Diesel Generator Engine Type L23 - 30 2 of 2 - Instruction Book

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DEP'T NO SHIP NO. SHIP TYPE
0033000 S157 11:i 000 nWT r.T.ASS r.RIIDF. on. r.ARR TF.R
TEL. DESIGN OFFICE SHIP NAME
MACH. OUTFITTING DESIGN DEP'T
2973 SINOVA
S. T. Cheong TITLE ME-DE-A.
APPROVT='.n
DIESEL GENERATOR
CHECKED BY C. H. Chung ENGINE (2/2)
DRAWN BY Young-Jin Kee
-
~
SCALE DWG NO.
6U-2831-10l ·5S-Q
DATE CONSOLIDATED NO. REV.NO.
HYUNDAI SAMHO HEAVY ItIDUSTRIES CO., LTD 2003. 05.28 M-59 F
INSTRUCTION BOOK
VOLUME IT
•
Engine type
L23/30
~HYUNDAI HEAVY INDUSTRIES CO., LTD.

ENGINE & MACHINERY DIVISION
1. Cheonha-Dong, Dong-Gu, Ulsan, Korea
TEL: (82) (52) 230-7412 (Spare Part Sales)
(52) 230-7418 (After Service)
FAX: (82) (52) 230-7210n320
E-Mail: engineas@hhi.co.kr
http://www.hhi.co.kr
•
This book must In no case be wholly or partially copied and published
or passed to unauthorized persons without the permission of HYUN-
DAI HEAVY INDUSTRIES CO., LTD. ENGINE & MACHINERY DIVISION.
..
,;.
•
OPERATING MANUAL FOR
• EXHAUST-GAS TURBOCHARGERS
TYPE
NR15/R
SERIAL NO.
•
MAN B&W DIESEL AKTIENGESELLSCHAFT
STADTBACHSTRASSE 1
0-86153 AUGSBURG
D365654-2E
•
'.
OPERATING MANUAL FOR
• EXHAUST-GAS TURBOCHARGERS
TYPE
NR15/R
SERIAL NO .
•
MAN B&W 0IESEL AKTI ENGESELLSCHAFT
STADTBACHSTRASSE 1
0-86153 AUGSBURG
D365654-2E
INTRODUCTION
Our turbochargers are the result of decades of systematic research and development
work. They will meet all service requirements at any time to the full satisfaction of the
owner; provided they are properly serviced. Timely execution of the specified
maintenance work will ensure efficient operation and long life. The OPERATING
MANUAL is intended to help achieve this object.
The Operating Manual contains ·all necessary information for planned maintenance as
well as for the general overhaul of the turbochargers and should therefore be placed in
the hands of the operating personnel. A thorough study and repeated reading· to
commit the instructions to memory will enable the personnel to gain complete
understanding of the turbochargers. With this knowledge the personnel will be in the
position to run the turbochargers properly, recognize possible irregularities at an early
stage and rectify them before serious damage occurs.
•
Proper maintenance and overhaul of the turbochargers definitely require skilled
personnel. It is understood that the personnel assigned to this work has had the
necessary training and no further mention will be made of it in this operating manual.
We shall not entertain any guarantee claims based on a lack of particular instructions in
this manual in the event of damage caused by faulty handling.
Individual parts of the turbocharger may be altered due to technological development

without corresponding changes being made in this operating manual. The text and all
data apply at the time of going to print.
Letters and enquiries relating to the turbocharger should incl.ude the type and serial
number which will be found on the name plate.
This publication is copyright. Reprinting and other duplication and for-

waro'"ll'tO third parties may only take place with our written approval.
TIE
•
NR 15/R
• Section 1 TECHNICAL DATA

TABLE OF CONTENTS
D36 5654-2 E
Sheet
1
Brief description 51
Operating data 51
Pipe connections _.. _ 51
Weights _ 51
Longitudinal section _ 51
Gaps and clearances 52
Section 2 DESCRIPTION OF SYSTEM 2
• Lubricating oil system _. ._ 51
Abschnitt 3 OPERATION 3
Starting . . _. ._ 51
Operation _.. _ _. __ _ 51
Stopping . _. __ . _ _ 51
Operating difficulties __ . _.. __ 52
Cartridge _. .._ __ __ 52
Emergency operation with inoperative turbocharger . . . . .. . . . . . . . . . . . . .. 53
•
Fault·finding chart _. __ .. _. __ . . . . _. 54
Section 4 MAINTENANCE 4
Maintenance schedule _ _. _ 51
Maintenance work 52
Checking components 53
Work cards (description) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 54
Hints . _. _.. _. . . . _.. _ _ 55
List of work cards .. _ _ _. _. _ 500.01-
Section S SPARE PARTS LIST 5
•
Ordering spare parts
List of single parts
0365654-2 E 489
ABGASTURBOLADER
1
•
EXHAUST-GAS TURBOCHARGER
TURBOCOMPRESSEUR A GAZ D'ECHAPPEMENT
TURBOSOBREAlIMENTADOR DE GAS DE ESCAPE
SOBREAlIMENTADORES
TURBOSOFFIANTI A GAS DI SCARICO
50
TECHNISCHE DATEN
TECHNICAL DATA
CARACTERISTIQUES TECHNIQUES
DATOS TECHNICOS
• DADOS TECNICOS
DATI TECHNICI
• 0365650 1.50-1 11.78

TECHNICAL DATA NR15/R 1
• BRIEF SPECIFICATION
B~ief specification. ope~a1ing data.
pipe connections. weights
Tu~bocha~ge~ with one ~adial-flaw tu~bine stage and one ~adial-flow comp~esso~ stage
51
Roto~ mounted on two floating plane bea~ings a~~anged inboard

Turbine wheel with integral shaft. compressor wheel arranged on shaft subsequently
Admission of exhaust gases matched to exhaust pipe arrangement
Compressor with one outlet socket
Air intake casing or silencer
Bearing lubrication integrated in engine lube oil circuit
No water cooling
OPERATING DATA
Maximum admissible operating speed nmax (see type plate on compresso~ casing]
Exhaust gas temperature before turbine .......•...........•. (see Engine Operating Manual]
Lube oil pressure (measuring point directly before
• Ihe connection on the bearing casing] ..•.•.•.....•.•...bar 1.5 ± 0.2
Lube oil requiremenls (SAE 30/60'C or SAE 40/65'C)
at a turbocha~ger speed of 20.000 rpm .••......•....•. l/h 600
at a turbocharger speed of 53.000 rpm l/h 400
Lube oil fil tered 10 conlaminants smaller than mm 0.05
Maximum admissible oi I inlet temperature ~ .'C 75
Maximum admissible oil autlet temperature .'C 105
For furlhe~ operaling data. see. engine acceptance record.
PIPE CONNECTIONS
Lube oil Supply on lop of bearing casing ..•....... screw connection for pipe 12 x 1.5
Additional lubricalion
lalerally on bearing casing ..•....... screw connection for pipe 8 x 1.5
• WEIGHTS
Drain al bottom of bearing casing
•Jet assisI' {if filtedl.
(approximate vaLues)
Complete turbocharger with silencer
flange connection for pipe
flange canneclion for pipe
kg
28
25 x 2
132
x 2
Complele tu~bocharger with air intake casing kg 123

Silence~ with air filter kg 18
Air intake casing kg 9
Compressor cas ing ...•.•..•.•..•....•................................•.•.... kg 26
Replacement cartridge ... {bearing casing plus rotorJ .................••..... kg 26
Gas adm iss ion cas i ng plus lagg ing kg 45
Gas aullet diffuser kg 16
Bearing casing kg 20.5
Rotor ... lturbine ~otor 3.5 kg. compressor wheel 1.5 kgl ..........•....... kg 5.5
• 8
Turbine nozzle ring
Final diffuser
D36-5654
L - E 1.51-2
kg
~ .......•....... kg
-=-
Page 1 of 2
1.5
1.5
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"-' 501 Gas admission casing 517 Bearing casing 544 Si lencer 562 Electronic revolution counter
509 Gas outlet diffuser 520 Rotor 545 Air intake casing 579 Compressor cleoning system
513 Turbine nozzle ring 542 Final diffuser 546 Compressor casing 591 Lagging on gos admission casing
• • • •
TECHNICAL DATA 1
•
NR15/R
Gaps and CLearances
52
• Posn.No.
520.005
When new Replace or

in Designation of Ports (Port No.) remachine parts
II lustrat . min [mm) max [mm] min [mm) max [mm)
Compressor wheel (520.005)
CD Compressor casing (546.001)
Radial gap 0.50 0.60 0.40 0.70
CD + Compressor wheel
Compressor casing
(520.005)
(546.001) Axial gap 0.30 0.90 0.25 1.00
Turbine rotor (520.001)
0) Gas-admission casing (501.001)
Radi 01 gap 0.50 0.57 0.40 0.70
Turbine rotor (520.001)
(fJ ++ Gas-admission casing (501.001) Axial gap 0.50 0.90 0.40 1.00
• ® Bearing bush
Labyrinth ring
(517.002)
(520.006)
Axial
cl earonce
0.20 0.27
Admissible aberrat ion from the plane of rotation of compressor wheel

0.33
(measured with dial gauge at largest radial distance) ....•..........•... max 0.06 mm
Admissible transverse play of rotor in bearings ............... see work card 500.06
Measure radial gaps CD and 0) using feeler (thickness) gauge, and axial gaps CD
and (fJ by means of soft metal imprint (lead wirel. Always measure at 3 paints an the
circumference and calculate mean value.
Apply dial gauge to suitable axial surface and measure axial clearance
by vigorously moving the rotor in the directions Aand B.
® of rotor
+ Measured with rotor pushed up in the direction A } !If
• =
++
D36 5654 E
Measured with rotor pushed up in the direction B
With the rotor pushed up in opposite direction, withdraw measured axial clearance
1.52-2
®.
ABGASTURBOLAOER
•
EXHAUST-GAS TURBOCHARGER 2
TURBOCOMPRESSEUR A GAZ O'ECHAPPEMENT
TURBOSOBREALlMENTAOOR DE GAS DE ESCAPE
SOBREALlMENTAOORES 50
TURBOSOFFIANTI A GAS 01 SCARICO
•
SCHEMABESCHREIBUNGEN
DESCRIPTIONS OF SYSTEMS
DESCRIPTIONS DES CIRCUITS
DESCRIPCIONES ESQUEMATICAS
DESCRI<;:OES DE ESQUEMAS
DESCRIZIONE SCHEMI
• 0365650 2.50-1 04.82

DESCRIPTION OF SYSTEMS NR 2
• Priming right before start
Lubricating Oil System
Interval type priming

or continuous priming
51
2 2
t t
t 7
1
•
36 42 263
LEGEND
1 Supply pipe (engine) 5 Turbocharger (bearing casing)
2 Supply pipe (turbocharger) 6 Discharge pipe (turbocharger)
3 Throttle point 7 Non-return (check) valve
4 Pressure check point (pressure gauge) S Supply pipe [priming of turbocharger}
For.priming and during operation, the turbocharger is connected to the lube oil circuit
of 1he engine. The oil serves for bearing lubrication and also for dissipation of heat.
Lube oil supply, connected to the top of the bearing casing(5):
Engines being primed immediately before start-up
Supply pipe(2) with throttle point(3J and pressure check point(4).
Engines with interval or continuous type priming system
• Supply pipe[2J with throttle point[)) and pressure check paint(4). Additional supply piperS)
for turbocharger priming, connection laterally at bearing casing.
In compliance with plant layout, non-return valve(7) must be closed during priming and with
the lube oil pumps at rest and open during operation, thus preventing the turbocharger from
being flooded during priming.
Lube oil discharge, connected to the bottom of the bearing casing[5):
Discharge pipe[6) to be layed with Q maximum possible slope(min. t5 degrees). In case of
marine plants: At least 5 degrees more than maximum possible inclination of ship.
The discharge of lube oil must be unrestricted. .
Lube oil pressure, lube oil requirement, temperature and grade of filtration:
See operating data in sect ion 1, sheet 51.
The required tube oil pressure is adjusted by a throttle point[)) connected in the supply
pipe(2), e.g. by on orifice plate.
Connection for pressure check(~) is to take place immediately before the supply pipe
connection to the bearing casing(5).
Limit values for alarm triggering and engine shut-down depend on operating conditions.
• a;;
~ 036 5649 E 2.51-2 Page 1 of 2
~
Delayed engine shut-down during lube oil pressure fall
LEGEND
1 SuppLy pipe [engine)
2 SuppLy pipe (turbocharger)
2 3 ThrottLe point
4 Pressure check poin! (pressure gauge)
t 5 Turbocharger (bearing casing)
8 & Discharge pipe !turbocharger)
7 Non-return [check) valve
8 Supply pipe [priming and additionaL
t 1
Lubrication). if fitted
9 Hydro-pneumatic accumuLator
36 43 055
DeLayed engine shut-davn gives 0 short period of time to decide to either shut dovn the engine,
in order to ovoid damage to the turbocharger and engine. or to carry out 0 necessary manoeuvre,
to prevent greater damage. To be abLe to do this on oiL accumuLator is required to take over the ~
Lubrication of the turbocharger.
A hydro-pneumatic accumuLator (10 Litres) makes 0 deLay of max. 10 seconds possibLe.
ALonger deLay vouLd jeopardise operationaL safety and risk damaging the turbocharger.
The hydro-pneumatic accumuLatar(9) is pLaced at 0 suitabLe point lax. 2 I beLov the highest point
of the suppLy pipe(2) and is connected betveen the throttLe point[3) and the non-return vaLve(7).
Operating temperatur~ is max. +80·C.
Function: The accumuLator tank contains a bubbLe fiLLed vith nitrogen, vhich is compressed as
the oiL pressure increases and vhich forces out the oil stored in the tank to the
turbocharger os the oiL pressure faLLs. .
Note: For checking the pressure and fiLLing the bubbLe there is 0 vaLve on the top of the
accumuLator tank (beneath protective cop).
OnLy fiLL vith nitrogen. on no account use oxygen (danger of expLosion).
FiLLing pressure 0.5 - 0.& bar for a pressureLess lube oil system.
~
D30 5649 E / 2.51-2 Page 2 van 2
ABGASTURBOLADER
•
SOBREAlIMENTADORES 50
•
BETRIEB UND BETRIEBSSTORUNGEN
OPERATION AND OPERATING DIFFICULTIES
FONCTIONNEMENT ET INDIDENTS DE FONCTIONNEMENT
• SERVICIO E IRREGULARIDADES EN EL FUNCIONAMIENTO
OPERACAO E ANOMALlAS DURANTE A OPERACAO
ESERCIZIO ED AVARIE DI FUNZIONAMENTO
• D365650 3.50-1 04.82

·3
•
opERATION
Starting, Operation, Shutting, Down NR
51
Preparations for Operation

-
The bearing points of the turbocharger need be primed (prelubricated) prior to start-up of the
engine. Depeding on plant layout, two types of priming systems are available: Priming right _
before start-up, or interval type priming with breaks not exeeding a duration of 2 hours.
For lube oil system, refer to section 2, sheet 51.
Storting
The turbocharger being driven by the exhaust gases of the engine wi 11 start up automatically
as the engine is started.
Operation I-
•
Instrument readings should be taken at regular intervals during aperati on to the extent
instrumentation is provided:
1. Exhaust temperoture at inlet of turbine
2. Charge air pressure at outlet of compressor
3. Lubricating ail pressure at inlet of turbocharger
Furthermore, the following checks should be made at regular intervals:
4. Exhaust, charge air and oil pipes for tightness
5. Air filter and silencer for fouling (if fitted)
6. Turbine rotor whether it is running freely
7. Turbocharger whether it is running smoothly
Incipient rotor or bearing damage is usually indicated by erratic operation caused by

I
imbalance or contact of rotating parts with stationary components. Erratic operation can
often be determined at an early stage by listening for unusual operating noises. In such
cases the engine should be stopped immediately, if possible, and the turbocharger inspected.
•
Ser ious damage can thus usua IIy be prevented.
Rotor speed and charge air pressure are interdependant, i. e. the rotor turns at a certain speed
at a given charge air pressure provided the air ducts of the compressor are in clean condition.
The charge air pressure can thus be used to approximate the rotor speed.
Shutting Down
After shut-down of engine, the rotor of the turbocharger continues running for some period
of time due to its flywheel effect. Sudden stoppage is indicative of mechanical defects
(defective bearings, compressor or turbine wheel making contact with stationary parts,
obstructions caused by foreign matter etc.).
On stopping the engine, the turbocharger requires no additional measures for lubrication as
it is connected to the force-feed lubricating system of the engine.
Measures for Laying Up

For preserving the turbocharger, if it is to be laid up for a long period of time, proceed in
•
accordance with the instructions, as applicable, given for the Diesel engine (See Engine
Operating Manual).
D365649 E 3.51- 1
3
•
OPERATION
Cperating Difficulties NR
52
Operating Difficulties
As 0 rule, faults developing in the turbocharger ore accompanied by abnormal instrument
readings (exhaust gas temperature, charge air pressure and speed), high noise level or leaking -
lubricating oil pipes. If any irregularities should be noticed in 0 turbocharger during start-up
or operation of the engine, the cause should be determined at once and remedial action token.
Failure to attend to what may be 0 minor defect initially is liable to give rise to serious conse-
quential damage to the turbocharger and even to the engine. If there ore any irregularities,
reduce the engine load or shut-down the engine, if possible, and do not restart it until after
the cause of the trouble has been removed.
Hit-and-miss tadics in attending to trouble should be avoided as they are rarel y successful.
The instructions given hereunder and the fault-finding chart are intended to assist in diagnosing
the cause of irregularities experienced accurately and suggest how the problem con be overcorr -
•
quickly.
Cartridge
Repair of 0 defective rotor in general requires the skill and the tools of specialised s~ops, as
the ports rotating at very high speeds are sensitive to any unbalance. However, wit" 0 spore
cartridge kept on stock the operator of 0 plant will be able to bring 0 defective turbocharger
back irto operating condition within 0 short time and with 0 minimum of assembly work.
The cartridge, comprising the complete bearing casing with the 2 bearings and the balanced
rotor, is ready for installation. Effective, on the spot overhaul.of the turbocharger is thus
quite simple os the casings on the ccmpressO" side and on the turbine side con be removed from
the cartridge with the use of standard tools only.
We would therefore recommend that a cartridge be included in your spare ports stock so os to
hove it available when needed. The cartridge con be ordered under the order no. 599.001
either frcrn the manufacturer's works or one of our representatives. The defective cortridge
(Dn then be sent in for repair either to us or one of our representatives.
• N
ex:>
N
D36 5642 E 3.52-1
• OPERATION
3
NR
Operating Difficulties 53
Emergency Operation with Inoperative Turbocharger

If, for the time being, there is no possibility to repair the in-
operative turbocharger(s), the engine can, in absolute emergencies,
be further run with reduced load.
In such a case, fuel admission and thus the engine output must be reduced
so far that the maximum admissible exhaust gas temperatures and, on .
engines with 2 turbochargers, the maximum permissible speed of the one
turbocharger still in operation are not exceeded.
In addition, the following applies to the inoperative turbocharger:

1. Interruption of engine operation not possible:
•
The inoperative turbocharger remains in place.
This emergency situation should be confined to an absolute minimum of
time as additional damage to the turbocharger cannot be excluded.
In the event of rotor being stationary, lube oil supply to the faulty
turbocharger must at any rate be cut off due to risk of fire.
2. Interruption of engine operation possible for ash 0 r t period of time
For measures to be taken on the engine, refer to Operating Instructions
concerning the engine.
In case that further conduction of the exhaust gases through the faulty
turbocharger is compulsory:
Remove cartridge of faulty turbocharger and replace by sealing cover
(refer to section 4, work card 500.05).
If, in case of engine with 2 turbochargers, close-off of the charge air

and/or exhaust line on the faulty turbocharger is required:
•
Remove faulty turbocharger complete (cf section 4, work card 500.10).
Depending on engine version, close off (seal) or reconnect the lines
concerned.
• 036 5642 E 3.53-2

3
•
NA
FAULT-FINDING CHART
NR
54
DEFICIENCES ~
C-
L
~
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~ ~
§ =
0 =
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-
L
~ L
~
0
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L
;;
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L ~
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= = ~
0
L
~ - L
~
L
'n;,
C
POSSIBLE CAUSES
=
•
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~
~
.<'
~
U ~
=
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~
0
~
C ~
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~ ~
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~ ~ ~
~ U ~
= = ~
C
•
X X
~ ~ ~
= =
Silencer respa air filter clogged
Cor-Dressor dirty
linzle ri:lt;! d1 d~
l::...· 1r.taKE- ai r i:err.oerature
jl,j r Oilar,ifolc leaking
Exhaust pipe leaking
high gas backpressure after turbine
Fau1ty fuel injection on engine
• Bearing damage
Turbine or impeller damaged

Rotor contact
forEi~n Datter ;r. turbine or impeller
Labyrinth ring or locating ring damaged
SE2:S ria~aged, connections leaking
lUbe oil passages, filter clogged
Excessive pressure in oil discharge or in crankcase

In1e: ano/r'Jr exhaust valves di rty
LOCk-air ineffective
•
011 pressure gauge defecti VE-
Hi::r eil 2C:::; ssion temnerature
3.54 -1
ABGASTURBOLADER
•
SOBREAllMENTADORES
50
• WARTUNG
MAINTENANCE
ENTRETIEN
ENTRETENIMIENTO
MANUTENCAO
• 0365650 4.50-1
MANUTENTIONE
11.87
•
MAINTENANCE 4
Maintenance Schedule NR
51
The MAINTENANCE SCHEDULE is a summary of all the maintenance work up to a major overhaul of the
turbocharger every 12,000 - 18,000 operating hours.
Whenever major overhaul of the turbocharger has been carried out - for practical considerations in
common with an engine maintenance being due - the maintenance schedule is to be started anew.
In consideration of the operational safety of the turbocharger and engine, the maintenance work should be
carried out as timely as possible and not later than scheduled.
Cross-sections of the compressor being reduced by layers of dirt will adversely effect the performance of
the engine. Therefore, areas of heavy dust concentrations in the air, shorter cleaning intervals for
the compressor components may be required.
For checks to be carried out during operation at regular intervals, refer to section 3, sheet 51.
•
Item MAINTENANCE WORK Service Interval Work
No. in Hours Card No.
501 *) TURBINE CLEANING (dry cleaning) every 500.07

during operation: 24
Actuate turbine cleaning device
502 *1 TURBINE CLEANING (wet cleaning) every 500.07

during operation: 100
Actuate turbine cleaning device
503 COMPRESSOR CLEANING every 500.08

during operation: 100 -200
Actuate compressor cleaning device
504 + 1 AIR FILTER CLEANING: every 500.11

Air filter removed from silencer 250 - 500
505 INSPECTION: with new or 500.10
•
Check all mounting screws, casing screws overhauled
and pipe line connections for tight fit turbocharger
by tapping, retighten if necessary once after
1 000
506 COMPRESSOR CLEANING every 500.14

in dismantled condition: 5000 -
Compressor inner components, diffuser, compressor wheel 6000
507+) SILENCER CLEANING every 500.12

in dismantled condition 5000 -
Silencer felt linings 6000
508 MAJOR (GENERAL) OVERHAUL: every 500.06

Dismantling, cleaning, inspection, 12000 - 500.10
checking and cleaning cartridge, checking bearing clearances, 18000 etc.
checking gaps and clearances on reassembly
Pressure check of the hydro-pneumatic oil accumulator, if
provided (refer to section 2, sheet 51).
• D36 5649 E
If operated on heavy oil: Either Item No. 501 or 502 depending on version
Version with silencer only
4.51-2 09.95
4
• Maintenance Work
MAINTENANCE
Maintenance Work
NR
52
In order to ensure continued safe and reliable operation, and to keep the turbo-
-
charger in good condition, it is necessary that the inspections and checks to _
be made at certain intervals are carried out in accordance with the Maintenance
Schedule (sheet 4.51). Careful observation of the turbocharger performance wl11
enable the personnel to detect any deficiencies in good time. .
Dismantling or partial disassembly of the turbocharger should, however, be lim-
ited to the work to be carried out within the scope of the Maintenance Schedule.
Minor deficiencies can normally be repaired by the engine room personnel. But
any investigations or work beyond this scope or the repair of major damage
should only be carried out in the manufacturer's works or by one of the service
stations because they are equipped with the necessary balancing machines for
determining any rotor imbalance, as these high-speed rotating parts are sensi- ~
tive to any rotor-mass eccentricity.
• It is recommended that a cartrid~e be kept on stock or be ordered in the event

of rotor or bearing damage as thlS is the quickest way of repair and resuming
engine operation. This cartridge comprises the bearing casing with bearings and
the fitted and balanced rotor and thus all wear parts. The seals and gaskets
necessary for installation of a new cartridge are supplied with it.
The work to be performed on the turbocharger is exactly described on the work
_
cards step by step in sequential order. The question whether it will be easier
to disassemble the turbocharger in place or after removing it, depends on the
space conditions in the engine room. In most cases it will be sufficient for the
purpose of carrying out maintenance and inspection work to remove only sections
of the unit. Dismounting the complete turbocharger from the engine is normally _
necessary only for a general overhaul.
If, during disassembly, any bolt or nut should resist removal because it has
seized, avoid using excessive force WhlCh is liable to destroy the part and
necessitate replacement. Also, this may result in the need to recut threads or
to drill out fractured bolts that are stuck in the casing. The best method to
start with is to try to free the threads by turning the bolts or nuts carefully
back and forth, using Diesel fuel or a highly fluid special agent (e.g. Caramba
•
or Omnig1iss). These solvents should be applied liberally and allow to act upon
the bolted or screwed joint for some time (1/2 hour or more) so that they will
be able to penetrate right down into the threads. The recommendations issued by
the makers of such solvents should be observed.
Bolts and nuts used in joints exposed to elevated temperatures· are made of non-
scallng materla1s. In order to prevent normal bolts and nuts being substituted
I
by mistake, non-scaling nuts are identified by a small collar at their end face,
and non-scaling bolts are marked by identification letters on their head. Bolts
and nuts made of normal material are unsuitable for assembly of these components
During disassembly, care should be taken to see that these non-scaling bolts and
nuts are not mixed up with normal ones; if necessary, they should be kept sep-
arate until reassemb1y. In order to prevent bolts and nuts from carboning in
place and to facilitate futur dismantling, such screwed connections and the
seating areas should be coated with special lubricants every time they are as-
sembled. This applies especially to all bolts and nuts on the turbine end. Suit-
able lubricants are, for instance, MoS2-based lubricants which are available in
form of pastes (e.g. Mo1ykote HSC) for this purpose. Before applying these 1u- _
bricants, the threads should be thoroughly cleaned from all foreign matter.
Threads of stud bolts remain untreated.
• .... L.- 036 5649 E 4.52-2 P.LO. ---J

Cleaning Air Filter and Silencer
The air filter and the silencer must be cleaned as necessary, the intervals
between cleaning being dependent on the contamination of the air drawn in.
Cleaning Compressor
Fouling of the air passages in the compressor will reduce the amount of air
•
delivered. This is indicated by a decrease in charge air pressure at a given
operat i ng poi nt of the engi ne and, as -a resul t, exhaust gas temperatures and
fuel consumption will go up. The intervals at which cleaning is required vary
according to specific operating conditions and the relative purity of the air
drawn in. It is recommended that the compressor be cleaned or washed when the
charge air pressure at a given operating point and a given temperature of the
alr enterlng the compressor has dropped more than 4% though the air filter is
in a clean condition.
There are two methods of cleaning:
1. Mechanical Cleaning
In order to clean out dirt deposits mechanically, it is necessary to remove
the silencer and the complete compressor casing. The compressor wheel (impe11er
is left on the rotor shaft (turbine shaft) during the cleaning operation. •
Fuel or another liquid solvent is used to wash off the deposits. Great care
must be taken to keep the liquid out of the bearing bush and the charge air
pipe.
2. Cleaning of Compressor during Operation by Washing Syst~~
A washing system is available to clean the compressor also during operation as
long as deposit build-up is not too far advanced (.ef work card- 500.08).
C1ea~ing of Turbine
It is possible that a washing device for cleaning the turbine during operation
is mounted (optional equipment) - (cf work card 500.07).
Inspecting/Checking Component Parts
On occasion of a general (major) overhaul of the turbocharQer, or when under-
going repairs, and when essential components are concerned, we recommend to
make notes on the condition of the individual parts and to enter them into
the log book. -
A blank form "Test Results" is attached as a sample.
For judgement of wear, refer to table "Gaps and Clearances" in section 1. •
D36 5649 E / 4.52-2 •

CHECK LIST .
•
Date :
Turbocharger: NR .. ./ .
~
With Engineer's Report dId
-L_ _:""':'---':''':'-'-_--:-
.
-j Ser ial No. : ..
Nale of custoler ...................................................
Address . Engine type :
Site / ship's nOle . Serial No. :
Turbocharger inspected - overhauled on ....•.......... by ............•..•.•...•...••...•..••.....

ReQson ., '.0 ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••
Last inspection - overhaul on by .
Service hours since the last inspection _ overhaul ..•..•..•..•..•••..••.•.••.••.....•..•.•.•... h
Service hours since cOlllissioning h
CONDITION OF COMPONENTS
Si lencer t O O clean
8 Gas-admission casing,
• Air-intake casing
condition
of fel t plates
--------------
to dusty
oily
0 sooty
O satisfactory
o
bad
Inser t piece t
Gas exit diffusor + 0 clean
o rusty
o sooty
o scaled
o cracked
COlpressor casing, 0 clean Stud screws 0 sol isfac10ry
Insert piece t 0 dusty 0 broken
o
oily
traces
of rotor contac1 ........ 0 no 0 yes
troces 0 sooty o
local ....•... !clockJ
of rotor contact. ....... O no 0 yes
o o
total circumference
local: ....... (clock)
o o
radial 0 axial
tolal circumference
o
radial 0 oxial
o
reused
o
reused
o
replaced
1--------------
o
replaced Cartridge in assembled state
0 satisfactory
•
Diffusor turbine side 0 clean
o
o
bent
cracked oo oil troces
carbon residue of oil
o loose o heavy fuel coating
o reused lurbine rotor O 'satisfactory ill
o 0
--------------
Turbine nozzle ring
replaced
0 satisfactory
(blades)
damaged by foreign 8 bent
cracked
..
o ben I
matter....
o
on leading edges
o cracked
traces of contacl ..... O
on blades
0
o no yes
oo
scaled
o eroded
local
o loose
o
total circumference
radial 0 axial
o damaged br foreign
ma 11 er compressor side 0 clean
o reused o dusty
o replaced o sooly
- --
o oily
•
+ if prov ided
a:>
a:> D365649E 4.53-2 PTO
0
Compressor .heel
8 satisfactory Gaps and cl earanceslsecl-i on I, sheet 52)
(blades)
do_aged by rare ign
.alter
o
bent
cracked
0 on leading edges
on blades
traces of contact.. ... O no 0 yes
Transverse ploy of rotor ....................
Axial runout
of compressor ,heel
Radial gap (1)
~ ,.
•_
m_
.
•
oolocal
total circumference Axial gap (2) mm
oradial 0 axial (1) .
Cartridce (599.001) .... 8 reused
replaced
Radial gap
Axial goP
Axial cleorance
@
@
.
mm
o di sasse_bled
CONDITION OF SINGLE PARTS OF CARTRIDGE
Bearing casing(517.001) 0 reused
o replaced
Sealing cover, compressor side
(517.017) or (517.087) t
o reused
o replaced
0
L
loc~-alr
•
8
passages ~
clean
. d reason:
car bon covere
.
•
'l
passages - - - - - - - - - - - - - -
01
Turbine rotor{520.001) 0 reused
o
clean
restricled
o replaced
o 0 clogged frictional oxidation O no
Oyes
reason: .
~-------------- reason: .
Bearing bushl517.oo2l 0 reused Compressor ,heelI520.005l o reused
Oturbine side 0 replaced o replaced
Ocompressor side
reason:
,.. - - - - - - -- - - - - - -
Spacer sleeve(517.003) 0 reused
.
quality of fit. ..
8osatisfactory
medium
poor
o replaced reason:
reoson: . Labyrinth ringI520.006) o reused
--------------
Bearing sleeve(517.oo8J t 0 reused o replaced
o replaced
•
reason: .
--------------
reason: R t (520 000) .
--------------~ .
Cover 1517 .(09) + 0 reused rebal anced 0 no
o replaced 0 yes
condition before
reason: ..........•.............................. rebalancing O satisfactorT
--------------
Sealing cover. turbine side 0 reused o bad
(517.017) + 0 replaced ~--------------
reason: ..
Seal~ ·········8 ~:~r:~ed
+ if provided
Remarks:
D36 5649 E / 4.53-2

...... ................
signature
•
4
•
IvIAINTENANCE NR
Work Cords
54
Work Cords
The Work Cords supplied with the ~erating Manual ore consecutively numbered and arranged I-
in the order of operations requiTed for maintenance and inspecti on as well os the replacement
of the cartridge (cf List of Work Cords 500.01). The instructions given on the individual cords
relate only to the job stated in the heading. Depending on the scope of overhaul or repair
work, one or several Work Cords may be required (see Reference Table).
The numbering of the Work Cords is bosed on 0 five-digit code, the first 3 digits of which are
the component code which is 500 for turbochargers, the last 2 digits being 0 consecutive num-
ber. -
Example:
500 12
• 1 L
T Consecutive Number (12 Cord)
Code Number for Turbocharger
The Work Cords include guiding information on the amount of time and manpower required
(monhours). Thetime indicated applies only to the set of operations for the job described
(1. for disassembly or removal and 2. for assembly or installation) on the cord concerned.
The information given is on the uridet'Standing that the personnel employed is familiar with the
work involved and that 011 necessary tools are at hand. It is also assumed that the turbocharger
is readily accessible and that 0 hoist is available for lifting off the heavy parts. Furthermore, _
the times shown ore based on a normal condition of maintenance. The named times maybe
considerably exceeded when parts hove suffered damage.
• 0365642 E 4.54-3
4
• Brief Hints
MAINTENANCE
Brief Hints
NR /R
55
The table below lists those work cards which are required for typical
maintenance jobs.
Maintenance Job Work Cards required
CLEANING COMPRESSOR
during operation ............•.. 500.08
in disassembled condition . 500.10 through 500.14
• CLEAN ING TURB INE

during operation ....•..........
in disassembled condition ......
CLEANING AIR FILTER
500.07
500.10 through 500.19
in disassembled condition . 500.11

CLEANING SILENCER
in disassembled condition 500.11 through 500.12
CHECKING CARTRIDGE (check of bearing
clearances)
with cartridge removed . 500.10 through 500.17 and 500.06
in disassembled condition . 500.10 through 500.18
REMOVAL AND MOUNTING OF COMPLETE
• TURBOCHARGER
GAPS AND CLEARANCES
. 500.10
see section 1, sheet 52
• 036 5649 E 4.55-3

•
NR15/R 1500
LIST OF WORK CARDS "rbeillkorle·Nr.
Work cord No.
Carle lro..oil No.
Torjelo lrob<ljo No. 500.01
Work Card Designation
500.05 PUTTING EXHAUST TURBOCHARGER OUT OF OPERATION

(emergency operation of engine)
500.06 CHECKING ROTOR FOR TRANSVERSE MOVEMENT (bearing clearance)
500.07 * CLEANING TURBINE (wet cleaning) during operation
500.07 * CLEANING TURBINE (dry cleaning) during operation
500.0B CLEANING COMPRESSOR during operation
500.10 REMOVING AND MOUNTING TURBOCHARGER
Separating and reconnecting the connections
• 500.11
500.12 *
* CLEANING AIR FILTER
REMOVING AND REFITTING SILENCER

Removing revolution transmitter (if fitted)
Dismantling and cleaning
500.13 * REMOVING AND REFITTING AIR-INTAKE CASING
Removing revolution transmitter (if fitted)
500.14 REMOVING AND REFITTING COMPRESSOR CASING
Removing final diffuser
Removing insert (if fitted)
Cleaning
500.16 REMOVING AND INSTALLING CARTRIDGE
500.17 CHECKING AND CLEANING CARTIRDGE
500.18 DISMANTLING AND REASSEMBLING CARTRIDGE,
INSPECTION OF COMPONENT PARTS
•
500.19 REMOVING AND INSTALLING GAS ADMISSION CASING,
GAS OUTLET DIFFUSER, TURBINE NOZZLE RING
* These work cards are required only if they apply

I
to the turbocharger version in question
• 036 5654 E
500.01-2
•
PUTTING TURBOCHARGER NR15/R 500
OUT OF OPERATION ~ka" ••Nr.
WD"k ClIIrd No.
(Engine Emergency Operation) Cone lro-.oil No. 500.05

Torjeto ~iD No.
associated work cards ••••••••• 500.10

th.ough 500.16
-I -+- -- - ----.L-..J,I-H,L, rOOlS REQUIREO

1 Open end wrench. AIF 13
2 Open end .,rench. AIF 17
501.001 2 Open end wrench, A/F 19
, / 1 Socket wrench,Alr 17
<
<
> 1 Screwdriver
501 .008 1 lifting gear with rope
<
<
501.007
501.005 SPECIAL TOOL
<
) (available on special order)
S96.027 Cove.
• lEGENO
501.001 Gas
501.005 Clamping shoe
501.007 lockwasher
ad~ission casing
501.008 He1agoft nut

596.027
GENERAL
ro~ given possibilities and instructions with ~e9a~d to engine eDe~gency operation. ~efer
to section 3. sheet 53.
S;~RlING POSITION
Full downflow of the exhaust gases tn~ough the defective tu~bocha~ger must be Daintained.
• SEOUENCE OF OPERATIONS
1.
2.
3.
Disconnect all connections until the cart~idge can be ~eaoved (cf vo~k ca~d 500.10).
Reaove individually or in co••on: Silence~ o~ air intake casing. compressor casing.
and cartridge (see work cards 500.12 through 500.16).
Using claoping sho.s (501.00S). lock.ash•• s (501.007) and h•• agon nuts (SOl.00B), oount
cov•• (S96.027) to the gas adoission casing (501.001).
4. Seal·up lube oil supply line and lube oil discha~ge line.
5. Seal up line for jet assist (if fitted).
"ote: Dependent on engine version it eight be necessary to also seal up the charge
air line (refer to the Operating Instructions for the engine).
In Clse of elergency operation of the engine, its performance has to be limited
to such a degree that the aaxiaua permissible exh~ust te.peratu~es are not exceeded.
• o L
036 555"
500.05-1
.. r...·,n.·
","on."Q 1,_
O"rft O~ "D~Q"
•....: ....•
- 5o,_o~"
_ 1-10 ,
_ ""'- 1.
••:.
....!...::'.::.~::.~.~.~ ~.~ ~~-::.:H~.::
J:t A''''
(.......
la.,.". It'.
..!..._.:..:::.~_...l..:C::.~.::<
As required
:....
k ...... l).~·
Qc>r'O""9
..
..., ..-", O~ _.~_
Of'...
"0 ,
••::•.:.:.': ": ;'.:;:.'.::'.:.....J

.:H~.:::
CHECKING ROTOR FOR NR15/R 500
• 520.005
TRANSVERSE PLAY
(Bearing Clearance)
520.001
TOOLS REOU IRED
o 1 Dial gauge
1 Dial gauge holder
LEGEND
517.002 Bearing bush
520.001 Turbine rotor
~'!--'
tt I
520.005 Compressor wheel
Ii
36 35 634 IX "--.--../-L.-'
• GENERAL
Judgement on condition of bearing by measuring transverse play is only possible in case of
labyrinth seals already run in (after approx. 500 operating hours).
STARTING POSITION
Silencer or air intake casing and compressor casing removed. or cartridge removed.
SE~UENCE OF OPERATION
1. Attach dial gauge with holder in such a way that the measuring pin of the gauge contacts the
compressor end of the rotor shaft in the radial position.
2. Tilt the rotor shaft by hand vigorausly in both directions perpendicular to its axis, while
taking gauge readings which are to be noted down.
3. Recommended measures. especially when clase to the upper limit:
Measuring range [mm] Remarks
• ta 0.85
0.85 to 1.10
Range of admissible transverse play (corresponds to the tolerances
af the radial bearing clearance for new turbochargers)
Inspection of single ports af the cartridge by special ized service
personnel during the next opportunity.
Checking: Quality and pressure of the lube oil.
above 1.10 Operating ret iability endangered.
Replace the respective parts through specialized service personnel
or exchange cartridge.
Checking: Qual ity and pressure of the lube oil.
~ 036 5654 E A,.b"ihuit

Working ti..
- Stunden
- Hou,..
All.
E....rr Bedarf B.t"i.butund."
eo.roting hou,..
~ 500.06-2 Our•• d. travail
Ti •• po d. traboj.
- He...,.••
_ Hor(lS
Tout." l ••
Cod.
H.UI'.. d. _orc:h.
H.,.o" d........ i,i.
I 500
•
HR, HA
CLEANING TURBINE Ar1loeit,kone·Nr.
Wet Cleaning (Washing)

W(N'k card No.
Carl. lravuil No.
500.07
TorjetQ IrcbGjo No.
LEGEND
1 Exhaust gas turbocharger
2 Exhaust .anifold
3 Water supply (fresh water)
4 Water drain after turbine (if installed)
C B
(:l:>
~~
t . A Stop cock
B Pressure reducing valve with pressure gauge
C Three-way-cock with plate: ZERO-BLOWING OUT-WASHING
...
":l I 0 Three-way-cock with plate: • (-Zero position)
y 3
E Drainage cock (if installed)
•• (.Check position)
(.Washing position)
• Note Nu~ber and arrangement of exhaust manifolds depend on engine type and may not coincide with
illustration ror washing the turbocharger, each individual exhaust gas line is equipped
with a separate three-way-cock (0).
Use only fresh water for washing.
To avoid danger of burns, use protective gloves.
GENERAL
Cleaning interval: Refer Maintena!'lce Schedule Section 4, Sheet 51
In order to save time, washing is recommended briefly after starting the engine, as at that time.
the parts to be washed are not yet too hot. Thus, operation as per step 2 of sequence becomes obsolete
SEQUENCE OF OPERATIONS
Also refer to plate on the engine with cleaning instructions.
1. Reduce engine load to 10 - 15 ;.
2. Following reduction of engine load from a higher range. wait for approx. IS minutes
(status of inertia).
3. Examine all three-way-cocks (0) consecutively, first in Check position • • • (i f exhaust gas
does not blowout, the aperture to the exhaust gas line is blocked and must be freed with a
2.5 mm dia. piece of wire),
then set to Washing position = • • •
4. Open drainage cock (El of water drain (4), check if exhaust gas blows out. if necessary. free
opening (if provided).
S. Set three-way cock (C) to Blowout position.
6. Open stop cock (A) of water supply (3). set water pressure to 2 bar at pressure reduction valve (B)
check pressure gauge.
7. Set three-way cock (C) to Washing position.
8. Washing period IS 10 minutes at 2 bar water pressure (check at pressure gauge).
9. Close stop cock lA) of .ater supply (3).
ID. Set three-way-cock (C) briefly to position Blowing out. then to position Zero.
11. Set all three-way-cocks (0) to position Zero = •
12. Close drainage cock (E) (if provided).
13. Run the exhaust gas turbocharger at reduced engine load for 10 minutes to allow turbine to dry.
then 9.radually increase load. If vibrations of turbOCharger are observed that did not exist be-
fore cleaning, repeat waShing process.
Note If vibrations cannot be eliminated by washing on account of extreme deposits of dirt, the
turbOCharger must be dismantled and the respective parts must be cleaned mechanically.
036 5649 E A'bc,hJti' - ShmCl"n Allt fIc",tbl\.l"nCle n

WO'~'f\O;Ilim" _ Ho"" E.",,. NR:l00, NA:250 0"""0'''''9 ,",av_,
500.07-1 D",t" Cl" "0..0,1
T.empo Cle "ObOIO
- Htv,t\
kO'ol
1.0 To",,,, It I
COda As required
H"",,,, Cl" _,~ ..."
Ho,a< Clt ~ .....""o
CLEANING TURBINE NR,NR/R,PT,PTG 500
• (Dry Cleaning)
4
LEGEND
~b.lt.korl.-Nr.
Work oord....
Cart. trayail Na.
TorJoto freboJo No.
500.07
1 Container
2 Stop cock
5-7 bar 3 Stop cock
4 Hose for compressed air
36 43 037
•
GENERAL
Number and arrangement of exhaust manifolds depend on engine type and may not coincide with
illustration. For cleaning the turbine, each individual exhaust gas line is equipped with
a separate connection with stop cock(2J and plugging nipple at short distance before
turbine, so that the contoiner(1l may be coupled on.
For cleaning the turbine, granulated nut shells, activated carbon or rice of 1 mm
(max, 1,5 mm) grain size con be used.
During the cleaning process it is possible that dirty particles may be emitted through the
chimney.
To avoid danger of burns, use protective gloves.
Cleaning interval: Every 24 operating hours
Cleaning to be carried out at normal operational load of engine (~ 75 %MCRl.
Therefore, do not use water when cleaning turbine with that eQuiment.
• Also refer to plate on the engine with cleaning instructions.

1. Check free passage by opening the stap cock(2l, if need be, free apening with a piece
of wire. Close stop cock(2).
2. Fill granulated material into the container(1l, fill-in Quantities for:
NR15/R, PT18, PTG18
NR20, NR20/R, PT23, PTG23 ..... 0.2 - 0.3 liters
NR24/R, PT26 , PTG26
NR26, NR26/R, PT30, PTG30 ..... 0.3 - 0.4 l iters
3. Connect compressed air hose(4) at position(Al and container(1) at position(B). Container
hanging down.
4. Open cack(2l. Open cock(3) slowly until a whisling saund indicates that blowing-in
of granulated material takes place. Injection time approx. 2 minutes.
5. Close cocks(2 and 3). Container(1) and compressed air hose(4) to be disconnected.
Repead operations 1-5 for remaining exhcust gas lines, if more than one.
0' 036 5649 E All.

Evo", 24 B.trlob•• fundon
""woo! I n~ h..u".
<0
C>
500.07-3 Tout •• l ••
Codo As required H.ur.. d. a."ch.
Horoo 00 ••"vlol.
NR
• ClEANING COMPRESSOR
500
A,~il.kOr1It·N, .
Wo,k cord No.
Cor,. Irovoil No.
TorjclQ 'robGjo No.
500.08
TOOLS REQUIREO 1001 Ho.

1 Open-end wrench, size 17
1 Syringe •••••••••••••••• 579.119
LEGEHO
544.084 Scre. plug
544.085 Seal ring
57•.111----<
545.018 Scre. plug
545.019 Seal ring
r
\
~\
1.1-_.- I
"'....
5".Dl4~~ jI
• - .. ...J
1. Run the engine with as high a load as possible (80 - 100%).
2. Unscrew the screw plug (544.084) together with seal ring (544.085) from silencer, or
unscrew the screw plug (545.018) together with seal ring (545.019) from the air-intake
casing.
Fill the syringe (579.119) with clean, fresh water, and insert it through the screw-plug
opening.
Inject the complete content of the syringe within a period of 4 - 10 seconds.
Run the engine for another about 10 minutes at the same load.
Hake comparative measurements of the operating data (engine power and charge-air pressure).
These measurements will indicate the success or not of the washing procedure.
If necessary. carry out the washing again.
Screw in the screw plug (544~084) together with the seal ring (544.085) at the silencer,
or screw the screw plug (545.018) together with the seal ring (545.019) into the air-intake
casing.
Note The cleaning process is only to be carried out when the engine is at operating
temperature and when it is loaded as far as possible at full foad. After cleani~g.
the engine must not be shut off immediately.
Compressor cleaning using the syringe is only suitable when a high degree of
dirt is not present. If there is too much dirt deposited in the compressor,
the compressor components must be dismantled and cleaned mechanically (refer
to Work Card 500.14).
• 036 5649 E
500.08-1
_ Aroe.IU .. "
Work,nQ " ... ~
OUrll" d~ 1'(1'0"
T,t"mI>O de "ol,.o,o
__ S'un(l( n
_ Hou"
-- H~U'""
-~ Ho'o-,
0.3
AlI~
EW~r7
Tou'~s l~s
Codo.
as required
kl' i~t>\S'und~'"
OQl".o.,ng '"0.... '
H~ .... r~s d~ "'Qr("~
HO'(I' d~ ,~rvi(io
NR,NA 579
•
CLEANING THE COMPRESSOR
(with separate tank)
Arbeitskarte Nr.
Work Card No. 500.08
Carte travail No.
Tarjeta trllblljo
LEGEND
1 Charge air line
9 2 Pipe
3 Hydrometer cock
4 Hose
5 Tank
1 6 Screw-type cap
7 Hose
8 Injection pipe
9 Turbocharger
2 10 Intercooler
•
3
36 43 160
GENERAL
Depending 0':1 type of engine and turbocharger, the arrangement of the individual parts may not coincide
completely with the ones shown in the drawing.
Cleaning must only be made with the engine warm and running at full load.
Engine must not be shut down immediately after completion of the cleaning process.
Use only fresh water for cleaning.
When injecting, the water droplets. due to the high speed of the rotor. are hitting the blades of the
compressor wheel and the final diffuser at high velocity, thus removing the dirt deposits mechanically.
CLEANING INTERVALS IRefer also to Maintenance Scheduie. Section 41
• The cleaning intervals depend on the degree of contamination of the air taken in. In the smaller
. turbocharger sizes (NR. NA34. NA401, the dirt deposits on blades of compressor wheel and final diffuser
may lead to a considerable drop of efficiency.
From turbocharger size NA48 onwards. compressor cleaning is not necessary if the air filter mat is serviced
as per instruction.
We recommend the following cleaning intervals:
NR turbochargers: every 100 - 200 operating hours (dependent on turbocharger size and dirt accumulation)
NA turbochargers: every 100 - 200 operating hours (dependent on turbocharger size and dirt accumulation I
See also cleaning instructions given in plate (mounted to the enginel
1. Operate engine at full load.
2. Open screw-type cap (61 and fill tank (5) with clean. fresh water.
3. Close tank by means of screw-type cap (6),
4. Depress pushbutton of hydrometer cock (3) for about 20 seconds.
• D36 5649 E 500.08-2 09.95

579
•
CLEANING THE COMPRESSOR NR,NA
(by means of water injector)
Arbeitlkerte NI.
Work Card No. 500.08
Carte travail No.
Tarjeta trabajo
~===1F.F=_-1 " 10 xl)
."
579.103 Xl r~~:J:J: .
579 .1307'~~l--;;~1~
,x'
,/
ri' L_
~)W11:'·
-$-. I~
1'-::::-
. .' ,. •: I' -$' X 2:1
579.029----r-----
-$-.( ;$--$- 57 9.095
,., 579.0096
• 579 .102
579 .100
579 .101
IY
'/
1!J
~'090 579.091
36 43 117
GENERAL
Depending on type of engine and turbocharger. the arrangement of the individual parts may not coincide
completely with the ones shown in the drawing.
Cleaning must only be made with the engine warm and running at full load.
Engine must not be shut down immediately after completion of the cleaning process.
Use only fresh water for cleaning.
When injecting, the water droplets. due to the high speed of the rotor. are hitting the blades of the
compressor wheel and the final diffuser at high velocity, thus removing the dirt deposits mechanically.
CLEANING INTERVALS (Refer also to Maintenance Schedule. Section 4)
• -The cleaning intervals depend on the degree of contamination of the air taken in. In the smaller
turbocharger sizes (NR. NA34, NA401. the dirt deposits on blades of compressor wheel and final diffuser
may lead to a considerable drop of efficiency.
From turbocharger size NA48 onwards, compressor cleaning is not necessary if the air filter mat is serviced
as per instruction.
We recommend the following cleaning intervals:
NR turbochargers: every 100 - 200 operating hours (dependent on turbocharger size and dirt accumulation)
NA turbochargers: every 100 - 200 operating hours (dependent on turbocharger size and dirt accumulation)
SE~UENCE OF OPERATIONS
See also cleaning instructions given in plate (mounted to the tank)
1. Operate engine at full load.
2. Turn handle on pressure sprayer tank (579.029) in counter-clockwise direction and take out the pump.
3. Fill maximal 2 litres of fresh water into the tank (up to the 2 L mark on the tank).
4. Screw in the pump and operate until the pressure relief valve blows off.
5. Connect hose with plug-in nipple 1579.096 with the coupling (579.095l.
6. Depress pushbutton (see big arrow in drawing) on the hand valve until the water is completely
•
injected into the compressor (for approx. 30 seconds).
7. Release plug-in connection and vent the tank. For venting. pull spindle on the safety valve outwards
(see small arrow in drawing).
0365649 E 500.08-3 09.95

NR15/R 500
•
REMOVING AND MOUNTING
Arbeit.kol1e·Nr.
TURBOCHARGER Work cord No.
CarlclfO>OQil No. 500.10
Tar,eIO Irabojo No.
5 TOOLS REOU IREO

I Open end wrench A/F 13
2 Open end wrench A/F 17
545-1--
_ _t 8
--- ~1
::::::::
--Cl
I Socket wrench A/F 17
I Screwdriver
I lifting gear with rope
I MoS' lubricant
WEIGHT of turbocharger
with air intake casing
123 k9
• 544---lH-
-0
3
,
,.
·1
&-10 '--
9
6
-.J 36 42 682
'with silencer ••. 132 kg
LEGEND
544 Silencer 4 Jet assist 9 Lube oil outlet
545 Air intake casing 5 Air outlet 10 Casing foot
1 Compressor cleaning 6 Shield. 2-part 11 Exhaust exit
equiptlent 7 lube oil admission 12 Exhaust inlet
2 Revolution transmitter 8 Additional lubrication
3 Air admission system
GENERAL
• Depending upon the space conditions in the engine rOOlll, the decision must be made as to whether
the turbocharger is to be dismantled completely or it will suffice merely to remove sub-assecblies
from the turbocharger.
SEQUENCE OF OPERATIONS 1:
1. Remove line from
Disconnecting connections
connection for compressor cleaning device (1).
2. Disconnect cable terminal of revolution transmitter (2) (if fitted).
3. Remove line from air admission (3) of air Intake casing (545) (if fitted).
4. Remove line from connection for jet assist (4) (if fitted).
5. Detach or remove line from air outlet (5) of compressor, watching out for the seal.
Note: Removal of the compressor casing is now possible.
6. Re.ove shield, 2-parl (6) (if Filled)_
7. Disconnect lines for lube oil admission (7), additional lubrication (8) and lube oil outlet (9).
B. Remove screws from casing foot (10), depending on arrangement (if fitted).
Note: Removal of the cartridge (bearing casing and rotor) is now possible.
• 036 5654 E
500.10-2
ArOC,lntl'
Worlo.,,,o "me
O",r"= dt Iro ..oil
1,,,mIl0 dc 1r0bOl0 _
_
_
_
Sh,""Cl""
Ho",n
H"",rtl
.... OrOI
AUt
E.... ry
TO u '''' 1..1
Cedo
Page 1 of 2
as required
k"leou'","d~"
00... e ..... 9 "Our,
........·c, dt merc", ..
....oro. de I'" ..,( '0
SEQUENCE OF OPERATIONS 2:
10.
11.
Removing (dismounting) the complete turbocharger
Points I to 8 sale as'in Sequence of Operations I.
9. Detach or remove line at e.haust e.it (11).

Hang the complete turbocharger onto the lifting gear with rope slung around bearing casing.
Detach or remove line from e.haust inlet (12), watching out for the seal.
•
12. Raise the turbocharger carefully and deposit it on wooden supports. When doing, so, pay
attention to lagging of gas admission casing and silencer (if installed).
Note: During periods of storage and for the process of mounting, all apertures for air,
e.haust gas and lube oil are to be sealed carefully to avoid penetration of foreign
particles or water.
SEQUENCE OF OPERATIONS 3: Remounting the cOlplete turbocharger and installing connections
Remounting of the turbocharger or sub-assemblies as well as installation of connections

is to be done in opposite sequence to that of removal.
Note: Prior to remounting, remove protective plugs from pipes.
•
When remounting, use only seals and lockwashers. that are in perfect condition.
Screws and nuts for the connection of the exhaust gas lines are to be treated
with HoSt high-temperature lubricants (e.g. Molykote HSC).
036 5654 E I 500.10-2 Page 2 of 2

•
500
•
CLEANING AIR FILTER HR
Arbcit,karte·Nr.
(Air Filter Kat) Work CGrd No.
Cct1.lrovail No.
Torjeto tl'Qbojo No. 500.11
------~
( J X 544.201
-~
--544.202
~. 544.205
~ I /
- -- --~--
~ t-'
B !
~
544.202
& 544.034--,
e--544.202
-
r--.y
• -f
1\
f-}---
_/
- -
~I
Y
36 42 499
2,1 -"'L...I""
'I'OOl.5 RE;UIRED
1 Key wrench 544.034 Protectioo grid (perforated plate)

1 Cleaning vat 544.201 Air filter mat
1 Cleansing fluid 544.202 Clamping collar
1 canpressioo air tap 544.205 Cover plate
GmDlAL
The dirty air filter mat (544.201) can be cleaned several times or replaced by a new roe.
Replacement is required if the air filter mat is cxnsiderahly dilated, plucked or perforated.
'I1Ie increase of pressure loss by cootaminatioo of the air filter mat is insignificant and does
not serve as an indicatioo of the time cleaning is required .
• CLEANING INl'mVALS
Depending 00 the dirt cootent of the air passing through the intake, every 250 - 500 operating hairs.
'I1Ie optimal timing for cleaning is attained when the inside of the air filter mat <XIIIIlenCeS to dis-
colour. 'l1Ien the filter is saturated and the cootaminatioo starts to advance towards the CXIlIPl"essor
and the intercooler. 'I1Ie inside of the air filter mat may be inspected by loosening the external
clamping collar (544.202).
SE:XJWCE OF OPmATIctlS
1. !£losen clamping collars (544.202), rElIOVe cover plate (544.205) and air filter mat (544.201).
2. Air filter mat to be cleaned by flushing with warn water to which fine cleanser had been added.
Avoid intense mechanical stress (e.g. wringing, sharp water jet). SUbsequently.. blow air filter
mat through with canpressed air.
In case of intense cootamination it may also be necessary to :intrerse the air filter mat in the
cleanser and soak it for several hours. It is, therefore, advisable, to keep a sea:m air filter
mat available for exchange.
3. Place air filter mat (544.201) over protectioo grid (544.034) and cover plate (544.205) over joint
of air filter mat and fasten, using the clamping collars (544.202).
~ting positioo of air filter mat: canpressed (IOOre solid) side of fleece facing the inside.
D36 5658E Arbeilue;l

Work 'no lime
_ $Iundet>
_ Hou,. 1.: 0.1 AliII'
ever, 250 - 500 kl'iot'b"h."....
ODerotOftg ~
500.11-1 Our~c: de: l,awo;1 _ Heures
3.: 0.1 TOUlel le' as required HtUf'"nde mGr"l:'-e
T ,emoo de lrobojo - HorOl Codo HorOl de W,..,K io
•
REMOVING AKD REFITTIKG KR15/R 500
SILKKCKR ArbciI11t0t1e·Nr.
Work cord No.
Corle IrcM:lil No. 500 . 12
Tarjeto lrobcljo No.
SILlllCDl. 544/1 (without revolutioo transmitter) associated wrk card ••••• 500.11
544.201 544.032 r--544.205 n:ru; Rm/1Rrn

1 Open eM wrench AIF13
544.202 - - - 1
~~~~~~~1~544.202
!f 544.034
1 Open eM wrench AIF17
1 Sc:reMdrivel"
1 Cleansing fluid
544.074 - -:§~~~~=~=~~~~~~54~6~.0~0;5 1 CcuIpressed air tap
ux;mo
544.069 - - + , * " " - ' 544.001 Rear wall
544.021 ~ing plate
544.032 Spacer bush
544.041 ~!l-----1~-544.021 544.034 Screen grid
544.001 544.041 Froot wall
544.074 IIexagm nut
544.085 544.201 Air filter
• 544.084
-E:-:-.~'m::=j'-C:.
544. 090 ----I~~
=. ---+
546.001
546.005
1lEIGln'
Volute casing
Clamping collar
Silencer 544/1 •....•• 15 kg
36 42 679
STARTING rosmCN
Connectioo for canpressor wash.iDJ device released (if fitted).
sgum:E or OPffiATICNS 1: Re!D:lval

1£>osen clamping collar (546.005). ,take off COIlPlete silencer in an axial directioo. and lower it
ooto "OOden supports.
sgum:E or OPffiATIClIS 2: Refitting
•
Iblnt COIlPlete silencer by means of clamping collar (546.005) to the volute casing (546.0011.
Tightening torque to be applied 00 either side 8 rtln].
sgum:E or OPffiATIClIS 3: Dismantling. cleaning. reassanbling

For cleaning intervals. refer to Maintenance Schedule. sectim 4. sheet 51. and instructions in
given in sheet 4.52.
1. Detach and clean air filter (544.2011 - see wrk card 500.11.
2. Unscrew hexagon nuts (544.074). and take oot front wall (544.041). screen grid (544.034).
damping plates (544.021) and spacer bushes (544.032) me after the other.
3. Clean all CCIIlJlCIlent parts of the silencer.
Cleaning the felt linings. If the fooling matter is dIy. the felt linin!l is cleaned best using
an air hose or a brush,which is oot too bard. In case of "smear type" ccataminatim or dirt.
Diesel fuel or ccaventiooal hoosehold cleansers can be used. Solvents ccataininq acetme are
not to be used though. especially '"l'ri" (trichlorethylene). because this will dissolve the
adhesive joints.
If felt linings have becaoe extrmely wavy or corrugated (with the result that the cross-
sectioo for ineaning air is reduced). these are to be replaced.
4. Reassembly is a reversal of the dismantling procedure.
•
SILlllCDl. 544/2 (with revolution transmitter): See page 2 Page 1 of 2
D36 56541r:;A:;;; ..:::,.=~..:::.::"=.noun

....;;;';;;..;;.":---::-:-;':;::'":;,,.::.":------;I-:~::-tt:::--Ir;:AO;;:'.----------...,....-: ...:::,,:---1
500.12-2 OWort'''9'''''C - Ho.,n
.. reeClelro~alf -l-teur.,1 1.: 0.1 . tttt E"oe'r
CT~
••'."1IU 5,000 - 6,000 O~r01II"1g
Heu,cldcmcl'(I'oC
T,~rnoo de 1,0boJo - Ho.o, • O. as Hero. Oe .er"icto
•
SIUNDl 544/2 (with revolution transmitter) associated ..,rk card ..... 500.11
544.201 544.205 'lOJI.S

1
RWJIRED
Open end wrench A/Fl3
544.202':"'-I~~~~~~E~~~544.202
544.069 544.034 1
1
1
Open end wrench A/Fl7
Scxket wrench
serewdri ver
A/FlO
544'074=~III;I:~I=~f,~:54~6~'0~Ol5
1 Cleansing fluid
544.041 1 CoDpressed air tap
ux;nm
544.001 Rear wall
544.230.~~~~ B$:j--I81-d-544.021 544.021 Dampin] plate
544.231 544.001 544.032

544.033
Spacer hlsh
Center:in] l>Jsh
544.222 544.033 544.034
544.041
SCreen grid
Fralt wall
-E'='=m~~~~~:. _;-;544.090 544.067

544.074
Hexagoo nut
Hexagon nut
544.201 Air filter
544 '08:~511~~:~'~~~~~~5~44~'~06~6~:~56~2~'Oi4~0 ~~
544.222 Cover
544.~
36 42 680
544.231
546.001
546.005
562.004
562.040
Hexagoo nut
Volute casin]
Clampin] collar
Retaining plate
Revolution
transmitter
•
lIEIGIrI'
Silencer 544/2 .•..• 18 kq
STAR'I'I»:' POSITIal
Camectioo for revolutioo transmitter released.
camectioo for ccmpressor washing device released (if fitted).
sgum;:E OF OPDlATIalS 1: RemJVal

1. !a:lsen and remove hexagoo nuts (544.2311, renove cover (544.222).
2. !a:lsen and remove hexagoo nuts (544.067), rem:>ve retaining plate (562.004), -and carefully
pull out revolutioo transmitter (562.040). Caution: Do not spoil both the pole shoes at
revolutioo transmitter end by bending.
3. !a:lsen clampin] collar (546.005), take off cxmplete silencer in an axial directioo, and lower
•
it ooto wooden supports.
sgum;:E OF OPDlATIalS 2: Refittin]

Refitting is a reversal of the renoving procedure.
Tightening torque for clampin] CXlllar -(546.005) on either side 8 no).
sgum;:E OF OPDlATIalS 3: Dismantlin], clean:in;J, reassanblin]
For cleaning intervals, refer to llaintenance SChedule, seetioo 4, sheet 51 und instructions
o:ntained in sheet 4.52.
1. Detach and clean air filter (544.2011 - see lIOrk card 500.11.
2. UDscrew hexagoo nuts (544.074), and take out froot wall (544.041), screen grid (544.034),
damping plates (544.021), spacer bushes (544.032) frail outer reference circle (pitch circle),
and center:in] bushes (544.033) fron inner reference circle (pitch circle) one after the other.
3. Clean all o::mp;:tk!llt parts of the silencer.
Cleaning the felt linings. If the foulin] matter is dry, the felt lining is cleaned best usin]
an air base or a brush which is not too hard; In case of "smear type" o:ntaminatioo or dirt,
Diesel fuel or o:nventiooal household cleansers can -be used. Solvents o:ntaining acetone are
not to be used though, especially "Tri" (trichlorethylene), because this will dissolve the
adhesive joints.
If felt linings have bea:me extreoely wavy or corrugated (with the result that the cross-
sectioo for ineaning air is reduced), these are to be replaced. •
4. Reassernbly is a reversal of the dismantling prOcedure.
036 5654£ I 500.12-2 06.90 Page 2 of 2

•
REMOVIIIG AIID REFITTIHG IIR15/R 00
AIR IIITA~B CASIIIG Ar!>ei.,kQr1e_Nr.
~o:;~~~~. SOD .13

Tarjeta lrabojo No.
associated work card ••••• 500.10

~ I •
- - - - -----1f--- - - - -
~ RmlIRID
1 Open end wrenc:h A/Fl3
1 Socket wrench A/Fl0
545.014
1 SCrewdriver
w:;mo
545.001 545.001 Air intake casing
545.069 I/exagal nut
546.001 Volute casing
546.005 Clamping collar
545.018 562.004 Retaining plate
545.019 562.040 Revo1utioo
transmitter
• 545.068
545.069
VEIGlfl'
Air intake casing •.. 9 kq
36 42 681
• S'I'AR'I'IJ«; FOSlTICfl
Air line has been rEm:lVed fran inlet port of air intake casing.
Coonectioos for ex:tnpIessor washing device aI¥1 revo1utioo transmitter are released .lif fitted).
SE;Um:E or OI'DlATICflS 1: RE!IIDVal

1. In case a revolutioo transmitter (562.040) has been installed: Unscrew hexagoo nut (545.069).
rE!llDVe retaining plate (562.004). aI¥1 pull out revolutioo transmitter (562.040) carefully.
cautioo: Il:> not spoil both the pole shoes at revolutioo transmitter end by bending.
2. Loosen clamping collar (546.005).
3. Take off air intake casing (545.001) in an axial directioo. aI¥1 lower it ento lIOOden supports.
SE;Um:E or OI'DlATICflS 2: Refitting

Refitting is a reversal of the rEmJVinq procedure.
Tightening torque for clamping rollar (546.005) to be applied en either side is 8 [IG].
• D36
SOO • 13 - 2 WO'ki"'Oll,"'e
o...r~e de ,ra ..o'l
- Ho""
_ Hev',l'1
Tllrmoo de IrabCl;O _ HOral
:::.::"------;I;-J:t---tt:-..,....."A1::"I.-------------:
5654E:r..:;;...::.;;,,,,:::.,::'",-----;:"::::o..
l' 0 1
••
•
•
J:t E~', . ed
as requ1I'
To... I'I le.
Codo
.,...'..,.~.,..-...--~.--1
Ooerc:rting 1'10"''1
Hell'.' dl _"<"-
Hoto. de I.,.. icio
•
REMOVIHG ABD REFITTIHG BR15/R 500
COMPRESSOR CASIBG Ibbci"lr.orle_Nr.
WOf"Ir. card No.
c.n.'~~i1No. 500.14
Torjcla Irabaio No.
associated lOJrk cards

••••••• 500.10 t~ 500.13
'f(W) RE::UIRm
1 Open end wrench W8
1'-+--1--517 .063 1 Open end wrench WF13
546.025 1 Open end wrench WF17
546.026---~r--tJ 1 Screwdriver
546.001---\"'- 1 Brush
'flt--HH--t--542.001 1 Cleaning fluid and vat
546.020------~~~~ . 1 l:ai;lressed air tap
546.024-==~1~ "l-i7-t-599.001 1 Lifting gear with rope
546.023- ~-rT/
546.018-~~~~~ w;mn
517.063 o-ring
542.001 Finai diffuser
•
546.001 Volute casing
546.005 Clamping collar
546.008 COOntersunk screw
546.018 Insert
546.021 Hexaqon nut
546.022 Spring washer
546.023 o-ring
546.024 Hexagon nut
599.001 Cartridge
(=517.000 and 520.000)
'"
<Xl
546.008 '"
N IlEIGHI'
546.021 '" of canpressor casing •..•• 26 ;q
'"'"
546.022
546.051
•
546.052--/
STARTING FOSlTICll
Silencer or air intake casing reroved, piping rem:wed fran air ootlet of canpressor.
Connections for jet assist and revolution transmitter (if fitted) rem:wed.
sgxJIIm:E OF OPOOTICllS 1: RE!ll)ving/Dismantling

1. Hang canp1ete canpressor casing with rope onto lifting gear and take the slack oot of the
rope.
2. !tJosen clamping collar (546.005) and cautioos1y extract canplete canpressor casing in an axial
direction fran the cartridge (599.ooll and lower it onto WlXXIen supports.
3. If the final diffuser (542.001) is to be rem:wed:
Rerove hexagon nut (546.021), spring washer (546.022) and countersunk screw (546.008) and take
off diffuser in axial direction.
4. If the insert (546.018) - if fitted - is to be rem:wed:
!tJosen hexagoo nut (546.024) and withdraw insert in axial direction, taking care of the o-ring
(546.023).
•
Page lof 2
D35 56 Arbc'hrei'
Worl""ql,me:
_ Slu"",e:n
'_ Ho,,",
Alle:
Every
, kl~iorbUh'nclc:"
Ooeral;ng ho.... '
500.14-2 Duree de Iro ..oil _ Heur~~ TO<,II'" In as required He,,"'" de morcr.e
T,crnDO dr Itabo,o _ HorOI Codo Hora. de H',,;cio
SIDJrnCE OF omu.TIalS 2: Ile!lJ:llntinq
Rem:JUIltinq is a reversal of the rem:JVinq/dismantlinq procedure.
\/hen rem:JUlltinq, pay attentioo to the o-rings, (517.063), 1546.023 if fitted) and canpressor
wheel.
All 10ckwashers and seals must be in perfect calditioo.
•
Tighteninq torque tor clamping Collar (546.005) 00 either side is 8 [NIl].
sgum::E OF omu.TIalS 3: Cleaninq

For cleaninq intervals, refer to llaintenance Schedule, sectioo 4, sheet 51. and instructioos in
given in sheet 4.52.
1. Clean volute casinq (546.ooll. final diffuser (542.ooll and insert (546.0181 with fuel or sane
other cleaninq fluid and brush until all dirt, especially in the air ducts, has been rSll:lVed.
2. Clean canpressor wheel in the same way.
The cmprl!SSOI" wheel is to be left installed in the cartridge (599.0011.
Note: The cleaninq fluid and thus the dissolved dirt lIllSt not be allowed to penetrate
inside the cartridge and to enter the bearinqs or the lube oil circuit.
•
The gaps behW the cmpressor wheel slxW.d, therefore, be covered with suitable means.
3. Dry all cleaned parts with an air hose.

4. 0Ieck rotor for free and e=t 1IJ:JVe!lIl!IIt.
D36 5654E / 500.14-2 06.90 Page 2 ot 2 •

00
•
REMOVING AND INSTALLING NR1S/R
CARTRIDGE Arb"i"kort,,·Nr.
Work tord No.
Corle Iro_il No.
Torj.elo Irobftjo No.
SOO.16
associated work cards 500.06, 500.10 through 500.14
,.,.... Tool No.
.,.,
."
ell
."
3 Ring segment • • • • • •• 596.008
3 Spindle •••••••••••• 596.009
6 Hexagoo nut • • • • • • •• 596.010
1 Open end wrench 13 A/F
1 sere>olriver
1 Lifting gear with rope
•
SOL 001Gas admission casing
SOL005 Clamping shoe
SOL 007UXkwasher pair
S01.OO8Hexagon nut
591.060Shield, 2-part
599.001cartridge
501 .005 -tiiHt-tf---l 7 Oil admission line
501. 007 --H1I'IH+--..l 8 Additional lubricating
501. 008 ----i1-lJlJl--f-lil system
9 Oil discharge line
10 Casing foot
·591.060
IlEIGIlT of cartridge •••• 26 kg
RenovaJ. of cartridge for inspection and, if necessary, replaCElleIlt is only required in the
following cases:
1. If admissible transverse lJDVability is exceeded (cf work card 500.06) •
•
2. For major overhaul of turbocharger (cf Maintenance Schedule, Section 4, Sheet 51).
3. If there are any signs of irregularities in service which might lead to subsequent damage
of the turbocharger, e.g. unusual running noise, turbine or canpressor side oil leakage,
previously not experienced turbocharger vibrations or abnormal readings (exhaust gas
temperature, charge air pressure. turbocharger speed) - if canpressor or turbine cleaning
during operation prove unsuccessful.
4. In case of damage to turbocharger, e.g. bearing damage, (owing to oil starvatioo or coo-
taminated oil), damage caused bY foreign matter or fracture of turbine rotor or canpressor
lIheel due to vibration, casing cracks.
mRTING I'OSITIetl
Silencer andIor air-intake casing resp., and canpressor casing removed. The gas admissioo
casing is not normally raooved and remains connected to the exhaust gas line.
SIl:W1!CE OF OPDlATIetlS 1: R~
1. Take off shield, 2-part, (591.060), if fitted.

2. Remove oil supply line (7), additional lubricating system (8) and oil discharge line (9) fran
bearing casing.
6 5654E 1.: 1.5 .

11Ht~ i
A'bc,IU",' _ Sluncl"" ~ k,.;"'b1o$'''ftCk..
Work",,:! li~ _ Ho"" E~",,' Ocloeroh"'9 "ovH
.16-2 Oure-e de ItOrool _ Heu'.I'1
T,ernDQ doe Ifobo,o _ Hon;rs
2.: 2.5 Tou.el 10:, as required ~ ...r " C1c ft'\Or~"e
CodO HoIo' ok K ... i(Oo
3. Dependinq on type of IOOUIIting, loosen or relll:>Ve casing foot llO). •
4. Ilith the use of rope, attach cartridge to lifting gear, cautiously
take the slack out of rope.
5. SCrew off hexagon nuts (501.oo8), relll:>Ve lockwasher pairs (501.001) and clamping shoes
(501.oo5) •
6. Press cut cartridge (599.01) uniformly at 3 points of circ:urnference, using tools (596.008,
596.009, 596.010), cautiously IIJJVe it cut in axial direction (do not damage turbine rotor in
the process), and carefully deposit it on wooden support.
-~
A-B
~~=~==1- 12 : 1)
596.009
596.010
596.008 - - - { A
599. 001 ~"'VI
CIIrX:ICm> AND CLEANING CAR'lll1DGE: Refer to work card 500.11

36 42 980
•
sgmrg or OPDlATICNS 2: Installing
1. ~ the gaps, (refer to Sectim i, Gaps and Clearances).

- SCrew cartridge (temporarily for measurement oo1y) to canpressor casing while measuring axi
gap (point 2) by lead imprint and radial gap (point 1) by feeler (thickness) gauge three
times m the circumference. .
- Insert cartridge (temporarily for measuranent oo1y) carefully into the gas admissim casing
and screw together. IIeasure axial gap (point 4) by lead imprint and radial gap. (point 3) by
means of feeler (thiclmess) gauge (oo1y if gas cutlet side is accessible) three times m the
circumference.
2. Using the rope, suspend cartridge to lifting gear and insert it cautiously into the gas
admissim casing (do not damage turbine rotor).
3. Fix cartridge with clamping shoes (501.00s), lock washer pairs (501.oo1) and hexagon nuts
(501.008) to gas admissim casing (tightening torqUe 11 [Ib]). •
500.16-2 12.90 Page 2 at 3

• 4. Recamect oil discharqe line (9), additional lubricating system (8) and oil supply line (7).
Dlsure that protective plugs, if any, have been rEm:>Ved before reconnectioo.
5. Fasten casing foot (510) depending on type of =ting, if fitted.
6. Mount shield, 2-part (591.060), if fitted.
Note Apply MoS2-based high-temperature lubricants (e.g. 1Io1ycote BSC) to bolts and nuts,
do not coat screw-in threads with this lubricant if studs had been replaced.
L:x:kwasher pairs (501.007): 1Ltlg wedge-shaped surfaces facing ooe another (on inside).
Otherwise, there is no securing effect.
• 036 5654£ 500.16-2 12.90 Page 3 of 3

NR15/R
CHECUNG AND CLEANING
CARTRIDGE
---
,........".....""*.
e-t-" .....
T_"'~No.
associated work cards ••• 500.06 and 500.16

500.17
500
GENERAL
Checking .nd c1e.ning is restricted to the cartridge in Isst.bled condition.
Oilanub) y of cartridge for cl,aning and replacing co.ponent parts .ust be carried out by
educated service staff only (Set notes in section 3, sheet 52 - Cartridge - and in section
4, sheet 52 - "aint,nence - and work ca.d 500.06).
Note: If • ca,.tri dge i. to be sent to a.nuflcturer or service point for overhaul • it aust
- - be packaged carefully to avoid additional dUlg, in transit.
STARTING POSITION
Cartridge reloved fro. turbocharger.
CHECKING THE CARTRIDGE

Ihe fc)]owing CHECK LIST includes data fo. evaluation and. if nHtSSa,.y. 'enures to be taken
fo. repairing th, cartridge.
Where several pc~sibi)ities ar, lIarked off. the technical optillUII i. to be selected.
--
Noh:
• EVALUATION CRITERIA
On part D' pei I"tt
COf\dition
CARTRIDGE
- Di sassubl e. ('heeM ct'lIlponents, rep I Jee whe"e
necessary ( by educated service staff on) y)
- Replace
- Reuse. chan
TRANSVE RSE "OVABlLITY OF ROTOR
rf wc,.k card 500.06
Measured value: perlli ssi bIe ....................................................... X
Measured value: tIcessive ...................................................... X X
TOUCH "ARKS
Blade contour turbine whee-l ( .otor) and/or eOllpresso r wheel
One-sided on circullference; Signs of illba]anee ......................................... X X
Unjforll on ci·rcullference: Check gaps and charances ( see section 1) X X X
FOULING
On gap afhr turbine wheel (.oto.) di se
t-Ial"'row oil trace: HarD]ess ••ay be caused by run down lubrication ................. X
•
Heavy fuel residues ....................................................................... X
Thick cover of oil coke distributed ov~r the entire d rcullhrente: Indicates
seYere oi] leakage. hads lIostly to sluggish running of the turbi ne ·...heel (.oto.) X X
Turbine whee] (.oto.) - (visible pl.t of bladed .h.el)
Heavy fuel residues or other fouling cover ....................................... X
Co.pressor wheel (iapelle.) - (visible .part of bladed .h.el)
DAMAGE
Dusty, oily cover ............................................................... X I
Turbine wheel (rotod, to.pressor vheel (i_peUe.), bearing tuing
Turbocha~ging severely impaired. seYere oil leakage, strength impaired •••••••••• X X
SLUGGISH RUNNING or ROTOR
Very sluggish or blocked: Oil coke deposits after turbine wheel (roto.) or in
J abyrinth seal, or bearing defect ................................................. X X
--
Note: Running-in labyrinths aay cause sOlle sluggishness -in rotation of new or
used turbochargers .. This is har.less because in operation the rotor floats
and then runs free.
Test: lift rotor to concentric position and rotate.
• '"
'"
o
036 565' E
500.17-J
It.r.... UIt"
Wor"'""CI
1
'_
D"rH CIIt fro_,t
-5._",
-
_
ToIl"'DO IIfIt Irtll)ChO _
........,
Hit....*l
........
I I:t.
....
i"it'• .,
TOol'" Iitt
c-
15.000 + 500
as required
Page I of 2
kuOlt".'--'
OPt'r.·...o .........
_ ...It.1ItIt _'Cfoll
_ D ' CIIt ....... 00
CLEANING THE CARTRIDGE
Burnt-in layers of dirt, particularly on tbe turbine side (e.g .. heavy fuel layers, oil coke)
are to be removed by soaking in P3 water solution and brushing. If necessary, repeat this
process several ti.es. Next neutralize with. soda water.
Reaove oily layers by .eans of fuel or soae other liquid cleaning agent.
Note: The cleaning liquid and the dissolved dirt must not enter the interior of the cartridge
and thus bearings or the lube oil circuit. The gaps after the turbine wheel.(rotor)
disc and the co.pressor wheel (impeller) should therefore be covered with suitable
means.
For soaking layers of dirt on the turbine wheel (rotor) disc. the cartridge can be
placed vertically, turbine side downwards, into a container with suitable seatings.
Fill the container with cleaning liquid only to a certain level which .ust not be
exceeded in order to prevent the liquid from entering the interior of the cartridge
(see illustration).
•
o 238 n dia.
H 70 ..
m
'..
599.001 =
(517.000 + 520.0001
36 42 674
•
o 36 565' E /500.17-1 Page 2 of 2 •

•
DISMANTLING AND REASSEMBLING NR 15/R 500
CARTRIDGE Arbeil1lr.o.r1e·N, .
INSPECTION OF COMPONENT PARTS ~o;;~::~o~~o. 500.18
Tor,elQ Irobajo No.
lOOLS REQUIRED associated work cards •••• 500.06, 500.10 through 500.17
1 Opend-end wrench A/f 30
1 Pounding log or copper bolt
1 Hammer
1 Dial gauge
517.001 520.001
520.018
517.002
•
517.003 517 .009
LEGEND 520.001 lurbine roto r

520.009 520.005 Compressor whee
517.001 Bearing casing 520.006 Labyrinth ring
520.011 /520.124 517.002 Bearing bush 520.009 Carrier
517.003 Spacer sleeve 520.011 tap nut
517.00~ Holding screw 520.018 feather key
517.009 Intermediate 520.124 Magnetic nut
ring
W= Balancing marks
JIARIING POSITION
• Cartridge (599.001) detached from turbocharger.

Oisassembly of cartridge required, refer to work card 500.17.
Oisassembly of cartridge to be carried out be educated service staff.
SEOUENCE Of OPERA liONS 1: Disassembly (dismantling)

1. Unscrew thread cap nut (520.011) or magnetic nut (520.124) (version with revolution counter)
while holding turbine rotor in place.
2. Extract carrier (520.009).
3. Extract compressor wheel (520.005) by hand in axial direction.
Note: If compressor wheel should have seized (e.g. due to fretting corrosion), feed highly
fluid special solvent (e.g. Caramba) into groove of shaft seat and allow to react. Ihen
withdraw compressor wheel by moving it back and forth.
4. Lift turbine rotor (520.001) slightly and move it out in direction of turbine side as centrically
as possible.
Note: Adhesion of labyrinths (from running-in)or coke deposits may impede the process.
If so, use pounding log. By removing the rotor, the labyrinth ring (520.006) is being
• = 036 565~ E
eT-
;; l...:5:,:0:::0.:..
stripped off. The two feather keys (520.018) are normally not to be detached, however,
take care that they are not lost.
.,~"'''''' -
T ,,,moo de trOl:>o'Q _ Heroi
1.: 0.5 I ItIt ~:~"
~18:::-:.:1~_L2r;~~;~'~~"'d~o.':.:,,;,~0:~o,~, :...==..::~~~~::;,:..."_2_._:_1_.O_-.!...!!.~~_--l~T o~v~"'_'_,,
SOv"""
Code
15.000 ±. 500
a_s_r_e_q:..u_,_re_i:f
Page 1 of
kl,iebu,,,,nd("n
0..'0""9
~
- =~: ~ : :~: .:'.: :'.: :;.:.:.~.::~:::i:e_l

_Ov",
•
517.063 517.023
517.024
517.001
517.009
517.034
517 .016
520.011
520. 124 1
-E~~_-~~~ - = ~.~
•
52O.018~
520.009 - /
520.001 - "
520.006 -~--
52O.005-~-
,
! B
~
517.122--~
517.123 -~
A-B
•
517.121 ----JC4 . 517.014
517.015 ----~~
517.015
517.001 - 4 . \ '"
r-
'".
'"
,.,'"
036 5654 E / 500.18-1 Page 2 of 4

•
• 5.
6.
Take out labyrinth ring (520.006) fro~ bearing casing.
Take out the two bearing bushes (517.002) froD bearing casing.
Note: In case the labyrinth ring sticks in the bearing casing. it may be pressed out in
COlaon with the sp~cer sleeve (517.003) and the compressor-side bearing bush after
having reloved the turbine-side' bearing bush (as described in 8. and 9.).
7. Re.ove intermediate ring (517.009).
8. Re.ove holding screw (517.004) (right-hand thread).
9. Press out spacer sleeve (517.003) in direction of compressor side.
Note: In the event of spacer ~eeve seizlng. it Day be forced out by light ha••er blows
or using a press together with a wooden bolt or one of copper.
INSPECTION OF COMPONENT PARTS: See Sequence of Operations 3.
SEQUENCE OF OPERATIONS 2: Reasse.bly

When reassembling the cartridge. particular attention Dust be paid to the cleanliness of xhe
component parts. Sliding surfaces of bearing bushes and turbine rotor thread must be slightly
•
moistened with clean lubricating oil. On assembly, apply an e~tremely thin protective film of
Molykote G Rapid, Molykote G-n or Molykote 0 on turbine ~haft fitting surfaces.
1. Insert spacer sleeve (517.003) -into the bearing casing, paying attention to install in
correct position. Axial distance of holding screw (517.004) taphole is smaller towards
the compressor side.
2. Screw home holding screw (517.004) to the stop. Tighten lightly only.
3. Insert bearing bushes (517.002) into the bearing casing on turbine and compressor sides.
Bearing bushes are symmetric, thus, mounting position at discretion.
4. Place intermediate ring (517.009) on bearing casing centering.
5. Cautiously insert turbine rotor (520.001) in axial direction. do not damage labyrinth tips.
6. Hove in labyrinth ring (520.006). Balancing marks nw"~ of labyrinth ring and turbine rotor
must correspond radial1y rega~ding angle position.
7. Insert feather keys (520.018) into turbine shaft, if they had been removed.
8. Fix turbine rotor at end position towards compressor side and against turning, either by
hand or with suitable mean$. Next slip compressor wheel (520.005) and carrier (520.009)
over the turbine shaft up to the end position. Ensure that t~e balancing marks 'IWII of
turbine rotor (520.001), labyrinth ring (520.006), compressor wheel (520.005) and carrier
(520.009) correspond radially regarding angle position.
9. Screw on cap nut (520.011) or magnetic nut (520.124) - (version with revolution counter only) -
•
and tighten with a torque of 20 (Nm).
10. Using the dial gauge, measure aberration from plane of rotation of compressor wheel at the
largest radial distance.
For admissible rate. refer to Operating Instructions. Section I, Gaps and Clearances.
11. Using the dial gauge, measure axial clearance of rotor.
For admissible rate, refer to Operating Instructions, Section I, Gaps and Clearances,
posn. 5.
SEQUENCE OF OPERATIONS 3: Inspection of component parts

The component parts to be inspected are to be cleaned as described hereunder.
Burnt-in dirt layers, particularly on turbine side (e.g. heavy fuel residues, oil coke) are to
be soaked with P3-water solvent and brusned off. If required. this process is to be
repeated several times. Next neutralize with soda water.
Layers of oily dirt .are to be removed with fuel oil or any other liquid cleansing agent.
Bores for sealing air ~nd lube oil are to be flushed with fuel oil and then blown through
with an air hose .
.The following CHECK LIST comprises details on evaluation and measures required for repairing
•
the cartridge. Where several possibilities are marked off, the technical optimum is to be
selected.
o
D36 5654 E I 500.18_1 Page 3 of 4
..
Pa,.t No.
Ord, ..
No.
---------
CHECI LIST
Co.paRent pa,.t (individual part)

Condition
Oi.ension of
Send In part fa,. repair
Replace (renew) part

•
rejection: 0 = ouUr diJ,o, d = Inne,. di •• , b = lIIIidth
517.001 Bearing clung

O.llg' or incipient cracks (fissures), if stibility or oil-proof condition
at" i.pe,.i led ••••••••••••••••.•....••••••••••••••.•••••••..••••••••••••••..• x
Traces of seizure or wear In bearing bore: d > 42.03 ml dia .••.••••••••••••• X
Running-in patter-n abnorul by tips of labyri";;'th rings •. o • • • • • • • • • • • • • • • • • • • X
Note: labyrinth clearance IS slalle,. than the bearing clearance. Therefo", •.
the laby,.inth tips are running into the bore of the bearing casing.
The l"'Unnlng-ln grooves .are, according to the position of the rotor,
soaewhat one-side~ on the circumference.
517.002 Bearing bush (2 units, identical for turbine and compressor side)
•
Traces of seller ln contact pattern of axial surfaces ....••........•........ x
Wear: 0 < 41".8511111 dia., d) 24.04 am dia., b < 23.9511111 . X
~ U;ifora layer of lacquering is no cause-of concern, lnner and outer
diameters cannot be evaluated by visual inspection.
517.003 Spacer sletve
Traces of selZure on axial surfaces ...•............................•........ X
517.009 Intermediate ring

Damage. if function or strength are endangered •••••••.•••••.••••.•••••••••••• X
520.001 Turbine rotor

Damage to blades, e.g. by foreign matter •••..••••.•••.........•.•.......••.. X
Incipient cracks (fissures) - (crack test e.g. sound test, fluorescent dye check X
Touching traces on blade contour, one-sided on circumference, are indication
of iabalance .......•..... ...•.•.••.••••....•••...••.•......••••.. •••........ X X
Touching traces on blade contour, over entire circu.ference: if peraissible gap
has been exceeded (cf Operating Manual, GAPS AND CLEARANCES, its. 3 and ~)... X
Labyrinth tips damaged or worn: 0 < 49.85 a. dia. •••. X
Bearing points damaged or worn: 0 < 23.94 •• dia •••••••...•••....•••_........ X X
Concentric runnlng test: clean centering points, allocate ln points for
520.005
centering, aeasure concentric runnlng at the t~o bearing points and at seat
of coapressor wheel (3 points), if run-out exceeds 0.01 a. .•••••••••••••••••
N~ If eccentricity at those 3 points lS 1n the sa.e position on the C1r-
cuaference and runs linear, the centering points are daaaged ar.d the
real run-out fr?a concentric lS saaller Caax. per.issible 0.01 aa)
Compressor whetl
X X
•
Oa.age to blades, e.g. by foreign aatter ••••••••••••••••••.•.••.•.•••••••••. X
Incipient cracks (fissures},(crack test e.g. sound test, fluorescent dye check) X
Touching, traces on blade contour. one-sided on circuaference indicates i.balance X X
Touching traces on blade contour. over entire circuaference:'if per.issible 'gap
hiS been exceeded (cf Operlting ""n.II, GAPS AND CLEARANCES, its. 1 Ind 21 X
520.006 labyrinth rIng
labyrtnth Ups daaaaed or .. orn: 0 < 49.85 •• dia. X
036 5654 E I 500.18-1 Plge 4 of 4 •

REMOVING AND INSTALLING NR15/R 500
• ~
ADMISSION CASING, GAS OUTLET
DIFFUSER, TURBINE NOZZLE RING
"~bC;IJltOr1e-N~.
~~: ~:~~.
Tar,ela trabGio No.
associated work cards ••• 500.10 tnrough

500.16
500. 19
; rrtn
-f-I,- L !- - - - t - - - - TOOLS REQUIRED
r - I _ I'I! W 2 Open end wrench A/Fig
1 Socket wrench A/FI3
~/ 1 Piercer
, 1 Hammer
,
/
~
\"'"1"'"1.-'1' ( lEGEND
,
/
/
501.001 Gas admission casing
501.009 Collared bolt
509.001 Gas outlet diffuser
509.103 Hexagon nut
509.107 Lockwashers, Pair of
•
513.001 Turbine nOlzle ring
WEIGHTS
Gas admission casing 45 kg
Gas outlet diffuser 16 kg
Turbine nozzle ring ..••.. 1.5 kg
501.008 51 3. 001 <'<:::<:ZZ:Z:Z:ZZ:;:ZZ:Z:Z:~1:Z:::J

501,007 501.009
501.005 , -" ,-509.001
~~IA
501.006
W. ~
'---1H ~v
~
"
.
, ,
vV
• STARTING POSITION
36 42 677
Exhaust gas line after turbine has been removed or flange connection disconnected, or complete
turbocharger has been separated from engine. Cartridge has been removed.
GENERAL
Removal of the gas admission casing is only necessary in case of exchange or if the exhaust gas
line after turbine cannot be dismantled, and gas outlet diffuser or turbine nozzle ring must be
replaced.
SEQUENCE OF OPERATIONS 1: Removal

1. In case the gas admission casing (SOl.OOI) must be removed: Remove fastening screws on exhaust
inlet. Remove gas admission casing and deposit it on wooden supports while paying attention
to gasket land lagging, if fitted).
2. Unscrew hexagon nuts (509.103), pairs of lockwashers (509.107) and take off gas outlet
diffuser (509.001).
3. Remove turbine nOlzle ring (513.001) by means of pounding with invariable force in direction A
• '"
with hammer and a piercer onto 4 collared bolts (501.009).
036 5654 E
500.19-1
Artlt,hlt',
WOH,,,O ""'t
D ..rt,t dt 'ro"oil
_
_
_
T ''''''00 d~ Irot.o,o _
S'ur>O.,,,
I-Io u "
Htu,.,>
I-Iorol
AU~
E,,~r.,
Toul~, In
Codo
as required
Page 1 of 2
!lct'"ebu'undl!"
OOt'rOhf\9 "Ovrl
Ht'"rtl dt mcu~"t
Horo~ dt ~."i<io
SEQUENCE or OPERATIONS 2: R••ounting/installing
Ae.ounting/installing is a reversal of the reDoYing procedure.
Apply NaS,-based high-teaperature lubricant (e.g. Molykote HSC) to bolts and nuts, however.
do not apply this lubricant to screw-in threads if studs are replaced.
Fitting instructions for pairs of lockwashers (506.107): Serrated surfaces to face each other.
•
When Daunting the turbine nOlzle ring (513.001). the following instructions are to be observed:
1. Press the 4 collared bolts (SOl.009) with their lo"~er, tapered portion into the gas
ad.ission casing up to the stop.
2. Place turbine nOlzle ring (513.001) onto collared bolts (501.009) in a aanner so that
the corner-shaped nozzle vanes are in congruence with the separating walls of the gas
admission casing (refer to .arks "Z" in the illustration). Depending on design, there
are I, 2, 3 or 4 separating walls.
3. Press in turbine nozlle ring unifor.Jy and evenly, do not tilt a~d do not apply pressure
on nozzle vanes.
DJ5 S554 E / 500.19-1 Pa9. 2 of 2

•
ABGASTURBOLADER
•
500.01
EXHAUST TURBOCHARGER
TURBOSOBREALIMENTADOR DE GAS DE ESCAPE 1
VERZEICHNIS DER EINZELTEILE FOR

ABGASTURBOLADER
•
LIST OF SINGLE PARTS FOR
EXHAUST TURBOCHARGER
L1STE DES PIECES CONSTITUTIVES POUR

INDICE DE LAS PIEZAS INDIVIDUALES PARA

TURBOSOBREALIMENTADOR DE GAS DE ESCAPE
• ( D36 5654 -2 )
0365650 500.0111 2.88
VERZEICHNIS DER EINZElTEIlE
•
500.01
LIST OF SINGLE PARTS
lISTE DES PIECES CONSTITUTIVES
IN DICE DE LAS PIEZAS INDIVIDUAlES 2
E rsatztei I bestell u ng
Fur die Bestellung von Ersatzteilen ist das Verzeichnis der Einzelteile mit den dazugehorenden Bildern zu
verwenden. Die ersten 3 Stellen der Teilnummern bezeichnen die Baugruppe und die restlichen Zahlen sind
eine Zlihlnummer. Um Ruckfragen und Unklarheiten zu vermeiden, sind bei Bestellung folgende Angaben
erforderlich.
1. Typ des Turboladers xxx 5. Bestell-Nr. xxx.xxx

2. Werk-Nr. des Turboladers x xxx xxx 6. Benennung xxx
(3. Typ des Motors) xxxxx 7. StUckzahl xxx
(4. Werk-Nr. des Motors) x xxx xxx 8. Versandadresse xxx
Adresse Hausadresse Telefon: (0821) 322-0

MAN B&W Diesel AG MAN B&W Diesel AG Telex: 53 796-0 man d
Postfach 100080 Stadtbachstr. 1 Telegrammanschrift: manbw
0-86135 Augsburg 0-86153 Augsburg Telefax: (0821) 322-3998
•
Reserveteile
Auf gesonderte Bestellung wird eine Grundausstattung von ErsaUteilen als sogenannte Reserveteile
geliefert, deren Umfang im Verzeichnis der Reserveteile aufgefUhrt ist. Die Nummern in der liste sind gleich
den Bestell-Nr. und stimmen mit denan den Teilen angebrachten Nummern uberein. Alle Teile, soweit nicht
in Plastikbeutel verpackt, sind stets gut gefettet aufzubewahren. Rostig gewordene Teile sirid zu reinigen
und einzufetten.
Es wird empfohlen, verbrauchte Reserveteile sofort nachzubestellen, da Transport (und Zollabfertigung) die
Anlieferung der Teile sehr verzogern konnen. Fur Reparaturarbeiten ist es jedoch wesentlich, die
erforderlichen Teile moglichst sofort greifbar zu haben.
Werkzeuge
Die dem Turbolader mitgegebenen Werkzeuge sind in einer Kiste verpackt und in einer liste am Deckel der
Werkzeugkiste aufgefuhrt. Fur die Behandlung und Nachbestellung von Werkzeugen gelten die gleichen
Anweisungen wie fUr Ersatzteile. Die Baugruppe fUr Werkzeuge ist 596.....
Ordering Spare Parts

Reference should be made to the list of single parts and the relevent drawings in preparing orders for spare
parts. The first three digits of the part numbers designate the equipment group and the last digits represent
a consecutive number.
•
In order to avoid confusion and queries make it a point to include the following information in your orders.
1. Type of turbocharger xxx 5. Order No. xxx. xxx

2. Works-No. of turbocharger x xxx xxx 6. Designation xxx
(3. Type of engine) xxxxx 7. Quantity xxx
(4. Works-No. of engine) x xxx xxx 8. Shipping address xxx
Mail box adress Postal adress Telephone: (0821) 322-0

P.O.P 100080 Stadtbachstral3e 1 Cables: manbw
Reserve Parts
If ordered separatly a basic provision of spare parts will be delivered as so called" reserve parts", the range
of which is listed in the table. The numbers in the list should be quoted in your order and coincide with the
numbers with which the parts are marked. All parts, unless packed in plastic bags should be kept well
greased during storage. Any parts showing rust deposits should be cleaned and coated with grease.
It is recommended that any reserve parts installed should be re-ordered at once, seeing that transport (and
customsdearance) may cause considerable delays in the delivery of the parts. Prompt repairs depend on any
necessary parts being at hand when needed.
•
Tool s
The tools supplied with the turbochargers are packed in a case and tabulated in a list attached to the lid of
the tool box. In handling and re-ordering tools, the same instructions as given for.spare parts should be
followed. The code number for tools is 596. ... . .
T.5.V.P. - sigue al dorso
D365650 500.0112 2.94
Commande de pieces de rechange
. Pour la.commande de pieces de rechange, il convient d'utiliser la liste des pieces constitutives avec les figures •
correspondantes. les 3 premiers chiffres de numeros de pieces designent le sous-groupe, tandis que les
autres chiffres constituent un numero compteur.
Afin d'eviterdes demandes de renseignements et des imprecions, il s'impose de donner les renseignements
suivants lars d'une commande:
I..Type du turbocompresseur xxx 5. No. de commande xxx.xxx

2. No. d'usine du turbocompresseur x xxx xxx 6. Designation xxx
(3. Type du moteur) xxxxx 7. Nombre xxx
(4. No. d'usine du moteur) x xxx xxx 8. Adresse d'expedition xxx
Adresse Siege Telephone: (0821) 322-0

Postafach 100080 Stadtbachstr. 1 CAble: manbw
0-86 135 Augsburg 0-86 1S3 Augsburg Telefax: (0821) 322-3998
Pieces de reServe
Sur demande speciale. il est fourni un equipement de base de pieces de rechange en tant que pieces dites de
reserve, dont I'etendue est portee dans la liste des pieces de reserve. les numeros indiques sur la liste sont en
meme temps les numeros de commande et correspondent Aceux appliques aux pieces memes. Dans la
mesure o'u les pieces ne sont pas emballees dans des sacs en matiere plastique. il convient de les stocker bien
graissees. Des pieces devenues rouilll!es doivent etre nettoyees etgraissees.
11 est recommande de commander de nouveau des pieces de reserve usees tout de suite apres leur con- •
sommation. parce que le transport (et les formalites douanieres) peuvent beaucoup retarder la livraisen des
pieces. Or, pour des travaux de reparation, il est essentiel d'avoir les pieces necessaires sur place.
o u ti I s
les outiles fournis avec le i.urbo-compresseur sont emballes dans une caisse et enumeres sur une Iiste ap-
pose au couvercle de la caisse Aoutils. Pour le traitement et la commande des outils s'appliquent les memes
instructions que celles donnees pour les pieces de rechange. le sous-groupo pour les outils est S96.....
Pedidos de repuestos
Para pedir repuestos. se debe utilizar el indice de las piezas individuales con sus figuras correspondientes. las
primeras 3 cifras de los n"merosde referenda indican el grupo parcial componente del turbosobreali-
mentador, las cifres restantes son de enumeraci6n.
Para evitar demandas de aclarad6n y confusiones. es necesario indicar los siguientes datos en los pedidos:
1. Tipo del turbosobrealimentador xxx 5. No. de pedido XXx.xxx

2. No. de fabrica del turbosobre- x xxx xxx 6. Designaci6n xxx
•
alimentador
(3. Tipo del motor) xxxxx 7. Cantidad xxx
(4. No. de fabrica del motor) x xxx xxx 8. 5elias a d6nde
mandar el pedido xxx
Direcci6n postal 5ede Teletono: (0821) 322-0

Postfach 10 00 80 5tadtbachstr. ·1 Direcci6n telegrMrica: manbw
Piezas de reServa
Por encargo especial.se suministra un equipo basico de piezas de recambio como piezas lIamadas de reserva.
cuyo volumen se halla indicado en el registro de las piezas de reserva. los numeros de la lista son al mismo
tiempo los de referencia y coinciden con los n"meros marcados en las piezas. Todas las piezas. menos
aquellas que vienen en bolsas de plastico. deben almacenarse siempre bien engrasadas. las piezas que se
hayan oxidado. deben limpiarse y lubricarse.
Se recomienda pedir las piezas de reserva utilizadas en seguida de nuevo. ya que el transporte (y el despacho
en la aduana) pueden retrasar mucho el suministro de las piezas. Sin embargo, para peder efectuar trabajos
de reparaci6n. es de importancia fundamental tener las piezas necesarias en seguida a mano 0 10 antes
posible.
Herramientas.
las herramientas que se entregan junto con el turbosobrealimentador vienen embaladas en una caja y estan •
enumeradas en una lista que esta pegada en la tapa de dicha caja. Para el tratamiento y los. pedidos de
herramientas valen las mismas indicaciones que para los repuestos. El grupo de herramientas lIeva el n"mero
596.....
036 5650/500.01 12
SAUGRUPPENOBERSICHT
•
NRI5/R 500.02
LIST OF ASSEMBLIES
lISTE SUR TOUS LES GROUPES
LISTA DE TODOS LOS GRUPOS 3
Gruppe
Benennung Des i gnat ion
Group
500 Turbolader, komplett Turbocharger, complete

501 Turbinen-Zustromgehause Gas-admission casing
509 Tu rbi nen-Abstromd iffusor Gas exit diffuser
513 Turbinenleitapparat Turbine nozzle ring
S17 Lagerung Bearing
520 Laufer Rotor
542 Nachleitapparat Diffusor
544 Schalldampfer Silencer
545 Ansauggehause Air-intake casing
546 Verdichtergehause Compressor casing
562 Elektronische Drehzahlmesseinrichtung Electronic speed measuring device
57S' Reinigungseinrichtung fur Turbine Cleaning device for turbine
•
579 Reinigungseinrichtung fur Verdichter Cleaning device for compressor
591 Verschalung am Turbinenzustromgehause Cover on gas-admission casing
599' Rumpfgruppe bestehend aus Lagerung (SI7) Cartridge consists of bearing (517)
und Laufer (520) and rotor (520)
, Diese Baugruppen sind im Bild 1 nicht , These assemblies are not shown in the
sichtbar figure 1
Groupes
Designation Designaci6n
Grupos
500 Turbocompresseur, compi. Turbosobrealimentador, compi.

501 Corps d'admission de turbine ·Caja de afluencia de turbina
509 Diffuseur d'echappement de trubine Difusor de evacuaci6n de la turbina
•
513 Distributeur de turbine Distribuidor de gases de turbina
517 Logement Alojamiento
520 Rotor Rotor
542 Diffuseur final Difusor final
544 Silencieux Silenciador
545 Corps d'aspiration Caja de aspiraci6n
546 Corps de compresseur Caja del compresor
562 Dsipositif electroniquede mesure de regime Instalaci6n eleetonica para el medici6n del
numero de revoluciones
57S' Dispositif de nettoyage pour turbine Dispositivo de lavado para turbi na
579 Dispositif de nettoyage pour compresseur Dispositivo de lavado para compresor
591 Revetement sur corps d'admission de turbine Revestimiento en caja afluencia de la turbina
599' Groupe bas comprenant longement (517) Grupo base intergrado por alojamiento
et rotor (520) (517) y rotor (520)
" Ce SQus-groupe n'est pas visible sur la , Este grupo constructivo no esta visible
•
figure 1 en la figura 1
0365654 500.02/3 4.B9

BAUGRUPPENOBERSICHT
•
NR IS/ R SOO.02
LIST OF ASSEMBLIES
L1STE SUR TOUS LES GROUPES
LISTA DE TOOOS LOS GRUPOS L 1S 323 4
Bild 1 - Figure 1 - Figure 1 - Figura 1
,:
r~ i
!
g;
r\ -. '"
• . !....l-i- . _
/'\ i
UI
._
I", '.i •
.1..
.r:::=.- _L •
L..._...,;
•
~.~('~::;::;
<
<
,I
\
\
T-
,
)
\L __
..
'"
r-
'"Il
•
...
D36 S6S4 SOO.02/4 4.89

VERZEICHNIS DER EINZELTEILE
•
NR1S/R 500.02
lISTE DES PIECES CONSTITUTlVES
IN DICE 'DE LAS PIEZAS INDIVIDUALES 5
Bestell·Nr Norm Nr.

Order No. Benennung Designation Standard No.
No. de c.de. Designation Designa.Cl6n No. standard
Node pedldo Nodenorma.
500.000 Abgasturbolader, komplett Exhaust turbocharger,

complete
Bild 1 Figure 1
Turbocompresseur a gaz Turbosobrealimentador de
d'~chappement,.compl gas de escape. corn pI.
Figure 1 Figura 1
501.000 Turbinen-Zustromgehause Gas-admission casing -0443

Bild 2 Figure 2 -0465
Corps d'admission de turbine Caja de afluencia de la turbina
Figure 2 Figura 2
• 501.001
501.005
501.006
Turbinen-Zustromgehause
Corps d'admission de turbine
Spannpratze
Griffe de serrage
Stiftschraube
Goujon
Gas-admission casing
Cajade afluencia de turbina
Clamping claw
Oreja de apriete
Stud screw
Prisionero
AM 1701-MBx18
501.007 Sicherungsscheibenpaar Lock discs (pair) MAN 361-8,4-nr St

Paire de rondelles d'arret Par de arandelas de seguridad
501.008 Sechskantmutter Hexagon nut AM 1702-M8
Ecrou a six pans Tuerca hexagonal
501.009 8undbolzen Collar bolt
Boulon ~ collet Perno con collar
509.000 Turbinen-Abstromdiffusor Gas exit diffusor -0085

Bild2 Figure 2
Diffuseur d'~chappementde Difusor de evacuaci6n de
turbine la turbina
• 509.001
506.101
506.103
Figure 2
Abstromdiffusor
Diffuseur d'echappement
Stiftschraube
Goujon
Sechskantmutter
Figura 2
Gas exit diffusor

Difusor de evacuaci6n
Stud screw
Prisionero
Hexagon nut
AM 1701-M8x25
AM 1702·M8
506.107 Sicherungsscheibenpaar Lock discs (pair) MAN 361-8,4-nr5t
Paire de rondelles d'arret 'Par de arandelas de seguridad
513.000 lurbi nenleitapparat Turbine nozzle ring

Bild 2 Figure 2
Distributeur de turbine Distribuidor de gases de
turbina
Figure 2 Figura 2
513.001 Turbinenleitapparat Turbine nozzle ring

Distributeur de turbine Distribuidor de gases de
•
turbina
siehe Ruckseite· PTO
t.s.v,p, - sigue al dorso
0365654 500.02/5 2.91

. - -
Bestell·Nr. Norm Nr.
•
No. decde. Designation Designaci6n No. standard
Node pedldo Node norma
517.000 lagerung Bearing -0340

Bild 3 Figure 3
Logement Alojamiento
Figure 3 Figura 3
517.001 Lagergehause Bearing casing

Boitier de paliers Caja de cojinetes
517.002 Lagerbuchse Bearing bush
Douille de palier Casquillo de cojinete
517.003 Abstandhulse 5pacer sleeve
Douille d' ecartement Manguito distanciador
517.004 Halteschraube Holding screw
Vis de retenue Tornillo fiador
517.009 Zwischenring Intermediate ring
Bague intermediaire Anillo intermedio
517.014 Verschlul3schraube Screw plug DIN 908-M30xl,5-5.8
•
Bouchon filete Tornillo de cierre
517.015 Dichtring Seal ring DIN 7603-A30x36-Cu
Anneau-joint Anillo de junta
517.016 Verschlul3schraube Screw plug DIN 7604-Ml0xl-5.8
517.023 Verschlul3schraube Screw plug DIN 7604-M 12x 1,5-5.8
517.024 Dichtring Seal ring DIN 7603-A12xI6-Cu
517.034 Dichtrfng Seal ring 01 N 7603-A 1Ox 14-Cu
Anneau·joint Anillo de junta
517.063 Runddichtring O-ring
Joint-torique Anillo circular de junta
517.121 Verschlul3schraube Screw plug
517.122 Einspritzrohr Injection pipe
Tuyau d'injection Tubo de inyecci6n
517.1.23 Dichtring Seal ring DIN 7603-A 12x 16-Cu
520.000 Uiufer
Bild 3
Rotor
Figure 3
RQ!Q!:
Figure 3
Rotor
Figura 3
-1256
•
520.001 Turbinenlaufer Turbine rotor
Rotor Rotor
520.005 Verdichterrad Compressor wheel
Roue de compresseur Rodete compresor
520.006 Labyrinthring Labyrinth ri ng
Anneau labyrinthe Junta laberintica
520.009 Mitnehmer Carrier
Entraineur Arrastrador
520.011 Abschlul3mutter Cap nut
Ecrou de fermeture Tuerca terminal
0365654/500.0215 •
•
NR1S/R 500.02
L1STE DES PIECES CONSTITUTIVES
INDICE DE LAS PIEZAS INDIVIDUALES 6
Bestell-Nr Norm Nr.

No.de cde. Dtsignation Designa"ci6n No. Standard
Node pedido Node norma.
520.018 PaBfeder Feather key DIN 6885·A4x4x 1o-C45K

Clavette Cheveta de ajuste
520.124 Magnetmutter, nur bei Magnetic nut, only for design
AusfUhrung mit Drehzahl- with speed transmitter,
geber, anstelle von 520.011 instead of 520.01 1
Ecrou a aimant, seulement Tuerca con iman, solamente
pour version avec trans- para ejecuci6n con transmisor
metteur de vitesse, au lieu de velocidad, en lugar de
de 520.011 520.011
• 542.000
542.001
Nachleitapparat
Bild 6
Diffuseur final
Figure 6
Nachleitapparat
Diffuseur final
Diffuser
Figure 6
Difusor final
Figura 6
Diffuser
Difusor final
544.000 Schalldampfer Silencer ·0404

54411 ohne Drehzahlgeber 54411 without speed transmitte
S44I2 mit Drehzahtgeber 54412 with speed transmitter
falls vorhanden if provided
Bild 4 Figure4
Silencieux Silenciador
54411 sans transmetteur de 54411 sin transmisor de
vitesse velocidad
S44I2 avec transmetteur de 54412 con transmisor de
vitesse velocidad
•
s'il existe si existe
Figure4 Figura 4
544.001 Ruckwand Rear wall

Paroi arriere Pared posterior
544.021 Dampfungsplatte Damping plate
Plaque amortisseur Placa amortiguador
544.032 Distanzbuchse Spacer bush
Douille d'ecartement Casquillo distanciador
544.033· Zentrierbuchse Centring bush
Douille de centrage Casquillo de centraje
544.034 Schutzgitter Protection grate
Grill protectrice Rejilla protectora
544.041 Vorderwand Front board
Paroi en avant Pared delantero
544.066· Stiftschraube Stud screw DIN 83S-M6x16-5.8
Goujon Prisionero
544.067· Sechskantmutter Hexagon nut M 1S36-AM6-6
• D36S654 500.0216 4.89

siehe Ruckseite - PTO
t.s.v.p.· sigue at dorso
Benell-Nr. Norm Nr.
•
Order No. _ Benennung Designation Standard No.
No. de cde. ; Designation Designaci6n No. standard
No de pedido Node norma
544.069 5tihschraube Stud screw

Goujon Prisionero
544.074 5echskantmutter Hexagon nut M 1536-AM 10
544.084 Verschlullschraube Screw plug DIN 910-M16xl,5-5.8
544.085 Dichtring Seal ring DIN 7603-A 16x20-vf
544.090 Einspritzrohr, nur bei Turbo- Injection pipe, only for turbo-
lader mit Reinigungsein- . charger with cleaning device
richtung 579/2 579/2
Tuyau d'injection, seulement Tubo de inyecei6n, solamente
pour turbocompresseur ~wec para turbosobrealimentador
dispositif de nettoyage 579/2 con dispositivo de lavado 579/2
544.201 Luhfilter Air filter
Filtre d'air Filtro de aire
544.202
544.205
544.222"
544.230·
5pannschelle
Etrier de serrage
Abdeckblech
Tole de recouvrement
Deckel
Couvercle
5tiftschraube
Fitting strap
Brida tensora
Cover sheet
Chapa de revestimiento
Cover
Tapa
Stud screw DIN 835-MBx20-B.B
•
Goujon Prisionero
544.231· 5echskantmutter Hexagon nut M 1536-AM 8
Ecrou a six'pans Tuerca hexagonal
• nur bei Schalldampfer mit Drehzahlgeber

. only for Silencer with speed transmitter
seulement pour silencieux avec transmetteur de vitesse
solamente para silenciador con transmisor de velocidad
D36 5654/500.0216
•
VERZEICHNIS DER EINZELTEILE NRI5/R
•
500.02
LIST OF SINGLE PARTS -
L1STE DES PIECES CON5TITUTIVES
IN DICE DE LAS PIEZA5 INDIVIDUALES 7
Bestell-Nr Norm Nr.

NO.de (de. O~signatlon DesignatiOn No. standard
Node pedldo No de norma.
545.000 Ansauggehause Air·intake casing -0130

Bild 5 Figure 5
Corps d'aspiration Caja de aspiraci6n
Figure 5 Figura 5
545.001 Ansauggehause Air-intake casing
Corps d'aspiration Caja de aspiraci6n
545.014 Sechskantschraube Hexagon bolt DIN 933-MSx30-S.S
Boulon il six pans Tornillo hexagonal
545.01S Verschlul3schraube Screw plug DIN 91Q-MI6xl.5-5.S
• 545.019
545.06S·
545.069·
Bouchon filete
Dichtring
Anneau-joint
5tiftschraube
Goujon
Sechskantmutter
Ecrou it six pans
Tornillo de cierre
Seal ring
Anillo de junta
Stud screw
Prisionero
Hexagon nut
Tuerca hexagonal
DIN 7603-A 16x20-Vf
DIN S35-M6x 16-5.S
M 1536-AM 6-6
545.090 Einspritzrohr, nur bei Turbo- Injection pipe, only for turbo-
lader mit Reinigungsein- charger with c1eani'ng device
richtung 57912 ·57912
Tuyau d'injeetion. seulement Tubo de inyecci6n, solamente
pour turbocompresseur avec para turbosobreal imentador
dispositif de nettoyage 57912 con dispositivo de lavado 5791,
• Nur bei Turbolader mit Drehzahlgeber
only for Turbocharger with speed transmitter
seulement pour turbocompresseur avec transmetteur
de vitesse
solamente para turbosobrealimentador con transmisor
de velocidad
• 546.000 Verdichtergehause
Bild 6
Corps de compresseur
Figure 6
Compressor casing
FIgure 6
Caja del compresor
Flgura 6
-0459
-0620
546.001 5piralgehause Volute casing

Corps il vol ute Caja espi ral
546.005 V-Profi Ispannschell e Clamp
Bride de serrage Brida
546.00S 5enkschraube Countersunk screw DIN 963M5x25-4.8
Vis il tete noyee Tornillo avellanado
546.01S· EinsatzstUck Insert piece
Insert Pieza de'inserci6n
546.020· Stiftschraube Stud screw DIN 939-MSx25-S.S
Goujon Pi"isionero.
546.021 5echskantmutter Hexagon nut DIN 934-M5-S
Ecrou il si x pans Tuerca hexagonal
546.022 5icherungsscheibe Lock disc AM 12S-5xl
•
Disque de securite Disco de seguridad
t.s.v.p. - sigue al dorso
D3656S4 SOO.0117 2. .91
Bestell-Nr. Norm Nr.
•
- .
No. de (de. Designation Designaci6n No. standard
Node pedido Node norma
546.023' Runddichtring' O-ring

Joint torique Anillo circular de junta
546.024' 5echskantmutter Hexagon nut M 1536-AM 8
a
Ecrou six pans Tuerca hexagonal
546.025 Firmenschild . Name plate
Plaque d'usine Placa de fi\brica
546.026 Halbrundkerbnagel 5plined pin DIN 1476-3x8-St
Clou cannel atfHe ronde Pasador redondo estriado
546.050' Flansch Flange R571-TV 78x48
Bride Brida
546.051' Dichtring Seal ring M 618-27x38-Cu
Anneau·joint Anillo de junta
546.052' 5echskantschraube Hexagon bolt DIN 933-M10x30-8.8
a
Boulon six pans Tornillo hexagonal
, Nur bei Turbolader mit Lufthilfsantrieb
only for Turbocharger with air auxiliary drive
•
seulement pour turbocompresseur avec commande
auxiliaire pneumatique
solamente para turbosobrealimentador con accionamiento
neumatico auxiliar
562.000 Drehzahlgeber Speed transmitter -0107

Bild 4 und 5 Figure 4 and 5
Transmetteur de vitesse Transmisor de velocidad·
Figure 4 et 5 Figura 4y 5
562.004 Haltescheibe Holding disc

Disque de retenue Disco de sejeci6n
562.040 Drehzahlgeber Speed transmitter
Transmetteur de vitesse Transmisor de velocidad
578.000/1 Reinigungseinrichtung fOr Cleaning device for turbine -0012
•
Turbine (Nassreinigung) (wet cleaning)
Bild7 Figure 7
Dispositif de nettoyage pour DispositivQ de lavado para
turbine turbina
(nettoyage I'eau) a (Limpieza por via humeda)
Figure 7 Figura 7
578.002 Verschraubung Screw connection DIN 2353-CL15-St

Vissage Racor
578.003 Dichtring Seal ring DIN 7603-A 18x24-Cu
578.005 Dichtring Seal ring DIN 7603-A 14xl8-Cu
578.006 Druckminderstation Pressure reducing station
Station de reduction de Equipo de reducci6n de
pression presi6n
578.010 Schild Metal plate
Plaque Chapita
•
578.020 Dreiwegehahn Three-way cock
a
Robinet trois voies Grifo de tres pasos
036 56541 500.0217

VERZEICHNIS DER EINZELTEILE NR157R 500.02
•
L1STE DES PIECES CON5T1TUTIVES
INDICE DE [AS PIEZAS INDIVIDUALES 8
Bestell-Nr Norm Nr.

No. de (de. Designation Designaci6n No. standard
Node pedldo No de norma.
578.000/2 Reinigungseinrichtung fur Cleaning device for turbine -0041

Turbine (Trockenreinigung) (Dry cleaning)
Bild8 Figure 8
Dispositif de nettoyage pour DispositivQ de lavado para
turbine turbina
(nettoyage a sec) (Limpieza en seco)
Figure 8 Figura 8
578.501 Abblasepistole.komplett Blow-gun, complete
•
mit Pos. 578.001-578.006 with items 57B.001-57B.006
Pistolet de purge, compl. Pistola de soplado, compl.
avec rep. 578.001-578.006 con pos. 578.001-578.006
578.001 Kupplung mit Gewinde Coupling with thread
Conneeteur filete Acoplamiento roscado
578004 Absperrhahn Stop cock
Robinet d'arret Grifo de cierre
578.005 Nippel mit Gewinde Nipple with threaded
Raccord filete Boquilla roscada
578.006 Kupplung fUr Schlauch Coupling for hose
Conneeteur pour flexible Acoplamiento para manga
578.502 Absperrhahn, komp'lett Stop cock, complete

mit Pos. 578.011-578.013 with items 578.011-578.013
Robinet d'arret. compl. Grifo de cierre, compl.
avec rep. 578.011-578.013 con pos. 578.011-578.013
578.011 Absperrhahn Stop cock
Robinet d'arret Grifo de cierre
578.013 Nippel mit Gewinde Nip'ple with threaded
•
Raccord filete 80quilla roscada
578.035 Schild Metal plate

Plaque Chapita
579.00011 Reinigungseinrichtung fur Cleaning device for

Verdichter compressor
Dispositi f de nettoyage pour Dispositivo de lavado para
compresseur compresor
579.119 Handspritze Syringe

Seringue it main Jeringa
• 0365654 500.02/8 10.91

t.s.v.p. - sigue al dorso
Bestell·Nr_ Norm Nr.
•
Order No. Benennung De~ignation Standard No.
No. de cde. DesIgnation Designaclon No. standard
Node pedido Node norma
579.000/2 Reinigungseinrichtung fur Cleaning device for -0057

Verdichter compressor .
Bild 9 Figure 9
Disqositif de nettoyage pour Dispositivo de lavado para
compresseur comprMor
Figure 9 Figura 9
579.029 Behiilter Tank

Reservoir Recipiente
579.030 SchraubverschluB Screw plug
Vis de fermeture Tap6n roscada
579.042 Sechskantschraube Hexagon bolt DIN 931-MBx65-8.8
Boulon a six pans Tornillo hexagonal
579.044 Sicherungsblech Lockwasher DIN 432-B,4-St
Chapa de seguridad
•
Tole d'arret
579.0BO Saugrohr Suction pipe
Tuyau d'aspiration Tubo de aspiracion
579.0B9 Schlauch Hose
Tuya flexible Tubo flexible
579.090 Schlauch Hose
Tuyau flexible Tubo flexible
579.091 Schlauchschelle Hose damp R 597-E21x12
Collier Abrazadera
579.120 AnschluBstUck Connection piece
Piece de raccord Pieza de racor
579.121 Metallkleber Metal adhesive
Adhesiv de metal Adhesivo de metal
579.122 Hydrometerhahn Cock
Robinet Grifo
579.123 Dichtung Gasket M 618-21x27-Vf
Joint Junta
579.124 Verschraubung Screw connection DIN 2353-DL15-St
Vissage Racor
579.126 Rohr Pipe
•
Tuyau Tubo
·579.127 Schlauch Hose
Tuyau flexible Tubo flexible
579.12B Schlauchschelle Hose damp R 597-E14x12
Collier Abrazadera
579.130 Halterung Bracket
Support Soporte
579.17B Schild Metal plate
Plaque Chapita
0365654/500.02/8
•
•
NR15/R 500.02
L15T OF SINGLE PARTS
L15TE DES PIECES CON5TITUTIVES
INDICE DE LAS PIEZAS INDIVIDUALES 9
Bestell-Nr Norm Nr.

No. de cde. Designation DesignaciOn No. standard
Node pedido Node norma.
591.000 Verschalung am Cover on

Turbinenzustromgehause Gas·admission casing
Bild 2 Figure 2
Revetement sur corps Revestimiento en ca;a
d'admission de turbine afluencia turbina
Figure 2 Figura 2
591.001· Verschalung und Isolierung Covering and isolation

Revetement et ealorifugeage Revestimiento yaislamiento
• 591.060 5child, zweiteilig Metal plate. two part

Plaque, deux pieces Chapita, dos piezas
591.066 Dichtring Seal ring DIN 7603-A 16x2()'Cu
591.085 VerbindungsstUek Connection piece
Pi ece de raccord Pieza de raeor
* Nur in Verbindung mit Turbinenzustromgehause lieferbar

Can only be supplied with gas-admission casing
Livrable seulement en liaison avec bati d'admission
de turbine
Se suministra s610 junto con la caja de admision de
aire a la turbina
• 599.001 Rumpfgruppe
(= 517.000 + 520.000)
Bild 3 und 10
Groupe base
(= 517.000 + 520.000)
Figure 3 et 10
Cartridge
(= 517.000 + 520.000)
Figure 3 and 10
Grupo base
(= 517.000 + 520.000)
Figura 3 y 10
• 0365654 500.0219 4.89

TURBINEN-ZUSTROMGEHAUSE
•
NR15/R 500.02
GAS-ADMISSION CASING
CORPS D'ADMISSION DE TURBINE
CAJA DE AFLUENCIA DE TURBINA L 15 322 10
TURBINEN-ABSTROMDIFFUSOR TURBINENLEITAPPARAT
GAS EXIT DIFFUSOR TURBINE NOZZLE RING
DIFFUSEUR D'ECHAPPEMENT DE TURBINE DISTRIBUTEUR DE TURBINE
DIFUSOR DE EVACUACION DE LA TURBINA DISTRIBUIDOR DE GASES DE TURBINA
VERSCHALUNG AM TURBINEN-ZUSTROMGEHAUSE
COVER ON GAS-ADMISSION CASING
REVETEMENTSUR CORPS D'ADMISSION DE TURBINE
REVESTIMIENTO EN CAJAAFLUENCIA TURBINA
Bild 2 - Figure 2 Figure 2 - Figura 2
• ~
---r-
I --.--
; r
.~.. ~
n
- -
591.085-
591.066---.
• 501.008 513 . 001

~.O~
'-C:Z:Z:Z:Z::Z:Z:1:Z:::l::z:z:z::<;~J
_
501.007
501.005 1/ .JI I 509.001
501.006
['~A
36 42 677
• 036 S6S4 500.02110 4.89

LAGERUNG,LAUFER
•
NR15/R 500.02
BEARING, ROTOR
LOG EM ENT, ROTOR
ALOJAMIENTO, ROTOR L15321 11
Bild 3 - Figure 3 Figure 3 • Figura 3
517.063 517.023
517.024
517.001
• 520.011
520. 124 1
W
t.·
520.018
520.009
520.001
520.006
520.005
,
!B
~
• 517.122
~ ..
A-B
517.123
517.121
517.014
517.015
,517.015
• D365654 500.02/11 4.89

•
SCHALLDAMPFER,DREH2AHLGEBER NR15/R 500.02
SILENCER, SPEED TRANSMITIER
51LENCIEUX, TRANSMETIEUR DE VITESSE L 15 325
SILENCIADOR, TRANSMI50R DE VELOCIDAD L 15326 12
Bild 4 • Figure 4 Figure 4 Figura 4
544.000/1
544.201 544.032 ,..---544.205
544.202 --I~~~~~~~ll544.202 Ausfuhrung ohne Drehzahlgeber
Design without speed transmitter
544.034 Version sans transmetteur de v;tesse
. . :§~~~~~~~~~~~~5~46~.;00;5
Ejecuci6n sin transmisor de velocidad
544.074
544. 069 _--+~--l
544.041 ~oI--~~-544. 021

544.001
• 544.085
544.084
-E:----:-.~.~:::-j:c=::=-:: -~
544.090 ---~~N-J
36 42 679
544.201 544.032 544.205 544.000/2

544.202 544.202
Ausfuhrung mit Drehzahlgeber
• 544.069 544.034 Design with speed transmitter

544.074 546.005 Version avec transmetteur de vitesse
Ejecuci6n con transmisor de
velocidad
544.041
544.230
544.021
544.231 544.001
544.222 544.033
:_ .r;544.090
-E-:-'
544.085 562.040
544.084
•
• D365654 500.02/12 4.B9

36 42 680
ANSAUGGEHAUSE,DREHZAHLGEBER
•
NRI5/R 500.02
AIR·INTAKE CASING, SPEED TRANSMITIER
CORPS D'ASPIRATION, TRANSMETIEUR DE VITESSE
CAJA DE ASPIRACION. TRANSMI50R DE VELOCIDAD L15327 13
Bild 5 - Figure 5 Figure 5 • Figura 5
~ I
- - ----L
____ - - t - - - -_-
545.014
•
545.001
545.018
545.019
545.068
545.069
562.040
562.004
• 0365654 500.02/13 4.89

VERDICHTERGEHAUSE, NACHLEITAPPARAT
•
NR15/R 500.02
COMPRESSOR CASING, DIFFUSOR
CORPS DE COMPRESSEUR, DIFFUSEUR FINAL
CAJA DEL COMPRESOR, DIFUSOR FINAL L 15 329 14
Bild 6 • Figure 6 • Figure 6 - Figura 6
546.025 517 .063

546.026
• 546.001
546.020
546.024
546.023
546.018
542.001
599.001
I
I '"co
'"cv
•
546.008
546.021 .-
546.022
'"'"
546.051
546.052---'
• 0365654 SOO.02/14 4.89

REINIGUNGSEINRICHTUNG FOR TURBINE
•
500.02
(NASSREINIGUNG)
CLEANING DEVICE FOR TURBINE (WET
CLEANING) L 15201 15
DISPOSITIF DE NETIOYAGE POUR TURBINE
(NETIOYAGE A L'EAU)
DISPOSITIVO DE LAVADO PARA TURBINA
(L1MPIEZA POR VIA HUMEDA)
Bild 7 - Figure 7 Figure 7 - Figura 7
• + +
+ + \
\
o
o '""'!_---<
o
cO
.... ....
<X>
'" '"
•
M N
o 0
o 0
........
<X> <X>
'" '"
I
._.-J-._.
• D3656S4 500.02/15 4.B9
REINIGUNG5EINRICHTUNG FOR TURBINE
•
NRI5/R 500.02
(TROCKENREINIGUNG)
CLEANING DEVICE FOR TURBINE (DRY CLEANING) I--------I------l
DI5P051TIF DE NETIOYAGE POUR TURBINE L 15 369 16
(NETIOYAGE A SEC)
DISPOSITIVO DE LAVADO PARA TURBINA
(LIMPIEZA EN SECO)
Bild 8 . - Figure 8 Figure 8 - Figura 8
-.D
o
o -I~:::::I
•
co
~~-I
co
r- '
-
o
""
""cor-
""
u
-
o
C> _ _~::::J
"
0'0
0 co
r-
""..-,
""
----I.
co x
r- 0
"" E
•
..-, ,
<5 .
co .
r-
""
..-,
o ""
co
r-
""
- ~t:t:::;;d
c,"\'}. ·s C>
o o
~ .• ;, ,
•
o o
0365654 500.02116 10.91

REINIGUNGSEINRICHTUNG FOR VERDICHTER
•
NR1S/R SOO.02
CLEANING DEVICE FOR COMPRESSOR
DISPOSITIF DE NETIOYAGE POUR
L 15228 17
COMPRESSEUR
DISPOSITIVO DE LAVADO PARA COMPRESOR
Bild 9 • Figure 9 - Figure 9 - Figura 9
• - - . _ . H-+-'r-\-- . - \
G 1/2 )
579.089 it
. I
579.091
546.001 579.123
579.124
579.126----;.
579.090
579.122 . '
579.121 h 579.121
579.120, =\ 579.124
• A
579.127
579.128
579.029
.- - .==:::--::
579.,78
0
• A-B
579.130
579.042
579.044
~ ",,--;
----. ,.
""";:;0:;:<,,...,....,..
3& 42 280/2
Ma .YI--
• D3656S4 500.02117 4.89

RUMPFGRUPPE
•
NR 151 R 500.02
CARTRIDGE
GROUflE BAS
GRUPOBASE L1S'318 18
8ild 10 - Figure 10 - Figure 10 - Figura 10
• ---j
501 .005
501.007
501. 008 --tIiIH..oa I
I9
i ;I
591.060 t~.
10~1
____._-l
• 0365654 500.02/18 4.89

Sonderliererung VERZEICHNIS DER RESERVETEILE NR15/R 500.02
•
Extra supply LIST OF SPARE PARTS
Livraisan speciale LISTE DES PIECES DE RESERVE X11.59400-0087
Suminis1ro especial LISTA DE PIEZAS DE RESERVA 511.59400-0086 21
Mange - Quantity
Kis1.1 Box 1 Caisse 1 Caja , X11.59500-0114 Ouontiti-Condidod
B•• tell-N... Ben.nnung Sk In. Beaerkungen Reserve B.trl.b
Ordor No O•• ignation Skotch Relllark. Spare Working
No.co ••and O6olgnotlon Croqula Re.or-ques R'serve Fonctlon
No.podid. Oecignacion CroQuic ObcervQcion8 .. Recer-vo Funcion
rOr Turbln,nzustr&.gehaus. for Ga.-ad.l.slon coslno
pour corps d'ad.lesion d. turbine para coja d. ofluencio d, turblno
501 .006 Stiftschraube

stud screw ~M ~~ 6 24
-
Gaujan .cc
Ill-
Prisionero
29.8 t
24 24
•
501.007 Sicherungsscheibenpaor 13.5
Lock discs (poir)
Poire de rond.lles d'orr_l
Par d. orond.los d. s.guridod
¥ f
501.008 Sechskantmutter
Hexagon nut
,
Eerau a six pans
Tuerea hexagonal
VMW
Jl;
6 24
rur lagerung for bearing

I
pour logeeent para aloJamlento
517.002 Lagerbuehse
. 2 2
~
11
Bearing bush ~
-J"
(\I
Douille de pal ier 11
•
Casqui lla de coj inete 042
517.063 Runddichtring - 1 1
D-ring
Joint-torique I ~~ 11
Anillo circular de j unto
'- ~
• D365654 500.02/21 12.90

VERZEICHNIS DER WERKZEUGE NR15/R 500.02
•
LIST OF TOOLS
LISTE D'OUTILLAGE Xl.l.59600-0125
LISTA DE HERRAMIENTAS Ell.59600-o124
31
Kiste / Box / Caisse / Caja : X11.59700-0117

Bect.ll-Nr. Benennung Skizze (G.. icht kg) Menge ellllrkungln
Order No Designation Sketch (11. ight kg) Quantity Re.arks
N~.co•• and. Di.ignatian Croqui. (P.id. kg) Quant i t6 Obcervocionec
No.pedido Oesionoeion Croqui. (P... kg) Candidad R•• arQue,
596.008 Segment 3
Segment 70 0'-
Segment .",'"
Segmento
(0.300)
• 596.009 SpindeL
SpindLe
Broche
HusiLLo
70 3 e)
(0.051)
596.010 Sechskantmutter 19 6 e)
Hexagon nut
Ec~ou 0 six pans
Tuerca hexagonaL
L *.00171
• e) Abbou Rumpfgruppe(599.001)
Removing cortridge(599.001)
Oemontage du groupe de base(599.001)
Oemontaje deL grupo bose(599.001)
• 0365654 500.02/31 12.90

00'"0£0
• WOODWARD
®
UG DIAL
• GOVERNOR
WOODWARD GOVERNOR COMPANY
• MANUAL 030400

Diesel Generator Engine Type L23 - 30 2 of 2 - Instruction Book

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Diesel Generator Engine Type L23 - 30 2 of 2 - Instruction Book

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~HYUNDAI HEAVY INDUSTRIES CO., LTD.

OPERATING MANUAL FOR

OPERATING MANUAL FOR

Individual parts of the turbocharger may be altered due to technological development

This publication is copyright. Reprinting and other duplication and for-

• Section 1 TECHNICAL DATA

Section 2 DESCRIPTION OF SYSTEM 2

• Lubricating oil system _. ._ 51

Section S SPARE PARTS LIST 5

• 0365650 1.50-1 11.78

Roto~ mounted on two floating plane bea~ings a~~anged inboard

Complele tu~bocharger with air intake casing kg 123

When new Replace or

Admissible aberrat ion from the plane of rotation of compressor wheel

DESCRIPTIONS DES CIRCUITS

• 0365650 2.50-1 04.82

Interval type priming

OPERATION AND OPERATING DIFFICULTIES

FONCTIONNEMENT ET INDIDENTS DE FONCTIONNEMENT

• SERVICIO E IRREGULARIDADES EN EL FUNCIONAMIENTO

OPERACAO E ANOMALlAS DURANTE A OPERACAO

ESERCIZIO ED AVARIE DI FUNZIONAMENTO

• D365650 3.50-1 04.82

Preparations for Operation

Incipient rotor or bearing damage is usually indicated by erratic operation caused by

Measures for Laying Up

Emergency Operation with Inoperative Turbocharger

In addition, the following applies to the inoperative turbocharger:

If, in case of engine with 2 turbochargers, close-off of the charge air

• 036 5642 E 3.53-2

Silencer respa air filter clogged

l::...· 1r.taKE- ai r i:err.oerature

jl,j r Oilar,ifolc leaking

Exhaust pipe leaking

high gas backpressure after turbine

Fau1ty fuel injection on engine

Turbine or impeller damaged

forEi~n Datter ;r. turbine or impeller

Labyrinth ring or locating ring damaged

SE2:S ria~aged, connections leaking

lUbe oil passages, filter clogged

Excessive pressure in oil discharge or in crankcase

Hi::r eil 2C:::; ssion temnerature

501 *) TURBINE CLEANING (dry cleaning) every 500.07

502 *1 TURBINE CLEANING (wet cleaning) every 500.07

503 COMPRESSOR CLEANING every 500.08

504 + 1 AIR FILTER CLEANING: every 500.11

505 INSPECTION: with new or 500.10

506 COMPRESSOR CLEANING every 500.14

507+) SILENCER CLEANING every 500.12

508 MAJOR (GENERAL) OVERHAUL: every 500.06

• It is recommended that a cartrid~e be kept on stock or be ordered in the event

• .... L.- 036 5649 E 4.52-2 P.LO. ---J

D36 5649 E / 4.52-2 •

Turbocharger inspected - overhauled on ....•.......... by ............•..•.•...•...••...•..••.....

D36 5649 E / 4.53-2

Maintenance Job Work Cards required

• CLEAN ING TURB INE

in disassembled condition . 500.11

• 036 5649 E 4.55-3

Work Card Designation

500.05 PUTTING EXHAUST TURBOCHARGER OUT OF OPERATION