Intake/exhaust system H01

M5h01002 Page 1 of 3

Intake/exhaust system H01

Contents

Page 2 Schematic

Page 3 Introduction

Page 3 Instrumentation

Intake/exhaust system Ruston RK215

M5h01002 Page 2 of 3 Section H01

Intake/exhaust system Ruston RK215


Introduction

A single, exhaust gas driven, axial flow type turbocharger is fitted to each engine. The turbine driven centrifugalcompressor draws air through the locomotive mounted filter and compressed air is passed through a charge aircooler to the cylinders. Exhaust gas, from the turbocharger is fed into an exhaust outlet duct.

A butterfly valve (SV1) is fitted to the compressed air outlet from the turbocharger. This closes in the event of anengine overspeed or emergency stop shutdown signal.

The engine mounted charge air cooler reduces the temperature of the air delivered by the turbocharger foroptimum power and economy.

Instrumentation

Please refer to the Instrument Schedule in Section N

Document intentionally blank


Turbocharger H02

Turbocharger part No. 80.580.02443.104

Contents

Page 2 Diagram

Page 3 Introduction

Page 3 Maintenance

Turbocharger Ruston RK215


Turbocharger Ruston RK215


Introduction

The exhaust gas from the engine is directed, via the exhaust manifold, to the gas intake casing of theturbocharger. The gas thus collected is directed by the blades of the nozzle ring towards the blades of the turbinewheel so as to drive the latter.

The turbine wheel drives the centrifugal compressor by means of a shaft. The rotation of the compressorpressurises the air and imparts kinetic energy to it. Most of this energy is transformed into pressure by means ofthe radial-flow and axial-flow diffusers.

The volute shaped compressor casing directs the pressurised air into the engine.

Speed pick up installation and adjustment.

For diagram refer to figure 5.1 in the manufacturers instuction manual.

The following procedure is to be carried out instead of the one outlined in the instuction manual.

1. Remove the speed pick-up and insert mechanism (82) into the shaft which has a slot which will locate on theend of the mechanism and lock in position.

2. Remove the mechanism (82) and rotate the shaft by 90o

3. Screw in the speed pick-up slowely in order to avoid damage to the tip .4. When the tip comes in contact with the surface of the shaft turn the speed pick-up probe back 90o this will set

a gap of 0.40mm which gives the best output for recording.5. Lock in position with the counternut to a torque of 8 mKg.

Maintenance

For full maintenance details refer to the suppliers literature.

Interval – A

Visually inspect the turbocharger and check for leaks. The turbocharger will require cleaning if there is anoticeable drop in discharge pressure.

Interval – F

Check and overhaul


USINE DE BEZONS35, rue Jean Jaurès

95870 BEZONS - FRANCETéléphone : 01 34 34 50 50

Téléfax : 01 34 34 50 00

TURBOCHARGER DIVISION

SPECIFICATION : HS 5808 A1L 81 MS 157

SERIAL N° : 515 000

PART N° : 078677

ENGINE : MAN-B&W-RUSTON 16 RK 215

ILLUSTRATED PARTS CATALOG

TURBOCHARGER MODEL HS 5800 NGTSerial Number : 515000

EDITION N°6 : Jun. 2004

TURBOCHARGER HS 5800 NGT Page 2/16

1 SUBJECT

This document allows the end user of the TURBOMECA turbocharger toidentify and locate the differents components of the unit.

2 COMPOSITION

The illustrated part catalog provides :

• the complete list of the HS 5800 NGT turbocharger components,• the list of specific tools for maintenance and overhaul,• the list of parts included in the kits for general overhauls.

The HS 5800 NGT components are divided in 4 main groups, i.e. :

A Group parts belonging to the main rotating assembly (common to all HS5800 NGT models).Refer to : pages 5 - 6 - 7

B Group parts common to all HS 5800 NGT models but not belonging to themain rotating assembly (Group A).Refer to : pages 8 - 11

C Group all specific parts concerning a single model of HS 5800 NGTturbocharger or HS 5800 turbocharger belonging to the samegroup of serial numbers.Refer to : pages 9 – 10 - 11

D Group adaptation parts of the turbocharger on the engine as well asoptional items.Refer to : page 12

.../...


The parts lists are included in the enclosed documents. Each part list(enclosed documents) shows four columns with the following titles (from leftto right side) :

• Item No• 6 digit part number of the part• Part description• Part quantity per turbocharger.

As for A and C groups, and when referring to the drawings, the list of the partsshows the sub-assemblies and its corresponding individual components.

• An individual part shown with two (2) dots (• •) belongs to a sub-assemblyindicated just above and shown with only one (1) dot (•).

• A sub-assembly shown with one (1) dot (•) includes all the parts indicatedjust below and shown with two (2) dots (• •).

3 USEFUL INFORMATIONS

3.1 SPARE PARTS STOCK

Upon request, spare part lists recommendation can be providedaccording to the type of application, site and average operating time.This request should be addressed to the After-Sales department ofTURBOMECA Turbocharger Division, hereafter.

3.2 SPARE PARTS ORDER

For every spare parts order, it is required to give :

• the turbocharger serial number,• the manufacturer part number,• the description,• the quantity.

.../...


Orders must be sent to :TURBOMECA

TURBOCHARGER DIVISION

35, Rue Jean Jaures

95870 BEZONS

FRANCE

Tél.- (33) 1 34 34 50 50

Fax.- (33) 1 34 34 50 00

NOTA.- Ordering a sub-assembly implies the delivery of all componentswhich are immediately listed below the same sub-assembly.

.../...


A GROUP : MAIN ROTATING ASSY NOMENCLATURE : 078280 FIG. : Page 7/16

ITEM. PART No DESCRIPTION QTY

1(*) 078280 MAIN ROTATING ASSEMBLY 1

2 078486 • Complete exhaust casing 13 078242 • • Exhaust casing 14 078240 • • Hiding flange 25 319328 • • Lock washer 66 436398 • • Screw hexagonal head 6

(**) 078245 • Plate 1(**) 426999 • Screw 2(**) 401673 • Plate washer 27 441841 • Screw 48 078251 • Double locktab 19 078250 • Double locktab 110 078071 • Centering pin 411 125046 • Lock washer 1012 078941 • Screw 1013 078485 • Main casing, equiped 114 460775 • • Gasket 215 220635 • • Plug 216 078259 • • Plug 117 078021 • • Main casing 118 460772 • Gasket 119 078261 • Plug 120 436399 • Screw 421 125098 • Lock washer 422 297495 • O-ring 123 125070 • Labyrinth, compressor side 12425 427678 • Screw 626 078248 • Lock washer 227 078249 • Lock washer 128 078852 • Labyrinth 129 078237 • Front bearing 1

.../... NOTA : (*) refer to page 11 (**) not illustrated Edition : 6 (***) not to be sold separately, included only in suassy

Date : Jun. 2004


A GROUP : MAIN ROTATING ASSY NOMENCLATURE : 078280 FIG. : Page 7/16


30 078253 • O-ring 231 078376 • Adjusting shim 132 078252 • O-ring 133 078088 • Shaft 134 078267 • Centering pin 335 078235 • Rear bearing 1(**) 460005 • • Centering pin 2(**) 436395 • • Screw hexagonal head 2(**) 320171 • • Lock washer 236 078024 • Heat insulation 1(**) 078382 • • Heat insulation, upper 1(**) 078383 • • Heat insulation, lower 137 078025 • Heat insulation 138 078067 • Seal ring 139 078026 • Heat insulation, main 1(**) 078380 • • Heat insulation, right 1(**) 078381 • • Heat insulation, left 140 460772 • Gasket 141 078261 • Plug 142 078859 • Labyrinth assembly, turbine side 1(**) 078857 • • Labyrinth turbine 1(**) 078856 • • Labyrinth ring 143 078096 • Air deflector 144 464175 • Clips 145 053788 • Screw 846 078553 • Double locktab 4

NOTA : (*) refer to page 11 (**) not illustrated Edition : 6


(***) not to be sold separately, included only in suassy

Date : Jun. 2004

B GROUP : COMMON PARTS NOMENCLATURE : 078950 FIG. : Page 11/16


70 263441 Rivet 471 298508 Identity plate 172 078004 O-ring 173 078068 Centering pin 474 078373 Adjusting shim 476 408566 Locktab 477 441866 Screw 478 078004 O-ring 179 078406 Spring washer 180 078269 Screw 3(**) 125097 Locktab 381 078089 Ring 185 078005 O-ring 187 078005 O-ring 195 078079 Compressor nose 1(**) 078935 Spline 1296 078945 Stud 2497 078075 Compressor nut 198 078074 Spring washer 199 078073 Tie rod 1106 078069 Centering pin 4107 078258 Screw 3108 078269 Screw 2109 078262 Seal ring 1115 078263 Screw 4116 078271 Double locktab 2117 078917 Centering pin 4118 078947 Nut 24119 442310 Lock washer 24123 078555 Double locktab 6

NOTA : (*) refer to page 11


(**) not illustrated Edition : 6 (***) not to be sold separately, included only in subassy

Date : Jun. 2004

C GROUP : SPECIFIC PARTS NOMENCLATURE : 078677 FIG. : Page 11/1


75 078545 • Ported-shroud assembly 182 078869 • Diffuser elbow 183 078822 • Axial diffuser assembly 1(**) 297499 • • Deswirler 1484 441832 • • Screw hexagonal head 28(**) 401668 • • Plan washer 28(**) 078771 • • Plate 1486 078609 • Radial diffuser 188 078936 • Complete compressor casing 189 220635 • • Plug 390 460747 • • Gasket 392 504585 • • Helicoil 12(**) 096947 • • Helicoil 28(**) 332866 • • Helicoil 3(**) 078375 • • Insert 4100 12589009 • Compressor wheel assembly 1

101(***) 078008 • • Centering pin 4102(***) 078003 • • Insert 1103(***) • • Compressor wheel 1

104 078231 • Turbine 1105 125050 • Diffuser ring 1(**) 078848 • Nozzle assembly 1110 078734 • • Labyrinth 1111 298698 • • Nozzle 1112 078743 • • Plate 1113 078740 • • Double locktab 6114 078749 • • Screw hexagonal head 12120 297921 • • Inlet casing 1(**) 394317 • • Plug ½ BSP 2(**) 394318 • • Copper washer Ø½ 2122 078748 • • Screw hexagonal head 12(**) 078815 • Support parts 1150 125021 • • Rear bracket assembly, left 1(**) 298483 • • • Bloc 1(**) 078864 • • • Support plat 1


NOTA : (*) refer to page 11 (**) not illustrated Edition : 6 (***) not to be sold separately, included only in suassy

Date : Jun. 2004

C GROUP : SPECIFIC PARTS NOMENCLATURE : 078677 FIG. : Page 11/1


(**) 282906 • • • External split pin 1(**) 468084 • • • Internal split pin 1(**) 125021 • • Rear bracket assembly, right 1(**) 298483 • • • Bloc 1(**) 078864 • • • Support plate 1(**) 282906 • • • External split pin 1(**) 468084 • • • Internal split pin 1151 053515 • • Screw hexagonal head 4152 440179 • • Locktab 2(**) 440185 • • Locktab 2153 078907 • • Front bracket, left 1(**) 078906 • • Front bracket, right 1154 427696 • • Screw hexagonal head 4155 125046 • • Lock washer 4


NOTA : (*) refer to page 11 (**) not illustrated Edition : 6 (***) not to be sold separately, included only in suassy

Date : Jun. 2004

Obs : 1-Part numbers 91/94/121 were eliminated 2-The gas inlet casing illustred(120) is a generic casing

D GROUP : OPTIONAL AND ADAPTATION PARTS

PART No DESCRIPTION QTY

393971 SPEED PICK-UP 1

297877 AIR FILTER SILENCER 1

297864 • Air filter assembly 1297863 • • Air filter 1297225 • • • Air filter cartrigde 1394455 • • Pressure loss indicator 1394456 • • Connexion of pressure loss indicator 1394036 • Gasket 1442310 • Lock washer 12427698 • Screw hexagonal head 12

297879 AIR INLET ELBOW 1

297260 • air inlet elbow 1297878 • Impeller washing injecteur 1405957 • Screw 1220635 • Plug 3460775 • Gasket 3394036 • Gasket 1427698 • Screw hexagonal head 12401673 • Washer 12


Edition : 6 Date : Jun. 2004

601599-78 - SET OF TOOLS FOR OVERHAUL

PART No DESCRIPTION QTY

601547-78 COMPULSORY TOOLS601531-78 Lock shaft tool 1601532-78 Tighten compressor cap tool 1

601548-78 AUXILIARY TOOLS601059-78 Extractor turbine tool 1601527-78 Guide ¯ 10 2601528-78 Guide ¯ 8 2601529-78 Extractor ¯ 6 4601530-78 Guide ¯ 6 2601538-78 Tool for assembling the rotating seal 1601539-78 Extractor ¯ 8 2601540-78 Extractor ¯ 10 2601057-78 Circlips plier 1

601549-78 TOOLS FOR NOZZLE THROAT ADJUSTEMENT601804-78 Tool for locating the sphere of 601508-78 1601536-78 Dog for throat change 1601545-78 Lovcating arc for serie 8 1600014-78 Dial indicator 1601508-78 Tool for bore measure 10 to 18 mm 1


Edition : 6Date : Jun. 2004

KIT FOR GENERAL OVERHAUL P/N 078457 - LIST OF COMPONENTS

ITEM PART No DESCRIPTION QTY PAGE

5 319328 Lockwasher 6 7/166 436398 Screw 2 7/167 441841 Screw 1 7/168 078250 Double locktab 1 7/169 078251 Double locktab 1 7/16

10 078071 Centering pin 1 7/1611 125046 Lockwasher 11 7/1612 078941 Screw 3 7/1614 460775 Seal ring 2 7/1618 460772 Seal ring 1 7/1620 436399 Screw 1 7/1621 125098 Lockwasher 4 7/1622 297495/078004 O-ring 1 7/162425 427678 Screw 2 7/1626 078248 Lockwasher 2 7/1627 078249 Lockwasher 1 7/1630 078253 O-ring 2 7/1631 078376 Adjusting shim 1 7/1632 078252 O-ring 1 7/1634 078267 Centering pin 1 7/1640 460772 Seal ring 1 7/1645 053788 Screw 2 7/1646 078553 Double locktab 4 7/1672 078004 O-ring 1 11/1673 078068 Centering pin 1 11/1674 078373 Adjusting pin 4 11/1676 408566 Locktab 4 11/1677 441866 Screw 1 11/1678 078004 O-ring 1 11/1680 078269 Screw 1 11/16(**) 125097 Locktab 3 11/1684 441832 Screw 6 11/16(**) 401668 Washer 6 11/16(**) 078771 Plate 6 11/1685 078005 O-ring 1 11/16


87 078005 O-ring 1 11/1696 078945 Stud 6 11/16




(**) 078935 Spine 6 11/16106 078069 Centering pin 1 11/16107 078258 Screw 1 11/16108 078269 Screw 2 11/16109 078262 Joint METAFLEX 1 11/16113 078740 Double locktab 6 11/16114 078749 Screw 12 11/16115 078263 Screw 1 11/16116 078271 Double locktab 2 11/16117 078917 Centering pin 1 11/16118 078947 Nut 6 11/16119 442310 Lockwasher 24 11/16122 078749 Screw 12 11/16123 078555 Double locktab 6 11/16151 053515 Screw hexagonal head 4 11/16152 440179 Locktab 2 11/16(**) 440185 Locktab 2 11/16154 427696 Screw hexagonal head 4 11/16155 125046 Lock washer 4 11/16






078457 Kit for general overhaul 129 078237 Front bearing 1 7/1635 078235 Rear bearing 1 7/16115 078263 Screw hexagonal head 4 7/16




M5H03012 Page 1 of 3

Air shut-off system H03

Contents

Page 2 Diagram

Page 3 Introduction

Page 3 Operation

Page 3 Resetting

Page 3 Maintenance

Page 3 Data

Air shut-off system Ruston RK215

M5H03012 Page 2 of 3 Section H03

Air shut-off system Ruston RK215

M5H03012 Page 3 of 3 Section H03

Introduction

An air butterfly valve is fitted, between the turbochargerair outlet and intercooler ducting, to shut off the airsupply in the event of an engine overspeed occurring.Under normal conditions an electro-magnet is energisedto hold the valve open for running (Fig.1).

In the event of an overspeed condition the electro-magnet is de-energised and the valve closes (Fig.2).

Operation

A speed pick-up (Fig.3) sensing the passing of theflywheel ring gear teeth sends a signal to a speedsensing switch.

The switch is set to operate at approx. 15% above thenormal maximum engine speed. The switch de-energises the electro-magnet allowing the valve to close.

CAUTION:-Running of the engine either with shut down

butterfly valves in part-closed condition or with onlyone valve open will result in damage to

turbochargers.

Resetting

The air shut-off system should only be reset once allcauses and investigations into the shut-off have beenrectified.

The valve can be reset by rotating the shaft at thesquare drive (Fig.4), opening the valve and re-engagingthe armature plate with the magnet.

MaintenanceFor maintenance hours see scheduleB-Interval

Check the integrity of all wiring, pipework andconnections in the system.

C-IntervalClean and lubricate

F - IntervalRemove the air shut-off valves from the engine,dismantle and check for wear.

DataSpeed switch setting 1150r/min

Fig.1 Electro-magnet is energised to hold open the valve

Fig.2 Electro-magnet de-energises to close the valve

Fig.4 Reset the drive by rotating the shaft as shown.

Fig.3 The speed pick-up positioned by the flywheel.



Chargecooler H04

For service information on this component refer to thesuppliers literature at the end of this instruction

Manufacturer – Bloksma

Ruston Ref:- 80.580.02441.C01

Contents

Page 2 Introduction

Page 2 Maintenance

Page 2 Dismantling

Page 2 Chargecooler performance/cleaning

Chargecooler Ruston RK215


Introduction

The chargecoolers are tube heat exchangers. The hot compressed air from the turbocharger is cooled by flowingover the outside of the tubes.

The chargecooler is mounted in air ducts between the turbocharger and the engines integral air chest.

Maintenance

B-Interval

Check for air/water leaks with engine running.

E-Interval

Dismantle and clean. Renew joints and clean air ducts.

G-Interval

Dismantle and overhaul.

Dismantling

Drain down the cooling water system, disconnect the associate water pipes and air ducting and remove thechargecooler(s) from the engine.

Chargecooler performance/cleaning

For information on chargecooler performance checks and cleaning instructions refer to the following suppliersliterature.



CONTENTS

1. INSTRUCTIONS FOR INSTALLATION AND OPERATION 4

A. CLEANLINESS PROVISIONS 4B. RECEIPT 4C. LEVELING 4D. INSTALLATION 4E. PERFORMANCE OF THE HEAT EXCHANGER 4F. OPERATION OF THE HEAT EXCHANGER 4G. FLUID FLOW 4H. VENTS 4

2. INSTRUCTIONS FOR MAINTENANCE 5

A) INSPECTION OF THE HEAT EXCHANGER 5B) DISASSEMBLING THE HEAT EXCHANGER 5C) GASKET REPLACEMENT 5D) CLEANING, GENERAL INFORMATION 5E) CLEANING WATER SIDE 5F) CLEANING AIR SIDE 5

3. TROUBLE SHOOTING 6

A) PERFORMANCE TOO LOW 6B) LEAKING TUBES / TUBE-TO-TUBESHEETCONNECTION 6C) LEAKING GASKET OR O-RING 6

4. INSTRUCTIONS FOR CONSERVATION 7

A) GENERAL 7B) SHORT TERM CONSERVATION 7C) LONG TERM CONSERVATION 7

5. SPARE PARTS 7

A) PARTS 7

6. INSTRUCTIONS REGARDING GASKETS AND BOLTING 8

A) FLAT GASKETS 8B) BOLTING, WITH A FLAT GASKET DESIGN 8C) STORAGE OF FLAT GASKETS 9D) O-RINGS 9



1. INSTRUCTIONS FOR INSTALLATION AND OPERATION

a) CLEANLINESS PROVISIONS

Remove protective plugs and covers of the connecting flanges before installing the heat exchanger.Protective plugs and covers should not be removed until just prior to installation.

b) RECEIPT

Upon receipt of the heat exchanger it should be checked that during shipment no damage has occurred.The heat exchanger (and or its casing) may not show any visible damage. Transport damage has to bereported to Bloksma.

c) LEVELING

Heat exchangers must be set level and square so that pipe connections may be made without forcing.

d) INSTALLATION

During installation, make sure that no unacceptable thermal or mechanical stresses are exerted on theconnections, otherwise expansion bellows must be fitted.Before connecting piping to the heat exchanger flanges, make sure that the gasket surface is clean andfree from scratches and other defects. Gaskets should be properly positioned. Always use new gaskets,of the type that is required for the flange connection. An incorrect flange assembly may result in leakageand/or damage to the flange construction.Although every heat exchanger has been hydrostatic tested in our factory, normal relaxing of the gasketjoints may occur in the interval between hydrostatic tests and installation at jobsite. Before putting theheat exchanger into operation it is required to check the flange connection (torque) in accordance withsubject "Instructions regarding gaskets and bolting".

e) PERFORMANCE OF THE HEAT EXCHANGER

Correct installation and preventive maintenance are user responsibilities. Failure of the heat exchangerto perform satisfactory may be caused by:• Improper start-up or shutdown sequences.• Excessive fouling.• Operating conditions differing from the design conditions.• Maldistribution of flow through the heat exchanger.

f) OPERATION OF THE HEAT EXCHANGER

Before placing the heat exchanger in operation, reference should be made to the drawings, specificationsheet and nameplate for any special instructions. The heat exchanger must not be operated atconditions which exceed those specified on the name plate and specification sheet. Exchangers shouldnot be subjected to abrupt temperature fluctuations, which can cause leaking of tube-to-tubesheet and /or bolted flanged joints.

g) FLUID FLOW

The performance of some heat exchanger types is dependent on the direction of the airflow andwaterflow. These types have an arrow plate or a cast on arrow on the waterbox (channel), indicating thedirection of the airflow. The waterflow and, for heat exchangers with more than one water circuit, thecircuit connection is indicated on the heat exchanger drawing.

h) VENTS

After installing the heat exchanger, the cooling water should be circulated and the water side vented.



2. INSTRUCTIONS FOR MAINTENANCE

a) INSPECTION OF THE HEAT EXCHANGER

At regular intervals and as frequent as experience indicates, an examination should be made of theinterior and exterior condition of the heat exchanger. Where suspicious fluid quality occurs or whensacrificial anodes are used, the inspection interval should be determined by initially choosing a shortinspection interval (weekly). Based upon the results of these inspections the final inspection interval canbe determined. Insufficient inspection could cause severe thermal strains, leaking tube joints or structuraldamage to other components. Heat exchangers subject to fouling should be cleaned periodically.

b) DISASSEMBLING THE HEAT EXCHANGER

Before disassembly any part of the heat exchanger, make sure that the system of which the heatexchanger is part of, is de-pressurised, cooled down to ambient temperature and fully drained.

c) GASKET REPLACEMENT

All disassembled joints the gaskets (and O-rings) must be replaced by new ones. Before installing newgaskets (O-rings) make sure that the gasket surface is clean and free from scratches and other defects.Gaskets should be properly positioned especially when the gasket has a partition.Bolted joints are designed for a particular use, with the type of gasket as specified by Bloksma.Substitution of a gasket of a different make or of different dimensions may result in leakage and/ordamage to the flanged construction. Before putting the heat exchanger into operation it is required tocheck the flange connection (torque) in accordance with subject "Instructions regarding gaskets andbolting".

d) CLEANING, GENERAL INFORMATION

Depending on the air and cooling water quality the heat exchanger must be periodically cleaned. As aguide an interval between cleaning periods of half a year is a good figure.An effective method to clean air and waterside is to have the complete heat exchanger cleaned by aspecialised cleaning service company.

e) CLEANING WATER SIDE

Cleaning of the waterside can be done chemically and by brushing.

Chemical cleaning of the waterside:If suitable connections and valves are available this can be done by circulating a solvent (chemicalsolution) through the heat exchanger. When this is not the case, the heat exchanger should bedismantled and treated in a tank.

Solvents can be dangerous to the heat exchanger.The supplier of the solvent (chemical solution) should verify and confirm the compatibility of his productwith the materials given on the heat exchanger drawing. Mechanical cleaning of the waterside:Mechanical cleaning can be done by means of brushes. The material of the brushes must be equivalentof the material of the tubes. In case of internally coated tubes only nylon brushes are allowed.

f) CLEANING AIR SIDE

When the air circuit is broken beware of dirt and chips entering the system. This can damage the heatexchanger and engine. Remove the heat exchanger and disassemble the waterbox(es)/cover.

Dip the cooling element in a solvent tank and give it some time to loosen the deposits.Afterwards blow out the dirt with compressed air or steam. If necessary repeat the process.



Solvents can be dangerous to the heat exchanger.The supplier of the solvent (chemical solution) should verify and confirm the compatibility of his productwith the materials given on the heat exchanger drawing.

3. TROUBLE SHOOTING

a) PERFORMANCE TOO LOW

Depending on the quality of the fluids and operating conditions, the heat exchanger must be cleanedperiodically. See also “Instructions for maintenance”.

Check the following items:• Have the heat exchanger and the system been vented properly? Air can obstruct the flow! Subsequently, open all vents and repeat the same with circulating water.• Are the flows according to the specification? Check all valves, lines and pumps. If applicable, check the specified air flow direction through the heatexchanger.• Are the water and air side of the heat exchanger clean? Fouling can cause a drop in performance and an increased pressure loss. An increased pressure drop isa good indication that cleaning should take place. Proceed as given under CLEANING.

b) LEAKING TUBES / TUBE-TO-TUBESHEETCONNECTION

Leakage can occur due to a leaking tube or due to a leaking tube-to-tubesheet connection.

First it should be determined where the leakage occurs. In many cases this is a time consumingexercise. There are special tools available for locating both type of faults. We advise to contact BloksmaBV, service department for further instructions (+ 31 36 5320214).

Leaking tube-to tubesheet connection:The tubes are roller expanded into the tubesheet.Expanding should be done by means of a tube expander of the right size and length. Expansion has tobe done over 80% of the tube plate thickness. When expanding a leaking tube, also re-expand theadjacent tubes lightly because they may be affected. Because tube expanding without experience is noteasy, we advise to contact Bloksma BV, service department for further instructions (+ 31 36 5320214).For ordering an expander, follow the instructions as described in subject "Spare parts".Leaking tube:A leaking tube cannot be removed or replaced, but it can be plugged off. When tubes are plugged off,the tube-to-tubesheet connection should be checked by hydrotesting.Proceed as follows:• Disassemble the channel as described in subject "Disassembling and assembling the heatexchanger".• Hydrotest the shell side of the heat exchanger at operating pressure.• Plug off the leaking tubes at both sides by means of Bloksma tube plugs. By using non original plugs,there is a possible chance that the adjacent tubes will leak.• Do not hammer too strong.For ordering plugs follow the instructions as described in subject "Spare parts".

c) LEAKING GASKET OR O-RING

Check the gasket / O-ring surface of the components.If necessary, remove dirt and corrosion residues and bring the surface into good shape again. Mountnew gaskets / O-rings in accordance with subject "Instructions regarding gaskets and bolting".For ordering gaskets and / or O-rings, follow the instructions as described in subject "Spare parts".



4. INSTRUCTIONS FOR CONSERVATION

a) GENERAL

Due to the materials of the exchanger, some attention must be paid for conservation; especially whenthe exchanger is not put into operation within a short time after delivery.

b) SHORT TERM CONSERVATION

(up till approximately 6 months)At the Bloksma factory, all exchangers are treated internally with a rust preventive coating on the tubeside.Under not extreme conditions this layer will give protection against rust for a period of maximum 6months.

c) LONG TERM CONSERVATION

(up till approximately 24 months)Beware of condensation in the exchanger; this can be caused by fluctuating temperatures.When a dry atmosphere in the exchanger can be guaranteed during an extended period of time, nospecial treatment is necessary.If this is not the case, fill the exchanger with an inert gas and close all openings airtight. Additionally silicagel can be used to absorb any liquid. Alternatively, the exchanger can be treated with a rust preventiveliquid of a type suited for long term conservation.The preservation liquid must be removed with a mineral solvent (petroleum) before the exchanger is putinto operation.

5. SPARE PARTS

a) PARTS

• Gaskets and / or O-rings• Plugs• Tube expander• Bolts / nuts



6. INSTRUCTIONS REGARDING GASKETS AND BOLTING

a) FLAT GASKETS

The gasket surface has to be cleaned and remains of old gaskets have to be removed. Please take carethat the gasket surface is not damaged when scrapers are used. The surface has to be cleaned in acircumferencial direction in order to avoid that radial grooves are created.

The gaskets used are of an multi-layered graphite-stainless steel type.Do not re-use the same gasket again. The gasket will have lost its recovery characteristics through use.Always use the original gaskets for replacements. Low-priced replacements are a false economy due totheir shorter lifetime and higher failure rate.

It is required to re-tighten the gasket before it is exposed to the operating temperature. Especially after along storage period, the torque can loose its original value.

After exposure to elevated temperatures, re-tightening is not allowed anymore due to hardening of thegasket material. Before installing the gaskets, please check for cracks, damaged surfaces anddimensional differences.

Attention must be paid that the gasket is placed on the centre line of the heat exchanger. The partition ofthe gasket must be centred on the centreline of the heat exchanger. It is not allowed for the gasket tocover any tube.

b) BOLTING, WITH A FLAT GASKET DESIGN

The bolts and nuts have to be checked for damages. In order to ensure a proper sealing, the thread hasto be lubricated slightly. The bolts are to be tightened with controlled torque, so a torque tensioningdevice has to be used.The bolts are to be tightened in three stages. At first the torque has to be 50 %, then 80 % and finally100 % of the end value to ensure an equal load on the gasket and avoid flange distortion.

The tightening torque is as follows (based on friction factor 0.2 and 50% yield):

Bolt material Bolt size Moment Nm Bolt size Moment Nm8.8 M10 33 3/8” 28

M12 58 1/2" 68M16 148 5/8” 136

Bolt material Bolt size Moment Nm Bolt size Moment Nm12.9 M10 56 3/8” 47

M12 99 1/2" 114M16 249 5/8” 229

Bolt material Bolt size Moment Nm Bolt size Moment NmA 193 B7 M10 38 3/8” 31

M12 66 1/2" 76M16 166 5/8” 153

THE GASKETS MUST BE MOUNTED WITHOUT ANY SEALING AID, JOINTING COMPUND,MOLYCOTE, GRAPHITE, GREASE OR OTHER LUBRICANT.SO THE GASKETS MUST BE APPLIED COMPLETELY DRY.

ANY SEALING-AID WILL DESTROY THE SEALING CAPABILITY OF THE GASKET.ANY WARRANTY CLAIM WILL BE REJECTED WHEN SEALING-AID IS USED.



c) STORAGE OF FLAT GASKETS

The gaskets consist of some rubber, which is subjected to ageing.

It is strongly recommended that the gasket are:• Stored in a dry atmosphere at a reasonably steady temperature of around 20 °C or less.• Not subjected to changes in temperature or humidity.• Stored in dark conditions, away from direct sunlight.• Stored in a flat position, i.e. they are not either hung on hooks/peg-boards - which leads tophysical damage - or folded, which can cause cracking.

d) O-RINGS

The O-rings used are of an E.P. (Ethylene-propylene) type. Do not re-use the same O-rings again.Always use the original O-rings for replacements. Low-priced replacements are a false economy due totheir shorter lifetime and higher failure rate. It is not required to re-tighten the O-ring connection before itis exposed to the operating temperature.

THE O-RINGS MUST BE MOUNTED WITH A SPECIAL O-RING LUBRICANT. THE USE OFLUBRICANTS WHICH ARE NOT COMPATIBLE WITH THE O-RING CAN DESTROY THE

SEALING CAPABILITY OF THE O-RING.ANY WARRANTY CLAIM WILL BE REJECTED WHEN AN IMPROPER SEALING-AID IS USED.



Exhaust manifold H05

Contents

Page 2 Diagram

Page 3 Introduction

Page 3 Maintenance

Page 3 Removal

Page 3 Refitting

Page 3 Data

Exhaust manifold Ruston RK215




Introduction

The exhaust manifold is built up with a series of commoncomponents; an exhaust pipe is fitted to each cylinderhead and these are connected together with eitherexpanding bellows or a turbocharger inlet pipe.

Maintenance

G-Interval

Renew bellows and joints. Inspect pipes.

H-Interval

Renew exhaust system.

Removal

The design of the manifold is such that it is onlynecessary to remove the component requiring attention.

Refitting

The exhaust system is to be assembled to the engineusing setting gauges in place of the bellows and gasketsto ensure that the correct exhaust manifold toturbocharger (fig.2) and exhaust manifold to exhaustmanifold spaces (fig.3) as quoted under DATA.

When refitting a component renew all joints and coatbolt/screw threads with anti-seizure compound.

1. Assemble all exhaust branches to cylinder headsand tighten fasters loosely.

2. Starting at the turbocharger end insert theappropriate setting gauge as quoted underSPECIAL TOOLS.

3. Ensuring turbocharger flange face is square toexhaust manifold flange face on cylinders A8 andB8 tighten cylinder head exhaust manifold fasters totorque quoted under DATA.

4. Repeat this process for the rest of exhaustbranches.

All bellows to be stretched on assembly to the figuresquoted under DATA.

Fig.1 Exhaust system as fitted to the engine.

Fig.2 Exhaust manifold to turbocharger setting gauge.

Fig.3 Exhaust manifold to exhaust manifold setting gauge.



Special tools

Turbocharger to exhaust manifold bellow setting gauge 80.561.02617.200

Exhaust manifold to exhaust manifold bellows setting gauge 80.561.02616.200

Data

Manifold to Bellows bolt torque 120Nm

Manifold to cylinder head screw torque 70Nm

Turbocharger to exhaust manifold bellow setting 84.8/85.0mm

Exhaust manifold to exhaust manifold bellows setting 82.8/83.0mm

Turbocharger bellow stretch figure 5.14mm

Exhaust manifold stretch figure 3.14mm

Documents

Intake/exhaust system H01