ASB2011/12/09

Alert SB-Nr.: ASB2011/12/09

Subject Product safety warning for TCR14, TCR16, TCR18, TCR20 and TCR22
turbochargers
Important operational instruction relating to safety and the safe operation of the
above turbochargers

Serial Numbers concerned All

Reason In December 2009 MAN Diesel & Turbo by ASB2009/12/23 initiated a product
recall of the TCR turbochargers produced until then. With that bulletin we informed
all customers that due to a failure of the flange connection, in case of a damage to
the compressor wheel there is a risk that fragments of the compressor wheel could
be released. This risk poses a substantial subsequent risk to the health and safety
of the operating personnel. In consequence, we conducted a recall and update
action with an updated flange connection, which we have also introduced in our
subsequent serial production of TCR turbochargers.

We take safety issues relating to our products very seriously and have therefore
subsequently extended our efforts regarding safety related research through the
further development of critical testing procedures and processes. As a responsible
manufacturer of premium quality products, we are committed to keeping you
informed of any significant changes in the perceptions of risk caused by such
research where those changes in perception relate to the safe operation of our
products.

Consequently, we need to inform you today that, while there have been no field
incidents with TCR turbochargers updated or produced since 2009, recent tests
and investigations have shown that the recall and update action of December 2009,
and the corresponding design change of our TCR turbochargers, reduced but did
not fully eliminate the risk. Even with the updated flange connection, it is still
possible that fragments with high kinetic energy can be released from the
turbocharger if the compressor wheel breaks.

According to our investigations, a breakage of the compressor wheel will occur only
if there is a pre-damaged compressor wheel or turbine wheel, both resulting in a
spontaneous major unbalance of the rotor at high turbocharger speed. Such a pre-
damage of the mentioned components can in particular be caused by the impact of
foreign particles, poor fuel quality or improper handling.
ALERT Service Bulletin

If the compressor wheel breaks and parts are released from the turbocharger,
personnel in the vicinity of the turbocharger may be seriously or even fatally injured
as a result, and there is also a risk of damage to adjacent machines or property,
including the risk of fires.

Compliance Mandatory / immediate action required

Description So far, the few observed containment failures of TCR turbochargers occurred
exclusively at or above 66% engine load. We do not know any case where a
compressor wheel broke below that engine load, and have no evidence that in such
a case, fragments of the wheel would be released from the turbocharger.
Therefore, based on the information currently available to us, we recommend that
no personnel should stay in the vicinity of the turbocharger during operating
times in which the engine load exceeds 60%. As already mentioned in your
turbocharger operating manual, we further recommend not to dwell or idle in the
vicinity of the turbocharger at all during engine operation, regardless of the engine
load.

The risk of a critical compressor wheel damage can be minimized by actively

avoiding foreign object impact (e.g. by ensuring a clean air supply and keeping the
exhaust valves in good condition), and by regular maintenance work carried out by
authorized personnel. Therefore, please ensure that the recommended inspection
and maintenance schedule as described in your turbocharger operating manual is
strictly adhered to. Until further notice we recommend to conduct the following
inspections and maintenance measures only during times when the engine load
does not exceed 60%:
compressor cleaning (maintenance 915);
turbine dry cleaning (maintenance 911);
daily checks (inspection 901 and 903).
Please instruct your operating personnel accordingly.

To assess and reduce the potential risk of a critical compressor wheel damage we
further recommend inspecting the compressor wheel for pre-damage. You can
conduct the inspection with your own personnel at your own convenience. Our
Service Department (contact details: see below) can provide the necessary
information.

Furthermore we explicitly request of you to forward this ASB to all your clients or
charterers using the affected TCR turbochargers.

Please accept this ASB as an initial information. It is being issued so that you are in
a position to take the proper precautionary measures quickly. Further information
on technical remedies will follow. Please be assured that we regret the
inconvenience caused and that we are working with the highest priority on an
update solution.

2-3
ALERT Service Bulletin

Contact Our Service Department is always at your disposal:

MAN Diesel & Turbo SE
86224 Augsburg
Germany
Hotline: +49 821 322 4402
e-mail: primeserv-tc-warranty@mandieselturbo.com

Please forward this information to your technical operating personnel and/or your clients!

3-3
 ASB2011/12/10

Alert SB-Nr.: ASB2011/12/10

Subject Product safety warning for TCA33 turbochargers

Important operational instruction relating to safety and the safe operation of the
above turbochargers

Serial Numbers concerned All

Reason We take safety issues relating to our products very seriously. We have recently
extended our efforts regarding safety related research through the further
development of critical testing procedures and processes. As a responsible
manufacturer of premium quality products, we are committed to keeping you
informed of any significant changes in the perceptions of risk caused by such
research where those changes in perception relate to the safe operation of our
products.

Consequently, we need to inform you today that, while there have been no field
incidents with TCA turbochargers, recent tests and investigations have shown that
with the current design of our TCA33 turbochargers, due to an insufficient flange
connection there is a risk that if the compressor wheel breaks, wheel fragments
with high kinetic energy can be released from the turbocharger.

According to our investigations, a breakage of the compressor wheel will occur only
if there is a pre-damaged compressor wheel or turbine wheel, both resulting in a
spontaneous major unbalance of the rotor at high turbocharger speed. Such a pre-
damage of the mentioned components can in particular be caused by the impact of
foreign particles, poor fuel quality or improper handling.

If the compressor wheel breaks and parts are released from the turbocharger,
personnel in the vicinity of the turbocharger may be seriously or even fatally injured
as a result, and there is also a risk of damage to adjacent machines or property,
including the risk of fires.

Compliance Mandatory / immediate action required

Description So far we have not observed a containment failure of a TCA33 turbocharger in the
field, but only a few cases involving other turbochargers with a similar compressor
section design. Those containment failures occurred exclusively at or above 66%
engine load. We do not know any case where a compressor wheel broke below
ALERT Service Bulletin

that engine load, and have no evidence that in such a case, fragments of the wheel
would be released from the turbocharger. Therefore, based on the information
currently available to us, we recommend that no personnel should stay in the
vicinity of the turbocharger during operating times in which the engine load
exceeds 60%. As already mentioned in your turbocharger operating manual, we
further recommend not to dwell or to idle in the vicinity of the turbocharger at all
during engine operation, regardless of the engine load.

The risk of a critical compressor wheel damage can be minimized by actively

avoiding foreign object impact (e.g. by ensuring a clean air supply and keeping the
exhaust valves in good condition), and by regular maintenance work carried out by
authorized personnel. Therefore, please ensure that the recommended inspection
and maintenance schedule as described in your turbocharger operating manual is
strictly adhered to. Until further notice we recommend to conduct the following
inspections and maintenance measures only during times when the engine load
does not exceed 60%:
compressor cleaning (maintenance 915);
turbine dry cleaning (maintenance 911);
daily checks (inspection 901 and 903).
Please instruct your operating personnel accordingly.

To assess and reduce the potential risk of a critical compressor wheel damage we
further recommend inspecting the compressor wheel for pre-damage. You can
conduct the inspection with your own personnel at your own convenience. Our
Service Department (contact details: see below) can provide the necessary
information.

Please accept this ASB as an initial information. It is being issued so that you are in
a position to take the proper precautionary measures quickly. Further information
on technical remedies will follow. Please be assured that we regret the
inconvenience caused and that we are working with the highest priority on an
update solution.

Contact Our Service Department is always at your disposal:

MAN Diesel & Turbo SE
86224 Augsburg
Germany
Hotline: +49 821 322 4402
e-mail: primeserv-tc-warranty@mandieselturbo.com

Please forward this information to your technical operating personnel and/or your clients!

2-2
Customer Information

CUS 318 07/12

Turbochargers TCR14, TCR16, TCR18, TCR20 and TCR22

Containment safety upgrade
Effectivity
All TCR14, TCR16, TCR18, TCR20 and TCR22 turbochargers

Reason
With alert service bulletin ASB2011/12/09 MAN Diesel & Turbo released a product
safety warning. Now a validated upgrade kit is available which allows us to retract the
restrictions associated with this alert service bulletin.

Compliance
Highly recommended

Description
In December 2011 MAN Diesel & Turbo released the safety warning ASB2011/12/09.
With this ASB we informed all customers that in the rare instance of a damage to the
compressor wheel, there was a risk that fragments of the compressor wheel could be
released from the casings which posed a substantial subsequent risk to the health and
safety of the operating personnel. As a short term counter-measure we recommended
not to dwell in the vicinity of the turbocharger as long as the engine is operating above
60% engine load.
In the meantime we have developed an upgrade kit to address this risk for the above
mentioned turbochargers. This improvement comprises the following design features:

Reinforced clamping claw

Improved crash zone
Compressor casing with 24 bolts*
*-41/-42/-21/-24/-25 versions only

The new design was validated by a comprehensive set of containment tests for each
turbocharger frame size which included the application of the strictest containment
rules in our test facilities. Upgrade kits for the conversion of the turbochargers in the
field are now available. With immediate effect the new design features are being
introduced into the current production line.

1
Following the installation of the upgrade kit, we deem that the containment safety of
the turbocharger is confirmed. The restrictions set out by our alert service bulletin then
no longer apply and the normal safety instructions in your manual are fully valid.

Material / Spares
In case MAN Diesel & d you for the upgrade, please contact
PrimeServ.
Contact
Should you have any questions, please do not hesitate to contact our Technical
Service Department for further assistance:

MAN Diesel & Turbo

86224 Augsburg
Germany

Tel.: +49 821 322-4020

Fax: +49 821 322-3998
E-mail: primeserv-tc-technical@mandieselturbo.com

Please forward this information to your technical operating personnel!