the silencer is heavily contaminated or if an inspection is carried out, the silencer

has to be cleaned completely.

1. Dismount the silencer (9010) (see chapter 7.4.7).

2. Subsequently, externally clean with a soft brush and let dry.
3. Install the silencer (9010).

To operate the exhaust gas turbocharger without a filter mat is not permitted!
Pay attention to applicable accident prevention regulations (handling of hazardous,
volatile, combustible solvents) and fire protection regulations (DIN 14096). Cleaning
by P3-solution or trichlorethylene is prohibited. If other solvents are used, check the
compatibility with the filter material. In case of ship operation pay attention to the
regulations of the classification societies with regard to washing liquids.

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7.4.4 Shutting down the exhaust gas turbocharger

F
In case of a TC damage especially at the rotor or bearing, it is recommended to shut
down the TC in order to avoid any further damage.
Pay attention to the operating instructions of the engine manufacturer.

When the engine is operated with a defective exhaust gas turbocharger, limit the
engine output in order to prevent the exhaust gas temperature from exceeding
admissible values downstream of the cylinder.

Related chapters
7.5.7, 7.5.9, 7.5.10

Initial condition: The turbocharger is mounted on the engine.

Mass of the silencer approx. 22 kg
Mass of the air intake bend approx. 7 kg
Mass of the compressor casing, compl. approx. 34 kg
Mass of the cartridge approx. 39 kg
Mass of the sealing device (9704) approx. 8 kg

Work sequence:
1. Disassemble the silencer (9010) / air intake bend (9020) (see chapter 7.4.7).
2. Loosen all piping at the compressor casing (6010).
3. Disassemble the compressor casing (6010) (see chapter 7.4.8).
4. Remove the cartridge (1200) (bearing casing with rotor) and turbine nozzle ring
(7010) from the turbine casing (5010) (see chapter 7.4.9).

Use a hoist!

F Caution in removing the cartridge in order to avoid damage to the turbine blades.

5. Attach the sealing device (9704) to the turbine casing (5010) and screw tight the
clamping flanges (5150) with washer (5100) and hexagon nut (5080).
6. Screw the sealing device (9704) to the engine console.

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7.4.5 Disassembly of the complete turbocharger

a)

b)

Mass of complete TC is approx. 161 kg

Make sure to observe the following accident prevention regulations:
• winches, hoisting and drawing gear (BGV D 8)
• load take-up devices for hoisting operations (BGR 500 chapter 2.8)
Pay attention to piping and sheathings!

Work sequence :
1. Remove the sheathings from the turbine casing and loosen the exhaust gas piping if
necessary.
2. Loosen the exhaust gas piping from the turbine casings. Pay attention to gaskets!
3. Loosen the piping at the compressor casing (6010), remove them if necessary.
4. Attach the exhaust gas turbocharger to a hoist. For this purpose
a) Screw the eye bolt (3015) into the cartridge (1200) or
b) Put two ropes around the flange between the silencer and the compressor casing
and between the turbine casing and the exhaust-gas elbow.
5. Loosen and remove the foot screws (A) at the sides of the cartridge (1200).
6. Lift and carefully place the exhaust-gas turbocharger on a wooden base, secure
against tilting.
7. Cover the openings of the lubricating oil pipes in the engine console in order to
prevent dirt from entering the lubricating oil system.

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7.4.6 Assembly of the complete turbocharger

a)

b)

Mass of complete TC is approx. 161 kg

Make sure to observe the following accident prevention regulations:
• winches, hoisting and drawing gear (BGV D 8)
• load take-up devices for hoisting operations (BGR 500 chapter 2.8)
Pay attention to piping and sheathings!
Tightening moment of foot screws (A) 192 Nm

Work sequence :
1. Attach the complete TC to a hoist (see chapter 7.4.5) and put it onto the engine
console. Pay attention to the pipe connections!
2. Screw in and tighten the foot screws (A) at the sides of the cartridge (1200).
3. Connect the exhaust gas piping to the turbine casings.
4. Attach the sheathing.
5. Connect the charge air piping.
6. Connect the water and air piping for compressor washing.
7. Tighten the bolts at the connecting pipes.
8. Supply lubricating oil to TC and check all flanged connections for leakages.

After having installed the TC, check that the assembly is free of stresses and forces.
Rework piping, if necessary.

Only use perfect gaskets for the pipe joints. Apply molybdenum sulphide lubricant to

F
the connecting bolts of the exhaust gas piping prior to installation.
Replace the O-rings and sealings!
Use the assembly protecting sheet (9712) to protect the O-rings when mounting the
exhaust gas turbocharger on the engine bracket!

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7.4.7 Assembly and disassembly of the silencer or air-intake bend

Mass of the silencer approx. 22 kg

Mass of the air-intake bend approx. 7 kg
Tightening moment of V-band 35 Nm !

Legend
6010 Compressor casing
6020 V-band, compressor
6190 Hexagon socket screw
9010 Silencer
9020 Air intake bend

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7.4.8 Assembly and disassembly of the compressor casing

Mass of cartridge (bearing casing with rotor) approx. 39 kg.

Mass of compressor casing complete approx. 34 kg.
Make sure not to damage the compressor impeller during assembly and disassembly
of the compressor casing.

F Replace the O-ring (6030) each assembly and disassembly!

Assembly the shims (8011-8015) that the sealing air line Z is free!

Legend
1200 Cartridge 6140 Clamping flange 8010 Diffuser
5010 Turbine casing 6150 Stud bolt 8011-8015 Shim
6010 Compressor casing 6160 Hexagon nut 8040 Cylindrical screw
6030 O-ring, compressor casing 6170 Washer

F When installing the clamping pieces (6140), make sure that there is free access to the
speed sensor (see B) and the notches in the clamping piece (6140) and compressor
casing (6010) coincide (see A).

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7.4.9 Disassembly and assembly of the cartridge

Mass of the cartridge approx. 39 kg

Mass of turbine casing complete approx. 38 kg
Caution in disassembling and assembling in order to avoid damage to the turbine
blades.
Use the press-off-tool (9726) to push the cartridge (1200) out of the turbine casing.
Use Diesel oil or rust remover if the connection seized!
Caution in disassembling the turbine casing in order to prevent the turbine nozzle ring
from falling out!
Tightening moment of foot screws (A) 192 Nm

F Replace O-rings (console) by assembly!

O-Rings are included in the scope of delivery of the engine manufacturer!
Use assembly protecting sheet (9712) to protect the O-rings!
Legend
1200 Cartridge
3015 Eye bolt
5010 Turbine casing
5080 Nut
5100 Ribbed washer
5130 Stud bolt
5150 Clamping flanges
7010 Nozzle ring
7020 Locating bolts
7040 Metal seal (only at single-nozzle turbine casing)
9712 Assembly protecting sheet
9726 Press-off tool
A foot screw

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7.4.10 Disassembly of the exhaust-gas elbow

Mass of the exhaust-gas elbow (9100) approx. 22 kg

Mass of the insert, turbine casing (5020) approx. 6 kg
Mass of the Containment ring approx. 2 kg

Legend
5010 Turbine casing
5020 Insert, turbine casing
5090 Nut
5101 Ribbed washer
5220 Containment ring
9100 Exhaust gas elbow

The turbine casing insert (5020) and the containment ring (5220) could be fall out if the
exhaust gas elbow (9100) is disassembled.
During transport save the insert turbine casing (5020) with two nuts!

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 Operating Instructions
Chapter 8 ST3 Exhaust Gas Turbocharger

8 SPARE PARTS AND TOOLS

8.1 General
The following details are required for an order:
1. Address of orderer
2. Type of turbocharger
3. Serial number of turbocharger (see name plate on page 2)
4. Specification number of turbocharger (see name plate on page 2)
5. Part number, designation and quantity
6. Shipment address

The spare parts box supplied by order contains a selection of the most important wear parts
and a relevant listing.

F The parts contained in the spare parts box are preserved for a storage period of two
years.

A certain selection of tools is also supplied if ordered. These tools are necessary to quickly
restore the operability of the engine after a TC damage by replacing the cartridge and are
not included in the basic equipment of every workshop.

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8.2 Spare parts

8.2.1 Exhaust gas turbocharger, complete (1000)

Part No. Quantity Designation Remarks

1200 1 Cartridge
3140 2 Screw plug
3150 2 Gasket
5000 1 Turbine casing
5210 1 Containment shield
6000 1 Compressor casing
6020 1 V-band
6190 2 Hexagon socket screw
9010 * Silencer
9012 1 Filter mat optional with silencer
9014 2 Tension tape optional with silencer
9020 * Air intake bend
9025 * Air inlet flange
9030 2 Screw plug optional with intake bend
9040 2 Gasket optional with intake bend
9050 1 Screw plug
9055 1 Screw plug
9060 1 Gasket
9065 1 Gasket
9070 1 Screw plug
9080 1 Gasket
9100 1 Exhaust gas elbow
9101 3 Flange
9102 12 Hexagon screw
9103 12 Ripped washer
9104 3 Gasket
9110 1 Speed sensor optional, or screw plug (3140) with gasket
(3150)
9120 1 O-Ring only for gas engines
* optional, depending on TC specification

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8.2.2 Exhaust gas turbocharger, basic unit (1100)

Part No. Quantity Designation Remarks

1200 1 Cartridge
5010 1 Turbine casing
5080 16 Nut
5100 16 Ribbed washer
5130 16 Stud
5150 8 Clamping flange
6010 1 Compressor casing
6030 1 O-ring, compressor casing
6140 4 Clamping flange
6150 12 Stud
6160 12 Nut
6170 12 Ribbed washer
7010 1 Turbine nozzle ring
7020 3 Locating bolt
7040 1 Metal seal only at single-nozzle turbine casing
8010 1 Compressor diffuser
8011 *
to Shim *according clearance setting
8015 *
8040 3 Hexagon socket screw

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8.2.3 Turbine casing complete

Part No. Quantity Designation Remarks

5010 1 Turbine casing
5020 1 Insert, turbine casing
5050 3 Screw plug per gas inlet
5060 3 Gasket per gas inlet
5071 2 Stud bolt
5072 2 Locking washer
5080 16 Nut
5090 12 Nut
5100 16 Ribbed washer
5101 12 Ribbed washer
5110 12 Stud bolt
5120 4 Stud bolt optional for motor mounting
5130 16 Stud bolt
5150 8 Clamping flange
5210 1 Containment shield
5220 1 Containment ring
5230 6 Hexagonal head screw number depends on the TC specification
5250 6 washer number depends on the TC specification

ST3EN08_20150624.doc 8th Edition (06/2015) Page 41 of 50

 Operating Instructions
Chapter 8 ST3 Exhaust Gas Turbocharger
8.2.4 Compressor casing complete

Part No. Quantity Designation Remarks

6010 1 Compressor casing
6040 1 Insert, compressor casing
6041 2 O-ring, insert, compressor casing
6050 1 Screw plug
6060 1 Gasket
6090 1 O-ring, insert, compressor casing
6110 1 Screw plug optional: connection for jet assist
6120 1 Gasket optional: connection for jet assist
6130 2 Retaining plate
6131 4 Hexagon socket screw
6132 4 Washer
6140 4 Clamping flange
6150 12 Stud bolt
6160 12 Nut
6170 12 Washer

Page 42 of 50 8th Edition (06/2015) ST3EN08_20150624.doc

 Operating Instructions
ST3 Exhaust Gas Turbocharger Chapter 8

8.2.5 Gaskets and shims (9910)

Part No. Quantity Designation Remarks

9911 1 Gaskets
9912 1 Shims

8.2.5.1 Gaskets (9911)

Part No. Quantity Designation Remarks

2070 1 Compression ring
2090 1 Compression ring
3051 1 O-Ring
6030 1 O-Ring, compressor casing
6041 2 O-Ring, compressor casing insert
6090 1 O-Ring, compressor casing insert
7030 1 Sealing cord
9104 3 Gasket

8.2.5.2 Shims (9912)

Part No. Quantity Designation Remarks

3071 2 Shim (0.1)
3072 2 Shim (0.15)
3081 1 Gasket, bearing cover (0.1)
3082 1 Gasket, bearing cover (0.15)
3083 1 Gasket, bearing cover (0.2)
3084 1 Gasket, bearing cover (0.3)
3085 1 Gasket, bearing cover (0.5)
8011 1 Shim (0.1)
8012 1 Shim (0.15)
8013 1 Shim (0.2)
8014 1 Shim (0.3)
8015 1 Shim (0.5)

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 Operating Instructions
Chapter 8 ST3 Exhaust Gas Turbocharger
8.2.6 Connection elements (9921)

F Set (9921) contains all connection elements of compressor side.

Part No. Quantity Designation Remarks

3012 2 Screw plug
3014 2 Gasket
3015 1 Eye bolt
3140 2 Screw plug
3150 2 Gasket
6050 2 Screw plug
6060 2 Gasket
6110 1 Screw plug
6120 1 Gasket
6130 2 Retaining plate
6131 4 Hexagon socket screw
6132 4 Washer
6150 12 Stud bolt
6160 12 Hexagon nut
6170 12 Washer
6190 2 Hexagon socket screw
8040 3 Hexagon socket screw
9030 2 Screw plug
9040 2 Gasket
9070 1 Screw plug
9080 1 Gasket

Page 44 of 50 8th Edition (06/2015) ST3EN08_20150624.doc

 Operating Instructions
ST3 Exhaust Gas Turbocharger Chapter 8

8.2.7 Connection elements (9930)

F Set (9930) contains all connection elements of turbine side.

Part No. Quantity Designation Remarks

5050 6 Screw plug per gas inlet
5060 6 Gasket per gas inlet
5071 2 Stud bolt
5072 2 Locking washer
5090 12 Nut
5101 12 Washer
5110 12 Stud bolt
5120 4 Stud bolt optional for motor mounting
5230 6 Hexagonal head screw for containment
5250 6 Washer for containment
9050 1 Screw plug
9055 1 Screw plug
9060 1 Gasket
9065 1 Gasket
9102 12 Hexagon head screw
9103 12 Washer
9931 1 Connection elements (9931)

ST3EN08_20150624.doc 8th Edition (06/2015) Page 45 of 50

 Operating Instructions
Chapter 8 ST3 Exhaust Gas Turbocharger
8.2.8 Connection elements (9931)

F Set (9931) contains all connection elements for turbine side to replace the cartridge
and is contained in set (9930).

Part No. Quantity Designation Remarks

5080 16 Nut
5100 16 Ribbed washer
5130 16 Stud bolt
7020 3 Locating bolt

8.3 Tools

F Tools are an option and therefore should be purchased separately by an official order
from customer.

8.3.1 Tool set (9700)

F Tool set (9700) contains tool for replacement of cartridge.

Part No. Quantity Designation Remarks

9712 1 assembly protecting sheet protected the o-rings on engine console
9714 1 crowfoot wrench for speed sensor
9716 1 extension for 9714
9726 3 Press-off tool for turbine and compressor casing
9765 2 hexagonal head screw for air intake bend and exhaust gas
elbow
9782 2 eye bolt for compressor-, turbine casing,
silencer and cartridge
9792 2 eye nut for air intake bend and exhaust gas
elbow

Page 46 of 50 8th Edition (06/2015) ST3EN08_20150624.doc

 Operating Instructions
ST3 Exhaust Gas Turbocharger Chapter 8

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 Operating Instructions
Chapter 8 ST3 Exhaust Gas Turbocharger

8.3.2 Optional Tools

Part No. Quantity Designation Remarks

9704 1 Sealing device stoppage of the exhaust gas turbocharger

Page 48 of 50 8th Edition (06/2015) ST3EN08_20150624.doc

 Operating Instructions
ST3 Exhaust Gas Turbocharger Chapter 9

9 APPENDIX
Overview Service Stations

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 Operating Instructions
Chapter 9 ST3 Exhaust Gas Turbocharger

Page 50 of 50 8th Edition (06/2015) ST3EN08_20150624.doc

 Service Stations

Overview Service Stations

Please visit www.kbb-turbo.de for updates.

Argentina Guatemala Norway

Australia Hungary Pakistan
Bangladesh Iceland Philippines
Brazil India Poland
Canada Indonesia Russia
Chile Italy Singapore
China Japan Spain
Denmark Korea Turkey
Ecuador Namibia UAE
Germany Netherlands UK
Greece New Zealand USA

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 Service Stations

Argentina
Turbogen de Pascual Mario Ruffa
Lugones 1851 / 55
1430 Buenos Aires
Phone: +54 11 4521 5667/ 1914
Fax: +54 11 4521 8283
Mobile: +54 911 4440 7867
E-mail: [email protected]
www.turbogen.com

Australia
MTQ Engine Systems (Aust) Pty Ltd.
1 Westside Drive
Laverton
Melbourne Victoria 3026
Phone: +61 3 9315 1633
Fax: +61 3 9315 3984
Mobile: +61 411 748 001
E-mail: [email protected]
www.mtqes.com.au
Further branches in: Adelaide, Brisbane, Dandenong, Darwin, Perth, Rockhampton, Sydney,
Toowoomba and Townsville

Bangladesh
Dalwin Marine Bangladesh Ltd.
Fouzderhat Station
CDA Road Bhatiary
Sitakund, Chittagong, 4315
Phone: +880 3 12780222
Fax: +880 3 12780200
Mobile: +880 18193 18410
E-mail: [email protected]
www.dalwin.com

Brazil
American Turbo I.C. Ltda.
Rua Gibraltar Nº 280
Sao Paulo – SP (04755-070)
Phone: +55 11 5641 3600
Fax: +55 11 5641 5550
E-mail: [email protected]

Canada
Allied Marine & Industrial Inc.
118 West Street, Port Colborne
Ontario, L3K 4C9
Phone: +1 905 834 8275
Fax: +1 905 834 5645
E-mail: [email protected]
www.allmind.com

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 Service Stations

Dynamic Engineering Inc.

1270 Frances Street
Vancouver, B.C. V6A 1Z5
Phone: +1 604 253 4427
Fax: +1 604 253 3553
E-mail: [email protected]
www.dynamicengineering.com

Chile
Maestranza Diesel Ltda.
Santa Elena 1433
Santiago
Phone: +56 2 5502000
Fax: +56 2 5550938
E-mail: [email protected]
www.md.cl

China
Tru-Marine Machinery
Engineering Shanghai Co., Ltd.
No. 318 Cheng Yin Road
Baoshan Urban Industrial Park
Baoshan, Shanghai 200444
Phone: +86 21 65204 220
Fax: +86 21 6520 6639
E-mail: [email protected]
www.trumarine.com

Tru-Marine Cosco (Tianjin) Engineering Co., Ltd.

No. 26 Lu Shan Road
Tgeda Tanggu
Tianjin P.C. 300451
Phone: +86 22 2521 2086
Fax: +86 22 2521 2300
E-mail: [email protected]
www.trumarine.com

Tru-Marine Machinery Engineering Guangzhou Co. Ltd.

No. 1168 Kangnan Road
Yunpu Industrial Park
Huangpu District, Guangzhou
P.R. China, P.C. 510760
Phone: +86 20 8222 7678
Fax: +86 20 8222 7578
E-mail: [email protected]

Kemklen Technical Services Ltd.

Shop No. 8, G/F., Block B, Vigor Industrial Bldg.,
14-20 Cheung Tat Road, Tsing Yi, N.T. Hong Kong.
Phone: +852 2861 2812
Fax: +852 2861 1168
E-mail: [email protected]
www.turbokts.com

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 Service Stations

K&C Global Ltd.

Block M, Yiu Lian Dockyards
No 1-7, Sai Tso Wan Road
Tsing Yi Island, New Territories
Hong Kong
24 Hours: +852 9449 4281
Phone: +852 2435 7880
Fax: +852 2432 1001
E-mail: [email protected]
www.kc-global.com

Denmark
PJ Diesel Engineering A/S
Skudehavnsvej 14
DK-2150 Nordhavn Copenhagen
Phone: +45 3929 1553
Fax: +45 3927 1054
E-mail: [email protected]
www.pjdiesel.com

Ecuador
Turbomotores Ecuatorianos S.A.
Grupo TME
Av. Maldonado 10324 – Quito
Phone: +593 2 267 5605
Fax: +593 2 268 2097
E-mail: [email protected]
www.grupotme.com

Germany
Barthels & Lüders a Division of Blohm + Voss Repair GmbH
Hermann-Blohm-Str. 2
20457 Hamburg
Phone: +49 40 311 88 126
Fax: +49 40 311 88 155
E-mail: [email protected]
www.barthels-lueders.com

Scan Turbo Handels- und Service GmbH

Kleiner Westring 15
27568 Bremerhaven
Phone: +49 471 969 165 0
Fax: +49 471 969 165 20
E-mail: [email protected]
www.scan-turbo.com

Turbinen & Motoren – Service GmbH

Kleiner Westring 7
27572 Bremerhaven
Phone: +49 471 97 202 0
Fax: +49 471 97 202 39
E-mail: [email protected]
www.turbinen-motoren.de

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 Service Stations

Treckel Schiffsservice GmbH & Co. KG

Warnowpier 403
18069 Rostock
Phone: +49 381 811331 – 5/6
Fax: +49 381 811331-7
E-mail: [email protected]

Greece
Turbomed Yiannis Paraskevopoulos S.A.
Schisto Industrial Park (VIPAS), Block 2 Str. 1 & 2
18863 Perama, Piraeus
Phone: +30 210 4000111
Fax: +30 210 4000225
Helpline: +30 6932210060
E-mail: [email protected]
www.turbomed.gr

Guatemala
Elliott Turbocharger Guatemala, S.A.
4 Av. 4-44 Z.8 San Cristobal, Sector A-5
Mixco
Phone: +502 2427 9696
Fax: +502 2427 9608
E-mail: [email protected]
www.elliott-guatemala.com

Hungary
Ferryker Turbo Kft.
Janos Apostol u. 186799 hrsz.
1239 Budapest
Phone: +361 2870 256
Fax: +361 2870 514
E-mail: [email protected]
www.ferrykerturbo.hu

Iceland
Framtak Blossi EHF
Dvergshöfda 27
110 Reykjavik
Phone: +354 535 5850
Fax: +354 535 5851
E-mail: [email protected]
www.blossi.is

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 Service Stations

India
Dalwin Marine Turbo Engg Pvt Ltd.
R-307, Rabale
TTC Industrial Area
Navi Mumbai, Maharashtra
India – 400701
Phone: +91-22-27602239
Fax: +91-22-27602931
E-mail: [email protected]
www.dalwin.com

Dalwin Marine Turbo Engg Pvt Ltd.

Plot-50A, AIE
Pedagantyada Road No. 10
Visakhapatnam, Andhra Pradesh
India – 530044
Phone: +91-891-2707053
Fax: +91-891-2707053
Mobile: +91 932 4265196
E-mail: [email protected]
www.dalwin.com

Indonesia
PT. Trimanunggal Perkasindo
Bizpark Commercial Estate Block A7#21.
Jalan Raya Bekasi Km.21.5, Jakarta 13920.
Phone: +62 21 2936 8722
Fax: +62 21 2936 8724
E-mail: [email protected]

Italy
La Meccanica Turbo Diesel srl
Calata Gadda
Ship repair area
16128 Genova Porto
Phone: +39 010 246 7499
Fax: +39 010 246 1144
E-mail: [email protected]
www.mtd.it

Japan
Kobayashi Industries, Ltd.
1025-176, Hamano-Cho, Chuo-Ku,
Chiba 260 0824
Phone: +81 43 208 0511
Fax: +81 43 208 1511
E-mail: [email protected]

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 Service Stations

Sanyo Marine Industry Co., Ltd.

Nishinakamachi 2-44
Hyogo-ku, Kobe
652-0835
Phone: +81 78 681 3491
Fax: +81 78 681 0780
E-mail: [email protected]

Korea
Jonghap Maritime Inc.
27, Haeyang-ro 23 beon-gil,
Yeongdo-gu, Busan (zip code: 606-822)
Phone: +82 51 413 4277 (24hrs on duty)
Fax: +82 51 413 7442
E-mail: [email protected]
www.jonghap.co.kr

Namibia
Namib Diesel CC
28, 2nd Street East
P.O. Box 2449
Walvis Bay
Phone: +264 64 203971
Fax: +264 64 203255
Mobile: +264 81 1283987
E-mail: [email protected]
www.namibdiesel.com.na

Netherlands
Tru-Marine Rotterdam
Nieuwe Waterwegstraat 17
3115 HE Schiedam
Phone: +31 10 426 7383
Fax: +31 10 473 3050
E-mail: [email protected]
www.trumarine.com

New Zealand
NZ Marine Turbochargers Ltd.
136 Vanguard Street
Nelson
Phone: +64 3 546 6188
Fax: +64 3 548 0974
E-mail: [email protected]
www.turbocharger.co.nz
Further branch in Auckland

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 Service Stations

Norway
Frydenbo Industri AS, avd. Ost
Lurudveien 5
2020 Skedsmokorset
Phone: +47 6387 1635
Fax: +47 6387 1667
E-mail: [email protected]
www.frydenbo-industri.no
For emergency 24/7
Phone: +47 913 90 916

Pakistan
Orient Energy Systems (Private) Ltd.
Plot No 09
Sector 24
Korangi Industrial Area
Karachi
Phone: +92 21 111507 507
Fax: +92 21 3507 2095
E-mail: [email protected]
www.orient-power.com

Philippines
Turbo Engine Recovery , Inc.
# 1274 Batangas St., San Isidro
Makati City
Philippines 1234
Phone: +2 888 6399
Fax: +2 888 6457
E-mail: [email protected]
www.teriph.com

Poland
Cassiopeia Ltd.
5A, Uczniowska Str.
70-893 Szczecin, Poland
Phone: +48 504 926 696
Fax: +48 91 469 3064
E-mail: [email protected]
www.cassiopeia-service.com

Russia
Baltic Turbo Ltd.
Serdobolskaya str. 7, office 412
197343, St. Petersburg
Phone: +7 812 4960512
Fax: +7 812 4960540
E-mail: [email protected]
www.balticturbo.ru

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 Service Stations

Singapore
Tru-Marine Pte Ltd.
35 Tuas Basin Link
Singapore 638769
Phone: +65 6861 8398
Fax: +65 6861 8396
E-mail: [email protected]
www.trumarine.com

Spain
Turbo 10, S.L.
Avda. Balaidos, 9
36210 Vigo
Phone: +34 986213669
Fax: +34 986 214 077
E-mail: [email protected]
www.turbo10.es

Turbo Cadiz S.L.

Poligono Industrial PELAGATOS
C/ Del Progreso 17A – 20A
11130 – Chiclana de la Frontera
Cadiz
Phone: +34 956 407 949 / 950
Fax: +34 956 407 951
E-mail: [email protected]
www.turbocadiz.com

Turbo Cadiz S.L. - Las Palmas

Puerto de Las Palmas
Av Pantalan de Cory - Esq. Compañia Navegacion Paquet
35008 – Las Palmas de Gran Canaria
E-mail: [email protected]
www.turbocadiz.com

Turkey
Istanbul Marine Turbine Service Ind. & Trd. Co. Ltd.
Istanbul Deri Organize Sanayi Sitesi
1. Yol X5-A Parsel Aydinli-Orhanli Mevkii
34953 Tuzla / Istanbul
Phone: +90 216 394 04 73
Fax: +90 216 394 04 75
E-mail: [email protected]
www.istmarin.com

UAE
Tru-Marine PTE LTD SHJ. BR.
Plot No. 2, Sharjah Industrial Area 17,
P.O. Box 37529, Sharjah
Phone: +971 6 5349 357
Fax: +971 6 5349 356
E-mail: [email protected]
www.trumarine.com

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 Service Stations

UK
Marine Turbo Engineering Ltd.
Abbey House
Priory Trading Estate
Birkenhead, Merseyside
CH 415 JU
Phone: +44 151 647 8141
Fax: +44 151 666 2143
E-mail: [email protected]
www.marineturbo.co.uk

USA
Motor-Services Hugo Stamp Inc.
3190 S.W. 4th Avenue
Ft. Lauderdale, Florida 33315
Phone: +1 954 763 3660
Fax: +1 954 713 0440
E-mail: [email protected]
www.mshs.com

L.A. Maritime
327 Lecouvreur Avenue
Los Angeles, CA 90744, USA
Phone: +1 310 518 1718
Fax: +1 310 549 1122
E-mail: [email protected]
www.la-maritime.com

Tru-Marine Houston
808 West 13th Str. Deer Park
Houston, Texas 77536, USA
Phone: +1 281 930 7680
Fax: +1 281 930 7681
E-mail: [email protected]
www.trumarine.com

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